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Aspen HYSYS Training
Module 3: Basic Equipments in HYSYS
Tutor:
M. Ersharry Yunashtanto
Zayyanatun Zulfa
Ikha Muliawati
Mada Harahap
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
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
1. Mixer (Cont’d)
A. Set Outlet to Lowest Inlet
1. Mixer (Cont’d)
B. Equalize All
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
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.
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
3. Separator
Important Design
Parameter
• Delta P (Pressure Drop)
• Inlet
• Vapor Outlet
By Default: Delta P = 0
Actual : Delta P > 0
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
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
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
4. Pump
Important Design
Parameter
• Delta P
• Adiabatic Efficiency
• Duty (Pump Horse Power)
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
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
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
5. Compressor
Important Design Parameter
• Compressor Efficiency:
• Adiabatic Efficiency
• Polytropic Efficiency
• Duty
• Operating Mode
• Centrifugal
• Reciprocating
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
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
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
6. Expander
Important Design Parameter
• Expander Efficiency:
• Adiabatic Efficiency
• Polytropic Efficiency
Expander : liquid, Turbine : gas
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
7. Valve
Important Design
Parameter
• Delta P
• Specified by user.
8. Cooler
Heat Duty
Theory
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 (-)
8. Cooler
Important Design
Parameter
• Delta P
• By Default=0 or
• Specified by user.
• Duty
8. Cooler
Heat Duty
Theory
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 (+)
9. Heater
Important Design
Parameter
• Delta P
• By Default=0 or
• Specified by user.
• Duty
10. Heat Exchanger
Theory
1. Type of HE based on flow direction
10. Heat Exchanger
2. Energy Balance
Duty which increase
the temperature
Duty which decrease
the temperature
3. Heat Exchanger Duty
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
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
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
10. Heat Exchanger
Parameter to be specified:
- Temperature/ Delta Temp.
- Minimum Appro. Temp.
- UA
- LMTD
- Duty
- Duty Ratio
- Flow
Ada contoh kasus error
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.
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.
Principle
Minimum number of tray
Parameter adjustment
Design of Distillation Column
Obtain:
• Operating pressure
Obtain:
• Initial value of number
of tray
• Initial value of feed
stage
Optimization
• 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
• 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
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.
Example Using Reactor in Simulation
How to Add Reaction Set
Choose Reaction type
Input component
involved in reaction
Input stoichiometric
coefficient
Add Reaction to Fluid Package
How to Add Reactor (1st method)
How to Add Reactor (2nd method)
click Double
click
Reactor Designs Tab
Reactor Reactions Tab (To Add Rxn set to Reactor)
Click to select Rxn and Rxn
Set
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
REACTOR EXERCISE ANSWER
Thank You
M. Ersharry Yunashtanto
Zayyanatun Zulfa
Ikha Muliawati
Mada Harahap
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
• 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

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Module 3 - Basic Equipment

  • 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.
  • 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
  • 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
  • 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
  • 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