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Getting Started
Getting Started
Workshop
The Getting Started module introduces you to some of the basic
concepts necessary for creating simulations in HYSYS. Some of the
things you will learn from this module are:
You will use HYSYS to define three streams. You will learn how to
determine the properties of these streams by using the Property Table
utility.
Learning Objectives
Once you have completed this section, you will be able to:
Getting Started
Getting Started
Getting Started
1.
2.
3.
Click the Activity Model radio button and choose NRTL as the
Property Package.
4.
5.
Getting Started
You can select components for your simulation using several different
methods:
To Use
Do This
Match Cell
1.
2.
3.
Component List
1.
2.
Family Filter
1.
2.
3.
4.
Getting Started
5.
6.
Getting Started
2.
3.
Enter a unique name (Stripper) for the Fluid Package and press
the OK button.
Now that the Fluid Package is now fully defined, you are ready to move
on and start building the simulation. Press the Enter Simulation
Environment button or the Interactive Simulation Environment
button in the Button Bar.
Getting Started
3.
If it is not already selected, select the desired unit set. Both Field
and SI units will be given in this course; you are free to use
whichever is more comfortable for you.
4.
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Getting Started
10
Getting Started
11
Adding Streams
In HYSYS, there are two types of streams, Material and Energy. Material
streams have a composition and parameters such as temperature,
pressure and flowrates. They are used to represent Process Streams.
Energy streams have only one parameter, a Heat Flow. They are used to
represent the Duty supplied to or by a Unit Operation.
There are a variety of ways to add streams in HYSYS.
To Use This
Do This
Menu Bar
Workbook
Object Palette
In this exercise, you will add three streams to represent the feeds to an
air stripper. Each stream will be added using a different method of
installation.
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12
Getting Started
Press the <F11> hot key. The Stream Property view is displayed:
You can change the stream name by simply typing in a new name in the
Stream Name box.
2.
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Getting Started
13
Do This
Conditions page
Composition page
3.
Double click on the Mass Flow cell. The Input Composition for
Stream view displays.
4.
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14
Getting Started
5.
14
Chloroform
2.5 (5.0)
Toluene
Ethanol
300 (600)
H2O
Oxygen
Nitrogen
6.
Press the OK button when all the mass flows have been entered.
7.
Getting Started
15
1.
2.
Chloroform
1.5 (3.0)
Toluene
140 (280)
Ethanol
H2O
Oxygen
Nitrogen
3.
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16
Getting Started
If the Object Palette is not open on the Desktop, press the <F4>
hot key to open it.
Double Click on the Material Stream button. The Stream
Property view displays.
2.
Material Stream button (Blue)
3.
4.
Double click on the Molar Flow cell and enter the following
stream compositions:
Chloroform
Toluene
Ethanol
H2O
Oxygen
0.21
Nitrogen
0.79
Save button
From the File menu select Save to save your case with the
same name.
Form the File menu select Save As to save your case in a
different location or with a different name.
Press the Save button on the button bar to save your case with
the same name.
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Getting Started
17
Flash Calculations
2.
3.
17
18
Getting Started
Attaching Utilities
The utilities available in HYSYS are a set of useful tools that interact
with your process, providing additional information or analysis of
streams or operations. Once installed, the utility becomes part of the
Flowsheet, automatically calculating when conditions change in the
stream or operation to which it is attached.
As with the majority of objects in HYSYS, there are a number of ways to
attach utilities to streams.
To Use the
Do this
Menu Bar
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Getting Started
19
4.
5.
6.
7.
For the Pressure variable, use the drop down menu to change its
mode to State, and enter the following values: 90 kPa (13 psia),
100 kPa (14.5 psia), 101.3 kPa (14.7 psia), 110 kPa (16.0 psia), and
120 kPa (17.4 psia).
8.
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20
Getting Started
20
9.
Select the Bulk radio button and highlight a cell in the Property
matrix.
10.
11.
Select the Liquid radio button, and select the Viscosity property.
12.
Select the Aqueous radio button, and select the Aq. Mass Fraction
property.
13.
Select the Vapour radio button, and select the Vapour Mass
Fraction property.
14.
Getting Started
21
Temp., C (F)
Eth rich
15C (60F)
Tol rich
15C (60F)
Strip Air
25C (77F)
Add a flowrate of 18 000 kg/h (39, 700 lb/hr) to the stream Strip Air.
2.
3.
Move the mouse cursor to the left or right side of the view until
the cursor changes to resizing arrows.
4.
Press and hold the left mouse button and drag the edge of the
view until all the phases can be seen.
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22
Getting Started
The pages Properties and Composition also show data for the
individual phases.
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Getting Started
23
2.
3.
Under the Workbook Tabs group, press the Add button, and in
the view which appears, select +Stream and press OK.
4.
5.
Highlight the Name cell in the Tab Contents group, and change
the name to Other Prop.
6.
In the Variables group, press the Delete button until all the
default variables are removed.
7.
Click the Add button to view the list of variables grouped under
the Select Variable(s) For Main page.
8.
From the Variables list, select Vap Frac on a Mass Basis and click
OK.
Workbook button
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24
Getting Started
9.
10.
The Workbook now contains the tab Other Prop which shows the
vapour fraction on a mass basis, the molecular weight, the mass density
and the mass enthalpy for all the components for the three streams.
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Getting Started
25
2.
Right click (Object Inspect) the Workbook title bar. The Print
Datasheet or Open Page pop-up menu appears.
3.
4.
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26
Getting Started
26
Getting Started
27
Exercise 1
A. Use the Workbook to find the following values:
1.
2.
The bubble point pressure of stream Tol rich at 15C (60 F).
__________
3.
The dew point pressure of stream Strip Air at 25C (77 F).
__________
4.
The vapour fraction of stream Eth rich at 15C (60 F) and 101 kPa
(14.7 psia). __________
2.
The temperature of stream Tol rich at 101 kPa (14.7 psia) and 0.5
vapour fraction. __________
3.
4.
The mass density of stream Strip Air at 25 C (77 F) and 101 kPa
(14.7 psia). __________
5.
Exercise 2
The stream Eth Rich is stored in a 200 m3 (7000 ft3) vessel. Assuming the
storage vessel has a 45 minute hold-up and the vessel is at atmospheric
conditions (1 atm, 25C, 77 F):
What is the composition of the vapor space? _________
How full is the storage vessel? __________
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28
Getting Started
28
Workshop
One of the main assets of HYSYS is its strong thermodynamic
foundation. Not only can you use a wide variety of internal property
packages, you can use tabular capabilities to override specific property
calculations for more accuracy over a narrow range. Or, you can use the
functionality provided through OLE to interact with externally
constructed property packages.
However, there are cases when the parameters calculated by HYSYS are
not accurate enough, or cases when the models used by HYSYS do not
predict the correct behaviour of some liquid-liquid mixtures
(azeotropic mixtures). For those cases it is recommended to use
another of Hyprotechs products, DISTIL. This powerful simulation
program provides an environment for exploration of thermodynamic
model behaviour, proper determination and tuning of interaction
parameters and physical properties, as well as alternative designs for
distillation systems.
Learning Objectives
Once you have completed this module, you will be able to:
Type of System
TEG Dehydration
PR
Sour Water
PR, Sour PR
PR, PRSV
Air Separation
PR, PRSV
PR, PR Options, GS
Vacuum Towers
Ethylene Towers
High H2 Systems
Reservoir Systems
PR, PR Options
Steam Systems
Steam Package, CS or GS
Hydrate Inhibition
PR
Chemical Systems
HF Alkylation
PR (Contact Hyprotech)
Equations of State
For oil, gas and petrochemical applications, the Peng-Robinson EOS
(PR) is generally the recommended property package. HYSYS currently
offers the enhanced Peng-Robinson (PR) and Soave-Redlich-Kwong
(SRK) equations of state. In addition, HYSYS offers several methods
which are modifications of these property packages, including PRSV,
Zudkevitch Joffee (ZJ) and Kabadi Danner (KD). Lee Kesler Plocker
(LKP) is an adaptation of the Lee Kesler equations for mixtures, which
itself was modified from the BWR equation. Of these, the PengRobinson equation of state supports the widest range of operating
conditions and the greatest variety of systems. The Peng-Robinson and
Soave-Redlich-Kwong equations of state (EOS) generate all required
equilibrium and thermodynamic properties directly. Although the
forms of these EOS methods are common with other commercial
simulators, they have been significantly enhanced by Hyprotech to
extend their range of applicability.
Activity Models
Although equation of state models have proven to be very reliable in
predicting properties of most hydrocarbon based fluids over a large
range of operating conditions, their application has been limited to
primarily non-polar or slightly polar components. Polar or non-ideal
chemical systems have traditionally been handled using dual model
approaches.
Activity Models are much more empirical in nature when compared to
Margules
van Laar
Wilson
NRTL
UNIQUAC
Binary Systems
Multicomponent
Systems
LA
LA
Azeotropic Systems
Liquid-Liquid
Equilibria
N/A
Dilute Systems
Self-Associating
Systems
N/A
N/A
N/A
N/A
Polymers
Extrapolation
A = Applicable
N/A = Not Applicable
? = Questionable
G = Good
LA = Limited Application
Overview of Models
Margules
One of the earliest activity coefficient expressions was proposed by
Margules at the end of the 19th century.
van Laar
The van Laar equation was the first Gibbs excess energy representation
with physical significance. This equation fits many systems quite well,
particularly for LLE component distributions. It can be used for
systems that exhibit positive or negative deviations from Raoults Law.
Some of the advantages and disadvantage for this model are:
The van Laar equation implemented in HYSYS has two parameters with
linear temperature dependency, thus making it a four parameter
model. In HYSYS, the equation is empirically extended and therefore its
use should be avoided when handling multicomponent mixtures.
Wilson
The Wilson equation, proposed by Grant M. Wilson in 1964, was the
first activity coefficient equation that used the local composition model
to derive the Gibbs Excess energy expression. It offers a
thermodynamically consistent approach to predicting multicomponent behaviour from regressed binary equilibrium data.
The Wilson equation CANNOT
be used for problems involving
liquid-liquid equilibrium.
NRTL
10
UNIQUAC
The UNIQUAC (UNIversal QUAsi Chemical) equation proposed by
Abrams and Prausnitz in 1975 uses statistical mechanics and the quasichemical theory of Guggenheim to represent the liquid structure. The
equation is capable of representing LLE, VLE and VLLE with accuracy
comparable to the NRTL equation, but without the need for a nonrandomness factor, it is a two parameter model.
The UNIQUAC equation is significantly more detailed and
sophisticated than any of the other activity models.
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11
Chien-Null
Chien-Null is an empirical model designed to allow you to mix and
match models which were created using different methods and
combined into a multicomponent expression. The Chien-Null model
provides a consistent framework for applying existing activity models
on a binary by binary basis. In this manner, Chien-Null allows you to
select the best activity model for each pair in the case. For example,
Chien-Null can allow the user to have a binary defined using NRTL,
another using Margules and another using van Laar, and combine them
to perform a three component calculation, mixing three different
thermodynamic models.
The Chien Null model allows 3 sets of coefficients for each component
pair, accessible via the A, B and C coefficient matrices.
Henrys Law
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12
Ideal
The ideal gas law can be used to model the vapour phase. This model is
appropriate for low pressures and for a vapour phase with little
intermolecular interaction. The model is the default vapour phase
fugacity calculation method for activity coefficient models.
Virial
The Virial option enables you to better model vapour phase fugacities
of systems displaying strong vapour phase interactions. Typically this
occurs in systems containing carboxylic acids, or compounds that have
the tendency to form stable H2 bonds in the vapour phase.
Care should be exercised in
choosing PR, SRK, RV or Virial
to ensure binary coefficients
have been regressed with the
corresponding vapour phase
model.
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13
Binary Coefficients
For the Property Packages which do include binary coefficients, the
Binary Coefficients tab contains a matrix which lists the interaction
parameters for each component pair. Depending on the property
method chosen, different estimation methods may be available and a
different view may be shown. You have the option of overwriting any
library value.
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14
If you are using PR or SRK (or one of the Sour options), two radio
buttons are displayed at the bottom of the page in the Treatment of
Interaction Coefficients Unavailable from the Library group:
The interaction parameters for each binary pair will be displayed. You
can overwrite any value or use one of the estimation methods.
Note that the Kij = Kji rule does not apply to Activity Model interaction
parameters.
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15
Estimation Methods
When using Activity Models, HYSYS provides three interaction
parameter estimation methods. Select the estimation method by
choosing one of the radio buttons in the Coeff Estimation window. The
options are:
UNIFAC VLE
UNIFAC LLE
Immiscible
You can then invoke the estimation by selecting one of the available
cells.
For UNIFAC methods the options are:
Row in Clm pair estimates the parameters such that the row
component (j) is immiscible in the column component (i).
Clm in Row pair estimates parameters such that the column
component (j) is immiscible in the row component (i).
All in Row estimates parameters such that both components
are mutually immiscible.
In Module 1, you chose the NRTL Activity Model, then select the
UNIFAC VLE estimation method (default) before pressing the
Unknowns Only cell.
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16
Basic Data
Activity coefficient models are empirical by nature and the quality of
their prediction depends on the quality and range of data used to
determine the parameters. Some important things you should be aware
of in HYSYS.
UNIFAC or no UNIFAC?
UNIFAC is a handy tool to give initial estimates for activity coefficient
models. Nevertheless keep in mind the following:
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17
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18
Exercise 1
Di-iso-Propyl-Ether/H2O Binary
This example effectively demonstrates the need for having interaction
parameters. Do the following:
1.
2.
Conditions
Vapour Fraction
0.0
Pressure
1 atm
Molar Flow
1 kgmole/h (1 lbmole/hr)
Composition
di-i-P-Ether
50 mole %
H2O
50 mole %
3.
Close the stream view and press the Enter Basis Environment
button.
4.
Select the Binary Coeffs tab of the Fluid Package. Notice that the
interaction parameters for the binary are both set to 0.0.
5.
Press the Reset Params button to recall the default NRTL activity
coefficient model interaction parameters.
6.
7.
8.
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19
19
20
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Exercise 2
Phenol/H2O Binary
This binary shows the importance of ensuring that properly fitted
interaction parameters for the conditions of your simulation are used.
The default parameters for the Phenol/H2O system have been
regressed from the DECHEMA Chemistry data series and provide very
accurate vapour-liquid equilibrium since the original data source (1)
was in this format. However, the Phenol/Water system is also shown to
exhibit liquid-liquid behaviour (2). A set of interaction parameters can
be obtained from sources such as DECHEMA and entered into HYSYS.
The following example illustrates the poor LLE prediction than can be
produced by comparing the results using default interaction
parameters and specially regressed LLE parameters.
1.
2.
Conditions
Temperature
40C
Pressure
1 atm
Molar Flow
1 kgmole/h (1 lbmole/hr)
Composition
Phenol
25 mole %
H2O
75 mole %
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22
To provide a better prediction for LLE at 40 oC (105 oF) the following Aij
interaction parameters are to be entered. To enter the parameters do
the following:
1.
2.
Close the stream view and press the Enter Basis Environment
button.
Ensure the Fluid Package view is open and select the Binary
Coeffs tab.
3.
4.
5.
6.
7.
8.
The figures on the following page (figures 3 and 4) show the difference
between the two sets of interaction parameters. Therefore, care must be
exercised when simulating LLE as almost all the default interaction
parameters for the activity coefficient models in HYSYS are for VLE.
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23
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Exercise 3
Benzene/Cyclohexane/H2O Ternary
This example again illustrates the importance of having interaction
parameters and also discusses how the user can obtain parameters
from regression. To illustrate the principles do the following:
1.
2.
Conditions
Temperature
25C
Pressure
1 atm
Composition
Benzene
20 mole %
H2O
20 mole %
CC6
60 mole %
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25
1.
2.
Open the Fluid Package view and move to the Binary Coeffs tab.
3.
4.
5.
6.
7.
8.
The figures on the following page (figures 5 and 6) clearly show the
behaviour of the ternary system. Without the regressed CC6/H2O
binary, the thermodynamic property package incorrectly predicts the
system to be miscible at higher CC6 concentrations. This prediction is
correct given properly regressed CC6/H2O parameters.
References
1. Schreinemakers F.A.H., Z. Phys. Chem. 35, 459 (1900).
2. Hill A.E. and Malisoff W.M., J. Am. Chem. Soc.
48 (1926) 918.
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26
Flowsheeting
Flowsheeting
Flowsheeting
Workshop
In evaporation, a solution consisting of a non-volatile solute and a
volatile solvent is concentrated by the addition of heat. In multiple
effect evaporation, the volatile solvent recovered from the first
evaporator is condensed and used as a heat source for the next
evaporator. This means that the second evaporator must operate at a
lower temperature and pressure than the first evaporator.
In this module you will simulate a series of three evaporators to
concentrate a solution of sucrose/water. Each evaporator is modelled
using a flash tank. You will convert the completed simulation to a
template, making it available to connect to other simulations.
On the next page, a Process Overview is shown. This represents the
actual process. On the third page a Simulation PFD is shown. This
represents the simulation as you will build it in this module. Building
the simulation in this way allows more flexibility in the design.
Learning Objectives
Once you have completed this section, you will be able to:
Prerequisites
Before beginning this section you need to know how to:
Process Overview
Simulation PFD
Flowsheeting
1.
2.
3.
The program warns you that the binary coefficients have not been
determined and the model will assume values of zero. Answer OK to
this message. Enter the Simulation Environment.
Flowsheeting
4.
In this cell
Enter
Name
Feed
Vapour Fraction
Pressure
Flowrate
0.3
0.7
5.
In this cell
Enter
Name
Steam
Vapour Fraction
1.0
Pressure
1.0
Flowsheeting
Do this
Menu Bar
Workbook
Object Palette
PFD/Object Palette
Flowsheeting
Adding a Separator
The Evaporator is modelled using a Separator in HYSYS.
The Separator will be added using the <F12> hot key.
1.
2.
3.
4.
Note: Drop down boxes, such as for Feed and Product streams, contain
lists of available streams which can be connected to the operation.
Flowsheeting
Adding a Cooler
Add the first Cooler using the same method.
1.
2.
3.
4.
5.
10
Flowsheeting
6.
7.
8.
10
Flowsheeting
11
3.
4.
5.
6.
7.
8.
11
12
Flowsheeting
Separator button
12
1.
2.
Flowsheeting
13
3.
4.
13
14
Flowsheeting
3.
14
Flowsheeting
15
3.
Click the left mouse button to drop the Cooler onto the PFD.
There are two ways to connect the operation to a stream on the PFD:
To connect using the
Do this
Insert Icon
<Ctrl> key
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16
Flowsheeting
4.
Double click on the Cooler icon on the PFD. The Cooler property
view displays. Enter the data shown below:
5.
6.
16
2.
Drag n drop the Separator onto the PFD. Connect the stream L2
as the Feed to the Separator.
Double click on the Separator. Make the following connections:
3.
Flowsheeting
17
Set Operation
1.
2.
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18
Flowsheeting
Add an Adjust
The Adjust operation is a Logical Operation - a mathematical operation
rather than a physical operation. It will vary the value of one stream
variable (the independent variable) to meet a required value or
specification (the dependant variable) in another stream or operation.
1.
2.
3.
From the Object list select q1. From the Variable list which is now
visible, select Heat Flow.
4.
Press the OK cell to accept the variable and return to the Adjust
property view.
5.
18
Flowsheeting
19
6.
7.
8.
Switch to the Parameters tab, and enter 2000 kJ/h (1900 Btu/hr)
as the Step Size.
9.
Press the Start button to begin calculations. Note: once the case is
solved (OK status), this button will disappear from the property
view.
10.
19
20
Flowsheeting
20
Flowsheeting
21
PFD
Unit Operations
Streams
21
22
Flowsheeting
2.
3.
3.
In the Setup view, press the Add button in the UnitOps group.
4.
5.
22
Flowsheeting
23
1.
2.
3.
4.
5.
6.
Create two tables for the streams Feed and L3 showing the
Component Mass Fraction of Sucrose and the Mass Flow.
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24
Flowsheeting
24
Flowsheeting
25
2.
3.
4.
5.
6.
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26
Flowsheeting
26
Reactions
Reactions
Reactions
Workshop
This module demonstrates the HYSYS philosophy for building
reactions within a simulation. HYSYS defines reactions within the
context of the Fluid Package. This is important for a number of reasons:
Learning Objectives
Once you have completed this section, you will be able to:
Prerequisites
Before beginning this section you need to know how to:
Reactions
Process Overview
Reactions
Steam-Methane Reformer
Steam reformation of methane is often undertaken in conjunction with
processes which require large amounts of hydrogen for instance
hydrotreating, ammonia production, or any process which may utilise
such a synthesis gas. Successive reaction stages take advantage of
thermodynamics and catalysts to enhance the production of hydrogen
at the expense of the by-product gases carbon monoxide and dioxide.
Finally, remaining carbon oxides are converted back into methane as
completely as possible to minimise CO and CO2 carryover into the
downstream process.
In the course of this problem, we will use two of the reactor types in
HYSYS to simulate the reactors in the steam reformation train: the
Conversion and Equilibrium reactors.
Reactions
Reaction
Reform1
Reform2
Shift1
Meth1
2.
Open the Fluid Package and select the Rxns tab. Press the
Simulation Basis Mgr button to open the Simulation Basis
Manager view.
Press the Add Comps button to open the component selection
view. Here, we will select the components that we will have use in
our reactions.
Reactions
3.
Ensure that the FPkg Pool radio button is selected. Press the Add
This Group of Components button. This moves the entire
component list over to the Selected Reaction Components group.
4.
Return to the Simulation Basis Manager view and press the Add
Rxn button. Choose Equilibrium as the type from the displayed
list.
5.
Move to the Basis tab and click the K vs T Table radio button.
Reactions
7.
Temperature, C (F)
Keq
595C (1100F)
0.5
650C (1200F)
705C (1300F)
14
760C (1400F)
63
815C (1500F)
243
870C (1600F)
817
8.
9.
Temperature, C (F)
Keq
675C (1250F)
1.7
705C (1300F)
1.5
730C (1350F)
1.3
760C (1400F
1.2
790C (1450F)
1.1
815C (1500F)
1.0
Reactions
10.
11.
12.
13.
Move to the Basis tab and enter CO as the Base Component and
enter 100 for the Co term.
14.
Once all four reactions are entered and defined, you can create reaction
sets for each type of reactor.
1.
Reactions are added by highlighting the <empty> field in the Active List
group, and selecting the desired reaction from the drop down list. The
10
Reactions
2.
Name
Active List
Shift1
Meth1
2.
Select the only available Fluid Package and press the Add Set to
Fluid Package button.
3.
Repeat Steps 1 and 2 to add all three reaction sets (Reformer, Shift
and Methanator).
Once all three reaction sets are added to the Fluid Package, you can
enter the Simulation Environment and begin constructing the
simulation.
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Reactions
11
Enter...
Conditions
Name
Natural Gas
Temperature
20C (70F)
Pressure
Mass flow
Composition
Mass Fraction CH4
1.0
Name
Steam
Temperature
180C (360F)
Pressure
Composition
Mass Fraction H2O
1.0
Add a Mixer
In This Cell...
Enter...
Connections
Name
Mix-100
Inlets
Outlet
Mixed Feed
On the Parameters page, select the Set Outlet to Lowest Inlet radio
button.
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12
Reactions
Add a Heater
A Heater is needed to heat the feed to the reaction temperature.
Add a Heater with the following information:
In This Cell...
Enter...
Connections
Name
HX1
Inlet
Mixed Feed
Energy
HX1-Q
Outlet
Reform Feed
Parameters
Delta P
Worksheet
Reform Feed, Temperature
12
760C (1400F)
Reactions
13
Enter...
Connections
Name
SET-1
Target Object
Source
Natural Gas
Parameters
Multiplier
2.5
Offset
Enter...
Connections
Name
Reformer
Inlet
Reform Feed
Vapour Outlet
Reform Prod
Liquid Outlet
Reform Liq
Energy
Reform Q
Parameters
DeltaP
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14
Reactions
1.
On the Parameters page, select the Heating radio button for the
Duty.
2.
3.
On the Reactions tab, select the Reformer Rxn Set as the Reaction
Set. This will automatically connect the proper reactions to this
Reactor and the Reactor will solve.
What is the % conversion of Methane? __________
How much CO and H2 were produced in the reaction; i.e.
what is the molar flowrate of these two compounds in the
reactors product stream? __________ & __________
Add a Cooler
Add a Cooler to cool the stream Reform Prod down to the Shift
Reactors temperature. Enter the connections with the following
information:
In This Cell...
Enter...
Connections
Name
HX2
Inlet
Reform Prod
Energy
HX2-Q
Outlet
Shift Feed
Parameters
Delta P
Worksheet
Shift Feed
14
427C (800F)
Reactions
15
Enter...
Connections
Name
Shift
Inlet
Shift Feed
Vapour Outlet
Shift Prod
Liquid Outlet
Shift Liq
Energy
Shift Q
Parameters
Delta P
Worksheet
Shift Prod, Temperature
1.
2.
430C (800F)
On the Parameters page, choose the Cooling radio button for the
Duty.
On the Reactions tab, select Shift Rxn Set as the Reaction Set.
This will automatically connect the proper reactions to this
reactor.
15
16
Reactions
Add a Cooler
Add a Cooler to cool the stream Shift Prod down to the Amine Plants
temperature (the Amine Plant will be added next). Make the
connections as follows:
In This Cell...
Enter...
Connections
Name
HX3
Inlet
Shift Prod
Energy
HX3-Q
Outlet
Amine Feed
Parameters
Delta P
35 kPa (5 psi)
Worksheet
Amine Feed, Temperature
16
38C (100F)
Reactions
17
Enter...
Connections
Name
Amine Plant
Inlet
Amine Feed
Overhead Outlet
Sweet Gas
Energy Stream
AmPl Q
Bottoms Outlet
CO2 Off
Parameters
Overhead Pressure
Bottoms Pressure
Worksheet
Sweet Gas, Temperature
138C (280F)
17
18
Reactions
Add a Heater
A Heater is needed to heat the feed to the Methanator Reactor
temperature.
Add a Heater with the following information:
In This Cell...
Enter...
Connections
Name
HX4
Inlet
Sweet Gas
Energy
HX4-Q
Outlet
Methanator Feed
Parameters
Delta P
21 kPa (3 psi)
Worksheet
Methanator Feed, Temperature
18
260C (500F)
Reactions
19
Enter...
Connections
Name
Methanator
Inlet
Methanator Feed
Vapour Outlet
Product
Liquid Outlet
Meth Liq
Energy
Meth Q
Parameters
Delta P
35 kPa (5 psi)
Worksheet
Product, Temperature
280C (536F)
On the Reactions tab, choose the Methanator Rxn Set from the
Reaction Set drop down menu.
19
20
Reactions
20
1.
From the Tools menu select Databook, or use the <Ctrl><D> Hot
Key to open the Databook.
2.
On the Variables tab, press the Insert button to open the Variable
Navigator.
3.
Select Shift Prod as the object, Comp Molar Flow as the variable,
and CO2 as the variables specific.
Reactions
21
4.
5.
6.
7.
8.
21
22
Reactions
22
9.
Enter values for Low Bound, High Bound, and Step Size of 1.5,
4.0 and 0.25 respectively.
10.
11.
Reactions
23
Exercise
Using the Adjust Operation
In this exercise, we will use the Adjust operation in HYSYS to determine
what temperature in the Shift 1 reactor will produce a molar ratio of
hydrogen to methane of 10:1 in the final product.
The Adjust operation in HYSYS is similar to a "steady state controller."
It will manipulate one process variable (this variable must be
specifiable) until another variable is equal to a set target value. In this
case, we will manipulate the temperature of the outlet stream from the
Shift 1 reactor until the desired molar ratio is achieved in the final
product.
Normally, the target variable can be selected using the variable
navigator; however, this is not the case here. The molar ratio of
methane to hydrogen is not a normal process variable; therefore, we
must use the Spreadsheet operation to calculate this value and transfer
its value to another location that can be selected using the variable
navigator.
The process for doing this will be given here:
1.
2.
3.
4.
23
24
Reactions
5.
In This Cell...
Enter...
Adjust Variable
Target Variable
10
6.
In This Cell...
Enter...
Method
Secant (default)
Tolerance
0.01
Step Size
25
Maximum Iterations
30
7.
24
Reactions
25
Challenge
A new application of the Product stream has been found. However, it
requires that the amount of methane in the stream be less than 1% of
the amount of hydrogen. In other words, the molar ratio must be
increased to 100.
25
26
Reactions
26
Column Operations
Column Operations
Column Operations
Workshop
In this module, you will simulate an Ethanol Plant. You will get more
practice with the Column unit operation of HYSYS by:
Column Operations
Learning Objectives
Once you have completed this section, you will be able to:
Prerequisites
Before beginning this section, you need to be able to:
Process Overview
Column Operations
Column Overviews
CO2 Wash
Concentrator
Lights
Column Operations
Rectifier
Column Operations
2.
3.
On the Binary Coeffs tab of the Fluid Package use UNIFAC VLE
and press the Unknowns Only button to estimate the missing
interaction parameters.
Enter...
Conditions
Stream Name
Wash H2O
Temperature
25C (77F)
Pressure
Mass Flow
100%
Column Operations
Conditions
Stream Name
FromFerm
Temperature
30C (86F)
Pressure
Mass Flow
0.0637
H2O
0.8759
CO2
0.0601
Methanol
4.433e-5
Acetic Acid
1.026e-5
1-Propanol
2.802e-5
2-Propanol
2.808e-5
1-Butanol
2.505e-5
3-M-1-C4ol
9.727e-5
2-Pentanol
2.457e-5
Glycerol
3.141e-5
Conditions
Stream Name
Steam A
Temperature
140C (284F)
Pressure
Mass Flow
100%
Column Operations
Enter...
Conditions
Name
CO2 Vent
Inlets
FromFerm
Vapour Outlet
To CO2 Wash
Liquid Outlet
Beer
10
Column Operations
Parent Simulation
Environment button
10
Column Operations
11
Column Types
HYSYS has several basic Column Templates (pre-constructed column
configurations) which may be used for installing a new Column,
allowing HYSYS to model several different separation processes.
This module will introduce the Absorber. Subsequent modules will
present different columns so that, by the end of this course, most types
of columns will have been used.
Initial Estimates
In order to calculate, the Column solver in HYSYS requires usersupplied estimates ranging from condition parameters to feed and
draw locations. These data can be supplied in several ways. The first
interface when you select a Column requires values for the Number of
Trays, Reflux, Pressure, and so on. In the Column Solver, on the Work
Sheet tab, Conditions page, data can also be supplied. On the Design
tab, Specs page, HYSYS allows you to choose from a library of
specifications gathered in the Column Specification Types window,
activated when you press the Add button. Specification Types can be
supplied as Estimates or as Active specifications. Only Active
specifications fill the Degree of Freedom of the Column which must be
zero for the solver to calculate. Inactive specifications (Estimates) are
used only as initial estimates for the convergence algorithm and never
use a degree of freedom. Alternatively, Estimates can be supplied on the
Estimates page under the Parameters tab. However, they will not
appear on the Monitor, and hence cannot be set as Active
specifications.
If the user does not have initial estimates HYSYS generates them.
However for chemical systems, it is recommended to use the HYSYS
Estimate Generator tool. In the Column Environment, on the
Parameters tab, Solver page, there is the Initial Estimate Generator
11
12
Column Operations
Parameters box. By checking the box, the IEG will perform iterative
flash calculations to provide the initial estimates for the temperature
and composition profiles. No user estimates are required when the
Iterative IEG check box is activated.
12
Column Operations
13
2.
3.
4.
13
14
Column Operations
Concentrator
This tower removes most of the Methanol from the Fermentor
products.
The Concentrator is an Absorber with a side vapour draw.
In This Cell...
Enter...
Connections
Column Name
Conc
No. of Stages
17
Feed
Ovhd Vapour
To Light
Bottoms Liquid
Stillage A
Pressure
Top Stage Pressure
Temperatures
Stage 1 Temp Estimate
90C (195F)
110C (230F)
14
Column Operations
15
1.
2.
3.
Select the specification you want from the list that appears.In this
case, we want to add a Column Component Recovery
specification.
4.
15
16
Column Operations
5.
This specification will set the ratio of ethanol recovered in the specified
stream compared to the amount of ethanol fed to the column. Here, we
have set this ratio at 0.95, meaning that 95% of the ethanol supplied to
the column is recovered in the Rect Feed stream.
We are not concerned about where the other 5% goes, although it must
exit the column in one of the other product streams.
6.
7.
We can now start the column runner and allow HYSYS to find a
solution for this column. Press the Run button now to begin the
column solver.
8.
16
Column Operations
17
Lights
The Lights Tower is a purification tower.
Add the Refluxed Absorber column and enter the following data.
Refluxed Absorber button
In this cell...
Enter...
Lights
No. of Stages
To Light
Condenser Type
Partial
Bottoms Liquid
To Rect
Condenser Energy
CondDuty
Overhead Outlets
0 kPa (0 psi)
Condenser Pressure
Reflux Ratio
17
18
Column Operations
Enter...
Name
Ethanol Purity
Stage
Condenser
Flow Basis
Mass Fraction
Phase
Liquid (default)
Spec Value
0.88
Component
Ethanol
18
Column Operations
19
Rectifier
The primary product from a plant such as this would be the azeotropic
mixture of ethanol and water. The Rectifier serves to concentrate the
water/ethanol mixture to near azeotropic composition. The Rectifier is
operated as a conventional distillation tower. It contains a partial
condenser as well as a reboiler.
Distillation column button
Enter...
Connections
Column Name
Rect
No. of Stages
59
Inlet Streams
ToRect, Stage 38
RectFeed, Stage 44
Condenser Type
Partial
Overhead Vapour
RectVap
Overhead Liquid
RectDist
Bottoms Liquid
Stillage B
Condenser Energy
RectCond Q
Reboiler Energy
Rect Reb Q
Pressures
Condenser
Reboiler
Specifications
Reflux Ratio
7100
Distillate Rate
19
20
Column Operations
Remember that when we added the two side draw streams to the
column, HYSYS automatically created Draw Rate specifications
for those streams. On the Monitor page, enter the following
values for these two Draw Rate specifications.
Specification 1
Specification 2
Name
Fusel Rate
Spec Value
3000 kg/h
2 kg/h (5 lb/hr)
(6500 lb/hr)
2.
In This Cell...
Enter...
Name
Product Purity
Target Type
Draw
1st Prod
Basis
Mass Fraction
Spec Value
0.95
Component
Ethanol
3.
20
Reflux Ratio
Ovhd Vap Rate
Distillate Rate
Fusel Rate
Product Purity
Column Operations
21
4.
5.
6.
Press the Run button to converge the column. If the column does
not converge quickly, stop the solver and increase the Fusel draw
rate spec value to 10 kg/h (20 lb/hr), and try again. Once the
column has converge, the Fusel draw rate can be returned to its
original level.
What is the mass fraction of Ethanol in the "1st Prod"
stream when the column is converged? ____________
21
22
Column Operations
2.
3.
Press the View Graph button. In this view we can see the
compositions on each tray.
22
Column Operations
23
Optional Challenge
Replacing the Kettle Reboiler with a
Thermosyphon Reboiler
In this portion of the module, we will replace the default kettle type
reboiler on the Rectifier column with a "Thermosyphon" type reboiler.
Thermosyphon reboilers are commonly used in this type of
application, and it is often desired to use HYSYS to simulate the
operation of the column with this type of reboiler as it will provide a
more accurate simulation of the actual physical set-up of the
equipment.
In order to change the kettle reboiler to a thermosyphon, we will have
to add one additional stage to the column. This additional stage
functions as a liquid sump that allows liquid to be drawn from the
column and liquid to be fed to the column from the reboiler. With
thermosyphon reboilers, both liquid and vapour are returned to the
column rather than just the vapour that is returned to the column with
standard kettle reboilers.
Following the steps below will allow you to replace the standard kettle
reboiler with a thermosyphon type reboiler.
1.
Change the number of stages in the column to 60. This value can
be accessed from the Connections page of the columns property
viewer.
2.
3.
Disconnect the "Stillage B" stream from the reboiler and reattach
it as a material withdraw stream from stage 60.
4.
5.
23
24
Column Operations
6.
7.
8.
In This Cell...
Enter...
Name
Reboiler V.F.
Stage
Reboiler
Spec Value
0.9
9.
24
Workshop
Ethylene glycol has many industrial uses: a feed stock for polyester
resins, a hydrate inhibitor in natural gas pipelines, an all-weather
antifreeze and coolant, or an industrial solvent. Ethylene oxide and
water are fed to a reactor to produce ethylene glycol. The product
stream is fed to a distillation column where the excess water and
ethylene oxide are stripped off the top and the ethylene glycol is the
bottom product.
Learning Objectives
After completing this module, you will be able to:
Prerequisites
Before beginning this module, you need to be able to:
Process Overview
Column Overview
3.
4.
In This Cell...
Enter...
Basis
Basis
Molar Concn
Base Component
C2Oxide
Rxn Phase
Combined Liquid
Basis Units
kgmole/m3
Rate Units
kgmole/m3-s
Parameters
Forward Reaction
A
5.0e+06
5.0e+04
5.
6.
Enter...
Conditions
Name
EOx Feed
Temperature
25C (77F)
Pressure
Molar Flow
Composition
C2Oxide
1.0
H2O
0.0
EGlycol
0.0
Conditions
Name
Water Feed
Temperature
25C (77F)
Pressure
Molar Flow
Composition
C2Oxide
0.0
H2O
1.0
EGlycol
0.0
CSTR button
Enter...
Connections
Name
Reactor
Inlets
EOx Feed
Water Feed
Vapour Outlet
Rx Vapour
Liquid Outlet
Rx Liquid
Energy
Rx Coolant
Parameters
Pressure Drop
Volume
2 m3 (71 ft3)
1.
On the Reactions tab, select the Global Rxn Set and Rxn-1 as the
Reaction.
2.
Enter...
Connections
Name
T-100
No. of Stages
10
Inlet
Rx Liquid, Stage 5
Condenser Type
Partial
Ovhd Vapour
Vent
Ovhd Liquid
Distillate
Bottoms Liquid
Bottoms Product
Condenser Energy
Cond Duty
Reboiler Energy
Reboiler Duty
Pressures
Condenser
Condenser Delta P
0 kPa (0 psi)
Reboiler
Specs
Vapour Rate
Reflux Ratio
3.0
Reboiler Temperature
150C (300F)
10
The Recycle installs a theoretical block in the process stream. The feed
into the block is termed the calculated recycle stream, and the product
is the assumed recycle stream. The following steps take place during
the convergence process
10
11
Install a Recycle block operation. The inlet stream is the Distillate and
the outlet stream should be mixed with the pure Water Feed stream,
before entering the Reactor.
Delete the specified molar flow rate of the Water Feed stream. This
value will be back-calculated from the outlet of the mixer.
Specify the molar flow of the mixer outlet stream, Water to Reactor, as
150 kgmole/h (330 lbmole/hr). Once the flow rate in this stream is set,
HYSYS will automatically calculate the flowrate of the Water Feed
stream. If we had not deleted the specified value, HYSYS would report a
consistency error, because a the two values would be in conflict with
each other.
What value does HYSYS calculate for the flowrate of the
stream "Water Feed"? __________
11
12
Parameters tab
Tolerance page
HYSYS allows you to set the convergence criteria or tolerance for each
of the Recycle variables. In this example, leave everything at the default.
Numerical Page
This page contains the options for the two types of Recycles, Nested
and Simultaneous.
12
13
Monitor tab
This page displays convergence information as the calculations are
performed. Any variable that changes between iterations is displayed in
this table.
Worksheet tab
The Recycle WorkSheet page displays the Inlet and Outlet stream
information. In this instance, notice that the Inlet and Outlet streams
have the same values. This is because before we installed the Recycle,
the Inlet stream was already calculated by HYSYS. When the Recycle
was connected, the known Inlet conditions were automatically passed
to the Outlet stream to serve as the starting guess.
13
14
Exercise 2
Set up an Adjust operation to make sure the molar flow of Ethylene
Glycol in the Rx Liquid stream is equal to 110 kgmole/h (240 lbmole/
hr), by adjusting the EOx Feed molar flow with a step size of 1 kgmole/h
(2 lbmole/hr).
What EtOx feed rate is required to produce the specified
molar flow of Ethylene Glycol? __________
14
15
Advanced Modelling
Because the Recycle operation is a mathematical representation of a
physical process, its location in a simulation is a particularly important
one. The location of the tear stream can often determine success or
failure to converge a recycle
15
16
Recycle Exercises
Choosing the Right Location
When installing Recycle operations in a HYSYS simulation, it is vital
that right location for the operation be chosen. Several guidelines were
given on a previous page, and several different problems will be given
here. Note that some of these flowsheet may require more than one
Recycle operation.
Flowsheet 1
Where should the Recycle be placed in this flowsheet and why? Assume
that you know the following information:
16
17
Flowsheet 2
Where should the Recycle be placed in this flowsheet and why?
Assume that the Feed is fully defined, Shell and Tube Side pressure drops
are known, as well as the Column Feed temperature.
Flowsheet 3
Where should the Recycle be placed in this flowsheet and why?
Assume the Feed is completely defined, shell and tube side pressure drops
for E-100 and E-101, and the temperatures of streams 3 and 4 are known.
17
18
Flowsheet 4
Where should the Recycle be placed in this flowsheet and why?
Assume the Feed is completely defined, and the shell and tube side
pressure drop for E-100 is known.
18
Aromatic Stripper
Aromatic Stripper
Aromatic Stripper
Workshop
This example demonstrates a typical application of the recycle
operation. An aromatic stripper to remove Benzene and Toluene from
water is simulated with the help of a reboiled absorber. The column has
two feeds: the main column feed and a reflux, which is the recycled
overhead vapour after being cooled and going through a three phase
separator.
This example will also illustrate the flexibility of HYSYS that allows the
user to use a different Fluid Package in the column subflowsheet from
the one in the main flowsheet. This allows the user to use a property
package tailored towards a certain behaviour in the Main Flowsheet
and another package tailored towards a different behaviour in the
Column environment.
Here, the feed stream is mostly water that is laced with a small amount
of benzene and toluene. The objective of this process is to produce two
product streams, one of virtually pure water, and the second, a
concentrated stream of aromatics.
Learning Objectives
Once you have completed this section, you will be able to:
Process Overview
Column Overview
Aromatic Stripper
VLE Case
1.
Go to the Binary Coefficients tab. For this case the default values
for Aij and Alphaij are used (Bij is empty).
LLE Case
1.
2.
Use the Copy button to make a copy of the Arom Strip Fluid
Package. Name the new Fluid Package Condenser.
3.
4.
Aromatic Stripper
The Activity Coefficients for Aij, Bij, and Alphaij are shown below:
Aij Interaction
H2O
H2O
Benzene
Toluene
11090.13
4788.593
Benzene
-1973.516
-14.555
Toluene
-1973.516
3.389
H2O
Benzene
Toluene
-37.12
-7.364
Bij Interaction
H2O
Benzene
50.206
0.00
Toluene
21.172
0.00
H2O
Benzene
Toluene
0.038
0.200
Alphaij Interaction
H2O
Benzene
0.038
Toluene
0.200
0.303
0.303
Aromatic Stripper
5.
6.
Aromatic Stripper
Enter...
Conditions
Stream Name
Feed
Temperature
95C (205F)
Pressure
Mass Flow
H2O
0.9982
Benzene
0.0013
Toluene
0.0005
Stream Name
Reflux
Temperature
35C (95F)
Pressure
Molar Flow
H2O
1.0
Benzene
Toluene
Aromatic Stripper
Add A Mixer
Install a Mixer with the following values:
In this cell...
Enter...
Connections
Name
MIX-100
Inlets
Feed, Reflux
Outlet
Strip Feed
In this cell...
Enter...
Connections
Column Name
Stripper
No. of Stages
Strip Feed
Vapour
RebQ
Bottoms
Reboiler Pressure
1.
2.
3.
10
Aromatic Stripper
4.
Assign Arom Strip as the Fluid Package to use for the column.
5.
Note: A message will appear warning you about the P-H Flash as a
transfer basis. Because we are now using two fluid packages with
different interaction coefficients, the program allows you to select the
type of flash that will occur between the two fluid packages, i.e.,
between the column overhead vapour product (using VLE data) and the
condenser unit (using LLE data).
Use the default flash, P-H, and press the Return to Simulation
Environment button again.
6.
10
Open the Stripper property view and press the Run button. Close
the view once it has converged.
Aromatic Stripper
11
Add a Cooler
In This Cell...
Enter...
Connections
Name
Condenser
Inlet
Vapour
Energy
Cond Q
Outlet
Condensed
Parameters
Delta P
30 kPa (4 psi)
Worksheet
Vapour Fraction, Condensed
0.0
Enter...
Connections
Name
Separator
Feeds
Condensed
Vapour
Cond Ovhd
Light Liquid
Aromatic Product
Heavy Liquid
Heavy Liquid
11
12
Aromatic Stripper
Add a Pump
In This Cell...
Enter...
Connections
Name
Pump
Inlet
Heavy Liquid
Outlet
To Recycle
Energy
Pump Q
Parameters
Delta P
40 kPa (6 psi)
Enter...
Connections
Name
RCY-1
Inlet
To Recycle
Outlet
Reflux
12
Aromatic Stripper
13
13
14
Aromatic Stripper
14
The Optimizer
The Optimizer
The Optimizer
Workshop
Fast track to page 9.
Learning Objectives
Once you have completed this section, you will be able to:
Prerequisites
Before beginning this section you need to be able to:
Process Overview
Column Overview
The Optimizer
1.
On the Binary Coeffs tab, check that the UNIFAC VLE estimation
method is chosen, and press the Unknowns Only button to
estimate the missing Interaction Parameters.
2.
Enter...
Conditions
Name
Feed
Temperature
10C (50F)
Pressure
Mass Flow
0.44
Toluene
0.56
The Optimizer
Enter...
Connections
Column Name
T-100
No. of Stages
10
Feed
Feed, Stage 5
Condenser Type
Total
Bottoms Liquid
Toluene
Ovhd Liquid
THF
Cond Q
Reb Q
Pressure
Delta P, Condenser and Reboiler
0 kPa
Condenser
Reboiler
Enter...
Specs
Reflux Ratio
2 (Estimate)
Distillate Rate
The Optimizer
These two specifications should be Active. The DOF for the column
should now be 0.
The column should now solve automatically. If it does not, press the
Run button to start the solver.
The Optimizer
2.
Enter 1e-6 for both the tolerance values. These cells are located in
the Solving Options group box.
The Optimizer
10
The Optimizer
F pMp FfMf OC
p
where:
PF
= Profit Function/time
FpMp
FfMf
OC
= Operating Costs
10
The Optimizer
11
Variables tab
When you invoke the Optimizer for the first time, you are placed on the
Variables tab. On the Variables tab you define the Adjusted (Primary)
Variables to be used in the optimization.
In this case, our Primary Variables are the purity of our products, THF
and Toluene.
1.
Press the Add button to add the first variable, T-100, Spec Value,
THF Purity Spec.
2.
Set the Upper Bound at 0.9, and the Lower Bound at 0.90.
3.
Add the second variable, T-100, Spec Value, Toluene Purity Spec,
with the same bounds as above.
11
12
The Optimizer
The Spreadsheet is an
operation and thus the
Spreadsheet cells get updated
when Flowsheet variables
change
The Optimizer has its own Spreadsheet for defining the Objective and
Constraint functions. Primary Variables may be imported and
functions defined within the Optimizer Spreadsheet, which possesses
the same capabilities as the Main Flowsheet Spreadsheet
1.
2.
12
The Optimizer
13
Adding Formulas
Complex mathematical formulas can be created, using syntax that is
similar to conventional Spreadsheets. Arithmetic, logarithmic and
trigonometric functions can be performed in the Spreadsheet.
All common functions must be preceded by a + symbol. Special
Functions must be preceded by the @ symbol.
Some of the functions available are:
Object...
Variable...
B1
Cond Q
Heat Flow
B2
Reb Q
Heat Flow
B3
THF
Mass Flow
B4
THF
B5
Toluene
Mass Flow
B6
Toluene
B7
Feed
Mass Flow
13
14
The Optimizer
Value (Field)
Comment
D1
0.471 ($/kWh)
138 ($/MMBtu)
Cooling Cost
D2
0.737 ($/kWh)
216 ($/MMBtu)
Heating Cost
D7
0.05 ($/kg)
0.024 ($/lb)
Feed Cost
Cell
Equation
(SI Units)
Equation (Field)
Description
D4
+0.333*b4^3 ($/kg)
+0.151*b4^3 ($/lb)
D6
+0.163*b6^3 ($/kg)
+0.074*b6^3 ($/lb)
Toluene Price
(corrected for purity)
+(b3*d4+b5*d6)-b7*d7-(b1*d1+b2*d2)/3600
Pay special attention to the units in this equation. If using field units,
you may have to add an additional term to this equation to convert
between hours and days.
What is the value of cell D8, the Profit? __________
14
The Optimizer
15
Functions tab
The Functions tab contains two groups, the Objective Function and the
Constraint Functions. However, in this example we do not have
constraint functions.
1.
2.
15
16
The Optimizer
Parameters tab
The Parameters tab is used for selecting the Optimization Scheme.
1.
2.
Monitor tab
The Monitor tab displays the values of the Objective Function and
Primary Variables during the Optimizer calculations.
1.
Move to the Monitor tab and press the Start button to begin the
optimization.
16
The Optimizer
17
1650.8 kg/h
(3639.4 lb/hr)
THF purity
0.95
2049.2 kg/h
(4517.7 lb/hr)
Toluene purity
0.95
Cond duty
9.926e5 kJ/h
(9.408e5 Btu/hr)
Reb duty
1.5980e6 kJ/h
(1.5146e6 Btu/hr)
Profit
106.3 $/hr
Optimized Case
17
18
The Optimizer
Exercise 1
We are going to introduce a constraint on the liquid volume flow of the
stream THF and examine how it affects the results, profit and products
purities.
First, the case must be set back to its state before the optimization.
1.
2.
On the Design tab, Monitor page, enter the initial value of 0.95 for
the THF and Toluene purity specifications.
3.
The constraint on the liquid flow is that it must not exceed 1.85 m3/h
(65.5 ft3/hr).
The THF Liquid Flow must first be imported into the spreadsheet (use
an empty cell), and the constraint value must be written in the
spreadsheet. Remember to write the comments next to the values so
that they can be understood.
18
1.
2.
3.
In the Cond column, use the scroll down arrow to find the less
than sign. Type in the reference of the cell where the value of the
constraint is written.
4.
The Optimizer
19
What differences, if any, does the constraint make to the first optimized
solution? Fill in the following table:
Base Case
THF Mass Flow
1650.8 kg/h
THF Purity
0.95
Toluene Mass
Flow
2049.2 kg/h
Toluene Purity
0.95
Cond Duty
9.926e5 kJ/h
Reb Duty
1.5980e6 kJ/h
Profit
106.3 $
Optimized
Case
Optimized
Case 2
19
20
The Optimizer
Exercise 2
Here, we are going to model the reboiler with a steam-heated shell and
tube heat exchanger. The heat exchanger will be modelled with 115 psia
steam and the maximum flow of steam available to the reboiler is
limited to 840 kg/h (1850 lb/hr). (Note that there are a few approaches
that can be taken with the heat exchanger modelling so two of the
possibilities are listed). The cost of the 115 psia steam is 0.682 $/kWh
($200/MMBtu).
Use the Mixed optimization
scheme for this exercise.
1.
2.
3.
Add a new internal stream (on the Flowsheet tab), ToReb with the
following attributes:
In This Cell...
Enter...
Type
Liquid
Net/Total
Total
Stage
10
Export
Yes
4.
5.
Return to the Main Environment (notice that the "To Reb" stream
is now shown on the PFD. Add a heat exchanger. The stream
ToReb is the shell side feed and steam is on the tube side.
6.
7.
8.
Add a Duty Spec to the Heat Exchanger but do not specify a value
(pass is Overall).
What is the Heat Exchanger Duty? __________
20
The Optimizer
21
9.
10.
Export the RebQ Heat Flow value (you will have to make this
Exportable first) from the Optimizer spreadsheet into the Target
value for the Adjust operation. A cell on the spreadsheet can not
be simultaneously imported and exported. Copy the value of cell
B2 to another empty cell by entering the formula "+B2". The
value in this new cell can then be exported to the Target Value of
the Adjust operation.
11.
12.
Add the Steam Mass Flow (must be less than 840 kg/h (1850 lb/
hr)) constraint to the Optimizer.
13.
21
22
The Optimizer
22
Workshop
An azeotropic mixture of Benzene and Cyclo-Hexane is to be separated
in a distillation column using Acetone as the entrainer. Nearly pure
Benzene is produced from the bottom of the column, while a near
azeotropic mixture of Acetone and Cyclo-Hexane is produced
overhead. The overhead mixture will be separated in a Liquid-Liquid
extractor using water as the solvent, with Cyclo-Hexane being
recovered as the overhead product. The Acetone/Water mixture will
then be separated in a vacuum tower with the Acetone and Water
products being recycled through the flowsheet.
The process will be separated into four sections, the Azeotrope tower,
the Liquid-Liquid extractor, the Solvent Recovery tower and finally the
recycling system.
Learning Objectives
Once you have completed this section, you will be able to:
Process Overview
Add the first Fluid Package in the usual manner and change the
default name to VLE Basis.
On the Binary Coeffs tab, view the binary coefficients for the
UNIQUAC activity model.
1.
On the Fluid Pkgs tab of the Simulation Basis Manager, press the
Import button and import the Fluid Package LLEBasis.fpk. This
file should be located on the course disk supplied with this
material.
2.
Press the View button to see the new Fluid Package. Go to the
Binary Coeffs tab to view the binary coefficients.
If you examine the LLE Coefficients for VLE Basis and LLE Basis you will
see they are different, because they have been taken from different
sources.
VLE Basis will be used for most of the simulation, while LLE Basis will
be used as the Fluid Package for the Liquid-Liquid Extractor.
Enter the Simulation Environment.
In this cell...
Enter...
Conditions
Stream Name
Azeo Feed
Temperature
77C (170F)
Pressure
Mass Flow
0.518
Cyclohexane
0.482
2.
In This Cell...
Enter...
Conditions
Stream Name
Acetone
Temperature
55C (130F)
Pressure
Mass Flow
3.
Azeotrope Tower
Published documentation on this process indicates that the overhead
composition from the Azeotrope Tower is a near azeotropic mixture of
Acetone and Cyclohexane. Using less Acetone than is necessary to
produce the azeotrope will prevent the original Benzene/Cyclohexane
azeotrope from being separated.
In This Cell...
Enter...
Connections
Column Name
T-100
No. of Stages
28
Q-Cond
Inlet Streams
Condenser Type
Total
Overhead Liquid
Azeo Liq
Benzene
Q Reb
Pressures
Delta P
Condenser
Reboiler
Temp. Estimates
Condenser
55C (130F)
Reboiler
80C (175F)
Specifications
Because we expect an
azeotrope to be present in this
column, we must check the
Azeotropic box on the Solver
page.
0.998
0.998
10.0
2.
3.
10
10
Property Package
The Liquid-Liquid Extractor cannot be used with the following property
packages:
Wilson
Antoine
BraunK10
Esso Tabular
Steam
Amine
Chao-Seader
Grayson-Streed
Sour PR
Sour SRK
Overhead Estimate
You will not be required to provide an estimate for the Overhead
Product Flow. The Extractor will generate an estimate from a mole
weighted TP-Flash of the combined tower feeds.
Stage Efficiencies
The HYSYS Extraction algorithm models the Extractor as a staged
tower, allowing you to specify either ideal stages or actual stages with
efficiencies.
Side Draw
If you require a Side Draw on the Extractor, you can choose to draw
either the Light or Heavy phase from a stage. HYSYS will perform a
three phase flash on the entire contents of the stage to produce the
conditions and composition of the specified draw.
11
11
12
In This Cell...
Enter...
Conditions
12
Stream Name
Water
Temperature
25C (77F)
Pressure
Mass Flow
1.0
2.
In this cell...
Enter...
Connections
Column Name
T-101
No. of Stages
20
Water
Azeo Liq
CycloC6
Rich Solv
Pressures
Top Stage
Bottom Stage
Temperature Estimates
Top Stage
25C (77F)
Stages 2-18
25C (77F)
Stage 19
28C (82F)
Stage 20
33C (91F)
3.
13
13
14
14
4.
5.
In This Cell...
Enter...
Connections
Column Name
T-102
No. of Stages
20
Inlet Streams
RichSolv, Stage 17
Condenser Type
Total
Overhead Liq
AcetRich
H2O Rich
RecCond Q
RecReb Q
Pressures
Condenser Pressure
Reboiler Pressure
56 kPa (8 psia)
Temperature Estimates
Condenser
35C (95F)
Reboiler
80C (175F)
Specifications
Reflux Ratio
0.9998
2.
3.
15
15
16
Solvent Recycles
Finally, the two products from the Solvent Recovery tower have to be
recycled to the previous two towers. Because of the temperature and
pressure of the Solvent Recovery tower, each recycle stream will require
a Pump and a Cooler/Heater operation to return the stream to the
necessary tower conditions.
Add a Pump
Add a Pump to the stream H2O Rich with the following information:
In This Cell...
Enter...
Connections
Name
P-100
Inlet
H2O Rich
Outlet
H2O Atm
Energy
Q 100
Parameters
Adiabatic Efficiency
75%
16
Add a Cooler
Add a Cooler downstream of P-100 with the following information:
In This Cell...
Enter...
Connections
Name
E-100
Inlet
H2O Atm
Energy
Q102
Outlet
H2O Cool
Parameters
Delta P
0 kPa
17
17
18
Enter...
Connections
Name
P-101
Inlet
Acet Rich
Outlet
Acet Atm
Energy
Q 101
Parameters
Adiabatic Efficiency
75%
Add a Heater
Add a Heater operation downstream of Acet Atm with the following
information:
In This Cell...
Enter...
Connections
Name
E-101
Inlet
Acet Atm
Energy
Q 103
Outlet
Acet Warm
Parameters
Delta P
0 kPa
18
19
19
20
Enter...
Connections
Name
BAL-1
Inlet Streams
Benzene
Outlet Streams
Rec Acet
1.
2.
3.
In This Cell...
Enter...
Connections
Name
BAL-2
Inlet Streams
CycloC6
Outlet Streams
Rec H2O
1.
2.
20
Enter...
Connections
Name
X-100
Inlets
Rec H2O
Overhead Outlet
H2O Make-up
Bottoms Outlet
Frac CycloC6
Parameters
Overhead Pressure
Bottoms Pressure
Splits
Benzene
CycloC6
Acetone
1.0
H2O
1.0
21
21
22
In This Cell...
Enter...
Connections
Name
X-101
Inlets
Rec Acet
Overhead Outlet
Acet Make-up
Bottoms Outlet
Frac Benzene
Parameters
Overhead Pressure
Bottoms Pressure
Splits
Benzene
CycloC6
Acetone
1.0
H2O
1.0
22
Enter...
Connections
Name
Inlets
MIX-100
Acet Warm
Acet Make-up
Outlet
Acet to Rec
Connections
Name
MIX-101
Inlets
H2O Cool
H2O Make-up
Outlet
H2O to Rec
23
23
24
Enter...
Connections
Name
RCY-1
Inlet
H2O to Rec
Outlet
Water
Parameters
Vapour Fraction
10.0
Temperature
10.0
Pressure
10.0
Flow
1.0
Enthalpy
10.0
Composition
1.0
Connections
Name
RCY-2
Inlet
Acet to Rec
Outlet
Acetone
Parameters
24
Vapour Fraction
10.0
Temperature
10.0
Pressure
10.0
Flow
1.0
Enthalpy
10.0
Composition
1.0
25
25
26
26
Reactive Distillation
Reactive Distillation
Reactive Distillation
Workshop
With the continuous removal of reaction products, reactive distillation
has found acceptance as a means of improving the technical and
economic operation of processes where it is applicable. Advantages of
this process include higher yields, energy savings and reduced capital
costs.
Fast Track to page 7
Learning Objectives
Once you have completed this section, you will be able to:
Process Overview
Column Overview
Reactive Distillation
Enter...
Conditions
Stream Name
Feed
Temperature
75C (165F)
Pressure
Molar Flow
0.4
Acetic Acid
0.4
M-Acetate
0.1
Water
0.1
Reactive Distillation
Enter...
Connections
Column Name
Reactive Distil
No. of Stages
15
Feed
Feed, Stage 10
Condenser Type
Total
Ovhd Liquid
Distillate
Bottoms Liquid
Bottoms
Condenser Energy
Cond Q
Reboiler Energy
Reb Q
Pressure
Delta P, Condenser
0 kPa (0 psi)
Condenser
Reboiler
Specs
Reflux Ratio
Distillate Rate
Go to the Monitor page of the Design tab and run the column.
Complete the following table with information from the simulation:
Component
Methanol
Acetic Acid
Methyl Acetate
Water
Distillate - Mole
Fraction
Bottoms - Mole
Fraction
Reactive Distillation
3.
Select Kinetic from the list of reactions and press the Add
Reaction button.
4.
5.
6.
7.
Add the Global Rxn Set to the Current Reaction Sets group by
pressing the Add Set button.
Reactive Distillation
1.
On the Reactions tab, press the New button. Enter the following
data:
2.
3.
4.
Run the column. (The column may run automatically after the
solver is changed.)
5.
6.
7.
You can view the results on the Performance tab, and the
reaction results on the Reactions tab, Results page.
Reactive Distillation
8.
Component
Distillate - Mole
Fraction
Bottoms - Mole
Fraction
Methanol
Acetic Acid
Methyl Acetate
Water
Does the reaction inside the column have any effect on the
compositions of the product streams? __________
10
Reactive Distillation
10
Introduction
In previous modules, we have installed distillation columns design for
two phases. However, these columns will not work for three phase
systems. When dealing with three phase systems, it is necessary to use a
different type of column that uses a different Input Expert, and a
different default solver.
Due to the addition of a second liquid phase in the column, it is very
difficult to model this type of column. For this reason, we must use the
Sparse Continuation Solver to solve these systems.
The three phase system in this example consists of a 2-butanol, water,
n-butyl-acetate system. The feed to the column is saturated liquid at
atmospheric pressure. The liquid product from the condenser is 98%
pure water, and the liquid product from the reboiler is a mixture of the
two other components (2-butanol and n-butyl-acetate).
Learning Objectives
In this module, you will learn:
Prerequisites
Before beginning this module, you should have some experience with
installing distillation columns in HYSYS. Previous experience with
normal two phase systems will help you understand the principals
behind the operation of three phase systems.
Background
The three phase stream that will be distilled here will consists of three
components: water, n-butyl-acetate, and 2-butanol. The ternary
diagram for these three components at 25 oC (77 oF) and 101.3 kPa (14.9
psia) looks something like this:
This plot was generated using the DISTIL software package produced
by AEA Technology Engineering Software.
The composition of the feed stream is given in the following table:
Component
Mole Fraction
Water
0.35
n-Butyl-Acetate
0.40
2-Butanol
0.25
As you can see (using the ternary graph above), this stream will lie
within the two liquid phase region.
Different Solvers
With two phase distillation the most common solver that is used is the
"HYSIM Inside-Out" solver. This solver is good for most hydrocarbon
systems, but it can not handle highly non ideal chemical systems,
including three phase systems.
The default solver for three phase columns is the "Sparse
Continuation" solver. This more advanced solver is able to handle three
phase, non ideal chemical systems, that other solvers can not calculate.
Process Overview
Column PDF
Water
2-Butanol
n-B-Acetate
On the Binary Coefficients tab, press the Unknowns Only button.
Enter the Simulation Environment.
In This Cell...
Enter...
Name
Feed
Vapour Fraction
0.0
Pressure
Molar Flow
0.35
0.25
0.40
Note: Make sure that you install the Three Phase column operation, not
the two phase one.
As mentioned before, the Input Expert for the Three Phase column is
slightly different than the one used for an ordinary Two Phase column.
For this reason, each page will be shown here.
The input expert for the three-phase distillation column is different
from the input expert that was seen previously. The first page of the
expert allows you to select the type of column that you want to add to
the model. Select the Distillation radio button and press the Next
button.
On the next page, set the number of stages at 6, and set the "Two Liquid
Phase Check" on the top five stages.
On the third page, enter names for the streams around the condenser.
For this column, the Reflux Stream will be the Lights only; therefore,
select the appropriate radio button in this group box.
10
On the fourth page, set the vapour rate to 0.0 and the Light Reflux
Fraction to 1.0. The degrees of freedom should read 0, once both of
these values are entered.
On the fifth page, attach the Feed stream to stage 1. Also, define the
reboiler energy stream and attach a liquid product stream to the
reboiler. From now on, the screens will look familiar to the input expert
screens that you have seen previously.
10
11
On the next page, set the condenser pressure at 101 kPa (14.9 psia), and
the reboiler pressure at 105 kPa (15.5 psia).
11
12
We are now done. Press the Done button to close the input expert. Note
that if the formation of azeotropes were a concern in this column, the
Azeotropic Initialization button would have been pressed, and HYSYS
would have checked for possible azeotropes among the selected
components.
You are automatically placed on the Columns property view; move to
the Monitor page of the Design tab.
How many Degrees of Freedom are shown here? __________
Enter a Bot Prod Rate of 33 kgmole/h (75 lbmole/hr). Press the Run
button to converge the column; the column should start to solve, and
will reach a converged solution quickly. If the column does not solve in
the first attempt, increase the Bot Rate Spec value to 35 kgmole/h
(80 lbmole/hr) and try again. Once the column converges, decrease the
spec back to its original value.
12