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Getting Started
Workshop
The Getting Started module introduces you to some of the basic
concepts necessary for creating simulations in HYSYS. Some of the
things you will learn from this module are:
You will use HYSYS to define three streams. You will learn how to
determine the properties of these streams by using the Property Table
utility.
Learning Objectives
Once you have completed this section, you will be able to:
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Getting Started 3
3
4 Getting Started
You can use the <Ctrl><B> hot key to re-enter the Simulation Basis
Manager from any point in the simulation or choose the Enter Basis
Environment button from the button bar.
Basis Environment button
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Getting Started 5
5
6 Getting Started
You can select components for your simulation using several different
methods:
To Use… Do This…
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Getting Started 7
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8 Getting Started
Now that the Fluid Package is now fully defined, you are ready to move
on and start building the simulation. Press the Enter Simulation
Environment button or the Interactive Simulation Environment
button in the Button Bar.
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Getting Started 9
3. If it is not already selected, select the desired unit set. Both Field
and SI units will be given in this course; you are free to use
whichever is more comfortable for you.
4. Close the window to return to the simulation.
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10 Getting Started
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Getting Started 11
Adding Streams
In HYSYS, there are two types of streams, Material and Energy. Material
streams have a composition and parameters such as temperature,
pressure and flowrates. They are used to represent Process Streams.
Energy streams have only one parameter, a Heat Flow. They are used to
represent the Duty supplied to or by a Unit Operation.
In this exercise, you will add three streams to represent the feeds to an
air stripper. Each stream will be added using a different method of
installation.
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12 Getting Started
1. Press the <F11> hot key. The Stream Property view is displayed:
You can change the stream name by simply typing in a new name in the
Stream Name box.
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Getting Started 13
3. Double click on the Mass Flow cell. The Input Composition for
Stream view displays.
4. We want to define the composition of this stream by specifying
the mass flows for each component. By default, HYSYS has
chosen the basis for defining the composition as mass fraction.
Press the Basis button and select the Mass Flows radio button in
the Composition Basis group. You are now able to enter the data
in the desired format.
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14 Getting Started
Toluene 0
Oxygen 0
Nitrogen 0
6. Press the OK button when all the mass flows have been entered.
7. Close the Stream Property view.
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Getting Started 15
Workbook button 1. Enter the stream name, Tol rich in the **New** cell.
2. Enter the following component mass flow rates. You will have to
change the basis again.
Ethanol 0
Oxygen 0
Nitrogen 0
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16 Getting Started
Chloroform 0
Toluene 0
Ethanol 0
H2O 0
Oxygen 0.21
Nitrogen 0.79
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Getting Started 17
Flash Calculations
HYSYS can perform five types of flash calculations on streams: P-T,
Vf-P, Vf-T, P-Molar Enthalpy and T-Molar Enthalpy. Once the
composition of the stream and two of either temperature, pressure,
vapour fraction or molar enthalpy are known, HYSYS performs a flash
Only 2 of these 4 stream
parameters, Vapour Fraction, calculation on the stream, calculating the other two parameters.
Temperature, Pressure or
Molar Enthalpy can be
supplied.
If you try to supply temperature, pressure and vapour
fraction, a consistency error can occur.
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18 Getting Started
Attaching Utilities
The utilities available in HYSYS are a set of useful tools that interact
with your process, providing additional information or analysis of
streams or operations. Once installed, the utility becomes part of the
Flowsheet, automatically calculating when conditions change in the
stream or operation to which it is attached.
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Getting Started 19
A Property Table utility will be added to the stream Tol rich from the
stream property view.
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20 Getting Started
9. Select the Bulk radio button and highlight a cell in the Property
matrix.
10. Choose Mass Density from the drop down list.
11. Select the Liquid radio button, and select the Viscosity property.
12. Select the Aqueous radio button, and select the Aq. Mass Fraction
property.
13. Select the Vapour radio button, and select the Vapour Mass
Fraction property.
14. Press the Calculate cell to generate the Property Table.
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Getting Started 21
Add a flowrate of 18 000 kg/h (39, 700 lb/hr) to the stream Strip Air.
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22 Getting Started
The pages Properties and Composition also show data for the
individual phases.
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Getting Started 23
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24 Getting Started
The Workbook now contains the tab Other Prop which shows the
vapour fraction on a mass basis, the molecular weight, the mass density
and the mass enthalpy for all the components for the three streams.
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Getting Started 25
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26 Getting Started
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Getting Started 27
Exercise 1
Exercise 2
The stream Eth Rich is stored in a 200 m3 (7000 ft3) vessel. Assuming the
storage vessel has a 45 minute hold-up and the vessel is at atmospheric
conditions (1 atm, 25°C, 77 °F):
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28 Getting Started
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Thermodynamics and HYSYS 1
Workshop
One of the main assets of HYSYS is its strong thermodynamic
foundation. Not only can you use a wide variety of internal property
packages, you can use tabular capabilities to override specific property
calculations for more accuracy over a narrow range. Or, you can use the
functionality provided through OLE to interact with externally
constructed property packages.
However, there are cases when the parameters calculated by HYSYS are
not accurate enough, or cases when the models used by HYSYS do not
predict the correct behaviour of some liquid-liquid mixtures
(azeotropic mixtures). For those cases it is recommended to use
another of Hyprotech’s products, DISTIL. This powerful simulation
program provides an environment for exploration of thermodynamic
model behaviour, proper determination and tuning of interaction
parameters and physical properties, as well as alternative designs for
distillation systems.
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Thermodynamics and HYSYS 3
Learning Objectives
Once you have completed this module, you will be able to:
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4 Thermodynamics and HYSYS
TEG Dehydration PR
Hydrate Inhibition PR
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Thermodynamics and HYSYS 5
Equations of State
For oil, gas and petrochemical applications, the Peng-Robinson EOS
(PR) is generally the recommended property package. HYSYS currently
offers the enhanced Peng-Robinson (PR) and Soave-Redlich-Kwong
(SRK) equations of state. In addition, HYSYS offers several methods
which are modifications of these property packages, including PRSV,
Zudkevitch Joffee (ZJ) and Kabadi Danner (KD). Lee Kesler Plocker
(LKP) is an adaptation of the Lee Kesler equations for mixtures, which
itself was modified from the BWR equation. Of these, the Peng-
Robinson equation of state supports the widest range of operating
conditions and the greatest variety of systems. The Peng-Robinson and
Soave-Redlich-Kwong equations of state (EOS) generate all required
equilibrium and thermodynamic properties directly. Although the
forms of these EOS methods are common with other commercial
simulators, they have been significantly enhanced by Hyprotech to
extend their range of applicability.
Activity Models
Although equation of state models have proven to be very reliable in
predicting properties of most hydrocarbon based fluids over a large
range of operating conditions, their application has been limited to
primarily non-polar or slightly polar components. Polar or non-ideal
chemical systems have traditionally been handled using dual model
approaches.
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6 Thermodynamics and HYSYS
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Thermodynamics and HYSYS 7
Binary Systems A A A A A
Multicomponent LA LA A A A
Systems
Azeotropic Systems A A A A A
Liquid-Liquid A A N/A A A
Equilibria
Dilute Systems ? ? A A A
Self-Associating ? ? A A A
Systems
Extrapolation ? ? G G G
• A = Applicable
• N/A = Not Applicable
• ? = Questionable
• G = Good
• LA = Limited Application
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8 Thermodynamics and HYSYS
Overview of Models
Margules
One of the earliest activity coefficient expressions was proposed by
Margules at the end of the 19th century.
van Laar
The van Laar equation was the first Gibbs excess energy representation
with physical significance. This equation fits many systems quite well,
particularly for LLE component distributions. It can be used for
systems that exhibit positive or negative deviations from Raoult’s Law.
The van Laar equation Some of the advantages and disadvantage for this model are:
performs poorly for dilute
systems and CANNOT • Generally requires less CPU time than other activity models.
represent many common
systems, such as alcohol- • It can represent limited miscibility as well as three phase
hydrocarbon mixtures, with equilibrium.
acceptable accuracy. • It cannot predict maxima or minima in the activity coefficient
and therefore, generally performs poorly for systems with
halogenated hydrocarbons and alcohols.
• It also has a tendency to predict two liquid phases when they
do not exist.
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Thermodynamics and HYSYS 9
The van Laar equation implemented in HYSYS has two parameters with
linear temperature dependency, thus making it a four parameter
model. In HYSYS, the equation is empirically extended and therefore its
use should be avoided when handling multicomponent mixtures.
Wilson
The Wilson equation, proposed by Grant M. Wilson in 1964, was the
first activity coefficient equation that used the local composition model
to derive the Gibbs Excess energy expression. It offers a
thermodynamically consistent approach to predicting multi-
component behaviour from regressed binary equilibrium data.
The Wilson equation CANNOT • Although the Wilson equation is more complex and requires
be used for problems involving more CPU time than either the van Laar or Margules
liquid-liquid equilibrium. equations, it can represent almost all non-ideal liquid solutions
satisfactorily except electrolytes and solutions exhibiting limited
miscibility (LLE or VLLE).
• It performs an excellent job of predicting ternary equilibrium
using parameters regressed from binary data only.
• It will give similar results to the Margules and van Laar
equations for weak non-ideal systems, but consistently
outperforms them for increasingly non-ideal systems.
• It cannot predict liquid-liquid phase splitting and therefore
should only be used on problems where demixing is not an
issue.
NRTL
The NRTL (Non-Random-Two-Liquid) equation, proposed by Renon
and Prausnitz in 1968, is an extension of the original Wilson equation. It
uses statistical mechanics and the liquid cell theory to represent the
The additional parameter in
the NRTL equation, called the liquid structure. These concepts, combined with Wilson’s local
alpha term, or non- composition model, produce an equation capable of representing VLE,
randomness parameter, LLE, and VLLE phase behaviour. Like the Wilson equation, the NRTL
represents the inverse of the
model is thermodynamically consistent and can be applied to ternary
coordination number of
molecule “i” surrounded by and higher order systems using parameters regressed from binary
molecules “j”. Since liquids equilibrium data. The NRTL model has an accuracy comparable to the
usually have a coordination Wilson equation for VLE systems.
number between 3 and 6, you
might expect the alpha
parameter between 0.17 and • The NRTL combines the advantages of the Wilson and van
0.33. Laar equations.
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10 Thermodynamics and HYSYS
UNIQUAC
The UNIQUAC (UNIversal QUAsi Chemical) equation proposed by
Abrams and Prausnitz in 1975 uses statistical mechanics and the quasi-
chemical theory of Guggenheim to represent the liquid structure. The
equation is capable of representing LLE, VLE and VLLE with accuracy
comparable to the NRTL equation, but without the need for a non-
randomness factor, it is a two parameter model.
In its simplest form it is a two parameter model, with the same remarks
as Wilson and NRTL. UNIQUAC needs van der Waals area and volume
parameters, and those can sometimes be difficult to find, especially for
non-condensable gases (although DIPPR has a fair number available).
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Thermodynamics and HYSYS 11
The Chien Null model allows 3 sets of coefficients for each component
pair, accessible via the A, B and C coefficient matrices.
Henry’s Law
Henry’s Law cannot be selected explicitly as a property method in
HYSYS. However, HYSYS will use Henry’s Law when an activity model is
selected and "non-condensable" components are included within the
No interaction between "non- component list.
condensable" component
pairs is taken into account in
the VLE calculations. HYSYS considers the following components non-condensable:
Methane, Ethane, Ethylene, Acetylene, Hydrogen, Helium, Argon,
Nitrogen, Oxygen, NO, H2S, CO2, and CO.
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12 Thermodynamics and HYSYS
Ideal
The ideal gas law can be used to model the vapour phase. This model is
appropriate for low pressures and for a vapour phase with little
intermolecular interaction. The model is the default vapour phase
fugacity calculation method for activity coefficient models.
Virial
The Virial option enables you to better model vapour phase fugacities
of systems displaying strong vapour phase interactions. Typically this
occurs in systems containing carboxylic acids, or compounds that have
the tendency to form stable H2 bonds in the vapour phase.
Care should be exercised in HYSYS contains temperature dependent coefficients for carboxylic
choosing PR, SRK, RV or Virial
to ensure binary coefficients acids. You can overwrite these by changing the Association (ij) or
have been regressed with the Solvation (ii) coefficients from the default values.
corresponding vapour phase
model. This option is restricted to systems where the density is moderate,
typically less than one-half the critical density.
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Thermodynamics and HYSYS 13
Binary Coefficients
For the Property Packages which do include binary coefficients, the
Binary Coefficients tab contains a matrix which lists the interaction
parameters for each component pair. Depending on the property
method chosen, different estimation methods may be available and a
different view may be shown. You have the option of overwriting any
library value.
Kij = Kji
so when you change the value of one of these, both cells of the pair
automatically update with the same value. In many cases, the library
interaction parameters for PRSV do have Kij = Kji, but HYSYS does not
force this if you modify one parameter in a binary pair.
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14 Thermodynamics and HYSYS
If you are using PR or SRK (or one of the Sour options), two radio
buttons are displayed at the bottom of the page in the Treatment of
Interaction Coefficients Unavailable from the Library group:
The interaction parameters for each binary pair will be displayed. You
can overwrite any value or use one of the estimation methods.
Note that the Kij = Kji rule does not apply to Activity Model interaction
parameters.
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Thermodynamics and HYSYS 15
Estimation Methods
• UNIFAC VLE
• UNIFAC LLE
• Immiscible
You can then invoke the estimation by selecting one of the available
cells.
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16 Thermodynamics and HYSYS
Basic Data
Activity coefficient models are empirical by nature and the quality of
their prediction depends on the quality and range of data used to
determine the parameters. Some important things you should be aware
of in HYSYS.
UNIFAC or no UNIFAC?
UNIFAC is a handy tool to give initial estimates for activity coefficient
models. Nevertheless keep in mind the following:
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Thermodynamics and HYSYS 17
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18 Thermodynamics and HYSYS
Exercise 1
Di-iso-Propyl-Ether/H2O Binary
This example effectively demonstrates the need for having interaction
parameters. Do the following:
Conditions
Pressure 1 atm
Composition
di-i-P-Ether 50 mole %
H2O 50 mole %
3. Close the stream view and press the Enter Basis Environment
button.
4. Select the Binary Coeffs tab of the Fluid Package. Notice that the
interaction parameters for the binary are both set to 0.0.
5. Press the Reset Params button to recall the default NRTL activity
coefficient model interaction parameters.
6. Close the Fluid Package view.
7. Return to the simulation environment by pressing the Return to
Simulation Environment button.
8. Open the stream view by double clicking on the stream DIIPE/
H2O.
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Thermodynamics and HYSYS 19
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20 Thermodynamics and HYSYS
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Thermodynamics and HYSYS 21
Exercise 2
Phenol/H2O Binary
This binary shows the importance of ensuring that properly fitted
interaction parameters for the conditions of your simulation are used.
The default parameters for the Phenol/H2O system have been
regressed from the DECHEMA Chemistry data series and provide very
accurate vapour-liquid equilibrium since the original data source (1)
was in this format. However, the Phenol/Water system is also shown to
exhibit liquid-liquid behaviour (2). A set of interaction parameters can
be obtained from sources such as DECHEMA and entered into HYSYS.
The following example illustrates the poor LLE prediction than can be
produced by comparing the results using default interaction
parameters and specially regressed LLE parameters.
Conditions
Temperature 40°C
Pressure 1 atm
Composition
Phenol 25 mole %
H2O 75 mole %
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22 Thermodynamics and HYSYS
To provide a better prediction for LLE at 40 oC (105 oF) the following Aij
interaction parameters are to be entered. To enter the parameters do
the following:
1. Close the stream view and press the Enter Basis Environment
button.
2. Ensure the Fluid Package view is open and select the Binary
Coeffs tab.
3. Enter the Aij interaction parameters as shown here:
The figures on the following page (figures 3 and 4) show the difference
between the two sets of interaction parameters. Therefore, care must be
exercised when simulating LLE as almost all the default interaction
parameters for the activity coefficient models in HYSYS are for VLE.
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Thermodynamics and HYSYS 23
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24 Thermodynamics and HYSYS
Exercise 3
Benzene/Cyclohexane/H2O Ternary
This example again illustrates the importance of having interaction
parameters and also discusses how the user can obtain parameters
from regression. To illustrate the principles do the following:
Conditions
Temperature 25°C
Pressure 1 atm
Composition
Benzene 20 mole %
H2O 20 mole %
CC6 60 mole %
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Thermodynamics and HYSYS 25
The figures on the following page (figures 5 and 6) clearly show the
behaviour of the ternary system. Without the regressed CC6/H2O
binary, the thermodynamic property package incorrectly predicts the
system to be miscible at higher CC6 concentrations. This prediction is
correct given properly regressed CC6/H2O parameters.
References
1. Schreinemakers F.A.H., Z. Phys. Chem. 35, 459 (1900).
2. Hill A.E. and Malisoff W.M., J. Am. Chem. Soc.
48 (1926) 918.
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26 Thermodynamics and HYSYS
26
Flowsheeting 1
Flowsheeting
Workshop
In evaporation, a solution consisting of a non-volatile solute and a
volatile solvent is concentrated by the addition of heat. In multiple
effect evaporation, the volatile solvent recovered from the first
evaporator is condensed and used as a heat source for the next
evaporator. This means that the second evaporator must operate at a
lower temperature and pressure than the first evaporator.
Learning Objectives
Once you have completed this section, you will be able to:
Prerequisites
Before beginning this section you need to know how to:
2
Process Overview
Simulation PFD
Flowsheeting 5
The program warns you that the binary coefficients have not been
determined and the model will assume values of zero. Answer OK to
this message. Enter the Simulation Environment.
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6 Flowsheeting
Name Feed
Vapour Fraction 0
Note that the composition
values for this stream are in Pressure 101.3 kPa (14.7 psia)
Mass fractions. Double-click
on the Mass Flow cell to enter Flowrate 50 kg/h (110 lb/hr)
these values.
Mass Fraction Surcose 0.3
Name Steam
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Flowsheeting 7
In this exercise, you will add each operation using a different method of
installation.
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8 Flowsheeting
Adding a Separator
Note: Drop down boxes, such as for Feed and Product streams, contain
lists of available streams which can be connected to the operation.
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Flowsheeting 9
Adding a Cooler
Add the first Cooler using the same method.
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10 Flowsheeting
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Flowsheeting 11
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12 Flowsheeting
Separator button
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Flowsheeting 13
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14 Flowsheeting
In order for the energy to flow from Cooler 2 to Effect 2, the Separator
outlet temperature must be cooler then the condensate from the
Cooler. A Set operation will be used to maintain this relationship.
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Flowsheeting 15
There are two ways to connect the operation to a stream on the PFD:
Attach Mode toggle button Press the Attach Mode toggle button.
Insert Icon Place the cursor over the operation.
The Feed stream connection point is
highlighted in dark blue.
Move the cursor over the stream you
want to connect.
Press and hold the left mouse
button.
Move the cursor to the operation
icon and release the mouse button.
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16 Flowsheeting
4. Double click on the Cooler icon on the PFD. The Cooler property
view displays. Enter the data shown below:
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Flowsheeting 17
Set Operation
1. Add a Set operation and complete the Connections page as
shown here:
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18 Flowsheeting
Add an Adjust
The Adjust operation is a Logical Operation - a mathematical operation
rather than a physical operation. It will vary the value of one stream
variable (the independent variable) to meet a required value or
specification (the dependant variable) in another stream or operation.
Adjust button 1. Add the Adjust operation. The Adjust property view displays.
2. Press the Select Var… button in the Adjusted Variable group to
open the Variable Navigator.
3. From the Object list select q1. From the Variable list which is now
visible, select Heat Flow.
The adjusted variable must
always be a user specified
value.
4. Press the OK cell to accept the variable and return to the Adjust
property view.
5. Press the Select Var… button in the Target Variable group.
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Flowsheeting 19
9. Press the Start button to begin calculations. Note: once the case is
solved (OK status), this button will disappear from the property
view.
10. To view the progress of the Adjust, go to the Monitor tab.
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20 Flowsheeting
If you enter a step size too large for the energy HYSYS will not calculate
because all the liquid has been flashed. You need to decrease the step
size, enter a new value for q1 and restart the simulation.
Note that HYSYS does not predict the formation of solids; this will have
to be verified separately.
You can perform many of the tasks and manipulations on the icons in
the PFD by using Object Inspection. Place the mouse pointer over the
icon you wish to inspect and press the secondary mouse button. An
appropriate menu is produced depending upon the icon selected
(Stream, Operation, Column, or Text Annotation).
A list of the objects which you can Object Inspect are shown below with
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Flowsheeting 21
PFD
Unit Operations
Streams
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22 Flowsheeting
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Flowsheeting 23
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24 Flowsheeting
Watch for cases when the Adjust block takes too large of a step in energy,
causing all of the liquid to be flashed.
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Flowsheeting 25
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26 Flowsheeting
26
Reactions 1
Reactions
Workshop
This module demonstrates the HYSYS philosophy for building
reactions within a simulation. HYSYS defines reactions within the
context of the Fluid Package. This is important for a number of reasons:
Learning Objectives
Once you have completed this section, you will be able to:
Prerequisites
Before beginning this section you need to know how to:
2
Reactions 3
Reactions can also occur in the Tank, Separator, and Three Phase
Separator Unit Operations if a reaction set is attached.
3
Process Overview
Reactions 5
Steam-Methane Reformer
Steam reformation of methane is often undertaken in conjunction with
processes which require large amounts of hydrogen – for instance
hydrotreating, ammonia production, or any process which may utilise
such a synthesis gas. Successive reaction stages take advantage of
thermodynamics and catalysts to enhance the production of hydrogen
at the expense of the by-product gases carbon monoxide and dioxide.
Finally, remaining carbon oxides are converted back into methane as
completely as possible to minimise CO and CO2 carryover into the
downstream process.
In the course of this problem, we will use two of the reactor types in
HYSYS to simulate the reactors in the steam reformation train: the
Conversion and Equilibrium reactors.
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6 Reactions
Reaction
Reaction
Name
1. Open the Fluid Package and select the Rxns tab. Press the
Simulation Basis Mgr button to open the Simulation Basis
Manager view.
2. Press the Add Comps button to open the component selection
view. Here, we will select the components that we will have use in
our reactions.
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Reactions 7
3. Ensure that the FPkg Pool radio button is selected. Press the Add
This Group of Components button. This moves the entire
component list over to the Selected Reaction Components group.
4. Return to the Simulation Basis Manager view and press the Add
Rxn button. Choose Equilibrium as the type from the displayed
list.
5. Press the Add Reaction button and enter the necessary
information as shown:
Note that reactants are defined with negative coefficients and products
have positive coefficients; this is the HYSYS standard. All reactions
must be defined this way.
6. Move to the Basis tab and click the K vs T Table radio button.
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8 Reactions
650°C (1200°F) 3
705°C (1300°F) 14
760°C (1400°F) 63
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Reactions 9
10. Add the third Equilibrium reaction by selecting the reaction type
as Equilibrium. On the Library tab, highlight the reaction with
the form CO + H2O = CO2 + H2. Press the Add Library Rxn button.
This adds the reaction and all of the reaction’s data to the
simulation.
11. Rename the reaction Shift1.
12. Add a Conversion reaction for the reverse of reaction number 1.
The reaction is:
13. Move to the Basis tab and enter CO as the Base Component and
enter 100 for the Co term.
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10 Reactions
Once all three reaction sets are added to the Fluid Package, you can
enter the Simulation Environment and begin constructing the
simulation.
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Reactions 11
Conditions
Composition
Name Steam
Composition
Add a Mixer
Connections
Name Mix-100
On the Parameters page, select the Set Outlet to Lowest Inlet radio
button.
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12 Reactions
Add a Heater
A Heater is needed to heat the feed to the reaction temperature.
Connections
Name HX1
Energy HX1-Q
Parameters
Worksheet
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Reactions 13
Connections
Name SET-1
Parameters
Multiplier 2.5
Connections
Name Reformer
Energy Reform Q
Parameters
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14 Reactions
1. On the Parameters page, select the Heating radio button for the
Duty.
2. On the Worksheet tab, set the temperature of Reform Prod to
760°C (1400°F).
3. On the Reactions tab, select the Reformer Rxn Set as the Reaction
Set. This will automatically connect the proper reactions to this
Reactor and the Reactor will solve.
Add a Cooler
Add a Cooler to cool the stream Reform Prod down to the Shift
Reactor’s temperature. Enter the connections with the following
information:
Connections
Name HX2
Energy HX2-Q
Parameters
Worksheet
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Reactions 15
Connections
Name Shift
Energy Shift Q
Parameters
Worksheet
1. On the Parameters page, choose the Cooling radio button for the
Duty.
2. On the Reactions tab, select Shift Rxn Set as the Reaction Set.
This will automatically connect the proper reactions to this
reactor.
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16 Reactions
Add a Cooler
Add a Cooler to cool the stream Shift Prod down to the Amine Plant’s
temperature (the Amine Plant will be added next). Make the
connections as follows:
Connections
Name HX3
Energy HX3-Q
Parameters
Worksheet
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Reactions 17
Connections
Parameters
Worksheet
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18 Reactions
Add a Heater
A Heater is needed to heat the feed to the Methanator Reactor
temperature.
Connections
Name HX4
Energy HX4-Q
Parameters
Worksheet
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Reactions 19
Connections
Name Methanator
Energy Meth Q
Parameters
Worksheet
On the Reactions tab, choose the Methanator Rxn Set from the
Reaction Set drop down menu.
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20 Reactions
1. From the Tools menu select Databook, or use the <Ctrl><D> Hot
Key to open the Databook.
2. On the Variables tab, press the Insert button to open the Variable
Navigator.
3. Select Shift Prod as the object, Comp Molar Flow as the variable,
and CO2 as the variable’s specific.
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Reactions 21
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22 Reactions
9. Enter values for Low Bound, High Bound, and Step Size of 1.5,
4.0 and 0.25 respectively.
10. Press the Start button to begin the case study analysis.
11. Press the Results button to view the calculations.
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Reactions 23
Exercise
Using the Adjust Operation
In this exercise, we will use the Adjust operation in HYSYS to determine
what temperature in the Shift 1 reactor will produce a molar ratio of
hydrogen to methane of 10:1 in the final product.
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24 Reactions
Tolerance 0.01
Step Size 25
Maximum Iterations 30
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Reactions 25
Challenge
A new application of the Product stream has been found. However, it
requires that the amount of methane in the stream be less than 1% of
the amount of hydrogen. In other words, the molar ratio must be
increased to 100.
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26 Reactions
26
Column Operations 1
Column Operations
Workshop
In this module, you will simulate an Ethanol Plant. You will get more
practice with the Column unit operation of HYSYS by:
The feed to the Rectifier (Rect) is the bottoms product of the Lights
purification tower and the vapour draw from the concentration tower.
The Rectifier is operated as a conventional distillation tower.
2
Column Operations 3
Learning Objectives
Once you have completed this section, you will be able to:
Prerequisites
Before beginning this section, you need to be able to:
3
Process Overview
Column Operations 5
Column Overviews
CO2 Wash
Concentrator
Lights
5
6 Column Operations
Rectifier
6
Column Operations 7
Conditions
H2O 100%
7
8 Column Operations
Conditions
Ethanol 0.0637
H2O 0.8759
CO2 0.0601
Methanol 4.433e-5
1-Propanol 2.802e-5
2-Propanol 2.808e-5
1-Butanol 2.505e-5
3-M-1-C4ol 9.727e-5
2-Pentanol 2.457e-5
Glycerol 3.141e-5
Conditions
H2O 100%
8
Column Operations 9
Conditions
Inlets FromFerm
9
10 Column Operations
Column SubFlowsheet
A SubFlowsheet contains equipment and streams and exchanges
information with the Parent Flowsheet through the connected streams.
From the Main Environment, the Column appears as a single, multi-
feed multi-product operation. In many cases, you can treat the column
in exactly that manner.
10
Column Operations 11
Column Types
HYSYS has several basic Column Templates (pre-constructed column
configurations) which may be used for installing a new Column,
allowing HYSYS to model several different separation processes.
Initial Estimates
In order to calculate, the Column solver in HYSYS requires user-
supplied estimates ranging from condition parameters to feed and
draw locations. These data can be supplied in several ways. The first
interface when you select a Column requires values for the Number of
Trays, Reflux, Pressure, and so on. In the Column Solver, on the Work
Sheet tab, Conditions page, data can also be supplied. On the Design
tab, Specs page, HYSYS allows you to choose from a library of
specifications gathered in the Column Specification Types window,
activated when you press the Add button. Specification Types can be
supplied as Estimates or as Active specifications. Only Active
specifications fill the Degree of Freedom of the Column which must be
zero for the solver to calculate. Inactive specifications (Estimates) are
used only as initial estimates for the convergence algorithm and never
use a degree of freedom. Alternatively, Estimates can be supplied on the
Estimates page under the Parameters tab. However, they will not
appear on the Monitor, and hence cannot be set as Active
specifications.
If the user does not have initial estimates HYSYS generates them.
However for chemical systems, it is recommended to use the HYSYS
Estimate Generator tool. In the Column Environment, on the
Parameters tab, Solver page, there is the Initial Estimate Generator
11
12 Column Operations
Parameters box. By checking the box, the IEG will perform iterative
flash calculations to provide the initial estimates for the temperature
and composition profiles. No user estimates are required when the
Iterative IEG check box is activated.
The Input Expert will guide you through the installation of the column.
12
Column Operations 13
13
14 Column Operations
Concentrator
This tower removes most of the Methanol from the Fermentor
products.
Connections
No. of Stages 17
Pressure
Temperatures
However, in this case, we do not need a Draw Rate specification for this
stream; therefore, we need to replace the Draw Rate specification that
HYSYS added automatically with one that we will define to meet our
simulation needs.
14
Column Operations 15
15
16 Column Operations
This specification will set the ratio of ethanol recovered in the specified
stream compared to the amount of ethanol fed to the column. Here, we
have set this ratio at 0.95, meaning that 95% of the ethanol supplied to
the column is recovered in the Rect Feed stream.
We are not concerned about where the other 5% goes, although it must
exit the column in one of the other product streams.
16
Column Operations 17
Lights
The Lights Tower is a purification tower.
Add the Refluxed Absorber column and enter the following data.
No. of Stages 5
Not Required
Reflux Ratio 5
17
18 Column Operations
Stage Condenser
Component Ethanol
So, deactivate the Reflux Ratio specification and activate the Ethanol
Purity specification.
18
Column Operations 19
Rectifier
The primary product from a plant such as this would be the azeotropic
mixture of ethanol and water. The Rectifier serves to concentrate the
water/ethanol mixture to near azeotropic composition. The Rectifier is
operated as a conventional distillation tower. It contains a partial
condenser as well as a reboiler.
Connections
No. of Stages 59
Pressures
Specifications
19
20 Column Operations
We will add two Column Draw Rate specifications and one Component
Fraction specification.
1. Remember that when we added the two side draw streams to the
column, HYSYS automatically created Draw Rate specifications
for those streams. On the Monitor page, enter the following
values for these two Draw Rate specifications.
Specification 1 Specification 2
Component Ethanol
20
Column Operations 21
21
22 Column Operations
22
Column Operations 23
Optional Challenge
Replacing the Kettle Reboiler with a
Thermosyphon Reboiler
In this portion of the module, we will replace the default kettle type
reboiler on the Rectifier column with a "Thermosyphon" type reboiler.
Following the steps below will allow you to replace the standard kettle
reboiler with a thermosyphon type reboiler.
1. Change the number of stages in the column to 60. This value can
be accessed from the Connections page of the column’s property
viewer.
2. Enter the Column Environment by pressing the Column
Environment button on the property viewer.
3. Disconnect the "Stillage B" stream from the reboiler and reattach
it as a material withdraw stream from stage 60.
4. Disconnect the "Boilup" stream from stage 60 and reattach it to
stage 59. You will need to expand the trays shown by the column
icon in order to attach the stream to this tray. Right-click on the
tray section, and select Show Trays. Use the Radio button to
select Full Expansion, or scroll down and check to Show box for
stage 59.
5. Attach the reboiler’s liquid product outlet (formerly the location
of "Stillage B" stream) to the inlet point on stage 60.
23
24 Column Operations
Stage Reboiler
Note that adding the additional stage and modifying the reboiler has
not changed the operating behaviour of the column. The bottom stage
of the column (#60) does not function like a true equilibrium stage
(there is no contacting vapour from the bottom). The boil-up provided
by the thermosyphon reboiler will be the same as for the kettle reboiler.
This is independent of the reboiler type.
24
Ethylene Glycol Plant 1
Workshop
Ethylene glycol has many industrial uses: a feed stock for polyester
resins, a hydrate inhibitor in natural gas pipelines, an all-weather
antifreeze and coolant, or an industrial solvent. Ethylene oxide and
water are fed to a reactor to produce ethylene glycol. The product
stream is fed to a distillation column where the excess water and
ethylene oxide are stripped off the top and the ethylene glycol is the
bottom product.
Learning Objectives
After completing this module, you will be able to:
Prerequisites
Before beginning this module, you need to be able to:
2
Process Overview
Column Overview
Ethylene Glycol Plant 5
Go to the Binary Coeffs tab. Select UNIFAC VLE as the Coeff Estimation
method to estimate the missing binary coefficients and press
Unknowns Only. This will estimate the coefficients for the ethylene
oxide / ethylene glycol pair.
5
6 Ethylene Glycol Plant
Basis
Parameters
Forward Reaction
A 5.0e+06
E 5.0e+04
6
Ethylene Glycol Plant 7
Conditions
Composition
C2Oxide 1.0
H2O 0.0
EGlycol 0.0
Conditions
Composition
C2Oxide 0.0
H2O 1.0
EGlycol 0.0
7
8 Ethylene Glycol Plant
CSTR Reactor
Add a CSTR operation and enter the following information. Be sure to
assign the Global Rxn Set as the Reaction Set for the separator to model
CSTR button the reactor.
Connections
Name Reactor
Energy Rx Coolant
Parameters
1. On the Reactions tab, select the Global Rxn Set and Rxn-1 as the
Reaction.
2. Specify the temperature of stream Rx Liquid to be 65°C (150°F).
8
Ethylene Glycol Plant 9
Connections
Name T-100
No. of Stages 10
Pressures
Specs
9
10 Ethylene Glycol Plant
The Recycle installs a theoretical block in the process stream. The feed
into the block is termed the calculated recycle stream, and the product
is the assumed recycle stream. The following steps take place during
In general, a Recycle operation the convergence process
is required for material
transfer and not for thermal
recycles.
• HYSYS uses the conditions of the assumed stream (outlet)
and solves the flowsheet up to the calculated stream (inlet).
• HYSYS then compares the values of the calculated stream to
Always supply a guess or those in the assumed stream.
starting point for the outlet
stream of the Recycle, never • Based on the difference between the values, HYSYS modifies
the inlet. A guess close to the the values in the calculated stream and passes the modified
solution will result in a faster values to the assumed stream.
convergence time.
The calculation process repeats until the values in the calculated
stream match those in the assumed stream within specified tolerances.
10
Ethylene Glycol Plant 11
Delete the specified molar flow rate of the Water Feed stream. This
value will be back-calculated from the outlet of the mixer.
Specify the molar flow of the mixer outlet stream, Water to Reactor, as
150 kgmole/h (330 lbmole/hr). Once the flow rate in this stream is set,
HYSYS will automatically calculate the flowrate of the Water Feed
stream. If we had not deleted the specified value, HYSYS would report a
consistency error, because a the two values would be in conflict with
each other.
11
12 Ethylene Glycol Plant
Parameters tab
Tolerance page
HYSYS allows you to set the convergence criteria or tolerance for each
of the Recycle variables. In this example, leave everything at the default.
Numerical Page
This page contains the options for the two types of Recycles, Nested
and Simultaneous.
12
Ethylene Glycol Plant 13
Monitor tab
This page displays convergence information as the calculations are
performed. Any variable that changes between iterations is displayed in
this table.
Worksheet tab
The Recycle WorkSheet page displays the Inlet and Outlet stream
information. In this instance, notice that the Inlet and Outlet streams
have the same values. This is because before we installed the Recycle,
the Inlet stream was already calculated by HYSYS. When the Recycle
was connected, the known Inlet conditions were automatically passed
to the Outlet stream to serve as the starting guess.
13
14 Ethylene Glycol Plant
Remember to save the file under a different name if you wish to save it!
Exercise 2
Set up an Adjust operation to make sure the molar flow of Ethylene
Glycol in the Rx Liquid stream is equal to 110 kgmole/h (240 lbmole/
hr), by adjusting the EOx Feed molar flow with a step size of 1 kgmole/h
(2 lbmole/hr).
14
Ethylene Glycol Plant 15
Advanced Modelling
Because the Recycle operation is a mathematical representation of a
physical process, its location in a simulation is a particularly important
one. The location of the tear stream can often determine success or
failure to converge a recycle
15
16 Ethylene Glycol Plant
Recycle Exercises
Choosing the Right Location
When installing Recycle operations in a HYSYS simulation, it is vital
that right location for the operation be chosen. Several guidelines were
given on a previous page, and several different problems will be given
here. Note that some of these flowsheet may require more than one
Recycle operation.
Flowsheet 1
Where should the Recycle be placed in this flowsheet and why? Assume
that you know the following information:
16
Ethylene Glycol Plant 17
Flowsheet 2
Assume that the Feed is fully defined, Shell and Tube Side pressure drops
are known, as well as the Column Feed temperature.
Flowsheet 3
Assume the Feed is completely defined, shell and tube side pressure drops
for E-100 and E-101, and the temperatures of streams 3 and 4 are known.
17
18 Ethylene Glycol Plant
Flowsheet 4
Assume the Feed is completely defined, and the shell and tube side
pressure drop for E-100 is known.
18
Aromatic Stripper 1
Aromatic Stripper
Workshop
This example demonstrates a typical application of the recycle
operation. An aromatic stripper to remove Benzene and Toluene from
water is simulated with the help of a reboiled absorber. The column has
two feeds: the main column feed and a reflux, which is the recycled
overhead vapour after being cooled and going through a three phase
separator.
This example will also illustrate the flexibility of HYSYS that allows the
user to use a different Fluid Package in the column subflowsheet from
the one in the main flowsheet. This allows the user to use a property
package tailored towards a certain behaviour in the Main Flowsheet
and another package tailored towards a different behaviour in the
Column environment.
Here, the feed stream is mostly water that is laced with a small amount
of benzene and toluene. The objective of this process is to produce two
product streams, one of virtually pure water, and the second, a
concentrated stream of aromatics.
Learning Objectives
Once you have completed this section, you will be able to:
2
Process Overview
Column Overview
Aromatic Stripper 5
VLE Case
1. Go to the Binary Coefficients tab. For this case the default values
for Aij and Alphaij are used (Bij is empty).
LLE Case
1. Return to the Fluid Pkgs tab of the Basis Manager.
2. Use the Copy button to make a copy of the Arom Strip Fluid
Package. Name the new Fluid Package Condenser.
3. Go to the Binary Coefficients tab. Here, we will enter parameters
that have been specifically regressed for these components.
4. Enter the values given on the next page.
5
6 Aromatic Stripper
The Activity Coefficients for Aij, Bij, and Alphaij are shown below:
Aij Interaction
Bij Interaction
Alphaij Interaction
6
Aromatic Stripper 7
7
8 Aromatic Stripper
Conditions
H2O 0.9982
Benzene 0.0013
Toluene 0.0005
H2O 1.0
Benzene 0
Toluene 0
8
Aromatic Stripper 9
Add A Mixer
Connections
Name MIX-100
No. of Stages 2
9
10 Aromatic Stripper
4. Assign Arom Strip as the Fluid Package to use for the column.
Note: A message will appear warning you about the P-H Flash as a
transfer basis. Because we are now using two fluid packages with
different interaction coefficients, the program allows you to select the
type of flash that will occur between the two fluid packages, i.e.,
between the column overhead vapour product (using VLE data) and the
condenser unit (using LLE data).
Use the default flash, P-H, and press the Return to Simulation
Environment button again.
6. Open the Stripper property view and press the Run button. Close
the view once it has converged.
10
Aromatic Stripper 11
Add a Cooler
Connections
Name Condenser
Inlet Vapour
Energy Cond Q
Outlet Condensed
Parameters
Worksheet
Connections
Name Separator
Feeds Condensed
11
12 Aromatic Stripper
Add a Pump
Connections
Name Pump
Outlet To Recycle
Energy Pump Q
Parameters
Connections
Name RCY-1
Inlet To Recycle
Outlet Reflux
12
Aromatic Stripper 13
13
14 Aromatic Stripper
14
The Optimizer 1
The Optimizer
Workshop
In this example, a simple distillation column to separate
Fast track to page 9. Tetrahydrofuran (THF) from Toluene is simulated. The object of the
exercise is to select the product specifications such that profit is
maximized. A special tool in HYSYS, the Optimizer, will be used to find
the optimum operating conditions.
Learning Objectives
Once you have completed this section, you will be able to:
Prerequisites
Before beginning this section you need to be able to:
2
Process Overview
Column Overview
The Optimizer 5
1. On the Binary Coeffs tab, check that the UNIFAC VLE estimation
method is chosen, and press the Unknowns Only button to
estimate the missing Interaction Parameters.
2. Enter the Simulation Environment.
Name Feed
THF 0.44
Toluene 0.56
5
6 The Optimizer
Connections
No. of Stages 10
Pressure
Specs
6
The Optimizer 7
These two specifications should be Active. The DOF for the column
should now be 0.
The column should now solve automatically. If it does not, press the
Run button to start the solver.
7
8 The Optimizer
We want to set the value for both of these tolerances at 1e-6. Note that
this will increase the solving time of the column, but this column solves
very fast anyway, so the tighter tolerances are acceptable in this case.
8
The Optimizer 9
9
10 The Optimizer
where:
PF = Profit Function/time
OC = Operating Costs
10
The Optimizer 11
Variables tab
When you invoke the Optimizer for the first time, you are placed on the
Variables tab. On the Variables tab you define the Adjusted (Primary)
Variables to be used in the optimization.
In this case, our Primary Variables are the purity of our products, THF
and Toluene.
1. Press the Add button to add the first variable, T-100, Spec Value,
THF Purity Spec.
2. Set the Upper Bound at 0.9, and the Lower Bound at 0.90.
3. Add the second variable, T-100, Spec Value, Toluene Purity Spec,
with the same bounds as above.
11
12 The Optimizer
12
The Optimizer 13
Adding Formulas
13
14 The Optimizer
Equation
Cell Equation (Field) Description
(SI Units)
Pay special attention to the units in this equation. If using field units,
you may have to add an additional term to this equation to convert
between hours and days.
14
The Optimizer 15
Functions tab
The Functions tab contains two groups, the Objective Function and the
Constraint Functions. However, in this example we do not have
constraint functions.
15
16 The Optimizer
Parameters tab
Monitor tab
The Monitor tab displays the values of the Objective Function and
Primary Variables during the Optimizer calculations.
1. Move to the Monitor tab and press the Start button to begin the
optimization.
16
The Optimizer 17
17
18 The Optimizer
Exercise 1
We are going to introduce a constraint on the liquid volume flow of the
stream THF and examine how it affects the results, profit and products
purities.
First, the case must be set back to its state before the optimization.
The constraint on the liquid flow is that it must not exceed 1.85 m3/h
(65.5 ft3/hr).
The THF Liquid Flow must first be imported into the spreadsheet (use
an empty cell), and the constraint value must be written in the
spreadsheet. Remember to write the comments next to the values so
that they can be understood.
18
The Optimizer 19
What differences, if any, does the constraint make to the first optimized
solution? Fill in the following table:
Optimized Optimized
Base Case
Case Case 2
Profit 106.3 $
19
20 The Optimizer
Exercise 2
Here, we are going to model the reboiler with a steam-heated shell and
tube heat exchanger. The heat exchanger will be modelled with 115 psia
steam and the maximum flow of steam available to the reboiler is
limited to 840 kg/h (1850 lb/hr). (Note that there are a few approaches
that can be taken with the heat exchanger modelling so two of the
possibilities are listed). The cost of the 115 psia steam is 0.682 $/kWh
($200/MMBtu).
Use the Mixed optimization
scheme for this exercise. 1. Add Water as a component. This must be done in the Basis
Environment.
2. Open the Column’s Property viewer; on the Monitor page, reset
the THF and Toluene purity specifications to 0.95.
3. Add a new internal stream (on the Flowsheet tab), ToReb with the
following attributes:
Type Liquid
Net/Total Total
Stage 10
Export Yes
20
The Optimizer 21
10. Export the RebQ Heat Flow value (you will have to make this
Exportable first) from the Optimizer spreadsheet into the Target
value for the Adjust operation. A cell on the spreadsheet can not
be simultaneously imported and exported. Copy the value of cell
B2 to another empty cell by entering the formula "+B2". The
value in this new cell can then be exported to the Target Value of
the Adjust operation.
11. Change the Heating Cost value to 0.682 $/kWh ($200/MMBtu)
(Cell D2 on the spreadsheet) and Start the Adjust.
12. Add the Steam Mass Flow (must be less than 840 kg/h (1850 lb/
hr)) constraint to the Optimizer.
13. Start the Optimizer.
21
22 The Optimizer
22
Azeo Distillation with LL Extractor 1
Workshop
An azeotropic mixture of Benzene and Cyclo-Hexane is to be separated
in a distillation column using Acetone as the entrainer. Nearly pure
Benzene is produced from the bottom of the column, while a near
azeotropic mixture of Acetone and Cyclo-Hexane is produced
overhead. The overhead mixture will be separated in a Liquid-Liquid
extractor using water as the solvent, with Cyclo-Hexane being
recovered as the overhead product. The Acetone/Water mixture will
then be separated in a vacuum tower with the Acetone and Water
products being recycled through the flowsheet.
The process will be separated into four sections, the Azeotrope tower,
the Liquid-Liquid extractor, the Solvent Recovery tower and finally the
recycling system.
Learning Objectives
Once you have completed this section, you will be able to:
2
Process Overview
4 Azeo Distillation with LL Extractor
4
Azeo Distillation with LL Extractor 5
1. Add the first Fluid Package in the usual manner and change the
default name to VLE Basis.
2. On the Binary Coeffs tab, view the binary coefficients for the
UNIQUAC activity model.
1. On the Fluid Pkgs tab of the Simulation Basis Manager, press the
Import button and import the Fluid Package LLEBasis.fpk. This
file should be located on the course disk supplied with this
material.
2. Press the View button to see the new Fluid Package. Go to the
Binary Coeffs tab to view the binary coefficients.
If you examine the LLE Coefficients for VLE Basis and LLE Basis you will
Ensure that VLE Basis is the see they are different, because they have been taken from different
Default Fluid Package when sources.
you leave the Basis
Environment.
VLE Basis will be used for most of the simulation, while LLE Basis will
be used as the Fluid Package for the Liquid-Liquid Extractor.
5
6 Azeo Distillation with LL Extractor
Conditions
Benzene 0.518
Cyclohexane 0.482
Conditions
6
Azeo Distillation with LL Extractor 7
Azeotrope Tower
Published documentation on this process indicates that the overhead
composition from the Azeotrope Tower is a near azeotropic mixture of
Acetone and Cyclohexane. Using less Acetone than is necessary to
produce the azeotrope will prevent the original Benzene/Cyclohexane
azeotrope from being separated.
7
8 Azeo Distillation with LL Extractor
8
Azeo Distillation with LL Extractor 9
Connections
No. of Stages 28
Pressures
Delta P 0
Temp. Estimates
Specifications
9
10 Azeo Distillation with LL Extractor
10
Azeo Distillation with LL Extractor 11
Property Package
The Liquid-Liquid Extractor cannot be used with the following property
packages:
• Wilson
• Antoine
• BraunK10
• Esso Tabular
• Steam
Use only property packages
that support 2 liquid phases. • Amine
• Chao-Seader
• Grayson-Streed
• Sour PR
• Sour SRK
Overhead Estimate
You will not be required to provide an estimate for the Overhead
Product Flow. The Extractor will generate an estimate from a mole
weighted TP-Flash of the combined tower feeds.
Stage Efficiencies
The HYSYS Extraction algorithm models the Extractor as a staged
tower, allowing you to specify either ideal stages or actual stages with
efficiencies.
Side Draw
If you require a Side Draw on the Extractor, you can choose to draw
either the Light or Heavy phase from a stage. HYSYS will perform a
three phase flash on the entire contents of the stage to produce the
conditions and composition of the specified draw.
11
12 Azeo Distillation with LL Extractor
Conditions
12
Azeo Distillation with LL Extractor 13
Connections
No. of Stages 20
Temperature Estimates
13
14 Azeo Distillation with LL Extractor
14
Azeo Distillation with LL Extractor 15
Connections
No. of Stages 20
Pressures
Temperature Estimates
Specifications
Reflux Ratio 7
15
16 Azeo Distillation with LL Extractor
Solvent Recycles
Finally, the two products from the Solvent Recovery tower have to be
recycled to the previous two towers. Because of the temperature and
pressure of the Solvent Recovery tower, each recycle stream will require
a Pump and a Cooler/Heater operation to return the stream to the
necessary tower conditions.
Add a Pump
Add a Pump to the stream H2O Rich with the following information:
Connections
Name P-100
Energy Q 100
Parameters
16
Azeo Distillation with LL Extractor 17
Add a Cooler
Add a Cooler downstream of P-100 with the following information:
Connections
Name E-100
Energy Q102
Parameters
Delta P 0 kPa
17
18 Azeo Distillation with LL Extractor
Connections
Name P-101
Energy Q 101
Parameters
Add a Heater
Add a Heater operation downstream of Acet Atm with the following
information:
Connections
Name E-101
Energy Q 103
Parameters
Delta P 0 kPa
18
Azeo Distillation with LL Extractor 19
A Mole Balance operation will be used to create two streams (Rec Acet
and Rec Water) with the same flowrates and compositions as the tower
product streams Benzene and CycloC6, respectively.
These streams are then sent to a Component Splitter and split into two
streams: one containing the product and the other containing traces of
the lost solvent.
The streams containing the lost solvents are the make-up streams
which will be mixed with the recycled streams from the solvent
Recovery Tower.
19
20 Azeo Distillation with LL Extractor
Connections
Name BAL-1
Connections
Name BAL-2
20
Azeo Distillation with LL Extractor 21
Connections
Name X-100
Parameters
Splits
Benzene 0
CycloC6 0
Acetone 1.0
H2O 1.0
21
22 Azeo Distillation with LL Extractor
Connections
Name X-101
Parameters
Splits
Benzene 0
CycloC6 0
Acetone 1.0
H2O 1.0
22
Azeo Distillation with LL Extractor 23
Connections
Name MIX-100
Connections
Name MIX-101
23
24 Azeo Distillation with LL Extractor
Connections
Name RCY-1
Outlet Water
Parameters
Temperature 10.0
Pressure 10.0
Flow 1.0
Enthalpy 10.0
Composition 1.0
Connections
Name RCY-2
Outlet Acetone
Parameters
Temperature 10.0
Pressure 10.0
Flow 1.0
Enthalpy 10.0
Composition 1.0
24
Azeo Distillation with LL Extractor 25
25
26 Azeo Distillation with LL Extractor
26
Reactive Distillation 1
Reactive Distillation
Workshop
With the continuous removal of reaction products, reactive distillation
has found acceptance as a means of improving the technical and
economic operation of processes where it is applicable. Advantages of
this process include higher yields, energy savings and reduced capital
costs.
Fast Track to page 7
In this example, you will study the manufacture of Methyl Acetate, an
important oil resin used in the manufacture of artificial leathers. You
will simulate the synthesis of Methyl Acetate from Methanol and Acetic
Acid in a catalytic distillation column.
Learning Objectives
Once you have completed this section, you will be able to:
2
Process Overview
Column Overview
Reactive Distillation 5
Conditions
Methanol 0.4
M-Acetate 0.1
Water 0.1
5
6 Reactive Distillation
Connections
No. of Stages 15
Pressure
Specs
Reflux Ratio 5
Go to the Monitor page of the Design tab and run the column.
Complete the following table with information from the simulation:
Methanol
Acetic Acid
Methyl Acetate
Water
6
Reactive Distillation 7
Open the case OptReact.hsc The reaction occurring in this simulation is a Kinetic reaction,
7
8 Reactive Distillation
1. On the Reactions tab, press the New button. Enter the following
data:
8
Reactive Distillation 9
Methanol
Acetic Acid
Methyl Acetate
Water
Does the reaction inside the column have any effect on the
compositions of the product streams? __________
9
10 Reactive Distillation
10
Three Phase Distillation 1
Introduction
In previous modules, we have installed distillation columns design for
two phases. However, these columns will not work for three phase
systems. When dealing with three phase systems, it is necessary to use a
different type of column that uses a different Input Expert, and a
different default solver.
Learning Objectives
In this module, you will learn:
Prerequisites
Before beginning this module, you should have some experience with
installing distillation columns in HYSYS. Previous experience with
normal two phase systems will help you understand the principals
behind the operation of three phase systems.
2
Three Phase Distillation 3
Background
The three phase stream that will be distilled here will consists of three
components: water, n-butyl-acetate, and 2-butanol. The ternary
diagram for these three components at 25 oC (77 oF) and 101.3 kPa (14.9
psia) looks something like this:
This plot was generated using the DISTIL software package produced
by AEA Technology Engineering Software.
Water 0.35
n-Butyl-Acetate 0.40
2-Butanol 0.25
As you can see (using the ternary graph above), this stream will lie
within the two liquid phase region.
3
4 Three Phase Distillation
Different Solvers
With two phase distillation the most common solver that is used is the
"HYSIM Inside-Out" solver. This solver is good for most hydrocarbon
systems, but it can not handle highly non ideal chemical systems,
including three phase systems.
You already have experience with two phase systems, and you will find
that setting up the three phases system is not that much more
complicated.
4
Process Overview
6 Three Phase Distillation
Column PDF
6
Three Phase Distillation 7
Begin a new HYSYS case and select the NRTL Activity model as the
Property Package. The three required components are:
• Water
• 2-Butanol
• n-B-Acetate
Name Feed
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8 Three Phase Distillation
As mentioned before, the Input Expert for the Three Phase column is
slightly different than the one used for an ordinary Two Phase column.
For this reason, each page will be shown here.
8
Three Phase Distillation 9
On the next page, set the number of stages at 6, and set the "Two Liquid
Phase Check" on the top five stages.
On the third page, enter names for the streams around the condenser.
For this column, the Reflux Stream will be the Lights only; therefore,
select the appropriate radio button in this group box.
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10 Three Phase Distillation
On the fourth page, set the vapour rate to 0.0 and the Light Reflux
Fraction to 1.0. The degrees of freedom should read 0, once both of
these values are entered.
On the fifth page, attach the Feed stream to stage 1. Also, define the
reboiler energy stream and attach a liquid product stream to the
reboiler. From now on, the screens will look familiar to the input expert
screens that you have seen previously.
10
Three Phase Distillation 11
On the next page, set the condenser pressure at 101 kPa (14.9 psia), and
the reboiler pressure at 105 kPa (15.5 psia).
11
12 Three Phase Distillation
We are now done. Press the Done button to close the input expert. Note
that if the formation of azeotropes were a concern in this column, the
Azeotropic Initialization button would have been pressed, and HYSYS
would have checked for possible azeotropes among the selected
components.
Enter a Bot Prod Rate of 33 kgmole/h (75 lbmole/hr). Press the Run
button to converge the column; the column should start to solve, and
will reach a converged solution quickly. If the column does not solve in
the first attempt, increase the Bot Rate Spec value to 35 kgmole/h
(80 lbmole/hr) and try again. Once the column converges, decrease the
spec back to its original value.
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