Aspen HYSYS - Basic Course (SS)

Chemical Engineering Guy
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1. Course Objectives
2. Introduction to Aspen HYSYS
3. User Interface & Getting Help
4. Environment I: Physical Properties
5. Environment II: Introduction to Flowsheet
6. Basic - Unit Operation Models
7. Basic Reporting of Data and Results
8. Worked Case Studies (I, II and III)
9. Individual Case Study – IV and V
10. Conclusion

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
 Oil&Gas
 Other commodities such as:
 Sulfuric acids
 Chlorine/Caustic industry
 Coatings
 Ammonia
 Hydrogen Gas

 Helps us:
 Stream flow rates
 Compositions of streams
 Physical properties such as P, T, v of streams
 Unit operation operating conditions; Heat duty, T, P, Electricity, efficiency, Power…
 Preliminary equipment sizing ideas/design
 Important operational/design concerns/issues
 As any Engineering problem, we require to set some data:
 Mass & Energy balances
 Transport phenomena (momentum, heat, mass)
 Equilibrium relationships (Gibbs free energy, entropy, thermos’s law)

 DESGIN:
 Decrease in time
 Decrease or experimental requirements
 Improves Pilot Plants and Tests
 Explore proprietary/experimental process technology
 Allows Equipment design
 OPERATION:
 Helps to improve existing processes
 Set possible set of scenarios
 Determine best operational input
 Safety Analysis (Safety Regulations)
 Emissions studies (Environmental)

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

2. Introduction to Aspen HYSYS
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”  build, navigate, optimize
 Basic – Most Common Unit Operations
 Workshop Practice – Hands on!
 Basic Reporting of Data and Results (tables, graphs, raw data)
 Technical Stuff (extensions, versions, exporting, saving, etc...)

 Course Approach
 Theory
 Practice
 More Practice via Workshops
 3 Case Studies Fully Developed
 1 Final Case Study – Only data is given!
 Presentation of Results
 Analysis of Data
 Conclusions

 1st Day
 Getting started
 User Interface & Getting Help
 Physical Properties
 Introduction to Flowsheet
 Unit Operation Models
 2nd Day
 Case Studies I,II and III
 4th Day
 Case Studies IV
 Review and Selfassesment

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

From the website:
“Aspen HYSYS is the energy industry’s leading process simulation software that’s
used by top oil and gas producers, refineries and engineering companies for process
optimization in design and operations.”
http://www.aspentech.com/products/aspen-hysys/

 My version V8.8 (May 2015)
 Most recent version V10 & 10.1 (Nov 2017)
 https://home.aspentech.com/en/v10
 Main differences:
http://origin-www.aspentech.com/products/aspen-hysys/whats-new/

V9
 Refinery Planning Models are Easier to Update
 Improvements to Acid Gas Cleaning
 Reduce Risk with Sulfur Recovery Modeling
 Get a More Detailed View of Your Distillation Columns
V10
 Sequence With Staggered Analysis
 Calibrate Models With Plant Data
 More Accuracy for Dehydration With CPA
 Predict Sulsim Degasser Performance
 Improve CDU Modeling Using EO
 New Solvents for Acid Gas Cleaning
http://origin-www.aspentech.com/products/aspen-hysys/whats-new/

 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…
 “NEW” – Cases
 Existing - Templates

 One Aspen HYSYS “Project” may involve:
 HYSYS Simulation Case (.hsc)
 HYSYS Template; HYSYS Column Template
 HYSYS HSP file (.hsp - a snapshot taken during dynamics modeling.)
 HYSYS HFL File (.hfl, save a selected part of a flowsheet to a file - import it to another flowsheet.)
 HYSYS XML file
 HYSYS backup simulations (*.bk0)
 HYSYS Compound File (.hscz, zip file of all relevant attached files to the case file)
 Fluid package file: *.fpk
 Component list file: *.cml
 Component List (*.cml)
 Fluid Package (*.fpk)
 Assay (*.oil)
 Column Template (*.col)
 Workbook (.wrk)

 Prepared “properties/preferences for
the user
 Absorber
 Sweetener
 Reformer
 Catalytic Cracker
 User defined
 “User” SI or English units

 Start Page
 New, Open
 Button (Ribbons) bar

 001 Lading Page

 Properties Environment – all the steps needed to
fully define the physical property input
 Simulation Environment – used to build and run
Safety and Energy Analysis – Environments are not part of the scope of this course

Properties Environment:
 Component selection and characterization
 Select a property package
 Create a Fluid Package
 Setup assays and blends via Oil Manager
 Create reactions
 And more…

 Simulation Environment Models, and review/analyze results
 Build and specify process flowsheets
 Create and run analyses (Case Studies, Optimization, Equipment Sizing,
etc.)
 Data Fit to match model data to measured data
 Transfer simulation data to other AspenTech products:
 Aspen EDR
 Flare Network Design & Rating
 Process Economic Analyzer
 Many others

 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

 In this course and other users (recommended)
 Aspen Tech directly, groups or direct contact
 By yourself (Help Menu and other manuals)

 Direct Contact
 Via Udemy Private Messages/Discussion boards
 Via e-mail
 Contact@ChemicalEngineeringGuy.com
 Chemical.Engineering.Guy@gmail.com
 Forums & Groups
 http://www.egpet.net/
 http://www.cheresources.com/
 http://www.eng-tips.com/threadminder.cfm?pid=137
 Facebook Group:
 https://www.facebook.com/groups/aspenplushysysforum/ (250)

 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)

 Help Topics
 Select Help Topics from the Help button on the ribbon
to launch online help:
 Contents: Browse through the documentation and Help article by topic, including Reference
Manuals
 Index: Search for help on a specific topic using the index entries
 Search: Search for a help on a topic that includes any word or words
 F1 Help
 With the cursor in the desired field, press the <F1> function key to bring up help for field
and/or sheet

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

REFORMER

 003 Getting Help - Help Button

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…

Set up “your” Universe
 Components List
 (H2O, ethanol, butane, etc…)
 Databank (Hypo, Pure Comp.)
 Fluid Package: 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

 (Component List)
 (Fluid Packages)
 Petroleum Assays*
 Reactions
 Component Maps*
 User Properties*

 Aspen HYSYS Library Components
 Sufficient for the majority of hydrocarbon-based processes
 Search by component name, alternate name, or formula
 Can filter search based on component family
 Aspen Properties Database
 Represents many component databanks covering a variety of process industries
 NIST Pure component data and NIST Thermo Data Engine (TDE) for improved data fitting and
estimation
 Hypothetical Components***
 Minimum data entry is one property (NBP, MW, density…)
 Select desired methods to estimate unknown properties
 Option to either define a single hypo or create a Hypo Group
More Advanced Courses –
Unique for HYSYS!

 Specification
 Database (HYSYS)
 Component (from Databases)*
* At least 1 is required
All other Databases/Options/Hypo are
studied in other advanced courses

 Property Package Selection
 Plenty of packages!
 Each has its specification…
 Typically, you will know which Package to Apply
 Recommended  Method Asistant OR  USE HELP BUTTON
 SERACH: Aspen HYSYS Property Package Selection Assistant


 Choose the Method Assistant
 Actually, it pop-ups a Help Site
 Then, choose either Help button or
Method assistant

 Start by selecting one of the following options:
 Specify component type
 Select the type of component system:
 Chemical system
 Hydrocarbon system
 Special (water only, amines, Sour water, electrolyte, aromatics only, thiols and hydrocarbons)
 Specify process type
 Select the type of process or application:
 Chemical
 Electrolyte
 Environmental
 Oil and Gas processing
 Mineral and metallurgical
 Petrochemical
 Power
 Refining
Example:
 Process
 Gas dehydration
 Use Peng-Robinson
 CPA
 Glycol Package.

 IT also recommends!
 Water + Ethanol
 Choose Peng Robinson
 NOT RECOMENDED

 STATEMENT
 A stream of 10 kg/h of ethanol is added to another stream of 50 kg/h of water.
 Both at 25°C and 1 atm.
 They are mixed.
 There is no heat exchange with the surroundings (no heat gain/loss)
 The mixtures it then transported to ta Heater which increases Temp. from 25°C to 77°C
 The streams go out in a single pipe
 Verify new compositions
 Physical Properties ONLY!

 Fill up all required Physical Properties
 Components  Water, Ethanol
 Fluid Package  NRTL

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

 004 Filling Physical Properties Environment
 Try different Packages
 Show “not recommended”

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…
DONE

 Set/Build 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)

Ribbon Tabs

Navigation Pane

Object
Palette

Zoom
Slider

Trace
Window

Status
Window

Environment
Selection

Flowsheet

Blocks

Streams

 Conveniently organized menus

 Right click on any PFD object to:
 Rotate or flip the icon
 Format the label
 Hide the object
 Display a summary table
 Change the icon
 Cut/copy/export the object
 Right click on the PFD background to:
 Add a Workbook table
 Change label variable (i.e. show stream pressure instead of name)
 Reveal hidden objects
 Paste/import an object

 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

 This is seen in Section – UNIT OPERATIONS – specifically
 In the meantime, just add simple Unit Operations
 Mixer
 Heater

 STATEMENT
 A stream of 10 kg/h of ethanol is added to another stream of 50/h kg of water.
 They are mixed.
 Fill up the Simulation Environment!
 Streams must be specified
 Unit Operations must be specified
 Connections must be specified

 Stream 1. Water
 Stream 2. Ethanol
 Stream 3. Mixed Product
 Stream 4. Mixed Product after heating
 Stream 5. Heat Duty Stream (heater)

 Mixing unit…
 Heater unit…
 No need to add specifications/properties…
 JUST add the unit and connect to the streams

 Process Diagram
After Input

 006 Filling the Simulation Environement

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

 Solutions
 Product Composition = 0.9275
 Stream Results
 Mixture: 60 kg/h; T = 25°C
 Product: 60 kg/h; T = 77°C
 Heat Duty = 1.274E04 kJ/h
 *** More info in Section 7. Flowsheet Results

 STATEMENT
 A stream of 10 kg/h of ethanol is added to another stream of 50/h kg of water.
 They are mixed.
 Verify the new composition and conditions (T,P,Duty)

 006 Environment Conclusion

 Basic
 Common
 Columns
 Advanced
 Upstream
 Refining
 Dynamics
 Custom
* Not Relevant in this Course

 Model Categories

 Or use F-12 Key

 008 Introduction to Unit Operations

 Mixer
 Tee

 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
 Pressure drop may be added
Either Mass, Q or W!

 Required
 One streams inlet (MASS)
 One stream outlet (MASS)
 Useful for
 Stream separation
 Pressure drop may be added
Just Mass, NOT: Q or W!

 008 Mixers & Tees
 Mixer:
 Stream 1 – inlet, P = 1 atm, T = 25°C (25% Benzene, 50% Toluene, 25% Xylene). FlowRate =
100 kg/h
 Stream 2 – inlet, P = 1 atm, T = 25°C (50% Cyclohexane, 50% n-Hexane). FlowRate = 150
kg/h
 Stream 3 – outlet, (Resulting T, P, Composition, Flow Rate)
 Tees
 Stream 3 – inlet,
 Stream 4 – outlet, 33% of original  Flow rate?
 Stream 5 – outlet, 67% of original  Flow rate?
FP: PR

 Typical Unit operation models:
Cooler
LNG
Exchanger
Fired Heater
Air Cooler
Heat
Exchanger
Heater

 Models only one side of an exchanger
 Can be used to:
 Heating or cooling
 Condense or evaporate
 Designed for simple heat transfer calculations
 preliminary design
 Precursor
 Not a detailed design!

 Used to model heat transfer between two process streams (H/C)
 Aspen EDR rigorous modeling software can be accessed through
Heat Exchanger (Advanced/specific Courses)
 Select preferred Heat Exchanger Model depending on required
simulation detail
 Recommended:
 calculate heat transfer coefficient
 pressure drop
 exchanger geometry

 LNG Exchanger
 can be used to represent heat transfer between multiple hot and
cold streams
 Air Cooler
 Uses air to cool or heat a process stream to some specified
condition
 Fired Heater
 Performs heat and material balances on furnace-type fired heater
*Not part of this course!

 Governing Equation
Q = U × 𝐴 × 𝐿𝑀𝑇𝐷

 009 Heater and Cooler
 Heater
 Stream 1 – inlet, T = 25°C, P = 1 atm; (50% water, 50% ethanol) FlowRate = 10 kg/min
 Q = ?, dP ?
 Stream 2 – outlet, T = 50°C, P = 0.93 atm, Composition?, FlowRate?
 Cooler
 Stream 2 – inlet, T = 50°C, P = 0.93 atm
 Q = 20000 kJ/h off of Duty , dP = 0.03
 Stream 2 – outlet, T = ? , P = atm, Composition? FlowRate?
FP: PRSV

https://www.youtube.com/watch?v=QlpfaVVZffc
 Used to separate liquid vs. vapors
 This is called “Flash” separation
 The stream must be at is vapor-
liquid equilibrium (VLE)
 Typically, no Heat Duty (Adiabatic)
 You can still define Heat Duty
 Inlet is mix
 Outlet is a Vapor and Liquid stream

https://www.youtube.com/watch?v=QlpfaVVZffc
 Drop in Pressure can be stated
 Volume of Vessel can be stated
 Liquid volume ratio as well

 010 – Flash Drum
 Stream inlet
 Composition: 15% ethane, 20% propane, 60% i-butane, 5% n-butane
 T = 32°F, P = 50 psia, FlowRate = 100 lb/h
 Find Vapor FlowRate and composition
 Find Liquid FlowRate and composition
Fluid Package:
Peng Robinson

 4 standard column templates are available
 Distillation Column
 Refluxed Absorber
 Absorber
 Reboiled Absorber
 Three phase distillation column
 Liquid-liquid extractor
 Rate based column
 Custom column templates
 Shortcut distillation

 Distillation column: contains a tray section, condenser and reboiler
 With a total/full reflux condenser  DOF = 2
 With a partial condenser  DOF = 3
 Refluxed absorber: contains a tray section and a condenser
 With a total/full reflux condenser  DOF = 1
 With a partial condenser  DOF = 2
 Absorber: contains only a tray section
 DOF (Degrees of Freedom ) = 0
 no additional operating specification can be given
 Reboiled absorber: contains a tray section and a reboiler
 DOF = 1, one additional operating specification has to be given

 The “Distillation” Template looks like this:
 Condenser
 Reflux flow
 Distillate
 Boilups
 Bottoms
 Total Stages
 Feed (1)
Parent Environment Column Environment

 Distillation Column
 Requires plenty of input!
 It is done in 5 Steps
 You must run/reset simulation
Parent Environment

 Step 1: Connections (Mass and Energy streams, specifications, trays)
 Step 2: Reboiler Configuration (Type and Reboiler Selection)
 Step 3: Pressure Profile
 Condenser/Reboiler Pressures.
 Pressure drop in column and each equipment is optional
 Step 4: Optional Estimates
 Optional  aids in convergence
 Temperature of Equipment
 Step 5: Specifications (Reflux and/or FlowRate)
 RUN!

 Step 1
 Step 2
 Step 3
 Step 4
 Step 5
 RUN!

 013 - Columns
 Input Data:
 Inlet Stream (F)
 T = 60°C , P = 106 kPa,
 FlowRate = 100 kmol/h, 40% Benzene, 60%Toluene (molar)
 Distillate = D, Bottoms = B
 Heat Duty Compressor Qc; Heat Duty Reboiler Qr
 Stages: N = 10, Feed = 5
 Condenser: Total, P = 101 kPa, Reflux = 2.0 molar
 Reboiler: Default HYSYS, P = 111 kPa
 Distillate Rate = 40 kmol/h
 Change of No. Trays  from N = 10, to N = 20

 Moving fluids
 Pressure change mainly
 Friction generation  Temperature
 Contains piping-specific unit ops
 Pipe Segment (pressure loss)
 Various fittings
 Decrease Pressure  Valves, expander
 Increase Pressure  Compressor/Pump
 Transport Fluids  Pipings
• Advanced  Gas Gathering Examples

 Used to increase pressure in a liquid
 Move a liquid
 Recover loss of pressure
 Increase Pressure
 Inputs are
 Inlet stream (mass)
 Outlet stream (mass)
 Inlet stream (Work)
 You can assign 1 fluid package for it!
 dP, Pressure Ratio, Adiabatic Eff.
 Pump Curves, NPSH Curves, Efficiency Curves

 014 – Pumps
 Input data:
 Inlet Stream
 T = 25°C, P = 1 atm
 Pure water
 P final Required = 10 atm
 Final Data:
 Outlet Temperature
 Workload required (KW, HP)

 Used to increase pressure in a gas
 Move a gas
 Recover loss of pressure
 Increase Pressure
 Inputs are
 Inlet stream (mass)
 Outlet stream (mass)
 Inlet stream (Work)
 dP, Pressure Ratio, Adiabatic/Polytropic Eff.

 015 – Compressor
 Input data:
 Inlet Stream
 Enriched Oxygen Air (34% Nitrox)
 T = 30°C, P = 14.7 psia
 P final Required = 3000 psig
 % efficiency = 65%
 Final Data:
 Outlet Temperature
 Workload required (KW, HP)

 “Common”
 Continuous Stirred Tank Reactor (CSTR)
 Plug Flow Reactor (PFR)
 “Column”
 Gibbs Reactor
 Equilibrium Reactor
 Conversion Reactor
 Yield Shift Reactor

 You must add and specify the type of reaction
 Types:
 Conversion
 Equilibrium
 Kinetic
 Rate

 C + O2 = CO2
 C + ½ O2 = CO
 H2O = H2 + O2
 H2O = 2H + O

 It is based on Conversion of a reactant (X)
 Requires Reaction
 Stoichiometry!
 All other calculations are based upon this
 Enthalpy of reaction
 Final T, P
 Requires exact Stoichiometry
 Final Composition

 Requires Reaction
 Stoichiometry!
 Forward-Reverse reactions
 Based on activity coefficients  Keq
 Keq given
 Keq calculated via Gibbs Free energy
 Keq tabulated
 All other calculations are based upon this
 Reaction extent
 Temperature, Pressure changes
 Final Composition

 014 - Reactors (Conversion)
 Reactors Specs
 Conversion if 95%
 Adiabatic (Q= 0)
 Methane Combustion (15% excess oxidant)  CH4 + 2O2 = CO2 + 2H2O
 Via pure oxygen
 Inlet Fuel = 100 mol of CH4
 Inlet Oxidant = 230 mol of O2
 Final T
 Final flowrates + composition
 Via air (21% O2, 79% N2)
 Inlet Fuel = 100 mol of CH4
 Inlet Oxidant = 1095 mol of Air (230 mol of O2, 865 mol of N2)
 Final T
 Final flowrates + composition

 File  Options 
 Simulation
 Reports
 Equipment
 Units of Measurement

 All info regarding:
 Material Streams
 Compositions
 Energy Streams
 Unit Operations

 Workbook “Menu”
 Save/Export Workbook

 Streams
 Mass
 Energy
 Compositions

 Export to Excel!
 Engineers love Excel!

 Printable Version of Workbooks
 Add multiple datasheet of interest
 Can be formatted and fitted to many page-sizes

 Now you know how to model the most Basic Unit Operations of Aspen HYSYS ®
 You can model plenty of Common Processes by now!
 Get to practice on the Workshops!
 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!

 VIDEOS
 The Workbook
 Exporting Data to Excel
 Creating Reports

 Explain how to use the workshop
1. Statement
 Read it carefully, write down all important data. Find data that might be useful
2. Building the Flowsheet
 Build the diagram accordingly, “after”, “before” and “then”, “pre” are pretty important words
3. 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
4. Run Simulation
5. Results
 Go to results; review there are no warnings, errors.
6. Analysis&Conclusion
 Make an analysis and make your final conclusion

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

 We have a stream containing 15% ethane, 20% propane, 60% i-butane and 5% n-butane at T =
50°F and P = 1 atm. Flow rate is 100 kg/h
 It will be compressed to P = 50 psia and cooled down to 32°F.
 The chiller has a pressure loss of 10 kPa.
 The resulting mixture must be splitted into liquid (valuable product for our client) and a gas
(must be burnt with air)

 A) How much mass is lost in flare?
 B) How much product is recovered?
 C) Specifications of liquid product.
 C) Compressor Workload
 D) Chiller Heat Duty requirements

 Feed:
 Comopsition = 15% ethane, 20% propane, 60% i-butane and 5% n-butane (molar)
 FlowRate = 100 kg/h
 Temperature = 50°F
 Pressure = 1 atm
 Unit Operations Required
 Compressor
 Cooler
 Separator

 Compressor
 P = 50 psia
 %efficiency adiabatic = 75% (assumed)
 Cooler
 T final = 32°F
 dP = 10 kPa
 Separator
 Adiabatic
 Liquid/Vapor outlet

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

A B
C
D E

 016 Case Study I – Solvent

 Sour water stripper  Sample Aspen HYSYS

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

 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

 https://www.youtube.com/watch?v=1eGg1bW3LxY

 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
 Compressor 2 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)

 https://www.youtube.com/watch?v=uMw3A_NIEVc

 WRITTEN STATEMENT

 Select the best Unit Operations for the stated processes
 Select all stream requirements

 The most interesting part!
 Add all numerical DATA!

 Run the simulation
 Verify Errors
 Debug / Troubleshooting required?

 Verify your Results
 Compare

 PERSONAL VIDEO!

 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...)

2. Introduction to Aspen Plus
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

 Continue with the next course Intermediate and Advance!
 Other specific courses
 Dynamic
 Oil & Gas applications
 Petroleum Assay
 Economic Analysis
 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

 Dymamics/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)
 Reactor Engineering
 Modeling for mechanisms and kinetic theory
 Extractions
 Logical Operators
 Hydraulics (pressure drops, equipments)
 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
 Set
 Recycle

 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

 Coupons
 Contact Info
 Extra Content!

 Try “Aspen Plus – Basic Process Modeling” Course with a 90% off discount
 Coupon Code = 90OFF-HYSYS-STUDENT
 Link
 https://www.udemy.com/aspen-plus-process-modeling/?couponCode=90OFF-HYSYS-STUDENT

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