EHY202

Aspen HYSYS®:
Advanced Process
Modeling Topics
AspenTech Customer Education
Training Manual

Course Number EHY202.10.01

Copyright © 2017 by Aspen Technology, Inc. 20 Crosby Drive, Bedford, Massachusetts
01730, USA. All rights reserved. This document may not be reproduced or distributed in
whole or part in any form or by any means without the prior written permission of Aspen
Technology, Inc.

The information contained herein is subject to change without notice, and Aspen
Technology assumes no responsibility for any typographical or other errors that may
appear.

Aspen Technology may provide information regarding possible future product

developments including new products, product features, product interfaces, integration,
design, architecture, etc. that may be represented as “product roadmaps.” Any such
information is for discussion purposes only and does not constitute a commitment by
Aspen Technology to do or deliver anything in these product roadmaps or otherwise. Any
such commitment must be explicitly set forth in a written contract between the customer
and Aspen Technology, executed by an authorized officer of each company.
 Contents

Sections
Introduction 1–1

Getting Started 2–1

Workshop # 1: Getting Started Workshop 3–1
Advanced Columns 4–1

Workshop # 2: Advanced Columns Workshop 5–1

Real Separators 6–1

Workshop # 3: Real Separators Workshop 7–1

Safety Analysis Environment 8–1

Workshop # 4: Safety Analysis Workshop 9–1
Optimization 10 – 1
Workshop # 5: Optimization Workshop 11 – 1
Reactors 12 – 1
Workshop # 6: Reactors Workshop 13 – 1
BLOWDOWN™ 14 – 1
Workshop # 7: BLOWDOWN™ Workshop 15 – 1
Acid Gas Cleaning 16 – 1
Workshop # 8: Acid Gas Cleaning Workshop 17 – 1
Sulfur Recovery Unit (Sulsim) 18 – 1
Workshop # 9: Sulfur Recovery Unit Workshop 19 – 1
Equation-Oriented Simulation 20 – 1
 Aspen Rate-Based Distillation (Aspen RateSep) Introduction

Aspen HYSYS: Advanced Process Modeling

Topics
EHY202 V10.0

©2011 AspenTech. All Rights Reserved. Page 1 Aspen Technology, Inc.

 Aspen HYSYS: Advanced Process Modeling Topics Introduction

Disclaimer

• Aspen Technology may provide information regarding possible future product developments including
new products, product features, product interfaces, integration, design, architecture, etc. that may be
represented as “product roadmaps.” Any such information is for discussion purposes only and does not
constitute a commitment by Aspen Technology to do or deliver anything in these product roadmaps or
otherwise. Any such commitment must be explicitly set forth in a written contract between the customer
and Aspen Technology, executed by an authorized officer of each company.

2 © 2017 Aspen Technology, Inc. All rights reserved.

©2011 AspenTech. All Rights Reserved. 2 Aspen Technology, Inc.

 Aspen HYSYS: Advanced Process Modeling Topics Introduction

Introductions
Instructor Student
• Name • Name, company, and position

• AspenTech Experience • Process simulation experience

• Educational Background • Expectations for the course

• Industry Experience

• Other

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 Course Title Chapter or Lesson Title

Course Objectives

• Create custom column configurations

• Perform complex calculations and analyses using the Spreadsheet operation and Case Study tool

• Review how to optimize your Aspen HYSYS simulation

• Model liquid carryover and imperfect separation

• Simulate vessel depressurization and complex relief scenarios

• Build a Sulfur Recovery Unit and Acid Gas Cleaning Process

• Define reaction sets and utilize different types of reactor models

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 Aspen HYSYS: Process Modeling Presentation Material

Course Agenda – Day 1

• Getting Started

• Advanced Columns

• Real Separators

• Safety Analysis

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 Aspen Rate-Based Distillation (Aspen RateSep) Introduction

Course Agenda – Day 2

• BLOWDOWN

• Acid Gas

• Sulsim

• Optimization

• Reactors

• Equation Oriented

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Virtual Etiquette

• Inform instructor if you have: Hi,

this is
– Technical issues Lucy.
– To leave the course for a moment

• State your name when you speak

• Mute/turn off mobile devices

• Actively participate!

7 © 2017 Aspen Technology, Inc. All rights reserved.

Not relevant if it’s not virtual class- this and next slide (slide 11)

INSTRUCTOR NOTES:

Tell the students the instructor wants to know when someone has to leave because the course
material builds upon itself.

Tell the students to actively participate by asking questions, providing relatable feedback, etc.

©2011 AspenTech. All Rights Reserved.

WebEx Tools
Raise your hand
next to your
participant name

Polling
questions

Chat

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INSTRUCTOR NOTES:
These are panels on the right-side of the WebEx meeting window.

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Complete the Course Evaluation—thank you!

• You will receive an email with a link to the course evaluation, or you can fill out a hard copy provided by
your Instructor.

Complete the evaluation to

download your certificate!

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INSTRUCTOR NOTES:
Your feedback is highly appreciated and will help us maintain our high standards and improve training
quality.

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AspenTech Contact Information

• Web: http://support.aspentech.com

• http://training.aspentech.com

• Email: [email protected]

• [email protected]

• Phone: Regional and in-country toll-free numbers at http://support.aspentech.com/contacts

• Technical Support Hotline

• Training

• Customized Support Services

• Knowledge Base Solutions

NALA EMEA APAC
• Product Patches
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PURPOSE: These slides contains items that are common to all courses and classes. Skip over any
parts that don’t seem to apply as they still make good advertising.

©2011 AspenTech. All Rights Reserved.

 Aspen HYSYS: Advanced Process Modeling Topics Introduction

Additional Training Resources

EHY223
Aspen HYSYS Dynamics:
Introduction to Dynamics
Modeling

EHY2311
Developing Automation
Solutions for Aspen HYSYS

EHY2351
Modeling Heavy Oil and
Gas Production Using
Aspen HYSYS Upstream

EHY2611
Heat Transfer Modeling
Using Aspen HYSYS

https://training.aspentech.com/catalog

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E-Learning in Aspen HYSYS
Empowering Users to Learn Faster
CBTs & Technical
E-learning Webinars

Jump Start Guides

Video Tutorials

Example Models

Knowledge Base
Solutions

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 Aspen Rate-Based Distillation (Aspen RateSep) Introduction

Getting Started
Aspen HYSYS: Advanced Process Modeling Topics
EHY202 V10.0

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 Aspen HYSYS: Process Modeling Additional Topics Presentation

Section Objectives

• Apply Aspen HYSYS simulation-building techniques to build a turbo expander/fractionation plant model

• Use the LNG Exchanger operation to simulate multi-pass heat exchangers

• Link process variables using the Set logical operation

• Apply physical properties via the Correlation Manager

• Workshop: Construct a comprehensive Turbo Expander/Fractionation Plant Model

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 Aspen HYSYS: Process Modeling Additional Topics Presentation

Workshop Flowsheet

Turbo Expander/
Fractionation Plant

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 Aspen HYSYS: Process Modeling Additional Topics Presentation

Multi-Pass Heat Exchanger

• Known as LNG Exchanger in Aspen HYSYS

– Multiple hot and/or cold streams

• Degrees of freedom approach works much like a column operation in Aspen HYSYS
– Need to provide sufficient process information and constraints to satisfy unknown variables (DOF = 0)
– Various heat transfer specifications can be provided: outlet temperatures, UA, temperature approach, etc.

• You can enter as many specifications as required; only the active specifications are used to solve the
operation

• Two solutions approaches:

– For single unknown, exchanger energy balance is computed
– For multiple unknowns, iterative calculation is used to satisfy energy balance and any exchanger specifications

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 Aspen HYSYS: Process Modeling Additional Topics Presentation

Set Operation

• Fix the value of a specific process variable relative to the same variable in another object

• Using the Set operation, one can establish a linear relationship between the two variables:
– Y = m*X + b
– where m = multiplier, b = offset

• In the workshop, we will use the Set operation to fix the pressure of various streams relative to another:
– 8P=5P
– 9 P = 5 P – 5 psia
– 10 P = 5 P

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 Aspen HYSYS: Process Modeling Additional Topics Presentation

Correlation Controls/Correlation Manager

• Allows user to customize viewable stream properties

– Correlation Controls used for customizing a single material stream
– Correlation Manager oversees applied correlations on all streams

• Both include framework to rapidly add/maintain property correlations to Aspen HYSYS

– Easily allows software to respond to customer needs

• Allows user definable parameters in some correlations

• Correlation types include

– Gas properties & RVP correlations
– Electrolyte and Black Oil properties
– Correlations associated with Aspen HYSYS Upstream and HYSYS Petroleum Refining

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 Aspen HYSYS: Process Modeling Additional Topics Presentation

Stream Properties View – Local Controls

Remove single/all
Correlations Save Correlation Set

Append New Move/Sort To add correlation,

Correlation Correlations select and click Apply

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 Aspen HYSYS: Process Modeling Additional Topics Presentation

Correlation Sets

• User-defined set of property correlations

• A collection of correlation sets is stored in an XML file external to Aspen HYSYS

– …\Support\StreamCorrSets.xml (don’t edit this file!)

• Advantages:
– Available to any Aspen HYSYS case opened on your computer
– Quickly build custom sets for various purposes
– Can be applied locally or globally
– Can apply multiple sets to a local stream

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 Aspen HYSYS: Process Modeling Additional Topics Presentation

Using the Correlation Manager

• Add/remove stream properties globally

• Tracks which streams each correlation is connected to

• Central location where correlations are managed

– Updates & validates correlations as before applying them to a stream (some correlations are only valid with certain
licenses)
– Passes stream data to external property calculators and the resulting properties back to the stream

• Globally modify any user-definable correlation parameters

• Clone properties

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 Aspen HYSYS: Process Modeling Additional Topics Presentation

Correlation Manager – Global Controls

List of streams
where correlation is
used

Activate Global
correlation
Correlation removal
options

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 Aspen HYSYS: Advanced Process Modeling Topics Getting Started

Applying Properties in the Flowsheet

• Workbook & Flowsheet Tables

– Access Correlation Manager properties through the
Calculator variable in the Variable Navigator

• Certain variables available in

flowsheet/workbook may not be found in
Correlation Manager
– Specific gravity, for example

• Accessing Correlation Manager properties

follows same procedure in Logical operations
– Spreadsheet, Adjust, etc.

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 Aspen HYSYS: Process Modeling Additional Topics Presentation

Workshop: Getting Started

• Task 1 – Configure the Turbo Expander

• Task 2 – Adding the Fractionation Columns

• Task 3 – Sales Gas Compression

• Task 4 – Customizing Stream Properties

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 Getting Started Workshop
Files can be found in folder: 01_GettingStarted

Objective
In this workshop, you will build a turbo expander and NGL fractionation plant model. You
will also use the LNG Exchanger unit operation to simulate a multi-pass heat exchanger.
The liquids produced from the inlet hydrocarbons will feed into a fractionation section
consisting of a pair of distillation columns for liquefied gas recovery. You will also review
reporting in Aspen HYSYS by applying desired physical properties via the Correlation
Manager.

You will build the flowsheet that will be used throughout most of the modules of this
course. The process is a turbo expander plant where LPG product is obtained from a feed
natural gas stream through cooling, expanding, separating, and distilling the condensed
liquids. The remaining gas is then re-compressed for export.

The workshop is an introduction to the multi-pass exchanger unit operation and to the
different options available to display properties on the streams and on tables.

This workshop includes the following tasks:

▪ Task 1 – Configure the Turbo Expander

▪ Task 2 – Adding the Fractionation Columns
▪ Task 3 – Sales Gas Compression
▪ Task 4 – Customizing Stream Properties

Task 1 – Configure the Turbo Expander

You will begin this turbo expander/fractionation process model from scratch. The first step
in HYSYS is to set up the Properties Environment. Begin by defining a suitable property
package and component list for use in the simulation.

1. Start a new case by opening Aspen HYSYS and selecting the New option.

3-1
 2. Select the Component Lists folder on the Navigation Pane and click on the Add
button at the bottom of the page to create a new component list.

3. Select Nitrogen, CO2, Methane, Ethane, Propane, i-Butane, n-Butane, i-Pentane, n-

Pentane, n-Hexane, n-Heptane, n-Octane, and H2O.

Note: You can reorder components by clicking on the name on the component that you
want to move and dragging it to the desired position on the component list.

3-2
4. Click the Fluid Packages folder in the Navigation Pane and Add a new Fluid
Package.

5. Scroll down through the Property Package Selection list and select Peng-
Robinson.

6. Select the Simulation button below the Navigation Pane to enter the Simulation
Environment.

3-3
 7. Add a Material Stream to represent a mixture of natural gas, condensate, and
produced water:

Name Feed Gas

Name Feed Mix

Temperature 22 ºC (71.6 ºF)
Pressure 3500 kPa (508 psia)
Flow rate 4145 kgmole/h (9138 lbmole/hr)

Component Mole Fraction

Nitrogen 0.0108
CO2 0.0017
Methane 0.4127
Ethane 0.1643
Propane 0.1149
i-Butane 0.0441
n-Butane 0.0313
i-Pentane 0.0302
n-Pentane 0.0296
n-Hexane 0.0274
n-Heptane 0.0193
n-Octane 0.0165
H2O 0.0972

Before sending the feed mixture on to the turbo expander and fractionation sections, it
would be wise to attempt an inlet separation to knock out any water and as much liquid
condensate as possible. Use the standard Aspen HYSYS 3-Phase Separator to perform this
separation.

8. Add a 3-Phase Separator to your flowsheet. Define the separator using the
connections listed below:

3-4
 In This Cell... Enter...

Connections

Name Inlet Sep

Inlet Feed Mix

Vapour Product Inlet Sep Vap

Light Liquid Product Inlet Sep Liq

Heavy Liquid Product Inlet Sep Water

Multi-pass exchangers are known as Liquefied Natural Gas (LNG) Exchangers in Aspen
HYSYS. The LNG Exchanger allows for multiple hot and cold streams, while the Heat
Exchanger model allows only one hot side stream and one cold side stream.

The LNG Exchanger model solves heat and material balances for multi-stream heat
exchangers and heat exchanger networks. The solution method can handle a wide variety
of specified and unknown variables. This allows you to specify various parameters,
including heat leak/heat loss, UA, and temperature approach.

For this unit operation, two solution methods are employed. In the case of a single
unknown, the solution is calculated directly from an energy balance. When there are
multiple unknowns, an iterative approach is used to attempt to determine the solution that
satisfies the energy balance and any constraints such as temperature approach or UA.

9. Double click on the LNG Exchanger button on the Object Palette.

LNG Exchangers require inlet and outlet stream(s), pressure drops for each stream, and
Hot/Cold side designations. These will be used as an estimate for calculations and for
drawing the flowsheet. If a designated hot pass is actually cold (or vice versa), the operation
will pick the required designation and still solve properly. The actual Hot/Cold designation
(as determined by the LNG Exchanger) can be found on the Performance tab in the Results
page.

10. View the LNG Exchanger menu and select the Design | Connections page. Specify
the following stream connections:

3-5
 Inlet Stream Outlet Stream Pressure Drop Hot/Cold
Inlet Sep Vap 1A 20 kPa (2.9 psia) Hot
7 7A 20 kPa (2.9 psia) Cold
9 9A 20 kPa (2.9 psia) Cold

Hint: To fill in the third side stream connections, click the Add Side button at the bottom
of the Design | Connections page. This will add a side to the LNG Exchanger.

11. Select the Design | Parameters (SS) page. No changes will be made here, but feel
free to read the options available on this form:

The Exchanger Design (Weighted) method splits the heating curves into intervals rather
than simply considering the end points. The number of intervals is set in the Exchanger
Details table. The Step Type parameter sets whether Aspen HYSYS splits the curves by
temperature, enthalpy, or automatically to minimize the errors.

By selecting the Dew/Bub pt. checkboxes, Aspen HYSYS will include points on the
heating curves for any phase changes that occur. The Pressure Profile options set how
Aspen HYSYS decides the pressure profile during the iteration.

Heat Losses will not be considered. All streams on the same side with the Equilibrate
checkbox selected are considered to be in equilibrium before entering the exchanger
calculations. Thus, the driving force will be reduced. These options are discussed in more
detail in the Aspen HYSYS Operations Guide.

3-6
 12. Go to the Design | Specs (SS) page.

The Degrees of Freedom Analysis display should show 6 because there are 7 unknown
variables and 1 constraint so far. You will add two extra specifications in addition to the
default Heat Balance specifications (i.e., conservation of energy).

LNG Exchangers, like normal Aspen HYSYS Heat Exchangers and Column models, allow
you to enter as many specifications as required. Only the active specifications are used to
solve the operation.

If the Est. checkbox is selected, Aspen HYSYS will use the specified value as an initial
estimate in its iterative solution. Hence, specifications can be used for more than just being
an active specification. They can provide an initial estimate only (Uncheck Active, Check
Est.) or be used to monitor how important variables change as the operation iterates
(Uncheck Active and Est.).

13. Click on the Add button twice to add two new specifications.

Create the first specification to ensure the two cold side streams have the same outlet
temperatures and the second specification to set the overall minimum approach
temperature in the exchanger is 10 ºC (18 ºF). Use the images below as a guide:

14. Make sure the Active checkbox is selected for both of these two new specifications.

By adding two new specifications, the number of degrees of freedom is reduced to 4. Later,
when more of the flowsheet is built, these 4 degrees of freedom will be used up and the
exchanger will have enough information to solve. For now, leave it this way and continue
to build the simulation.

15. Return to the flowsheet and double click on the Cooler icon on the Object Palette,
thus adding it to the flowsheet. Specify the following parameters:

3-7
 In This Cell… Enter…
Connections
Name E-100
Inlet 1A
Outlet 2
Energy Q-100
Parameters
Pressure Drop 20 kPa (2.9 psia)
Worksheet
Stream 2, Temperature -62 °C (-79.6 °F)

The necessary cooling duty in the E-100 Cooler is provided through an ethane/propane
refrigeration skid. This refrigeration skid can be modeled easily in HYSYS. In fact, a
HYSYS template file already exists that you can quickly incorporate into your model. This
refrigeration loop model is included with your provided training course HYSYS files.

HYSYS templates can be readily added to any other HYSYS simulation. As long as the
template file does not introduce any kind of numerical inconsistency or thermodynamic
incompatibility, they are very useful features.

16. Add a Standard Sub-Flowsheet to your simulation:

17. Select the option to Read an Existing Template.

18. Browse to the folder location containing your provided HYSYS course files and
select the MixedRefrig.tpl file.

19. Re-name the Sub-Flowsheet as Mixed Refrig Unit, on the Connections tab.

3-8
 20. Define the Inlet Connection to the Sub-Flowsheet as Q-100 on the Connections tab.
This should be selected in the Inlet Connections to Sub-Flowsheet section next to
the Q-Chill energy stream. See below:

Note: Even though the E-100 Cooler is not fully calculated, the material stream 2 is. You
can continue building the Turbo Expander portion of the model using this stream.

21. Add another 3-Phase Separator to your flowsheet. Define it with the following
connections:

In This Cell... Enter...

Connections
Name V-100
Inlet 2
Vapour Product 3
Light Liquid Product 4
Heavy Liquid Product Waste Water

22. Select the Expander operation from the Object Palette and add it to your flowsheet;
define it as follows:

3-9
 In This Cell... Enter...
Connections
Name K-100
Inlet 3
Outlet 5
Energy QK-100
Worksheet
Stream 5, Pressure 2800 kPa (406.1 psia)

QUESTION: What is the power produced by the K-100 Expander? [Write your
answer below]

23. Add a two-phase Separator to the flowsheet and define it as shown:

In This Cell... Enter...

Connections
Name V-101
Inlet 5
Vapour Outlet 7
Liquid Outlet 6

The liquid from the first Separator (V-100) is flashed down to the same pressure as the
Expander (K-100) outlet. When the simulation is manipulated later, the Turbo Expander
outlet pressure is one of the process parameters that will be changed. Hence, it makes sense
to link these parameters within Aspen HYSYS rather than manually changing both. Use a
Set logical operation to achieve this.

24. Add a Valve to the flowsheet using the following connections:

In This Cell... Enter...

Connections
Name VLV-100
Inlet 4
Outlet 8

3 - 10
 25. Double click on the Set icon on the Object Palette and install a Set with the
following parameters:

In This Cell… Enter…

Connections
Target Variable Object Stream 8
Target Variable Pressure
Source Stream 5
Parameters
Multiplier 1
Offset 0 kPa (0 psi)

26. Save your case as 01-GettingStarted.hsc.

Task 2 – Adding the Fractionation Columns

The vapor phase hydrocarbons that are processed in the Turbo Expander model have now
been isolated. You will turn your attention back to that side of the process later.

Now you will combine the hydrocarbon liquids (liquefied natural gas and condensate) and
further process those material streams. As of now, your flowsheet should consist of three
primarily liquid phase hydrocarbon streams (6, 8, and Inlet Condensate). Stream 6 only
contains a small amount of material flow. Assume that this stream will be collected, stored,
and used on a batch-wise basis.

Streams 8 and Inlet Condensate will be passed on to a pair of fractionation columns. The
first, a Demethanizer, will attempt to draw a methane rich product off its overhead. The
bottoms liquids will continue on to a Deethanizer column, where an ethane-rich product is
taken form the overheads, and a draw of propane and heavier hydrocarbons are drawn off
the bottoms.

The Inlet Condensate stream still exists at its feed conditions, while stream 8 has been
refrigerated and brought to a lower pressure. The Inlet Condensate also needs to be brought
to the proper thermodynamic conditions. The means for doing this in practice are not of
concern in this model, so you will use a simple HYSYS Cooler to set the conditions of the
Inlet Condensate to required values.

27. Add a Cooler to the flowsheet with the following data:

3 - 11
 In this cell... Enter...
Connections
Name E-200
Inlet Inlet Sep Liq
Outlet 10
Energy Q-200
Worksheet
Stream 10 Temperature -85 °C (-121 °F)
Stream 10 Pressure 2790 kPa (404.7 psia)

28. Add a Material Stream named 11 to the flowsheet. This will be used to represent
the Demethanizer column bottoms liquid product stream.

29. Add a Set operation to define the pressure of stream 11 so that it is the same as that
of stream 5.

30. Add another Set to your flowsheet. Set this one so that the stream 9 pressure is 35
kPa (5 psi) less than that of stream 5.

3 - 12
The Column is a special type of Sub-Flowsheet in Aspen HYSYS. Sub-Flowsheets contain
equipment and streams and exchange information with the parent flowsheet through the
connected streams. From the Main Flowsheet, the Column appears as a single, multi-feed,
multi-product operation. In many cases, you can treat the Column in exactly that manner.

Using the Column Sub-Flowsheet provides a number of advantages, such as isolation of

the Column solver, optional use of different fluid packages, construction of custom
templates, and the ability to solve multiple towers simultaneously.

By isolating the column solver, the Column Build Environment allows you to make
changes and focus on the column without the re-calculation of the entire flowsheet.

The Column Sub-Flowsheet uses a simultaneous solver where all operations within the
Sub-Flowsheet are solved simultaneously. The simultaneous solver permits you to install
multiple interconnected columns within the Sub-Flowsheet without the need for Recycle
blocks.

Aspen HYSYS allows you to specify a unique (different from the Main Flowsheet) fluid
package for the Column Sub-Flowsheet. This may be useful in instances such as when a
different fluid package is better suited to the column (for example, a Gas Plant using PR
may contain an amine contactor that needs to use the Acid Gas property package). This
feature is also useful to speed up column convergence when the column property package
does not need to use all the components used in the Main Flowsheet.

After the column is created, you can enter the Column Sub-Flowsheet by clicking the
Column Environment button on the Column Property View. This lets you review the results
and configuration of the column and also to customize the Sub-Flowsheet using various
combinations of equipment. When you are inside the Column Environment, you can return
to the Parent Environment by clicking either the Parent Environment button on the Column
Runner view or the Go to Parent button on the ribbon.

3 - 13
 31. Add the first column model (the Demethanizer) by selecting the Columns section
of the Object Palette and adding a Reboiled Absorber operation.

Note: Aspen HYSYS includes an Input Expert to guide you through setting up the Column.
The Input Expert has five pages; you must enter all the required information on each page
before the Next button will become active.

32. Double-click the Reboiled Absorber icon that now appears on your Main
Flowsheet. The Column Input Expert should appear. Enter the following
information on the Connections page. When finished, click the Next button.

Connections
Column Name Demethanizer
No. of Stages 10

Top Stage Inlet 10

Optional Inlet Stream / Stage 8 / Stage 2_Main Tower
Overhead Vapour Product Stream 9

Bottom Product Stream 11

Reboiler Energy Stream Q-102

33. Click the Next button to proceed to the Reboiler Configuration page. Select the
desired Reboiler Configuration using the available radio buttons. Accept the
default Once-through / Regular HYSYS reboiler.

34. Since the product stream pressures have already been defined (via the Set
operations), the Pressure Profile page automatically picks these up. Click Next to
continue.

3 - 14
 35. Go to the Optional Estimates page by clicking the Next button. Temperature
estimates are used to aid in convergence and help a column solve more rapidly – or
solve period! If you already have an idea of the conditions in the column (for
example, if you are modeling an existing plant), then you can enter the information.
In this exercise, the temperatures are not known, so these estimates will be left
blank.

36. Click the Next button to move to the final page. The final page of the Column Input
Expert always has some typical specifications for the particular type of column. If
different specifications are used, these must be added after the Input Expert has
been completed. Keep this form blank and click the Done button.

Before the column is ready to run, some more information must be entered. Add an
additional Inlet Stream and new specifications.

3 - 15
37. Return to the Main Flowsheet and create an Energy Stream. Title this energy
stream Side Duty and specify a Heat Flow value of 3.3 E+06 kJ/h (3.128 E+06
Btu/hr).

38. Connect the Side Duty stream to stage 4_Main Tower in the Optional Inlet
Streams box on the Design | Connections page.

39. Go to the Design | Monitor page and review the existing column specifications.

3 - 16
Since no values were entered for the specifications in the Input Expert, no values are
present here. Since the column has fully defined feeds, the pressures are known, and one
specification is activated, the Degrees of Freedom display is showing 0. Of course, that
active specification has no numeric value, rendering it useless!

40. Specify a value of 800 kgmole/h (1764 lbmole/hr) for the Ovhd Prod Rate.

41. Navigate to the Parameters tab and select the Solver page. Ensure that No 2 Liq
Check is selected for the Two Liquids Check option.

42. Click the Run button to run the column if it does not solve automatically.

3 - 17
QUESTION: Go to the Performance | Summary page. What is the mole fraction of
methane in stream 9? [Write your answer below]

It is preferred to solve this Demethanizer column with a different specification from the
default overhead molar flow rate. You will instead use a specification for the Reid Vapor
Pressure (RVP) of the bottoms product (stream 11).

43. Return to the Design | Monitor form and click the Add Spec…button to add the
specification described below:

Spec Data
Type Column Vapour Pressure Spec
Name Btms RVP
Stage Reboiler
Type Reid Vap Pressure
Phase Liquid
Spec Value 1380 kPa (200 psia)

44. Modify the existing Ovhd Vap Rate specification to be set up as an Estimate.
Make the Btms RVP specification Active and Run the column.

Note: The other unused specifications can be deleted by going to the Specs page on the
Design tab and pressing the Delete button, or by double-clicking the specification on the

3 - 18
Monitor page on the Design tab and clicking Delete button. If desired, you may leave them
in place for reporting/analysis purposes.

You should see some messages in the Trace Window (bottom right message pane of the
HYSYS window) as the column solves. When the column has solved, the LNG Exchanger
should then fully calculate, along with all remaining material streams in the flowsheet.

QUESTION: What is the new overhead molar flow rate? [Write your answer below]

QUESTION: What happened to the mole fraction of methane in stream 9? Did it increase?
Decrease? [Write your answer below]

45. Save your case.

Stream 11, the Demethanizer bottoms, will now be further processed. A Deethanizer
column removes ethane and lighter components in the overhead draw, while propane and
heavier hydrocarbons are drawn from the bottoms. Continue by adding this column to your
flowsheet.

46. Add a Distillation Column from the Columns section of the Object Palette. Define
the Connection page of the Input Expert as follows. Click the Next button when
finished.

In this cell... Enter...

Connections (Page 1)
Column Name Deethanizer
Number of Stages 16
Inlet Stream / Inlet Stage 11 / 7_Main Tower
Condenser Type Full Reflux
Overhead Vapour Product 12
Bottoms Liquid Outlet 13
Condenser Energy Stream Q-103
Reboiler Energy Stream Q-104

3 - 19
 47. For the Reboiler Configuration page, keep the default settings. Click Next.

48. Define the Pressure Profile page with the following. Click Next to move on.

In this cell... Enter...

Pressures (Page 3)
Condenser Pressure 2730 kPa (396 psia)
Condenser Pressure Drop 20 kPa (2.9 psi)
Reboiler Pressure Drop 0 kPa (0 psi)
Reboiler Pressure 2785 kPa (404 psia)

Continue through the Temperature Estimates and Specifications forms of the Input
Expert without entering any inputs. Click Done once you reach the last page of the Input
Expert.

49. Move to the Design | Monitor page On the Column Property View window.

QUESTION: How many degrees of freedom currently are present on the Deethanizer?
[Write your answer below]

50. On the Monitor page, the specification for Reflux Ratio should be present. Specify
a value of 3.0 for it.

51. One more specification is needed. Specify a fractional recovery specification for
propane using the data below:

Spec Data
Type Column Component Recovery
Name C3 Recovery
Flow Basis Molar
Draw 13 @COL2
Spec Value 0.95
Components Propane

52. Check the Active boxes for the Reflux Ratio and C3 Recovery specifications. Run
the column.

3 - 20
QUESTION: What is the molar recovery of ethane in the overhead stream 12? [Write your
answer below]

53. Save your case.

Task 3 – Sales Gas Compression

The simulation is almost complete. The two product gas streams from the LNG Exchanger
will now be mixed and re-compressed for export.

54. Add a Mixer operation to the flowsheet and define it using the following table:

In This Cell... Enter...

Connections
Name MIX-100
Inlets 9A, 7A
Outlet 14

55. Add a Compressor to the flowsheet. Connect QK-100 (the energy stream
connected to the K-100 Expander) as the energy input. See the following screenshot
for the inlet and outlet connections:

3 - 21
 56. Add one last Compressor defined with the parameters listed below:

In this cell... Enter...

Connections
Name Export Gas Comp
Inlet 15
Outlet Sales Gas
Energy QK-102
Worksheet
Outlet Pressure 6000 kPa (870.2 psia)

57. Save your case.

In this Aspen HYSYS exercise, the two compressors are specified differently. K-101 has a
fully specified inlet stream and a specified duty calculated via expander K-100, while the
Export Gas Compressor has a fully specified inlet stream and a specified outlet pressure.

Aspen HYSYS can also solve for a flow rate given an otherwise fully specified feed stream,
a duty, and an outlet pressure. Additionally, Aspen HYSYS compressors can be supplied
with head and efficiency curves. This allows the discharge pressure to be calculated as a
function of the inlet flow rate and operating speed. These curves can be obtained from
vendors, online databases, and through aspenONE Exchange.

3 - 22
Task 4 – Customizing Stream Properties
In this part of the workshop, you will modify the properties being displayed on each stream.
You can add or remove properties (also referred to as Property Correlations), change the
order of the properties, and save sets of property correlations to apply them on other streams
in the simulation.

There are two places in Aspen HYSYS where these correlations are controlled. The
Property Correlation Controls section on the stream Properties page allows the correlations
for an individual stream to be customized. To make changes to the property correlations
for the whole case, use the Correlation Manager on the Home tab on the ribbon.

58. To modify the properties at stream level, use the buttons at the bottom of the stream
window on the Properties page on any stream.

These buttons have the following functions:

Button Flyby Text Notes

View Correlation Set List Allows you to pick from a list of previously defined
correlation sets.

Append New Correlation Brings up a window where all correlations are

displayed in a tree and can be selected and added.
Correlations are added to the bottom of the list.
Move Selected Correlation
Down

Move Selected Correlation Up

Sort Ascending

Remove Selected Correlation

Remove All Correlations

Save Correlation Set to File The Correlation Set can then be loaded with the
View Correlation Set List function.

View Selected Correlation See settings specific to the selected correlation.

View All Correlation Plots See all correlation plots for the stream. Currently
greyed out as none of the correlations have plots.

3 - 23
 59. Double click on the Inlet Sep Vap stream. Go the Properties menu and click the
Remove All Correlations button ( ) to clear all the correlations on the stream.

60. Click on the Append New Correlation button ( ) and add Gas – HC Dew
Point. Click on Apply.

61. Repeat the same steps for Gas | HHV Molar Basis, Gas | LHV Molar Basis, Gas
| Wobbe Index and Standard | Std Gas Flow. Close the Correlation Picker
window when finished.

62. On the Inlet Sep Vap stream Properties page, select the HHV Molar Basis [Gas]
entry in the table.

63. Click the View Selected Correlation button ( ).

A window appears giving details of the property.

Note that the reference temperature option cannot be changed here as it appears in black.

3 - 24
64. Back on the Inlet Vapor stream Properties page, click the Save Correlation Set to
File button ( ) to save the properties in this stream as a correlation set called
Inlet Sep Vap-CorrSet.

65. Open the Properties page for the Sales Gas stream. Remove all the existing
correlations and add the Inlet Sep Vap-CorrSet correlation set to the stream using
the View Correlation Set List button ( ).

3 - 25
Note: All user-defined correlation sets are stored by default on the file.
StreamCorrSets.xml under the \Support subdirectory of the Aspen HYSYS installation. The
name and location of this file can be configured on the Preferences menu located under
File | Options from the HYSYS ribbon. This file is not created until a correlation set is
added.

To customize the properties for all the streams in the simulation, Aspen HYSYS includes
a Correlation Manager where global changes for the whole case can be made. This
Correlation Manager is accessed through the Simulation section on the Home menu on the
ribbon.

66. Navigate to the Home ribbon tab and select the Correlation Manager. See the
screenshot below for guidance:

The Correlation Manager contains a listing of available properties and correlations much
like the one used in the Correlation Picker menu that can be accessed for a single material
stream. It also contains a section describing a selected correlation and displaying where in
the simulation it is applied.

At the bottom of the Correlation Manager is collection of controls similar to those seen on
the Properties form of a single material stream. The functions of the buttons are shown on
the next page:

3 - 26
 Button Flyby Text Notes
Scan System Correlations Click this icon to manually scan the system
registry and build a list of available property
correlations.
Clone Selected Correlation Only enabled when a property with variable
parameters is selected (details are given in
the following sections).
Delete Cloned Correlation From List Only enabled when a previously cloned
property is selected in the Clone part of the
tree and when no streams are showing the
property.
Activate Selected Global Adds the selected property correlation to all
Correlation the streams in the case.

Remove Selected Global Removes the selected property correlation

Correlation from all the streams in the case.

Remove All Global Correlations Removes all the property correlations from
all the streams in the case.

Some properties, like Higher Heating Value, have user-adjustable parameters that can only
be modified from the Correlation Manager. You will now learn how to customize these
parameters.

67. Select the Gas | HHV Molar Basis property from the property tree in the
Correlation Manager.

68. Change the Ref. Temp. Option to 0.0 °C using the drop-down menu.

69. Go back to the Main Flowsheet and note that the HHV-Molar Basis values
calculated in the Inlet Sep Vap and Sales Gas streams have changed due to the
altered reference state.

3 - 27
When you change a correlation’s parameters, all the streams displaying the correlation will
use the new parameters. Hence, Aspen HYSYS has a clone feature that allows multiple
copies of the same correlation to be used. Cloned correlations can have different parameter
values to the original correlation.

70. Return to the Correlation Manager and make sure the HHV Molar Basis
correlation is selected. Click the Clone Selected Correlation button ( ) to clone
the Higher Heating Value property.

71. Find the cloned property in the User section of the property tree.

72. Add this correlation to all the streams in the case using the Activate Selected
Global Correlation button ( ).

Verify that the reference temperature for the cloned correlation is different from the
original correlation (i.e. original is set at 0 °C and the clone’s is at 15 °C).

73. Compare the values of the two correlations for the Inlet Sep Vap and Sales Gas
streams.

3 - 28
 When viewing a single correlation/property in the Correlation Manager, you will
notice that there are six bars at the right side of the window on the Status group. They
are described on the following table. This Status section indicates the statues of the
selected correlation in your simulation.

Status Bar Description

Stream Indicates that the correlation can only be applied to
material streams.
Point/Potable Indicates whether the property correlation is a point
or potable property.
Black Oil/Electrolyte/ Indicates which correlation type the property
Gas/RVP/Solid/ correlation resides within the Available Correlations
Standard/User/Clone list.
Active/Inactive Indicates whether the property correlation has been
activated by the correlation manager.
If the status bar is green, any new stream added to
the flowsheet with the same fluid type as the
correlation will automatically have the property
correlation added.
In Use/Not in Use Indicates whether the property correlation is being
used by a stream in the case.
Available/Unavailable Indicates whether the property correlation exists in
the window registry of the system.

The View Global Correlation Set List button in the Stream Correlation Set Controls
(Global) group allows a previously saved Correlation Set to be displayed for all the streams
in the case

3 - 29
With this option, you can load a defined set of correlations to all streams in a given
simulation. This can be very beneficial in cases where you wish to standardize physical
property reporting, simplify the display of stream properties, or otherwise customize your
property reporting techniques.

74. Click the button to Remove All Global Correlations.

75. Click the View Global Correlation Set List by clicking the appropriate icon.

76. Select the Inlet Sep Vap-CorrSet and click the Apply button to load the
correlation set to all streams in the flowsheet.

QUESTION: What is the standard gas flow rate of stream 12? [Write your answer below]

77. Save your case as 01-GettingStartedCorr.hsc.

3 - 30
Recommended Reading
Knowledge Base Solution 114348
How do I customize stream properties for all my streams in the HYSYS case?

3 - 31
Notes:

3 - 32
 Getting Started Solutions
Files can be found in folder: 01_ GettingStarted\Solutions

Questions
Task 1
QUESTION: What is the power produced by the K-100 Expander?

60.79 kW (81.53 hp)

Task 2
QUESTION: Go to the Performance | Summary page. What is the mole fraction of
methane in stream 9?

0.9242

QUESTION: What is the new overhead molar flow rate?

768.7 kgmole/h (1695 lbmole/hr)

QUESTION: What happened to the mole fraction of methane in stream 9? Did it increase?
Decrease?

0.9547; Yes, it increased from the original case

QUESTION: How many degrees of freedom currently are present on the Deethanizer?

Two (do not be deceived by any Active specifications that have no value!)

QUESTION: What is the molar recovery of ethane in the overhead stream 12?

98.56%

Task 4
QUESTION: What is the standard gas flow rate of stream 12?

14470 STD_m3/h (12.26 MMSCFD)

3 - 33
Results Summary

Feed Mix Inlet Sep Inlet Sep Inlet Sep Liq

Vap Water
Vapour Fraction 0.5374 1 0 0
Temperature C 22 22 22 22
Pressure kPa 3500 3500 3500 3500
Molar Flow kgmole/h 4145 2227.57 400.36 1517.07
Mass Flow kg/h 139412.09 51027.53 7212.89 81171.67
Liquid Volume Flow m3/h 297.79 141.74 7.23 148.82
Heat Flow kJ/h -512256461 -183170676 -114661141 -214424644

7 9 1A 7A
Vapour Fraction 1 0.9998 0.9039 1
Temperature C -70.481 -63.712 -8.831 12
Pressure kPa 2800 2765 3480 2780
Molar Flow kgmole/h 1074.133 768.735 2227.571 1074.133
Mass Flow kg/h 18799.338 12888.333 51027.530 18799.338
Liquid Volume Flow m3/h 59.074 41.898 141.740 59.074
Heat Flow kJ/h -83929144 -60796333 -189277976 -80211713

9A 2 3 4
Vapour Fraction 1 0.4895 1 0
Temperature C 12.000151 -62 -62 -62
Pressure kPa 2745 3460 3460 3460
Molar Flow kgmole/h 768.73 2227.57 1090.36 1135.28
Mass Flow kg/h 12888.33 51027.53 19231.46 31761.26
Liquid Volume Flow m3/h 41.90 141.74 60.23 81.48
Heat Flow kJ/h -58406463 -202942268 -85349436 -117027649

Waste 5 6 8
Water
Vapour Fraction 0 0.9851 0 0.0842
Temperature C -62 -70.481 -70.481 -67.317
Pressure kPa 3460 2800 2800 2800
Molar Flow kgmole/h 1.93 1090.36 16.23 1135.28
Mass Flow kg/h 34.81 19231.46 432.12 31761.26
Liquid Volume Flow m3/h 0.03 60.23 1.15 81.48
Heat Flow kJ/h -565183 -85568295 -1639151 -117027649

3 - 34
 10 11 12 13
Vapour Fraction 0 0 0.9997 0.0000
Temperature C -85 66.200 9.124 127.558
Pressure kPa 2790 2800 2730 2785
Molar Flow kgmole/h 1517.07 1883.62 611.96 1271.66
Mass Flow kg/h 81171.67 100044.60 18709.79 81334.80
Liquid Volume Flow m3/h 148.82 188.40 51.45 136.95
Heat Flow kJ/h -232792150 -251652845 -55712341 -179301039

14 15 Sales Gas
Vapour Fraction 1 1 1
Temperature C 11.887 15.460 84.986
Pressure kPa 2745 2858 6000
Molar Flow kgmole/h 1842.87 1842.87 1842.87
Mass Flow kg/h 31687.67 31687.67 31687.67
Liquid Volume Flow m3/h 100.97 100.97 100.97
Heat Flow kJ/h -138618176 -138399317 -133970603

3 - 35
 Aspen HYSYS: Advanced Process Modeling Topics Advanced Columns

Advanced Columns
Aspen HYSYS: Advanced Process Modeling Topics
EHY202 V10.0

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 Aspen HYSYS: Process Modeling Additional Topics Advanced Columns

Section Objectives

• Build customized column model configurations in Aspen HYSYS

• Introduce efficiency by discussing theoretical versus actual stage calculation approaches

• Perform hydraulic calculations on column trays and packing using the Aspen HYSYS Column Analysis

• Workshop: Customize standard HYSYS column models for more detailed condenser and reboiler
modeling and investigate the influence of stage efficiencies and column internals on tower performance

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 Aspen HYSYS: Advanced Process Modeling Topics Advanced Columns

Custom Columns

• Six Pre-built Column Templates:

– Absorber: no reboiler, no condenser
– Refluxed Absorber: absorber with condenser
– Reboiler Absorber: absorber with reboiler
– Distillation Column: absorber with both reboiler and
condenser
– Three Phase Distillation: similar to Distillation
Column with allowances for liquid-liquid phase
equilibrium
– Liquid-Liquid Extractor: stage section computing
liquid-liquid phase equilibrium

• Customize a Column Template in two ways:

– Modify a pre-built column (inside column sub-
flowsheet)
– Construct a new column template
3 © 2017 Aspen Technology, Inc. All rights reserved.

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 Aspen HYSYS: Process Modeling Additional Topics Presentation

Column Sub-Flowsheet

• Aspen HYSYS is capable of modeling columns that do not match any of the pre-built configurations
– Possible to model multiple columns within one sub-flowsheet

• Operations can be deleted, modified, replaced and controlled; however the number of operations is
limited
– Allows rating and sizing of reboilers
– Can model thermosyphon reboilers

• Column Sub-flowsheet solves simultaneously

– Recycles not required
– Faster and more robust solution

• Use of internal and external streams to connect between parent and sub-flowsheet environments

4 © 2017 Aspen Technology, Inc. All rights reserved.

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 Aspen HYSYS: Advanced Process Modeling Topics Advanced Columns

Detailed Equipment Modeling

• Possible Options:
– Reboiler
– Steam is used as the energy source for the heat
exchanger
– Heat exchanger can be rated and sized
– A thermosyphon reboiler can be used in place of
a generic kettle reboiler
– Condenser
– Cooling water or refrigerant is used as coolant
– Include pump and separator

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 Aspen HYSYS: Process Modeling Additional Topics Presentation

Workshop – Task 2

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 Aspen HYSYS: Process Modeling Additional Topics Presentation

Internal Streams

• Column models only display inlet/outlet streams on main flowsheet

– To view internal flows (i.e. reflux, boilup, etc.) you need to enter Column Environment
– Some internal flows (i.e. vapor flow from stage 5 to stage 4) are not represented by streams

• These internal flows can be displayed on main flowsheet

– Create an Internal Stream

• Places a material stream on the main flowsheet

– Stream does not affect overall material balance
– Not an actual “draw” from the column

• Useful for related-equipment modeling (i.e. reboilers, reflux pumps, etc.) outside of column solver

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 Aspen HYSYS: Process Modeling Additional Topics Presentation

Workshop – Task 1

“To Cond” is an
Internal Stream

Represents the vapor flow

from the top stage to the
internal condenser

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 Aspen HYSYS: Process Modeling Additional Topics Presentation

Column Efficiency

• By default, column calculations assume a

theoretical, equilibrium stage model
– Number of stages defined refers to theoretical
stages

• To adjust column performance towards real

behavior, enter efficiency data; two types
available:
– Stage efficiency
– Component efficiencies

• Value of 1.0 assumes perfect, theoretical

equilibrium separation

• Stage efficiencies useful for tuning a column to

produce more realistic results
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 Aspen HYSYS: Process Modeling Additional Topics Presentation

Column Analysis (1)

• Allows sizing, rating, and debottlenecking of column internals based on hydraulic calculations

• Created from the Column-Internals Tab

• Features:
– Design and Rating modes with both trays and packing
– Section capability (for multi-section towers or side-by-side comparisons)
– Can export pressures back to column (when in Rating mode)

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 Aspen HYSYS: Advanced Process Modeling Topics Advanced Columns

Column Analysis (2)

• Column Analysis lets you analyze different column Internals configurations in detail

Interactive visual interface for tray geometry input

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 Simulation of Electrolytes Processes with Aspen Plus Introduction

Column Analysis (3)- Hydraulic Plots

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The Hydraulic Plots form is divided into these main sections: The column diagram appears on the upper left.
Below it, when a tray is selected, the downcomer loading and weir loading diagrams appear. The large plot on
the right is the stability diagram. Below it is the carousel, which shows a small version of the stability diagram for
each of several stages.

©2011 AspenTech. All Rights Reserved.

 Simulation of Electrolytes Processes with Aspen Plus Introduction

Column Analysis (4) – Sizing and Rating

• Easy comparison of alternative designs

– Sizing
– Rating

• Different internals (valves, sieve, packed)

• Different tray diameters

13 © 2017 Aspen Technology, Inc. All rights reserved.

The Hydraulic Plots form is divided into these main sections: The column diagram appears on the upper left.
Below it, when a tray is selected, the downcomer loading and weir loading diagrams appear. The large plot on
the right is the stability diagram. Below it is the carousel, which shows a small version of the stability diagram for
each of several stages.

©2011 AspenTech. All Rights Reserved.

 Aspen HYSYS: Process Modeling Additional Topics Presentation

Workshop: Advanced Columns

• Task 1 – Simulate a Condenser Externally

• Task 2 – Modify the Column Sub-Flowsheet Reboiler

• Task 3 – Tune Stage Efficiency

• Task 4 – Perform Column Internals Sizing and Rating

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©2011 AspenTech. All Rights Reserved. 14 Aspen Technology, Inc.

 Advanced Columns Workshop
Files can be found in folder: 02_AdvancedColumns

Objective
In this workshop, you will learn about customizing Column configurations for enhanced
condenser and reboiler modelling. This can be done either inside or outside of the
Column Sub-Flowsheet. Another aspect of the exercise is to learn about Column stage
efficiencies and how they can influence the separation performance of your Column
models. You will also learn how to perform tray sizing and rating calculations with the
Aspen HYSYS Column Analysis tool.

In this module, the prebuilt LPG Recovery Column from the last workshop will be
modified. You will learn about Column stage efficiencies and how to use the Column
Analysis tool to size and rate Column tray sections in the Column.

This workshop includes the following tasks:

▪ Task 1 – Simulate a Condenser Externally

▪ Task 2 – Modify the Column Sub-Flowsheet Reboiler
▪ Task 3 – Tune Stage Efficiency
▪ Task 4 – Perform Column Internals Sizing and Rating

Task 1 – Simulate a Condenser Externally

The default Condenser and Reboiler operations that Aspen HYSYS utilizes inside the
Column Environment are ideal operations. For instance, the standard Condenser is
essentially the condenser heat exchanger, accumulator, and reflux/distillate all in one.
This setup, while convenient for steady state process simulation, presents some difficulty
if you are interested in equipment sizing or in detailed dynamic calculations.

One potential method of simulating a condenser or reboiler with a Heat Exchanger is to

use the Internal Streams feature of the HYSYS Column models and then to make a copy
of the condenser/reboiler on the Main Flowsheet. This approach is very convenient as it
does not affect the internal Column solver or the solving of any other flowsheet objects.
Think of it as a side calculation entirely dedicated to the study of your condenser or
reboiler.

In this portion of the workshop, you will further study the condenser on your Deethanizer
Column. This way of modeling the condenser is just as accurate as adding the heat

5-1
exchanger to the Column Sub-Flowsheet, although it may look a bit odd as there are in
essence two condensers: one integrated with the Column Sub-Flowsheet, and another “for
calculation purposes.”

Again, to make this approach work, you will be using an Internal Stream. This is a special
Aspen HYSYS stream that represents a fluid inside the Column (for example, the vapor
leaving the top tray, or the liquid leaving the bottom tray). Internal Streams are copies of
flows inside the Column and not material draws from the Column. Thus, they do not
affect the overall mass and energy balance.

1. Start with the supplied starter file (02-AdvColumnsStarter).

2. From the Main Flowsheet, double-click the Deethanizer column icon.

3. Go to the Flowsheet | Internal Streams page and click on the Add button.

4. Type in To Cond as a stream name and select 1_Main Tower as the Stage.

5. Select Vapour and then click the Export check box.

6. Run the column and you should see the To Cond stream out on the Main
Flowsheet.

Note: The Net/Total column is relevant only in the case of streams with external draws.
When Total is selected, the draws are included, i.e. the total flow leaving the stage is
considered. When Net is chosen, only the flows in the column are considered, and the
effect of external draws is excluded.

7. Add a Heat Exchanger to the flowsheet and define it with the following
specifications:

5-2
 In This Cell… Enter…
Connections
Name Condenser
Tube Side Inlet To Cond
Tube Side Outlet To Acc
Shell Side Inlet Cool In
Shell Side Outlet Cool Out
Parameters
Heat Exchanger Model Simple Weighted
Shell Side Pressure Drop 7 kPa (1 psi)
Tube Side Pressure Drop 20 kPa (2.9 psi)

8. View the Cool In material stream and select the Composition form. Assume the
Cool In stream is a mixed refrigerant with composition of 95% mole propane
and 5% mole ethane. Specify the corresponding mole fractions for Cool In.

9. Assume a Vapor Fraction of 0.0, a Pressure of 260 kPa (37.71 psia), and a Molar
Flow of 880 kgmole/h (1940 lbmole/hr) for the Cool In process conditions.

QUESTION: What is the temperature of Cool In? [Write your answer below]

10. Use a Set operation to specify the To Acc stream temperature to be the same as
stream 12@COL2 (thus giving the Main Flowsheet Condenser the same heat load
as the Deethanizer column Condenser).

5-3
 11. Add a Separator to the Main Flowsheet and define it as follows:

In This Cell... Enter...

Connections
Name Accumulator
Inlet To Acc
Vapour Outlet Ovhd Prod
Liquid Outlet Reflux

12. Save your case as 02-AdvColumnsCond.hsc

QUESTION: What is the calculated UA of the Condenser? LMTD? [Write your

answer below]

Task 2 – Modify the Column Sub-Flowsheet Reboiler

Whenever a column is added into an Aspen HYSYS simulation, a Column Sub-
Flowsheet is created. The Sub-Flowsheet is essentially another layer in the Aspen
HYSYS simulation. The nature of the layering scheme can be seen by selecting the hot-
key <CTRL+P>, where the Column is listed under the Main PFD. Selecting the desired
flowsheet and clicking the View button will open that particular layer for viewing.

5-4
Alternatively, the flowsheet of a particular column can be seen by right-clicking the
Column Sub-Flowsheet icon and choosing Open Flowsheet as New Tab.

In order to edit the column (for example, to add and modify operations), it is best to enter
the Column Environment. The Column Environment is accessed through the Column
Property View. To bring up the Column Property View, double-click the column icon on
the parent flowsheet. With the Column Property View as the active view, click the
Column Environment button. This will make Aspen HYSYS display the Column
Environment and Column Runner menu. The operations within the Column Sub-
Flowsheet can be deleted, modified, replaced, and controlled just like ordinary unit
operations in the Main Environment.

When in the Column Environment, you can return to the Main Environment by clicking
the Go to Parent button located on the Flowsheet/Modify toolbar.

This task will involve the Demethanizer column you built in the Getting Started module.
The column was constructed as a generic reboiled absorber with a generic type reboiler.
An energy stream applied to the reboiler partially vaporizes the liquid from the bottom
stage. The vapor returns to the bottom stage of the column, and the liquid leaves the
reboiler as a product draw. The generic reboiler will be replaced with a HYSYS Heat
Exchanger unit operation.

13. From the Main Flowsheet, double click on the Demethanizer column.

14. Go to the Parameters | Solver form and change the Solving Method to Modified
HYSIM Inside-Out.

Note: The Modified HYSIM Inside-Out is a general-purpose method which allows

additional unit operations such as Mixers, Pumps, Tees, Valves and Heat Exchangers
inside the Column Sub-Flowsheet.

5-5
 15. After changing the solving method, the column will become unsolved. Click the
Run button to re-calculate.

Now that the proper solver strategy is in place, you are ready to begin modifying the
Column Sub-Flowsheet.

16. Click the Column Environment button on the Demethanizer column window.

5-6
Note: As an alternative option, you may return to the Main Flowsheet and right-click on
the column icon. From there, select Open Flowsheet as New Tab. By right-clicking the
column icon and opening the flowsheet in a new tab, you can view both the Main and
Column Flowsheets in distinct windows. Clicking the Column Environment button
changes the flowsheet window in HYSYS from the Main Flowsheet to the Column Sub-
Flowsheet (i.e. only one flowsheet can be displayed in your workspace).

17. Delete the existing Reboiler and associated energy stream (Q-102) from the
Column Sub-Flowsheet view.

The generic HYSYS reboiler has no pressure drop. You will be replacing it with a Heat
Exchanger that has some assumed pressure drop. Therefore, you must add a Pump to the
Sub-Flowsheet to “push” the fluid through the exchanger.

18. Display the Column Sub-Flowsheet Object Palette and add a Pump to the Sub-
Flowsheet. Configure the Pump with the following specifications:

In This Cell... Enter...

Connections
Name Reboiler Pump
Inlet Stream To Reboiler
Outlet Stream Pump Out
Energy Stream Pump-HP
Parameters
Delta P 75 kPa (10.9 psia)

19. Continue by adding a Heat Exchanger to the Column Sub-Flowsheet and define
it with the following connections and input:

In This Cell... Enter

Connections
Name Reboiler
Tube Side Inlet Stream Steam In
Tube Side Outlet Stream Steam Out
Shell Side Inlet Stream Pump Out
Shell Side Outlet Stream Reboiler Out
Parameters
Shell Side Pressure Drop 75 kPa (10.9 psi)
Tube Side Pressure Drop 50 kPa (7.25 psi)

5-7
 20. Define the Steam In stream as superheated steam at 200 °C (392 °F) and 1500
kPa (217.6 psia). The mass flow rate is 17125 kg/h (37750 lb/hr). Remember to
define its composition as well!

21. Finish the Column Sub-Flowsheet by adding a Separator with the following
connections:

In This Cell... Enter...

Connections
Name V-100
Inlet Stream Reboiler Out
Vapour Outlet Stream Boilup
Liquid Outlet Stream 11

22. Return to the Main Flowsheet by clicking the Go to Parent button on the
Flowsheet/Modify tab of the Ribbon.

Note: If you are viewing the Column Sub-Flowsheet as a unique tabbed window, click the
tab for the Main Flowsheet.

Normally, when the reboiler is deleted from the Column Sub-Flowsheet, the pressure that
was specified at the bottom of the column is lost and must be added back on the
Parameters | Profiles page. However, in this case the pressure at the bottom of the column
is set by the pressure in the bottoms liquid product stream 11, which is linked to the
Turbo Expander outlet pressure by a Set operation. Your pressure profile should be intact.

However, since the Reboiler was deleted, Aspen HYSYS removed the reboiler liquid
Reid Vapor Pressure specification. Therefore, you need to add this specification back to
the column.

5-8
 23. Double click on the Demethanizer column, view the Design | Monitor page, and
select Add Spec - Column Vapour Pressure Spec:

RVP Spec...
Type Column Vapour Pressure Spec
Name Btms RVP
Stage V-100
Type Reid Vapour Pressure
Phase Liquid
Spec Value 1380 kPa (200 psia)

Since the Heat Exchanger was installed in the Column Environment, its specifications
appear on the Design | Monitor page along with the specifications of the column. Heat
Exchanger specifications can be activated and deactivated just like column specifications.
They can also be added in exactly the same manner as Column specifications.

24. Ensure that the two active specifications for the column are the Btms RVP and E-
100 Heat Balance.

Column Sub-Flowsheets containing more complex unit operations, such as Heat

Exchangers, tend to have more tricky convergence requirements than standard columns.
To address these convergence issues, you will need to make a few adjustments to the
Demethanizer solving parameters to enable it to solve.

5-9
25. Move to the Parameters | Solver form. Reduce the Equilibrium Error
Tolerance to 1.0 E-06 and the Heat/Spec Error Tolerance to 5.0 E-05.

26. Run the column.

5 - 10
Hint: You will likely receive a Consistency Error message when you try to solve the
Demethanizer. Do not worry – the problem is not over specified. You should note that the
Consistency Error points out a very slight difference in calculated enthalpy values for a
stream inside the Column Environment. These slight discrepancies are usually caused by
small numerical inconsistencies and often are not a problem. Follow the procedure below
to fix this issue.

27. Close any Consistency Error message windows you might have received. View
the Home ribbon tab and click the Active button to make the HYSYS Solver
active once again. The Main Flowsheet should now be fully calculated.

QUESTION: What is the minimum approach temperature of the Reboiler heat

exchanger? [Write your answer below]

QUESTION: What is the vapor fraction of the Reboiler Out material stream in the
Column Sub-Flowsheet? [Write your answer below]

28. Save your case as 02-AdvColumnsReb.hsc.

Task 3 – Tune Stage Efficiency

Aspen HYSYS column models employ a theoretical stage model. This means that the
specified stages are all assumed to be theoretical equilibrium stages rather than actual
trays or packing. While you will investigate the influence of actual column internals in
the next section of the workshop, it is important to note that these calculations will not
affect the separation results of a given column; they only predict hydraulic effects.

Since real columns in the field do not experience perfect theoretical equilibrium, it is
important to know how to adjust the theoretical column stages for a more realistic
performance. The approach to do is by working with efficiencies. Aspen HYSYS allows
you to modify efficiencies on a stage basis and on a component basis. In this task, you
will work with and manipulate stage efficiencies for the Deethanizer column to approach
a more realistic performance.

29. Double-click the Deethanizer column.

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 30. Start by recording the molar recovery of ethane in the overhead product. This
value can be found on the Performance | Summary form.

QUESTION: What is the current molar recovery of ethane in the overhead product?
[Write your answer below]

31. Navigate to the Parameters | Efficiencies form.

The current solution for the Deethanizer assumes 16 theoretical equilibrium stages in
addition to a full reflux condenser and a reboiler. The design targets for the column were
a molar reflux ratio of 3.0 and a fractional recovery of propane in the bottoms product of
0.95.

As the Deethanizer column goes to detailed engineering design, your designers inform
you that they are likely going to use trays for the column stages. These trays have,
according to the vendor, a percentage efficiency of about 70% with the current process
fluids in the Deethanizer.

32. Click and highlight all non-condenser/reboiler stages in the Stage Efficiency list.

33. Enter 0.7 in the Eff. Multi-Spec field on the Parameters | Efficiencies form.

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 34. Select all the non-condenser/reboiler stages and click the Specify ---> button to
write this efficiency in for all non-condenser/reboiler stages.

35. Allow the column to re-calculate.

QUESTION: What is the new calculated molar recovery of ethane in the overhead
product? [Write your answer below]

QUESTION: What happened to your calculated recovery of ethane? Did it decrease or

increase? Why would you expect it to do so? [Write your answer below]

Feel free to explore other column performance parameters as you experiment with
varying the stage efficiency.

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 36. Save your case as 02-AdvColumnsEfficiency.hsc.

Task 4 – Perform Column Internals Sizing and Rating

Aspen HYSYS contains a Column Analysis tool that greatly simplifies the hydraulic
design of a distillation column. You can size full towers or just sections of towers by
specifying information related to various tray or packing types.

While Aspen HYSYS is able to size and rate tray sections, the values that it provides are
only estimates and should be treated as such. It is also important to note that these
internals calculations only return hydraulic results. They do not influence or modify the
separation calculations within the tower. Those are still based upon the equilibrium-
related assumptions and efficiencies defined in the column model.

For this step of the module, you will perform some hydraulic calculations on the
Deethanizer column using the HYSYS Column Analysis.

37. You can use the Internals tab for the Column to explore multiple column
configurations or use the flowsheet icon to perform the analysis.

Note: The Internals tab includes pages for each tower within your Column Sub-
Flowsheet; Main Tower, Side Strippers, and Side Rectifiers.

When you open a HYSYS case in V9.0 that includes a column, icons on the flowsheet are
color-coded to indicate the status of the column internals:

• For columns without internals, a gray icon appears to the left of the column.
• For columns with internals specified and without errors, a blue icon appears to the
left of the column
• For columns with internals specified and with errors, a red icon appears to the left
of the column.

You can click on that icon to navigate to the same Internals page of the column.

The Aspen HYSYS Column Analysis lets you add trays or packing to any section of
stages. This section could be an entire tower, a portion of stages in a singles tower, or a
side stripper column. The Analysis also lets you add multiple sections which all calculate
at the same time. This is particularly useful for comparing the performance of different

5 - 14
tray/packing types, modeling different sections of a column with different internals
simultaneously, or for any other reason.

38. Click the Add New button to create a new internals section. A row appears,
named CS-1 by default. Enter Sizing Case for the Column Description.

Note: If you click the Auto Section button, HYSYS automatically creates column
sections based on feed and draw locations or internal flow rates.

39. Keep the default Sieve tray internals. Note the default calculation type of
Interactive Sizing.

40. Click the View to open the Geometry Form to specify more details for the
column internals.

You will notice that the default column internals sizing has resulted in some errors. The
Column Analysis tools identifies and reports hydraulic issues such as weeping, jet
flooding, downcomer backup, etc. This lets you ensure that your column is properly sized
and that the proper tray materials are being employed to handle the vapor and liquid
traffic.

5 - 15
41. Move to the Messages Tab to view the error warnings or select View Hydraulic
Plots and click the Stages with Errors/Warnings tab to view only the stages
with errors or warnings. The Column Analysis tool generates these plots to help
visualize the hydraulic operating conditions inside of the column and how the
current operating point compares against hydraulic operability limits.

The Hydraulic Plots interface is divided into several sections. On the top left-hand
pane, the Stages View shows a representation of the entire column. The stages are

5 - 16
 color-coded to indicate their status: blue for OK, yellow for warning, and red for
error. If the diameter of the column varies at each stage, the image will be scaled in
proportion to the stage diameters.

The top right-hand window shows a hydraulic plot for a single stage. You can select
the stage for which you want to view the hydraulic plot by clicking on the
corresponding stage on the Stage View. The plot will change in form depending on
whether you have selected trays or packing for that particular stage. This particular
example shows a trayed stage. The blue region on the plot represents the operability
boundaries. A black dot on the plot corresponds to the current vapor and liquid
traffic, which are the vertical and horizontal axes of the plot, respectively. To ensure
safe and reliable column operation, the black dot should lie in the blue region. If the
black dot is operating close to the edge or outside of the blue region, the program
will generate a warning or error. You can use these plots to troubleshoot causes of
column instability and hydraulic problems.

At the bottom of the interface, the program displays a carousel with a scaled-down
view of the hydraulic plot at each stage. You can scroll through the carousel and
select a stage to zoom in on the hydraulic plot on that stage.

42. The initial design contains several stages with hydraulic concerns. After
examining the hydraulic plots, your engineers decide to remediate the problem by
increasing the tray spacing or downcomer clearance. First, try increasing the
downcomer clearance. On the Geometry form, change the Downcomer
Clearance to 58.80 mm (2 in) for the column.

43. There is still a problem with weeping. In order to remedy this, decrease the Hole
Area to Active Area ratio to 0.06.

5 - 17
By reducing the Hole Area To Active Area, the velocity of the vapor going through each
hole will be higher and has more momentum to push the liquid away from the hole.
Therefore, weeping will be less likely.

44. Accept all of the remaining default values that are presented.

45. Move to the Results Tab | Summary page to check the Design calculation
results.

46. You could also select View Internals Summary option to review the results.

5 - 18
This will take you to the Performance tab | Internals Results page for your column. Here
you can view Internals results data for the entire Tower when you use Column Analysis.

Aspen HYSYS will calculate the dimensions of the column using preset and user-defined
values for the column internals and for other various parameters. The results are
presented on the Results tab. HYSYS estimates the total pressure drop over the section
and the maximum pressure drop per tray.

The Number of Flow Paths corresponds to the number of times liquid crosses the tray.
Most trays are single-pass and have an NFP of 1. The Maximum Downcomer Backup
represents the maximum amount of liquid hold-up in the downcomer that can be tolerated
by the column before flooding occurs. The Maximum Weir Loading measures the amount
of liquid flowing over the weir.

QUESTION: What is the required section diameter? [Write your answer below]

QUESTION: What is the section height? [Write your answer below]

QUESTION: What is the section pressure drop? [Write your answer below]

47. Save your case as 02-AdvColumns-Sizing.hsc.

5 - 19
You will now notice that for the Deethanizer column, a blue icon appears to the left of the
column indicating that this column with internals specified has no errors.

5 - 20
Notes:

5 - 21
 Advanced Columns Solutions
Files can be found in folder: 02_AdvancedColumns\Solutions

Questions
Task 1
QUESTION: What is the temperature of Cool In?

-23.83 °C (-10.89 °F)

QUESTION: What is the calculated UA of the Condenser? LMTD?

UA: 5.495 E+05 kJ/°C-h (2.893 E+05 Btu/°F-hr)

LMTD: 30.41 °C (54.73°F)

Task 2
QUESTION: What is the minimum approach temperature of the Reboiler heat
exchanger?

133.80 °C (240.9 °F)

QUESTION: What is the vapor fraction of the Reboiler Out material stream in the
Column Sub-Flowsheet?

0.541

Task 3
QUESTION: What is the current molar recovery of ethane in the overhead product?

Ethane in Ovhd: 98.56%

QUESTION: Allow the column to re-calculate. What is the new calculated molar
recovery of ethane in the overhead product?

Ethane in Ovhd: 93.7%

QUESTION: What happened to your calculated recovery of ethane? Did it decrease or

increase? Why would you expect it to do so?

5 - 22
The calculated recovery decreased. It decreased (thus giving a less pure overhead
product) due to the decrease in stage efficiency. The less efficient stages provide poorer
separation quality, hence the lower recovery of ethane.

Task 4
QUESTION: What is the required section diameter?

2.644 m (8.676 ft)

QUESTION: What is the total section height?

9.754 m (32 ft)

QUESTION: What is the section pressure drop?

133.4 mbar (53.61 inH2O 60̊F)

5 - 23
6-1
6-2
6-3
6-4
6-5
6-6
 Real Separators Workshop
Files can be found in folder: 03_RealSeparators

Objective
In this workshop, you will review the options for including non-ideal separation
calculations in a given process design problem. The two options studied are a direct
specification of multi-phase carryover from a separator and the calculation of the
carryover based on vessel geometry and inlet conditions. The workshop will also explore
how to model an exit device to mitigate carryover of liquids in the vapor phase product
from a separator.

The Aspen HYSYS Separator unit operation assumes perfect phase separation by default.
However, it can also be configured to model imperfect separation, either by specifying
the carryover or calculating carryover using a built-in correlation.

The real separator calculation ability includes carryover options so that your model better
matches your process mass balance or separator design specifications. When correlation
based approaches are invoked, it also predicts the effect of residence time, vessel volume,
nozzle characteristics, and exit devices on phase separation.

In this workshop, you will review the concepts needed to use these real separator
features. You will focus on using the Aspen HYSYS Real Separator capabilities to model
imperfect separation in a 3-phase oil-water-gas separator. This workshop also includes an
exercise where a demister pad is added to the model as a secondary separation device to
reduce liquid carryover into a vapor product.

This workshop includes the following tasks:

▪ Task 1 – Specifying Carryover Effects

▪ Task 2 – Using Carryover Correlations
▪ Task 3 – Adding a Secondary Separation Device

Task 1 – Specifying Carryover Effects

In real world separators, separation is not perfect; liquid can become entrained in the gas
phase, and each liquid phase may include entrained gas or entrained droplets of the other
liquid phase. In many cases, the vessel internals (i.e. mesh pads, vane packs, weirs, etc.)
are applied to reduce the carryover of entrained liquids or gases.

7-1
The Aspen HYSYS separator unit operations allow you to directly specify what fraction
of each feed phase is entrained in other phases. Product-based specifications are also
allowed. These options provide simple methods that can be used to match your HYSYS
simulation results to your design assumptions, a known material balance, or to field data
from a real separator.

You will begin by looking at phase separation and carryover in the Inlet Sep separator in
your workshop simulation. The Inlet Sep separator is a HYSYS 3-Phase Separator
operation. It produces distinct vapor, oil/organic, and water/aqueous product streams.
This workshop will study the separation taking place in this vessel and explore the
downstream effects of the separation. You will begin by assuming a specified phase
carryover.

1. To begin the workshop, open the case 03-RealSeparatorsStarter.hsc. It should

be available in your course files folder provided by your instructor.

2. View the Main Flowsheet and double-click the Inlet Sep separator.

3. Navigate to the Worksheet tab and check the default separation results.

QUESTION: What is the vapor fraction of the Inlet Sep Vap stream? Is there any liquid
phase (organic or aqueous) flow in the vapor? [Write your answer below]

Recall again that separator operations in HYSYS operate under an assumption of perfect
equilibrium separation by default. This means that no assumption of volume or residence
time is made. The separator will always produce pure vapor, light liquid and heavy liquid
products.

Assume that you know (from a plant mass balance or from a design assumption) that
approximately 1800 kg/h of light liquid (condensate/oil) and 300 kg/h of heavy liquid
(water) is entrained in the vapor product stream. You can specify this in your model and
ensure an accurate mass balance.

4. Select the Rating tab, C.Over Setup form for Inlet Sep separator.

Note: You will see that the Carry Over Model selected by default is the None option. This
indicates no carryover is assumed and perfect separation will result.

7-2
 5. Select Product Basis as the active model and select the Flow radio button to
define the carryover by flow rate.

There will be warning related to Column feed stream, just click ok.

6. Change the basis to Mass and enter the following flow rates:

In This Cell… Enter…

Light liquid in gas 1800 kg/h (3968 lb/hr)

Heavy liquid in gas 300 kg/h (661 lb/hr)

7. Select the Rating | C.Over Results form. This form will show fraction and flow
based carryover results around the separator.

7-3
QUESTION: What is the vapor fraction of the Inlet Sep Vap material stream now?
[Write your answer below]

8. Save your case as 03-RealSeparatorsSpec.hsc.

Task 2 – Using Carryover Correlations

As an alternative to defining imperfect separation amounts, Aspen HYSYS allows gas
and liquid carryover to be calculated by using three different correlations. These
correlations are the Generic, the Horizontal Vessel, and the Profes ProSeparator models.

All the three correlations follow the same basic calculation sequence. First, the program
calculates the initial phase dispersion based on the feed flow through an inlet nozzle. All
three methods assume the inlet dispersion follows a Rossin Rammler distribution.

After this inlet dispersion is calculated, the correlations calculate the carryover after the
primary separation (gravity settling) of each phase in every other phase, i.e. the light
liquid entrained in the vapor, the heavy liquid entrained in the vapor, the vapor entrained

7-4
in the light liquid, the vapor entrained in the heavy liquid, the light liquid entrained in the
heavy liquid, and the heavy liquid entrained in the light liquid.

Finally, based on the separation extent from the previous step, the program calculates the
effect of any installed secondary separation device (e.g., demister pads or vanes) on the
liquid carryover into the vapor product. This is only available in to the Horizontal and
Profes ProSeparator correlations.

The Generic Correlation should be used when your only criterion for separation is
specifying a critical droplet size. Inlet phase dispersion is calculated using a generic
method that ignores the vessel geometry. You specify inlet splits and Rossin Rammler
parameters, which are used to calculate the inlet dispersion. Carryover is calculated by
assuming that all liquid droplets smaller than a user-specified critical droplet size are
carried over into the vapor product.

The Horizontal Vessel Correlations are designed with the horizontal 3-phase separator
in mind. Inlet phase dispersion is calculated using inlet device efficiency (rather than
specified splits) and user-supplied Rossin Rammler parameters. Primary separation has
two contributions: Gas-Liquid and Liquid-Liquid. Gas-Liquid separation is calculated
based on settling velocities of each liquid from the gas and from a residence time of gas
in the liquid. A droplet will be carried over if it does not travel far enough (back to its
parent bulk phase) in the time allowed. The Liquid-Liquid separation is calculated in a
similar way.

The Profes ProSeparator correlations are rigorous but are limited to calculating liquid
carryover into gas. Both light and heavy liquid entrainment is calculated, but no carryover
calculations are done for gas in the liquid phases. Inlet phase dispersion is calculated
based on the inlet flow conditions and the inlet nozzle size. ProSeparator calculates its
own Rossin Rammler parameters using this information, while the primary separation is
based on critical droplet size. The critical droplet size is not user-specified, but calculated
using gas velocity through the vessel.

Rossin Rammler distributions are defined by:

F = exp(–d/dm)z)
Where:
F = fraction of droplets larger than d
dm is related to d95
x = RR index
d95 = 95% of droplets are smaller than this diameter for the specified dispersion
RR Index = exponent used in the RR equation (also known as the “spread parameter”)
Real Separators in Aspen HYSYS

7-5
If desired, you can select a different correlation for each of the calculation steps. If that
was the case, a correlation is specified for each sub-calculation rather than specifying an
overall correlation. Only those parts of the correlation that apply to the particular sub-
calculation will be used. In this exercise, sub-calculations will not be used.

You will explore the Profes ProSeparator correlation via the Inlet Sep separator in your
flowsheet.

9. Return to the Main Flowsheet of your simulation and double-click the Inlet Sep
separator.

10. Navigate to the Rating | C.Over Setup form and choose the Correlation Based
option.

11. Select the Profes ProSeparator correlation as the Overall Correlation.

12. Click the View Correlation button for further customize the correlation-based
approach.

In this case, the Setup | Inlet page can be left as is. The ProSeparator correlations will
calculate the inlet dispersion without the need for further information.

You will not initially have an Exit Device on this separator. That being the case, go to the
Setup | Vap. Exit Device page. Select Mesh Pad and enter a Pad Thickness of 0.0.

7-6
 13. Close the Correlation window and return to the Rating | C.Over Setup form.

Now that a correlation has been identified and its preferences/options defined, you can
move on to provide the dimensions and other details of your vessel.

14. Select the Dimensions Setup radio button.

Enter the dimensions of an available separator vessel that your vendor has can provide.
The goal of the study will be to see if this vessel is compatible with your overall process.

15. Make sure the Vessel Orientation is set as Horizontal, and enter the vessel
dimensions as follows: Length = 5.486 m (18 ft), Diameter = 1.524 m (5.0 ft),
and Light liquid level = 0.762 m (2.5 ft).

7-7
You can keep the default Boot sizing information and leave all other inputs empty. Move
on by clicking on the DP / Nozzle Setup radio button.

16. Enter the following values for the Nozzle Location (i.e. the horizontal distance
from the feed location):

In This Cell... Enter...

Feed Mix 0 m (0 ft)

Inlet Sep Vap 5.029 m (16.5 ft)

Inlet Sep Liq 5.486 m (18 ft)

Inlet Sep Water 4.267 m (14 ft)

7-8
 17. Keep the default values for Nozzle Diameter and Height.

18. Review the results on the Worksheet tab.

QUESTION: What is the vapor fraction of the Inlet Sep Vap stream? [Write your
answer below]

19. Select the Rating tab and click the C.Over Results page. This form presents total
flows or fractions of phase carryover with little detail.

7-9
20. Click the View Dispersion Results button to view the carryover details

21. Save your case as 03-RealSeparatorsCorr.hsc.

7 - 10
Task 3 – Adding a Secondary Separation Device
While the separator studied in the previous task seems to work well enough, your heat
exchanger designer is a bit concerned. The LNG-100 LNG Exchanger brings in the Inlet
Sep Vap stream as its hot side inlet. Based on your correlation-based real separator
calculations, a significant flow of liquid droplets will feed into the exchanger. Your
exchanger designed is concerned about these droplets and their effects at high velocity.

You need to look into using some kind of secondary separation device (i.e. mesh pad,
vane pack, etc.) to try and knock out these liquid droplets. Your target is to remove 99%
of all liquid droplets 50-55 microns (0.05-0.055 mm) in diameter.

22. Open the Rating tab on the Inlet Sep separator and select the C.Over Setup
page.

23. Select the Correlation Setup radio button and click the View Correlation
button.

24. Go to the Setup | Vap. Exit Device page and make sure Mesh Pad is selected.
Enter a Pad thickness of 100.0 mm (4 in).

7 - 11
 25. Go back to the Rating | C.Over Setup form. To check the efficiency of the mesh
pad separation device, you can get more direct results by viewing the correlation.

26. Click the View Correlation button.

27. Select the Results | Exit Dev. Eff’cy form.

QUESTION: Does the 100 mm (4 inch) mesh pad remove at least 99% of the 50-55
micron droplets? [Write your answer below]

28. Save your case as 03-RealSeparatorsMesh.hsc.

7 - 12
Recommended Reading
Knowledge Base Solution 113864
Real Separator User Guide: How to model carry over in separators?

Knowledge Base Solution 132569

Three-phase separator horizontal correlation enhanced in Aspen HYSYS V7.3.1 with
variable feed nozzle location.

7 - 13
Notes:

7 - 14
 Real Separators Solutions
Files can be found in folder: 03_RealSeparators\Solutions

Questions
Task 1
QUESTION: What is the vapor fraction of the Inlet Sep Vap stream? Is there any liquid
phase (organic or aqueous) flow in the vapor?

Vapor fraction = 1.0; No, there are no liquids in the Inlet Sep Vap stream

QUESTION: View the Inlet Sep Vap material stream. What is the vapor fraction of this
stream now?

0.9779

Task 2
QUESTION: What is the vapor fraction in the Inlet Sep Vap stream?

0.9711

Task 3
QUESTION: Does the 100 mm (4 inch) mesh pad remove at least 99% of the 50-55
micron droplets?

Yes, the separation efficiency is 0.9992 for light liquid and ~0.999 for heavy liquid

7 - 15
 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Safety Analysis Environment

Aspen HYSYS: Advanced Process Modeling Topics
EHY202 V10.0

©2009 AspenTech. All Rights Reserved. 1 Aspen Technology, Inc.

 Process Modeling Using Aspen HYSYS Presentation Material

Section Objectives

• Introduce the HYSYS Safety Analysis Environment as a comprehensive, process-wide pressure relief
modeling tool

• Size and rate pressure safety valves (PSVs) for single or multiple relief scenarios

• Demonstrate how to setup and report results from PSV calculations in the Safety Analysis Environment

• Workshop: Perform pressure safety valve (PSV) sizing calculations for various relief scenarios and
generate compliance records

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 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Process Safety

• To assure safe and reliable operation of process equipment, process safety calculations must be
applied

• Situations to consider:
– Startup/shutdown
– Over-pressurization of vessels and piping
– Fires and other emergencies

• Process conditions vary vastly at different locations

– Using hand/spreadsheet calculations for pressure relief is inefficient

• Relief valve sizing capabilities in Aspen HYSYS uses available process data to quickly and reliably size
any pressure relief valves

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 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Safety Analysis Environment

• Perform relief valve sizing and rating calculations in the Safety Analysis Environment
– Introduced in Aspen HYSYS V8.3
– Can be used as an alternative to HYSYS Dynamic Depressuring

• Contains full capabilities for PSV sizing calculation and report generation

• Enter Safety Analysis Environment from Home tab in ribbon or from Environment-selection menu

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 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Pressure Relief Calculations (1)

• Use the Safety Analysis menu to select a unit operation or stream

• Selection designates a PSV to be attached to that object

• PSVs can also be added from the HYSYS ribbon directly onto flowsheet

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 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Pressure Relief Calculations (2)

• Begin by describing the unit operation to be protected by the PSV

– Define operating and design conditions for the equipment
– Conditions may be referenced from simulation results, or user-specified

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 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Pressure Relief Calculations (3)

• Defined relief valves should have at least one associated Scenario

– Scenario describes the relieving calculation methodology, system pressures, and other considerations

• Multiple scenarios can be linked to one PSV

• Allows for selection of an industry-standard PSV orifice

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 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Pressure Relief Calculations (4)

• Select from a listing of available relief scenario types and define the relief valve flow rate

Select relief scenario type;

scenario options will
populate based on selection

Relief flow can be

manually entered,
referenced from
HYSYS flowsheet, or
calculated by
standard models
(i.e. API, etc.)

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 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Pressure Relief Calculations (5)

• Review PSV sizing results from the Scenario

form
– HYSYS will calculate required orifice size
– User defines a selected orifice to determine
remaining results

• Scenarios can be selected for line sizing

calculations
– Use this tool to appropriately size PSV inlet
and outlet piping
– Results can be read in Aspen Flare System
Analyzer to further analysis

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 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Multiple Valve Analysis

• Multiple relief valves may be applied to a selected sizing case, providing numerous benefits:
– Relief rate is too large for a single valve
– Desired orifice cannot be used due to flange rating limitations
– More cost-effective installation of multiple smaller valves
– Accommodate multiple relief rates for multiple scenarios
– Additional capacity in the case of future expansion

• Once the additional valve is added, flow proportions, orifice designations, allowable
overpressure, etc. may be defined for each valve
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 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Storage Tank Protection

• Storage Tank Protection option provides ability to study the need for tank venting due to normal and
emergency venting
– Tank design options governed by API 650 and 620
– Pressure and vacuum protection governed by API 2000, after V8.8 you can select between: 6th Ed., 7th
Ed. And 7th Ed. Annex A

• Valid for tanks with design pressures from atmospheric up to 15 psig

• Results include inbreathing and outbreathing rates and calculated protection device orifice sizes

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 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Documentation Builder

• To assist with generating necessary safety

compliance documents; the Safety Analysis
Environment includes a Documentation Builder
– Based on Microsoft Access

• Provided user has MS Access capability valve

data sheets, calculation summaries, and ISA
forms can be generated
– Forms can be exported to MS Excel

• Internal HYSYS-based reports are also

available

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 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Workshop: Safety Analysis

• Task 1 – Perform a Dual-Scenario Relief Study

• Task 2 – Configure Multiple Valves

• Task 3 – Size a PSV for a Distillation Column

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 Safety Analysis Workshop
Files can be found in folder: 04_SafetyAnalysis

Objective
In this workshop, you will use the Safety Analysis Environment to analyze overpressure
scenarios, determine which contingencies will require pressure relieving devices, size
these devices according to appropriate standards, and generate required documentation.
The Safety Analysis Environment streamlines the workflow for designing overpressure
protection and saves numerous man-hours per project.

With the HYSYS Safety Analysis Environment, you have the ability to seamlessly
transfer process data from the Simulation Environment and make use of it for pressure
relief and other process safety calculations. This workflow greatly speeds up the sizing of
multiple relief devices for a variety of scenarios. Industry standard PSV design
capabilities have been introduced into the Safety Analysis Environment for consistent and
reliable relief valve calculations. This workshop will explore those capabilities.

In this workshop, you will apply the capabilities of the HYSYS Safety Analysis
Environment to perform some more versatile and wider range studies. Namely, you will
explore a dual-scenario relief situation around the Inlet Sep separator. You will also study
an overpressure situation on the Deethanizer column.

This workshop includes the following tasks:

▪ Task 1 – Perform a Dual-Scenario Relief Study

▪ Task 2 – Configure Multiple Valves
▪ Task 3 – Size a PSV for a Distillation Column

Task 1 – Perform a Dual-Scenario Relief Study

The Inlet Sep 3-Phase Separator needs to be outfitted with an appropriate pressure safety
valve (PSV) to handle a few types of potential overpressure situations. Using the Safety
Analysis Environment, you can define these overpressure scenarios all in one convenient
form. Your objective is to find a PSV that can handle the following scenarios: a blocked
outlet control valve, a fire case, and a local power failure.

1. To begin the workshop, open the case 04-SafetyStarter.hsc. It should be

available in your course files folder provided by your instructor.

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The Safety Analysis Environment in Aspen HYSYS makes it easy to use process
conditions from an existing steady state model for use in relief valve sizing calculations.
Since there are full results available around the Inlet Sep separator, you can move on and
pursue the necessary PSV sizing calculations.

2. Enter the Safety Analysis Environment by selecting the Safety Analysis button in
the bottom-left corner of your HYSYS window. (You can also click the Pressure
Relief button in the Home ribbon tab.)

The Safety Analysis Environment contains a unique Home tab menu. This menu contains
selections and options for units of measure, PSV design codes, output documentation
management, and the ability to add a PSV to your model.

3. Click the Home ribbon tab and review the options.

Notice also that the Navigation Pane at the left-hand side of the HYSYS window is
different. The Navigation Pane contains three items: Unit Operations, Unattached
Streams, and Storage Tank Protection. You can use the Unit Operations menu to view all
unit operations in your flowsheet. From these unit operations, you can add a PSV to that
operation.

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There are two ways you can add a PSV to the simulation. Either select the Add PSV icon
on the Home tab of the ribbon and connect it to an appropriate flowsheet object, or right-
click on a unit operation in the Navigation Pane and select and appropriate connection.

4. Expand the Unit Operations menu item In the Navigation Pane.

5. Locate the Inlet Sep menu item and right-click on it.

6. Expand the Create PSV menu item and select the Inlet Sep Vap option. This will
add a PSV to the vapor outlet side of the Inlet Sep separator.

The PSV will now be visibly attached to the Inlet Sep Vap stream out on the Main
Flowsheet of the Safety Analysis Environment.

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7. Double-click the PSV icon on your flowsheet to view the 100 PSV 001 menu.

8. Right-click on the 100 PSV 001 object and select Rename in the Navigation Pane.
Title the PSV as IS PSV 100.

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 9. Back on the Equipment tab of the IS PSV 100 menu, provide design conditions
for the protection unit operation. Begin by entering 40 °C (104 °F) as the Design
Temperature.

10. In the Design Pressure field, assume a value of 37 barG (536.6 psiG).

The design temperature and pressure are the conditions which you would like to protect
the equipment against and should be at or below the maximum allowable operating
temperature and pressure of the equipment in question. By default, the design pressure
will also be transferred to the set pressure of the PSV. You can also input your own set
pressure if you would like it to be different from the design pressure.

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At this point, all minimum required inputs for the protected vessel should be specified.
To size the proposed valve under some relief condition, you must add at least one
Scenario. Scenarios represent overpressure situations, such as a power failure, shut in
control valve, plant fire, etc. You can add as many Scenarios as you wish to a given PSV
and check the valve sizing requirements for each. From those results, you can select a
PSV size that will handle all required scenarios.

11. Select the Scenarios tab of the IS PSV 100 menu, to add scenarios to be
considered by the PSV,

12. Click the Create Scenario button to define a relief valve sizing scenario.

13. Note that a line item has now been added to the PSV window labeled as
Scenario100. Click Create Scenario once more to add another scenario to this
PSV.

14. Select the first scenario, Scenario100, and click the Open Scenario button.

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 15. Rename this scenario as Inlet Sep Blocked CV.

Relief Scenarios cover a wide variety of phenomena. As previously mentioned, this

exercise will cover two scenarios: a blocked outlet control valve and a fire case. Many
other types of overpressure scenarios are possible for a variety of equipment types.

The HYSYS Safety Analysis Environment contains a list of many common relief
scenario types. These can be selected on demand and used to fill in much of the required
input for your Scenario. You also have the ability to manually define a Scenario if greater
user control is needed.

16. Click the pull-down menu on the Scenario Type field and select the Blocked
Outlet option.

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This scenario will assess the pressure relief requirements in the case of a failure of an
outlet control valve on the Inlet Sep Vap stream. Assume that this valve fails closed, and
the vapor phase flow from the Inlet Sep needs to be relieved.

17. To set the flow rate of relieving fluid (equivalent to the Inlet Sep Vap flow rate),
click the Reference radio button at the bottom of the form. This will call in the
flow rate via the Reference Stream of the PSV (in this case Inlet Vapor).

18. Select Reference for the Relieving Temperature drop-down menu.

Selecting “Reference” for the relieving temperature and flow means that the steady-state
process stream conditions will be transferred to the PSV sizing calculations. These inputs
can also be overridden with user-defined values. Safety calculations are highly subjective
with regards to how conservative you would like your analysis to be. Also, for many
categories of emergency scenarios, there is little industry consensus on how the required
relieving flow should be determined. Therefore, it is up to you to check and ensure that
the inputs to the program are reasonable and follow your organization’s design criteria
and standards. The exercises in this workshop should merely serve as an introduction to
the workflow and are not meant to provide design guidelines.

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19. Click the Edit button next to the Relieving Pressure field. Keep the Allowable
Overpressure as 10% of Set Pressure and click OK.

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 20. Click the Edit button next to the Total Backpressure field. Specify a pressure of
2.2 bar (31.91 psi) for the Variable Superimposed BP. This assumes some
backpressure on the PSV due to other relieving PSVs in the system. Click OK
when finished.

The backpressure is the pressure at the outlet of the PSV. There are three components to
backpressure: constant superimposed backpressure, variable superimposed backpressure,
and built-up backpressure. These three terms are summed to obtain the total
backpressure.

Backpressure is an important factor when designing relief devices. Excessive

backpressure can prevent the PSV from properly opening and cause chattering, which can
damage the valve. A separate program, Aspen Flare System Analyzer, can be used to
model flare networks and calculate the backpressures on your relieving devices.

21. Back on the Scenario Setup form, HYSYS should inform you that the calculation
is complete. The Valve Results table in the top-right corner of the window should
show the Calculated Orifice area.

QUESTION: What is the calculated Orifice area for the Blocked CV Scenario? [Write
your answer below]

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 22. Choose the orifice size that corresponds to the next size larger than your
calculated orifice area, which is 23.225 (M).

23. Return to the IS PSV 100 menu and highlight the Scenario101. Click Open
Scenario to view it.

This next scenario will account for a potential fire case around the Inlet Sep. Define this
scenario using the following data:

In this cell… Enter

Scenario Name Inlet Sep Fire

Scenario Type General | Fire

For fire scenarios, HYSYS can make use of API 521 RP methodologies, which apply to
vessels with either vapor, liquid, or multi-phase inventories. It is important to make sure
the Scenario references the proper material stream that best represents the feed into the
protected unit operation. HYSYS provides several methods for calculating the required
relieving flow. Depending on the phase(s) present in the initial inventory, the program
will populate the calculation method with appropriate options.

In this case, the feed to the Inlet Sep (Feed Mix) should be accessed as the reference
stream. Since this is a multi-phase mixture, the API 521 calculation will propose either
the Wetted API, Semi-Dynamic Flash, or Supercritical models. Consult the Help for
documentation regarding these methods.

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24. Ensure that Wetted (API) is selected for the Calculation Method.

25. Click the Override checkbox next to the Reference Stream field, select the Feed
Mix stream and click OK.

Note that the Required Relieving Flow is calculated using the Wetted (API)
method.

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26. Make sure the Drainage & Firefighting parameter is set as Absent and the
Calculate Latent Heat? parameter is set as Yes.

27. Define the vessel size in the Vessel Parameters section. The Diameter should be
1.524 m (5 ft), Vessel Tan/Tan should be set at 5.486 m (18 ft), and assume a
Liquid Level of 0.6096 m (2 ft).

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The scenario should be solved.

QUESTION: What is the Calculated Orifice area for the Inlet Sep Fire? [Write your
answer below]

28. Select an Orifice to satisfy this calculated size. Is it larger or smaller than the
orifice needed for the Blocked CV scenario?

29. Save your case as 04-DualScenario.hscz

30. Save your case as a compound file. When you work with the Safety Analysis
Environment, the program will generate an .mdb and .hsc file. These two files
must be maintained together to avoid losing work. To avoid complications with
file handling, you can save your case as a Compound File with the .hscz
extension. This will zip the .mdb and .hsc files into one file for convenience.

Task 2 – Configure Multiple Valves

After performing the PSV sizing calculations for the Blocked Outlet and Fire scenarios of
the Inlet Sep, it should be clear that the Blocked Outlet scenario requires a much larger
PSV orifice than the Fire scenario. Since the vessel must be protected against both
scenarios, a PSV must be selected to handle the worst-case pressure relief. This could
cause a problem with the Fire scenario as the PSV would be grossly oversized. This could
lead to valve chatter and other undesirable behaviors.

The HYSYS Safety Analysis Environment offers a capability to set up multiple relief
valves for a given sizing case. This approach allows for split flow from an overpressure
situation into multiple PSVs. As a result, the combined area of the two valves could
support the larger relief scenario (Blocked Outlet in this case), while the smaller of the
two valves could support the lower flow scenario (Fire Case).

31. Click the checkbox for Sizing Case on the Blocked Outlet scenario on the
Scenarios tab. This sets the Blocked Outlet scenario as the relief situation
used for final valve sizing. The sizing case must be the scenario with the
highest required flow.

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 32. Move to the PRD Data tab and click the Add PRD button.

The relief system should now be configured with two relief valves in parallel to
accommodate the Inlet Sep relief flow.

33. Select the Rating tab, to configure the size and characteristics of the multiple
valves.

API 521 permits a 5% increase in the set pressure of the secondary valve. The relieving
material first opens the primary valve due to the lower set pressure. If the relief flow
overloads the capacity of the primary valve, the pressure in the system increases and
opens the secondary valve.

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The idea behind multiple-valve sizing is to find orifice sizes which meet the required
orifice areas of all scenarios without oversizing any orifice for any given scenario. As a
rule-of-thumb, the percent orifice area used should not fall below 30% as this can result
in chattering. However, industry standards vary on this lower limit.

34. For IS PSV 100 A, select the orifice 5.064 (H), and for IS PSV 100 B, select the
orifice 18.406 (L)

The PSV calculation should now be complete.

QUESTION: Analyze the results of the multiple-valve analysis. What happens in each of
the two scenarios?

Explore any of the other Results on the Rating tab. You can view various rating estimates
using the Displayed Rating Estimates field.

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 35. Save your case as 04-SplitPSV.hscz

Task 3 – Size a PSV for a Distillation Column

The Deethanizer column contains a full reflux condenser that requires some overpressure
protection. Namely, you wish to study the effects of a reflux failure on the overhead
accumulator of the column setup. You can use the Safety Analysis Environment to apply
a PSV to the Deethanizer column overhead.

Once you select an appropriate PSV orifice size, you will apply the Line Sizing option in
the Safety Analysis Environment to size inlet and outlet piping from your selected PSV.
HYSYS can check for any excessive pressure losses in this piping. You will conclude by
documenting your results with the Documentation Builder option in the Safety Analysis
Environment.

36. Return to the Main Flowsheet in the Safety Analysis Environment. Select the
Home tab in the ribbon and click the Add PSV icon.

37. Point and click on the stream 12 arrow to add a PSV to that stream. There should
be a small blue box you can click to make the connection.

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 38. Double-click the PSV icon that now appears on your Main Flowsheet.

39. On the PSV Equipment tab, enter a Design Temperature of 30 °C (86 °F) and a
Design Pressure of 28 barG (406.1 psiG).

40. Move to the Scenarios tab and click the Create Scenario button. Select the
scenario and click the Open Scenario button to view its input form.

Specify the following settings on the Scenario Setup form:

In this cell… Enter

Scenario Name Reflux Fail
Scenario Type Distillation Column/Tower | Reflux Failure
Relieving Flow Method Reference
Relieving Temperature Manual – 12 °C (53.6 °F)

QUESTION: What is the Calculated Orifice diameter? Which Selected Orifice would
be the best choice for this PSV? [Write your answer below]

41. Double-click on 100 PSV 001, which is attached to stream 12 on the flowsheet.
Return to the Scenarios menu and select this Reflux Failure scenario as the Sizing
Case.

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 42. Move to the PRD Data tab and change the Valve Type to a Pilot Operated valve.

The Safety Analysis Environment also offers line sizing capabilities. You can use this
feature to define PSV inlet and outlet piping specifications and ensure that they are
adequately sized to handle the flow.

43. Click the Line Sizing tab in the PSV window.

44. Keep the same sizes as the PSV inlet and outlet flanges for the connecting piping.
Enter the following pipe specifications:

In this cell... Enter...

In Line Nominal Diameter 3 in
In Line Pipe Schedule Sch. 40
Out Line Nominal Diameter 4 in
Out Line Pipe Schedule Sch. 40
Flow Rate Method Rated (area)

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The constraints for the line sizing calculations can be accessed by clicking the Constraint
Setting button. You can modify limits for inlet piping pressure drop, outlet pipe average
velocity, and outlet pipe exit velocity.

The Line Sizing feature also allows you to consider the length of inlet and outlet piping,
along with any fittings on those lines. Check the Calculate Equivalent Length checkbox
to access options for calculating equivalent lengths of the inlet and outlet piping.

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45. Click the Calculate Equivalent Length checkbox and view the options that
appear at the bottom of the form:

46. Enter the following piping details for the inlet and outlet lines from the PSV:

In this cell… Enter

PSV Inlet Line
Pipe Length 0.3 m
Nozzle Exit 1
PSV Outlet Line
Pipe Length 6m
Ball Valve 1
Elbow – 90 Degree Standard 2
Tee – Three Way Straight Through 1

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QUESTION Are there any concerns with the inlet piping configuration? Outlet piping
configuration? [Write your answer below]

47. Save your case as 04-ColumnPSV.hscz

To properly document and present results of PSV sizing calculations, many standard
forms are required to meet various regulatory and compliance requirements. The HYSYS
Safety Analysis Environment includes a Documentation Builder reporting environment to
help you generate these reports. The Document Builder is based on Microsoft Access
functionality, which must be installed on your computer in order to utilize.

48. Make sure you are viewing either the Home tab or the Reports tab in the ribbon.

49. Click the Documentation Builder icon.

Allow a moment for the Documentation Builder to load. Once it is available, you should
see the following menu:
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 50. Click the View icon, under the Process Data Sheets section. Use the arrow keys
at the bottom of the form to scroll through the pages of the report. After browsing
the process conditions, close the form.

51. Click and select the View ISA Form S20.53 button, under the Mechanical Data
Sheets section

52. Click on PRD Booklet Switchboard and click on Summary Data this will show
you the different reports you can have through Documentation Builder.

Browse through any other forms and reports in the Documentation Builder that you might
want to check out.

The Reports tab in the HYSYS Safety Analysis Environment ribbon contains links to
some additional reporting capabilities. The Built-in HYSYS Reports are set up as
follows:
• Calculation Sheet – Opens a calculation report of the scenario in the context of the
valve, or of the valve in the context of the scenario.

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 • Relief Load Calculation – A report pertaining to the Relief Load section within
the relief scenario.
• Line Sizing – Reports the key line sizing data pertaining to the line sizing
calculation (note that for single-phase flow situations, like Line Sizing report is
included with the Calculation Sheet report).
• Equivalent Length – Reports any data from the piping equivalent length
calculation, provided it was initiated during the Line Sizing calculation.

Browse through any of these built-in reports that you like. Use the arrows in the
Reporting window to move from one page to the next. You can zoom in on any of the
reports by right-clicking and choosing the Zoom option. These reports can easily be
printed as well.

Recommended Reading

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Knowledge Base Solution 140063
Jump Start Guide: Relief Sizing in Aspen HYSYS and Aspen Plus V8.6

Knowledge Base Solution 140065

Jump Start Guide: Multiple Relief Valve Analysis in Aspen HYSYS and Aspen Plus

Knowledge Base Solution 140066

Jump Start Guide: Storage Tank Protection in Aspen HYSYS and Aspen Plus

Knowledge Base Solution 140064

Fire Overpressure Analysis in Aspen HYSYS and Aspen Plus

Notes:

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9 - 26
 Safety Analysis Solutions
Files can be found in folder: 04_SafetyAnalysis\Solutions

Questions
Task 1
QUESTION: What is the calculated Orifice area for the Blocked CV Scenario?

18.67 cm2

QUESTION: What is the Calculated Orifice area for the Inlet Sep Fire?

3.227 cm2

QUESTION: Select an Orifice to satisfy this calculated size. Is it larger or smaller than
the orifice needed for the Blocked CV scenario?

The selected orifice has an area of 5.064 cm2 (H). This is smaller than the orifice for the
Block CV scenario, which required a 23.22 cm2 (M) orifice.

Task 2
QUESTION: Analyze the results of the multiple-valve analysis. What happens in each of
the two scenarios?

The fire care scenario has a lower required relieving flow. During this scenario, only IS
PSV 100 A opens and reaches 63.73% capacity used.

During the blocked outlet scenario, a much larger relieving flow is encountered. This
causes IS PSV 100 A to reach 100% capacity, and the remaining flow opens IS PSV 100
B and uses up 68.38% of its capacity.

Task 3
QUESTION: What is the Calculated Orifice diameter? Which Selected Orifice would
be the best choice for this PSV?

Calculated Orifice area = 4.365 cm2; Selected Orifice = 5.064 (H)

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QUESTION: Are there any concerns with the inlet piping configuration? Outlet piping
configuration?

The inlet piping checks out OK; the outlet piping shows OK

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 Aspen Rate-Based Distillation (Aspen RateSep) Introduction

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 Optimization Workshop
Files can be found in folder: 05_Optimization

Objective
In this workshop, you will make use of your Turbo Expander/Fractionation plant
simulation to introduce a pair of optimization techniques and to describe their
corresponding applicability. A Spreadsheet has been created for you, which contains a
user-defined cost calculation to calculate revenue, operating costs, and profit. You will
examine certain operating parameters, determine the impact of these operating parameters
on process economics, and then leverage the optimization tools to find an optimal
operating point.

First, you will further apply the Spreadsheet operation in Aspen HYSYS to define an
objective function for the Original Optimizer and find the maximum profit for the
process. Then, you will apply the Hyprotech SQP Optimizer to the same problem. By
trying both optimization techniques, you can test out their relative functionalities.

Aspen HYSYS contains a multi-variable steady state Optimizer tool. Once a flowsheet
has been built and a converged, the Optimizer can be used to find the operating
conditions that will minimize or maximize an Objective Function. The HYSYS Original
Optimizer has its own Spreadsheet to define the objective function and any constraint
expressions to be used. This gives the flexibility of constructing objective functions to
minimize utility usage, maximize profit, minimize exchanger UA, etc.

The Hyprotech SQP Optimizer will be presented as an alternative to the Spreadsheet-

based Original Optimizer. The Hyprotech SQP uses a sequential quadratic algorithm.
This algorithm can be used to solve complex problems containing many variables and
constraints and objective function elements (cost and profit items).

This workshop includes the following tasks:

▪ Task 1 – The Original Optimizer

▪ Task 2 – Hyprotech SQP Optimizer

Task 1 – The Original Optimizer

Optimization in steady-state Aspen HYSYS requires an iterative calculation that can be
tricky to converge. To help improve the convergence of the Optimization, it is useful to
tighten the convergence of any iterative objects within the flowsheet.

11 - 1
Before configuring the Original Optimizer, tighten the tolerance parameters for the two
column models and the LNG Exchanger. This should improve the accuracy of the
solution obtained via the optimization tools.

1. To begin the workshop, open the case 05-OptimizerStarter.hsc. It should be

available in your course files folder provided by your instructor.

2. Reset the stream 2 temperature at -62 °C (-79.6 °F) and the stream 5 pressure at
2800 kPa (406.1 psia).

3. Open the property view for the LNG Exchanger LNG-100 and change the
Tolerance value to 1.0 E-06 on the Design | Specs page.

4. View the Demethanizer column and change the Heat/Spec Error Tolerance to
1.0 E-06 on the Parameters | Solver page.

5. View the Deethanizer, set both the Equilibrium Error Tolerance and
Heat/Spec Error Tolerance to 1.0 E-06 on the Parameters | Solver page.

There are several optimization terms which will be used frequently in this portion of the
workshop.

• Primary Variables correspond to flowsheet variables whose values are

manipulated in order to minimize or maximize the objective function. You set the
upper and lower bounds for the primary variables and these are used to set the
search range. Only user-specified process variables (i.e. blue numbers) can be
used as Primary Variables.

• The Objective Function is the function which is to be minimized or maximized.

The function has to be defined within or referenced by the Optimizer Spreadsheet.
This allows the user a great deal of flexibility in defining the function.

• The Constraint Functions are inequality and equality functions that are defined
in the Spreadsheet. In solving the Objective Function, the Optimizer must also
meet any constraints that are defined by the user.

In your case, you want to maximize the total profit while achieving a Reid Vapor
Pressure (RVP) of 1380 kPa (200 psia) from the liquid outlet of the Demethanizer
column. You also need to limit the power drawn from the K-100 Expander to 50 kW. The
revenues from the plant are based on the Deethanizer products and the associated costs
are for power and waste water disposal. The profits are defined as the difference between
revenues and costs.

6. To invoke the Optimizer, select Optimizer under the Analysis section on the
Home tab of the Ribbon, or press F5 on the keyboard.

11 - 2
Note: The Optimizer is not a unit operation block and it will not show up on the
flowsheet. It is only available for steady state calculations and cannot be used inside a
Sub-Flowsheet.

The Optimizer window should now appear.

7. Select Original for the Data Model.

8. Go to the Variables tab, and click on the Add button to add the Process
(Adjusted) Variables used in the optimization.

The optimization calculation will utilize the same independent variables used in the Case
Study from the previous workshop.

9. Add the first of these variables: Stream 2 | Temperature.

10. Continue by adding the second independent variable, Stream 5 | Pressure.

11. Back on the Optimizer Variables form, set the Low Bound for the temperature at -
70 ºC and the High Bound at -40 ºC.

12. Define the pressure Low Bound at 2500 kPa and the High Bound at 3475 kPa.

11 - 3
 13. Check your Adjusted (Primary) Variables against the image below:

Note: Reasonable upper and lower bounds are important. Use values which can be
achieved in your actual design. In other words, do not set boundaries for a variable that
are less/more than what is available at your plant.

The Optimizer has its own Spreadsheet for defining the Objective Function and any
constraints. Primary Variables may be imported and functions defined within the
Optimizer Spreadsheet. This spreadsheet has the same capabilities as the standard
Spreadsheet operation.

14. Click the Spreadsheet button at the bottom of the Optimizer view to open the
Optimizer Spreadsheet.

15. Select the Optimizer Spreadsheet Parameters tab and make sure the Units Set is
SI.

16. Move to the Spreadsheet tab.

If the Profit Analysis spreadsheet were not pre-configured, you would have to add all the
process economic calculations to the new Optimizer Spreadsheet. But since all needed
economic variables are readily available, you can reference them within the Optimizer
Spreadsheet.

Since it is not possible to copy variables from one Spreadsheet and paste them into
another (i.e. all the variables will be pasted as numbers only, with no links to the
associated variables), you will import only the Temperature of stream 2, the Pressure of
stream 5, and the calculated Profit Value to the Optimizer Spreadsheet. The remaining
variables will be left in the existing Profit Analysis spreadsheet.

17. Enter the following labels into the Optimizer Spreadsheet:

Cell... Label…
A1 Stream 2 Temp

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 A2 Stream 5 Pres
A4 Profit - $/hr

18. Import the variables in the table below into the Optimizer Spreadsheet. Recall
you can import variables into a Spreadsheet in a variety of ways – use the
approach you prefer.

Cell... Object... Variable...

B1 Stream 2 Temperature
B2 Stream 5 Pressure
B4 Profit Analysis D9: Profit

After all of the necessary variables have been imported, the Spreadsheet should resemble
the following figure:

19. Close the Optimizer Spreadsheet and go to the Functions tab on the Optimizer
window.

The Functions tab in the Optimizer property view contains two groups: The Objective
Function and The Constraint Functions. This is where you will reference the item to be
optimized and any constraints that must be honored.

20. Click the drop-down menu in the field adjacent to the Cell entry in the Objective
Function group and select cell B4. Notice that the Current Value of the Objective
Function will be provided automatically.
11 - 5
 21. Select the Maximize radio button.

Recall that you wish to maintain a Reid Vapor Pressure in the Demethanizer column
bottoms at 1380 kPa (200 psia) and that the K-100 Expander power must be capped at 50
kW. The RVP constraint is already achieved by the column algorithm as a specification
and therefore does not need to be defined in the Optimizer. The K-100 Expander power
limitation, on the other hand, must be defined.

22. Click the Add button to add a constraint on the Functions tab of the Optimizer.

23. Open the Optimizer Spreadsheet once again. In cell A6, type in the label: K-100
Power. In cell A7, type in K-100 Power Limit.

24. Add an import in cell B6 to QK-100 | Power. In cell B7, type in 50. This value
will represent the 50 kW power limitation on the K-100 Expander.

25. Check your constraint inputs to the Optimizer Spreadsheet:

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 26. Close the Optimizer Spreadsheet and return to the Optimizer Functions tab. In the
space for your added constraint, click in the LHS Cell field and select cell B6. For
the RHS Cell field, select cell B7.

27. Ensure the condition of the constraint shows B6 to be less than B7, as the
calculated value of the K-100 power must be less than the 50 kW limit

Note: When a constraint is defined, the Constraint Function is multiplied by the Penalty
Value. The higher the Penalty Value, the more weight is given to that constraint.

28. Go to the Parameters tab and select the Mixed method as the scheme for the
optimizer.

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 29. Tighten the Tolerance to 1.0 E-06.

30. Keep the defaults for other parameters:

31. Click the Start button at the bottom of the form to begin the optimization. Allow
a few moments for all iterations to complete and the optimization algorithm to
converge. Note: The Optimizer may fail to find a solution with these initial
guesses. If that happens, click the Start button again. This will pick up where it
left off from the last iteration and should find a solution.

QUESTION: What is the maximum profit? What is the stream 2 temperature and stream
5 pressure at this maximum? [Write your answer below]

QUESTION: Are there any concerns with the simulation at this optimum state? [Write
your answer below]

32. Save your case as 05-OriginalOpt.hsc

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Task 2 – Hyprotech SQP Optimizer
The Hyprotech SQP Optimizer uses a sequential quadratic programming (SQP)
algorithm. This algorithm can be used to solve complex problems containing many
independent variables and constraints as well as complex objective function elements
(cost and profit items).

The Hyprotech SQP requires the use of the Aspen HYSYS Derivative Model Analysis
feature to hold all the data used to define the Optimizer variables, constraints, and the
objective function. The first step in setting up an SQP optimization problem is creating a
Derivative Analysis.

33. Continue with the HYSYS file you were utilizing at the conclusion of the last task
of this workshop.

34. Reset the original conditions in the material streams 2 and 5. Set the temperature
of stream 2 as -62 °C (-79.6 °F) and the pressure of stream 5 as 2800 kPa (406.1
psia).

35. Click on the Model Analysis folder in the Navigation Pane, then click Add and
select a Derivative Analysis. Alternatively, select the Model Analysis icon in the
Home tab of the Ribbon and select Derivative.

The Derivative Analysis property view appears.

11 - 9
The first step in setting up the Derivative Analysis is to define its scope. The Derivative
could govern a handful of unit operations, entire flowsheet, or just a single unit operation.
This provides some flexibility in that you can choose to optimize only a portion of your
overall model. This flexibility is just one of the enhancements the SQP Optimizer offers
over the Original Optimizer.

36. Click the Operation button found near the top of the Derivative Analysis form.

37. Choose the Flowsheet Wide option in the Object Filter group box near the
bottom-left corner.

38. Click the right-pointing arrows button in the middle of the form. FlowSheetWide
should then appear under the Scope Objects list.

39. Click Accept List when finished.

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The next step is to define the independent variables that the Optimizer will adjust/vary in
order to optimize the objective function. In the SQP Optimizer, these independent
variables are referred to as Optimization Variables, or OptVars. For this task of the
workshop, the optimization variables will be the same as for the previous task (Stream 2
Temperature and Stream 5 Pressure).

All Derivative Analysis variables (i.e. Optimization Variables, Constraint Variables, and
Objective Function variables) can be added directly from the Variables tab of the
Derivative Analysis window. There is a drop-down list in the top-right of the window
that allows you identify each one of these variable types. Clicking the Add button when
one of these options are visible adds one of those variable types to the Derivative
Analysis. There are four options: Process Constraints (ProcCons), Optimization Variables
(OptVars), Objective Function (ObjFunc), and State Variables (StateVars).

40. Select OptVars from the variable selection pull-down menu and click the Add
button. A variable selection menu should then appear.

41. Browse for Stream 2 as the Object, and Temperature as the Variable. Click Done
when finished.

An Optimization Variable is now created (Stream 2 Temperature) and has been added
into the Derivative Analysis. You can see your variable when viewing the Variables |
Config. view from the left-side menu. The new variable is given a default name,
OptV100. However, you can edit the variable name to a more descriptive term directly
from this form.

42. Make sure you are viewing the Variables | Config page of the Derivative
Analysis and rename the variable Chiller Exit Temp.

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In this Variables | Config. window, note that it is the Object Name column that lets you
modify the name of the created variables. In addition, the Attached Object and Property
columns are also displayed in the view, as well as the current value of the variable. These
indicate the flowsheet location of the variable.

The left-side menu on the Derivative Analysis window contains various views for each
selected variable type:

Option Description
All All Properties
Input Properties requiring user input
Output Calculated and outputted values
Results Solution results

The items on the Input form for optimization variables are: Optimize Flag, Minimum,
Maximum, Range (optional), Global Minimum and Global Maximum. The Global items
are appropriate only for real-time applications and can be left at the same values as the
Minimum and Maximum.

The Optimize Flag works in conjunction with the Optimizer to expose desired variables.
When the optimization problem is being set up, this flag is evaluated for each variable. If
the flag is false (un-checked), then the variable is not exposed to the Optimizer and the
value remains at its starting value for the duration of the solution. This allows you to
easily switch between optimization problems by turning variables and constraints on and
off.

The value for the variable Range is used in the calculation of a perturbation (i.e. the range
multiplied by the perturbation factor). If none is provided, the span (maximum -
minimum) is used for the calculations. Typically, this is left blank.

For this workshop exercise, you need to add all the remaining optimization variables.
Remember that only user defined variables can be selected as they must be available for
adjustment during the optimization.

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 43. Click the Add button with the OptVars option selected in the variable type drop-
down list.

44. Select stream 5 | Pressure and rename the new variable as Exp Exit Pres on the
Variables | Config. Form.

Your completed list of optimization variables should be as shown below:

Note: In case you added the wrong variable, or added one too many variables, you can
go back and delete anything that is unneeded. Simply double-click on the unneeded
variable and a separate window should appear. Click Delete on that new window.

45. Select the Variables | Input from the left-side menu.

46. Complete the Minimum and Maximum values for each of the variables.

Minimum Variable Maximum

-70 ºC Chiller Exit Temp -40 ºC
2500 kPa Exp Exit Pres 3460 kPa

47. Check your bounds against the image below:

The SQP Optimizer is able to solve constrained optimization problems. In the workshop
case, it will be necessary to maintain some power requirements within certain limits.
These limits will be added to the Derivative Analysis as constraint-type variables.

11 - 13
The SQP Optimizer treats all constraints as ranged constraints. This means that the value
of the constraint should lie between the minimum and maximum at solution. The Scale
value can be considered as an approach or as the boundary around the minimum and
maximum values that defines whether the constraint is active, or violated. This
information is reported during and after the solution as the status of the constraint.

It is a requirement that at least one constraint be defined when using the SQP Optimizer.
In your case, you will provide two constraints: the first will limit power produced by the
K-100 Expander at 50 kW; the second will limit the total power consumption of the
process at 6500 kW.

48. Select ProcCons (process constraint) as the variable type from the variable-type
selection menu in the top-right corner. Then click Add.

49. Choose QK-100 | Power and click Done in the variable selection window.

You should see the added variable under the Constraints/Objective Function tab of the
Derivative window. Look in the Process Constraint | Config. form and it should be
available.

50. Rename the newly added constraint to Expander Power.

51. Select the Process Constraint | Input view and define the minimum expander
power as 0 kW and the maximum value as 50 kW.

52. Set the Scale value to 1.0.

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 53. Click the Add button once again to add another constraint (ProcCons) variable.

This constraint will represent the total power of the process. This was calculated in your
Profit Analysis Spreadsheet. Select the proper variable most likely cell B7) and click
Done.

54. Rename the variable as Total Power, on the Process Constraint | Config form.

55. Move to the Process Constraint | Input form and set the Minimum to 0 kW and
the Maximum as 6500 kW. Make sure the Scale is set as 1.0.

Objective Function variables are installed individually, which facilitates the calculation of
the gradient during the course of Jacobian evaluations. Alternatively, an Objective
Function can be built in a Spreadsheet operation, with a single cell representing the

11 - 15
results and having a single Objective Function object attached to this result cell. This
approach aligns with your case as you have already computed the Profit of your process
in the Profit Analysis Spreadsheet.

All the variables with an associated cost or revenue may be entered on the Constraints/
Objective Function tab. The Hyprotech SQP Optimizer can either minimize or maximize
the Objective Function. Objective Function variables also include a Price input.
Typically, this Price value is set as positive for a credit and negative for a debit. Most
frequently the Price term is used when defining the Objective Function inside the
Derivative Analysis. In your case, you will just make sure the Price is a positive value
and you will choose to maximize the function. But in theory, you could set the Objective
Function as a negative, and set the Optimizer to minimize – but this is a bit backwards!

Every single objective function variable will have its current value multiplied by the
associated cost/revenue. The Jacobian will modify the individual values that will result in
a global optimum based on the sum of all the values from the list.

56. Click the Add button with the ObjFunc option selected to add an objective
function variable.

57. Browse for the Profit Analysis Spreadsheet as the Object, with D9: Profit as the
Variable. Click Done when finished.

The SQP Optimizer will be configured to maximize the objective function, so you must
ensure that the profit value that it sees is positive. This is achieved by giving it a price of
1.0.

58. Move to the Objective Function item in the left-side menu. Rename the
Objective Function variable as Profit.

59. Make sure the Price value reads as 1.0.

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Now that the optimization variables, constraints, and objective function have been
identified and defined, you are done with the Derivative Analysis. Recall that the purpose
of the Derivative Analysis is to hold and organize all the SQP Optimizer variables. The
actual settings for Optimization and numerical/convergence related items, are still
coordinated through the Optimizer menu.

60. Go back to the Optimizer window by selecting it from the Home tab of the
Ribbon, or pressing F5 on your keyboard.

61. Select Hyprotech SQP as the optimizer configuration, On the Configuration tab.

62. Click the Hyprotech SQP tab and select Maximize from the Objective Function
drop-down menu in the Setup group box. This option indicates that the objective
function defined in the SQP Derivative Analysis will be maximized.

63. Click on the Select Utilities to Run button in the bottom-left corner. In the pop-
up window select the check box next to the Derivative-FlowSheetWide utility to
activate it. Then close the pop up window. Check your settings against the
following image:

11 - 17
 64. Move to the Monitor tab so you can follow the optimization calculations as they
run. Then click the Start button to run the Optimizer.

65. Save your case as 05-SQPOpt.hsc.

QUESTION: What is the Profit value as derived from the SQP Optimizer? [Write your
answer below]

QUESTION: Are both constraints honored? What is the calculated K-100 Expander
power? Total power? [Write your answer below]

11 - 18
Recommended Reading
Knowledge Base Solution 109315
In the optimization problem, what is the difference in treatment of a constraint vs. a hard
constraint?

Knowledge Base Solution 109976

User Unit Operation to specify (and optimize) column feed location

11 - 19
Notes:

11 - 20
 Optimization Solutions
Files can be found in folder: 05_Optimization/Solutions

Questions
Task 1
QUESTION: What is the maximum profit? What is the stream 2 temperature and stream
5 pressure at this maximum?

Profit = 1110.3 $/hr; Temperature = -40.0 °C; Pressure = 3475 kPa

QUESTION: Are there any concerns with the simulation at this optimum state?

Yes – two problems stand out on the flowsheet

1) There is a pressure rise across VLV-100; the optimum pressure might be too high
2) The K-100 Expander power calculates as a small negative number; this affects the
K-101 Compressor – whose power is linked to the Expander

Task 2
QUESTION: What is the Profit value as derived from the SQP Optimizer?

1109.6 $/hr

QUESTION: Are both constraints honoured? What is the calculated K-100 Expander
power? Total power?

Yes; K-100 power = 0.145 kW; Total power = 3662.7 kW

11 - 21
 Aspen Rate-Based Distillation (Aspen RateSep) Introduction

Reactors
Aspen HYSYS: Advanced Process Modeling Topics
EHY202 V10.0

©2011 AspenTech. All Rights Reserved. Page 1 Aspen Technology, Inc.

 Aspen HYSYS: Process Modeling Additional Topics Presentation

Lesson Objectives

• Introduce the available reactor unit operation models in Aspen HYSYS

• Create chemical reactions and reaction sets

• Workshop: Model a simplified synthesis gas production flowsheet using a variety of reactor types

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©2011 AspenTech. All Rights Reserved. 2 Aspen Technology, Inc.

Reactor Types (1)

• Yield Shift
– Calculates product compositions based on physical property shift data entered by user

• Conversion
– Specify reaction stoichiometry and conversion; outlet composition calculated

• Equilibrium
– Specify reaction stoichiometry and define equilibrium constant; outlet composition calculated

• Gibbs
– Minimize Gibbs free energy of system to determine outlet equilibrium composition; no reaction stoichiometry required

3 © 2017 Aspen Technology, Inc. All rights reserved.

©2011 AspenTech. All Rights Reserved. 3

Reactor Types (2)

• CSTR
– Specify stoichiometry and define kinetic rate constant
– Contents assumed to be completely mixed (i.e. no temperature/concentration gradients); outlet conditions calculated

• PFR
– Specify stoichiometry and define kinetic rate constant
– Assumes stream passes through reactor in plug flow; outlet composition calculated

• Note: The Tank, Separator, and Three Phase Separator unit operations can also handle reactions

4 © 2017 Aspen Technology, Inc. All rights reserved.

Note: Please mention that refinery reactors are not covered because they are covered in EHY150

©2011 AspenTech. All Rights Reserved. 4

Conversion Reactions

• Conversion Reactions
– Supply a percentage conversion for each reaction
– Can be temperature invariant or dependent
– Can override default conversions locally within reactor

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©2011 AspenTech. All Rights Reserved. 5

Equilibrium Reactions

• Equilibrium Reactions
– Define the equilibrium constant (Keq), which can be temperature invariant, temperature dependent, or calculated
from Gibbs free energy data
– To simulate an equilibrium reaction at a departure from equilibrium, enter a fractional approach to equilibrium or a
temperature approach value
– When using a temperature approach, Keq is calculated at a different temperature; the heat of reaction will
determine in which direction (i.e. forwards or backwards) the reaction will depart
– Use the Library option to access pre-defined reactions

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©2011 AspenTech. All Rights Reserved. 6

Kinetic Reactions

• Kinetic
– Arrhenius parameters for forward and reverse reaction are required
– Reaction order exponents entered with stoichiometry

• Heterogeneous Catalytic
– Generalized Yang and Hougen form

r 
kinetic term  potential term 
adsorption term 
• Simple Rate
– Similar to kinetic reaction, however the reverse rate expression is derived from equilibrium data

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©2011 AspenTech. All Rights Reserved. 7

Tips for Defining Reactions

• Available components for reactions reference the simulation Component Lists

– Be sure to account for all reactants and potential products when building your component list

• Stoichiometric Coefficients
– Products are positive, reactants are negative

• Positive heat of reaction indicates an endothermic reaction

– Input of heat required for energy balance

• Negative heat of reaction indicates an exothermic reaction

– Removal of heat required for energy balance

• Reactions can be phase specific

– Useful when rate of reaction is different for each phase

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©2011 AspenTech. All Rights Reserved. 8

Specifying Reaction Sets (1)

• Create reaction sets and add the desired reactions to each reaction set

• Define individual reactions or add existing reactions to the reaction set

• Attach each reaction set to a Fluid Package

– In order to attach a reaction set to a reactor, the reaction set must be attached to the associated Fluid Package
– When a reaction set is added to a particular Fluid Package, components missing from the Fluid Package are added
to its respective component list

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©2011 AspenTech. All Rights Reserved. 9

Specifying Reaction Sets (2)

• All active reactions must belong to a Reaction Set; these Reaction Sets are linked to reactor unit
operations

• You can reuse reactions in multiple Reaction Sets

• Priority of reactions in a reaction set is determined by rank

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©2011 AspenTech. All Rights Reserved. 10

Synthesis Gas Production (1)

• Synthesis Gas Production

– A simple Synthesis Gas production facility will be modeled
– Synthesis gas (comprised of hydrogen along with carbon dioxide, carbon monoxide, and nitrogen) is used as a fuel
source, an intermediate for chemical production, and in production of synthetic petroleum

• Reforming Reactions:
– CH4 + H2O  CO + H2 CH4 + 2H2O  CO2 + 4H2

• Combustion Reactions:
– CH4 + O2  CO2 + 2H2O 2C2H6 + 7O2  4CO2 + 6H2O
– C3H8 + 5O2  3CO2 + 4H2O

• Water Gas Shift Reactions

– CO + H2O CO2 + H2

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©2011 AspenTech. All Rights Reserved. 11

 Aspen HYSYS: Advanced Process Modeling Topics Reactors

Synthesis Gas Production (2)

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 Aspen HYSYS: Process Modeling Additional Topics Presentation

Workshop: Reactors

• Task 1 – Isolate the Natural Gas Feed

• Task 2 – Set up Reactions and Reaction Sets

• Task 3 – Build the Synthesis Gas Process

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©2011 AspenTech. All Rights Reserved. 13 Aspen Technology, Inc.

 Reactors Workshop
Files can be found in folder: 06_Reactors

Objective
In this workshop, you will simulate a Synthesis Gas Production facility. This will
introduce you to the reaction modelling capabilities of Aspen HYSYS. You will define
chemical reactions and reactor unit operation models in Aspen HYSYS. You will also
work with various logical operations (Set, Spreadsheet, and Adjust models) to automate
certain specifications and meet targets in your model.

The production of synthesis gas is an important step in the production of many different
chemical products. The main role of the synthesis gas plant is to convert natural gas,
primarily methane, into hydrogen. Synthesis gas is comprised of hydrogen, nitrogen,
carbon dioxide, and carbon monoxide. Typically, the synthesis gas product is further
refined by removing carbon dioxide and carbon monoxide through amine contact,
pressure swing adsorption, or some other means. This workshop will focus on the
reaction portion of the process.

In most synthesis gas plants, four reactors are used. However, in your simulation, five
reactor unit operations will be used. This is because the combustion reaction, typically a
single vessel, will be modelled as two reactors in series with two different reaction types.
The first stage of the combustion will involve conversion-type reactions, while the second
will involve equilibrium reactions.

This workshop includes the following tasks:

▪ Task 1 – Isolate the Natural Gas Feed

▪ Task 2 – Set up Reactions and Reaction Sets
▪ Task 3 – Build the Synthesis Gas Process

Task 1 – Isolate the Natural Gas Feed

One of the products from your turbo expander/NGL fractionation plant is a high-pressure
gas product mainly consisting of methane. It has been decided to split off a fraction of
this gas product for sale to a neighboring plant with a synthesis gas production facility.

In your HYSYS simulation, you need to isolate the desired amount of natural gas flow for
transmission to the Syn Gas Plant. The natural gas also needs to be brought to the proper
conditions for the Syn Gas process. Set up these items in the first part of the workshop.

13 - 1
 1. Start with the supplied starter file 06-ReactorsStarter.

Viewing the Main Flowsheet, locate the portion with the K-101 compressor, material
stream 15, the Export Gas compressor, and the Sales Gas stream.

2. Break the connection between stream 15 and Export Gas Comp.

3. Add a Tee to the flowsheet and define it as follows:

In This Cell... Enter...

Connections

Name Gas Split

13 - 2
 Inlet 15

Outlets Export Gas

To Syn Gas

Worksheet

To Syn Gas, Molar Flow 90 kgmole/h (198.4 lbmole/hr)

4. Connect the Export Gas stream to the inlet of the Export Gas Comp.

The Synthesis Gas Process will be modeled within your current workshop flowsheet. But
to avoid having a Main Flowsheet window with excessive amounts of operations and
streams, you will make use of the Sub-Flowsheet modeling capability of Aspen HYSYS
and place the Syn Gas Process inside its own Sub-Flowsheet. This should help to better
organize your growing process model!

5. Add a Blank Sub-Flowsheet from the Object Palette and select the option to
Start with a Blank Flowsheet.

6. Double-click the Sub-Flowsheet icon that now appears on your Main Flowsheet.
On the Connections tab rename the Sub-Flowsheet as Syn Gas Plant.

7. List To Syn Gas as an External Stream in the Inlet Connections list.

8. Click the Sub-Flowsheet Environment… button to view the Syn Gas Plant Sub-
Flowsheet.

The To Syn Gas material stream you see in the Sub-Flowsheet is a mixture of light and
medium hydrocarbons, CO2, nitrogen, and a small amount of water. This stream needs
to be compressed and heated to certain conditions before it can enter the synthesis gas
reactor train.

It is also important to consider the components present in the stream and how/if they
will react in the synthesis gas process. To Syn Gas is primarily composed of methane,

13 - 3
 but there are also small amounts of ethane, propane, butanes, etc. As part of the
synthesis gas process, combustion of methane is a reaction of interest. If methane is
present and combusted, it can be reasoned that any other hydrocarbons would be
combusted as well. To simplify the reaction definitions, you will remove any
hydrocarbons heavier than propane prior to feeding the gas into the first reactor, thus
ignoring the combustion of any heavier hydrocarbons.

9. Add a Compressor to the Syn Gas Plant Sub-Flowsheet. Set it up with the
following connections and conditions:

In This Cell... Enter...

Connections
Name Natural Gas Comp
Inlet To Syn Gas
Outlet HP Gas
Energy QK-NGC
Worksheet
HP Gas, Pressure 3500 kPa (507.6 psia)

The HP Gas stream needs to feed into the reaction section at 370 °C.

10. Add a Heater to Heater model to do this.

In This Cell... Enter...

Connections

Name Natural Gas Heater

Inlet HP Gas

Outlet Hot HP Gas

Energy Q-NGH

Parameters

Delta P 0 kPa (0 psi)

Worksheet

Hot HP Gas, Temperature 370 °C (698 °F)

The last step before setting up the reactions and reactors is to remove all hydrocarbons
heavier than propane from the reactor train feed.

11. Use the HYSYS Component Splitter unit operation to do this. It can be added
from the Separator section of the Object Palette and define it as follows:

13 - 4
 In This Cell... Enter...
Connections
Name Remove Heavy HC
Inlet Hot HP Gas
Overhead Outlet Natural Gas
Bottoms Outlet Heavy HC
Energy Q-Split
Parameters
Stream Specifications Use Stream Flash Specifications
Equalize All Stream Pressures
Natural Gas Temperature 370 °C (698 °F)
Heavy HC Temperature 370 °C (698 °F)

12. Move to the Design | Splits form. For Natural Gas, enter a split of 1.0 for
Nitrogen, CO2, Methane, Ethane, Propane, and H2O.

13. Enter a split of 0.0 for all other species.

14. Save your case as 06-Reactors.hsc.

13 - 5
Task 2 – Set up Reactions and Reaction Sets
The definition of any chemical reactions to be considered within a HYSYS flowsheet
must be made in the Properties Environment. All tools and features needed for specifying
various classes of reactions are available there. Once the reactions have been defined,
specified, and properly assigned to the active Fluid Package they can be used in the
Simulation Environment. One more thing to consider – make sure any components
needed for the reactions are specified in your component list!

15. Return to the Properties Environment. Note that there are two Component Lists
and two Fluid Packages present.

The Basis-1 Fluid Package and Component List-1 are the active items for the Syn Gas
Plant Sub-Flowsheet.

16. Select Component List-1 from the Navigation Pane.

17. Add the following components to the list: CO, Hydrogen, and Oxygen.

18. Stay in the Properties Environment, select the Reactions folder on the Navigation
Pane and click the Add button to create a new Reaction Set or you can click on
the Reactions icon on the Home tab of the ribbon.

13 - 6
19. Click back on the Reactions folder in the Navigation Pane. Under the Name field,
re-name the created Reaction Set (Set-1) as Combustor Rxn Set.

20. Select the Combustor Rxn Set folder in the Navigation Pane; then click the Add
Reaction button at the bottom of the Reaction Set window.

21. Make sure the Reactant Source is set as HYSYS and choose Conversion as the
reaction type. Then click Add Reaction.

13 - 7
 22. Click Add Reaction four more times. You should have five reactions total (Rxn-
1, Rxn-2, Rxn-3, Rxn-4, and Rxn-5) when finished. Then you may close the Add
Reactions window.

23. Expand the Combustor Rxn Set folder in the Navigation Pane; you should see
the five reactions listed. Click on Rxn-1 to view it.

In the Stoichiometry Info section, list out Methane, H2O, CO, and Hydrogen. List their
stoichiometric coefficients as -1.0, -1.0, 1.0, and 3.0 respectively.

24. Make sure Methane is shown as the Base Component in the Basis section and
enter a percentage conversion of 35% in the Co field.

25. Check your inputs for Rxn-1 against the figure below:

13 - 8
26. Continue by defining the other four Conversion reactions in the Combustor Rxn
Set. Use the following characteristics:

Name Reaction Base Component Co

Rxn-2 CH4 + 2H2O  CO2 + 4H2 Methane 65

Rxn-3 CH4 + 2O2  CO2 + 2H2O Methane 100

Rxn-4 2C2H6 + 7O2  4CO2 + 6H2O Ethane 100

Rxn-5 C3H8 + 5O2  3CO2 + 4H2O Propane 100

27. Return to the Combustor Reaction Set folder and click on the Add to FP button.

28. Select the Basis-1 Fluid Package, and then click Add Set to Fluid Package.

13 - 9
29. Click back on the Reactions folder in the Navigation Pane and click Add to add a
new Reaction Set.

30. Rename this Reaction Set as Shift Rxn Set.

31. Click the Add Reaction button in the Shift Rxn Set and choose Equilibrium as
the reaction type.

32. View the created reaction (Rxn-6) and click the Library tab.

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33. Highlight the reaction with the form: CO + H2O11  1
 1CO2 + H2. Click Add
Library Rxn to set this as the reaction for Rxn-6.

34. Go back to the Shift Rxn Set folder and click on the Add to FP button. Add this
reaction set to the Basis-1 Fluid Package.

35. Return to the Reactions folder in the Navigation Pane and add one more Reaction
Set; title it Reformer Rxn Set.

36. View the Reformer Rxn Set menu and click the pull-down arrow on the Add
Reaction button. Select the Existing Reaction option.

13 - 11
37. Add Rxn-1 and Rxn-2 to the Reformer Rxn Set.

38. Click on the Add to FP button to attach this set to the Basis-1 Fluid Package.

39. Save your case.

13 - 12
Task 3 – Build the Synthesis Gas Process
There are six different reactor unit operation types in Aspen HYSYS. By using
combinations of these six operations, virtually any real reactor can be modeled given
sufficient information. The six reactor types available are Conversion, Yield Shift,
Equilibrium, Gibbs, Continuously Stirred Tank Reactor (CSTR), and a Plug Flow
Reactor (PFR).

The Conversion Reactor calculates the composition of the outlet stream given the
stoichiometry of all the reactions occurring and the conversion of the base component.
The Yield reactor does the same given an implied yield for each component.

In the case of the Equilibrium Reactor, it determines the composition of the outlet stream
given the stoichiometry of all reactions occurring and the value of the equilibrium
constant (or the temperature dependent parameters that govern the equilibrium constant)
for each reaction. The Gibbs Reactor valuates the equilibrium composition of the outlet
stream by minimizing the total Gibbs free energy of the effluent mixture.
In the case of the CSTR, it assumes that the reactor contents are completely mixed in
computing the outlet stream conditions, given the stoichiometry for all the reactions that
are occurring and the kinetic rate constant (or the temperature dependence parameters for
determining the kinetic constant) for each reaction. The PFR assumes that the reaction
stream passes through the reactor in plug flow in computing the outlet stream
composition, given the stoichiometry of all the reactions occurring and a kinetic rate
constant for each reaction.

For the synthesis gas reactions, you will be making use of the Conversion and
Equilibrium reactor models. Follow the steps below to build these reactors and their
associated operations.

40. Click on the Simulation Environment button.

If your flowsheet appears to be un-solved, return to the Parent Flowsheet (click Go to

Parent) in the Flowsheet/Modify ribbon tab) and allow the Main Flowsheet to solve.

Hint: You may see a message about a fatal error. Check your Demethanizer column to
ensure that it solved. If it did not, open the column property view and click the Reset
button, and then Run it. If you receive a Consistency Error message, just click to make
the Solver Active. The Main Flowsheet should solve at this point. If you have any further
problems check with your instructor.

41. Locate the Syn Gas Plant Sub-Flowsheet icon. Double-click on it and re-enter the
Sub-Flowsheet.

42. Create three new Material Streams with the following inputs:

13 - 13
 Name Reformer Air Combustor
Steam Steam

Temp., °C (°F) 250 (482) 16 (60.8) 250 (482)

Pressure, kPa (psia) <empty> <empty> <empty>

Molar Flow, kgmole/hr 240 (529.1) 90 (198.4) 140 (308.6)

(lbmole/hr)

Set 100% - H2O 79% - N2 100% - H2O

Molar Composition 21% - O2

The first reactor in the synthesis gas plant is the Reformer. This reactor will be modelled
as a Conversion Reactor and it will utilize the Reformer Reaction Set.

43. Add the Conversion Reactor into the flowsheet from the Reactor section of the
Object Palette

44. Name this reactor Reformer and attach Natural Gas and Reformer Steam as
inlets.

13 - 14
 45. Name the Vapour Outlet Combustor Feed and the Energy stream as Reformer-
Q.

Even though there will be no liquid flow from this reactor, you still must create a liquid
phase product stream for flowsheet connectivity purposes.

46. Name the liquid product stream as Reformer LP

47. Move to the Reactions | Details page and select Reformer Rxn Set as the
Reaction Set. This will automatically connect the proper reactions to this reactor.

13 - 15
48. Select the Conversion% radio button.

49. Select Rxn-1 from the Reaction drop down menu and change the Co value to be
40%.

50. Do the same for Rxn-2 and choose Co to be 30%.

13 - 16
Note: You have the ability to alter reaction specifications from their original settings
after you install them in a reactor block. This capability provides helpful flexibility to
adjust reaction data without having to go back into the Properties Environment.

51. Enter a temperature of 930 ºC (1706 ºF) for the outlet stream Combustor Feed,
on the Worksheet tab.

At this stage, the first reactor will not solve yet. The pressure is unknown in the Reformer
Steam stream. As you build the flowsheet, you will use a logical operation (Set) to define
this pressure. But you will add the next reactor in the sequence first.

The second reactor in a synthesis gas plant is the Combustor. The Combustor will be
modelled as a Conversion reactor and an Equilibrium reactor in series. This is because
Conversion reactions and Equilibrium reactions cannot occur in reactors of the opposite
type. That is, conversion reactions cannot be associated with equilibrium reactors, and
vice versa.

52. Add another Conversion Reactor with the following data:

13 - 17
 In This Cell... Enter...
Connections
Name Combustor
Inlets Air, Combustor Steam,
Combustor Feed
Vapour Outlet Mid Combust
Liquid Outlet Combustor LP
Reactions | Details
Reaction Set Combustor Rxn Set
Rxn-1 Conversion 35% (Default)
Rxn-2 Conversion 65% (Default)
Rxn-3 Conversion 100% (Default)
Rxn-4 Conversion 100% (Default)
Rxn-5 Conversion 100% (Default)

Recall that you did not enter any pressure data for the Air or Steam streams. To provide
the necessary pressures, you will use a pair of logical operations to call in known pressure
data on another material stream. First you will use the Set operation to link stream
pressures, and then you will apply the Spreadsheet operation as an alternate approach.

53. Add a Set operation.

54. Select Reformer Steam | Pressure as the Target Variable. Define Natural Gas
as the Source Object.

13 - 18
On the Parameters tab and ensure the Multiplier is set at 1 and the Offset at 0. For this
pressure association, you want equality between the two stream pressures, so a multiplier
of 1 and an offset of 0 will result in this type of relationship.

You also need to set the pressures of Air and Combustor Steam. Rather than take the Set
operation approach and require two additional unit operations, you can use a Spreadsheet.
You will find that a single Spreadsheet can do the same calculations as two Set
operations.

55. Add a Spreadsheet from the Object Palette. Rename it as Pressure Assignment.

56. Move to the Spreadsheet tab and provide the following labels:

In This Cell... Enter...

A1 Natural Gas Pressure
A3 Air Pressure
A4 Combustor Steam Pressure

57. Right-click in cell B1 and select the Import Variable option. Select Natural Gas
| Pressure from the variable browser menu.

58. Enter the following formulas into the cells indicated:

In This Cell... Enter...

B3 =B1*1
B4 =B1*1

59. Right-click on cell B3 and select the Export Formula Result option. Select Air |
Pressure from the variable browser menu.

60. Do the same for cell B4, exporting this result to the Combustor Steam material
stream.

QUESTION: What is the calculated heat flow/duty of the Reformer? [Write your
answer below]

As mentioned before, the Combustor is to be modelled as a Conversion reactor followed

by an Equilibrium reactor, so you must still add the Equilibrium side of the combustion.

13 - 19
The Shift Reactors will also be modelled as Equilibrium Reactors. Therefore, a total of
three equilibrium reactors must be added to complete the flowsheet.
61. Add an Equilibrium Reactor from the Columns section of the Object Palette
with the following information:

In This Cell... Enter...

Connections
Name Combustor Shift
Inlet Mid Combust
Vapour Outlet Shift1 Feed
Liquid Outlet Combustor Shift LP
Reactions | Details
Reaction Set Shift Rxn Set

QUESTION: What is the calculated outlet temperature from the combustion section of
the reaction train? [Write your answer below]

62. Add another Equilibrium Reactor with the following information:

In This Cell... Enter...

Connections
Name Shift1
Inlet Shift1 Feed
Vapour Outlet Shift2 Feed
Liquid Outlet Shift1 LP
Energy Stream Shift1-Q
Reactions | Details
Reaction Set Shift Rxn Set
Worksheet
Shift2 Feed, Temperature 450 °C (842 °F)

QUESTION: How much energy must be removed from Shift1 to meet the desired outlet
temperature? [Write your answer below]

13 - 20
 63. Add the third and final Equilibrium Reactor with the following information:

In This Cell... Enter...

Connections
Name Shift2
Inlet Shift2 Feed
Vapour Outlet Synthesis Gas
Liquid Outlet Shift2 LP
Energy Stream Shift2-Q
Reactions | Details
Reaction Set Shift Rxn Set
Worksheet
Synthesis Gas, Temperature 400 °C (752 °F)

QUESTION: What is the molar flow rate of hydrogen in the Synthesis Gas stream?
[Write your answer below]

QUESTION: What is the molar flow rate of nitrogen in the Synthesis Gas stream?
[Write your answer below]

QUESTION: What is the ratio of hydrogen to nitrogen in the Synthesis Gas stream?
What is the easiest way to calculate this value in HYSYS? (E.g. not using a calculator,
MS Excel, etc.) [Write your answer below]

13 - 21
 64. Save your case.

To control the temperature of the product stream leaving the combustion section (the
Shift1 Feed stream), the flow rate of steam to the Combustor Conversion reactor
operation is manipulated. It is desired to have an outlet temperature from the combustion
section of 930 °C (1706 °F). The steam flow can be adjusted manually until the desired
temperature is achieved. However, this might take a lot of time and will not be
automatically updated if something else in the process were to change. You can utilize
the Aspen HYSYS Adjust operation to adjust/manipulate one variable until the desired
condition is met for a define target variable

65. Select the Adjust unit operation from the Object Palette and add it to the
flowsheet.

66. Attach the Adjusted Variable, Target Variable, and Target Value as shown:

13 - 22
 67. Enter the Step Size as 20 kgmole/h (44 lbmole/hr) and define a Minimum of 0
kgmole/h on the Parameters tab.

A second Adjust operation will be used to manipulate the Air stream flow rate. This is
important as the Air flow rate determines the ratio of hydrogen to nitrogen in the
synthesis gas product. You want this value to be set at 3.5.

Since a component ratio is not a normally available HYSYS variable, it needs to be

calculated within the program and made available to other features. This is a great
opportunity to apply the HYSYS Spreadsheet. So if you did not already create a
Spreadsheet to compute the hydrogen-to-nitrogen ratio in the Synthesis Gas stream, you
might want to do so now!

13 - 23
 68. Add another Adjust operation to your flowsheet. Select Air | Molar Flow as the
Adjusted Variable.

69. Select the Spreadsheet operation containing your calculated hydrogen-nitrogen

ratio as a Target Variable, and the cell containing that value as the Variable.

70. Set a Specified Target Value of 3.5.

71. Enter the Step Size of 20 kgmole/hr (44 lbmole/hr and ensure a Tolerance of
0.001 is specified on the Parameters tab

In certain HYSYS simulations, solving two Adjust operations might result in the two
interfering with one another while they solve. This is because changing either one of the
adjusted variable may affect both target variables simultaneously. To prevent this
interference, the Adjusts can be set to solve simultaneously by using a different solution
algorithm.

72. Select the Simultaneous Solution checkbox on the Parameters tab of the ADJ-1
operation.

13 - 24
 73. Repeat this procedure for the second Adjust operation, ADJ-1.

74. Start the simultaneous Adjusts solving by clicking the Start button on either
Adjust block.

You can also open the Adjust Manager menu from the Home tab in the ribbon. The
Adjust Manager allows you to manage and solve any and all simultaneously solved
Adjust blocks through a common interface.

75. Start the Adjust calculations and allow them to solve. You may need to initiate the
calculations from one Adjust rather than the Adjust Manager to get things started.

QUESTION: What is the new Air stream molar flow rate? [Write your answer below]

QUESTION: What is the molar flow rate of the Synthesis Gas product? [Write your
answer below]

13 - 25
 76. Save your case.

Challenge Exercise
The Gibbs Reactor can be used to represent both equilibrium and constrained equilibrium
systems. Replace the Shift2 Equilibrium Reactor with a Gibbs Reactor, and specify the
same outlet temperature

1. Make the appropriate changes to the Gibbs Reactor to ensure the results are
consistent with the original simulation.

2. Save your case as 06-ReactorsChallenge.hsc.

13 - 26
Recommended Reading
Knowledge Base Solution 111551
How does HYSYS calculate the energy balance around a reactor?

Knowledge Base Solution 113034

Can I prioritize the reactions in a Conversion Reactor?

Knowledge Base Solution 126847

Equilibrium reactor predicts carbon formation while the Gibbs Reactor does not. Why?

13 - 27
Notes:

13 - 28
 Reactors Solutions
Files can be found in folder: 06_Reactors

Questions
Task 3
QUESTION: What is the calculated heat flow/duty of the Reformer?

2.197 E+07 kJ/h (2.082 E+07 Btu/hr)

QUESTION: What is the calculated outlet temperature from the combustion section of
the reaction train?

723.5 °C (1328 °F)

QUESTION: How much energy must be removed from Shift1 to meet the desired outlet
temperature?

8.234 E+06 kJ/h (7.804 E+06 Btu/hr)

QUESTION: What is the molar flow rate of hydrogen in the Synthesis Gas stream?

338.9157ole/h (747.1735 lbmole/hr)

QUESTION: What is the molar flow rate of nitrogen in the Synthesis Gas stream?

73.1597ole/h (161.2878 lbmole/hr)

QUESTION: What is the ratio of hydrogen to nitrogen in the Synthesis Gas stream?
What is the easiest way to calculate this value in HYSYS? (E.g. not using a calculator,
MS Excel, etc.)

4.633
Use a Spreadsheet; import in hydrogen and nitrogen molar flow rates in Synthesis Gas,
divide them by one another

QUESTION: What is the new Air stream molar flow rate?

117.2kgmole/h (258.4 lbmole/hr)

QUESTION: What is the molar flow rate of the Synthesis Gas product?

13 - 29
875.5 kgmole/h (1930 lbmole/hr)

13 - 30
 Aspen Rate-Based Distillation (Aspen RateSep) Introduction

BLOWDOWN™
Aspen HYSYS: Advanced Process Modeling Topics
EHY202 V10.0

©2011 AspenTech. All Rights Reserved. Page 1 Aspen Technology, Inc.

 Aspen HYSYS: Process Modeling Additional Topics Presentation

Section Objectives

• Use BLOWDOWN™ in Aspen HYSYS to predict process conditions inside vessels and associated
valves during pressure let-downs and emergency scenarios

• Size single pressure safety valves and blowdown valves to safely meet the relief conditions in your
process

• Workshop: Use BLOWDOWN™ Analysis to size a valve for vessel blowdown and rate a relief valve
for a fire case

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 Aspen HYSYS: Advanced Process Modeling Topics Dynamic Depressuring

Blowdown and Vessel Depressurization

• What is blowdown?
– Rapid emergency depressurization of vessel and
equipment
– Regulated by API 521, NORSOK, PED 97/23/etc.

• Why is it done?
– Protect plant assets against the effects of high
pressures or temperatures
– De-inventory hazardous material during plant
emergency • Can the vessel relieve
within safety standards?
• Why simulate? • Where is the temperature
too low?
– Select appropriate vessel materials to ensure vessel • What are the relief loads
will not rupture due to thermal shock & fatigue leaving the vessel into the
flare?
– Risk assessment
– Ensure flare network can handle required flow rates
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 Aspen HYSYS: Advanced Process Modeling Topics Dynamic Depressuring

Legacy HYSYS Depressuring Utility

• Previous depressurization technology in HYSYS

• Downsides:
– Entire system lumped into a single vessel – no inlet and outlet piping elements considered
– Standard Peng-Robinson failed to predict accurate thermodynamic properties during supercritical depressurization
– Model was highly dependent on unknown parameters (PV Work Term and Recycle Efficiencies) to tune the model to
match real-life data

– Gross overdesign due to uncertainties

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 Aspen HYSYS: Advanced Process Modeling Topics Dynamic Depressuring

BLOWDOWN™ Technology in Aspen HYSYS

• Depressurization simulation developed by professors at Imperial College London
– Acquired by AspenTech and initially released in HYSYS V9.0

• Proprietary equation-of-state model with superior thermodynamic predictions for supercritical fluids
– Fully rigorous; no need for tuning parameters like the legacy technology
– Property package only used in BLOWDOWN™ and not visible in the Properties Environment

• Validated against experimental data and also real-world emergency events

– Superior temperature prediction to within 3 Kelvin

• Proven 3-4 times in cost savings

– No need for conservative overdesign and use expensive construction materials

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Using BLOWDOWN™ (1)

Select “BLOWDOWN
and Depressuring”
on the Home ribbon

Then select
BLOWDOWN or
Staggered BLOWDOWN
Having streams in the
Main Flowsheet to
use as a source of
data for BLOWDOWN
may help

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©2011 AspenTech. All Rights Reserved. 6

 Aspen HYSYS: Advanced Process Modeling Topics Dynamic Depressuring

Using BLOWDOWN™ (2)

You can change the Select a template

name if required from the dropdown

Click on Start Analysis to

begin
(This uses a HYSYS Dynamics
License)

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 Aspen HYSYS: Advanced Process Modeling Topics Dynamic Depressuring

Using BLOWDOWN™ (3)

Numbers of
pipes in each
line
General
settings

Update the system configuration based

on your analysis needs

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 Aspen HYSYS: Advanced Process Modeling Topics Dynamic Depressuring

Back in Main Flowsheet – a sub-flowsheet is used for each

BLOWDOWN™ analysis

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 Aspen HYSYS: Advanced Process Modeling Topics Dynamic Depressuring

Using BLOWDOWN™ – Template Parameters

Specify parameters which are
constant for the entire system. Single
vessel template assumptions are
detailed in F1 Help.

Can be specified from a

stream in Main Flowsheet in
Initial Inventory section.

Blue – means
section is complete
Red – missing data

Define system elements

which are in the fire zone.

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 Aspen HYSYS: Advanced Process Modeling Topics Dynamic Depressuring

Using BLOWDOWN™ – Main Vessel Inventory (1)

Live-link to
stream in
simulation

One-time copy
of stream from
simulation

Or manually input
composition

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 Aspen HYSYS: Advanced Process Modeling Topics Dynamic Depressuring

Using BLOWDOWN™ – Main Vessel Inventory (2)

Can copy the stream T,P

to the Template
Parameters tab

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 Aspen HYSYS: Advanced Process Modeling Topics Dynamic Depressuring

Using BLOWDOWN™ –Vessel Definition

Specify key vessel
geometry, heat
transfer information,
and initial conditions.

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 Aspen HYSYS: Advanced Process Modeling Topics Dynamic Depressuring

Using BLOWDOWN™ – Pipes

Specify Pipe geometry,
heat transfer, and initial
conditions

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 Aspen HYSYS: Advanced Process Modeling Topics Dynamic Depressuring

Using BLOWDOWN™ – Orifice

Specify throat diameter

of valve or orifice (from
vendor).
Recommend not to alter
Discharge Coefficient

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 Aspen HYSYS: Advanced Process Modeling Topics Dynamic Depressuring

Component Mapping (Consolidation)

• A key part of the accuracy of the BLOWDOWN™ calculation is the special proprietary thermodynamics
package used

• Limited set of components available for this thermodynamics package

• The time it takes BLOWDOWN™ to solve, and the predictability with which BLOWDOWN solves, is
dependent on the number of components used in the analysis

• For this first release, BLOWDOWN™ restricts the total number of components to 15. AspenTech has
used a component consolidation routine which seeks to capture the consultants’ best practices when
consolidating the number of components

• Therefore need to map the process composition into the BLOWDOWN™ composition

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 Aspen HYSYS: Advanced Process Modeling Topics Dynamic Depressuring

Component Mapping BLOWDOWN™ Components

• Only the 52 components listed here are

supported for BLOWDOWN™ analysis.

• Hypothetical components are not supported

directly – they would have to be mapped on to
these components

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 Aspen HYSYS: Advanced Process Modeling Topics Dynamic Depressuring

Component Mapping

HYSYS tries to automatically

map the HYSYS components in
the feed on to the 52
BLOWDOWN components,
including Hypos

See the Help system

(press F1) for more
details of the mapping
algorithm

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 Aspen HYSYS: Advanced Process Modeling Topics Dynamic Depressuring

Component Mapping

Always check the Mapping form.

Messages will indicate if it has
not been able to map all
components

Can click on Edit Map to

manually edit the mapping

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 Aspen HYSYS: Advanced Process Modeling Topics Dynamic Depressuring

Edit Component Mapping

Select and Sort will let you choose
more possible BLOWDOWN
components for manual mapping

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 Aspen HYSYS: Advanced Process Modeling Topics Dynamic Depressuring

Using BLOWDOWN™ – Run Controls

Specify stop conditions

(Time and Pressure)
Then run the simulation

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 Aspen HYSYS: Advanced Process Modeling Topics Dynamic Depressuring

Using BLOWDOWN™ – Results

Pre-made charts to
highlight valuable
information (temperature,
mass flows, liquid levels)

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Using BLOWDOWN™ – Results
Major findings
(temperature concerns,
final pressure)
highlighted

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©2011 AspenTech. All Rights Reserved. 23

 Aspen HYSYS: Advanced Process Modeling Topics Dynamic Depressuring

V10.0 Improvements

• Added support for free-water phase

– V9.0 assumed that water is fully miscible in the hydrocarbon phase

• New templates added:

• Multi-Vessel Blowdown
– Simulate the effect of multiple discharges into a common flare header system

• Pipeline Pressurization
– Simulate dynamic pressurization of a pipeline and model the effects of the Joules-Thomson effect and heat of
compression

• Staggered Blowdown
– Time and stagger the opening sequence of multiple blowdown valves to reduce the peak flow to a flare header

24 © 2017 Aspen Technology, Inc. All rights reserved.

©2011 AspenTech. All Rights Reserved. 24 Aspen Technology, Inc.

 Aspen HYSYS: Process Modeling Additional Topics Presentation

Workshop: BLOWDOWN™

• Task 1 – Design an orifice for pool fire depressurization scenario

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©2011 AspenTech. All Rights Reserved. 25 Aspen Technology, Inc.

E-Learning Resources
Dynamics and Process Control

• How are PV, SP, & OP defined in the PID

Controller set up?
• What is the PID controller algorithm used by
Aspen HYSYS Dynamics?
• How can you view the list of controllers in the
simulation?
• Aspen HYSYS Dynamics Autotuning Method

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©2011 AspenTech. All Rights Reserved.

 Aspen HYSYS: Advanced Process Modeling Topics Dynamic Depressuring

Additional Training Resources

EHY223
Aspen HYSYS Dynamics:
Introduction to
Dynamic Modeling

https://training.aspentech.com/catalog

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 BLOWDOWN™ Workshop
Files can be found in folder: 07_BLOWDOWN

Objective
Significant challenges arise in the process industry to reduce the capital cost of pressure
relief systems while still ensuring the required safety standards. Simulation is widely used
during the design and revamp of pressure relief systems. Therefore, accurate models are
required. Although conservative approaches are often desirable for safety considerations,
uncertainties and inaccuracies can lead to gross overdesign.

The BLOWDOWN™ software program developed by Professor Stephen Richardson of

Imperial College London and Dr. Graham Saville formerly of Imperial College London
was acquired by AspenTech in 2015. BLOWDOWN™ has been used in hundreds of
studies in oil and gas and chemical companies to identify locations in a system where
temperatures can decline dramatically during depressurization.

BLOWDOWN™ was first incorporated in Aspen HYSYS V9.0 in order to provide an

accurate determination of these low temperatures, which is a critical activity in the design
and operation of every process plant as it can reduce capital cost but more importantly
improve the safety of the plant. Aspen HYSYS V10.0 introduces further enhancements to
BLOWDOWN™, including the modeling of multi-vessel systems, pipeline
pressurization, staggered blowdown, and free water. The V10.0 enhancements are outside
the scope and time constraints for this class.

This workshop will serve as an introduction to BLOWDOWN™, where you will use the
single-vessel template to design an orifice for pool fire depressurization scenario and
simulate a cold case depressurization scenario.

This workshop includes the following tasks:

▪ Task 1 – Design an orifice for pool fire depressurization scenario

Task 1 – Design an orifice for pool fire depressurization

scenario
The Inlet Sep 3-phase separator in your Main Flowsheet has been targeted for some
additional study. First off, you need to size an appropriate blowdown valve for pool fire
depressurization scenario.

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The BLOWDOWN Analysis flowsheet functions similarly to a HYSYS Sub-Flowsheet.
However, unlike a traditional HYSYS Sub-Flowsheets, you cannot add stream
connections between the BLOWDOWN Sub-Flowsheet PFD and the main PFD. Also,
the BLOWDOWN Sub-Flowsheet environment does not use traditional HYSYS solvers.

1. Open 07-BlowdownStarter.

The property package and calculations used to simulate the depressurization system in the
BLOWDOWN Analysis tool are proprietary and distinct from the main HYSYS
simulation. It is not available in the Properties Environment.

2. To add a BLOWDOWN unit, from the Home ribbon tab, under the Safety group,
click the BLOWDOWN and Depressuring button. On the Depressuring form,
click Add | BLOWDOWN Utility. The BLOWDOWN Analysis form appears.

Alternatively, from the Home ribbon tab, from the Safety Analysis group, click the arrow
next to the BLOWDOWN and Depressuring button, then click BLOWDOWN. The
BLOWDOWN Analysis form appears.

3. On the BLOWDOWN Analysis form, change the name to Fire Case. Then, from
the Template drop-down list, select the SingleVessel.blo - Single Vessel
BLOWDOWN Template.

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This template is a pre-configured template with the geometry and connections on the
BLOWDOWN flowsheet for a single vessel with piping.

4. Click the Start Analysis button.

5. On the Design tab of the BLOWDOWN Analysis form, you can set up the layout
of the unit operations in the simulation to fit the process equipment layout.

15 - 3
On this form, select an appropriate Inlet Line, Blowdown Line and Vapor Outlet Line
configuration.

6. For the Inlet Line, select the Without pocket option. This implies that all liquid
in the inlet line segments will drain towards the main vessel.

7. For the Blowdown Line, select the Attached to vessel option, implying that the
blowdown line is attached directly at the top of the vessel.

8. For the Vapor Outlet Line, select Leaves vessel vertically, indicating that the
initial orientation of the vapor outlet line is vertical.

Next, specify Number of Segments for each line. The rows in the Number of Segments
in Lines table change depending on the Inlet Line, Blowdown Line, and Vapor Outlet
Line configurations selected.

9. In this case, you are modeling a single vessel without piping, so set all of the line
segments to 0.

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Note: You can define a maximum of five pipe segments on each line. These inputs are
used to capture pipe diameter or metallurgy changes that can occur along the line. It is
recommended that you add the fewest possible piping segments. The goal is to try to
accurately capture the volume, surface area, and holdup in the equipment upstream of
the orifice. Therefore, only add additional piping segments if there is a significant change
in piping diameter or metallurgy along the line. Otherwise, one piping segment per
required line is sufficient for the analysis. The model assumes no pressure drop upstream
of the orifice.

Next, on the System tab, specify equipment, fluid, and ambient information for all
BLOWDOWN unit operations. Start by specifying Template Parameters which will
apply to the entire template.

10. In the Ambient Air Properties section, specify the Air Temperature
(Temperature of ambient conditions) as 21 °C (70 °F) and Air Speed (Speed of
air) as 2.438 m/s (8 ft/s).

11. Under the Define Fire Zone section, check the box next to Main Vessel.

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Note: These values apply to all unit operations on your BLOWDOWN Sub-Flowsheet.

For now, you will not specify Equipment Conditions Upstream of Orifice. These will
be updated from a HYSYS stream that will be linked in the Initial Inventory section.

Next, you must define the initial inventory in the system at time zero. In the Single
Vessel template, you can specify the inventory of the Main Vessel.

12. Expand Initial Inventory | Main Vessel, on the left-hand side of the System tab.

The composition used in the BLOWDOWN Analysis can be defined either manually, by
linking to a stream on the flowsheet, or by copying and pasting from a stream on the
flowsheet. In this you will choose the Manual option.

13. Select the Manual radio button, then click the Copy from Stream button.

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 14. Select the Feed_Mix_Fire_RP stream on the Select Process Stream dialog box
and then click OK. HYSYS copies the composition of the selected stream.

15. Click the Copy to Initial Conditions button. This button overwrites the Initial
Temperature and Initial Pressure values in the Equipment Conditions
Upstream of Orifice table in the Template Parameters section.

The Template Parameters section will have the icon indicating that you have
specified all of the inputs necessary for the BLOWDOWN run to begin.

Next, you must specify the Vessel Information.

16. Select Fire Zone Vessels in the left-hand pane to specify vessel information on
the Geometry, Heat Transfer and Initial Conditions tabs.

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17. On the Geometry tab provide the following geometry specifications.

Orientation Vertical

T/T Length 5.486 m (18.0 ft)

Cylinder Inner Diameter 1.524 m (5.0 ft)

Wall Material Carbon Steel

Cylinder Wall Thickness 25.40mm (1.0 in)

Head Wall Thickness 25.40mm (1.0 in)

Min Design Metal -20.0 °C (-4 °F)

Temperature
Max Design Metal 648.9 °C (1200 °F)
Temperature

15 - 8
 18. Move to the Simple Fire tab. Make sure Apply to liquid is selected as the Heat
Flux Method.

Note: The Help menu has details about the equation used by the available methods.

19. On the Initial Conditions tab, specify the Initial Liq. Volume Percent (%) as
50% which is the percentage of total volume that is filled by the liquid at the
beginning of the blowdown event.

Next, you must specify the Restriction Orifice Information.

20. For the Restriction Orifice geometry information, provide an orifice Diameter of
12.70 mm (0.50 in) and Discharge Coefficient of 1.0.

15 - 9
Once all of the icons appear as , you can move on to the Mapping tab. Read the
messages regarding component mapping, in particular the message regarding water.

View the component lists (HYSYS simulation components in the left pane and
BLOWDOWN components in the right pane). Observe that water is not automatically
mapped.

Water can either be modeled in BLOWDOWN as miscible in the hydrocarbon phase or

as a separate free-water phase. The component mapping messages provides the
workflows for how to select the water handling options. To model water as a free phase,
you must go back to the System tab and check the “Global Free Water Phase” box. To
model it as miscible in the hydrocarbons, you must manually add water to
BLOWDOWN’s component list and provide the component mapping. HYSYS V10.0

15 - 10
requires you to manually provide a selection to the water handling option to ensure that
special consideration is given to this input.

Modeling miscible water is not recommended since including water in the hydrocarbon
liquid or vapor phase may cause flash problems. If you do not provide a selection, water
will be excluded from the system entirely, which has the advantage of providing the most
conservative temperature predictions in the system. For your case, you will neglect the
presence of water.

Next, you must specify the Halt Conditions. BLOWDOWN can solve and show results
over any time range with second-by-second reporting of events.

You can control the solver’s behavior. On the Run Controls tab, you can define the
simulation time intervals and conditions.

21. Select the Run Controls tab of the BLOWDOWN Analysis form.

22. In the Halt Conditions group, type a halt time of 900 Seconds and halt pressure
of 14.70 psia. The simulation will stop when the first of the two halt conditions is
encountered.

Now the blowdown case has all the necessary inputs for it to be run.

23. To run the BLOWDOWN simulation, either click the Run button from
the BLOWDOW ribbon…

If you do not see the BLOWDOWN ribbon, click on the white background of the
BLOWDOWN flowsheet first.

15 - 11
24. Or on the BLOWDOWN Analysis form, click the Run BLOWDOWN button
on the bottom of the form.

25. When the BLOWDOWN simulation is finished, a message appears in the status
bar, indicating that the simulation run is complete.

26. On the Results Summary tab of the BLOWDOWN Analysis form, you can
review overall system plots and key results or warnings from the simulation.

27. Select the Major Findings page to view major findings from your BLOWDOWN
simulation.

28. Select the Plots page of the BLOWDOWN Analysis form to view in a graphical
format.

15 - 12
QUESTION: What is the Vessel Pressure at the final Halt Time? [Write your answer
below]

QUESTION: What is the Orifice Mass flow rate at the final Halt Time? [Write your
answer below]

29. Save your case as 07-FireCase.hsc

Next, the restriction orifice can be designed in BLOWDOWN using the Adjust unit
operation on the Main Flowsheet.

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30. Go to the halt conditions and set the final pressure as 0. This ensures that the
simulation always ends at the Halt Time rather than at the Halt
Pressure conditions.

31. Select the Run BLOWDOWN on input changes check box at the bottom of the
BLOWDOWN form.

32. Return to the Main Flowsheet using Go to Parent button on the BLOWDOWN
tab. This button is also on the Flowsheet/Modify tab.

33. Add an Adjust block to the flowsheet from the Object Palette.

34. On the Connections tab | Connections page, for the Adjusted Variable, specify
the Orifice Diameter.

35. For the Target Variable group, specify the Final Pressure.

15 - 14
36. For the Target Value group, select the User Specified option and specify 50% of
the Design Pressure which is 1825.015 kPa (250 psig).

37. On the Parameters tab | Parameters page, in the Tolerance field, specify a
tolerance of around 1-10% of your desired final pressure, so specify 4 psi (27.6
KPa) as the tolerance and 0.1 in (2.54 mm) as the Step Size.
15 - 15
 38. Start the Adjust block convergence.

QUESTION: What is the size of the Orifice? [Write your answer below]

39. Save your case as 07-FireCaseOrificeDesign.hsc

15 - 16
Recommended Reading
Knowledge Base Solution 146293
White Paper: BLOWDOWN™ Technology in Aspen HYSYS Validation

15 - 17
 Notes:

15 - 18
 BLOWDOWN™ Solutions
Files can be found in folder: 07_BLOWDOWN\Solutions

Questions
Task 1
QUESTION: What is the Vessel Pressure at the final Halt Time?

1517 KPa (220.1 psia)

QUESTION: What is the Orifice Mass flow rate at the final Halt Time?

1649 kg/hr (3636 lb/hr)

QUESTION: What is the size of the Orifice?

11.338 mm (0.4464 in)

15 - 19
 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Acid Gas Cleaning

Aspen HYSYS: Advanced Process Modeling Topics
EHY202 V10.0

©2009 AspenTech. All Rights Reserved. 1 Aspen Technology, Inc.

 Process Modeling Using Aspen HYSYS Presentation Material

Section Objectives

• Introduce the Acid Gas Property Packages

• Discuss how the Acid Gas Property Packages addresses the challenges of modeling acid gas cleaning
processes such as electrolyte thermodynamics, column non-ideality, and solvent make-up

• Workshop: Model an acid gas sweetening process using mixed amines and study the effect of
introducing a second amine to a blend

2 © 2017 Aspen Technology, Inc. All rights reserved.

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Gas Processing Overview

Gas sweetening step

Meet typical pipeline

specs:
4 ppm H2S
2 mole % CO2

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©2009 AspenTech. All Rights Reserved.

 Aspen HYSYS: Process Modeling Presentation Material

Acid Gas Package (1)

• Acid Gas property package addresses concerns in current property packages and separations
capabilities
– Use to simulate all types of amine-related models

• Acid Gas - Chemical Solvents for amine solvents with Gas-Liquid systems
– Based on Electrolyte NRTL model for electrolyte thermodynamics and Peng-Robinson EOS for vapor phase
– For Amine Solvents: MDEA, MEA, DEA, PZ, PZ+MDEA, DGA, DIPA, Sulfolane-DIPA, Sulfolane-MDEA, TEA

• Acid Gas - Physical Solvents for physical solvents

– Based on PC-SAFT method
– For Physical Solvents: DEPG (Selexol)

• Acid Gas - Liquid Treating for amine solvents with Liquid-Liquid systems

4 © 2017 Aspen Technology, Inc. All rights reserved.

- In the case of physical solvents, HYSYS automatically

selects the Acid Gas – Physical Solvents property package if
DEPG is already present in the component list.

- The Acid Gas - Liquid Treating property package includes the

same required components as the Acid Gas - Chemical
Solvents property package, but only supports a subset of the
amines/amine blends supported by the package.

©2009 AspenTech. All Rights Reserved. 4 Aspen Technology, Inc.

 Aspen HYSYS: Process Modeling Presentation Material

Acid Gas Package (2)

• Select from Fluid Packages folder in HYSYS

Properties Environment
– Required components are displayed upon selection
– CO2, H2S, H2O, various amines and their blends
– If DEPG is already present in the component list,
HYSYS automatically selects the Acid Gas –
Physical Solvents
– The Acid Gas - Liquid Treating property package
supports a subset of the amines/amine blends
supported by the Acid Gas - Chemical
Solvents property package

5 © 2017 Aspen Technology, Inc. All rights reserved.

- In the case of physical solvents, HYSYS automatically

selects the Acid Gas – Physical Solvents property package if
DEPG is already present in the component list.

- The Acid Gas - Liquid Treating property package includes the

same required components as the Acid Gas - Chemical
Solvents property package, but only supports a subset of the
amines/amine blends supported by the package.

©2009 AspenTech. All Rights Reserved. 5 Aspen Technology, Inc.

 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Acid Gas Package (3)

• Include Heat Stable Salts

– Salt species that are present during the amine
treating process
– Serve to decrease efficiency of the system
– Important to include in fluid package for most
accurate property modeling

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©2009 AspenTech. All Rights Reserved. 6 Aspen Technology, Inc.

 Aspen HYSYS: Process Modeling Presentation Material

Amine Reactions

• Heat stable salts and ionic species are produced by a series of equilibrium reactions

• HYSYS Acid Gas Package automatically generates these reactions based on your component list
– Reactions are shown in the Reactions folder of the Properties Environment

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©2009 AspenTech. All Rights Reserved. 7 Aspen Technology, Inc.

 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Acid Gas Modeling Opportunity

• High performance via two calculation models:

– Efficiency based (majority of user community)
Acid Gas
• Rate-based modeling (few expert users) Focus Cleaning
on seamless integration and usability

• Support the following: Efficiency Model Rate-based Model

– CO2 and H2S removal

– Heat stable salts
– Mercaptans and trace components
– Commonly used amines: MDEA, MEA, DEA, PZ,
PZ+MDEA, DGA, DIPA, Sulfolane-DIPA, Sulfolane-
MDEA, TEA
– Physical solvent DEPG

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©2009 AspenTech. All Rights Reserved. 8 Aspen Technology, Inc.

 Aspen HYSYS: Process Modeling Presentation Material

Efficiency Mode

• Distillation and absorber columns have an

additional Acid Gas Package capability

• Column tray and packing information can be

defined to calculate component efficiencies

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 Aspen HYSYS: Process Modeling Presentation Material

Rate-Based Mode (1)

• Column calculations can be converted from the default Efficiency-based calculation to an “Advanced
Modeling” approach

• Efficiency approach only calculates efficiencies for CO2 and H2S

• Advanced Modeling allows for a full, rigorous rate-based model for the entire column
– Better suited for separations including mercaptans, COS, and/or CS2

• Invokes the functionality of Aspen Rate-Based Distillation

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 Aspen HYSYS: Process Modeling Presentation Material

Rate-Based Mode (2)

Change Calculation
Type here

Additional rate-based distillation

settings are available to
configure convergence, reactions
behavior, etc.

Tray/Packing details from

Efficiency mode are maintained

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 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Components Modeled in Different Models

• Advanced Modeling: Mass transfer of all species in the system

– H2S and CO2
– Hydrocarbons
– Mercaptans (methyl and ethyl)
– Trace components (COS, CS2)

• Efficiency Modeling: Mass transfer of H2S and CO2 is calculated at each stage
– Efficiencies of other components such as mercaptans, COS, CS2 can be specified

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 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Acid Gas Separation Results

• The Acid Gas Package will include a dedicated results form in all absorbers and columns

Acid gas
compositions Lean / rich
amine details

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 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Amine Solvent Makeup

• Rich amine from absorption columns are further treated and recycled back for re-use

• However, losses are inevitable as the amine solution recirculates

• Earlier solvent makeup strategies would require accurate initial estimates, broad assumptions, and
additional calculations (i.e. Spreadsheets)
– Prone to convergence issues

• New Makeup unit operation eliminates many of these convergence concerns

– Define material stream connections
– Enter outlet amine solution desired concentration and flow rate
– Makeup block calculates the required solvent balance!

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 Process Modeling Using Aspen HYSYS Presentation Material

Makeup Unit Operation

Select from
Common tab of
Object Palette

Define stream
connections

Enter desired
outlet stream
flow and amine
concentration

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©2009 AspenTech. All Rights Reserved. 15 Aspen Technology, Inc.

 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Mixed Amines

• New Mixed Amines for Acid Gas – Chemical Solvents:

– MEA+MDEA
– DEA+MDEA
– Sulfolane + MDEA + PZ
– MDEA + DEA + MEA

• New Amines for Acid Gas – Liquid Treating

– MEA
– DEA
– MDEA
– DGA
– MDEA + PZ

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 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Acid Gas – Liquid Treating: Liquid-Liquid Extractor Column

• Pre-built column template available on palette

• Models series of equilibrium trays in column

• Analogous to Absorber Column in gas treating workflow

• Restricted to Liquid-Treating package

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 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Liquid-Liquid Treating: Supported Components

• Solvents: MDEA, PZ+MDEA, DGA, DEA, MEA

• Hydrocarbon phase：CH4, C2H6, C3H8, C4H10, C5+ (C5H12, C6H14, etc.)

• Aqueous phase: water, amine (MDEA, PZ+MDEA, DGA, DEA, MEA)

• Acid Gas: CO2, H2S

• Sulfur compounds: CH3SH (methyl-mercaptan), C2H5SH (ethyl-mercaptan), COS (carbonyl-sulfide),

CS2 (carbon di-sulfide)

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 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Liquid-Liquid Treating: Property Method

• ENRTL activity coefficient model modified to support 2 liquid system

• Liquid - Liquid Equilibrium (LLE)

– Hydrocarbon Phase: C2, C3, etch
– Aqueous Phase: Water + Amines
– Binary parameters (Henry constants, NRTL parameters and PR Kijs) between hydrocarbon and water + amine
calculate the equilibrium between the hydrocarbon phase and the aqueous phase

• Acid Gas Solubility/distribution

– Interaction parameters (Henry constants, NRTL parameters and PR Kijs) between the solute and the solvent:
calculate the solubility/distribution of the solute in the two liquid phases

• PR method applied to:

– Vapor stream
– Hydrocarbon rich (HC > 80%)

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©2009 AspenTech. All Rights Reserved. 19 Aspen Technology, Inc.

 Aspen HYSYS: Process Modeling (Oil & Gas Focus) Presentation Material

Workshop: Acid Gas Package

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 Aspen HYSYS Upstream: Modeling Oil & Gas Production Facilities Using the Upstream Option

Workshop: Acid Gas Package - Tasks

• Task 1 – Review the gas-liquid acid gas treating process using MDEA and add MEA

• Task 2 – Run a Case Study to determine the effect of adding MEA

21 © 2017 Aspen Technology, Inc. All rights reserved.

©2009 AspenTech. All Rights Reserved. 21 Aspen Technology, Inc.

 Acid Gas Cleaning Workshop
Files can be found in folder: 08_AcidGas

Objective
Acid gas removal is an important step in the oil and gas industries. Sulfur contaminants
are highly harmful to human health and the environment and can poison and deactivate
catalysts. High levels of CO2 lower the heating value of the products. Therefore, special
consideration must be taken to ensure that the final product meets target levels for sulfur
and CO2.

The industry-standard process for removing contaminants from an acid gas stream
involves treating the gas in an absorber. Sour gas enters the bottom stage of the absorber,
and an amine solution enters the top stage. The amine removes H2S, CO2, and other
contaminants such as mercaptans and sulfides. The overhead product from the absorber
continues on for further gas processing, and the bottoms product (rich amine) enters a
regenerator. The regenerator recovers the amine solution by removing the dissolved
acids, and the lean amine is recycled back to the absorber. Amine will unavoidably be
lost in the process, so a make-up mixer uses feed-forward control to calculate the exact
amount of amine make-up that is required to maintain a constant amine flow rate and
solution strength.

17 - 1
In this workshop, you will simulate the effect of adding monoethanolamine (MEA) to a
methyl diethanolamine (MDEA) gas treatment process. MDEA is highly selective
towards removing H2S, whereas MEA does not allow as much CO2 to “slip” into the
sweet gas stream as MDEA does. Experiments have shown that introducing a mixed
amine solution will combine the strengths of both amines and increase the recovery of
both CO2 and H2S.

This workshop includes the following tasks:

▪ Task 1 – Review the gas-liquid acid gas treating process using MDEA and add
MEAmine
▪ Task 2 – Run a Case Study to determine the effect of adding MEA

Task 1 – Review the gas-liquid acid gas treating process

using MDEA and add MEA.
1. Open the 08-AcidGasStarter.hsc from the workshop folder.

The example model removes H2S and CO2 from sour gas by using MDEA solvent. 10
MMSCFD of acid gas feed (2.5 mol% H2S and 5 mol% CO2) is fed to a high-pressure
absorber, where the acid gases are removed to a sweet gas specification of < 4 ppm H2S.
Acid gases are stripped from the MDEA solvent by a regenerator column at low pressure
and high temperature, and the solvent is recycled back to the absorber column. A makeup
block adds back the solvent that is lost in the process to maintain a constant solvent flow
rate and concentration.

QUESTION: What are the CO2 (mol %) and H2S (ppm) compositions in the Sweet Gas
stream? (Hint: you can find ppm composition levels by going to the Absorber block and
navigating to Performance | Acid Gas) [Write your answer below]

2. Navigate to the Properties Environment. Check which Acid Gas property

method is being used and the list of components added.

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In this case, the Acid Gas – Chemical Solvents is being it used. The Acid Gas -
Chemical Solvents property package was developed with the Peng-Robinson equation-
of-state for vapor phase and the electrolyte non-random two-liquid (ENRTL) activity
coefficient model for electrolyte thermodynamics (Song and Chen, 2009). The package
rigorously accounts for the thermodynamic, chemical, and transport properties of aqueous
amine solutions.

The models support thermodynamic and rate-based removal of CO2 and H2S with major
amine solvents such as MDEA, activated MDEA, DEA, MEA, DGA, etc. The related
contaminants such as heat stable salts, light mercaptans, carbonyl sulfide, and carbon
disulfide are also accounted for. Furthermore, the models support modeling of inert gases,
light hydrocarbon components, and petroleum hypothetical components. The model also
incorporates rate-based kinetics to model reactions that are rate-limited.

Reference papers citations are available in the Help menu.

3. Move to the Component Lists folder to review the component list.

4. Add MEAmine to the existing component list.

17 - 3
 5. Select the Reactions folder in the HYSYS Navigation Pane. You should be able
to review three reaction sets.

6. All required input for the Properties Environment has now been provided. Click
the Simulation button to enter the Simulation Environment.

Select No for the above message. Let the simulation run, this process might take a
couple of minutes.

7. Save your case as 08-AcidGasFluidPackage.hsc.

Once you move to the simulation environment in Active mode, the flowsheet will not
converge. The reason is because the MEAmine concentration is not yet defined.

17 - 4
Task 2 – Run a Case Study to determine the effect of
adding MEA
In this portion of the workshop, you will be studying the effect of adding MEA.

8. Add a Concentration of 0% for MEAmine in the Surge Tank and allow the
flowsheet to converge.

Now you will create the Case Study for determining the effect of adding MEAmine. The
Case Study tool lets you monitor the response of key variables to changes in your

17 - 5
process. The Case Study utility can easily manage hundreds of independent and
dependent variables and allows you to add and re-order variables.

9. Add a Case Study. Either select Case Studies from the Simulation Environment
navigation pane or on the Home ribbon tab, in the Analysis group, click Case
Studies.

10. On the Case Studies form, click the Add button.

11. On the Case Study form, select the Variables Selection tab.

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12. In the Independent Variables section, click the Find Variables button.
The Variable Navigator view appears, allowing you to select from the
following Input variables.

Independent Variables
Surge Tank – Outlet Concentrations (MDEAmine)
Surge Tank – Outlet Concentrations (MEAmine)

13. Select the desired Input variables, and then click Done.

14. In the Dependent Variables section, click the Find Variables button.
The Variable Navigator view appears, allowing you to select from the
following Output variables.

Dependent Variables
Case (Main) – Absorber – Sweet Gas H2S ppm

Case (Main) – Absorber – Sweet Gas CO2 Mole %

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 Case (Main) – Regen Bottoms – H2S Loading

Case (Main) – Regen Bottoms – CO2 Loading

15. After selecting the desired Output variables, click Done.

16. Once you have added the independent and dependent variables, your Case Study
Form should look like below.

Click to move the selected variable up or to move the selected variable down
to rearrange your variables.

17. On the Case Study Setup tab of the Case Study form, from the Case Study Type
drop-down list, you can select one of the following types:

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 Sensitivity: An isolated variable study which examines one variable at a time.
Nested: Examines every possible combination of variable changes.
Discrete: Allows you to specify the values of each variable for each case that you
want to run.
Base & Shift: Lets you set a number of base cases and shifts off of the base cases.

18. For his case, you will select Discrete Case Study Type with 5 States with the
following specifications:

• Vary the MDEAmine Concentration from 45% to 35% in equal

increments of 2.5%
• Vary the MEAmine Concentration from 0% to 10% in equal increments
of 2.5%
• Ensure each case maintains a total amine concentration of 45%

19. Run the Case Study. The Case Study must solve the simulation for each state, and
the simulation contains two columns and a recycle loop. Please be patient as the
Case Study will take a few minutes to converge.

20. You can use the Results tab of the Case Study form to view the case study
results.

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 Select the Transpose results check box to view the cases as rows and the variables as
columns. Click the Send to Excel button to save your results in a .csv format for
further analysis in Excel.

21. You can view case study plots on the Plots tab of the Case Study form. The plots
that appear vary depending on your selection from the Case Study drop-down list
on the Case Study Setup tab.

22. Save your case as 08-AcidGasCaseStudy.hsc.

QUESTION: What happened to the sweet gas H2S and CO2 concentrations in the sweet
gas? [Write your answer below]

QUESTION: What do you observe about the lean amine loading off the regenerator?
What are the implications of these results? [Write your answer below]

17 - 10
Recommended Reading
Knowledge Base Solution 137942
CBT: Getting Started With Acid Gas Cleaning in Aspen HYSYS V8.3

Knowledge Base Solution 140055

Enhancements to Acid Gas Cleaning in Aspen HYSYS

Knowledge Base Solution 140091

Acid Gas Cleaning using a Physical Solvent (DEPG)

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Notes:

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 Acid Gas Cleaning Solution
Files can be found in folder: 08_AcidGas/Solutions

Questions
Task 1
QUESTION: What are the CO2 (mol %) and H2S (ppm) compositions in the Sweet Gas
Stream?

1.100 mol%
3.819 ppm

Task 2
QUESTION: What happened to the sweet gas H2S and CO2 concentrations in the sweet
gas?

The composition of H2S and CO2 both increased, so we can conclude that using a mixed
amine solution does indeed improve the recovery of both contaminants

QUESTION: What do you observe about the H2S and CO2 loading in the lean amine
leaving the regenerator? What are the implications of these results?

The H2S loading decreased, whereas the CO2 loading increased. This has major
implications on the process. When the Absorber is able to recover more CO2, the
Regenerator must also remove more contaminants from the rich amine. If the Regenerator
cannot keep up with process demands, it will recycle more CO2 with the lean amine back
to the Absorber, and this can negatively impact the CO2 composition in the sweet gas.

This highlights the importance of modeling an integrated system with the complete amine
recycle loop. Modeling the Absorber and Regenerator separately will save time and make
convergence simpler, but such a model will fail to predict the effect of increased lean
amine loading. Thus, when performing process design and optimization, it is important to
keep in mind the scope of the optimization being performed and assess the global impact
of changing operating conditions in one unit operation.

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 Aspen HYSYS: Advanced Process Modeling Topics Advanced Columns

Sulfur Recovery Unit (Sulsim)

Aspen HYSYS: Advanced Process Modeling Topics
EHY202 V10.0

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 Aspen HYSYS: Process Modeling Additional Topics Advanced Columns

Section Objectives

• Discuss the modified Claus process, the reactions involved, and how to optimize its conversion

• Use Sulsim’s empirical models to develop predictive and fully-rigorous simulations of the sulfur
recovery process

• Introduce various Sulsim unit operation models and optimization techniques

• Workshop: Model a Sulfur Recovery Unit (SRU) by configuring the thermal and catalytic stages using
the Specialized Sulfur Recovery Sub-Flowsheet tools and increase the overall performance using the
Air Demand Analyzer

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 Aspen HYSYS: Advanced Process Modeling Topics Advanced Columns

What is Sulfur Recovery?

• The sulfur recovery unit (also called SRU, Gas/Oil Separation

sulfur plant, Claus plant) carries out a modified
Claus process to recover elemental sulfur from Acid Gas
Cleaning
gaseous H2S, COS, CS2, and SO2.
– Step One: Thermal Stage Sulfur
Dehydration
– Free-flame oxidation of 1/3 of H2S to SO2 Recovery

– Step Two: Catalytic Stage Mercury

Tail Gas Treating
– Reaction over catalyst of SO2 with remaining 2/3 Removal
of H2S
Nitrogen
3 Rejection
3𝐻 𝑆 + 𝑂 𝑆𝑂 + 2𝐻 𝑆 + 𝐻 𝑂
2
Catalyst NGL
NGL Recovery
Fractionation
170-370C 3
𝑆 + 2𝐻 𝑂
𝑥 Liquefaction/
Compression

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 Aspen HYSYS: Advanced Process Modeling Topics Advanced Columns

What does the Sulfur Recovery process look like?

THERMAL STAGE CATALYTIC STAGES

https://en.wikipedia.org/wiki/Claus_process

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 Aspen HYSYS: Advanced Process Modeling Topics Advanced Columns

Primary Objective : Maximum Sulfur Recovery

• Deviations from ideal capability include:

– Operation above the dew point
– Vapor losses through sulfur fog and mist
– Air-to-acid gas ratio control
– Realizable & practicable capability
– transitions, upsets, catalyst deactivation, equipment issues, acid gas cleaning issues, ambient conditions, etc.

• Ideal recovery (optimized performance):

– 3 stages: 99%
– 2 stages: 97.5%

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 Aspen HYSYS: Advanced Process Modeling Topics Advanced Columns

Sulsim in Aspen HYSYS

• New Sulfur Recovery fluid package and new sulfur components (S1-S8, Liquid Sulfur)

• Specialized SRU subflowsheet and input/reports

– 22 new unit operations added
– 11 existing HYSYS unit operations supported in SRU

• Converter to migrate existing SULSIM case files to HYSYS

• New models never implemented before in SULSIM provided by Sulphur Experts

– Incinerator kinetic correlations
– Titania catalyst model for catalytic converter
– 5 new empirical reaction furnace models
– SO2 absorber

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Sulfur Recovery Property Package

• Dedicated Sulfur Recovery Property Package

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Sulfur Recovery Sub-Flowsheet (1)

• Specialized Sulfur Recovery Sub-Flowsheet

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©2011 AspenTech. All Rights Reserved. 8

Sulfur Recovery Sub-Flowsheet (2)

• Specialized Sulfur Recovery Sub-Flowsheet

HYSYS Sulfur Recovery Sub-Flowsheet Environment

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Sulfur Recovery Object Palette

• Specialized Unit Operations Palette

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Sulsim Case Converter

• Utility to convert legacy Sulsim files to work in HYSYS

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 Aspen HYSYS: Advanced Process Modeling Topics Advanced Columns

Thermal Stage

• First step in sulfur removal process

• 60-70% of Sulfur is produced in this stage of an

SRU

• Reaction Furnace + Waste Heat Exchanger +

Condenser

• H2S partially oxidized with air in reaction

furnace at high temperature

• 2/3 of H2S reacts to Sulfur; some H2S remains

unreacted, and some SO2 is produced

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Objectives
• Burn 1/3 of the H2S to SO2 for subsequent reaction with the remaining 2/3 of the H2S in the
converters
• Produce elemental sulfur directly by the partial oxidation of H2S
• Destroy any contaminants in the H2S feed stream
• Cool the furnace exit gas stream to the lower temperatures that favor high sulfur yields
• Recover the energy released by the reactions in a usable form
Controls
• Temperature (defined in large part by feed composition)
– Air / oxygen / fuel gas spiking flow control
– Preheat train
– Inerts removal
• Optimize burn type and location

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 Aspen HYSYS: Advanced Process Modeling Topics Advanced Columns

Furnace Model

• There are 3 main options for determining the

reactor’s outlet composition.
– Empirical method (recommended)
– Thermodynamic method
– Outlet known method

• A two chamber option exists for additional

flexibility.

• The key reaction parameters which are

kinetically limited are:
– The extent of the conversion of H2S to sulfur
– The extent of the net H2, CO, COS, and CS2
formation
– Composition of S1-S8 vapor determined using FEM

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 Aspen HYSYS: Advanced Process Modeling Topics Advanced Columns

Furnace: Empirical Models

• The 9 kinetic models cater to different feed compositions and furnace configurations

Empirical model selection provided in Aspen

HYSYS V9 “F1” Help
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 Aspen HYSYS: Advanced Process Modeling Topics Advanced Columns

Waste Heat Exchanger Model

• The Waste Heat Exchanger cools hot gas from

the furnace outlet, generating steam.

• Model summary
– Applies pressure drop, temperature drop
– Calculates elemental sulfur distribution at outlet T, P
– Outlet split into vapor and liquid sulfur streams
– Option for entrainment of liquid in vapor stream
– Back reaction calculation option
– Single pass and double pass options
Single Pass WHE Double Pass WHE

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 Aspen HYSYS: Advanced Process Modeling Topics Advanced Columns

Catalytic Stages

• Follows thermal step in sulfur removal process

• Reheater + Catalytic Converter + Condenser

• Series of catalytic converters

– 2-4 depending on desired recovery

• Reaction:

• Decreasing temperature over each reactor

• Sulfur recovered in condenser for each reactor

set

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Claus Catalytic Converter Model

• Convert hydrogen sulfide to elemental sulfur

• Modeling Goals
– Determine Sulfur recovery
– Predict COS and CS2 Hydrolysis

• Two Types of Catalysts

– Alumina
– Titania

• Correlation to determine extent of COS and CS2

Hydrolysis over Alumina catalyst
– Reactor temperature
– Extent of Claus reaction as activity of the catalyst

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• A Claus catalytic converter is run with a porous catalyst which increases the kinetics of the reaction
and also hydrolyzes the carbonyl sulfide (COS) and carbon disulfide (CS2) generated from the
reaction furnace.
• They are run at temperatures above the sulfur dewpoint to prevent liquid sulfur from deactivating
the catalyst.
• The Claus catalytic converter model performs an isenthalpic equilibration using free energy
minimization while inhibiting certain components to represent the reactions present.
• The inputs to the unit are the approaches to equilibrium of the reactions that take place in the
converter.
• With a given approach to equilibrium of the Claus reaction, an empirical correlation developed by
Sulphur Experts will be used to determine the extent of the COS and CS2 hydrolysis reactions
over an alumina (Al2O3) catalyst.
• Changing the approach to equilibrium of the Claus reaction can be used to indicate different levels
of activity of the catalyst—a lower value can be used to represent a slightly deactivated catalyst
• The correlation uses the reactor temperature and the catalyst activity to determine defaults for the
approach to equilibrium for the COS and CS2 hydrolysis reactions.
• These default values from the correlation can be overwritten manually by user input.
• Results show the reaction extents which were actually achieved; how much H2S reacted and how
much COS and CS2 hydrolysis occured

©2011 AspenTech. All Rights Reserved. 17

Selective Oxidation Converter

• Can be used to model Jacobs

SUPERCLAUS selective oxidation
process

• Simple conversion reactor

– 2𝐻 𝑆+ 𝑂 →2𝑆+2𝐻 𝑂
– 2 𝐻 𝑆 + 3 𝑂 → 2 𝑆𝑂 + 2 𝐻 𝑂

• Specify conversion and selectivity

• Requires an additional air feed

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• The last converter is the selective oxidation converter, which is licensed from Jacobs and used in
the Jacobs SUPERCLAUS selective oxidation process.
• This is modeled as a simple conversion reactor for these two reactions, followed by insenthalpic
equilibration using free energy minimization to determine the distribution of the elemental sulfur
species.
• The unit takes as input a conversion for H2S reacted, and a selectivity for the first reaction over the
second.
• The unit has an air stream which is not present in the other converters.
• The unit is able to determine what air flow is necessary to achieve the conversion specified in the
unit

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 Aspen HYSYS: Advanced Process Modeling Topics Advanced Columns

Other Unit Operations (1)

• Incinerator: • Sulfur Condenser:

– Used to oxidize sulfur species in tail gas cleanup – Removes elemental sulfur vapor from streams in
– Breakthrough percentages to customize incinerator catalytic stage by condensing to liquid phase
behavior
• Direct Fired Heater:
– Catalytic Incinerator also available
– Burns a fuel gas or acid gas stream for heating
• Steam Saturator: purposes
– Saturates a process stream with water at specified
• Sulfur Coalescer:
conditions
– Typically follows final condenser of each train to
– Also available on HYSYS palette
provide additional sulfur recovery
• Quench Section:
• Reducing Gas Generator:
– Quenches reactions and components in streams
– Used in tail gas cleanup to reheat the process
– It is an optional part of the thermal stage and is stream (using partial burn) by mixing combustion
designed to follow a reaction furnace products from a fuel gas burner

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Other Unit Operations (2)

• Hydrogenation Bed: • Simple Amine Absorber:

– Similar operation to catalytic converter in tail gas – Simplified unit op to simulate the acid gas treating
treating section process as it applies to tail gas cleanup
– Converts sulfur compounds to H2S
• Redox Absorber:
• Quench Tower: – Extracts all sulfur present as H2S, except for small
– Takes cooled gas from the H-Bed to reduce amount which escapes with the vent gas
temperature and remove water as by-product – Remaining sulfur recovered as product

• SO2 Absorber: • Degasser (V10)

– Similar to other absorption processes with the goal – Uses gas to remove dissolved H2S from a liquid
of removing SO2 sulfur phase to a vapor phase

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Accessibility

• “Combinations” available for rapid flowsheet

building
– Available on palette and ribbon

• Performance Summary button gives insight to

overall conversion & recovery

• Performance tab gives insight to KPIs specific

to each unit op or stream

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 Aspen HYSYS: Advanced Process Modeling Topics Advanced Columns

Optimization in HYSYS Sulsim

• Sulfur recovery / plant experts have need to optimize the Claus process using simulation

• Legacy Sulsim had limited options, greatly expanded in Aspen HYSYS V9

– “Air Demand Analyzer” Unit Op
– Specific to Sulsim
– Find optimal air flow to reaction furnace
– “Adjust” Block
– Case Study
– Spreadsheets
– Optimizer
– Etc.

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 Aspen HYSYS: Advanced Process Modeling Topics Advanced Columns

Optimizing the Claus Process: General Guidelines

• Ensure active catalyst in all converters

• Ensure steady/reliable operation

• Mist elimination equipment installed at all sulfur condensers

• Reheat methods that bypass sulfur compounds around converters are avoided

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 Aspen HYSYS: Advanced Process Modeling Topics Advanced Columns

Operational Issues to Avoid

• Poor reaction stoichiometry

– i.e. H2S:SO2 ratio and avoiding excess air

• Catalyst deactivation
– i.e. contaminant breakthrough & inadequate COS / CS2 conversion

• Operating the first converter too cold

• Operating the second and third converters too hot

– i.e. recovery loss through vapor stream

• Bypassing process streams with contaminants around conversion stages

• High final condenser temperature

• Liquid sulfur entrainment

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 Aspen HYSYS: Process Modeling Additional Topics Presentation

Workshop: Sulsim

• Task 1 – Configure Sulfur Recovery Property Package

• Task 2 – Configure the Thermal Stage

• Task 3 – Configure the Catalytic Stages

• Task 4 – Configure the 2nd and 3rd Catalytic Stages

• Task 5 – Review the Performance and Optimize the Furnace Air Flow

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 Sulfur Recovery Unit Workshop
Files can be found in folder: 09_Sulsim

Objective
In the refining and midstream industries, the recovery of sulfur from oil & gas streams is
an essential and growing process. H2S is removed from sour natural gas and refining
crude oil, and the sulfur recovery process produces elemental sulfur from gaseous
hydrogen sulfide. Since H2S is harmful to the environment, extremely flammable, and
can dissolve in petroleum products and degrade quality, sulfur removal is a highly
important process.

In this workshop, you will build a Sulfur Recovery Unit (3 Stage Claus Process). The 3
Stage Claus Process consists of one thermal stage (Furnace, Waste Heat Exchanger, and
Sulfur Condenser), and three catalytic stages (Reheater, Catalytic Converter, and Sulfur
Condenser). You will learn how to set up the Sulsim property package, configure the
thermal and catalytic stages in the Sulfur recovery process, and optimize the recovery
process.

This workshop includes the following tasks:

▪ Task 1 – Configure Sulfur Recovery Property Package

▪ Task 2 – Configure the Thermal Stage
▪ Task 3 – Configure the Catalytic Stages
▪ Task 4 – Configure the 2nd and 3rd Catalytic Stages
▪ Task 5 – Review the Performance and Optimize the Furnace Air Flow

Task 1 – Configure Sulfur Recovery Property Package

The Modified Claus Process is the most common method of processing H2S-containing
streams and producing sulfur. Sulsim technology (created by Sulphur Experts) is
integrated in V9 of HYSYS. It incorporates industry knowledge and data to simulate the
recovery of elemental sulfur from gaseous H2S, COS, CS2, and SO2 via the Modified
Claus Process.

Sulsim integration includes a new Sulsim (Sulfur Recovery) property package. When you
add a Sulsim (Sulfur Recovery) property package to your simulation, the component list
will automatically include the required components and supported components, allowing
you to integrate your sulfur recovery process into a larger gas processing simulation.

19 - 1
In this portion of the workshop, you will add the Sulsim property package and create feed
streams for the Sulfur Recovery process.

1. Create a new HYSYS case.

2. Select Add to add a new a fluid package.

3. From the property packages selection, select Sulsim (Sulfur Recovery).

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4. HYSYS creates a compatible component list with full set of required and
supported components. It also features new sulfur components: S1 through S8 and
Liquid Sulfur.

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5. Enter the Simulation Environment. A Sulfur Recovery Unit Sub-Flowsheet will
be automatically added.

6. Select Start with a Blank Flowsheet.

7. Open the SRU-1 form and explore the options. Then enter the Sub-Flowsheet
Environment.

Note the options on the Sulfur Recovery Unit ribbon tab and the various unit ops
and combinations available.

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8. Add an Acid Gas material stream inside the Sulsim Sub-Flowsheet with the
following specifications:

• Temperature: 35 °C (95 °F)

• Pressure: 170.3 kPa (24.7 psia)
• Molar Flow: 100 kgmole/h (220.5 lbmole/hr)
• Composition by mole: 0.242 CO2, 0.75 H2S, 0.005 Methane, 0.002
Ethane, 0.001 Propane

9. Add an Air to Furnace material stream with the following specifications:

• Temperature: 50 °F (122 °F)

• Pressure: 170.3 kPa (24.7 psia)
• Molar Flow: 186.8 kgmole/h (411.8 lbmole/hr)
• Composition by mole: 0.7809 N2, 0.2095 Oxygen, 0.0093 Argon, 0.0003
CO2

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 10. Save your case as 09-SulsimFluidPackage.hsc

Task 2 – Configure the Thermal Stage

The first step in the sulfur recovery process is the thermal stage where 60-70% of sulfur
is produced in this stage of an SRU. In this stage, H2S is partially oxidized with air in the
reaction furnace at a high temperature. Two-thirds of the H2S reacts to sulfur, some H2S
remains unreacted, and some SO2 is produced.

The thermal stage includes all front-end process units excluding the initial train source
gas and inlet feed stream junctions. A standard SRU has a single thermal stage composed
of the following three units:

• Reaction Furnace
• Waste Heat Exchanger
• Sulfur Condenser (optional)

Additionally, the front-end of the process can include:

• A Tee (for split-flow or recycle configuration)

• Heaters, Coolers, or additional Inlet Streams

11. Add a Single Chamber Reaction Furnace unit to the flowsheet.

12. Configure the FUR-100 unit by double-clicking and navigating through the
various tabs on the form.

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 13. Connect the Acid Gas and Air to Furnace streams and add a Furnace Effluent
outlet gas stream. The unit should converge.

The Reaction Furnace model uses proprietary empirical relationships developed by

Sulphur Experts based on hundreds of sulfur plant tests. It predicts the unit conversion
efficiency as well as quantities of COS, CS2, H2, CO, and H2S at the outlet. The H2S and
CO2 content of the furnace feeds have a significant effect on the net reactions in the
furnace. However, many of the minor components (hydrocarbon, NH3) will also
influence the extent of various side reactions and the resulting concentration of the key
minor species, including H2, CO, COS and CS2.

The main sulfur products from the furnace are SO2 and Sx vapor. COS and CS2 are
typically produced in smaller quantities. The Reaction Furnace carries out combustion
reactions according the model selected and performs free energy minimization to
calculate the product composition.

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Although many factors influence the design and configuration of the Claus plant, the
concentration of H2S in the acid gas feed to the furnace is the largest contributor.

Typical configuration for various concentrations of H2S in feed is shown in the following
table.

Case H2S in Acid Gas Configuration

(mol %)
Rich Feed 50-100 Straight-Through
Lean Feed 20-50 Split-Flow

Lean Feed 10-20 Split-Flow with Preheat of Feed

Streams
Very Lean < 10 Sulfur Recycle
Feed
Very Lean <5 Direct Oxidation
Feed
NH3 50-100 Straight-Through w/ NH3
Destruction burning configuration

14. The Acid Gas inlet has a high concentration of H2S. So, select a Straight
Through Amine Acid Gas empirical model from the model drop-down list on
the Design| Parameters page (if not already selected) and specify a pressure drop
of 3 kPa (0.4 psi).

QUESTION: What is the Air Demand %? [Write your answer below]

19 - 8
Next, the Waste Heat Exchanger (WHE) is placed after the Reaction Furnace. It is
sometimes referred to as the waste heat boiler. The Waste Heat Exchanger cools hot gas
from the furnace outlet and generates steam. Some liquid sulfur may be recovered
depending on operating conditions. The Single Pass Waste Heat Exchanger includes an
inlet stream, an outlet stream for cooled vapor, and a second outlet stream for when liquid
sulfur is produced. You can also use a Double Pass Waste Heat Exchanger, which is used
when a Hot Gas Bypass stream is present for your Waste Heat Exchanger.

Here, you will add a Single Pass Waste Heat Exchanger.

15. Select the Waste Heat Exchanger (Single Pass) from the model palette.

16. Configure the WHE-100 unit by connecting the Furnace Effluent stream as Inlet
Gas stream.

17. Add WHE Outlet Gas, WHE Liquid Sulfur Outlet, and WHE Energy outlet
streams.

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18. Specify an outlet temperature (WHE Outlet Gas stream) as 300 °C (572 °F) on
the Design | Parameters page.

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By default, the “Allow simulation of back-reactions” in the WHE check box is selected.
You can clear it if desired. Various reactions occur in a typical Waste Heat Exchanger.
These reactions include H2+S re-association reactions and CO + S reactions. Select
this check box to use empirical models (originally created by Sulphur Experts) which
predict the extent of these reactions for your simulation.

Next, the Sulfur Condenser will be added to complete configuring the thermal stage. It
removes elemental sulfur vapor produced in reactors by condensing it to the liquid
phase. The Sulfur Condenser performs a flash calculation and a sulfur equilibration on
all of the sulfur species. The inlet stream is re-equilibrated at a desired temperature and
pressure, and the resulting sulfur liquid is removed to the extent required.

In the Sulfur Condenser, sulfur is recovered for each reactor set and these condensers
typically operate between 130 - 150 °C.

19. Select the Condenser or the model palette .

20. Configure the COND-100 unit by connecting the WHE Outlet Gas as Inlet Gas
stream.

21. Add COND100 Gas Outlet, COND100 Liquid Sulfur Outlet, and COND100
Energy outlet streams.

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 22. Specify an outlet temperature (COND100 Gas Outlet) as 135 °C (275 °F) on the
Design | Parameters page.

QUESTION: What is the sulfur recovery efficiency of the thermal stage condenser?
[Write your answer below]

Hint: Click the Performance tab on the COND-100 to check the recovery.

23. Save your case as 09-SulsimThermalStage.hsc

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Task 3 – Configure the Catalytic Stages
Catalytic stages normally appear in the process after an initial thermal stage. The catalytic
recovery of sulfur consists of three steps: heating, catalytic reaction with decreasing
temperature over each reactor, and condensation.

The following catalytic reaction occurs:

2 H2S + SO2 → 3 S + 2 H2O

These three steps are normally repeated a maximum of three times. When an incineration
or tail-gas treatment unit (TGTU) is added downstream of the Claus plant, only two
catalytic stages are usually installed.

A typical Sulfur Recovery Sub-Flowsheet may contain between one and four catalytic
stages composed of the following units:

• Heater or Direct Fired Heater (or Mixer, in some cases)

• A series of catalytic converters (between two and four, depending on desired
recovery)
• Catalytic Converter, Sub-Dew point Catalytic Converter, and/or Selective
Oxidation Converter
• Sulfur Condenser

Begin by adding the first simple unit of the catalytic stage, the Heater.

24. Add a Heater unit operation to the flowsheet from the object palette.

25. Connect the COND100 Gas Outlet as Inlet and add an E100 Energy stream and
an E100 Gas Outlet stream.

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 26. Specify an outlet temperature (E100 Gas Outlet stream) of 270 °C (518 °F) and
Delta P of 0.4 psi on the Design | Parameters page.

Next, you will add the Catalytic Converter, which is the central component of a
catalytic stage and provides sulfur conversion downstream of the reaction furnace.

HYSYS performs an isenthalpic, Free Energy Minimization calculation based on the

inlet materials and inlet temperature at the outlet pressure.

The stream CO, H2, NH3 HCN, mercaptans, and hydrocarbons are constrained from
reacting. The extent of the H2S/SO2 reaction (deactivation) is controlled through input
of a desired percent approach to equilibrium. CS2 and COS hydrolysis are predicted
using empirical data with consideration of the inlet materials and the temperature of the
reaction. You can edit calculated values to simulate any desired extent of hydrolysis.

27. Add a Catalytic Converter unit to the flowsheet.

28. Connect the E100 Gas Outlet as Inlet and then add CONV100 Effluent as Outlet
Gas.

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 29. Ensure Alumina Catalyst is selected and that 100% H2S/SO2 equilibrium is
reached on the Design | Parameters page.

Only the H2S/SO2 reaction value must be specified in order for the Catalytic Converter
to solve. You can adjust the values in the Approach to equilibrium (%) of section. Type
the percentage approach to equilibrium to specify the extent of the H2S/SO2 (modified-
Claus) reaction in the converter. This value controls the simulation of catalyst
deactivation in the unit. When the Catalytic Converter is not solved, the default value
is 100%, which simulates completely active catalyst with a 100% approach to
equilibrium. If you specify a value lower than 100%, HYSYS simulates deactivated
catalyst with a less than 100% approach to equilibrium.

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Next, the Sulfur Condenser will be added to complete configuring the catalytic stage. The
Sulfur Condenser is generally considered mandatory in the catalytic stage and is an
optional part of the thermal stage.

30. Add a Condenser unit op to the flowsheet and then connect the CONV100
Effluent as the inlet stream.

31. Then add COND101 Gas Outlet, COND101 Liquid Sulfur Outlet, and
COND101 Energy outlet streams.

32. Specify a temperature of 135°C (275°F) for the COND100 Gas Outlet and a
Delta P of 0.4 psi on the Design | Parameters page.

QUESTION: What is the sulfur recovery efficiency of the first stage condenser? [Write
your answer below]

33. Save your case as 09-SulsimCatalyticStage1.hsc

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Task 4 – Configure the 2nd and 3rd Catalytic Stages
In this task, you will add 2nd and 3rd catalytic sections to the flowsheet. You will add the
2nd stage by using the Combinations group option. Combinations are available for rapid
flowsheet building and can be added using either the palette or the Sulfur Recovery Unit
ribbon.

34. Add a catalytic section to the flowsheet by navigating to the Combinations tab on
the palette or on the ribbon.

35. Delete stream 1 to the E-101 heater and replace with the COND101 Gas Outlet
stream.

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36. Configure the E-101 unit by specifying a pressure drop of 3 kPa (0.4 psi) and an
outlet temperature of 220 °C (430 °F).

37. Next, configure the CONV-101 unit by choosing Titania as the catalyst on the
Design | Parameters page.

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 38. Specify a Space velocity of 1000 hr-1 on the Rating tab.

39. Configure the COND-102 unit by specifying a gas outlet temperature (stream 4)
of 135 °C (275 °F).

QUESTION: What is the sulfur recovery efficiency of the second stage condenser?
[Write your answer below]

40. Save your case as 09-SulsimCatalyticStage2.hsc

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Next, you will add the 3rd catalytic stage.

41. Start by adding a Direct Fired Heater to the flowsheet by selecting icon
from the model palette.

42. Then connect stream 4 (the outlet gas from COND-102) as the inlet gas.

The Direct Fired Heater burns a fuel gas stream and an air stream to heat a feed
stream.

43. Using the material stream option on the palette, add a Fuel Gas stream to the
flowsheet and specify the stream with 100% methane at 275 kPag (40 psig) and
15 °C (60 °F) and an estimated initial flow rate of 2 kgmole/hr (4.40 lbmole/hr).

44. Connect this Fuel Gas stream to DFH-100 as the fuel gas stream.

45. Add a new material stream to the flowsheet and name it DFH Air.

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 46. Use the Define from Other Stream option to clone the stream conditions from
Air to Furnace. Delete the total molar flow rate.

47. Connect the DFH Air stream to DFH-100 as the Air Stream.

48. Add a DFH outlet gas stream titled DFH Effluent.

You will notice that DFH Air stream flow is calculated.

QUESTION: What is the DFH Effluent temperature? [Write your answer below]

Next, you will attempt to achieve a target DFH Effluent temperature of 150 °C (302 °F)
as the current temperature is a bit high.

49. In order to target that temperature specification, add an Adjust block to the
flowsheet and specify the following:

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50. Specify a minimum of 0.1 kgmole/hr (0.22046 lbmole/hr) and a maximum of 5
kgmole/hr (11.023 lbmole/hr) on the Parameters tab. The unit op should iterate
and solve.

QUESTION: What is Fuel Gas flow rate now? [Write your answer below]

In this final catalytic stage, the Selective Oxidation Converter will be added. It uses a
selective oxidation catalyst and, if present, usually appears in the final catalytic stage.
The Selective Oxidation Converter is used in the Jacobs SUPERCLAUS selective
oxidation process. It is a simple conversion reactor in which the following reactions
occur:

2 H2S + O2 →2 S + 2 H2O
2 H2S + 3 O2 →2 SO2 + 2 H2O

You can specify conversion and selectivity. The Selective Oxidation Converter
requires an additional air feed. Normally, only one Selective Oxidation Converter
appears in a SRU train.

The reaction is implemented based upon the conversion specification (the Conversion
(H2S reacted) field on the Parameters tab), the Selectivity (reacted H2S to S) field on
the Parameters tab (percentage of H2S converted to elemental sulfur), and a measure
of air flow into the unit.

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51. Add a Selective Oxidation Converter to the flowsheet, by selecting icon
from the model palette.

52. Attach DFH Effluent as the inlet gas stream.

53. Create a new air stream named CONV102 Air and define stream conditions from
Air to Furnace. Do not specify a flow rate and attach this stream as the Air stream.

54. Add an outlet stream titled CONV102 Effluent.

55. In the CONV-102 unit op form, specify an Approximate O2 at outlet

concentration of 0.5 mol% on the Design | Parameters page.

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You can specify the percentage of the total available H2S that is reacted in the bed in
the Conversion (H2S reacted) field (The default value is 98%) and specify the
percentage of the total H2S that is converted to elemental sulfur in the Selectivity
(reacted H2S to S) field (The default value is 90%). The remainder is converted to
SO2.

You can either specify the Approximate O2 at outlet on this page or specify an air rate
on the Air Stream inlet property view. Due to Free Energy Minimization (FEM), this
can only be an approximation without additional looping. To achieve a precise O2
outlet concentration, you can use an Adjust operation.

56. To complete this stage, add a Condenser to the flowsheet.

57. Connect the CONV102 Effluent stream as the inlet.

58. Add COND103 Gas Outlet, COND103 Liquid Sulfur Outlet

and COND103 Energy streams to COND-103.

59. Specify a gas outlet temperature of 135 °C (275 °F) on the Design | Parameters
page.

QUESTION: What is the sulfur recovery efficiency of the third stage condenser?
[Write your answer below]

60. Save your case as 09-SulsimCatalyticStage3.hsc

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Task 5 – Review the Performance and Optimize the
Furnace Air Flow
In this task, you will review the overall performance of the Sulfur Recovery Unit
configured and optimize the Furnace Air Flow using the Air Demand Analyzer.

61. Click the Performance Summary button on the Sulfur Recovery Unit ribbon to
check overall performance.

QUESTION: Which units are performing well? [Write your answer below]

QUESTION: Which units may require some optimization? [Write your answer below]

Say, you are the Claus Plant process engineer and are tasked with improving the sulfur
recovery of your plant. You recognize that the air flow rate to the furnace is not

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optimized and may be a major factor as to why your sulfur recovery is lower than it
should be. You want to use HYSYS to determine a more ideal air demand.

To determine a more ideal air demand, you will use the Air Demand Analyzer (ADA).
The Air Demand Analyzer controls the air flow to a single upstream Reaction Furnace. It
adjusts the air flow into a Reaction Furnace and performs iterative calculations to meet
your specifications.

62. Open the FUR-100 form and note the current air demand (-11.12%)

63. Add an ADA to the flowsheet from the palette and open the ADA form.

The Air Demand Analyzer should be connected to a stream and a reaction furnace.

64. Select the outlet from the 3rd condenser as your sample stream (stream 4) and
target an Air Demand of 0% (ideal stoichiometric ratio of 1:2 SO2:H2S). Select
reaction furnace (FUR-100).

65. The solver should start automatically and should converge.

66. Click the Performance Summary button on the Sulfur Recovery Unit ribbon to
check overall performance improvement.

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QUESTION: How did the overall performance improve? [Write your answer below]

67. Save your case as 09-SulsimADA.hsc

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 Notes:

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 Sulfur Recovery Unit Solutions
Files can be found in folder: 09_Sulsim/Solutions

Questions
Task 2
QUESTION: What is the Air Demand %?

-11.12%

QUESTION: What is the sulfur recovery efficiency of the thermal stage condenser?

S Recovery Efficiency [%] = 99.75%

Task 3
QUESTION: What is the sulfur recovery efficiency of the first stage condenser?

S Recovery Efficiency [%] = 99.07%

Task 4
QUESTION: What is the sulfur recovery efficiency of the second stage condenser?

S Recovery Efficiency [%] = 97.07%

QUESTION: What is the DFH Effluent temperature?

305.1 ̊C (581.2 ̊F)

QUESTION: What is Fuel Gas flow rate now?

0.1606 kgmole/hr (0.3540 lbmole/hr)

QUESTION: What is the sulfur recovery efficiency of the third stage condenser?

S Recovery Efficiency [%] = 78.94%

Task 5

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QUESTION: Which units are performing well?

Thermal, CONV-100 and CONV-101

QUESTION: Which units may require some optimization? [Write your answer below]

CONV-102

QUESTION: How did the overall performance improve? [Write your answer below]

The S Recovery Efficiency % increased from 78.94% to 89.28% for CONV-102.

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Equation-Oriented Simulation
Aspen HYSYS: Advanced Process Modeling Topics
EHY202 V10.0

1
Aspen HYSYS: Process Modeling Presentation
Additional Topics

Section Objectives

• Introduction to Equation Oriented (EO) modeling in Aspen HYSYS V10.0

• Demo: Convert an existing case to EO and synchronize results

2 © 2015 Aspen Technology, Inc. All rights reserved.

Aspen Technology, Inc. 2

Differences between Sequential Modular (SM) and Equation-
Oriented (EO)
Sequential-Modular Simulation (“SM”) Equation-Oriented Simulation (“EO”)

Solves each block in the flowsheet in sequence Gathers all the model equations together and
solves simultaneously
Recycle (tear) streams and design specifications
are solved iteratively by trial & error techniques

Complex problems with nested recycle loops, Complex problems are “flattened” and solve
heat integration, multiple design specifications quickly and efficiently; more robust solution
can be tricky to converge
Can be difficult to enforce back-calculation, for Flexible, relatively easy to reverse calculations
example setting upstream pressures from by changing specifications of pairs of variables
downstream
Optimization & data regression requires Optimization & data reconciliation run very
hundreds or even thousands of flowsheet quickly – in minutes or seconds
evaluations – may take hours to run
3 © 2015 Aspen Technology, Inc. All rights reserved.

3
Improved Calibration & Optimization in Aspen HYSYS

• Improve performance & convergence

– Nested loops solve simultaneously
– One model for calibration and optimization with flexible variable specification
– Feasible optimization

• Customize EO for HYSYS users

– Improve usability
– Easy conversion from SM to EO

4 © 2015 Aspen Technology, Inc. All rights reserved.

4
Supported Unit Operations

• In addition, only Aspen Properties component lists and fluid packages are supported

5 © 2015 Aspen Technology, Inc. All rights reserved.

5
Converting an SM Model to EO

• Two options for creating an EO model

– Create a new model from scratch by adding an EO subflowsheet from the model palette
– Convert an existing SM model to EO by selecting all objects and clicking on “Convert to EO”

6 © 2015 Aspen Technology, Inc. All rights reserved.

6
HYSYS EO Run Modes

Mode Description

Simulation Default mode, solves the same problem as SM simulation

Maximize or minimize an objective function by varying the

Optimization
degrees of freedom (SM analogue: Optimizer)
Adjust parameters in order to find a best fit to measured data,
use when the number of measured variables is greater than the
Data Reconciliation
number of adjusted parameters and DOF > 0 (SM analogue:
Data-Fit)
Adjust parameters in order to match simulation results to
measured data, use when the number of measured variables is
Parameter Estimation
equal to the number of adjusted parameters and DOF = 0 (SM
analogue: Adjust blocks)

7 © 2015 Aspen Technology, Inc. All rights reserved.

7
Converting an SM Model to EO

• Open the case titled HYSYS EO CS&T Starter.hsc

• In order to utilize HYSYS EO, you must first create an EO subflowsheet. You can do this
in two different ways
– Convert an existing SM model to EO through the Convert to EO button on the Equation Oriented
tab of the ribbon
– Add a new EO subflowsheet to the ribbon from the model palette.

8 © 2015 Aspen Technology, Inc. All rights reserved.

8
Converting an SM Model to EO

• In our case, we will convert the existing SM case into an EO case.

• After creation, enter the EO subflowsheet and change the Run modfe from Sequential
Modular to Equation Oriented

• Run the case to synchronize in EO

9 © 2015 Aspen Technology, Inc. All rights reserved.