Aspen Plus - Basic Course (Student)

Chemical Engineering Guy
www.ChemicalEngineeringGuy.com

Change:
All T of Reactors
Feed Composition
No. of Plates in Distl. Col
T of Heat Ex
Gas Sep. T
Compressor P

 Makes us easier/faster work
 Multiple and Simultaneous Simulations
 Different Real-Life Scenarios
 Change on raw/feed materials scenario
 Pricing and Costs calculation
 Raw Materials
 Plant Cost
 Utilities
 How it would behave under different conditions
 High/Low Pressure
 Humidity Changes
 Temperature change (cool/warm days/seasons)

 Mainly:
 Petrochemical
 Pharmaceutical
 Fine chemicals
 Other commodities such as:
 Sulfuric acids
 Chlorine/Caustic industry
 Solvents
 Coatings
 Many more…

 Excelent for your curriculum as an engineer
 Perfect for analytical/numerical minds
 Good for debuging and fixing

1. Course Objectives
2. Introduction to Aspen Plus
3. User Interface & Getting Help
4. Physical Properties
5. Introduction to Flowsheet
6. Unit Operation Models
7. Reporting Results
8. Case Studies I, II and III
9. Case Study IV
10. Conclusion

 Basic Modeling of Substances & Processes
 General Flowsheet Concepts
 Basic Requirements to set up a Simulation
 Setting the adequate Physical Properties
 Flowsheet “manipulation”
 Major and Common Unit Operations
 Workshop Practice
 Reporting Results (Tables)
 Technical Stuff (extensions, versions, exporting, saving, etc...)

 Course Approach
 Theory
 Practice
 More Practice
 Analysis
 Course Structure (Intensive)
 1st Day
 2nd Day
 Course Structure (Recommended)
 1st
 2nd
 3rd
 4th
 5th
 6th

 About Aspen Plus ®
 Why Aspen Plus ®
 Benefits of simulations
 Aspen Plus® vs. HYSYS®

From the website:
“Aspen Plus is the market-leading chemical process optimization software
used by the bulk, fine, specialty, & biochemical industries, as well as the
polymers industry for the design, operation, and optimization of safe, profitable
manufacturing facilities.”
http://www.aspentech.com/products/engineering/aspen-plus/

 My version V8.2 and V8.8 (May 2013-2015)
 Most recent version V8.8 (May 2015)
 https://www.aspentech.com/products/Aspen-Plus/V88/
 Main differences:
 Solid Modeling
 Activated Heat Exchanger Sizing and Rating*
 Relief Sizing in the Safety Environment
 Search and Share Models with aspenONE Drive
 Access Aspen Process Manuals with aspenONE® Exchange

 Solid Modeling
 Solids Modeling for Polymers
 Particle Size Definition in Reactor Models
 Contact Dryer Model
 Conceptual Solids Models
 Fluidized Bed Reactor Model
 Spray Dryer Model
NOT included in the BASIC course!

 Aspen Plus
 Chemical Industry (H2SO4, Polymers, Coatings, etc.)
 Fine Chemistry (chemical reactions)
 Non-ideal models (azeotropes, L-V equilibriums, etc.)
 Electrolytes
 Equation Oriented Mode
 Aspen HYSYS
 Mainly Petrochemical (upstream/downstream)
 Hydrocarbon Oriented (Oil Industry)
 Assays (Mixture of petrochemicals, i.e. petroleum)
 Refinery Reactors (Catalytic reformer, FCC)

 Graphic User Interphase (GUI)
 New File, Existing simulations, Exporting, etc…
 Extension
 Getting Help

 These exercises will be mentioned as we do Workshops, Practice Scenarios
and Cases
 It is pretty straight forward really…
 When opening a New Project  Choose a Template and you’re done
 When saving; use “Save as… Aspen Plus Document”
 Exporting Files are not included in this Basic Course

 Start Page
 New, Open, Recent Files
 News
 Get Started
 Button (Ribbons) bar

 001 Lading Page

 One Aspen Plus “Project” may involve:
• Backup file (.bkp)
• Embedded backup file (.apmbd)
• FORTRAN files ( .dll, .dlopt, .obj, .F )
• Equipment design and rating files (.bjt, .edr, etc)
• etc.

File Type Extension Format Description
Compound *.apwz Binary Compressed file which contains the model (the BKP or APW
file) and external files referenced by the model. You can add
additional files such as supporting documentation to the APWZ
file.
Document *.apw Binary File containing simulation input, results and intermediate
convergence information
Backup *.bkp ASCII Archive file containing simulation input and results
Template *.apt ASCII Template containing default inputs

 Prepared “properties” and
preferences for the user
 Air Separation
 Chemical Processes
 Gas Processing
 Pharma
 Refinery (most extensive)
 Solids
 “User” SI or English units

 Properties
 Physical Properties
 Thermodynamic Properties
 Models of Equilibrium
 Gas models
 Simulation
 Flow Sheet
 Unit Operations “Blocks”
 Stream of Mass/Energy “Lines”
Setting the Universe
Setting the Process

Typically, once you set your
properties, you won’t be using
Properties Environment

 002 Environements & Physical Properties

Ribbons/Menu

“Workspace”
Streams, Unit Operations
of the Process goes HERE

Navigation Pane

Model Palette
Unit Operation Blocks

Material/Work/Heat Stream

Status Bar

 003 Simulation Evironment

 Direct Contact
 Via Udemy Private Messages/Discussion boards
 Via e-mail
 Contact@ChemicalEngineeringGuy.com
 Chemical.Engineering.Guy@gmail.com
 Q&A from Website (Click HERE)
 Forums & Groups
 http://www.egpet.net/
 http://www.cheresources.com/
 http://www.eng-tips.com/threadminder.cfm?pid=137
 LinkedIn
 Aspen Plus Users
 Official Aspen Plus User Community Official Aspen Plus User Community (869 users)
 Official Aspen HYSYS User Community (9,000 users)
 Aspen HYSYS® Dynamics UsersPrivate Group (1,800 users)
 Aspen Tech
 http://support.aspentech.com ***You got to be registered as a valid Aspen License User(s)

 Using Aspen Help Bar/Button
Help Bar/Help Button

 004 Getting Help - Help Button

Set up “your” Universe
 Setup “General”
 Components
 (H2O, ethanol, butane, etc…)
 Databank
 Methods
 Property Methods ***(Critical)
Other… (not relevant for this course’s level)
• Chemistry (bp, MW,
structure, visc, etc.)
• Gas V,P,T
• Ideal
• Real (Z, NRTL, VDK)
• Physical Chemistry
• Equilibrium L-V
• Ideal/Real Solutions
• Volatility
• Liquid activity
• Fugacity

 Specifications
 Units (SI, English, bar, etc.)
 Calculation Options
 Convergence Error
 Maximum Iterations
 # Errors
 Automatic Calculations
 Unit Set
 Enthalpy of Formation  kJ/mol
 Heating Value  Cal/g
 Modify “SI” or “English”
 Reporting Options

 Specification
 Component (from Databases)*
 Molecular Structure
.
.
.
 Polymers
* Required
All other folders are studied
in other advanced courses

 Specifications
 Global Property Method
 Property Methods
 Method Name
 Method Assistant!

 Component Type
 Chemical
 Hydrocarbon
 Special Chemical (water, amine, sour, electrolyte)
 Refrigerant
 Process Type
 Chemical, Electrolyte, Environmental, Mineral & Metallurgical
 Gas Processing, Oil and Gas, Petrochemical, Refining
 Polymer
 Power
 Pharmaceutical

 Method Assistant  Process Type  Petrochemical

Type of System Recommended Property Method
TEG Dehydration PR, Glycol Package
Sour Water Sour PR, Sour SRK
Cryogenic / Air Separation PR, PRSV, TST
Atmospheric Towers PR Options, GS, TST
Vacuum Towers PR Options, GS, TST, Braun K10, Esso Tabular
Ethylene Towers Lee-Kesler-Plocker
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 Amine Pkg, DBR Amine Package, Elec-NRTL
Electrolyte Systems Elec-NRTL

Model
Ideal
Equation of
State
Classic
Advanced
Activity
Coefficient
Binary
Predictive

Equation of States Activity Coefficients
Good for vapor phase modeling and liquids of
low polarity
Preferable for liquid phase
Try to avoid Non-Ideal Liquids Good for non-ideal liquid mixtures
Less binary parameters required Binary parameters required (liquid-liquid)
Extrapolation of Data Only valid in Temperature Ranges given
Good for Critical Region (Pc, Tc) Avoid critical region
Examples:
– PSRK
– PENG-ROB
– RK-SOAVE
Examples:
– NRTL
– UNIQUAC
– WILSON
– UNIFAC

Do you have polar components?
Is the pressure low <10 bar?
Equation of State such as SRK or PENG-ROB…
Advanced Equation of State such as PSRK or PC-SAFT…
Are there any supercritical components?
Activity coefficient model with Henry’s law
Activity coefficient Model (NRTL, UNIQUAC, …)
no
START
no
no

 A stream of 10 kg/h of ethanol is added to another stream of 50/h kg of water.
 Both at 25°C and 1 atm.
 They are mixed.
 There is no heat exchange with the surroundings (no heat gain/loss)
 Then we heat it from 25°C to 77°C
 The streams go out in a single pipe

 005 Filling Physical Properties Environment

 You are ready to run the property simulation
 Aspen will run
 Model Methods
 Compounds
 If any compound has a modeling problem, you will receive errors (non-typical)
 You are ready to work in the Simulation Environment!

Awesome!

 Set System/Process
 Must have 0 Degrees of Freedom (System is “Fixed”)
 Set Input Data in Streams (energy, work and materials)
 Set Properties to Unit Operations (Blocks)

1. Set Physical Properties (Physical Environment)
2. Set Process in Flowsheet
 Mass Streams (T,P, mass flow, fractions, etc.)
 Heat/Work Explicit Duties (Q,W)
 Unit Operations
 Mass transfer (Distillation, flashes, etc.)
 Heat Transfer (Heat Exchanger, single/double HEX, etc.)
 Momentum Transfer (mixing, transportation of fluids, pumps, compressors, etc.)
 Reaction Kinetic (Reactor, Equilibrium Reactors, Stoichiometric Reactors, etc.)
3. Run Simulation
4. Expect no Errors
 If no errors  Check solution in Reports
 If there are errors  Check type of error, try to fix if needed, re-run simulation
5. Analysis of Results, Sensitivity Analysis, Optimization, etc…

 Mass Streams Mainly
 All inlet to process (raw material)
 Intermediate streams (intermediate material)
 All outlet to process (final products & by-products)
 Heat and Work only if Required (direct Duty)
 500 kJ must be applied
 Loss of Heat due to cold temperature is 1054 KJ/s
 14 HP Shaft Power Requirement
 Pump has 12 BHP

 FINAL DIAGRAM

 Stream 1. Water
 Stream 2. Ethanol
 Stream 3. Mixed Product before heating
 Stream 4. Mixed Product after heating

 Mixing unit…
 Heater unit…

 Your Process is Set!
 Let’s Run the Simulation!
 As follows…

1 2 3 4
5
6
1. Run Complete Simulation
2. Step-by-Step Simulation
3. Stop Simulation
4. Purge/Reinitialize
5. Check Results
6. Next Input

 006 Filling the Simulation Environement

 No!
 Perfect!
 Continue with Results and Analysis

 Solutions
 Water + Ethanol mix will increase about 3°C due to its “real mixture”
 Stream Results
 Mixture: 60 kg/h; T = 301 K
 Product: 60 kg/h; T = 301 K
 Block Results
 Mixer Final Temperature = 310.71 K
 Heater Duty: 12360.66 kJ/h
 *** More info in Section 7. Flowsheet Results

 007 Results and Analysis

 Mixers/splitters
 Separators
 Exchangers
 Columns
 Reactors
 Pressure Changers
 Manipulators *
 Solids *
 Solid Separators *
 User Models *
* Not Relevant in this Course

 Separators
 Exchangers
 Columns
 Reactors
Momentum Heat
Kinetics Mass

 Separators
 Exchangers
 Columns
 Reactors
Momentum
Mixers/Splitters
Pressure Change
Heat
Exchangers
Kinetics
Reactors
Mass
Separators
Columns

 This data is from
Aspen Plus Help Data
Sheet

 008 Introduction to Unit Operations

 Mixer
 FSplit
 Ssplit*
*Basic Course does not includes SSplit

 Required
 One streams inlet (Q,W,M)
 One stream outlet (Q,W,M)
 Useful for
 In-pipe blending (T-shape)
 Mixing tanks (Adiabatic Only)
 Static Mixers
 Methods/Conditions
 Ideal, Adiabatic Mixing
 Pressure drop may be added
Either Mass, Q or W!

 Required
 One streams inlet (Q,W,M)
 One stream outlet (Q,W,M)
 Useful for
 Valves
 Tanks
 Back-Mixing
 Purge/Vents
 T-Shape Pipe
 Methods/Conditions
 N/A
Either Mass, Q or W!

 009 Mixers & Splitters

 Fash2
 Flash3*
 Decanter*
 Sep
 Sep2*
*Basic Course includes only Flash2 and Sep

 Separates feed into
 2 (vapor liquid) or 3 (vapor liquid liquid)
 using rigorous vapor-liquid or vapor-liquid-liquid equilibrium
 Required
 Inlet (1)
 Outlet (2)
 Recommended Use:
 Flash drums
 Evaporators
 Knock-out drums
 Single stage separators

 Separates inlet stream components into multiple outlet streams, based on
specified flows or split fractions
 Required
 (1) inlet
 (1) outlet
 Recommended Operations:
 Component separation operations
 Distillation
 Absorption,
 *** when the details of the separation are unknown or unimportant
 Essentially to avoid computation time
 Not that recommended actually
“Black Box”

 010 Separators

 Heater
 HeatX*
 MHeatX*
 HXFlux*
*Basic Course includes only Heater

 Heater/Cooler
 Determines thermal and phase conditions of outlet stream
 Required Streams
 (1) Inlet
 (1) Outlet
 Recommended Use
 Heaters
 Coolers
 Condensers
 Boilers
 Valves
 “Pipe” Joints

 Calculations:
 Bubble or dew point calculations
 Add or remove any amount of user specified heat duty
 Match degrees of superheating or subcooling
 Determine heating or cooling duty required to achieve a certain vapor fraction

 011 Exchangers

 DSTWU*
 Distl
 RadFrac
 Extract*
 MultiFrac*
 SCFrac*
 PetroFrac*
 ConSep*
 BatchSep*
*Basic Course includes only Distl and RadFrac

 Shortcut multicomponent distillation rating model
 Number of theoretical stages
 Reflux ratio
 Overhead product rate
 Determines separation based on reflux ratio, number of stages, and distillate-
to-feed ratio
 Assumes constant mole overflow and constant relative volatilities.
 Recommended Operation
 Columns with one feed and two product streams
**Edmister approachwww.ChemicalEngineeringGuy.com

 Rigorous fractionation
 Performs rigorous rating and design calculations for single columns
 Operation Recommendations
 Ordinary distillation
 Absorbers/Strippers
 Extractive and azeotropic distillation
 Three-phase distillation
 Reactive distillation

 Multistage Vapor-Liquid Calculations:
 Ordinary distillation
 Absorption
 Reboiled absorption
 Stripping
 Reboiled stripping
 Extractive and azeotropic distillation
 RadFrac is suitable for:
 Two-phase systems
 Three-phase systems (only in equilibrium mode)
 Narrow and wide-boiling systems
 Systems exhibiting strong liquid phase nonideality

 Model columns in which two liquid phases and chemical reactions occur
simultaneously, using different reaction kinetics for the two liquid phases.
 Can model both random and structured packings.
 Calculation of size and rate columns consisting of trays and/or packings.

 012 Columns

 Balance/Stoichiometry Based
 RStoic
 RYield
 Equilibrium Based
 Requil*
 Rgibbs*
 Kinetic Model Based
 RCSTR*
 Rplug*
 Rbatch*
*Basic Course includes only RStoic and RYield

 Stoichiometric reactor
 Models stoichiometric reactor with specified reaction extent or conversion
 Models:
 Reactors where reaction kinetics are unknown or unimportant but stoichiometry
and extent of reaction are known
 Reaction kinetics are unknown or unimportant and
 Stoichiometry and the molar extent or conversion is known for each reaction
 Performs:
 Product selectivity and heat of reaction calculations
 Simultaneously or sequentially

 Yield reactor
 Models reactor with specified yield
 Models:
 Reactors where stoichiometry and kinetics are unknown or unimportant but a yield
distribution is known
 Reaction stoichiometry is unknown or unimportant
 Reaction kinetics are unknown or unimportant
 Yield distribution is known

 013 Reactors

 Pump
 Compr
 Mcompr*
 Valve*
 Pipe*
 Pipeline*
*Basic Course includes only Pump and Compr

 Has 1 input and 1 output at least
 Must be in liquid state or incompressible gas. Otherwise, it must be stated
 It may also be used as a Turbine
 Pressure Ratio is allowed
 Power Requirements are also input/output

 At least 1 inlet and 1 outlet
 Excellent for Pressure Increases in gas phase
 It might be used as a Turbine
 Performance Curves are also included
 Pinlet/Poutlet
 Workload

 014 Pressure Changers

 BASIC approach
 Table
 Graph
 Chart
 Etc…
*** Continue to intermediate for more!

 015 Results P1
 015 Results P2

 Mixing, Splitting
 Flashing; evaporating
 Heating/Cooling
 Evaporation, Condensation
 Distillation
 Chemical Reactions
 Compression; Pressurization; depressurization

 Now you know how to model the most Basic Unit Operations of Aspen Plus ®
 You can model plenty of Common Processes by now!
 You should go now:
 Case Study I, II, III  Apply all the knowledge into one process, step by step.
 Case Study IV  Apply your knowledge by your own. Compare final results with the
template result!

 Lets do a a Workshop!
 No worries you won’t be alone!
 We will be analyzing 3 cases:
 Case Study I: Solvent Recovery (RadFrac, Mixers)
 Case Study II: Cumene Production (Rstoic, Flash2, Heater)
 Case Study III: 3 Gas Pressure (Compressor, Mixer, Valve, Heater)

 Statement
 Read it carefully, write down all important data. Find data that might be useful
 Building the diagram
 Build the diagram accordingly, “after”, “before” and “then”, “pre” are pretty important words
 Data Input
 Name Streams logically. Add all substances, fractions, masses that are required.
 Add Blocks, name them accordingly to their functions. Add all data needed
 Run Simulation
 Results  Go to results; review there are no warnings, errors.
 Write a Results Report & Check Results
 Finally, make an analysis and make your final conclusion

1. Statement
2. Building the diagram
3. Data Input
 Streams
 Blocks
4. Run Simulation
5. Results & Reporting
6. Analysis
7. Conclusion

 A previous process contains a mixture of solvents which we are required to
recover. We are interested in pure acetone, methanol and water.
 Source 1 (Process 1) – Contains a 5%-75%-20% water/acetone/methanol mix
 350 gal/h are being sub-produced
 Source 2 (Process 2) – Contains a 5%-35%-60% water/acetone/methanol mix
 50 gal/h are being currenty treated in an old storage facility
 You, as an junior engineer, propose a 2 separaton process: Split acetone (most
volatile); then Split water form methanol.
 The previous process was not suitable for the separation, it used flash drums.
Instead you propose a distillation column system.

 Since there is no CAPEX left; we are not able to do 2 separate process. The idea is to
mix both stream sources; add water for the methanol/water interaction.
 You decide to use an old distillation column from a Project which is in standby.
 It has 40 trays; it owns a kettle reboiler and a total condenser. After calculations you
got that you should start working with a reflux ratio of 1:2 with respect to mass
 The D/F ratio should be pretty similar, i.e. 1:1 per mole. Water is fed in the 12 stage
and the solvent mix in the 24th
 Operation Pressure is about P = 15 psia (it could be optimized)
 For the methanol-wáter rich bottom product; we require a NEW distillation column.
 The Senior Engineers recommended the next data:

 Total condenser, Kettle Reboiler, 17 Stages. Similar operater reflux ratios to your
initial column. It must be feed between 9 and 11 stage.
 Since you are operating at P = 15 psi, opérate at similar pressures
 Utilities:
 Water is available at 15 psia, T = 100 F.
 Mass balance calculation requires a Vol. Flow rate of 100 gal/h

 Find:
 Acetone purity
 Methanol purity
 Heat Duty in Reboiler-1
 Heat Duty in Condenser-1
 If methanol prices are $ 1.13 per gallon, how much money we earn per day?
 Is this water suitable for drinking?

 Feed:
 Water – 100 F; 15 psia; STVol = 100 gal/h
 Source 1- 100 F; 15 psia; STVol = 350 gal/h. (0.05-0.75-0.20; w,a,m)
 Source 2- 100 F; 15 psia; STVol = 50 gal/h. (0.05-0.35-0.60; w,a,m)
 Distillation Column 1
 RadFrac
 P = 15 psia
 Equilibrium operated, N-stages = 40, Total Condenser, Total Kettle Reboiler
 Reflux Ratio = 2 (per mass); D/F Ratio = 1 per mol
 Water Feed = 12; Solvents Feed = 24

 Distillation Column 2
 RadFrac
 P = 15 psia
 Equilibrium operated, N-stages = 17, Total Condenser, Total Kettle Reboiler
 Reflux Ratio = 2 (per mass); D/F Ratio = 1 per mol
 Water Feed = 10

 Run the simulation!
 Debug required?
 Warnings
 Errors?

 Acetone purity
 Methanol purity

 Are purities achieved?
 How much is recovered % of each material
 If methanol prices are $ 1.13 per gallon, how much money we earn per day?
 Is this water suitable for drinking?
 Is this better tan flashes? Why?

 016 Case Study I - Solvent Recovery

 Cumene is typically produced from a benzene + propylene reaction at very low
pressures (vaccum).
 The plant feedstock is 50%-50% B/P. It is about 80 lbmol/h.
 It comes from a pump which delivers it at T = 220 F and P = 36 psia
 The reactor is typically operated with a recycle stream of all volatile material in the
reactor’s outlet.
 Final Reactors Temerature is not know but tt is imperative to cool down at T = 130 F
 The sepation is carried out with a flash drum at P = 1 atm (for final product storage).
 The flash is operated adiabatically

 Find:
 Reactor’s Operation Temperature
 Heat Duty of Cooler
 Split Fraction of Separator
 Flow rate of Recycle
 Flow rate of product
 Mol fraction of Cumene in product
 Try it without recycle! (Same questions)

 Feed:
 P = 36 psi
 T = 220 F
 F = 80 lbmol/h
 X = 0.5 Benzene; 0.5 Propylene
 Reactor
 This is typically done via the reaction of Benzene + Propylene in a Reactor
 Use Rstoic
 Reaction is 1:1  1
 90% conversión with respect to Benzene
 Adibatical; i.e. Q = 0
 P = 0 atm

 Cooler:
 T cool = 130 F
 P final = -0.1 psia (i.e. vacuum)
 Flash Drum
 P = 1 atm (final product)
 Adiabatical, i.e. Q = 0
 Recycle vapors
 Liquids go to final product

 Products:
 X fraction of Cumene
 Mol Flow of Product Stream
 Recycle Mol flow stream
 Blocks:
 Reactor Temperature
 Coolers Heat Duty
 Recycle Split Fraction

 Recycling:
 Non-Recycling

 017 Study Case II - Cumene Production

 You are in charge of mixing, transport and compressing a mixture of gases used for a
furnace application. They are stored in separate tanks reservoirs.
 The furnace operates at 5 bar so we need to mix all gases and then transport it to the
furnace.
 Due to friction losses; we have a 1.5 bar pressure loss from the mixer to the furnace.
Compression is required.
 The methane gas (essentially natural gas) is stored at 15 bar; ethane gas is at 2 bar
and the propane gas is already at 5 bar.
 Compressors work with the given isentropic and mechanical efficiencies

 Find:
 Compressor 1 - Duty
 Compressor 2 - Duty
 Final Product Gas Composition
 Initial Temperature of mixture
 Final Temperature
 Try it with a final heater!
 Try it with a cooler before the Compressions!

 Feed:
 Methane – 30°C, 15 bar, 155 kg/h
 Ethane – 25°C, 2 bar, 200 kg/h
 Propane – 35°C, 5 bar, 120 kg/h
 COMP1
 Compressor
 Isentropic
 Discharge P = 5 bar
 95% Isentropic Efficiency
 88% Mechanical Efficiency

 Mixer:
 P = 5 bar
 Friction loss:
 Model as Valve
 Pressure Drop = 1.5 bar
 Adiabatic Flash
 COMP2
 Compressor
 Isentropic
 Discharge P = 5 bar
 90% Isentropic Efficiency
 85% Mechanical Efficiency

 Products:
 Mass Fraction of all gases
 Final Temperature
 Final Pressure
 Blocks:
 Compressor 1 Workload

 Tempearture increases:
 What if, cooling before any compression?
 Workload of heater/cooler vs. Compression
 Energy optimization?
 $$??

 018 Case Study III - Gas Compression

 Now its time to practice alone!
 Make your simulation
 Compare with the results shown in the Course’s Workshop
 If there are warning/error shown
 Try troubleshooting 
 Send your results to me! @CHEMENG (any contact given before)

 Problem: Petrochem – (Natural Gas Separation, LP Gas, Pentanes + Hexaes)
 Statement
 Diagram…
 Compare Results
 Analysis and Conclusion (send feedback to Contact@Course)

 A Petrochemical Industry requires to Split the next Stream
 Tank Status  150F; 800 psia
 Max. Flow Rate  1000 lbmol/h
 Composition of petroleum mix:
 Try using only 3 distillation columns!
 A flash drum s convenient for water removal prior to distillation.

 Find:
 Final composition of Natural Gas Line (C1 mainly)
 Final composition of Light gases (LPG C2-C4)
 Final composition of Heavy Keys (C5 and C6)
 Water flow rate from flash drum
 Blocks
 Heat Duty of Boiler + Condenser of each
 Final Product Pressures

 Try changing:
 Number of stages (trays)
 Distillate/Feed Ratio
 Reflux Ratio
 Pre-coolers and Pre-heater before distillation
 Pressure drop in columns

Light Distillation Column
Mid-Light Distillation Column
Heavy Distillation Column
Flash Separator

 Feed:
 T = 150F; P = 800 psia
 Max. Flow Rate  1000 lbmol/h
 Flash
 P = 300 psia
 Q = 0 (adiabatic flashing)
 Light Distillation
 RadFrac
 P = 150 psia; N = 18; feed = 10
 Partial-Vapor Condenser; Kettle Boiler
 Reflux Ratio = 2 (molar)
 D/F ratio = 0.5 (mass)

 Mid-Light Distillation
 RadFrac
 P = 15 bar psia; N = 25; feed = 12
 Partial-Vapor Condenser; Kettle Boiler
 Reflux Ratio = 8 (mass)
 Heavy Distillation
 RadFrac
 P = 250 psi; dP = 15psia; N = 15; feed = 8
 Total Condenser; Kettle Boiler
 Reflux Ratio = 8 (mass)

 Products:
 % composition of all products
 % vapor/liquid in products (should be either 1 or 0)
 Blocks:
 Distillators:
 Heat Duty of Condenser
 Heat Duty of Reboiler

 Download Results at  UDEMY!

 Heat load requirements if previous chilling/cooling
 Change in % composition due to Reflux Rate and F/D ratio
 Compare Flashing vs. Not Flashing
 Chance Flashing conditions (Pressure)
 Overall  Try to get better results for % compositions of streams!

 Finally! You made it!
 By now you should be able to know:
 General Flowsheet Concepts
 Basic Requirements to set up a Simulation
 Setting the adequate Physical Properties
 Flowsheet “manipulation”
 Major and Common Unit Operations
 Workshop Practice
 Reporting Results (Tables)
 Technical Stuff (extensions, versions, exporting, saving, etc...)

 Continue with the next course Intermediate and Advance!
 You will learn…

 Files:
 Creating and editing templates
 Reviewing samples/exercises/previous projects
 More on extensions and backup, onedrive
 Exchange, Support and Live chats
 Continuous training
 Physical Properties Environment:
 More on Methods and how to use them
 More on substances and YOUR own substances/assays
 Graphs + Substances Properties charts

 Transient State
 Steady vs. Unsteady/Transient states
 Batch modeling
 Economy Environment
 Safety Environment
 Energy Environment

 Unit Operations:
 Rigourous/Detailed Heat Exchange
 Rigourous/Detailed Distillation; Petroleum Refinery
 Batch Separation (Columns)
 MultiFrac and PetroFrac insights
 Reactors  All reactors left (Requil, Rgibbs, RCSTR, Rplug, Rbatch)
 Modeling for mechanisms and kinetic theory
 Extraction (liquid-liquid and many others)
 Manipulators/Calculators
 dP  Valves, Pipes, Pipelines and Piping (drop of pressure, frictions, duty load)
 Review of Unit Operations with Solids

 Running Simulations
 More on Debugging, warnings, and fixing Errors
 Degrees of Freedom
 Process simplification
 Reporting Results
 Excel export/import
 Sensitivity Analysis
 Charts, Graphs, Tables
 Programming tools
 Fortran coding
 Manipulator
 Hierarchy
 Calculator

 It was awesome to share the course!
 Hope you like it
 Please leave a Review! It really helps other students to find the course easier
 If I get students; I get motivated to do MORE material XD

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