The document provides information on getting started with Aspen Plus process simulation software. It discusses setting up a flowsheet with common unit operations like heat exchangers, reactors, pumps, compressors, and distillation columns. It also presents a case study on simulating the separation of aromatics via distillation and other unit operations. The case study involves modeling the plant using Aspen Plus to verify material and energy balances as well as results for specific units.
This is a slideshow / resource / support material of the course.
Get full access (videlectures)
https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
x-x-x
Requirements
Basic understanding of Plant Design & Operation
Strong Chemical Engineering Fundamentals
Aspen Plus V10 (at least 7.0)
Aspen Plus – Basic Process Modeling (Very Recommended)
Aspen Plus – Intermediate Process Modeling (Somewhat Recommended)
Description
This BOOTCAMP will show you how to model and simulate common industrial Chemical Processes.
It is focused on the “BOOTCAMP” idea, in which you will learn via workshops and case studies, minimizing theory to maximize learning.
You will learn about:
Better Flowsheet manipulation and techniques
Understand Property Method Selection and its effects on simulation results
More than 15 Unit Operations that can be used in any Industry
Model Analysis Tools required for process design
Reporting Relevant Results Plot relevant data
Analysis & Optimization of Chemical Plants
Economic Analysis
Dynamic Simulations
At the end of this Bootcamp, you will be able to model more industrial processes, feel confident when modeling new processes as well as applying what you have learnt to other industries.
This is a slideshow / resource / support material of the course.
Get full access (videlectures)
https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
x-x-x
Requirements
Basic understanding of Plant Design & Operation
Strong Chemical Engineering Fundamentals
Aspen Plus V10 (at least 7.0)
Aspen Plus – Basic Process Modeling (Very Recommended)
Aspen Plus – Intermediate Process Modeling (Somewhat Recommended)
Description
This BOOTCAMP will show you how to model and simulate common industrial Chemical Processes.
It is focused on the “BOOTCAMP” idea, in which you will learn via workshops and case studies, minimizing theory to maximize learning.
You will learn about:
Better Flowsheet manipulation and techniques
Understand Property Method Selection and its effects on simulation results
More than 15 Unit Operations that can be used in any Industry
Model Analysis Tools required for process design
Reporting Relevant Results Plot relevant data
Analysis & Optimization of Chemical Plants
Economic Analysis
Dynamic Simulations
At the end of this Bootcamp, you will be able to model more industrial processes, feel confident when modeling new processes as well as applying what you have learnt to other industries.
This is course on Plant Simulation will show you how to setup hypothetical compounds, oil assays, blends, and petroleum characterization using the Oil Manager of Aspen HYSYS.
You will learn about:
Hypothetical Compounds (Hypos)
Estimation of hypo compound data
Models via Chemical Structure UNIFAC Component Builder
Basis conversion/cloning of existing components
Input of Petroleum Assay and Crude Oils
Typical Bulk Properties (Molar Weight, Density, Viscosity)
Distillation curves such as TBP (Total Boiling Point)
ASTM (D86, D1160, D86-D1160, D2887)
Chromatography
Light End
Oil Characterization
Using the Petroleum Assay Manager or the Oil Manager
Importing Assays: Existing Database
Creating Assays: Manually / Model
Cutting: Pseudocomponent generation
Blending of crude oils
Installing oils into Aspen HYSYS flowsheets
Getting Results (Plots, Graphs, Tables)
Property and Composition Tables
Distribution Plot (Off Gas, Light Short Run, Naphtha, Kerosene, Light Diesel, Heavy Diesel, Gasoil, Residue)
Oil Properties
Proper
Boiling Point Curves
Viscosity, Density, Molecular Weight Curves
This is helpful for students, teachers, engineers and researchers in the area of R&D, specially those in the Oil and Gas or Petroleum Refining industry.
This is a "workshop-based" course, there is about 25% theory and about 75% work!
At the end of the course you will be able to handle crude oils for your fractionation, refining, petrochemical process simulations!
Based on the information provided, a hydrocarbon system and petroleum refining process type have been selected. The recommended property package is NRTL.
Does this help summarize the recommended package? Let me know if you need any clarification or have additional questions!
LINK:
https://www.chemicalengineeringguy.com/courses/aspen-plus-intermediate-course/
The INTERMEDIATE Aspen Plus Course will show you how to model and simulate more complex Processes
Analysis of Unit Operation will help you in order to simulate more complex chemical processes, as well as to analyse and optimize existing ones.
You will learn about:
- Better Flowsheet manipulation
- Hierarchy, Flowsheeting, Sub-flowsheet creation
- Logical Operators / Manipulators
- Understand Property Method Selection and its effects on simulation results
- Study of more rigorous unit operations
- Model Analysis Tools such as sensitivity and optimization
- Reporting Relevant Results Plot relevant data for Heaters, Columns ,Reactors, Pumps
- Temperature Profiles, Concentration Profile, Pump Curves, Heat Curves, etc…
- Up to 3 Case Studies (in-depth analysis)
All theory is backed up by more than 30 Practical Workshops!
At the end of the course you will be able to setup more complex processes, increase your simulation and flow sheeting techniques, run it and debugging, get relevant results and make a deeper analysis of the process for further optimization.
FULL COURSE:
https://courses.chemicalengineeringguy.com/p/flash-distillation-in-chemical-process-engineering/
Introduction:
Binary Distillation is one of the most important Mass Transfer Operations used extensively in the Chemical industry.
Understanding the concept behind Gas-Gas, Liquid-Liquid and the Gas-Liquid mass transfer interaction will allow you to understand and model Distillation Columns, Flashes, Batch Distillator, Tray Columns and Packed column, etc...
We will cover:
REVIEW: Of Mass Transfer Basics (Equilibrium VLE Diagrams, Volatility, Raoult's Law, Azeotropes, etc..)
Distillation Theory - Concepts and Principles
Application of Distillation in the Industry
Equipment for Flashing Systems such as Flash Drums
Design & Operation of Flash Drums
Material and Energy Balances for flash systems
Adiabatic and Isothermal Operation
Animations and Software Simulation for Flash Distillation Systems (ASPEN PLUS/HYSYS)
Theory + Solved Problem Approach:
All theory is taught and backed with exercises, solved problems, and proposed problems for homework/individual study.
At the end of the course:
You will be able to understand mass transfer mechanism and processes behind Flash Distillation.
You will be able to continue with Batch Distillation, Fractional Distillation, Continuous Distillation and further courses such as Multi-Component Distillation, Reactive Distillation and Azeotropic Distillation.
About your instructor:
I majored in Chemical Engineering with a minor in Industrial Engineering back in 2012.
I worked as a Process Design/Operation Engineer in INEOS Koln, mostly on the petrochemical area relating to naphtha treating.
There I designed and modeled several processes relating separation of isopentane/pentane mixtures, catalytic reactors and separation processes such as distillation columns, flash separation devices and transportation of tank-trucks of product.
The document discusses Aspen Plus and its physical property methods. It covers topics such as component specification, property methods, property sets, analysis tools, data regression, property estimation, and applications. Property methods include ideal, activity, equation of state, and special models. Parameters include pure component and binary interaction parameters. The document provides an overview of using Aspen Plus to model physical properties of pure components, binary mixtures, and more complex systems.
This document provides an overview of applied fluid dynamics related to pumps. It discusses various pump types including positive displacement and kinetic pumps. Positive displacement pumps are further divided into rotary and reciprocal types. Rotary positive displacement pumps include gear, screw, progressive cavity, lobe and peristaltic pumps. Reciprocal positive displacement pumps include piston and diaphragm pumps. Kinetic pumps discussed are centrifugal and axial flow pumps. The document also covers pump performance parameters such as head, efficiency and NPSH. Cavitation is explained as a phenomenon caused by vapor bubbles forming due to a drop in pressure below the vapor pressure. Methods to calculate NPSHA and determine if cavitation will occur are presented along with an example problem.
This is a slideshow / resource / support material of the course.
Get full access (videlectures)
https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
x-x-x
Requirements
Basic understanding of Plant Design & Operation
Strong Chemical Engineering Fundamentals
Aspen Plus V10 (at least 7.0)
Aspen Plus – Basic Process Modeling (Very Recommended)
Aspen Plus – Intermediate Process Modeling (Somewhat Recommended)
Description
This BOOTCAMP will show you how to model and simulate common industrial Chemical Processes.
It is focused on the “BOOTCAMP” idea, in which you will learn via workshops and case studies, minimizing theory to maximize learning.
You will learn about:
Better Flowsheet manipulation and techniques
Understand Property Method Selection and its effects on simulation results
More than 15 Unit Operations that can be used in any Industry
Model Analysis Tools required for process design
Reporting Relevant Results Plot relevant data
Analysis & Optimization of Chemical Plants
Economic Analysis
Dynamic Simulations
At the end of this Bootcamp, you will be able to model more industrial processes, feel confident when modeling new processes as well as applying what you have learnt to other industries.
This is a slideshow / resource / support material of the course.
Get full access (videlectures)
https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
x-x-x
Requirements
Basic understanding of Plant Design & Operation
Strong Chemical Engineering Fundamentals
Aspen Plus V10 (at least 7.0)
Aspen Plus – Basic Process Modeling (Very Recommended)
Aspen Plus – Intermediate Process Modeling (Somewhat Recommended)
Description
This BOOTCAMP will show you how to model and simulate common industrial Chemical Processes.
It is focused on the “BOOTCAMP” idea, in which you will learn via workshops and case studies, minimizing theory to maximize learning.
You will learn about:
Better Flowsheet manipulation and techniques
Understand Property Method Selection and its effects on simulation results
More than 15 Unit Operations that can be used in any Industry
Model Analysis Tools required for process design
Reporting Relevant Results Plot relevant data
Analysis & Optimization of Chemical Plants
Economic Analysis
Dynamic Simulations
At the end of this Bootcamp, you will be able to model more industrial processes, feel confident when modeling new processes as well as applying what you have learnt to other industries.
This is course on Plant Simulation will show you how to setup hypothetical compounds, oil assays, blends, and petroleum characterization using the Oil Manager of Aspen HYSYS.
You will learn about:
Hypothetical Compounds (Hypos)
Estimation of hypo compound data
Models via Chemical Structure UNIFAC Component Builder
Basis conversion/cloning of existing components
Input of Petroleum Assay and Crude Oils
Typical Bulk Properties (Molar Weight, Density, Viscosity)
Distillation curves such as TBP (Total Boiling Point)
ASTM (D86, D1160, D86-D1160, D2887)
Chromatography
Light End
Oil Characterization
Using the Petroleum Assay Manager or the Oil Manager
Importing Assays: Existing Database
Creating Assays: Manually / Model
Cutting: Pseudocomponent generation
Blending of crude oils
Installing oils into Aspen HYSYS flowsheets
Getting Results (Plots, Graphs, Tables)
Property and Composition Tables
Distribution Plot (Off Gas, Light Short Run, Naphtha, Kerosene, Light Diesel, Heavy Diesel, Gasoil, Residue)
Oil Properties
Proper
Boiling Point Curves
Viscosity, Density, Molecular Weight Curves
This is helpful for students, teachers, engineers and researchers in the area of R&D, specially those in the Oil and Gas or Petroleum Refining industry.
This is a "workshop-based" course, there is about 25% theory and about 75% work!
At the end of the course you will be able to handle crude oils for your fractionation, refining, petrochemical process simulations!
Based on the information provided, a hydrocarbon system and petroleum refining process type have been selected. The recommended property package is NRTL.
Does this help summarize the recommended package? Let me know if you need any clarification or have additional questions!
LINK:
https://www.chemicalengineeringguy.com/courses/aspen-plus-intermediate-course/
The INTERMEDIATE Aspen Plus Course will show you how to model and simulate more complex Processes
Analysis of Unit Operation will help you in order to simulate more complex chemical processes, as well as to analyse and optimize existing ones.
You will learn about:
- Better Flowsheet manipulation
- Hierarchy, Flowsheeting, Sub-flowsheet creation
- Logical Operators / Manipulators
- Understand Property Method Selection and its effects on simulation results
- Study of more rigorous unit operations
- Model Analysis Tools such as sensitivity and optimization
- Reporting Relevant Results Plot relevant data for Heaters, Columns ,Reactors, Pumps
- Temperature Profiles, Concentration Profile, Pump Curves, Heat Curves, etc…
- Up to 3 Case Studies (in-depth analysis)
All theory is backed up by more than 30 Practical Workshops!
At the end of the course you will be able to setup more complex processes, increase your simulation and flow sheeting techniques, run it and debugging, get relevant results and make a deeper analysis of the process for further optimization.
FULL COURSE:
https://courses.chemicalengineeringguy.com/p/flash-distillation-in-chemical-process-engineering/
Introduction:
Binary Distillation is one of the most important Mass Transfer Operations used extensively in the Chemical industry.
Understanding the concept behind Gas-Gas, Liquid-Liquid and the Gas-Liquid mass transfer interaction will allow you to understand and model Distillation Columns, Flashes, Batch Distillator, Tray Columns and Packed column, etc...
We will cover:
REVIEW: Of Mass Transfer Basics (Equilibrium VLE Diagrams, Volatility, Raoult's Law, Azeotropes, etc..)
Distillation Theory - Concepts and Principles
Application of Distillation in the Industry
Equipment for Flashing Systems such as Flash Drums
Design & Operation of Flash Drums
Material and Energy Balances for flash systems
Adiabatic and Isothermal Operation
Animations and Software Simulation for Flash Distillation Systems (ASPEN PLUS/HYSYS)
Theory + Solved Problem Approach:
All theory is taught and backed with exercises, solved problems, and proposed problems for homework/individual study.
At the end of the course:
You will be able to understand mass transfer mechanism and processes behind Flash Distillation.
You will be able to continue with Batch Distillation, Fractional Distillation, Continuous Distillation and further courses such as Multi-Component Distillation, Reactive Distillation and Azeotropic Distillation.
About your instructor:
I majored in Chemical Engineering with a minor in Industrial Engineering back in 2012.
I worked as a Process Design/Operation Engineer in INEOS Koln, mostly on the petrochemical area relating to naphtha treating.
There I designed and modeled several processes relating separation of isopentane/pentane mixtures, catalytic reactors and separation processes such as distillation columns, flash separation devices and transportation of tank-trucks of product.
The document discusses Aspen Plus and its physical property methods. It covers topics such as component specification, property methods, property sets, analysis tools, data regression, property estimation, and applications. Property methods include ideal, activity, equation of state, and special models. Parameters include pure component and binary interaction parameters. The document provides an overview of using Aspen Plus to model physical properties of pure components, binary mixtures, and more complex systems.
This document provides an overview of applied fluid dynamics related to pumps. It discusses various pump types including positive displacement and kinetic pumps. Positive displacement pumps are further divided into rotary and reciprocal types. Rotary positive displacement pumps include gear, screw, progressive cavity, lobe and peristaltic pumps. Reciprocal positive displacement pumps include piston and diaphragm pumps. Kinetic pumps discussed are centrifugal and axial flow pumps. The document also covers pump performance parameters such as head, efficiency and NPSH. Cavitation is explained as a phenomenon caused by vapor bubbles forming due to a drop in pressure below the vapor pressure. Methods to calculate NPSHA and determine if cavitation will occur are presented along with an example problem.
Aspen Plus basic course for Engineers.
Introduction to Process Modeling/Simulation Software.
INDEX:
Course Objectives
Introduction to Aspen Plus
User Interface & Getting Help
Physical Properties
Introduction to Flowsheet
Unit Operation Models
Reporting Results
Case Studies I, II and III
Case Study IV
Conclusion
This document describes a training course on process simulation using HYSYS V8. The course will teach participants how to build, navigate and optimize process simulations in HYSYS. The document provides an overview of HYSYS and its capabilities. It also outlines the modules to be covered in the course, including getting started, refrigerated gas plants, fractionation trains, and optimization. The course is intended for engineers who will use HYSYS in process design, optimization and plant operations.
The document provides an overview of distillation and APV's role in developing distillation systems. It discusses the basic principles of distillation, including vapor-liquid equilibrium and how differences in vapor pressure allow for separation of components. Distillation involves boiling the mixture to produce vapor with a different composition than the liquid, and then condensing and reboiling to gradually concentrate components. The key factors that determine how easily components can be separated are the relative volatility and vapor pressure. APV has over 70 years of experience providing customized distillation systems and services to various industries.
Tube Wall Temperature Measurement On Steam Reformers - Best PracticesGerard B. Hawkins
GBH Enterprises provides guidance on best practices for measuring tube wall temperatures in steam reformers using optical pyrometers. It is important to measure temperatures accurately to prevent overheating tubes while maximizing plant efficiency. GBH recommends taking multiple temperature and background readings per tube using handheld pyrometers and an emissivity correction factor. Safety precautions like protective equipment are also advised. Detailed procedures are outlined for top-fired, side-fired and terrace wall furnace configurations.
Isothermal Methanol Converter (IMC) UA Distribution AnalysisGerard B. Hawkins
Isothermal Methanol Converter (IMC) UA Distribution Analysis - Case Study: #0630416GB/H; ACME Co. 9,000 MTD MeOH
This converter uses plates instead of tubes to remove the heat from the reaction gas. The use of the plates and the orientation allow the heat transfer within the converter to be more accurately controlled to follow the maximum rate line.
This case study examines the Radial Flow – Isothermal Methanol Converter (IMC) for ACME Co. 9,000 MTD, based on the Casale Isothermal Methanol Converter (IMC) design.
Naphtha Steam Reforming Catalyst Reduction by NH3 CrackingGerard B. Hawkins
Procedure for Naphtha Steam Reforming Catalyst Reduction by NH3 Cracking
Scope
This procedure applies to the in situ reduction of VULCAN Series steam reforming catalysts using ammonia cracking to form hydrogen over the catalyst in the steam reformer. This procedure covers plants with a dry gas circulation loop for reduction. The procedure is likely to be applied to plants using only heavier feeds (e.g.: LPG and/or naphtha) and some combination of VULCAN Series catalysts.
Introduction
A small number of steam reforming plants do not have an available source of the commonly used reducing media (e.g.: hydrogen, hydrogen-rich off-gas, natural gas). These plants will usually operate on LPG and/or naphtha feed only where cracking of this hydrocarbon is not usually advised for reduction of the steam reforming catalyst. In such circumstances, the plant may be designed to use the installed steam reforming catalyst to crack ammonia to provide hydrogen for the reformer catalyst reduction....
1. This tutorial presents the design of a heat exchanger network for a crude pre-heat train. The network will heat crude oil using product streams before the oil enters a desalter and pre-flash unit.
2. Process and utility streams are created, including crude oil, product streams, cooling water, and boiler feed water. Heat exchangers are added to heat the crude using the product streams.
3. The worksheet is used to enter heat exchanger information and manipulate the network to complete the pre-flash section and overall heat exchanger network design.
This document contains details about 8 process simulation cases involving topics like flash separation, refrigeration cycles, distillation columns, gas processing, compression, and heat exchangers. Case 1 models a flash separation with specifications provided. Case 2 models a propane refrigeration cycle. Case 3 models a natural gas processing facility using propane refrigeration. The remaining cases involve additional simulations related to distillation, compression, and heat exchangers.
Determination of Inert Gas in Anhydrous Ammonia
ANHYDROUS AMMONIA: DETERMINATION OF INERT GASES
SCOPE AND FIELD OF APPLICATION
This packed-column GC method is suitable for the determination of hydrogen, nitrogen, oxygen, argon and carbon monoxide in anhydrous ammonia. The determinations of the gases are linear in the range O-100 ppm v/v.
This document provides an overview of the book "Practical Distillation Control" edited by William L. Luyben. The book contains 25 chapters contributed by various experts on distillation control. It aims to consolidate knowledge on distillation control techniques and methods that have proven useful, including dynamic modeling, simulation, system identification, and multivariable control methods. It also provides examples of applying these methods to specific distillation columns and classes of columns. The collection aims to provide a unique resource combining the extensive experience of over 400 years from leading authorities in the field.
This document summarizes a design project for a fixed bed catalytic reactor. It includes an executive summary highlighting the economic and environmental benefits of the project. The design basis and constraints are outlined. Environmental considerations like mist formation and corrosion are addressed. The design was optimized using software tools, and equipment was sized. Capital costs were estimated for the reactor and other plant equipment based on mechanical designs and cost data. Appendices provide detailed calculations and specifications for the reactor design and equipment.
This document discusses methanol synthesis from carbon dioxide and hydrogen. It provides details on the key synthesis reaction, kinetics, equilibrium, catalyst activity, byproducts and side reactions. The maximum rate of the methanol reaction is defined and diagrams show how operating conditions can be optimized to follow the maximum rate line for minimum catalyst volume. Potential byproducts like ethanol, ketones, and hydrocarbons are also summarized.
The document discusses removing ammonia from storm water through a stripping process. Key points:
1) Ammonia exists primarily as unionized NH3 above pH 10, allowing for easier removal. A pilot plant achieved over 90% removal at pH 11.
2) Mass and energy balances were performed on a simplified process involving preheating, alkalization with NaOH, and stripping ammonia with air in a column. Less than 20 ppm ammonia remained.
3) Hazards were analyzed through HAZOP. Key risks involved pressure buildup, which can be mitigated with flow and pressure controls. Maintaining proper pH is important for robust ammonia removal.
This document provides instructions for constructing an Aspen HYSYS simulation of cyclohexane production via benzene hydrogenation. It includes process details like feed streams, operating specifications, and reaction chemistry. The simulation involves building a flowsheet with a mixer, heater, conversion reactor, cooler, separator, recycle loops, and distillation column. Step-by-step instructions are provided to define each unit operation using the HYSYS interface and solve the simulation.
Hydrogenation Reactors
Stirred Vessels
Loop Reactors
Other reactor types
Appendix
- List of contact details for suppliers
- Information from supplier’s websites
Determination of Oxygen in Anhydrous Ammonia
SCOPE AND FIELD OF APPLICATION
This method is suitable for the determination of trace amounts of oxygen in Liquefied anhydrous ammonia.
The trace oxygen analyzer provides for trace oxygen analysis in decade steps ranging from 0 - 10 to 0 - 10,000 ppm v/v (full scale).
Role of gasification modelling in overall plant designIlkka Hannula
This document discusses gasification modelling and its role in the overall design of biomass-to-liquids (BTL) plants. It provides simplified block diagrams of a BTL plant and shows experimental conversions as a function of reactor temperature. Gasification modelling is important for validation against raw gas measurements, with typical errors of around 5%. The document also presents results from modelling different BTL plant designs, including capital and production costs. Overall, gasification modelling provides valuable insights for optimizing BTL plant design and economics.
Aspen HYSYS - Your very first HYSYS Simulation (1).pdfMoustaphaKONE5
The document discusses using process simulation software like Aspen HYSYS to model a chemical plant processing methane, iso-pentane, and dodecane. It provides step-by-step instructions on building a flowsheet in Aspen HYSYS that includes a flash drum, heater, reactor, distillation column, and other unit operations. It also describes performing case studies by changing process parameters like air flowrate and reactor temperature to analyze their effects. The overall document aims to provide an introductory knowledge of process modeling and simulation.
This document discusses condensate management and return systems. It describes various methods for returning condensate, including electric centrifugal pumps and mechanical pumps. Electric pumps require maintenance but are inexpensive, while mechanical pumps have fewer moving parts. The document also discusses considerations for closed-loop condensate return systems and recovering flash steam from condensate for uses like preheating.
Aspen Plus basic course for Engineers.
Introduction to Process Modeling/Simulation Software.
INDEX:
Course Objectives
Introduction to Aspen Plus
User Interface & Getting Help
Physical Properties
Introduction to Flowsheet
Unit Operation Models
Reporting Results
Case Studies I, II and III
Case Study IV
Conclusion
This document describes a training course on process simulation using HYSYS V8. The course will teach participants how to build, navigate and optimize process simulations in HYSYS. The document provides an overview of HYSYS and its capabilities. It also outlines the modules to be covered in the course, including getting started, refrigerated gas plants, fractionation trains, and optimization. The course is intended for engineers who will use HYSYS in process design, optimization and plant operations.
The document provides an overview of distillation and APV's role in developing distillation systems. It discusses the basic principles of distillation, including vapor-liquid equilibrium and how differences in vapor pressure allow for separation of components. Distillation involves boiling the mixture to produce vapor with a different composition than the liquid, and then condensing and reboiling to gradually concentrate components. The key factors that determine how easily components can be separated are the relative volatility and vapor pressure. APV has over 70 years of experience providing customized distillation systems and services to various industries.
Tube Wall Temperature Measurement On Steam Reformers - Best PracticesGerard B. Hawkins
GBH Enterprises provides guidance on best practices for measuring tube wall temperatures in steam reformers using optical pyrometers. It is important to measure temperatures accurately to prevent overheating tubes while maximizing plant efficiency. GBH recommends taking multiple temperature and background readings per tube using handheld pyrometers and an emissivity correction factor. Safety precautions like protective equipment are also advised. Detailed procedures are outlined for top-fired, side-fired and terrace wall furnace configurations.
Isothermal Methanol Converter (IMC) UA Distribution AnalysisGerard B. Hawkins
Isothermal Methanol Converter (IMC) UA Distribution Analysis - Case Study: #0630416GB/H; ACME Co. 9,000 MTD MeOH
This converter uses plates instead of tubes to remove the heat from the reaction gas. The use of the plates and the orientation allow the heat transfer within the converter to be more accurately controlled to follow the maximum rate line.
This case study examines the Radial Flow – Isothermal Methanol Converter (IMC) for ACME Co. 9,000 MTD, based on the Casale Isothermal Methanol Converter (IMC) design.
Naphtha Steam Reforming Catalyst Reduction by NH3 CrackingGerard B. Hawkins
Procedure for Naphtha Steam Reforming Catalyst Reduction by NH3 Cracking
Scope
This procedure applies to the in situ reduction of VULCAN Series steam reforming catalysts using ammonia cracking to form hydrogen over the catalyst in the steam reformer. This procedure covers plants with a dry gas circulation loop for reduction. The procedure is likely to be applied to plants using only heavier feeds (e.g.: LPG and/or naphtha) and some combination of VULCAN Series catalysts.
Introduction
A small number of steam reforming plants do not have an available source of the commonly used reducing media (e.g.: hydrogen, hydrogen-rich off-gas, natural gas). These plants will usually operate on LPG and/or naphtha feed only where cracking of this hydrocarbon is not usually advised for reduction of the steam reforming catalyst. In such circumstances, the plant may be designed to use the installed steam reforming catalyst to crack ammonia to provide hydrogen for the reformer catalyst reduction....
1. This tutorial presents the design of a heat exchanger network for a crude pre-heat train. The network will heat crude oil using product streams before the oil enters a desalter and pre-flash unit.
2. Process and utility streams are created, including crude oil, product streams, cooling water, and boiler feed water. Heat exchangers are added to heat the crude using the product streams.
3. The worksheet is used to enter heat exchanger information and manipulate the network to complete the pre-flash section and overall heat exchanger network design.
This document contains details about 8 process simulation cases involving topics like flash separation, refrigeration cycles, distillation columns, gas processing, compression, and heat exchangers. Case 1 models a flash separation with specifications provided. Case 2 models a propane refrigeration cycle. Case 3 models a natural gas processing facility using propane refrigeration. The remaining cases involve additional simulations related to distillation, compression, and heat exchangers.
Determination of Inert Gas in Anhydrous Ammonia
ANHYDROUS AMMONIA: DETERMINATION OF INERT GASES
SCOPE AND FIELD OF APPLICATION
This packed-column GC method is suitable for the determination of hydrogen, nitrogen, oxygen, argon and carbon monoxide in anhydrous ammonia. The determinations of the gases are linear in the range O-100 ppm v/v.
This document provides an overview of the book "Practical Distillation Control" edited by William L. Luyben. The book contains 25 chapters contributed by various experts on distillation control. It aims to consolidate knowledge on distillation control techniques and methods that have proven useful, including dynamic modeling, simulation, system identification, and multivariable control methods. It also provides examples of applying these methods to specific distillation columns and classes of columns. The collection aims to provide a unique resource combining the extensive experience of over 400 years from leading authorities in the field.
This document summarizes a design project for a fixed bed catalytic reactor. It includes an executive summary highlighting the economic and environmental benefits of the project. The design basis and constraints are outlined. Environmental considerations like mist formation and corrosion are addressed. The design was optimized using software tools, and equipment was sized. Capital costs were estimated for the reactor and other plant equipment based on mechanical designs and cost data. Appendices provide detailed calculations and specifications for the reactor design and equipment.
This document discusses methanol synthesis from carbon dioxide and hydrogen. It provides details on the key synthesis reaction, kinetics, equilibrium, catalyst activity, byproducts and side reactions. The maximum rate of the methanol reaction is defined and diagrams show how operating conditions can be optimized to follow the maximum rate line for minimum catalyst volume. Potential byproducts like ethanol, ketones, and hydrocarbons are also summarized.
The document discusses removing ammonia from storm water through a stripping process. Key points:
1) Ammonia exists primarily as unionized NH3 above pH 10, allowing for easier removal. A pilot plant achieved over 90% removal at pH 11.
2) Mass and energy balances were performed on a simplified process involving preheating, alkalization with NaOH, and stripping ammonia with air in a column. Less than 20 ppm ammonia remained.
3) Hazards were analyzed through HAZOP. Key risks involved pressure buildup, which can be mitigated with flow and pressure controls. Maintaining proper pH is important for robust ammonia removal.
This document provides instructions for constructing an Aspen HYSYS simulation of cyclohexane production via benzene hydrogenation. It includes process details like feed streams, operating specifications, and reaction chemistry. The simulation involves building a flowsheet with a mixer, heater, conversion reactor, cooler, separator, recycle loops, and distillation column. Step-by-step instructions are provided to define each unit operation using the HYSYS interface and solve the simulation.
Hydrogenation Reactors
Stirred Vessels
Loop Reactors
Other reactor types
Appendix
- List of contact details for suppliers
- Information from supplier’s websites
Determination of Oxygen in Anhydrous Ammonia
SCOPE AND FIELD OF APPLICATION
This method is suitable for the determination of trace amounts of oxygen in Liquefied anhydrous ammonia.
The trace oxygen analyzer provides for trace oxygen analysis in decade steps ranging from 0 - 10 to 0 - 10,000 ppm v/v (full scale).
Role of gasification modelling in overall plant designIlkka Hannula
This document discusses gasification modelling and its role in the overall design of biomass-to-liquids (BTL) plants. It provides simplified block diagrams of a BTL plant and shows experimental conversions as a function of reactor temperature. Gasification modelling is important for validation against raw gas measurements, with typical errors of around 5%. The document also presents results from modelling different BTL plant designs, including capital and production costs. Overall, gasification modelling provides valuable insights for optimizing BTL plant design and economics.
Aspen HYSYS - Your very first HYSYS Simulation (1).pdfMoustaphaKONE5
The document discusses using process simulation software like Aspen HYSYS to model a chemical plant processing methane, iso-pentane, and dodecane. It provides step-by-step instructions on building a flowsheet in Aspen HYSYS that includes a flash drum, heater, reactor, distillation column, and other unit operations. It also describes performing case studies by changing process parameters like air flowrate and reactor temperature to analyze their effects. The overall document aims to provide an introductory knowledge of process modeling and simulation.
This document discusses condensate management and return systems. It describes various methods for returning condensate, including electric centrifugal pumps and mechanical pumps. Electric pumps require maintenance but are inexpensive, while mechanical pumps have fewer moving parts. The document also discusses considerations for closed-loop condensate return systems and recovering flash steam from condensate for uses like preheating.
This document provides instructions for starting up a steam turbine. It outlines the sequence of operations that must be followed, including: opening drains, charging the steam line, starting the cooling water system, operating the condensate system, starting the oil system, putting the turbine on barring, building vacuum, charging gland steam, rolling the turbine, and synchronizing once full speed is reached. Special attention is given to ensuring auxiliary systems are operational and parameters are within limits at each stage to safely start the turbine.
Veera Babu Gollapalli is applying for a position as a Process Operator or Panel Operator with over 8 years of experience working in ammonia plants and utilities in India and Saudi Arabia. He has a Bachelor's degree in Chemistry and is proficient in plant operations, pre-commissioning, commissioning, and maintenance activities. His responsibilities have included operating equipment across various plant sections including reforming, synthesis, refrigeration, and more. He is skilled in operating systems like compressors, turbines, heat exchangers, and other process equipment.
This document provides a summary of an individual's qualifications for an operator role. It outlines 8.5 years of experience as an operator in India and Saudi Arabia, including experience operating ammonia plants and utilities. Educational qualifications include a Bachelor's degree in chemistry. Responsibilities have included operating equipment in areas like reforming, acid gas removal, refrigeration, and distillation. Safety training and qualifications are also mentioned. The individual is seeking an operator role utilizing their experience.
This presentation summarizes retrofit options for aging methanol plants to improve efficiency and increase production. Some options discussed include adding a secondary reformer, pre-reformer, saturator, combustion air preheat, and replacing the existing converter. Modeling the entire plant is important for evaluating retrofit options. Partner selection, project management, and hazard reviews are also critical success factors. GBHE Catalysts offers detailed models, engineering expertise, and a one-stop shop for feasibility studies, front-end engineering, and retrofit design.
Thermal Power Plant Simulator, Cold, warm and Hot rolling of Steam TurbineManohar Tatwawadi
The presentation describes the cold rolling, warm rolling and hot rolling and synchronising of steam turbine. The Temperature Matching Chart for Turbine metal and Steam is also discussed in the presentation
Three main methods are used to remove nitrogen from natural gas: cryogenic distillation, adsorption, and membrane separation. Cryogenic distillation involves using low temperatures and pressures to separate gas components. It is most effective at recovering ethane, propane, butane, and natural gasoline. Adsorption uses materials like molecular sieves to attract moisture and other compounds from the gas stream. Membrane separation exploits differences in molecular sizes to selectively permeate some components over others.
Process optimisation top energy efficiency solutions in waste energy.BRONSWERK
The AfvalEnergie Bedrijf (AEB) in Amsterdam aimed to maximize environmental efficiency in processing waste. To increase electricity production, AEB opted for a two-stage turbine with steam reheating between stages. This increased efficiency by over 30%, producing over 30% more electricity from the same fuel amount. Bronswerk supplied the reheater units and dump condenser, using innovative techniques like the High Pressure Compact Header, to provide AEB with a uniquely high efficiency incinerator.
The document describes the key components and operating parameters of high pressure ammonia feed pumps (P-1). P-1 pumps ammonia at high pressure from 20-240 kg/cm2. It consists of reciprocating plungers, packing seals, lube oil systems, and driving components. Critical parameters include plunger speed, discharge pressure, seal water pressure, and lube oil pressure which are monitored to protect the pump. Detailed startup, operation, and shutdown procedures are outlined to safely charge and depressurize the pump.
This document discusses how to optimize energy usage in pumps through condition monitoring techniques. Pumps use 25% of the world's motor-driven electricity, or around 6.5% of global electricity production. Condition monitoring can detect degradation in bearings, casing wear, misalignment, and internal wear in impellers and seals. Performance analysis by measuring head-flow curves is particularly useful for detecting internal wear and optimizing the timing of pump overhauls to balance repair costs and wasted energy. The document provides examples of using performance analysis on boiler feed pumps to schedule optimal overhaul times that minimize total costs.
Power Plant Simulator, Unloading and shutting the TurbogeneratorManohar Tatwawadi
The Presentation describes the steps for gradual unloading of the machine/turbogenerator for a planned shutdown. The steps are described in the presentation.
A six-stroke engine works by adding two additional strokes - a water injection stroke and power stroke - to the traditional four-stroke cycle. This allows the engine to extract more energy from the high temperatures in the cylinder after combustion. The water injection stroke cools the cylinder while powering the additional power stroke, improving efficiency by around 40% over a four-stroke engine. The document outlines the working principle, modifications needed to the engine design like camshaft and water injector, advantages like reduced emissions and fuel consumption, and limitations such as cold starting issues.
The document discusses auxiliary boilers used in heavy fuel oil power plants. It provides starting and stopping procedures for two different auxiliary boiler units, and discusses the importance of regular boiler blowdown to remove impurities. Blowdown helps prevent scaling, corrosion and carries over of contaminants with the steam. The document also covers feedwater quality standards, use of deaerators to remove dissolved gases, and the causes and effects of steam hammer in pipelines.
This document provides an overview of a gas turbine power station in Uran, India. It discusses the key components of the power plant including the filter house, compressor, combustion chamber, gas turbine, generator, waste heat recovery plant, boiler, steam turbine, air cooled condenser, and transformer. It also discusses the starting frequency converter, gas skid, fuel management, and concludes by thanking those involved in the training project.
The document summarizes the key components and processes involved in oil production from offshore platforms. It describes how oil and gas are separated after being extracted from subsea wells through manifolds and gathered into the platform. The separated oil, gas, and water then undergo further treatment processes like compression and removal of impurities. Final stages involve storage of oil and gas, metering for export, and transfer through pipelines or marine loading to tankers for transportation.
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1. See discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/332913072
Aspen Plus - Getting Started Prepared by Chemical Engineering Guy
Presentation · February 2019
DOI: 10.13140/RG.2.2.36814.72005
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3. Change:
• All T of Reactors
• Feed Composition
• No. of Plates in Distl. Col
• T of Heat Ex
• Gas Sep. T
• Compressor P
• Utility Costs
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5. ▪ 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)
www.ChemicalEngineeringGuy.com
6. ▪ Mainly:
▪ Petrochemical
▪ Pharmaceutical
▪ Fine chemicals
▪ Other commodities such as:
▪ Sulfuric acids
▪ Chlorine/Caustic industry
▪ Solvents
▪ Coatings
▪ Many more…
www.ChemicalEngineeringGuy.com
7. ▪ Excelent for your curriculum as an engineer
▪ Perfect for analytical/numerical minds
▪ Good for debuging and fixing “what if” scenarios
www.ChemicalEngineeringGuy.com
8. 1. Introduction
2. Our Chemical Process!
3. Setting up the Physical Property Environment
4. Simulation Environment I – The Flowsheet
5. Simulation Environment II – Unit Operations
6. Running, Results & Analysis
7. Case Studies (A,B,C,D)
8. Conclusion
www.ChemicalEngineeringGuy.com
9. ▪ Introductory Knowledge of Processes Modeling
▪ Setting the adequate Physical Properties
▪ General Flowsheet Concepts
▪ Basic Flowsheet “manipulation”
▪ Common Unit Operations
▪ Minimum Requirements to set up & run a Simulation
▪ Analyze several changes in process conditions
▪ Create an interest in Process Modeling
www.ChemicalEngineeringGuy.com
10. ▪ Please contact me if required (doubts, questions, comments, suggestions)
▪ Contact@ChemicalEngineeringGuy.com
▪ More courses…
www.ChemicalEngineeringGuy.com
14. ▪ A hydrocarbon feed rich in aromatics is to be separated via a series of
separation processes.
▪ It is sent from a previous plant at ambient temperature (15°C) and
pressurized to 10 bar.
▪ A total of 100 kmol/h must be treated
▪ Most of the hydrocarbons msut be recovered and the leftovers will be burnt in
a combustion chamber.
▪ The combustion chamber will burn all hydrocarbons to form carbon dioxide.
Assume 100% combustion. The air for combustion was previously adjusted to
50°C, 10bar. There is no pression loss in the combustion chamber.
▪ The liquified section must be de-pressurized in order to continue treatment. It
drops to 2 bar via a valve.
www.ChemicalEngineeringGuy.com
15. ▪ This stream is then fed to a Distillation Column.
▪ It currently has a total of 15 trays.
▪ Feed tray must be between 7 and 8.
▪ Recommended operation is partial vapor in order to avoid an extra stage. Reflux
▪ Ratio is set to 5 (molar) and the approx.
▪ Pressure drop is unknown, but can be assumed to be low or negligible.
▪ At least 20% of the feed must be recovered for further treatment
▪ The Distillate is to be treated in a following process. It must be compressed to
5 bar. We use a compressor with approx. 88% efficiency. It can be modeled as
an isentropic compression.
www.ChemicalEngineeringGuy.com
16. ▪ The bottoms of this column are not pure enough. Further distillation is
required.
▪ The following column requires a total of:
▪ 20 trays feeding in 50% approx.
▪ It uses a total condenser since the distillate is required as a liquid
▪ Recommended Distillate recovery is 60%
▪ Reflux is set to 4 molar
▪ The pressure drop is unkown, but current process has:
▪ Condenser working ate 1.90 bar
▪ Reboiler working at 2.10 bar
▪ The distillate can be sent for storage
▪ The bottom must be further pressurized +0.5 bar in order to allow for
pressure drop due to frictions. Efficiency of pump is 66.7%
www.ChemicalEngineeringGuy.com
17. ▪ Requirements:
▪ Model the plant using Aspen Plus in Steady State
▪ Verify Material/Energy Balances of the unit operations & processes
▪ Verify purity and composition of streams
▪ Verify conditions such as T, P and Flow rates.
▪ For specific unit operations, verify their relevant results
▪ Heater → Heat duty
▪ Combustion Chamber → T-max, Heat released by reaction
▪ Compressor/Pump → Required Work
▪ For the Columns → Reboiler & Condenser Duties
www.ChemicalEngineeringGuy.com
24. ▪ PDF of Process diagram
▪ Spreadsheet with Unit Operations & Process conditions
▪ Spreadsheet with Component list & database
www.ChemicalEngineeringGuy.com
26. ▪ Min. Requirements:
▪ Adding Components to the Component List
▪ Selecting a Physical Property Method (Thermodynamic pack)
▪ If you want to further explore this environment →
▪ Aspen Plus - Physical Properties
▪ Different Types of Components
▪ Methods (EOS, Activity, Mixed)
▪ Modeling new/inexistent components
▪ Physical & Chemical Property Analysis
▪ Thermodynamic & Transport Properties
www.ChemicalEngineeringGuy.com
27. ▪ Add the following compounds to the “Component List”
▪ Methane
▪ Ethane
▪ Propane
▪ N-Butane
▪ Cyclohexane
▪ Benzene
▪ Toluene
▪ Oxygen
▪ Nitrogen
www.ChemicalEngineeringGuy.com
28. ▪ Select Peng Robinson, as it is mostly non-polar system
▪ Most models will be “set-up”
▪ Pure substances Properties will be loaded
▪ Binary Interactions are calculated
▪ Tip: Use the Method Assistant
www.ChemicalEngineeringGuy.com
31. ▪ Get to know what is a flowsheet and how to manipulate it.
▪ Menus, Tool, Areas, etc…
▪ Important:
▪ General Setup
▪ Blocks: Unit Operations, Others
▪ Streams (Material, Heat, Work)
▪ Analysis tools
www.ChemicalEngineeringGuy.com
32. ▪ Manipulation of the Flowsheet:
▪ Adding Unit Operations
▪ Adding Material and Energy streams
▪ Moving
▪ Labeling
▪ Rotating
▪ Deleting
▪ Copy and Pasting
www.ChemicalEngineeringGuy.com
33. ▪ Typical Unit Operations
▪ Adding UO
▪ Setting up
▪ Connecting streams
▪ Inlet/outlet
www.ChemicalEngineeringGuy.com
34. ▪ A hydrocarbon feed rich in aromatics is to be separated via a series of
separation processes.
▪ It is sent from a previous plant at ambient temperature (15°C) and
pressurized to 10 bar.
▪ A total of 100 kmol/h must be treated
▪ Most of the hydrocarbons msut be recovered and the leftovers will be burnt in
a combustion chamber.
▪ The combustion chamber will burn all hydrocarbons to form carbon dioxide.
Assume 100% combustion. The air for combustion was previously adjusted to
50°C, 10bar. There is no pression loss in the combustion chamber.
▪ The liquified section must be de-pressurized in order to continue treatment. It
drops to 2 bar via a valve.
www.ChemicalEngineeringGuy.com
35. ▪ This stream is then fed to a Distillation Column.
▪ It currently has a total of 15 trays.
▪ Feed tray must be between 7 and 8.
▪ Recommended operation is partial vapor in order to avoid an extra stage. Reflux
▪ Ratio is set to 5 (molar) and the approx.
▪ Pressure drop is unknown, but can be assumed to be low or negligible.
▪ At least 20% of the feed must be recovered for further treatment
▪ The Distillate is to be treated in a following process. It must be compressed to
5 bar. We use a compressor with approx. 88% efficiency. It can be modeled as
an isentropic compression.
www.ChemicalEngineeringGuy.com
36. ▪ The bottoms of this column are not pure enough. Further distillation is
required.
▪ The following column requires a total of:
▪ 20 trays feeding in 50% approx.
▪ It uses a total condenser since the distillate is required as a liquid
▪ Recommended Distillate recovery is 60%
▪ Reflux is set to 4 molar
▪ The pressure drop is unkown, but current process has:
▪ Condenser working ate 1.90 bar
▪ Reboiler working at 2.10 bar
▪ The distillate can be sent for storage
▪ The bottom must be further pressurized +0.5 bar in order to allow for
pressure drop due to frictions. Efficiency of pump is 66.7%
www.ChemicalEngineeringGuy.com
37. ▪ Requirements:
▪ Model the plant using Aspen Plus in Steady State
▪ Verify Material/Energy Balances of the unit operations & processes
▪ Verify purity and composition of streams
▪ Verify conditions such as T, P and Flow rates.
▪ For specific unit operations, verify their relevant results
▪ Heater → Heat duty
▪ Combustion Chamber → T-max, Heat released by reaction
▪ Compressor/Pump → Required Work
▪ For the Columns → Reboiler & Condenser Duties
www.ChemicalEngineeringGuy.com
61. ▪ Manual “what if” cases
▪ Change several inputs to get new outputs
▪ Change of T Heat
▪ Change of P valve
▪ Change of P Reactor
▪ Changer of Reflux Dist1
▪ Change of Stages Dist2
www.ChemicalEngineeringGuy.com
62. ▪ Compare your results with mine:
www.ChemicalEngineeringGuy.com
63. ▪ Change T = 40°C to T = 30°C of Heater
www.ChemicalEngineeringGuy.com
64. ▪ Change Pressure of Valve
▪ P = 1 bar
▪ P = 5 bar
www.ChemicalEngineeringGuy.com
No Drastic
Change
65. ▪ Change Pressure of Reactor
▪ P = -5bar
▪ P = 1bar
www.ChemicalEngineeringGuy.com
66. ▪ Change Reflux Ratio from 4 to 2 and/or 6 and/or 15
www.ChemicalEngineeringGuy.com
67. 1. Introduction
2. Our Chemical Process!
3. Setting up the Physical Property Environment
4. Simulation Environment I – The Flowsheet
5. Simulation Environment II – Unit Operations
6. Running, Results & Analysis
7. Case Studies
8. Conclusion
www.ChemicalEngineeringGuy.com
68. ▪ Introductory Knowledge of Processes Modeling
▪ General Flowsheet Concepts
▪ Setting the adequate Physical Properties
▪ Basic Flowsheet “manipulation”
▪ Minimum Requirements to set up & run a Simulation
▪ Common Unit Operations
▪ Create an interest in Process Modeling
www.ChemicalEngineeringGuy.com
69. Change:
• All T of Reactors
• Feed Composition
• No. of Plates in Distl. Col
• T of Heat Ex
• Gas Sep. T
• Compressor P
• Utility Costs
www.ChemicalEngineeringGuy.com
70. ▪ Typically, you will follow your training with
▪ Basic Course
▪ What do you learn there:
▪ More on Aspen Plus
▪ More on Physical Property Environment
▪ Flowsheet techniques
▪ More Unit Operations
▪ Analysis Tools
▪ Plenty Workshops
▪ Process & Industry Case Studies
www.ChemicalEngineeringGuy.com
72. ▪ Aspen Plus – Training Bundle includes:
▪ Aspen Plus – Getting Started
▪ Aspen Plus – Basic Course
▪ Aspen Plus – Physical Properties
▪ Aspen Plus – Intermediate Course
▪ Aspen Plus – Boot camp: 12 Case studies
▪ All other new upcoming Aspen Plus courses
www.ChemicalEngineeringGuy.com
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