Problem No: 01

Simulation of a Flash Drum

Problem statement

A 100 kmol/h feed consists of 10, 20, 30 and 40 mole% of propane, n-butane, n-
pentane, and n- hexane, respectively, enters a flash chamber at 105 psia and 200ͦ F.
The flash drum (Flash2) is shown in following figure and it operates at 100 psia and
200ͦ F. Applying the SYSOP0 property method, compute the compositions of the
exit streams.

Figure: A flowsheet of a flash drum.

Problem No: 02

Simulation of a Flash Drum

Problem statement

A liquid mixture, consisting of 60 mole % benzene and 40 mole % toluene, is fed

with a flow rate of 100 kmol/h at 3 bar and 25◦C to a flash chamber (Flash2) operated
at 1.2 atm and 100◦C. Applying the SYSOP0 method, compute the amounts of liquid
and vapor products and their compositions.

Problem No: 03

Simulation of a Flash Drum

Problem statement

A liquid mixture, consisting of 60 mole % benzene, 30 mole % toluene and 10 mole

% o-xylene, is flashed at 1 atm and 110◦C. The feed mixture with a flow rate of
100kmol/h enters the flash drum (Flash2) at 1 atm and 80◦C. Using the SYSOP0
property method,

(a) Compute the amounts of liquid and vapor outlets and their compositions.
(b) Repeat the calculation at 1.5 atm and 120◦C (operating conditions).

Problem No: 04

Simulation of a Flash Drum

Problem statement

A hydrocarbon mixture with the composition, shown in Table, is fed to a flash

drum at 50◦F and 20 psia.

Table

Component Flow rate (lbmol/h)

i-C4 12

n-C4(LK) 448

i-C5 36
 n-C5 15

C6 23

C7 39.1

C8 272.2

C9 31

876.3

The flash chamber (Flash2) operates at 180◦F and 80 psia. Applying the SYSOP0
thermodynamic model, determine the amounts of liquid and vapor products and their
compositions.

Problem No: 05

Computation of Bubble Point Temperature

Problem statement

Compute the bubble point temperature at 18 bar of the following hydrocarbon

mixture (Table 5.1) using RK- Soave property method.

TABLE 5.1

Component Mole fraction

C1 0.05

C2 0.1

C3 0.15

i-C4 0.1
 n-C4 0.2

i-C5 0.25

n-C5 0.15

Assume the mixture inlet temperature of 25◦C, pressure of 19 bar and flow rate of
120 kmol/h.

Problem No:06

Computation of Dew Point Temperature

Problem statement

Compute the dew point temperature at 1.5 bar of the following hydrocarbon mixture,
shown in Table 3.1, using the RK-Soave property method.

TABLE 3.1

Component Mole fraction

C1 0.05

C2 0.1

C3 0.15

i-C4 0.1

n-C4 0.2

i-C5 0.25

n-C5 0.15
Assume the mixture inlet temperature of 25◦C, pressure of 5 bar and flow rate of
120 kmol/h.

Problem No: 07

Computation of Bubble Point & Dew Point Temperature

Problem statement

Find the bubble point and dew point temperatures of a mixture of 0.4 mole fraction
toluene and 0.6 mole fraction iso-butanol at 101.3 kPa. Assume ideal mixture and
inlet temperature of 50◦C, pressure of 1.5 atm, and flow rate of 100 kmol/h.

Problem No: 08

Computation of Bubble Point & Dew Point Temperature

Problem statement

Find the bubble point and dew point temperatures and corresponding vapor and
liquid compositions for a mixture of 33 mole % n-hexane, 33 mole % n-heptane and
34 mole % n-octane at 1 atm pressure. The feed mixture with a flow rate of 100
kmol/h enters at 50◦C and 1 atm. Consider ideality in both liquid and vapor phases.

Problem No: 09

Computation of Bubble Point & Dew Point Temperature

Problem statement

Compute the bubble point and dew point temperatures of a solution of hydrocarbons
with the following composition at 345 kN/m2 (see Table 9.1)

Table 9.1
 Component Mole fraction

C3 0.05

n-C4 0.25

n-C5 0.4

C6 0.3

The ideal solution with a flow rate of 100 kmol/h enters at 50◦C and 1 atm.

Problem No:10

Computation of Bubble Point Pressure

Problem statement

Calculate the bubble point pressure at 40◦C of the following hydrocarbon stream
(see Table 10.1)

Table 10.1

Component Mole fraction

C1 0.05

C2 0.1

C3 0.15

i-C4 0.1

n-C4 0.2

i-C5 0.15

n-C5 0.15
 C6 0.1

Use the SRK thermodynamic model and consider the inlet temperature of 30◦C,
pressure of 4.5 bar and flow rate of 100 kmol/h.

Problem No:11

T-xy and P-xy Diagrams of a Binary Mixture

Problem statement

A binary mixture consisting of 60 mole% ethanol and 40 mole% water, is introduced

into a flash chamber (Flash2) with a flow rate of 120 kmol/h at 1.013 bar and 70◦C.
The chamber operates at its input conditions. Using the NRTL property method:

(a) Produce T-xy plot at a constant pressure (1.013 bar)

(b) Produce xy plot based on the data obtained in part (a)
(c) Analyze the azeotropic behaviour of ethanol-water system
(d) Produce P-xy plot at a constant temperature (90◦C)
(e) Produce P-xy plot at a constant temperature (90 ◦C) using the NRTL
parameters given in the DECHEMA2 Chemistry Data Series (Vol. I, Part 1A,
p.129) as:
aij= -517.9603 cal/mol
aji= 1459.309 cal/mol
αij= 0.0878
Where, i and j correspond to ethanol and water, respectively.

Problem No: 12

T-xy and P-xy Diagrams of a Binary Mixture

Problem statement
A binary mixture, consisting of 50 mole % ethanol and 50 mole % 1-propanol, is fed
to a flash drum (Flash2) with a flow rate of 120 kmol/h at 3.5 bar and 30◦C. The
chamber operates at its input conditions

(a) Produce T-xy plot at a constant pressure (1.013 bar)

(b) Produce P-xy plot at a constant temperature (75◦C)
(c) Produce xy plot based on the data obtained in part (b)

Consider the RK-Soave thermodynamic model as a property method.

Problem No: 13

DATA REGRESSION

Problem statement

For a binary benzene/ethanol system, the experimental vapor-liquid equilibrium data

are given at 1 atm in Table 13.1.

Table 13.1

Temperature (T) Benzene in liquid (x) Benzene in vapor (y)

(◦C) (mole fract.) (mole fract.)

78.35 0.0 0.0

77.5 0.0148 0.074

75.1 0.0501 0.278

72.4 0.121 0.422

70.0 0.215 0.538

 68.6 0.305 0.602

67.5 0.682 0.678

68.5 0.805 0.726

72.3 0.912 0.817

75.0 0.951 0.877

77.4 0.978 0.952

80.0 1.0 1.0

(i) Perform the regression of the Wilson model parameters on the basis of the
experimental data summarized in Table 13.1.
(ii) Produce a T-xy plot to compare the estimated results with the experimental
data provided.

Problem No: 14

ASPEN PLUS SIMULATION OF A RStoic Model

Problem statement

Styrene is produced by dehydrogenation of ethylbenzene. Here we consider an

irreversible reaction given as:

C6H5-C2H5 C6H5-CH=CH2 + H2

Ethylbenzene Styrene Hydrogen

Pure ethylbenzene enters the RStoic reactor with a flow rate of 100 kmol/h at 260◦C
and 1.5 bar. The reactor operates at 250◦C and 1.2 bar. We can use the fractional
conversion of ethylbenzene equals 0.8. Using Peng-Robinson thermodynamic
method, simulate the reactor model.

Problem No: 15

ASPEN PLUS SIMULATION OF A RCSTR Model

Problem statement

The hydrogenation of aniline produces cyclohexylamine in a CSTR, according to

the following reaction:

C6H5NH2 + 3H2 C6H11NH2

Aniline Hydrogen Cyclohexylamine

The reactor operates at 40 bar and 120◦C, and its volume is 1200 ft 3(75% liquid).
For the liquid-phase reaction, the inlet streams have the specifications, as shown in
Table 2.1.

Table 2.1

Reactant Temperature (◦C) Pressure (bar) Flow rate (kmol/h)

Pure aniline 43 41 45

Pure hydrogen 230 41 160

Fake reaction kinetics data for the Arrhenius law are given as:
Pre-exponential factor = 5*105m3/kmol. s
Activation energy = 20,000 Btu/lbmol
[Ci] basis = Molarity
Use the SYSOP0 base property method in the simulation. The reaction is first- order
in aniline and hydrogen. The reaction rate constant is defined with respect to aniline.
Simulate the CSTR model and compute the component mole fractions in both the
liquid as well as vapour product.
Problem No: 16

ASPEN PLUS SIMULATION OF A RPlug Model

Problem statement

The combination of two benzene molecules forms one molecule of diphenyl and
one of hydrogen (Fogler,2005). The elementary reversible vapor-phase reaction
occurs in a plug flow reactor (PFR).

2C6H6 C12H10 + H2

Benzene Diphenyl Hydrogen

The forward and reverse reaction rate constants are defined with respect to benzene.
The vaporized benzene (pure) with a flow rate of 0.02 lbmol/h enters the reactor at
1250◦F and 15 Psia. The data for the Arrhenius law are given below.
Forward reaction: k = 3.2*10-6kmol/s.m3. (N/m2)2
E = 30200 cal/mol
Reverse reaction: k = 1.0*10-5kmol/s.m3. (N/m2)2
E = 30200 cal/mol
[Ci] basis = Partial Pressure
The reactor length is 36 in and diameter is 0.6 in. It operates at inlet temperature.
Applying the SYSOP0 thermodynamic model,

(a) Compute the component mole fraction in the product stream.

 (b) Produce a plot of ‘reactor molar composition’ (mole fraction) vs ‘reactor
length’ (in).
(c) Produce a plot of ‘reactor mass composition’ (mass fraction) vs ‘reactor
length’ (in).
(d) Produce a plot of ‘temperature’ vs ‘reactor length’ (in).
(e) Produce a plot of ‘pressure’ vs ‘reactor length’ (in).

Problem No: 17

ASPEN PLUS SIMULATION OF A RPlug MODEL USING LHHW

KINETICS

Problem statement
In acetic anhydride manufacturing, the cracking of acetone produces ketene and
methane according to the following irreversible vapor-phase reaction:
CH3COCH3 CH2CO + CH4
Acetone ketene methane
This reaction is first-order with respect to acetone. Pure acetone feed with a flow
rate of 130 kmol/h enters a PFR at 725◦C and 1.5 atm. The kinetic data for the Aspen
Plus simulation are given below.

k = 1.1 s-1
E = 28.5*107 J/kmol
n=0
T0 = 980 K
The unit of pre-exponential factor clearly indicates the [Ci] basis. To use the
Langmuir-Hinshelwood-Hougen-Watson (LHHW) kinetic model, set zero for all
coefficients under Term 1 and that for all coefficients except A under Term 2. Take
a very large negative value for coefficient A. The sample adiabatic PFR is 3 m in
length and 0.6 m in diameter. Applying the SYSOP0 base method, compute the
component mole fraction in the product stream.

Problem No: 19
ASPEN PLUS SIMULATION OF THE BINARY DISTILLATION COLUMNS
*Simulation of a DSTWU Model*
Problem statement
A feed stream, consisting of 60 mole% ethane and 40 mole % ethylene, enters a
DSTWU column having a flow rate of 200 lbmol/hr at 75◦F and 15 psia. This feed
is required to fractionate in a distillation column capable of recovering at least 99.6
% of the light key component in the distillate and 99.9 % of the heavy key component
in the bottoms. The sample process operates at 15 psia with zero tray-to-tray pressure
drop. The pressure in the reboiler as well as condenser is also 15 psia. In the
simulation, use total 30 theoretical stages (including a total condenser and reboiler).
Applying the RK-Soave property method, simulate the column and calculate the
minimum reflux ratio, actual reflux ratio, minimum number of stages, actual number
of stages, feed location, and mole fractions of both the components in distillate and
bottom products.

Problem No: 20
ASPEN PLUS SIMULATION OF THE BINARY DISTILLATION COLUMNS
*Simulation of a RadFrac Model*
Problem statement
We will continue the Problem No. 19 with few modifications. A hydrocarbon
stream, consisting of 60 mole% ethane and 40 mole % ethylene, enters a RadFrac
column having a flow rate of 200 lbmol/hr at 75◦F and 15 psia. The distillation
process that has total 30 theoretical stages (including a total condenser and reboiler)
operates at 15 psia with zero pressure drop throughout. The distillate rate, reflux
ratio and feed tray location are obtained in Problem No. 19 as 79.8 lbmol/hr, 4.856
(mole basis) and 19 (above-stage), respectively. Consider the RK-Soave property
method.
(a) Simulate the column and compute the compositions of top as well as bottom
products.
(b) Is there any discrepancy in product compositions obtained from RadFrac and
DSTWU columns? If yes, what is the main reason?

Problem No: 21
ASPEN PLUS SIMULATION OF THE MULTICOMPONENT DISTILLATION COLUMNS
*Simulation of a RadFrac Model *
Problem Statement
A multicomponent distillation column, specified in Figure 21.1, has total 20 stages
(including condenser and reboiler) with 60 % Murphree efficiency. A hydrocarbon
feed mixture enters above tray 10 of the RadFrac column. Apply the Peng-Robinson
correlation and consider 120 psia pressure throughout the column.

Figure 21.1 A flowsheet of a distillation column.

Vapor Distillate Specifications

Flow rate = 50 lbmol/h

 Reflux rate = 125 lbmol/h

Feed Specifications

Flow rate = 100 lbmol/h

Temperature = 120◦F

Pressure = 120 psia

Component Mole %

C3 5

i-C4 15

n-C4 20

i-C5 25

n-C5 35

(a) Simulate the model and calculate the product compositions,

(b) Produce a ‘Temperature’(◦F) vs ‘Stage’ plot, and
(c) Discuss the column sizing of the example multicomponent process.

Problem No: 22
SIMULATION OF A Distl Model
Problem statement
A feed stream, consisting of 50 mole % ethane and 50 mole % ethylene, enters a
Distl column having a flow rate of 200 lbmol/h at 75◦F and 15 psia. This separator
runs at 300 psia with no tray-to-tray pressure drop. The pressure in the reboiler as
well as condenser is also 300 psia. The feed enters the model at 6th stage and the
column has total 15 theoretical stages (including condenser and reboiler) and a total
condenser. If the reflux ratio is 7 and the distillate to feed ratio is 0.8, compute the
mole fraction of ethane in both the product streams with applying the RK-Soave
equation of state model.
Problem No: 23
SIMULATION OF A REACTIVE DISTILLATION COLUMN
Problem statement
In a reactive distillation (RD) column, shown in Figure 26.1, the decomposition of
HI to H2 and I2 is considered. The column has total 8 stages (including a partial
condenser and reboiler) and it operates at 22 bar pressure.

Figure 26.1 A schematic of a reactive distillation column.

Feed data

Temperature = 532.78 K

Pressure = 22 bar

Flow rate = 150 LPH

Feed stage = 7 (above-stage)

Component Mole %

HI 10

H2O 51
 H2 0

I2 39

Reflux ratio = 3.5 (mole basis)

D/F ratio = 0.55575 (mole basis)

The HI decomposition reaction (Belaissaoui et al., 2008)

2HI H2 + I2

is an equilibrium limited reaction taking place in the vapor phase. The chemical
equilibrium constant (Keq) is expressed as the ratio of the partial pressure P i of the
species i:

𝑃𝐻2 𝑃𝐼2
𝐾𝑒𝑞 = 2
𝑃𝐻𝐼

The expression of the HI decomposition chemical equilibrium constant as a function

of the temperature (T) is given as follows:

2772.7729
ln 𝐾𝑒𝑞 (𝑇) = −0.03684 −
𝑇

with T in K. The reaction occurs from 2nd to 6th stage. Using the NRTL property
method, simulate the reactive column (RadFrac).

Problem No: 24
SIMULATION AND ANALYSIS OF AN ABSORPTION COLUMN
Problem Statement
A hydrocarbon vapor enters an absorption column below the bottom stage and the
absorbent enters above the top stage. The column operates at 75 psia with no pressure
drop and it has four equilibrium stages. The absorber is specified in Figure 27.1.

Figure 27.1 A flowsheet of an absorption column

Absorbent

Pure n-C10

Temperature = 90◦F

Pressure = 75 psia

Flow rate = 1000 lbmol/h

Gas- feed

Temperature = 90◦F

Pressure = 75 psia

Flow rate = 1000 lbmol/h

Component Flow rate (lbmol/h)

C1 280

C2 150

C3 240
 n-C4 170

n-C5 150

Apply the Peng-Robinson equation of state model in the simulation.

(a) Simulate the absorber model (ABSBR2 under RadFrac) and compute the
product compositions.
(b) Perform the sensitivity analysis by examining the effect of absorbent flow
rate on the exiting C3 concentration in the top product.
(c) Compute the absorbent flow rate to keep 15 mole % of C3 in the gas product
(GAS-PDT)

Problem No: 25
Simulation of a Stripping Column
Problem statement
A reboiled stripper is to be employed to remove mainly propane and lighter
components from a feed stream, shown in Figure 28.1.

FIGURE 28.1 A flowsheet of a stripping column

It has total 6 stages (including condenser and reboiler) and no condenser. The
bottoms rate is 100 lbmol/h and the column pressure is 150 psia throughout. Using
the Peng-Robinson thermodynamic method, simulate the RadFrac model (STRIP2)
and find out the product compositions.

Feed

Temperature = 40◦F

Pressure = 300 psia

Feed stage = 1 (above stage)

Component Flow rate (lbmol/h)

C1 60

C2 75

C3 150

n-C4 175

n-C5 60

n-C6 35

Problem No: 26
Simulation of a PetroFrac Model
Problem statement
An artificial petroleum refining column (PRC), shown in Figure 29.1, consists of a
feed furnace and a distillation tower. The tower has two pumparound circuits, a
partial condenser and three side strippers. The furnace (single stage flash type)
operates at 25 psia and provides a fractional overflash of 40% (StdVol basis) in the
tower. The outlet stream of the furnace goes to the tower on Stage 22. The tower has
26 stages with a Murphree stage efficiency equal to 90%. A steam stream, STEAM,
is introduced at the bottom of the fractionator (26th stage with on-stage convention).
There are another three steam streams, STM1, STM2 and STM3, used in the side
strippers. The condenser runs at 15.7 psia with a pressure drop of 5 psi. The tower
pressure drop is equal to 4 psi. The distillate rate is 10000 bbl/day and the distillate
vapor fraction in the condenser is 0.2 (StdVol basis).

FIGURE 29.1 A flowsheet of a petroleum refining column.

A hydrocarbon mixture with the following component-wise flow rates enters the
furnace at 117◦F and 44.7 psia (see Table 29.1).

Table 29.1

Component Flow rate (bbl/day)

C1 3
 C2 65

C3 575

i-C4 1820

n-C4 7500

i-C5 30000

n-C5 42000

H2O 250

In Table 29.2, two pumparound circuits and three side strippers are specified.

Table 29.2

Location Specifications

Pumparound Draw stage Return stage Flow rate Heat duty

(drawoff type) (bbl/day) (MMBtu/h)

1 (partial) 8 6 49000 -40 (for cooling)

2 (partial) 14 12 1000 -17 (for cooling)

Location

Stripper No. of Stripper Draw Return Stripping Bottom product

stages product stage stage steam flow rate (bbl/day)

1 5 SID1 6 5 STM 11000

2 4 SID2 12 11 STM2 15000

3 3 SID3 19 18 STM3 8000

Four steam streams used in the column model are described in Table 29.3

Table 29.3
 Specifications

Steam stream Location Temperature Pressure Flow rate

(◦F) (psia)
(lb/h)

STEAM Main tower 350 50 11500

STM1 SID1 stripper 350 50 4000

STM2 SID2 stripper 350 50 1500

STM3 SID3 stripper 350 50 1000

Considering the ‘BK10’ base method under ‘REFINERY’ process type. Simulate
the PetroFrac column and report the flow rates (bbl/day) of all product streams.
(Furnace: Temperature = 117◦F & Pressure = 25 psia).

Problem No: 27
Simulation of a Petroleum Refining Column (PRC)
Problem statement
An artificial petroleum refining column (PRC) shown in Figure 33.1 consists of a
feed furnace and a fractionation tower.

FIGURE 33.1 A flowsheet of a petroleum refining column.

The tower includes one pumparound circuit, a partial condenser and one side
stripper. The furnace (single stage flash type) operates at 20 psia and provides a
fractional overflash of 50% (StdVol basis) in the tower. The outlet stream of the
furnace enters the tower on stage 18. The column has total 20 stages. A steam stream,
STEAM, is fed at the bottom of the fractionator (20th stage with on-stage
convention). There is another steam stream, STEM1, used in the side stripper. The
condenser runs at 15 psia with a pressure drop of 5 psi. The tower pressure drop is
equal to 5 psi. The distillate rate is 12000 bbl/day and the distillate vapor fraction in
the condenser is 0.25 (StdVol basis). The liquid product, SID1, is withdrawn from
5th stage with a flow rate of 2000 bbl/day.
A hydrogen mixture with the given component-wise flow rates (Table33.1) enters
the furnace at 120◦F and 45 psia.

TABLE 33.1
Component Flow rate (bbl/day)

C1 10

C2 100

C3 600

i-C4 1800

n-C4 7500

i-C5 30000

n-C5 42000

n-C6 250
 H2O 250

The pumparound circuit (for cooling) and the side stripper are specified with the
following information (see Table 33.2).
TABLE 33.2
Location Specifications

Pumparound Draw Return Flow rate Temperature

(drawoff type) stage stage (bbl/day) (◦F)

1 (partial) 8 6 40000 20

Location
Stripper No. of Stripper Draw Return Stripping Bottom product
stages flow rate (bbl/day)
product stage stage steam

1 5 SID2 12 10 STEM1 15000

Two steam streams, used in the column model, are described in Table 33.3

TABLE 33.3

Specifications

Steam stream Location Temperature (◦F) Pressure (psia) Flow rate (lb/h)

STEAM Main tower 350 50 12000

STEM1 Stripper 350 50 5000

Selecting the PENG-ROB base method under ‘REFINERY’ process type, simulate
the model using a PetroFrac column and report the flow rates (bbl/day) of all product
streams. (Furnace: Temperature = 120◦F & Pressure = 20 psia).

Problem No: 28
ASPEN PLUS SIMULATION OF A DISTILLATION TRAIN
Problem statement

A hydrocarbon stream H is supplied at 5◦C and 2.5 atm. The pump P1 discharges
the feed F at 10 atm. In Table 23.1 the component-wise flow rates are tabulated for
stream H.

Table 23.1

Component Flow rate (kmol/h)

C2 35

C3 50

i-C4 130

n-C4 200

i-C5 180

n-C5 200

n-C6 5

The schematic representation of the complete process integrated with a pump and
five DSTWU column models (C1, C2, C3, C4 and C5) is shown in Figure 23.1
 FIGURE 23.1 A flowsheet of a distillation train.

For Aspen Plus simulation of the distillation train, required information are given in
Table 23.2

Table 23.2

Column Condenser Reboiler

(abbreviation) pressure (atm) pressure (atm)

Deethanizer (C1) 9 9

Depropanizer (C2) 5 5

Deisobutanizer (C3) 4 4

Debutanizer (C4) 3 3

Deisopentanizer (C5) 2 2

Each distillation model has total 20 theoretical stages (including a total condenser
and a reboiler). For the light key (LK) and heavy key (HK), we expect 99.9 % and
0.1 % recovery, respectively, in the distillate of all columns. Using the Peng-
Robinson property method, simulate the distillation train and report the
compositions of all distillation products.
 Problem No: 29
ASPEN PLUS SIMULATION OF A VINYL CHLORIDE MONOMER
(VCM) PRODUCTION UNIT
Problem statement

The process flow diagram for Aspen Plus simulation of the vinyl chloride monomer
manufacturing plant is shown in Figure 24.1. The flowsheet has been developed
based on the VCM production technology reported in a book by Seider et al. (1998).

FIGURE 24.1 A flowsheet of a vinyl chloride monomer production unit.

Pure ethylene, stored as a gas at 70◦F and 1000 psia, with a flow rate of 20 tons/h,
and pure chlorine, stored as a liquid at 70◦F and 150 psia, with a flow rate of 50
tons/h enter the mixer block B1 operated at 2 atm. The mixer outlet F1 then goes to
the reactor B2 run at 363 K and 1.5 atm. In this stoichiometric reactor (RStoic), the
following chlorination reaction occurs with 98 % conversion of ethylene to 1,2-
dichloroethane:
 C2H4 + Cl2 C2H4Cl2
Ethylene Chlorine Dichloroethane
In the next, mixer B3 operated at 1.4 atm allows the mixing of the recycled stream
F12 with the reactor product F2. The outlet stream F3 is then condensed fully to
liquid phase in block B4 at 298 K before being pumped to an evaporator. The pump
B5 has discharged the liquid at 26 atm. The evaporator B6 performs the phase change
operation and then the vapor temperature is increased in the same unit to 515 K. In
the subsequent step, stream F6 is introduced in the reactor B7 (RStoic) in which the
following pyrolysis reaction occurs:
C2H4Cl2 C2H3Cl + HCl
Dichloroethane VCM hydrogen chloride
The dichloroethane is converted to VCM and it takes place spontaneously at 773 K
and 25 atm with 65 % conversion. To reduce carbon deposition in the heat
exchanger, the hot vapor stream leaving the reactor is quenched in block B8 yielding
a saturated vapor stream at 443 K. Quencher effluent stream F8 is condensed to
liquid phase in block B9 at 279 K and then fed a DSTWU column B10 as stream F9.
In the next, Stream F10 is introduced in another DSTWU column B11. The first
column mainly separates HCl from other components, while the second column
purifies VCM from the rests. Both the distillation columns have 10 theoretical stages
(including a total condenser and a reboiler) each along with the specifications, shown
in Table 24.1.

Table 24.1

% Recovery of LK/HK in distillate Pressure (atm)

Block Light key Heavy key (HK) Condenser Reboiler

(LK)
 B10 99.9 % of 0.1 % of VCM 20 22
HCl
B11 0.1 % of 7.5 8
99.9 % of dichloroethane
VCM

Finally, block B12 (FSplit) splits stream F11 to ensure the recycling of 99.999% of
F11 as F12 stream to mixer B3. A purge stream is introduced to prevent
accumulation of unreacted components.

Using the POLYSRK property method, simulate the complete plant to compute the
composition of all streams.

Problem No: 30
ASPEN PLUS SIMULATION OF A PETLYUK COLUMN WITH STREAMS RECYCLING
Problem statement

Naphtha reformate is extracted for aromatics and the aromatic compounds are
fractionated into benzene, toluene and xylene in sequence. This separation is
conventionally carried out using a series of binary-like columns. In order to improve
the thermodynamic and economic performance, Lee et al. (2004) proposed a fully
thermally coupled distillation column, which is also called the Petlyuk column.
Originally, the first two columns of the conventional process flowsheet are suggested
to replace with the Petlyuk column shown in Fig.25.1.
 FIGURE 25.1 A Petlyuk column.

The molar flow rate of liquid feed stream, namely FEED entering at 132.3◦C and
150 kPa is provided component-wise in Table 25.1.

Table 25.1

Component Flow rate

(kmol/h)
 Benzene 87.85

2,3-Dimethyl Pentane 0.0124

2-Methyl Hexane 0.0075

Toluene 338.10

n-Octane 0.049

Ethyl benzene 14.975

p-Xylene 57.798

m-Xylene 128.55

o-Xylene 60.16

n-Nonane 0.0057

n-Pentyl benzene 0.33

1-Methyl-2-ethyl benzene 26.01

1,3,5-Tri-methyl benzene 75.95

1-Methyl-2-n-propyl benzene 0.57

o-Diethyl benzene 0.33

1-Methyl-2-iso-propyl benzene 4.12

1,2,4,5-Tetra-methyl benzene 4.75

Penta-methyl benzene 2.2389

Table 25.2 specifies other two input streams introduced to the prefractionator
(PREFRAC) before connecting recycle streams (see Figure 25.2).

Table 25.2

Stream Phase Guessed Guessed Guessed composition

temperature Pressure
(mole fract)
(◦C) (kPa)

PD2 - 115.0 110 Benzene: 0.107

Toluene:0.893

PB2 vapor 155.4 177 Benzene: 0.0082

Toluene: 0.3618

Ethyl benzene: 0.02

p-Xylene: 0.09

m-Xylene: 0.19

o-Xylene: 0.09

1-Methyl-2-ethyl benzene : 0.07

1,3,5-Tri-methyl benzene: 0.17

 Figure 25.2

Two separators, namely PREFRAC and MAIN are detailed in Table 25.3. The
discharge pressure of both the PUMP and COMP (isentropic model) is 120 kPa.

Table 25.3

Column Specifications

PREFRAC No. of stages (no condenser and reboiler): 22

Entry of FEED stream: 7th stage (above stage)

Entry of PD2 stream: 1st stage (above stage)

Entry of PB2 stream: 23rd stage (above stage)

Exit of PD1 stream: 1st stage (vapor)

 Exit of PB1 stream: 22nd stage (liquid)

Column pressure: 70 kPa

MAIN No. of stages (including total condenser and reboiler): 89

Distillate rate: 86.8 kmol/h

Reflux rate: 1792 kmol/h

Entry of PD1R stream: 13th stage (above stage)

Entry of PB1R stream: 55th stage (above stage)

Exit of D stream: 1st stage (liquid)

Exit of S stream : 28th stage (liquid; 337.8 kmol/h)

Exit of B stream: 89th stage (liquid)

Exit of PD2R stream: 15th stage (liquid; 290.1 kmol/h)

Exit of PB2R stream: 60th stage (vapor; 492.9 kmol/h)

Column pressure: 110 kPa

Flow rates of PD2 and PB2 are fixed at 290.1 and 492.9 kmol/h, respectively. Using
the UNIQUAC thermodynamic property prediction method, simulate the flowsheet
for finding the composition of three product streams.

Problem No: 31
ASPEN PLUS SIMULATION OF A FLASHING AND STRIPPING OPERATION
Problem statement
A hydrocarbon stream with component-wise flow rates, shown in Table 30.1, enters
the isentropic compressor at 120◦F and 1 atm. The compressor has discharged the
vapor stream at 3 atm.

Table 30.1

Component Flow rate (lbmol/h)

C1 15

C2 95

C3 150

n-C4 25

n-C5 10

n-C6 100

The complete process flowsheet for flashing and stripping operation is shown in
Figure 30.1. The flash drum (Flash2) runs at 125◦F and 2.8 atm. The stripper
(STRIP2) has total 6 stages (including condenser and reboiler) and bottoms to feed
ratio (mole basis) is 0.8. The feed stream to the stripper is introduced above the top
stage and the pressure throughout the column is 2 atm.
 FIGURE 30.1 A flowsheet for flashing and stripping operation.

Using the UNIQUAC property method, simulate the plant to compute the product
compositions and flow rates.

Problem No: 32
ASPEN PLUS SIMULATION OF A Hydrocarbon separation process
Problem statement

A hydrocarbon stream H is at 5◦C and 2.5 atm. The pump has discharged the liquid
feed F at 5 atm. The component- wise flow rates are shown in Table 31.1 for
stream H.

TABLE 31.1

Component Flow rate (kmol/h)

C2 35

C3 50

i-C4 130
 n-C4 200

i-C5 180

n-C5 200

n-C6 5

In Figure 31.1 the schematic representation of a hydrocarbon separation process

integrated with a Pump, three DSTWU columns (C1, C2 and C3) and two RadFrac
(RECT) columns (CR1 and CR2) is shown.

FIGURE 31.1 A flowsheet of a hydrocarbon separation process.

All DSTWU fractionators have total 20 stages each (including condenser and
reboiler) and two RECT models have 10 stages each (including condenser and
reboiler) with no reboiler. The specifications, shown in Tables 31.2(a) and 31.2(b),
are required for simulating the process.

TABLE 31.2(a)

% Recovery of LK/HK Pressure (atm)

in distillate

Block Light key Heavy key Condenser (type) Reboiler

(LK) (HK)

C1 99 % of n- 1 % of i-C5 4 (partial condenser with all 4

C4 vapor distillate)
C2 2 % of n-C4 1.5
99 % of i- 1.5 (total condenser)
C3 4 % of n-C5 3
C4
3 (total condenser)
99 % of i-
C5

TABLE 31.2(b)

Block Condenser (type) Distillate to feed ratio Pressure (atm)

(mole basis)

CR1 Partial vapor 0.2 2

CR2 Total 0.5 1.5

Applying the Peng-Robinson property method, simulate the separation process to

compute the flow rates and compositions of all product streams.