CAPE 2050 Intro To HYSYS Session 1

CAPE 2050: Aspen HYSYS
CAPE 2050: ASPEN HYSYS:

Process Modeling and Simulation
Dr. Keeran Ward

School of Chemical and Process Engineering
University of Leeds
1
K.R.Ward@leeds.ac.uk
Lecture Objectives
At the end of this lecture, you will be able to:

 Understand the concept of process simulation
 Identify the characteristics and advantages of process simulation
 Appreciate computer-aided flowsheeting
 Understand the structure and function of Aspen HYSYS
2
Schedule
 Week 1- Introduction to HYSYS and Flowsheeting Basics/ Example Simulation
 Week 2- Tutorial 1- Modeling a Refrigeration plant
 Week 3- Reactors and Recycle Systems / Example Simulation
 Week 4- Tutorial 2- Modeling the HDA Process.
 Week 5- Revision Week- Tackling Process Simulation Examples.
 Week 9- Assessment
3
Practice Material
Reading Material:
ASPEN HYSYS
• http://home.aspentech.com/products/engineering/aspen-hysys
4
Characteristics of Process Simulation

Uses a computer program to model key equations of an
operating process
 Uses mass and energy balances and equilibrium relationships
5
Characteristics of Process Simulation

Process simulation software can predict:
• Stream flows, compositions and physical

properties
• Operating conditions for unit operations
• Preliminary sizing for equipment
• Concerns/issues regarding operation
6
Advantages of Process Simulation

Process simulation software can predict:
Process design and development

 Reduction in time for process design
 Improve existing processes
 Optimize plant performance
 Assists in plant operation
7
Simulation in Process Engineering

Main simulation activity in process engineering is FLOWSHEETING
FLOWSHEETING:
Uses computer-aids to perform energy and mass balancing, sizing
and costing of a process
8
Types of Flowsheets
 Block and Line
 Process Flowsheet
 Piping and Instrumentation Diagram
 Combined Process and Piping Flowsheet
 Utility Flowsheet
9
Types of Flowsheets
10
Basic Approaches to Flowsheeting

Sequential-Modular
Based on unit calculations
Some Commercial Uses: HYSYS, Aspen Plus, PROII, ChemCAD
Equation Oriented
Based on solving a system of simultaneous non-algebraic equations
Some Commercial Uses: gPROMS, Aspen Plus in EO, Aspen Custom
Modeler
Simultaneous-Modular
Combination of both Sequential-Modular and Equation Oriented
11
Sequential-Modular Approach
Basic element is the unit operation
 Computation takes place unit-by-unit following a calculation
sequence
 Sequence contains unit operations and convergence blocks
 Mostly used in steady-state flowsheeting software
 Simulation model contains non-algebraic equations describing
conservation of mass and energy
12
The condensed form for a modular simulator is:
𝑓(𝑥,𝑢,𝑑,𝑝)=0 and y=g(𝑥)
where:
𝑥 – internal state
𝑢– input variables
𝑑 – geometry
𝑝 – physical properties
𝑦 – output variables
13
Parameters and Specifications Geometry
Inlet Streams Outlet Streams

Duty UNIT OPERATION
Duty
MODEL
Work Work
Internal
Routines Sizing
14
Thermodynamic
methods
15
Aspen HYSYS
Background Information on Aspen HYSYS

 Developed by HYPROTECH, now owned by ASPEN TECH
 Process simulation software (computer-aided tools)
 Can perform steady-state and dynamic simulations
 Uses the sequential-modular approach
 Each block in the flowsheet computes an output stream from
feed streams and input parameters
 Blocks must be solved in sequence starting with the feed
Learning Objectives
In Aspen HYSYS:
o Specify components
o Select a Fluid Package
o Add reaction sets
o Add material streams
o Select units of measure
o Add unit operations
Ribbon
Activated
Analysis
Environment
Selection
Process Flowsheet
Aspen HYSYS Interface – Properties

Environment
Components List
 HYSYS has a databank of components
 Can select pure components or hypothetical components
 Components can be filtered by type
 Component search can be done by:
• Component name
• Alternate name
• Formula
Components List
Fluid Package
Selection of Fluid Package:

• Components
• Type of system
Fluid Package Selection (1)

Type of System Recommended Property Method
Midstream Oil and Gas/ Peng-Robinson (PR) or any cubic equation of state
Hydrocarbon Processing (EOS)
Downstream Hydrocarbon Refining Atm: Chao-Seader, PR, Soave-Redlich-Kwong
Vac: Braun K10, Antoine, Esso Tabular
With H2: PR, Zudkevitch-Joffee, Grayson-Streed
TEG Dehydration PR, Glycol Package
Sour Water Sour PR, Sour SRK
Cryogenic/Air Separation PR, PRSV, TST
Atmospheric Towers PR, GS, TST
Vacuum Towers PR, GS, TST, Braun K10, Esso Tabular
Ethylene Towers Lee-Kesler-Plocker
Fluid Package Selection (2)

Type of System Recommended Property Method
High H2 Systems PR, ZJ, GS, TST
Steam Systems NBS Steam, ASME Steam, CS, GS
Chemical Systems Activity Models (NRTL, UNIQUAC,…), PRSV
Compression/ Light Gases MBWR
Amine Systems Acid Gas, DBR Amine Package, Elec-NRTL
Electrolyte Systems Elec-NRTL
What if you’re unsure?

• Use Methods Assistant!
Adding Reactions
Aspen HYSYS Interface – Simulation

Environment
Adding Material Streams
Energy Stream
Material Stream
Tips:
• Palette – F4
• Add material stream – F11
Defining the Material Stream

Aspen HYSYS needs:
• Composition
• Two properties
• Flow rate
Note: One spec must be

temperature or pressure!
2nd Note: The arrow turns dark blue when

stream is fully defined
Data Fields – Colour Coding
Bold blue: Values you have specified
Black: Values calculated/ non-editable

Units of Measure
Default Units:
• SI
• EuroSI
• Field
How to create your own unit set?

• Select Unit Sets button
• Choose preferred units
• You can name your set (opt)
Unit operations in Aspen HYSYS

Options for adding unit operations:
o Double-click or click and drag operation from palette to
flowsheet
o Click Additional Flowsheet Commands and Add Operation
o Hit F12
Tips for using Aspen HYSYS

 Build flowsheets by blocks
 Ensure inputs are reasonable
 Check that results are realistic
 Save work frequently
Questions?
Example 1- Getting Started

Problem Statement: A 100 kmol/h gas stream of inerts and methanol
vapour at 95oC and 5 bar is contacted with water in a separator in an
effort to reduce the methanol molar concentration from 28.5% to
approximately 0.1%. The liquid stream from the separator is cooled to
30oC and split to a 99.9% molar methanol product and a water recycle
using a splitter unit operation. Model the process using Aspen HYSYS
and i) estimate the water molar flowrate to ensure the desired gas
purity specification and ii) the methanol product flowrate.

Step 1: Set up the Components for the process flowsheet. The model
comprises of CO, CH4, CO2, H2, H2O, CH3OH.

Step 2: Set up the property package. Use the Peng-Robinson equation of
state.

Step 3: Move to the Simulation Environment and Add your Gas and
Water Streams. Specifications as follows:
Stream Specification Stream Specification
Gas Composition mol % Water Composition mol %
CO 1.0 H2O 100.0
CO2 8.0 Temperature 25oC
H2O 2.0 Pressure 5 bar
CH4 0.5 Molar Flowrate 100 kmol/h
Methanol 28.5
H2 60.0
Temperature 95oC
Pressure 5 bar
Molar Flowrate 100 kmol/h

Step 3: Move to the Simulation Environment and Add your Gas and
Water Streams. Specifications as follows:

Step 4: Add the Separator Unit Operation from the model Palette.

• Step 5: Add the Cooler Unit Operation from the model Palette.
Set the pressure drop at 10kPa and the outlet temperature to
30oC

• Step 6: Add the Component splitter Operation from the model
Palette. Set the temperature at 45oC and 5 bar for both outlet
streams as well as the split fractions.

• Step 7: Add a block operation-Adjust function, to trial and
error the water flow rate until the methanol composition of the
Lights stream is 0.1%.

• Step 8: Read off the water flowrate required after running the
Adjust function. Read off the molar flowrate of the Methanol
product stream from the Splitter X-100. The completed process
flowsheet is given below.

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CAPE 2050: Aspen HYSYS

CAPE 2050: ASPEN HYSYS:

Dr. Keeran Ward

At the end of this lecture, you will be able to:

Characteristics of Process Simulation

 Uses mass and energy balances and equilibrium relationships

Characteristics of Process Simulation

• Stream flows, compositions and physical

Advantages of Process Simulation

Process design and development

Simulation in Process Engineering

Basic Approaches to Flowsheeting

Inlet Streams Outlet Streams

Background Information on Aspen HYSYS

Aspen HYSYS Interface – Properties

Selection of Fluid Package:

Fluid Package Selection (1)

Fluid Package Selection (2)

What if you’re unsure?

Aspen HYSYS Interface – Simulation

Adding Material Streams

Defining the Material Stream

Note: One spec must be

2nd Note: The arrow turns dark blue when

Data Fields – Colour Coding

Bold blue: Values you have specified

Black: Values calculated/ non-editable

How to create your own unit set?

Unit operations in Aspen HYSYS

Tips for using Aspen HYSYS

Example 1- Getting Started

Example 1- Getting Started

Example 1- Getting Started

Example 1- Getting Started

Example 1- Getting Started

Example 1- Getting Started

Example 1- Getting Started

Example 1- Getting Started

Example 1- Getting Started

Example 1- Getting Started

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