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

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 1. OIL CHARACTERIZATION

 OBJECTIVES

• Use the Oil Characterization option in HYSYS.

 PROCEDURE

• Create a Component List. Add methane, Ethane, Propane, i-Butane, n-Butane,

i-Pentane, n-Pentane
• Fluid Package: Peng-Robinson.

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1. OIL CHARACTERIZATION

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1. OIL CHARACTERIZATION

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1. OIL CHARACTERIZATION

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1. OIL CHARACTERIZATION

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1. OIL CHARACTERIZATION

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1. OIL CHARACTERIZATION

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1. OIL CHARACTERIZATION

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 1. OIL CHARACTERIZATION

 EXERCISE 1:

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1. OIL CHARACTERIZATION

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1. OIL CHARACTERIZATION

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 1. OIL CHARACTERIZATION

 EXERCISE 2: Heavy Oils Characterization

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1. OIL CHARACTERIZATION

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1. OIL CHARACTERIZATION

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1. OIL CHARACTERIZATION

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1. OIL CHARACTERIZATION

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1. OIL CHARACTERIZATION

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• We want to transport 600000 Kg/h of San Joaquin Crude but in this
example our transportation system will only accept crudes starting from 21
API.

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1. OIL CHARACTERIZATION

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 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.

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 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.

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 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.

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 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.

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 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.

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 2. DISTILLATION

 OUTCOME

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 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.

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 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.

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 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.

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 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.

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 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.

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3. ABSORBER

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 3. ABSORBER

 OUTCOME

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 4. PRE-HEAT TRAIN

 We use the previous module (Oil Characterization)

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 4. PRE-HEAT TRAIN

Mixer, select Equalize All in Parameters tab, and enter mole fraction of 1 and
conditions for Water stream

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 4. PRE-HEAT TRAIN

Add a Heater with Delta P = 0.5bar, then enter Temperature for Outlet stream 65 độ C

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 4. PRE-HEAT TRAIN

The pressure drops for the Tube and Shell sides, in field units, will be 35 kPa (5 psi)
and 5 kPa (0.7 psi), respectively

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 4. PRE-HEAT TRAIN

Go to Specs page, modify, and add a new specs as shown in the pictures.

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 4. PRE-HEAT TRAIN

Add a desalter with a Three-Phase Separator

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 4. PRE-HEAT TRAIN

Add a Heater with Delta P = 375 kPa (54 psi), then enter Temperature for Outlet stream
175 độ C

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4. PRE-HEAT TRAIN

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 4. PRE-HEAT TRAIN

Add the last Heater with Delta P = 2.5 bar, then enter Temperature for Outlet stream
400 độ C

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 4. PRE-HEAT TRAIN

Add a Balance with parameter is Component mole flow, and Temperature of 915 độ C
for Outlet stream

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 4. PRE-HEAT TRAIN

Set the Vapour Fraction to calculate the bubble point temperature

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 4. PRE-HEAT TRAIN

Add an Adjust to optimize the heating-train by specifying the Flowrate of Light Prod in
the Pre-Flash. Result is at about 172°C

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 4. PRE-HEAT TRAIN

Case study: to see the influence of temperature in Light Prod Flowrate

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4. PRE-HEAT TRAIN

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 4. PRE-HEAT TRAIN

EXERCISE 1: Add a Set to maintain the same value for the To desalter stream

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 4. PRE-HEAT TRAIN

EXERCISE 2: Add a adjust to achieve a molar fraction of light products (C1, C2, C3,
i-C4, n-C4, i-C5, n-C5 and Water) in the Bttm Liq of 0.12

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4. PRE-HEAT TRAIN

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 5. FLASH EQUILIBRIUM (ISOTHERMAL)

 OBJECTIVES

• Learn how to remove bulk of hydrogen using a cooler and a vapor liquid separator
• Learn how to use adjust block and spreadsheets
 PROCEDURE

• Create a Component List. Add Hydrogen, Methane, Ethylene, and Ethane to

the component list.
• Fluid Package: Peng-Robinson.

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 5. FLASH EQUILIBRIUM (ISOTHERMAL)

Add a cooler with Delta P = 0

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5. FLASH EQUILIBRIUM (ISOTHERMAL)

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5. FLASH EQUILIBRIUM (ISOTHERMAL)

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 5. FLASH EQUILIBRIUM (ISOTHERMAL)

The liquid stream does not have a flowrate of 0. And then add an adjust block and a
spreadsheet to find the cooler duty required to limit the loss of ethylene to the vapor
stream to less than 1%.

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 5. FLASH EQUILIBRIUM (ISOTHERMAL)

Add a spreadsheet. Enter the text “Fraction Ethylene Lost” in cell A3. In cell B3 enter
the following formula: = (B1-B2)/B1.

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 5. FLASH EQUILIBRIUM (ISOTHERMAL)

Add an adjust to limit the fraction lost to under 0.01. Parameters: Step Size of 1e+005
kcal/h and Maximum Iterations: 100.

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5. FLASH EQUILIBRIUM (ISOTHERMAL)

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5. FLASH EQUILIBRIUM (ISOTHERMAL)

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 5. FLASH EQUILIBRIUM (ADIABATIC)

 OBJECTIVES

• Learn how to specify compressors, heaters, and valves in Aspen HYSYS

• Understand a refrigeration loop
 PROCEDURE

• Create a Component List. Add 1,1,1,2-tetrafluoroethane to the component list.

• Fluid Package: NRTL.

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 5. FLASH EQUILIBRIUM (ADIABATIC)

Start with adding a Compressor, a Cooler, a Heater, and a Valve from Model Pallette.
End enter data for Compressor first, Outlet stream: Pressure of 10 bar

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 5. FLASH EQUILIBRIUM (ADIABATIC)

Cooler with Delta P = 0, Outlet temperature of 30 C

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 5. FLASH EQUILIBRIUM (ADIABATIC)

Valve with Outlet pressure of 1 bar

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 5. FLASH EQUILIBRIUM (ADIABATIC)

Heater with Delta P = 0, Outlet temperature of 25 C

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 5. FLASH EQUILIBRIUM (ADIABATIC)

Then we must now specify the molar flowrate and composition of the refrigerant.

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5. FLASH EQUILIBRIUM (ADIABATIC)

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7. ATMOSPHERIC CRUDE COLUMN

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 7. ATMOSPHERIC CRUDE COLUMN

 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.

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7. ATMOSPHERIC CRUDE COLUMN

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 7. ATMOSPHERIC CRUDE COLUMN

• Add AGO side stripper

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 7. ATMOSPHERIC CRUDE COLUMN

• Add AGO pump around

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 7. ATMOSPHERIC CRUDE COLUMN

• Add Diesel side stripper

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 7. ATMOSPHERIC CRUDE COLUMN

• Add Diesel pumd around

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 7. ATMOSPHERIC CRUDE COLUMN

• Add Kerosene side stripper

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 7. ATMOSPHERIC CRUDE COLUMN

• Add Kerosene pumd around

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7. ATMOSPHERIC CRUDE COLUMN

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 7. ATMOSPHERIC CRUDE COLUMN

EXERCISE 1:

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 7. ATMOSPHERIC CRUDE COLUMN

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7. ATMOSPHERIC CRUDE COLUMN

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7. ATMOSPHERIC CRUDE COLUMN

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 7. ATMOSPHERIC CRUDE COLUMN

EXERCISE 2:

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 7. ATMOSPHERIC CRUDE COLUMN

EXERCISE 3:

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8. REBOILER

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 8. REBOILER

 LESSON OBJECTIVES

• Learn how to calculate heat of vaporization using the heater block in Aspen
HYSYS.
• Understand the impact of heat of vaporization on distillation.

 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.

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 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.

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 8. REBOILER

• E-101

o Enter Worksheet at column Feed-3MH enter the parameters Pressure = 100 kPa,
Vapour Fraction = 0, and Molar Flow = 1 kgmole/h.
o Enter Composition enter parameters Mole Fraction of 3-methylhexane = 1.
o Enter Worksheet at column 3MH-Out enter the parameters Pressure = 100 kPa,
Vapour Fraction = 1.

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 8. REBOILER

• E-102

o Enter Worksheet at column Feed-1,1,2 enter the parameters Pressure = 100 kPa,
Vapour Fraction = 0, and Molar Flow = 1 kgmole/h.
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,
Vapour Fraction = 1.

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 8. REBOILER

 RESULTS

• E-100: Heat flow = 3.990e + 004

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 8. REBOILER

 RESULTS

• E-101: Heat flow = 3.052e + 004

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 8. REBOILER

 RESULTS

• E-102: Heat flow = 3.349e + 004

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 8. BLENDING / MIXING

Main simulation diagram

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 8. BLENDING / MIXING

Create the main component

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 8. BLENDING / MIXING

Select Fluid Pkgs

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 8. BLENDING / MIXING
After creating the lines. We proceed to add MIXER.

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 8. BLENDING / MIXING

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

Pressure = 1 bar.

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 8. BLENDING / MIXING

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

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 8. BLENDING / MIXING
In the Conditions in the Gasoline column enter Temperature = 25°C, Pressure =
1 bar , Mass Flow = 82.76 kg/h in the Gasoline column

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 8. BLENDING / MIXING
In the Composition in the Gasoline column enter the parameter 224-Mpentane
= 1 in the Gasoline column

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 8. BLENDING / MIXING

We have the data below.

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 8. BLENDING / MIXING

Create Spreadsheet

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 8. BLENDING / MIXING
We have the data below.

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 8. BLENDING / MIXING
Enter the spreadsheet according to the instructions, enter A1 and A2

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 8. BLENDING / MIXING
Import variables into B1

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 8. BLENDING / MIXING
Enter the calculation formula B2 = (B1*0.17243)/(1-0.17243).

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 8. BLENDING / MIXING

Output the formula result in the following

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 10. CSTR

 LESSON OBJECTIVES

• 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

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 10. CSTR

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

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 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

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 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.

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 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.

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 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.

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 11. PFR

 LESSON OBJECTIVES

• 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

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 11. PFR

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

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 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

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 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.

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 11. PFR

• Result received is shown in the pictures.

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 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.

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 12.INTEGRATION WITH RECYCLE

 LESSON OBJECTIVES

• Simulate CSTR reactors

• Simulate an Ethylene glycol plant

• Use the recycle operation in HYSYS

• Choose suitable locations for recycles

 PROCEEDING TO SIMULATE THE PROCESS

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 12.INTEGRATION WITH RECYCLE

• 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.

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 12.INTEGRATION WITH RECYCLE

• Step 3: Go to the Reactions and Add Reaction with the following data.

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 12.INTEGRATION WITH RECYCLE

• 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.

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 12.INTEGRATION WITH RECYCLE

• Step 6: Start simulating with 2 streams from Model Pallette. Then enter data
with the following information:

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 12.INTEGRATION WITH RECYCLE

• Step 7: Then add a CSTR Reactor and enter the following information.

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12.INTEGRATION WITH RECYCLE

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12.INTEGRATION WITH RECYCLE

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 12.INTEGRATION WITH RECYCLE

• Step 8: After entering enough information the Reactor converges and the result
we get is shown in the picture.

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 12.INTEGRATION WITH RECYCLE

• Step 9: Add a Distillation Column and enter data as shown in the pictures.

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 12.INTEGRATION WITH RECYCLE

• 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.

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 12.INTEGRATION WITH RECYCLE

• 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.

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 12.INTEGRATION WITH RECYCLE

• 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.

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 12.INTEGRATION WITH RECYCLE

• Step 13: Reconnect the Water to Reactor stream to the Reactor and the process
converges.
• Step 14: Result received is shown below.

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 12.INTEGRATION WITH RECYCLE

 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)

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