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Integrated Costing with Aspen HYSYS - PDF
Integrated Costing with Aspen HYSYS - PDF
Integrated Costing with Aspen HYSYS - PDF
Integrated Costing with Aspen HYSYS - PDF
Integrated Costing with Aspen HYSYS - PDF
Integrated Costing with Aspen HYSYS - PDF
Integrated Costing with Aspen HYSYS - PDF
Integrated Costing with Aspen HYSYS - PDF
Integrated Costing with Aspen HYSYS - PDF
Integrated Costing with Aspen HYSYS - PDF
Integrated Costing with Aspen HYSYS - PDF
Integrated Costing with Aspen HYSYS - PDF
Integrated Costing with Aspen HYSYS - PDF
Integrated Costing with Aspen HYSYS - PDF
Integrated Costing with Aspen HYSYS - PDF
Integrated Costing with Aspen HYSYS - PDF
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Integrated Costing with Aspen HYSYS - PDF

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The new integrated economics workflow provided by AspenTech enables process modelers to incorporate rigorous relative costs in their process modeling studies. This provides the business benefit of …

The new integrated economics workflow provided by AspenTech enables process modelers to incorporate rigorous relative costs in their process modeling studies. This provides the business benefit of better process designs that take into account capital and operating costs together with technical and process parameters.
Integrated economics brings the power of AspenTech’s rigorous economic modeling products (the ICARUS family) to the process model (Aspen Plus or Aspen HYSYS®). This enables the process designer to rapidly assess the relative costs of a proposed process design, thereby providing the means to screen alternatives based on a balance of technical, safety, environmental, and economic factors.

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  • 1. Getting Started with Relative Economicsin Aspen HYSYS ®A Brief Tutorial (and supplement to training and online documentation)By Dan McCarthy, Product Manager; Ron Beck, Marketing Manager;and Glenn Dissinger, Product Director, Aspen Technology, Inc© 2011 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, and the 7 Best Practices of Engineering Excellence are trademarks of Aspen Technology, Inc. All rights reserved.All other trademarks are property of their respective owners. 11-267-0211
  • 2. About AspenTechAspenTech is a leading supplier of software that optimizes process manufacturing—for energy, chemicals,pharmaceuticals, engineering and construction, and other industries that manufacture and produceproducts from a chemical process. With integrated aspenONE® solutions, process manufacturers canimplement best practices for optimizing their engineering, manufacturing, and supply chain operations.As a result, AspenTech customers are better able to increase capacity, improve margins, reduce costs,and become more energy efficient. To see how the world’s leading process manufacturers rely onAspenTech to achieve their operational excellence goals, visit www.aspentech.com.
  • 3. Getting Started with Relative Economics in Aspen HYSYS1. IntroductionThe new integrated economics workflow provided by AspenTech enables process modelers to incorporate rigorousrelative costs in their process modeling studies. This provides the business benefit of better process designs that take intoaccount capital and operating costs together with technical and process parameters.Integrated economics brings the power of AspenTech’s rigorous economic modeling products (the ICARUS family) to theprocess model (Aspen HYSYS or Aspen Plus). This enables the process designer to rapidly assess the relative costs of aproposed process design, thereby providing the means to screen alternatives based on a balance of technical, safety,environmental and economic factors.This document serves as a simple “getting started” guide, taking you through the most common progression of how wewould envision the process designer to use this integrated functionality. This guide is not meant to be used on a stand-alone basis. We would recommend that a range of other resources be called upon to give the new user a comprehensiveview of how to use this capability. This may include:• Online documentation – which can be accessed through the Aspen HYSYS and Aspen Process Economic Analyzer software user screens.• AspenTech support website (support.aspentech.com), which contains a wide range of knowledge base items, provides answers to frequently asked questions.• AspenTech courseware available in in-person and on-line versions, which provide formal training on process modeling and economic evaluation.• AspenTech business consultants.• Pre-recorded tutorials and webinars that provide another view of the information contained in this document (go to http://www.aspentech.com/solutions/industry_solutions/epc/integrated-economics.aspx for many of these resources).This document covers Aspen HYSYS. This guide assumes that the user has Aspen HYSYS V7.2 and Aspen ProcessEconomic Analyzer® V7.3 installed.A companion document to this one, providing similar information for users of Aspen Plus, is also available.(http://www.aspentech.com/uploadedFiles/Forms/Events/NALA/int_econ_tutorial.pdf)2. The Work FlowThe integrated economics solution is flexible in terms of the work flows that it supports. The work flow that we follow inthis guide is as follows:STEP ONE: incorporate operating costs in the Aspen HYSYS model.STEP TWO: converge the modelSTEP THREE: activate relative costingSTEP FOUR: select cost basis© 2011 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, and the 7 Best Practices of Engineering Excellence are trademarks of Aspen Technology, Inc. All rights reserved.All other trademarks are property of their respective owners. 11-267-0211 1
  • 4. Getting Started with Relative Economics in Aspen HYSYSSTEP FIVE: map unit operation models to equipmentSTEP SIX: sizing equipmentSTEP SEVEN: evaluate economics and reportThis entire workflow can be performed from WITHIN the familiar Aspen HYSYS user interface.3. Definition of Operating Cost Parameters within Aspen HYSYSThe current release of Aspen HYSYS (V7 and newer) provides the means to define utility (energy), feed and productstreams and costs.Feedstock and product stream pricing parameters are only needed if an ROI for the plant is desired. For estimating andcomparing capital and operating costs, the process stream costs are not required.Utility cost definition is RECOMMENDED but not a required step. If utility costs are not defined as described below, theeconomics ‘engine’ will assign the utilities and associated prices for each energy stream using built-in values, which is notas accurate as specifying them if known, but is pretty good at the conceptual design level. Each energy stream in theHYSYS model should be associated with a process utility. The costs of the process utilities should be specified in the utilitymanager or HYSYS worksheet. (see Figure 1 for an example of assigning a utility). Figure 1. Assigning a utility to an Aspen HYSYS energy stream© 2011 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, and the 7 Best Practices of Engineering Excellence are trademarks of Aspen Technology, Inc. All rights reserved.All other trademarks are property of their respective owners. 11-267-0211 2
  • 5. Getting Started with Relative Economics in Aspen HYSYSTo enter an individual stream’s cost factors, left-clickon any screen and scroll down the resultingnavigation pane to “cost parameters”. At that point,you may enter data for the price and flow basis ofthat stream (see Figure 2).In many cases, it is more efficient to enter the costparameters for a group of streams at once. Thestream and utility costs can be conveniently entered,reviewed and modified using the workbook withinAspen HYSYS. To do that, the needed parametersneed to be set up in the workshop view (this takesonly a few seconds.) With the workbook open (this isa necessary first step to see the pull-down menu)access the workbook setup (see Figure 3).Next enter the needed cost parameters for the feed,product and utility streams (see Figure 4). Figure 2: Assigning costs to an Aspen HYSYS stream Figure 3: Aspen HYSYS Workbook setupFigure Four: Add cost parameters to the stream workbook views© 2011 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, and the 7 Best Practices of Engineering Excellence are trademarks of Aspen Technology, Inc. All rights reserved.All other trademarks are property of their respective owners. 11-267-0211 3
  • 6. Getting Started with Relative Economics in Aspen HYSYSNow, the workbook can be used to review and enter/edit cost factors quickly for all the feed, product and utility streams.(see Figure 5).In most cases, a design case will involve multiple utility sources and multiple unit operations. The workbook (see Figure 5)is a convenient way to quickly review the streams and utilities selected and to review and modify utility selections andcost parameters. Figure 5: Feed and Product Stream Cost Factor Assignment using Workbook View Important Note: Once you have specified utility selections and costs and feed and product pricing within Aspen HYSYS, the resulting operating cost information produced by the Aspen HYSYS model run automatically updates the economics module in the subsequent steps in the integrated workflow.© 2011 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, and the 7 Best Practices of Engineering Excellence are trademarks of Aspen Technology, Inc. All rights reserved.All other trademarks are property of their respective owners. 11-267-0211 4
  • 7. Getting Started with Relative Economics in Aspen HYSYS4. The Costing Toolbar and Costing MenuIntegrated economics is accessed two ways in AspenHYSYS. First, there is a “costing toolbar” which isused to perform integrated cost evaluation (seeFigure 6). The same functionality may also be Figure 6: Costing Toolbar in Aspen HYSYSaccessed from the costing pull-down menu whichappears as a sub pulldown in the tools menu (seeFigure 7).Each step in the integrated economic evaluation isinitiated through the toolbar or the menu. First youactivate the costing engine, next you map unitoperations to equipment and perform sizing, finallyyou perform the evaluation and review the results.The results can be easily exported to MS Excel™ orreviewed within Aspen HYSYS.Depending on the level of control that the processengineer would like to maintain over the economicevaluation, steps can be individually performed orcan be skipped in favor of a “quick” and “automatic”evaluation based on default-assigned mappings andsizing algorithms.Figure 8 enumerates the work flow actions that each Figure 7: Pull-down Economics Sub-menu in Aspen HYSYSbutton in the toolbar governs. These will each beexplained during the course of this tutorial.5. Best Practice: Use a Converged Aspen HYSYS ModelThe Aspen HYSYS solver is always working in thebackground to attempt to solve the flow sheet as it isbeing constructed. Consequently, whatever processinformation exists when the economics is activatedand mapped will be used in analyzing relativeeconomics. It is a best-practice to work within HYSYSto always complete modeling to convergence prior toproceeding to the integrated economics step of theworkflow. You will NOT get any reminder to solve to aconverged model first before initiating the economicsworkflow. This is because there are some validengineering reasons why you may wish to define the Figure 8: Costing Toolbar actions in Aspen HYSYSrelative economics without having a converged model.© 2011 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, and the 7 Best Practices of Engineering Excellence are trademarks of Aspen Technology, Inc. All rights reserved.All other trademarks are property of their respective owners. 11-267-0211 5
  • 8. Getting Started with Relative Economics in Aspen HYSYS6. Activate Costing ModuleIntegrated economics functions by linking AspenHYSYS with Aspen Process Economic Analyzer. TheAPEA license key is checked out when you activatethe integrated economics feature. The APEA license Figure 9: Costing Activation Buttonkey is released when you de-activate integratedeconomics or exit Aspen HYSYS (see Figure 9). Note: The activation enables the other buttons/functions within economics (load simulation data, map, size, evaluate, equipment summary, deactivate7. Select a Standard Basis FileThe economics module functions through use ofwhat estimators call “standard basis” files. Theseprovide company-standardized, project-standardizedor default cost basis information on which the entirecosting is built. For example, “Gulf Coast Standard” isthe most commonly used generic process plant“standard basis” for developing estimates.Several standard basis files are available “out of thebox” with Aspen Process Economic Analyzer. Youshould establish within your process design group Figure 10: Project Description and Units of Measure Choice Boxwhich basis file(s) will be used for relative costingpurposes.If your estimating group has established company-specific bases, they can make these available to yourgroup as pull-down options within the integratedeconomics work flow.The first basis choice to make is the preferred unitsof measure. Select imperial or metric (see Figure 10).Add a Project Description as desired, then click OK.Next, select the cost basis to use from the pull down Figure 11: Select Standard Basis Filechoices (see Figure 11), then click OK.After making those selections, acosting file will be created (seeFigure 12) Figure 12: Create Costing Scenario File© 2011 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, and the 7 Best Practices of Engineering Excellence are trademarks of Aspen Technology, Inc. All rights reserved.All other trademarks are property of their respective owners. 11-267-0211 6
  • 9. Getting Started with Relative Economics in Aspen HYSYS8. Load Simulation DataThe simulation run data must be loaded from Aspen HYSYS into the costing engine.When you click on the “load simulation data” button this task will happen in the background. This transfers keyprocess information needed for the economics software to define the process flow schema and perform mapping andsizing operations.9. Economic Evaluation Status IndicatorsWhen the simulation data loading task, and otheraspects of the economics work flow, are beingperformed, status messages are presented in thestatus window in the lower left corner of the AspenHYSYS screen. During the workflow, you may beprompted to wait for the background modelcalculations to complete before proceeding (seeFigure 13 for a few examples of these messages). Figure 13: Workflow Status Indicator10. Map Unit Operations to Equipment ModelsA key step in integrated economics is mapping of unit operations models from the simulation to equipment models inAspen Process Economic Analyzer.The economic work flow is flexible and has both the ability to automatically establish “default” mappings, representingbest-engineering judgment contained within the software models, as well as the capability to over-ride these mappingsand substitute your own mappings, based on your engineering decisions as to which equipment models you select at thisstage of the design process.Figure 14 summarizes conceptually the operation which is performed during this mapping workflow. Each unit operationthat has been defined during the process modeling is mapped to an item of equipment, or a group of equipment items,that most feasibly represent that unitoperation. The sample depicted in theexample figure is a distillation column unitoperation in Aspen HYSYS), which mapsinto the economics software as acollection of equipment models, includinga packed column, condenser, exchangerpumps, a reboiler and othercomplementary equipment items. Figure 14: Unit Operation to Equipment Model Mapping Scenario© 2011 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, and the 7 Best Practices of Engineering Excellence are trademarks of Aspen Technology, Inc. All rights reserved.All other trademarks are property of their respective owners. 11-267-0211 7
  • 10. Getting Started with Relative Economics in Aspen HYSYSIn each case, there is a default mapping, but there are also other mappings that the engineer can select instead.Mapping workflow is invoked by the mapping button.This brings up a map dialog box (figure 15).Here are a few key points to remember when executing the mapping workflow: Figure 15: Using Default or else already used Mappings(1) Select “map all items,” the first time you use relative economic evaluation. The ‘Map selected items’ option is for changing/updating mappings when you have changed part of an established process design.(2) When you are first using economics for a model run you should always select “Default AND simulator data”. If you don’t select this option, the sizing performed in the simulation will not be carried across to the economics software!(3) If you change the operating conditions in a model or add equipment to a model, use the “Last Mapping” option The economic evaluation case remembers the mappings already established for a given simulation model. If you have made some custom mapping selections during a previous simulation run, and have modified some process parameters, your prior selections will persist in the software, and you can choose “last mapping” to re-use those already selected mappings (see Figure Fifteen, right hand side display).(4) If you delete unit operation models from your HYSYS case, you may need to remove mapped equipment items. Use the “Physical Component Mapping Preview” form to delete any unwanted equipment.(5) Even if you are planning to change some mappings, select, “default and simulator data.” Then a second dialog box will come up (see Figure 16) which will allow you to change mappings.(5) Click on size Icarus project components, to activate the economics sizing algorithms.© 2011 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, and the 7 Best Practices of Engineering Excellence are trademarks of Aspen Technology, Inc. All rights reserved.All other trademarks are property of their respective owners. 11-267-0211 8
  • 11. Getting Started with Relative Economics in Aspen HYSYS(6) Click OK.(7) The project components map preview dialog box will appear (see Figure 16).(8) To change mappings (away from the default mapping assigned by the system) follow the following steps: • All items which have been mapped appear in the simulator item window with an asterisk in front of their designation. • Select the item in the simulator item window (see Figure 17). Figure 16: Selecting Your Own Mappings • Delete the current mapping (select “delete one mapping” button) • Click on “new mapping” button. • Icarus Project Component selection dialog box will come up (see Figure 18). • Navigate the tree of available equipment models/components. • Select a component (s). • A mapping, of course, can be to more than one component (i.e. to a column and pumps and so forth). • Click OK to complete the mapping of each component. Figure 17: Project Component Map Preview Dialog Box • Repeat for each item mapped to a given unit operation. Figure 18: Icarus Project Component Selection Dialog Box© 2011 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, and the 7 Best Practices of Engineering Excellence are trademarks of Aspen Technology, Inc. All rights reserved.All other trademarks are property of their respective owners. 11-267-0211 9
  • 12. Getting Started with Relative Economics in Aspen HYSYS11. Sizing ActivityClicking on the sizing button initiates the sizing evaluation. The system performs the sizing with best availableinformation.Equipment sizes are determined from the simulation data if they are available. Missing data are estimated by the system.You can also override estimate sizes in the equipment grid.To access the equipment sizing grid click on the equipment grid button:You can review the sizing and materials of construction that were assigned during the economic evaluation in thesummary grid. The default material of construction for all equipment is Carbon Steel.For example, in Figure 19, we can see thematerials of construction and geometryfor a heat exchanger. We can use pulldown menus to select other materials ofconstruction. The tube materials selectionpull-down menu is open in this example.If you have better engineering informationor assumptions available, or havecompany-specific sizing algorithms toapply, these can be entered at this point.The equipment grid has one tab sheet foreach type of equipment. The columnsrepresent individual equipment items.The rows contain the key variables forthat equipment. After changing the datayou should re-size and re-evaluate thecosting. It is important to re-size theequipment first because equipment sizesmay depend on the physical properties ofthe materials of construction. For example,the area of an exchanger depends on the Figure 19: Equipment Summary Grid enables process designer to review and change sizing and materials of constructionthermal conductivity of the tubing. Re-sizingthe equipment ensures that the estimatedcosts are based on the changes in equipment size. Note: At this juncture, you may also interface to custom sizing programs that your company may be using that have been developed in MS Excel or equivalent. Covering that topic is an advanced topic beyond the scope of this introductory tutorial.© 2011 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, and the 7 Best Practices of Engineering Excellence are trademarks of Aspen Technology, Inc. All rights reserved.All other trademarks are property of their respective owners. 11-267-0211 10
  • 13. Getting Started with Relative Economics in Aspen HYSYS12. Materials of ConstructionCapital costs are very sensitive to the materials of construction selected. Process engineers often have a good idea of thematerial of construction that may be required due to the chemistry of a particular process that is being selected. Theprocess modeler can make that change at this point if he has that information (see Figure 20). Figure 20: Changing Material of Construction from Carbon Steel to Inconel Note: After you change sizing or materials of construction data, re-run the sizing and evaluation steps to update the economic results.13. Relative Cost EvaluationClick on the evaluate button for the economic evaluation tobe calculated.14. ReportingThe results of the economic evaluation can be reviewed andmanipulated in several ways.Summary and detailed economics can be reviewed by clicking onthe equipment grid button.This will give you access to a majority of the economic informationthat you will need to rapidly review the economic feasibility of amodeling scenario and to compare process alternatives.The report summary tab displays net results as displayed asshown in Figure 21. Figure 21: Summary report© 2011 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, and the 7 Best Practices of Engineering Excellence are trademarks of Aspen Technology, Inc. All rights reserved.All other trademarks are property of their respective owners. 11-267-0211 11
  • 14. Getting Started with Relative Economics in Aspen HYSYSFurther details of the equipment costs can be reviewed in the equipment summary table (see Figure 22). The individualtables by equipment type contain information about the design of each item of equipment. The equipment summariesare presented in a grid form. The Equipment Grid can be copied-and-pasted into external MS Excel ™ spreadsheets forfurther manipulation. Figure 22: Equipment summary displays “bare” equipment costs and indicates errors identified during the evaluation.For a more formal relative economics report, you may then click on the report button.This button creates a relative costing report in MS Excel ™ format (see Figure 23). This is a complete project economicsreport. If, for example, you have put in feedstock pricing at the initial stages, you can get an initial look at a project ROIwithin this report. The MS Excel ™ reports make it very easy to compare relative costs as the process design evolves.To understand the information available in this report, run through a scenario, produce a costing report, and explore thecontents of the report. Figure 23: Relative economics report for your process scenario© 2011 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, and the 7 Best Practices of Engineering Excellence are trademarks of Aspen Technology, Inc. All rights reserved.All other trademarks are property of their respective owners. 11-267-0211 12
  • 15. Getting Started with Relative Economics in Aspen HYSYS15. Managing and Transferring Cost FilesThe costing scenario created by Integrated Economics can be opened directly by Aspen Process Economic Analyzer or byAspen Capital Cost Estimator for further development.When you run the relative economics, Aspen HYSYS stores the associated economics files in a new working folder, whichyou will find as a sub-folder within your current HYSYS working folder. The resulting APEA files can be handed over to theestimating department and can be directly opened in the APEA and ACCE estimating software products from AspenTech,for further development or fine tuning of the cost estimate that has been preliminarily produced during this conceptualdesign workflow.16. Completion of Your Integrated Economics SessionAt the completion of your integrated economics session, you can deactivate and “release” the APEA economics softwarelicense by clicking the “depressed” activation button to deactivate it.17. Further ResourcesFor further information on this workflow, or any of the individual products or elements covered briefly in this writtentutorial please consult:Public website:The following web page provides links to a number of useful resources on integrated economics -http://www.aspentech.com/solutions/industry_solutions/epc/integrated-economics.aspxSupport website:The support website provides an extensive and growing knowledge base on simulation, economics and the integrated website.The following knowledge base article provides a getting-started location:http://support.aspentech.com/webteamasp/KB.asp?ID=130806Recorded tutorials are available at:“Brief Tutorial on relative costing during conceptual design with Aspen HYSYS”“Brief Tutorial on relative costing during conceptual design with Aspen Plus“Technical webinars on integrated economics can be viewed “on-demand” at“DSM Presents how to achieve better process designs with integrated economics”“Step-by-step Technical Webinar: Getting started with Integrated Economics with Aspen Plus”“Step-by-step Technical Webinar: Getting started with Integrated Economics with HYSYS”Or email us at AspenEconomicEvaluation@aspentech.com to get your specific questions answered.© 2011 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, and the 7 Best Practices of Engineering Excellence are trademarks of Aspen Technology, Inc. All rights reserved.All other trademarks are property of their respective owners. 11-267-0211 13
  • 16. Worldwide Headquarters Aspen Technology, Inc. 200 Wheeler Road Burlington, MA 01803 United States phone: +1–781–221–6400 fax: +1–781–221–6410 info@aspentech.com Regional Headquarters Houston, TX | USA phone: +1–281–584–1000 São Paulo | Brazil phone: +55–11–3443–6261 Reading | United Kingdom phone: +44–(0)–1189–226400 Singapore | Republic of Singapore phone: +65–6395–3900 Manama | Bahrain phone: +973–17–50–3000© 2011 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, and the 7 Best Practices of Engineering Excellence are For a complete list of offices, please visittrademarks of Aspen Technology, Inc. All rights reserved. All other trademarks are property of their respective owners. 11-267-0211 www.aspentech.com/locations

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