Process Engineering Simulation with Aspen HYSYS

1 Process Engineering Simulation with Aspen HYSYSU pdated: July 12, 2018 Copyright 2017 John Jechura Engineering SimulationCore chemical Engineering doctrine mass & energy balancesModes Steady state Simulation Dynamic simulationSimulation program features Components / chemical species Pure component data library Non library components Property models & methods Thermodynamic models Physical & transport properties Chemical reaction models & methods Unit operation models Flowsheet capabilities Recycle loops Graphical interface2 Updated: July 12, 2018 Copyright 2017 John Jechura as Process Engineering ToolOwned & marketed by Aspen Tech Developed by Hyprotech. Initially DOS based HYSIMCore calculations for steady state mass & energy balances Dynamic capabilities as add on packageHistorical orientation towards the oil & gas industry Components Extensive pure component database of hydrocarbons Generate pseudo components from crude oil assay information Property models Consistent with hydrocarbon systems relatively non ideal mixtures Capabilities for presence of typical non hydrocarbonsoSimplified methods for mixtures with wateroAcid gas components CO2& H2S Unit operation models Towers with pumparounds, side strippers.

2 Reaction system models CatCracker, Hydrocracker, Reformer3 Updated: July 12, 2018 Copyright 2017 John Jechura component database Typically use a small number of light hydrocarbons (C1 nC5), CO2, H2S, & H2 OPseudo/hypothetical components Narrow boiling point fractions from distillation analysis Assumption that all components in range will have the same split between vapor & liquid Not a good assumption if chemical structure plays a big part in separation or reaction Correlations to generate average properties for the fraction Empirical correlations based on boiling point, specific/API gravity, molecular weight Group contribution methodsElectrolyte mixtures may require explicit definition of ionic species4 Updated: July 12, 2018 Copyright 2017 John Jechura Components5 Updated: July 12, 2018 Copyright 2017 John Jechura Components from Assay6 Refinery Process ModelingGerald KaesAthens Printing Company.

3 , 2000, pg. 32 Updated: July 12, 2018 Copyright 2017 John Jechura Components from AssaySplit the yield curve into boiling point rangesUse the property curves to generate consistent with measured dataUse correlations to estimate unmeasured & unmeasurable properties Critical properties Accentricfactor Binary interaction coefficients7 Updated: July 12, 2018 Copyright 2017 John Jechura Components from Assay8 Updated: July 12, 2018 Copyright 2017 John Jechura Components from Assay9 Updated: July 12, 2018 Copyright 2017 John Jechura Components from Assay10 Updated: July 12, 2018 Copyright 2017 John Jechura Components from Assay11 Updated: July 12, 2018 Copyright 2017 John Jechura Components from Assay12 Updated: July 12, 2018 Copyright 2017 John Jechura Models & MethodsTypically use an equation of state (EOS) for properties Consistent properties for vapor, liquid, & transitions between Thermodynamic properties from the same set of equations Equilibrium coefficients (fugacity) Enthalpy Entropy Density Non ideal behavior from binary interaction coefficients Major effect on equilibrium coefficients Very small effect on other propertiesMay use other properties for other thermodynamic properties Lee Keslerfor enthalpy COSTALD for liquid density13 Updated: July 12, 2018 Copyright 2017 John Jechura Models & Methods14 Updated.

4 July 12, 2018 Copyright 2017 John Jechura Operation Models Typical unit operation models Valve Separators Heat exchangers Pumps Compressors Reactors CSTR & plug flow Towers with & without condenser & reboiler 15 Without Condenser WithCondenserWithout ReboilerAbsorberRefluxed AbsorberWith ReboilerReboiledAbsorber Distillation ColumnUpdated: July 12, 2018 Copyright 2017 John Jechura Operation Models for RefiningComplex tower configurations Pumparounds Side draws Side strippers Condenser with water draw Complex specifications ASTM temperature spec16 Updated: July 12, 2018 Copyright 2017 John Jechura Overall EfficienciesColumn ServiceTypical No. of Actual TraysTypical Overall EfficiencyTypical No. of Theoretical TraysSimple Absorber/Stripper20 30 20 30 Steam Side Stripper5 72 Reboiled Side Stripper7 103 4 Reboiled Absorber20 40 40 50 Deethanizer25 35 65 75 Depropanizer35 40 70 80 Debutanizer38 45 85 90 Alky DeiC4 (reflux)75 90 85 90 Alky DeiC4 (no reflux)55 70 55 65 Naphtha Splitter25 35 70 75C2 Splitter110 130 95 100C3 Splitter200 250 95 100C4 Splitter70 80 85 90 Amine Contactor20 244 5 Amine Stripper20 24 45 55 9 12 Crude Distillation35 50 50 60 20 30 Stripping Zone5 7302 Flash Zone 1st draw3 7301 2 1st Draw 2nd Draw7 10 45 50 3 5 2nd Draw 3rd Draw7 10 50 55 3 5 Top Draw Reflux10 12 60 70 6 8 Vacuum Column ( Operation)

5 Stripping2 41 Flash Zone HGO Draw2 31 2 HGO Section3 52 LGO Section3 52 FCC Main Fractionator24 35 50 60 13 17 Quench Zone5 72 Quench HGO Draw3 52 3 HGO LCGO6 83 5 LCGO Top7 105 7 Viscosity MaxwellDrickamer & Bradford in LudwigcPAve Viscosity of liquid on platesMolal Ave Viscosity of Process ModelingGerald Kaes, Athens Printing Company., 2000, pg. 32 Rules of Thumb for Chemical Engineers, 4th Branan, Gulf Professional Publishing, 2005 Engineering Data Book, 12th Processors Association, 2004 Updated: July 12, 2018 Copyright 2017 John Jechura Operations Results18 Updated: July 12, 2018 Copyright 2017 John Jechura Results19 Updated: July 12, 2018 Copyright 2017 John Jechura Stream Reports20 Updated: July 12, 2018 Copyright 2017 John Jechura InterfaceGraphically build the flowsheet by dragging & dropping unit modelsCalculations performed automatically as information is enteredCopy & paste capabilities Pasting in from other locations limitedAspen Simulation Workbook extends capabilities to put custom interface on top of simulation21 Updated.

6 July 12, 2018 Copyright 2017 John Jechura crude tower examplesOriginal tutorial available from Aspen Tech web siteAdditional problem developed specifically for this : July 12, 2018 Copyright 2017 John Jechura is a capable tool for performing mass & energy balancesProgram features make it convenient for petroleum refining applications Pure component data library & psuedo components from distillation analyses Property models & methods Thermodynamic, physical & transport property models appropriate for petroleum systems Chemical reaction models & methods Unit operation models Specific configurations for complex equipment Flowsheet capabilities Unit operation & stream results Graphical interface23