Aspen HYSYS Unit Operations: Reference Guide
Aspen HYSYS Unit Operations: Reference Guide
Reference Guide
Version Number: V12
October 2020
Copyright (c) 2020 by Aspen Technology, Inc. All rights reserved.
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Contents iii
Contents iii
Adding a Strip Chart from a Unit Operation 62
User Variables Page 63
Variable Navigator (Multi-Select) 65
Variable Navigator (Single-Select) 66
Select Type Dialog Box 67
Using the Select Type Dialog Box 68
Changing the Fluid Package for Multiple Unit Operations 68
Worksheet Tab 68
Stream Conditions 69
Stream Properties 69
Stream Composition 69
PF Specs 69
Flow Control Valve (FCV) View (Material Stream) 70
Flow Control Valve (FCV) View (Energy Stream) 71
Control OP Port View 73
iv Contents
Basic Column Parameters 118
Pressure Flow 119
Condensers and Reboilers 123
Column Installation 125
Input Experts 126
Templates 127
Contents v
Towers Page 181
Vessels Page 182
Equipment Page 182
Pressure Drop Page 182
Performance Tab 183
Summary Page 184
Column Profiles Page 184
Feeds / Products Page 184
Plots Page 185
Condenser / Reboiler Page 197
Viewing Internals Results 197
Flowsheet Tab 199
Setup Page 199
Flowsheet Variables Page (Main) 200
Internal Streams Page 201
Mapping Page 202
Lock Page 202
Reactions Tab 203
Stages Page 204
Column Reaction Property View 205
Results Page 206
Dynamics Tab 208
Vessels Page 208
Equipment Page 208
Holdup Page 208
Perturb Tab 209
Column Specification Types 210
Cold Property Specifications 210
Component Flow Rate 211
Component Fractions 211
Component Ratio 212
Component Recovery 212
Cut Point 213
Draw Rate 213
Delta T (Heater/Cooler) 213
Delta T (Streams) 214
Duty 214
Duty Ratio 214
End Point Based Column Cut Point 214
Feed Ratio 215
Gap Cut Point 215
Liquid Flow 216
Physical Property Specifications 216
Pump Around Specifications 217
Reboil Ratio 217
Recovery 218
Reflux Feed Ratio 218
Reflux Fraction Ratio 218
Reflux Ratio 219
vi Contents
Stream Property 220
Tee Split Fraction 220
Tray Temperature 221
Transport Property Specifications 221
User Property 221
Vapor Flow 222
Vapor Fraction 222
Vapor Pressure Specifications 222
Column Stream Specifications 223
Column-Specific Operations 224
Condenser Unit Operation 224
Reboiler 237
Column Tower 246
Tee 259
Running the Column 259
Run 260
Reset 261
Column Troubleshooting 261
Heat and Spec Errors Fail to Converge 262
Equilibrium Error Fails to Converge 265
Equilibrium Error Oscillates 265
Column Efficiencies 265
References 267
Contents vii
Viewing Tray Summary Results 314
Viewing Tray Geometry Results By Tray 316
Specifying Packing Geometry 319
Specifying Packing Geometry Design Parameters 321
Specifying Packing Constants 324
Viewing Packing Summary Results 324
Viewing Packing Results By Stage 325
Geometry Messages 327
Hydraulic Plots 327
Accessing Hydraulic Plots 327
Trayed Hydraulic Plots 328
Packing Hydraulic Plots 331
Hydraulic Plots Ribbon Tab 333
Importing Column Analysis Variables into a Spreadsheet 334
Exporting Column Results to Vendor Packages 335
Using Column Analysis Report Builder 337
Methods Used in Column Analysis 338
Column Sizing Algorithm 338
Swept-Back Weir Calculations 339
Chan and Prince Dump Point Correlation 340
Liquid Entrainment Correlations 341
Discharge Coefficient 343
Downcomer Relative Froth Density 343
Tray and Downcomer Area Calculations 345
Downcomer Backup Calculations 356
Maximum Capacity Calculations for Packing 357
Liquid Holdup Calculations for Packing 359
Foaming Calculations 359
Packing Types and Packing Factors 362
Downcomer Choke Flooding 362
Flooding Calculations for Trays 363
Kister & Haas Jet Flood Correlation 364
Fair and Fair72 Jet Flood Correlations 365
Smith, Dresser, and Ohlswager Jet Flood Correlation 367
Pressure Drop Calculations for Packing in Column Analysis 369
Sherwood/Leva/Eckert GPDC Pressure Drop Correlation for Packing 370
Aspen GPDC85 Pressure Drop Correlation for Packing 373
Wallis Pressure Drop Correlation for Packing 375
Billet-99 Correlation for Packing 379
Pressure Drop Calculations for Trays 380
viii Contents
Equations 386
Design Tab 386
Connections Page 387
Parameters Page 387
Solver Page 388
Rating Tab 388
Dynamics Tab 388
Contents ix
Nozzles Page 410
Performance Tab 410
Results Page 410
Profiles Page 411
Plots Page 411
Tables Page 411
Setup Page 412
Dynamics Tab 412
Model Page 412
Specs Page 413
Holdup Page 414
Malfunction Page 415
Rigorous Air Cooler Tab 416
Application Page 417
Process Data Page 418
Property Range Page 419
Result Summary Page 420
Setting Plan Page 420
Tube Layout Page 421
Profiles Page 421
Find Fouling Page 422
x Contents
Fired Heater Theory 435
Heat Transfer 436
Radiant Heat Transfer 439
Convective Heat Transfer 439
Conductive Heat Transfer 440
Pressure Drop 440
Minimum Specifications 441
Design Tab 441
Connections Page 442
Parameters Page 442
Rating Tab 443
Sizing Page 443
Nozzles Page 446
Heat Transfer Page 446
Prevent Wall-to-Fluid Temperature Cross 446
Performance Tab 447
Details Page 447
Plots Page 447
Tables Page 447
Setup Page 448
Dynamics Tab 448
Tube Side PF Page 448
Flue Gas PF Page 449
Holdup Page 450
EDR Fired Heater Tab 450
Viewing Performance Summary Information 451
Streams Page 452
Fuel Page 452
Flue Gas Page 453
Tube Banks Page 453
Operation Page 453
Property Table Page 453
Contents xi
Plot Tab 487
Nozzles Page 487
Heat Loss Page 488
Prevent Wall-to-Fluid Temperature Cross 488
Performance Tab 489
Details Page 489
Plots Page 489
Tables Page 490
Setup Page 490
Error Msg Page 490
Dynamics Tab 490
Model Page 490
Specs Page 494
Holdup Page 497
Malfunction Page 498
Rigorous Shell&Tube Tab 499
Specifying Application Information for Rigorous Shell&Tube 500
Specifying Exchanger Information for Rigorous Shell&Tube 503
Specifying Process Information for Rigorous Shell&Tube 510
Specifying Property Ranges for Rigorous Shell&Tube 511
Viewing Results Summary for Rigorous Shell&Tube 512
Viewing a Setting Plan for Rigorous Shell&Tube 513
Viewing Tube Layout Information for Rigorous Shell&Tube 514
Viewing Rigorous Shell&Tube Profiles Information 515
Specifying Find Fouling Calculation Options for Rigorous Shell&Tube 515
xii Contents
Dynamics Tab 538
Model Page 538
Specs Page 540
Holdup Page 541
Estimates Page 541
About the LNG Wound Coil Heat Exchanger 542
Wound Coil Heat Exchanger (WCHE) Reference Page 542
Wound Coil Heat Exchanger - Plate Fin Equivalents Reference 545
LNG EDR PlateFin Overview 552
EDR PlateFin Tab 553
Exchanger Design Ribbon Options 553
EDR PlateFin Process Page 555
EDR PlateFin Property Ranges Page 556
EDR PlateFin Results Summary Page 558
EDR PlateFin Results Geometry 559
LNG EDR CoilWound Overview 561
EDR CoilWound Tab 562
Exchanger Design Ribbon Options 562
Specifying LNG EDR CoilWound Process Information 564
Specifying LNG EDR CoilWound Property Ranges 565
Viewing LNG EDR CoilWound Results Summary 566
Viewing LNG EDR CoilWound Results Geometry 568
Modifying LNG EDR CoilWound Convergence Parameters 569
Contents xiii
Parameters Tab 587
Parameters Page 587
Simultaneous Adjust Manager 589
Options Page 591
Monitor Tab 591
Tables Page 591
Plots Page 592
Starting the Adjust 592
Individual Adjust 592
Multiple Adjust 593
21 Balance 595
Connections Tab 596
Connections Page 596
Balance Parameters 597
xiv Contents
23 Control Operations 619
Contents xv
Scheduling Page 675
Alarms Page 675
PV Conditioning Page 677
Signal Processing 678
Feed Forward Page 679
Model Testing Page 680
Initialization Page 680
Monitor Tab 681
xvi Contents
30 Multiplier 715
Specifying Multiplier Connections 715
Specifying Parameters for the Multiplier 716
31 Recycle 717
Calculations 718
Reducing Convergence Time 719
Connections Tab 719
Connections Page 720
Parameters Tab 720
Variables Page 720
Numerical Page 722
Convergence Page 725
Monitor Tab 725
Setup Page 725
Tables Page 726
Plots Page 726
Recycle Advisor 727
Using the Recycle Advisor 727
Recycle Setup Tab 727
33 Set 735
Connections Tab 735
Parameters Tab 736
34 Spreadsheet 737
Spreadsheet Functions 738
General Math Functions 739
Calculation Hierarchy 739
Logarithmic Functions 740
Trigonometric Functions 740
Logical Operators 741
IF/THEN/ELSE Statements 741
Spreadsheet Interface 742
Importing and Exporting Variables by drag and drop 742
Enumeration in Spreadsheet 742
Importing Variables by Browsing 743
Exporting Formula Results 743
View Associated Object 744
Function Help and Spreadsheet Only Buttons 744
Contents xvii
Spreadsheet Connections 745
Spreadsheet Parameters 745
Spreadsheet Formulas 747
Spreadsheet Tab 748
Spreadsheet Calculation Order 749
xviii Contents
Properties Page 780
Dynamics Tab 781
Specs Page 781
39 Mixer 783
Design Tab 784
Connections Page 784
Parameters Page 784
Rating Tab 785
Nozzles Page 785
Dynamics Tab 785
Specs Page 785
Holdup Page 786
Contents xix
41 Relief Valve 909
Design Tab 909
Connections Page 909
Parameters Page 910
Rating Tab 910
Sizing Page 911
Nozzles Page 914
Dynamics Tab 914
Specs Page 914
Holdup Page 915
Advanced Page 916
Malfunction Page 916
42 Tee 919
Design Tab 919
Connections Page 919
Parameters Page 920
Rating Tab 921
Nozzles Page 921
Dynamics Tab 921
Specs Page 921
Holdup Page 922
45 Conversion Reactor 967
Design Tab 967
xx Contents
Connections Page 967
Parameters Page 968
Reactions Tab 970
Details Page 970
Results Page 972
Rating Tab 973
Sizing Page 974
Nozzles Page 976
Heat Loss Page 976
Dynamics Tab 977
Specs Page 977
Holdup Page 979
Heat Exchanger Page 979
Contents xxi
Design Data Page 1006
Design Data: Base Page 1006
Design Data: Datasets Page 1006
Base Shifts Page 1007
Efficiencies Page 1008
Efficiencies Page 1008
Results Page 1008
Dynamics Tab 1008
Specs Page 1009
xxii Contents
Compressor Efficiencies Equations 1046
Compressor Head Equations 1047
Quasi-Dimensionless and Non-Dimensional Curves 1048
Compressor Curve Interpolation Details 1051
Expander References 1053
Expander Efficiencies Equations 1053
Expander Head Equations 1053
Atlas Copco Curves 1054
Mafi Trench Curves 1055
Centrifugal Compressor References 1055
Compressor Performance Curves: Off Design Corrections 1055
Using Momentum Equations 1058
Reciprocating Compressor Theory 1060
Rod Loading 1062
Flow 1063
Maximum Pressure 1063
Screw Compressor Theory 1064
Volumetric Efficiency and Leakage Flow Calculation 1064
Performance Curve Calculation 1065
References 1065
Wet Gas Compressor Theory 1066
Single GMF/GVF 1066
Multiple GMF/GVF 1066
References 1067
Compressor / Expander Design Tab 1067
Specifying Compressor Parameters 1067
Specifying Expander Parameters 1071
Specifying Compressor / Expander Connections 1072
Specifying Links for the Compressor / Expander 1073
Reciprocating Compressor Settings 1074
Screw Compressor Settings 1075
Compressor / Expander Rating Tab 1077
Specifying Centrifugal Compressor Curves 1077
Specifying Expander Curves 1084
Specifying Screw Compressor Curves 1090
Specifying Curves for the Wet Gas Compressor 1092
Curve Property View 1096
Compressor Curves Profiles 1096
Specifying Flow Limits 1097
Specifying Nozzle Information 1100
Specifying Inertia Parameters 1101
Specifying Electric Motor Information 1101
Speed vs Torque Curve Property View 1104
Compressor / Expander Performance Tab 1105
Viewing Results for the Compressor / Expander 1105
Viewing Power Results 1107
Compressor / Expander Dynamics Tab 1108
Setting Dynamic Specifications for the Compressor / Expander 1108
Compressor / Expander Holdup 1111
Contents xxiii
Surge Control View 1111
53 Pump 1115
Pump Theory 1115
Multiphase Pump 1117
Multiphase Pump Theory 1117
Use Correlation Option 1117
Use Curves Option 1118
Pump Design Tab 1118
Specifying Pump Connections 1119
Specifying Pump Parameters 1119
Generating Pump Curves Based on Coefficients 1120
Specifying Pump Links 1121
Pump Rating Tab 1122
Configuring Pump Curves 1122
Curve Property View 1125
Curves Profiles Property View 1127
Generate Curve Options Property View 1128
Specifying NPSH Information for the Pump 1129
Specifying Nozzle Information for the Pump 1135
Specifying Inertia Parameters for the Pump 1135
Specifying Electric Motor Information for the Pump 1136
Speed vs Torque Curve Property View 1139
Specifying Design Information for the Pump 1139
Pump Performance Tab 1140
Viewing Pump Performance Results 1140
Viewing Pump Power Results 1140
Pump Dynamics Tab 1140
References 1141
Pump Dynamic Specifications 1141
Pump Holdup 1143
Modeling Malfunction Scenarios for the Pump 1143
xxiv Contents
56 Separator, 3-Phase Separator, and Tank 1157
Separator, 3-Phase Separator, and Tank Theory 1159
Energy Balance 1160
Physical Parameters 1160
Ideal vs. Real 1161
Design Tab 1161
Connections Page 1161
Parameters Page 1162
Reactions Tab 1162
Results Page 1163
Rating Tab 1163
Sizing Page 1164
Nozzles Page 1166
Heat Loss Page 1167
Level Taps Page 1173
Options Page 1175
C.Over Setup Page 1175
Profes Carry Over Correlation View 1181
C.Over Results 1187
Dynamics Tab 1188
Specs Page 1188
Holdup Page 1190
Heat Exchanger Page 1191
60 Cyclone 1209
Design Tab 1209
Connections Page 1209
Parameters Page 1210
Contents xxv
Solids Page 1210
Rating Tab 1211
Sizing Page 1211
Constraints Page 1212
Performance Tab 1212
Results Page 1212
Dynamics Tab 1212
61 Hydrocyclone 1213
Design Tab 1213
Connections Page 1213
Parameters Page 1213
Solids Page 1214
Rating Tab 1214
Sizing Page 1214
Constraints Page 1215
Performance Tab 1215
Results Page 1215
Dynamics Tab 1215
xxvi Contents
Cake Page 1232
Dynamics Tab 1233
Contents xxvii
Subflowsheet Property View 1274
Adding a Subflowsheet 1274
Subflowsheet Connections 1275
Subflowsheet Parameters 1276
Subflowsheet Transfer Basis 1277
Subflowsheet Transition 1277
Subflowsheet Variables 1279
Lock Tab 1279
Index 1281
xxviii Contents
1 Unit Operations Overview
Multi-Flowsheet Architecture
The multi-flowsheet architecture of HYSYS is vital to this overall modeling
approach. Although HYSYS is designed to allow the use of multiple property
packages and the creation of pre-built templates, the greatest advantage of
using multiple flowsheets is that they provide an extremely effective way to
organize large processes. By breaking flowsheets into smaller components, you
can easily isolate any aspect for detailed analysis. Each of these sub-processes
is part of the overall simulation, automatically calculating like any other oper-
ation.
The design of the HYSYS interface is consistent, if not integral, with this
approach to modeling. Access to information is the most important aspect of
successful modeling, with accuracy and capabilities accepted as fundamental
requirements. Not only can you access whatever information you need when
you need it, but the same information can be displayed simultaneously in a vari-
ety of locations. Just as there is no standardized way to build a model, there is
no unique way to look at results. HYSYS uses a variety of methods to display
This section covers the various unit operations, template and column sub-
flowsheet models, optimization, and dynamics. Since HYSYS is an integrated
steady state and dynamic modeling package, the steady state and dynamic
modeling capabilities of each unit operation are described successively, illus-
trating how the information is shared between the two approaches. In addition
to the physical operations there is a chapter for logical operations, which do not
physically perform heat and material balance calculations, but that impart
logical relationships between the elements that make up your process.
Model Categories
The following is a brief definition of categories used in this volume:
Term Definition
Logical Oper- The Logical Operations presented in this volume are primarily used in
ations Steady State mode to establish numerical relationships between vari-
ables. Examples include the Adjust and Recycle. There are, however,
several operations such as the Spreadsheet and Set operation which
can be used in Steady State and Dynamic mode.
Subflowsheets You can define processes in a subflowsheet, which can then be inser-
ted as a “unit operation” into any other flowsheet. You have full
access to the operations normally available in the main flowsheet.
Columns Unlike the other unit operations, the HYSYS Column is contained
within a separate subflowsheet, which appears as a single operation in
the main flowsheet.
In this guide, each operation is explained in its respective chapters for steady
state and dynamic modeling. A separate guide has been devoted to the prin-
ciples behind dynamic modeling. HYSYS is the first simulation package to offer
dynamic flowsheet modeling backed up by rigorous property package cal-
culations.
Note: The HYSYS Dynamics license is required to use the features in the HYSYS dynamics
mode.
HYSYS has a number of unit operations, which can be used to assemble flow-
sheets. By connecting the proper unit operations and streams, you can model a
wide variety of oil, gas, petrochemical, and chemical processes.
Included in the available operations are those which are governed by ther-
modynamics and mass/energy balances, such as Heat Exchangers, Separators,
and Compressors, and the logical operations like the Adjust, Set, and Recycle.
A number of operations are also included specifically for dynamic modeling,
such as the Controller, Transfer Function Block, and Selector. The Spreadsheet
is a powerful tool, which provides a link to nearly any flowsheet variable, allow-
ing you to model “special” effects not otherwise available in HYSYS.
Degrees of Freedom
In modeling operations, HYSYS uses a Degrees of Freedom approach, which
increases the flexibility with which solutions are obtained. For most operations,
you are not constrained to provide information in a specific order, or even to
provide a specific set of information. As you provide information to the oper-
ation, HYSYS calculates any unknowns that can be determined based on what
you have entered.
For example, consider the Pump operation. If you provide a fully-defined inlet
stream to the pump, HYSYS immediately passes the composition and flow to
the outlet. If you then provide a percent efficiency and pressure rise, the outlet
and energy streams is fully defined. If, on the other hand, the flowrate of the
inlet stream is undefined, HYSYS cannot calculate any outlet conditions until
you provide three parameters, such as the efficiency, pressure rise, and work.
In the case of the Pump operation, there are three degrees of freedom, thus,
three parameters are required to fully define the outlet stream.
Static Pressure
When HYSYS reports the pressure, the static pressure is shown, rather than
velocity (dynamic) pressure or total pressure.
Where:
rho = Fluid density
V = Fluid velocity
Using SI units (kg/m3 for density and m/s for velocity), velocity pres-
sure is calculated in Pascal.
l Total pressure (Pt) is the sum of the static and velocity pressures, so
that:
(2)
Note: The standard Model Palette is available for the main flowsheet and the Standard
Sub-Flowsheet. However, Column Sub-Flowsheets, EO Sub-Flowsheets, Aspen Hydraulics
Sub-Flowsheets, and Sulfur Recovery Unit (SRU) Sub-Flowsheets feature different model
palettes. These palettes feature different unit operations depending on the sub-flowsheet
type.
l Press F4.
l Press F12.
button.
To add a stream:
Material Stream
Energy Stream
The upper-right corner of the model palette also allows you to add a Standard
Sub-Flowsheet or an EO Sub-Flowsheet.
Name Icon
Standard Sub-Flowsheet
EO Sub-Flowsheet
o Text View : Display the icon, name, and description for each
unit operation.
o Grid View : Displays only the icon for each unit operation.
You can hover over a unit operation to view the associated tool
tip.
2. You can either:
Note: The electrolyte operations are only available if your case is an elec-
trolyte system; the selected fluid package must support electrolytes.
3. Select the desired unit operation or sub-flowsheet. To add it to the PFD:
o Drag and drop the icon onto the PFD.
-or-
o Double-click the icon.
l Delete button. This button lets you delete the unit operation from the
current simulation case. Only the unit operation is deleted, any streams
attached to the unit operation is left in the simulation case.
l Status bar. This bar displays messages associated to the calculation
status of the unit operation. The messages also indicate the missing or
incorrect data in the operation.
l Ignore check box. This check box lets you toggle between including and
excluding the unit operation in the simulation process calculation.
o To ignore the operation during calculations, select the check box.
HYSYS completely disregards the operation until you restore the
operation to an active state by clearing the check box.
Note: You can also right-click and select the Ignore/Restore Unit Oper-
ation command to ignore or restore multiple selected flowsheet oper-
ations.
The Operation property view also contain several different tabs which are oper-
ation specific, however the Design, Rating, Worksheet, and Dynamics tabs
can usually be found in each unit operation property view and have similar func-
tionality.
Tab Description
Design Connects the feed and outlet streams to the unit operation. Other para-
meters such as pressure drop, heat flow, and solving method are also spe-
cified on the various pages of this tab.
Rating Rates and Sizes the unit operation vessel. Specification of the tab is not
always necessary in Steady State mode, however it can be used to cal-
culate vessel hold up.
Worksheet Displays the Conditions, Properties, Composition, and Pressure Flow val-
ues of the streams entering and exiting the unit operation.
Dynamics Sets the dynamic parameters associated with the unit operation such as
valve sizing and pressure flow relations. Not relevant to steady state mod-
elling.
For information on dynamic modeling implications of this tab, refer to the
HYSYS Dynamics section.
Note: If negative pressure drop occurs in a vessel, the operation will not solve and a warn-
ing message appears in the status bar.
The unit operation property view all have the following common commands in
the Object Inspect menu:
Command Description
Print Data- Lets you access the Select DataBlocks to Print property view.
sheet
Open Page Lets you open the active page into a new property view.
Find in PFD Lets you locate and display the object icon in the PFD property view.
This command is useful if you already have access to an object's prop-
erty view and want to see where the object is located in the PFD.
This command is only available in the Object Inspect menu of the HYSYS
stream & operation property views.
Connections Lets you access the Logical Connections For... Property View.
Note: The Logical Connections for... property view is different if accessed from a Spread-
sheet property view since there is an additional column (This Name) in the table. The This
Name column displays the spreadsheet cell that contains the information/variable con-
nected to the spreadsheet.
The table in the Logical Connections for... property view contains the following
columns:
Note: There is only one Show All check box for your HYSYS session. When the check box
is changed, the current setting is effective for all Logical Connections For... property view.