MÔ PHỎNG VÀ TỐI ƯU NHÀ MÁY LỌC DẦU

PETROVIETNAM
PETROVIETNAM UNIVERSITY
HYSYS SIMULATION
Instructor: PhD. Truong Thanh Tuan

Group 1:
• Nguyen Van An
• Le Ngoc Duc Anh
• Nguyen Xuan Cuong
• Huynh Truong Tuong Duy
• Truong Tuan Hai
• Doan Le Hien
CONTENT
1. CHARACTERIZATION
2. DISTILLATION
3. ABSSORBER
4. PRE-HEAT TRAIN
5. FLASH EQUILIBRIUM (ISOTHERMAL)
6. PLASH EQUILIBRIUM ADIABATIC REFRIGERATION
7. ATMOSPHERIC CRUDE COLUMN
8. REBOILER
9. BLENDING / MIXING
10. REACTOR (CSTR)
11. REACTOR (PFR)
12. INTEGRATION WITH RECYCLE
2
2. DISTILLATION
 OBJECTIVES
• Distillation column modeling.
• Column profiles.
• Custom stream results.
• Material balance across distillation colum.
 PROCEDURE
• Create a Component List. Add Ethane and Ethylene.
• Fluid Package: Peng-Robinson.
• Select Distillation Column.
• Enter 125 Stages and define the feed and product streams as shown below.
3
2. DISTILLATION
• In page 2 will appear. Select Regular Hysys reboiler for Reboiler Type
Selection, and select the Once-through radio button.
•Condenser Pressure and Reboiler Pressure: 300 psig.
•Select Mass for Flow Basis and enter 5000000 lb/day for Liquid Rate.
4
2. DISTILLATION
• Conditions: enter a pressure : 350 psig, a Vapour fraction : 1, and Mass Flow :
7.3e+06 lb/day for the Feed@COL1 stream.
5
2. DISTILLATION
• Compositions : Type a number into the Feed composition grid for Ethane to open
the Input Composition for Stream window. Mass Fractions : 0.315 for Ethane
and 0.685 for Ethylene.
6
2. DISTILLATION
• In the Column → Design | Specs. Make sure that the Distillate Rate value is
correct (9.450e+004 kg/h).
• In the Comp Frac Spec window select the Stream for Target Type,
Ethane@COL1 for Draw, Mass Fraction for Basis, and 9.0e-004 for Spec Value.
Select Ethylene for Components.
→ Converged.
7
2. DISTILLATION
 OUTCOME
8
2. DISTILLATION
 CONCLUSIONS
• The 125 stage column was able to exceed the specification of 99.96wt%
ethylene at 5 million lb/day, as well as the bottoms having less than 0.10wt%
ethylene.
• It could then be concluded that this column is capable of completing the
desired separation.
9
3. ABSORBER
 OBJECTIVES
• Use Aspen HYSYS to simulate a CO2 absorber column.
 PROCEDURE
• Create a Component list. Add water, carbon dioxide, nitrogen,

monoethanolemine, and oxygen.
• In the Fluid Packages : Amine Pkg.
10
3. ABSORBER
• Add a material stream. This will be the flue gas stream. Temperature : 65°C,
Pressure : 1.2 bar, and Mass Flow : 1000 tonne/day. In Composition enter Mole
Fractions : 0.10 for CO2, 0.70 for Nitrogen, 0.15 for Water, and 0.05 for Oxygen.
11
3. ABSORBER
•Add a second material stream. This will be the solvent stream. Temperature :
25°C, a Pressure : 1 bar, and a Mass Flow : 80,000 kg/h. In the Composition enter
Mass Fractions : 0.25 for MEA and 0.75 for water.
12
3. ABSORBER
• Add Absorber Column Sub-Flowsheet from the Model Palette. Open the
Absorber Column Input Expert. On the first page of the input expert select stream
Solvent as the Top Stage Inlet and stream Flue Gas as the Bottom Stage Inlet.
Create an Ovhd Vapour Outlet called Clean Air and a Bottoms Liquid Outlet
called Solution. Enter 20 for Stages.
• On the second page of the input expert enter a Top Stage Pressure of 1 bar and a
Bottom Stage Pressure of 1.2 bar. On the final page of the input expert enter Top
and Bottom Stage Temperature estimates of 50°C. The column property window
will now appear. Run to begin calculations → converge.
13
3. ABSORBER
14
3. ABSORBER
 OUTCOME
15
16
 LESSON OBJECTIVES
• Build and converge an Atmospheric Crude Column.
• Use HYSYS to analyse and predict the behaviour of a simulated column.
• Add side operations to a column to improve operation and efficiency.
• Add cut point specifications to increase side product quality and quantity.
 PROCEEDING TO SIMULATE THE PROCESS
• Reusing lesson results 01 Oil Characterization.
• Go to the simulation environment.
• Add Refluxed Absorber.
17
18
• Add AGO side stripper
19
• Add AGO pump around
20
• Add Diesel side stripper
21
• Add Diesel pumd around
22
• Add Kerosene side stripper
23
• Add Kerosene pumd around
24
25
EXERCISE 1:
26
27
28
29
EXERCISE 2:
30
EXERCISE 3:
31
32
8. REBOILER
33
8. REBOILER
• Learn how to calculate heat of vaporization using the heater block in Aspen
HYSYS.
• Understand the impact of heat of vaporization on distillation.
• Add feed: H2O, 3-methylhexane, 1,1,2-trichloroethane.
• Choose Fluid Package: UNIQUAC, choose Vapour Model is RK.
• Go to the simulation environment. Click Simulation button.
• Choose 3 Heater: E-100, E-101, E-102.
34
8. REBOILER
• E-100
o Enter Worksheet at column Feed-Water enter the parameters Pressure = 100 kPa,
Vapour Fraction = 0, and Molar Flow = 1 kgmole/h.
o Enter Composition enter parameters Mole Fraction of H2O = 1.
o Enter Worksheet at column Water-Out enter the parameters Pressure = 100 kPa,
Vapour Fraction = 1.
35
8. REBOILER
• E-101
o Enter Worksheet at column Feed-3MH enter the parameters Pressure = 100 kPa,
o Enter Composition enter parameters Mole Fraction of 3-methylhexane = 1.
o Enter Worksheet at column 3MH-Out enter the parameters Pressure = 100 kPa,
36
8. REBOILER
• E-102
o Enter Worksheet at column Feed-1,1,2 enter the parameters Pressure = 100 kPa,
o Enter Composition enter parameters Mole Fraction of 1,1,2-trichloroethane = 1.
o Enter Worksheet at column 1,1,2-Out enter the parameters Pressure = 100 kPa,
37
8. REBOILER
 RESULTS
• E-100: Heat flow = 3.990e + 004
38
8. REBOILER
 RESULTS
• E-101: Heat flow = 3.052e + 004
39
8. REBOILER
 RESULTS
• E-102: Heat flow = 3.349e + 004
40
8. REBOILER
 CONCLUSIONS
• Although water has small-molecular weight, its heat of vaporization is large.

Heat of vaporization for water is about 18% higher than that of 1,1,2-
trichloroethane and about 30% higher than that of 3-methylhexane.
• Of the three options, 3-methylhexane has to lowest heat of vaporization and
would require the least amount of energy as a solvent in a distillation.
41
Main simulation diagram
42
Create the main component
43
Select Fluid Pkgs
44
After creating the lines. We proceed to add MIXER.
45
Go to the Worksheet at ETBE, enter the parameter Temperature = 25°C,

Pressure = 1 bar.
46
In the Worksheet in the Composition column enter the parameter ETBE = 1
47
In the Conditions in the Gasoline column enter Temperature = 25°C, Pressure =
1 bar , Mass Flow = 82.76 kg/h in the Gasoline column
48
In the Composition in the Gasoline column enter the parameter 224-Mpentane
= 1 in the Gasoline column
49
We have the data below.
50
Create Spreadsheet
51
We have the data below.
52
Enter the spreadsheet according to the instructions, enter A1 and A2
53
Import variables into B1
54
Enter the calculation formula B2 = (B1*0.17243)/(1-0.17243).
55
Output the formula result in the following
56
10. CSTR
• Use chemical reaction kinetics to calculate the reactor volume required to

reach a desired conversion in a CSTR
• PROCEEDING TO SIMULATE THE PROCESS
• Add feed: cis2-Butene and tr2- Butene.
• Choose Fluid Package: NRTL
57
10. CSTR
• Go to the Reactions and Add Reaction with the following data.
58
10. CSTR
• Start simulating with a CSTR from Model Pallette. Then enter stream name
and and parameters for the Reactor as shown in the given pictures.
Start simulating with a CSTR from Model Pallette. Then enter stream
name and and parameters for the Reactor as shown in the given pictures
59
10. CSTR
• After entering enough data the Reactor converges, then we continuously add
adjust to adjust the reactor volume in order to achieve a reaction conversion of
90%with the following information.
60
10. CSTR
• Add a Spreadsheet with the following data. Import variables: B1: the Tank
Volume of CSTR-100, B2: Actual Volume Flow of stream LIQ-Product. In cell
B3 enter the following formula: =(B1/B2)*110.
61
10. CSTR
 Conclusion
• From the results received as shown in the picture, we can see Residence Time
to achieve 90% reaction conversion in a CSTR is about 39 minutes.
• Both the analytical solution and design spec in Aspen HYSYS produced the
same required residence time of the same value.
• The residence time for a CSTR is longer than for a batch reactor or PFR
because of the back-mixing: product is mixed in with the feed, slowing the
reaction.
62
11. PFR
• Use chemical reaction kinetics to calculate the reactor length required to reach
a desired conversion in a plug flow reactor.
• PROCEEDING TO SIMULATE THE PROCESS
• Add feed: cis2-Butene and tr2- Butene.
• Choose Fluid Package: NRTL
63
11. PFR
• Go to the Reactions and Add Reaction with the following data.
64
11. PFR
• Start simulating with a PFR from Model Pallette. Then enter stream name and
and parameters for the Reactor as shown in the given pictures.
Start simulating with a PFR from Model Pallette. Then enter stream name
and and parameters for the Reactor as shown in the given pictures
65
11. PFR
• After entering enough data the Reactor converges, then we continuously add
adjust to adjust the reactor volume in order to achieve a reaction conversion of
90%with the following information.
66
11. PFR
• Result received is shown in the pictures.
67
11. PFR
 CONCLUSION
• From the results received as shown in the picture, we can see the required
reactor length to achieve 90% reaction conversion in a PFR is about 8.3 m. This
same strategy can be applied for much more complex reactions and multi - tube
reactors, which would be much more difficult to attempt to solve using hand
calculations.
68
12.INTEGRATION WITH RECYCLE
• Simulate CSTR reactors
• Simulate an Ethylene glycol plant
• Use the recycle operation in HYSYS
• Choose suitable locations for recycles
69
• Step 1: Create a component list. Add Ethylene Oxide (C2H4O), Water (H2O) and
Ethylene Glycol to the component list.
• Step 2: Define property package. Select NRTL and then go to Binary Coeffs
tab, select UNIFAC VLE as the Coeff Estimation method to estimate the
missing binary coefficients and press Unknowns Only. This will estimate the
coefficients for the ethylene oxide / ethylene glycol pair.
70
• Step 3: Go to the Reactions and Add Reaction with the following data.
71
• Step 4: Attach the reaction to a fluid package. In the Set-1 (Reaction Set) form,
click Add to FP and select Basis- 1.
• Step 5: Go to the simulation environment. Click Simulation button.
72
• Step 6: Start simulating with 2 streams from Model Pallette. Then enter data
with the following information:
73
• Step 7: Then add a CSTR Reactor and enter the following information.
74
75
76
• Step 8: After entering enough information the Reactor converges and the result
we get is shown in the picture.
77
• Step 9: Add a Distillation Column and enter data as shown in the pictures.
78
• On page 2 of 5 choose one-through and Regular Hysys reboiler.
• On page 3 of 5 enter Condenser Pressure is 100 kPa and Reboiler Pressure is

105 kPa.
• On page 4 of 5 enter Optional Reboiler Temperature Estimate is 150°C.
• On page 5 of 5 enter Reflux Ratio is 3 and Flow Basis is Molar.
79
• Step 10: To make the tower converge we need to specify enough

specifications, and we enter 100 for Distillate rate, then the tower converges.
• Step 11: Install a Recycle and enter thư following information.
80
• Step 12: Add a Mixer,

delete specified molar
flow of the stream
Water Feed and break
connection to Reactor.
Then enter information
for Mixer as following.
81
• Step 13: Reconnect the Water to Reactor stream to the Reactor and the process
converges.
• Step 14: Result received is shown below.
82
 CONCLUSIONS
From the results received as shown in the pictures, we can see that Molar Flowrate
of Water Feed is 50 kgmole/h when Distillate Rate is 100 kgmole/h. The stream
Distillate contains mostly unreacted water. This water can be recycled to the reactor
in order to reduce the feed water requirements (as well as eliminate a waste stream)
83
84

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PETROVIETNAM

Instructor: PhD. Truong Thanh Tuan

• Distillation column modeling.

• Custom stream results.

• Material balance across distillation colum.

• Create a Component List. Add Ethane and Ethylene.

• Fluid Package: Peng-Robinson.

• Select Distillation Column.

• Use Aspen HYSYS to simulate a CO2 absorber column.

• Create a Component list. Add water, carbon dioxide, nitrogen,

Mass Fractions : 0.25 for MEA and 0.75 for water.

• Build and converge an Atmospheric Crude Column.

• Use HYSYS to analyse and predict the behaviour of a simulated column.

• Add side operations to a column to improve operation and efficiency.

 PROCEEDING TO SIMULATE THE PROCESS

• Reusing lesson results 01 Oil Characterization.

• Go to the simulation environment.

• Add Refluxed Absorber.

• Add AGO side stripper

• Add AGO pump around

• Add Diesel side stripper

• Add Diesel pumd around

• Add Kerosene side stripper

• Add Kerosene pumd around

 PROCEEDING TO SIMULATE THE PROCESS

• Add feed: H2O, 3-methylhexane, 1,1,2-trichloroethane.

• Choose Fluid Package​: UNIQUAC, choose Vapour Model is RK.

• Go to the simulation environment. Click Simulation button.

• Choose 3 Heater: E-100, E-101, E-102.

o Enter Composition enter parameters Mole Fraction of H2O = 1.

• E-100: Heat flow = 3.990e + 004

• E-101: Heat flow = 3.052e + 004

• E-102: Heat flow = 3.349e + 004

• Although water has small-molecular weight, its heat of vaporization is large.

Main simulation diagram

Create the main component

Select Fluid Pkgs

Go to the Worksheet at ETBE, enter the parameter Temperature = 25°C,

In the Worksheet in the Composition column enter the parameter ETBE = 1

We have the data below.

Output the formula result in the following

• Use chemical reaction kinetics to calculate the reactor volume required to

• Add feed: cis2-Butene and tr2- Butene.

• Choose Fluid Package​: NRTL

• Go to the Reactions and Add Reaction with the following data.

• Add feed: cis2-Butene and tr2- Butene.

• Choose Fluid Package​: NRTL

• Go to the Reactions and Add Reaction with the following data.

• Result received is shown in the pictures.

• Simulate CSTR reactors

• Simulate an Ethylene glycol plant

• Use the recycle operation in HYSYS

• Choose suitable locations for recycles

 PROCEEDING TO SIMULATE THE PROCESS

• Step 5: Go to the simulation environment. Click Simulation button.

• On page 2 of 5 choose one-through and Regular Hysys reboiler.

• On page 3 of 5 enter Condenser Pressure is 100 kPa and Reboiler Pressure is

• On page 5 of 5 enter Reflux Ratio is 3 and Flow Basis is Molar.

• Step 10: To make the tower converge we need to specify enough

• Step 12: Add a Mixer,

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• Choose Fluid Package: UNIQUAC, choose Vapour Model is RK.

• Choose Fluid Package: NRTL

• Choose Fluid Package: NRTL