A training file of Aspen HYSYS training designed by an expert team. It teaches the basic how to use Aspen HYSYS.

1. Supported by:
Aspen HYSYS Training
Module 3: Basic Equipments in HYSYS
Tutor:
M. Ersharry Yunashtanto
Zayyanatun Zulfa
Ikha Muliawati
Mada Harahap

2. 1. Mixer
2. Tee (Flow Splitter)
3. Separator
4. Pump
5. Compressor
6. Expander
7. Valve
BASIC EQUIPMENTS IN HYSYS
8.Cooler
9. Heater
10. Heat Exchanger
11. Reactor CSTR
12. Reactor PFR
13. Distilation Column

3. 1. Mixer
Unit Function
• To Mix/Combine
two/multiple feed streams
as one product stream
Important Design
Parameter
• Automatic Pressure
Assignment
• Equalize All
• Set Outlet to Lowest
Inlet
Objective of Unit
• To calculate the final properties of
mixed fluid (using flash calculation)
OPEN EXERCISE 3.1

4. 1. Mixer (Cont’d)
A. Set Outlet to Lowest Inlet

5. 1. Mixer (Cont’d)
B. Equalize All

6. 2. Tee (Flow Splitter)
Unit Function
• To divide one feed
stream into
two/multiple
product streams
Important Design
Parameter
• Flow Ratio
• Flow ratio (Fr) for
each stream
0 ≤ Fr ≤ 1
Objective of Unit
• To get multiple product streams
with same operating condition (P&T)
and composition as feed stream

7. 3. Separator
2-Phase
Separator
3-Phase
Separator
Why do we need
Separation ???
Disperse Phase can have
undesirable effects, i.e:
1. Steam which has a little
moisture entrained in it can
leave undesirable silica
deposits on superheater tube
2. Water carried over into turbine
from a boiler can erode the
blades.
3. Gas carried under into pump
from a vessel can erode the
impeller.

8. 3. Separator
Separation in HYSYS
1. HYSYS use P-H flash to determine
Products:
P : lowest Feed Pressure – Delta
Pressure
2-Phase
Separator
3-Phase
Separator
H: Sum of Feed Enthalphy ± Duty

9. 3. Separator
Important Design
Parameter
• Delta P (Pressure Drop)
• Inlet
• Vapor Outlet
By Default: Delta P = 0
Actual : Delta P > 0

10. 3. Separator
Unit Function
• To separate multiphase feed stream/streams into several “single”
phase product stream (vapor, light liquid, heavy liquid)
BY DEFAULT:
Separator Unit
in HYSYS
PERFECT
SEPARATION
ACTUAL:
NO PERFECT
SEPARATION
IF REQUIRED
Separator Unit
in HYSYS
can model
IMPERFECT
SEPARATION

11. 4. Pump
Basic Theory:
1. Objective of pump :
Transfer/move liquid from source to
destination (higher head)
Circulate liquid around a system
2. Pumping System Characteristic
Total Head = Static Head + Friction Head
Pump Performance Curve
Pump Operating Point
- Duty Point: rate of flow at certain head
- Pump Operating Point : intersection of
pump curve and system curve
System
head
Flow
Static head
Friction
head
System
curve
Flow
Head
Static
head
Pump performance
curve
System
curve
Pump
operating
point

12. 4. Pump
Unit Function
• To increase the head of inlet liquid
stream
Objective of Unit
• To calculate one of these unknown data:
• Pressure
• Temperature
• Pump Horse Power
• Pump Efficiency

13. 4. Pump
Important Design
Parameter
• Delta P
• Adiabatic Efficiency
• Duty (Pump Horse Power)

14. 4. Pump
Check this box to use
the pump curve
Flow
Head
Static
head
Pump performance
curve
System
curve
Pump
operating
point
Pump Curve Head Vs. Flow
Commonly, this curve is provided by vendor

15. 5. Compressor
Ideal Work is calculated for mechanically reversible process
Along a particular compression path
Adiabatic Compressor
- Follow Isentropic compression
path from inlet pressure to outlet
pressure
Polytropic Compressor
- Compression path is also
adiabatic or isothermal
Actual Work and ΔH is determined
from Wrev and Efficiency
T &/ or P is determined from ΔH

16. 5. Compressor
Unit Function
• To increase the head of inlet gas
stream by adding Work.
Objective of Unit
• To calculate one of these unknown data:
• Pressure
• Temperature
• Compressor Horse Power
• Compressor Efficiency

17. 5. Compressor
Important Design Parameter
• Compressor Efficiency:
• Adiabatic Efficiency
• Polytropic Efficiency
• Duty
• Operating Mode
• Centrifugal
• Reciprocating

18. 5. Compressor
Compressor Curve
Commonly, this curve is provided by vendor,
consists of: flow rate, pressure head , &
efficiency To choose Adiabatic/ Polytropic as Efficiency Basis
To enable the curve
Click to add the curve
Click to activate the curve

19. 5. Compressor
Optional if only 1 curve available
Input flow, head, &
efficiency data
Choose
the Unit
For Single Curve, the
combination of input data
will solve:
- Inlet pressure & flow
- Inlet pressure & duty
- Inlet and Outlet Pressure
- Inlet and efficiency

20. 6. Expander
Unit Function
• To decrease the pressure of inlet gas with
higher pressure into produced work
Objective of Unit
• To calculate the Work produced
Application
• As model for Turbine & Turbo Expander

21. 6. Expander
Important Design Parameter
• Expander Efficiency:
• Adiabatic Efficiency
• Polytropic Efficiency
Expander : liquid, Turbine : gas

22. 7. Valve
Unit Function
• To drop the pressure of the
inlet which has higher
pressure
Objective of Unit
• To calculate one of these unknown
conditions:
• Outlet T or Outlet P
• Inlet T or Inlet P

23. 7. Valve
Important Design
Parameter
• Delta P
• Specified by user.

24. 8. Cooler
Heat Duty
Theory

25. 8. Cooler
Unit Function
• To cool down the temperature of inlet
stream
Objective of Unit
• To calculate one of these unknown data:
• Outlet Temperature
• Cooler Duty
Cooler is one-sided Heat Exchanger,
Q is removed (-)

26. 8. Cooler
Important Design
Parameter
• Delta P
• By Default=0 or
• Specified by user.
• Duty

27. 8. Cooler
Heat Duty
Theory

28. 9. Heater
Unit Function
• To heat up the temperature of inlet
stream
Objective of Unit
• To calculate one of these unknown data:
• Outlet Temperature
• Heater Duty
Heater is one-sided Heat Exchanger
Q is added (+)

29. 9. Heater
Important Design
Parameter
• Delta P
• By Default=0 or
• Specified by user.
• Duty

30. 10. Heat Exchanger
Theory
1. Type of HE based on flow direction

31. 10. Heat Exchanger
2. Energy Balance
Duty which increase
the temperature
Duty which decrease
the temperature
3. Heat Exchanger Duty

32. 10. Heat Exchanger
Unit Function
• To transfer the energy from warmer
fluid to colder fluid
Objective of Unit
• To increase the energy efficiency of the
overall facility

33. 10. Heat Exchanger
Basic Equation:
[Mcold x ΔHcold – Qleak]- (Mhot x ΔHhot – Qloss]
= Balance Error = 0 (Typically)
Heat Exchanger has two sided:
- Hot Side
- Cold Side

34. 10. Heat Exchanger
Important Design Parameter
• Heat Transfer model
• End Point
• Weighted Point
• Steady State Rating
• Dynamic Rating
• Delta P
• On Shell & Tube Side
• Overall Heat Transfer Coeff. Area (UA)
• Heat Exchange Geometry
• Tube
• Shell

35. 10. Heat Exchanger
Parameter to be specified:
- Temperature/ Delta Temp.
- Minimum Appro. Temp.
- UA
- LMTD
- Duty
- Duty Ratio
- Flow
Ada contoh kasus error

36. 10. Heat Exchanger
Heat Exchanger Requires Recycle Operations:
1. Start with unconnected heater & cooler
2. Connect heater and cooler with one single energy stream
3. Replace heater and cooler with Unit Heat Exchaner
4. Use Recycle Block if the calculation seems difficult to be matched.

37. Distillation
• Distillation process use 40% of energy
in a chemical plant.
• The traditional approach for solving
distillation columns uses the concept
of equilibrium or theoretical stages.
This concept assumes the vapor and
liquid phases leaving any stage are in
thermodynamic equilibrium with each
other.

38. Principle
Minimum number of tray
Parameter adjustment

39. Design of Distillation Column
Obtain:
• Operating pressure
Obtain:
• Initial value of number
of tray
• Initial value of feed
stage
Optimization

40. • Design a distillation column to get propene in top stream with purity 96%
(mole).
Study Case
Components Mass Flow
(kg/h)
Ethane 4.1
Propane 4000.4
Propene 131.8
n-Butane 10498.2
Conditions Value
Temperature (C) 38
Vapour Fraction 0
Fluid Package Peng-Robinson

41. • Function : used when there is a reaction occurs in the process
simulation
• There are 6 type of reactors provided by hysys:
1. General reactors consist of : Gibbs Reactor, Equilibrium
Reactor, Conversion reactor, Yield Shift Reactor
2. Continuous Stirred Tank Reactor (CSTR)
3. Plug Flow Reactor (PFR)
• Before begin the simulation it is important to describe the
reaction on the hysys simulation basis manager.
11. Reactor

42. Type of Reactor
Can be used when we do not know the
reaction sets
Can be used for modelling conversion
reactions
Can be used for modelling equlibrium
reactions
can be used for complex reactors where no
model is available
CSTR Reactor
The CSTR is a vessel in which Kinetic, Heterogeneous Catalytic
and Simple Rate reactions can be performed.
The conversion in the reactor depends on the rate expression of
the reactions associated with the reaction type.
PFR Reactor
The PFR can modelled Kinetic, Heterogeneous Catalytic and
Simple Rate reactions.

43. Example Using Reactor in Simulation

44. How to Add Reaction Set
Choose Reaction type
Input component
involved in reaction
Input stoichiometric
coefficient

45. Add Reaction to Fluid Package

46. How to Add Reactor (1st method)

47. How to Add Reactor (2nd method)
click Double
click

48. Reactor Designs Tab

49. Reactor Reactions Tab (To Add Rxn set to Reactor)
Click to select Rxn and Rxn
Set

50. REACTOR EXERCISE
Problem Description:
One possible way to produce acetone is by dehydrogenation of Isopropyl Alcohol (IPA).
The Reaction mechanism is as follow:
With Reaction Rate:
By Using PFR as reactor, with design condition given as below, determine the acetone product
flowrate.
Type of reaction: Heterogeneous Catalytic Reaction
Basis of reaction: Vapor Phase, IPA
Pressure drop in the PFR is assumed to be zero
OPEN FILE:
IPA- REACTION EXERCISE-STARTER.HSC

51. REACTOR EXERCISE ANSWER

52. Thank You
M. Ersharry Yunashtanto
Zayyanatun Zulfa
Ikha Muliawati
Mada Harahap

53. Referensi
1. Separation. http://lhd52.files.wordpress.com/2011/09/group-6-separation-
operations.pdf
2. HYSYS Design Tutorial for CHEE470.
http://m.chemeng.queensu.ca/courses/CHEE470/documents/HYSYSTutorial.
pdf
3. HYSYS Tutorial Che 3G4.
http://jpkc.tongji.edu.cn/jpkc/hgyl/second/site/Hysys.pdf
4. http://www.departments.bucknell.edu/chem_eng/cheg200/HYSYS_Manual/a
_BlueHYSYS.pdf
5. Dr. Istadi, ST, MT. Perancangan Process Kimia (Chemical PRocess Design).
http://tekim.undip.ac.id/staf/istadi/files/2009/05/presentasi_perancangan_pr
oses_kimia_1.pdf
6. Tutorial Apps.
http://www.uam.es/personal_pdi/ciencias/vferro/documentacion/doc/Hysys
%203.2/Doc/HYSYS/TutApps.pdf
7. Peter Griffith. www.thermopedia.com/Vapor-Liquid Separation

54. • Aspen Hysys Unit Operation Guide, Aspen Technology, 2011
• Turton, R., Bailie, R. C., Whiting, W. B., Shaeiwitz, J. A., &
Bhattacharyya, D. (2012). Analysis,Synthesis, and Design of
Chemical Processes. Pearson Education, Inc.
REFERENCES