Aspen Plus Process Modeling Introduction to Flowsheet Simulation fap) \“aspeniec Introduction to Flowsheet Simulation Lesson Objectives + Introduce general flowsheet simulation concepts and Aspen Plus features ©2009 AspenTech, All Rights Reserved. 1 ‘Aspen Pechnology, Inc.Aspen Plus Process Modeling Introduction to Flowsheet Simulation (“aspento!: Flowsheet Simulation + Whatis flowsheet simulation? — Use of a computer program to quantitatively model the characteristic equations of a chemical process + Uses underlying physical relationships ~ Mass and energy balance = Equilibrium relationships = Rate correlations (reaction and mass/heat transfer) + Predicts ~ Stream flowrates, compositions, and properties ~ Operating conditions aspen: Advantages of Simulation + Reduces plant design time ~ Allows designer to quickly test various plant configurations. + Helps improve current process ~ Answers ‘what if questions = Determines optimal process conditions within given constraints ~ Assists in locating the constraining parts of a process (debottlenecking) ©2009 AspenTech, All Rights Reserved, 2 ‘Aspen Technology, Inc.Aspen Plus Process Modeling, Introduction to Flowsheet Simulation “aspeniects, General Simulation Problem + What is the composition of stream PRODUCT? RECO REACT] eeoLent ser + To solve this problem, we need: pry = Material balances ~ Energy balances aspenic::, Approaches to Flowsheet Simulation + Sequential Modular (SM) ~ Each unit operation block is solved in a certain sequence: ~ Used to solve a large number of blocks + Equation Oriented (EO) ~ All equations are solved simultaneously ~ A good starting point is necessary + Combination ~ Use the SM approach to initialize and/or get close to a solution, then use EO approach to solve the fiowsheet more precisely ~ Use the SM approach to get an inital solution, then use EO approach to do optimization or model tuning ©2009 AspenTech, All Rights Reserved. 3 Aspen Technology, Ine.Aspen Plus Process Modeling Introduction to Flowsheet Simulation CY aspenioc Good Flowsheeting Practice + Build large flowsheets a few blocks at a time ~ This facilitates troubleshooting if errors occur + Not necessarily a one-to-one correspondence between pieces of equipment in the plant and Aspen Plus blocks + Ensure flowsheet inputs are reasonable + Check that results are consistent and realistic aspenicci: Some Important Features of Aspen Plus + Rigorous Electrolyte Simulation ‘AspenTech provides + Solids Handling additional courses that cover each of these topics in greater detal Property Data Regression General Data Fiting Contact your Training + Property Estimation oT + Extensibility information = Custom Propertios = Custom Unit Operation todels Integration wih Microsoft® Exoe! ~ Integration wth ether applications through sutomation + Equation Oriented Modeling, incuting simulation, optimization, and data revoneilation + Integration to rigorous heat exchanger design tools + Integration wth rigorous east modeling ©2009 AspenTech. All Rights Reserved. 4 Aspen Technology, Inc.Aspen Plus Process Modeling ‘The User Interface aspenicct:, Lesson Objectives + Become comfortable and familiar with the Aspen Plus graphical user interface (©2009 AspenTech, All Rights Reserved. 1 Aspen Technology, Inc.Aspen Plus Process Modeling ‘The User Interface “aspeniec) The User Interface aspen’; Cumene Flowsheet Definition + Which Aspen Plus block would you use for each unit? Model Lome ©2009 AspenTech, All Rights Reserved. 2 ‘Aspen Technology, Inc.‘Aspen Plus Process Modeling ‘The User Interface Graphic Flowsheet Operations — Blocks (aspen + To place a block on the flowsheet: Click a model category tab in the Model Library 2, Select a unit operation model; click the drop-down arrow to select an icon for the model 3, Click the model and then click the flowsheet to place the block; you can also click the model icon and drag it onto the flowsheet 4. Cliok the right mouse button to stop placing blocks \“aspeniecn, Graphic Flowsheet Operations — Streams + To place a stream on the flowsheet: 4. Click the STREAMS icon in the Model Library 2. Ifyou want to select a different stream type (Material, Heat or Work), cick the down arrow next to the icon and choose a different type Click a highlighted port to make the connection Repeat step 3 to connect the other end of the stream To place one end of the stream as either a process flowsheet {eed or product, click a blank part of the Process Flowsheet 6. Click the right mouse button to stop creating streams ©2009 AspenTech. All Rights Reserved. 3 ‘Aspen Technology, Ine.Aspen Plus Process Modeling The User Interface © aspeniveis Automatic Naming of Streams and Blocks + Stream and block names can be assigned automatically by Aspen Plus or entered by the user when the object is created + To modify the naming options: 1. Select Options from the Tools menu 2. Cliok the Flowsheet tab 3. Check or uncheck the naming options desired + Stream and block names can be displayed or hidden 41. Select object, right-click, and choose Hide from the menu ‘aspen! Modifying Blocks and Streams. + To display Input and Results forms in the Data Browser: 1. Double-click the object of interest, or Select ne block or stream, ight-c, and sleet nut. rom 1 menu + To change the appearance of a block or stream: 4. Select object by clicking it wth the left mouse button 2. Click the right mouse button while the pointer is over the selected object icon to bring up the menu for that object 3. Choose appropriate menu item ©2009 AspenTech. AAll Rights Reserved. 4 Aspen Technology, Ine.Aspen Plus Process Modeling ‘The User Interface ~ aspeninx' Breaking and Splicing Streams + To break @ stream on the Process Flowsheet: 4. Select the stream on the flowsheet and right mouse click Select "Break Stream’ for the stream menu If results exist, you will be asked if you want to reconcile the stream 4, Enter the name of the new product stream created + To splice two streams: 41. Select the two streams to be spliced (using the Shift or Ctr key) 2. Right mouse click on one of the streams, select “Splice Streams" 3. Combined stream will have the name of the former feed stream a ‘aspen’ Inserting Blocks + To insert a block on the Process Flowsheet: Select the stream where you want to insert the block Right-click and select "Insert Block” results exist, you will be asked if you want to reconcile the stream 4. Select the new block ID and type 5, Tho old stream is connected to the first inlet and outlet port for the new block 6. Additional streams may need to be added to complete flowshest connectivity depending on the model ©2009 AspenTech. Ail Rights Reserved. s Aspen Technology, Ine.Aspen Plus Process Mod ‘The User Interface © gspeniaci Using the Mouse Buttons + Left-click > Selects a block, stream, object ID, or annotation + Right-click > Brings up menu for the selected stream, block, or flowsheet > Cancels placement of streams or blocks on the flowsheet * Double-left-click > Opens the Data Browser to the stream or block Input form, or Results form for intermediate streams > Edits text *aspen'ec. Saving an Aspen Plus Simulation + Tosavea file’ 1. Select Save As from the File menu 2, Choose a File name 3, Choose an appropriate Save As Type Document |*apw | Binary | File containing smaiaton input L Intermediate convergence ino Backup | “OK ‘ASCII Arcwe fe comaring simulation np a results ‘Gampound [apa [Binwy | Compressed te which contains the model he [BKP or APW fe) and extora le eforanced by the model. You can sod edd8cra les such as supperting documentation to te APWYZ fle ‘See Maintaining Aspen Plus Simulations section for information on other file formats ©2009 AspenTech. All Rights Reserved. 6 ‘Aspen Technology, Ine.Aspen Plus Process Modeling ‘The User Interface ‘aspenis) Benzene Flowsheet Definition Workshop + Objective: Create a graphical flowsheet ~ Start with the General with English Units template ~ Choose the appropriate icons for the blocks ‘hn finished, save as BENZENE FLOWSHEET.BKP ©2009 AspenTech. All Rights Reserved. 7 Aspen Technology, Ine.Aspen Plus Process Modeling Appendix B: Workshop Instructions Benzene Flowsheet Workshop Instructions Simulations Sheet Desktop Double-click the Aspen Plus User interlace icon ‘Aspen Pius form | Select the Template oplion and click the OK button. New form, ‘Select General with English Unis, use the default Flowsheel run ype, and click OK. [Aspen Pius menu ber To tum the automatic naming feature {cl Toois/Oplions from the menu bar, then on the Flowsheet tab, uncheck boxes 1 (block) and 3 (streams) Place Blocks Model Library, Heat Exchangers Sheet Click Heater, move the cursor into the Process Flowsheet Window and click where the héater should be located. Enter the name “COOLER’, Mode’ Library, ‘Separators Sheet Click Flash2, move the cursor into the Process Flowsheet Window and click where the separator should be located. Enter the name "FL1 Process Fiowsheet Window. Ciick Flash2, move the cursor into the Process Flowsheei Window and click where the separator should be located. Enter the name "FL2", | Model Library Establish Stream Connections Click Material STREAMS and move the cursor into the Process Fiowsheet — Window. Process Flowsheat ‘Window Note the inlet and outlet poris of the blocks are highlighted, Move ‘onto the Feed port of block COOLER; click. Move the cursor to the left, cick where the feed icon should be placed, name the stream "FEED". “Move the cursor onto the Product port of COOLER, click; move the cursor to the Feed port of FL1 and click, Name the stream "COOL". Now stream 2 from COOL to FL1 Is connected, Draw a siream named *LIQT™ from the Liquid port of FL1 to the Feed port ofF FL2. ‘Draw a stream named "VAPT" from the Vapor port of FL1 to the Feed por of FL2 a blank part ofthe flowsheet. Draw a stream named "L1Q2" from the Liquid port of FL2. Draw a stream named ‘VAP2" from the Vapor part of FL2 to a blank part ofthe flowsheet. Click the Select Mode bution fo leave the slream connection made. Save ‘Menu Bar From the File menu, select Save As, Save As dialog box From the Save as type dropdown menu selecl Aspen Plus Backup Files (C.bkp), fil in the File name line with BENZENE FLOWSHEET.BKP. ‘Aspen Pius box ‘Select No to save in bkp format only, ©2009 AspenTech. All Rights Reserved 2 ~~ Aspen Technology, Ine.‘Aspen Plus Process Modeling Basic Input Vaspeniach Basic Input Lesson Objectives + Introduce the basic input required to run an Aspen Plus simulation ©2009 AspenTech. All Rights Reserved. 1 Aspen Technology, Inc.Aspen Plus Process Modeling Basic Input Caspeniocs, Aspen Plus Interface + Graphical User Interface = Use Menus to specify program options and commands, Toolbars for direct access to certain poputar functions, and the Model Library to build the process flowsheet + Data Browser ~ Used to navigate the folders, forms, and sheets ~ Can be moves, resized, minimized, maximized or closed ~ Contains Object Managers, which allow for manipulation of discrete objects of information = Next Button: Checks if the current form is complete Ni] and moves to the next form which requires input ‘aspen Data Browser (1) + The Data Browser is a hierarchical tree structure view of the available simulation input, results, and objects that have been defined; it is used to navigate the folders, forms, and sheets [Folders + Refer to the root items in the Data Browser + Contain forms and/or other folders or object managers OForms + Used to enter data and view results Can be comprised of a number of sheets Are located in folders Sheets ‘Make up forms ‘Are selected using tabs at the top of each sheet ©2009 AspenTech. All Rights Reserved Aspen Technology, Inc,Aspen Plus Process Modeling Basic Input CP aspeniech, Data Browser (2) eee pam “aspeniccs, Functionality of Forms + When you click the left mouse button to select a field on a form, the Description area gives you information about that field. Use this content to help with data entry + Click the drop-down arrow in a field to bring up a list of possible input values for that field ~ Typing a letter will bring up the next selection on the list that begins with that letter + The Tab key will take you to the next field on a form + In tables, Aspen Plus always adds a sit le row below the last entry ©2009 AspenTech, All Rights Reserved, 3 Aspen Technology, Inc.Aspen Plus Process Modeling, Basic Input aspenie Basic Input + The minimum required inputs to run a simulation are: ~ Setup ~ Components = Properties ~ Streams = Blocks + Enter data on the input forms in the above order by clicking the Next button + Or, these input folders can be located quickly using the Data menu or the Data Browser toolbar buttons: aspenic:i: Status Indicators + Colors and shapes are used to describe the current status of input and results: 5 [Stat Input forte frm is nono Input for ta im is comple ‘No input forte frm has been entered is oponal [Bt input and resus exit ntl form Results fom exis. Rest for the form oxic, Sut here were Galeulaon rors este forthe form exit, bul here were ealultlon warnings Resulls forthe fom exist but nput has changed since the resis were generated & BE Blas plo S ©2009 AspenTech. All Rights Reserved. 4 ‘Aspen Technology, Inc.‘Aspen Plus Process Modeling, _Basie Input ‘" aspenizc'i Cumene Production Conditions REACTOR [re es (rake our} o(V} tocacon qe20r veoeuonr B23 P8 cy OroBtuhe T=130F zene: 40 mel Peron = O pst 0 pei Propylene: 40 mali, POOP ORS! Peron = 04 ei P=taum Q sot PROoUET Gite + City > Cathy Borzore Propylone Cumene (lspropyibenzane) ‘90% Conversion of Propylene Use the RK-SOAVE Property Method Sse CUMENE B42 * aspen’ Setup * Most of the commonly used Setup information is entered ‘on the Setup Specifications Global sheet ~ Flowsheet tite to be used on reports, ~ Run type ~ Input and output units ~ Valid phases: vapor-iquid (default) or vaportiquidtliquid — Ambient pressure + Stream report options are located on the Setup | Report Options | Stream sheet ©2009 AspenTech. All Rights Reserved s ‘Aspen Technology, Ine.Aspen Plus Process Modeling Basic Input aspeniocii Setup Specifications Form aspenic:ii, Setup Run Types. Run Type |Description Fionsheet | Standard flawshoet rons can conan propery eslinalon, aosny data ‘analysand property analyes ealeuaiens. These same oplons can bo onecuted standalone wiht a owsheo! ae doserbod below ‘Assay Dale | Use Assay Data Analysis to enalyzeaosay dota and generale [Analysis | pseudocompanents fr use i the Aspen Pus fowshee aa gression ) Obs Sol SLT ©2009 AspenTech. All Rights Reserved. 2 ‘Aspen Technology, Ine.Aspen Plus Process Modeling Basie Input aspenicc': Streams + Use Stream | Input forms to specify feed stream conditions, including two of the following: ~ Temperature ~ Pressure = Vapor Fraction + Plus, for stream composition either: ~ Total stream flow and component fractions ~ Individual component flows + Specifications for streams that are not feeds to the flowsheet are used as estimates aspenic!s, Streams Input Form ©2009 AspenTech, All Rights Reserved, B Aspen Technology, Ine.Aspen Plus Process Modeling Basic Input aspenio function key to bring up help for field and/or sheet \ aspen Troubleshooting Help + Troubleshooting using the online help £3} ~ Based on specific error and warning messages = Based on a description of the problem — Using diagnostic messages and rasutts of failed runs ©2009 AspenTech. All Rights Reserved. 15 Aspen Technology, Inc.Aspen Plus Process Modeling. Basic Input \Y aspenieci: Glossary Help * Glossary of terms used in Aspen Plus documentation * Cross-linked to other terms rs . (e aspen’ Starting the Run + Select Control Panel from the View menu or press the Next button to be prompted — Execute the simulation when all required forms are complete, Ifyou are unsure, use the Next button to take you to any incompiete forms ©2009 AspenTech, All Righis Reserved. 16 ‘Aspen Technology, Inc.‘Aspen Plus Process Modeling. Basic Input aspentec’ Control Panel + The Control Panel consists of a: ~ Message window showing the progress of the simulation by displaying the most recent messages from the calculations, ~ Status area showing the hierarchy and order of simulation blocks and convergence loops executed ~ Toolbar that you can use to contro! the simulation Run [Start oF continue calculations ‘Step [1S Step trough the flowshest one bioak ata time ‘Stop TTisl_[ Pause simulation caleviations Reiniaize | Lil | Purge simulation cesuts Results | | Check simulation results ‘aspenicc') On Demand and Automatic Runs + On Demand mode ~ Any blocks whose flowsheet connectivity and block input are ‘complete will be run ~ If the block was previously run, itis only re-run when conditions are changed + Automatic run mode: = On Demand runs are automatically performed each time a new portion of the flowsheet becomes fully specified -> These options are great when building a flowsheet! Normalan | [Run al boos (On Demand Run | & [Run any blocks thai are complete ‘Automatic Run | © [Run blocks automaticaly as soon as they are fully specified ©2009 AspenTech. All Rights Reserved 7 ‘Aspen Technology, IneAspen Plus Process Modeling Basic Input “aspenie') Reviewing Results + History file or Control Panel Messages ~ Contains any generated errors or warnings (Select History or Control Panel on the View menu to display the History file or ‘the Controt Pane!) + Block Results = Contains calculated block operating conditions (In the Blocks folder, click the block, then select the Results form) + Blocks with errors or warnings indicated with icons on. PFD ( - Error, - Warning) = Can be toggled on/off from Tools | Options | Results View dialog box CS aspentssh Block Summary + Block Summary Grid 8] ~ Use this grid to view a ‘summary of important variables of al unit. operation mode's. — The data appears split over separate tabs for each block type. ©2009 AspenTech. All Rights Reserved. 18 ‘Aspen Technology, inc.Aspen Plus Process Modeling Basie Input aspentec' Stream Results + Stream Results ~ Contains stream conditions and compositions (For all streams, click Results Summary | Streams; for individual streams, click the stream name in the Streams folder, then select the Results| form) + Custom Stream Results — Contains customized stream properties (For all streams, click Results Summary | Custom Stream Summary; for individual streams, click the stream name in the Streams folder, then solect the Custom Stroam Results form} ~ Can be selected as default view when you double-click 2 stream on the PFD from the Tools | Options | Results View menu dialog box aspen, Custom Stream Results + This feature makes it much easier to customize the stream report format + With Custom Stream Summary Views you can: ~ Select a list of streams to display ~ Select the properties to be displayed = Select the units of measure and numerical formats ~ Specify calculation options for each property Eliminate or change the labels used in the table + Custom stream summary views can be exported and imported as .APCSV files + You can use any number of custom views within the same simulation ©2009 AspenTech. All Rights Reserved. 19 ‘Aspen Technology, Inc.Aspen Plus Process Modeling. Basie Input “aspen Steps to Create Custom Stream Results + To create custom results: Right click the Default tab and select Add Give the new sheet a name Right click the new sheet and select Edit View Use the Wizard to select the streams and properties along with their display, calculation and label options. + See Custom Stream Summary Details section for detailed example aspen, Custom Stream Summary Form ©2009 AspenTech. All Rights Reserved. 20 ‘Aspen Technology, Ine.Aspen Plus Process Modeling Basic Input ‘aspen! Benzene Flowsheet Conditions Workshop (1) + Objective: Add the process and feed stream conditions to a flowsheet. Start with the Benzene Flowshee! (BENZENE FLOWSHEET.BKP). {mei} conver Te100%F P=500psia Feed T=1000F ——Parop=0 P=550psia Hydrogen: 405 lbmoli Methane: 95 tbmovar ‘Benzene: 95 lbmothe Toluene: 8 bmothe Use the PENG-ROB Property Mothod When finished, save: filename: BENZENE BK ~ aspen» Benzene Flowsheet Conditions Workshop (2) + Results = What is the heat duty of the COOLER biock? ~ What is the temperature in the FL2 block? Note: Answers for all of the workshops are located in the back of the course notes in Appendix C ©2009 AspenTech, All Rights Reserved. 21 Aspen Technology, Ine.Plus Process Modeling Basic Input aspenie:!: Benzene Flowsheet Conditions Workshop (3) Optional + Create a Custom Stream Summary with the following properties: = Temperature ~ Pressure ~ Total Mote Flow ~ Liquid and Vapor Component Mole Fiows = Liquid and Vapor Mixture Mass Density in gmn/oc ~ Liquid and Vapor Mixture Viscosity in eP ‘aspen! Benzene Flowsheet Conditions Workshop (4) ©2009 AspenTech, All Rights Reserved. 2 ‘Aspen Technology, Ine.Aspen Plus Process Modeling Appendix B: Workshop Instructions Benzene Workshop Instructions Start eee ee eee [Aspen Pius form | Open an existing simulation, benzene flowshestbkp. Global Specifications ‘Menu Bar ‘Gick the NExt billon to go to the nex required data entry fied ‘Components In the first Component ID field, fype HYDROGEN, and press Enter. Specifications Selection | In the next biank Component ID field, type METHANE, sheat Repeat for BENZENE and TOLUENE. Click the Nex! bution to goto the next required data entry field Broperlies Spacicalions [Click the arrow next fo the Property method tild; Global sheet Soro down the alphabetical lst, end select PENG-ROB; | The Parameters folder in the menu tree shows the required input | incomplete symbol, Cck the Nex! button Properies Parameters | View avalable binary inieracton parameters. Binary Interaction PRKBV- | Click the Next bution to go to the next required data entty field, 4 sheet Stream Specifications ‘Stream FEED Place the cursor in the biank fieid below Temperature in the State (MATERIAL) Input variable area. Specifications sheet Enter 1000, the unit F is appropriate; ‘Similarly, enter the pressure, 850 psi; In the Composition area, enter the mole flows of the individual ‘components. ‘Click the Next button to go to the next required data entry field. Block Specifications Blocks COOLER (Heater) | Specliy a temperalure of 200°F, anda pressure of O pala, Input Specifications sheet | Read that a pressure of 0 or less wl be taken as a pressure drop. Click the Next bution to go to the next required data entry field Blocks FL1 (Flash2) Input | Specify a temperature of 100°F and a pressure of 500 psia. ‘Specifications sheet Click the Next button to go to the next required data entry field. __ Blocks FL2 (Flash) Input _| Click the arrow next to the fied showing Temperature, select Heat duty | Specifications sheet from the drop-down list, and specify a value of 0; Enter a value of 1 for pressure and from the unit dropdown list, choose aim. Run Data Browser Toolbar | Glick the Next buiton to run the simulation, Required input complete form: click OK. Walch the progress of the simulation. Glick the Check results button on the toolbar to compare results. _| Glick the Streams form Save As... BENZENE. BKP, (©2009 AspenTech. Ail Rights Reserved 3 ~~ Aspen Technology, Inc.Procoss Modeling Using Aspen Plus Appendix C: Workshop Results Benzene Workshop Results _ Z [FEED at [VAP2 a2] Temperature, Fad 09] 9918 388) IPressure, psi 550) 500] 14,7] 147) Vapor Frac 1 i 1 o) [Mole Flow, lbmotfar 600) 98.276] 2762] 95.514 IMass Flow, loyhr 021,99) 10221.99| 268.668] 7693.324| 71.786] 7521.539] [Volume Fiow, cuftiny |" 17271.52| 6905.633| 6098.24] 143.354) 1123.627| 140.415] lEnthaloy, MMBIu/ne 7.364 o17| 2.76 2018] -0.023] 2.037) IMole Flow, Ibmolar HYDROGEN 205 405] 404.230) O7ei| 0.754] 0.007) METHANE, I 95) 95] 93.477| 4,523) 1.398] 0.125) 95) 99 3.935) 91.085] 0.6| 90.464) 3 s|___0.073[ 4.927] 001 4317] [Coot heat ay “7-19 Btu] #FL2 ouilel temperature | 98.83°F| (©2009 AspeiiTech, ATI Rights Reserved 2 ‘Aspen Technology, ne.