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Jump Start: Activated Energy Analysis in Aspen Plus and Aspen HYSYS
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Setting Up an Energy Analysis Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Generating Process Revamp Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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Jump Start: Activated Energy Analysis in Aspen Plus and Aspen HYSYS
Introduction
In todays business climate, profitability is of pinnacle importance. One of the challenges facing industrial plants in
reaching profitability is the minimization of annual costs related to utility consumption. In order to achieve a reduction
in utility costs, many plants choose to perform an integration of heat exchanger networks. The specific network of heat
exchangers that make best use of the available in-house heating and cooling is constructed using pinch calculations.
However, these calculations can be daunting for simple plant setups with little equipment, and only increase in difficulty
with a higher sophistication of plant design.
To respond to this challenge, Aspen Technology has introduced an innovative approach to reduce energy use and
greenhouse gas outputs in its Activated Energy Analysis offering. Activated Energy Analysis works inside of Aspen
HYSYS and Aspen Plus, with no need to operate another program concurrently.
Using Activated Energy Analysis, a summary of annual process energy and greenhouse gas consumptions and
expenditures, along with potential savings through process upgrades and redesign, are provided. Activated Energy
Analysis generates extensive revamp scenarios that can be implemented to reduce fresh utility dependence, and shows
details relevant to the optimization including required capital cost, annual reduction in utility cost, and payback period for
investment.
The basic steps towards best utilizing Activated Energy Analysis will be described in this guide, as will advanced
techniques. Some features denoted in this guide are only available in the V8.8 or later release of Activated Energy
Analysis, but all basic workflow is included in Activated Energy Analysis V8.0 and higher.
As a reminder, it is free for current AspenTech customers to upgrade to the latest version of the aspenONE
Engineering suite. Simply contact AspenTech support via http://support.aspentech.com to do so.
This document is not meant to be used as a stand-alone reference document. AspenTech recommends that a range of
other resources be referenced to give the user a comprehensive view of how to use Activated Energy Analysis. These may
include:
AspenTech support website (http://support.aspentech.com)
AspenTech courseware available in on-line and in-person versions
AspenTech business consultants
Additional Jump Start Guides, available on a variety of related topics
This guide covers how to utilize Activated Energy Analysis to analyze and optimize energy in Aspen Plus and Aspen
HYSYS. It assumes that the user has Aspen HYSYS or Aspen Plus V8.0 or higher installed on her or his computer and a
functional process design completed.
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Jump Start: Activated Energy Analysis in Aspen Plus and Aspen HYSYS
Figure 1a.Utilizing the Energy Panel to launch the energy configuration page.
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Jump Start: Activated Energy Analysis in Aspen Plus and Aspen HYSYS
The energy configuration page provides areas to specify parameters of the project before activating energy analysis.
Areas that can be customized include: process type, approach temperature, carbon fee, and scope, as well as the utility
assignments table. The process type can be customized by clicking the drop down menu and selecting the correct
process type, as shown in Figure 2a. Approach temperature is defaulted based on the process type, but this value and
the carbon fee value can be customized by entering specified amounts, as seen in Figure 2b. The desired flowsheets and
sub-flowsheets included in Activated Energy Analysis can be specified by selecting the Define Scope button and using
the check boxes on the Energy Analysis Scope window that appears, select the regions of the flowsheet that should be
analyzed as seen in Figure 2c. In this example, only the Preheat Train (TPL1) was chosen to be analyzed.
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Jump Start: Activated Energy Analysis in Aspen Plus and Aspen HYSYS
Figure 2a.Specifying process type parameters utilizing the energy configuration form.
Figure 2b.Specifying approach temperature and carbon fee in the energy configuration form.
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Jump Start: Activated Energy Analysis in Aspen Plus and Aspen HYSYS
Figure 2c.Specifying the energy analysis scope using the energy analysis form.
Once the parameters for your analysis have been set, run the targeting step utilizing Activated Energy Analysis. This can
be completed in a few different ways. The first way is to select the Analyze Energy Savings button at the bottom of the
Energy Configuration Page, as shown in Figure 3. Additionally, this step can be run by either scrolling or clicking on the
off button at the bottom right corner of the blue Energy Panel of the Activation Dashboard, also shown in Figure 3.
Figure 3. Launching Activated Energy Analysis through the energy analysis form or Energy Panel.
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Jump Start: Activated Energy Analysis in Aspen Plus and Aspen HYSYS
Once Activated Energy Analysis is turned on, it will go through a series of calculation steps, outlined on the top of blue
energy panel as Loading Analysis and Calculating, shown in Figure 3. Once these steps are completed, the available
energy savings of the process are reported. An overall report of the available energy savings is displayed on the blue
Energy Panel of the Activation Dashboard, as highlighted in Figure 4.
Figure 4. An overview of potential energy savings highlighted in the energy panel and the Savings Summary form.
The number reported on the left hand side of the Energy Panel is the potential amount of energy that could be saved
and the number reported on the right hand side is the percent, as compared to the current energy expenditures, that the
energy could be reduced. These values are calculated using the difference between the actual utility consumption on
the flowsheet and the utilities target, calculated by pinch technology. More detailed savings are reported in the Savings
Summary tab shown in Figure 4. The savings summary tab can be shown as both the duty and cost savings by selecting
the corresponding radio button. The savings are displayed for the total, heating and cooling utilities, and the carbon
emissions. The graphs at the top of the Savings Summary tab display the current actual utility, or carbon of the process,
compared to the target, or ideal utility or carbon emission of the process. The table below highlights each of these
parameters in table format to numerically organize potential savings.
For ease of use, the user can right click on the Energy Analysis tab and select New Vertical Tab Group to view the
Energy Analysis results side-by-side with simulation. This new feature is shown in Figure 5 below.
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Jump Start: Activated Energy Analysis in Aspen Plus and Aspen HYSYS
Figure 5. The energy analysis form can be viewed side-by-side with the simulation for ease of use.
Click on the utilities tab under the Energy Analysis parent tab to view more detailed information of each utilitys target
and consumption amounts. Figure 6 shows the information presented in the Utilities tab.
Figure 6. Utilities tab displays detailed utilities information for activated energy analysis.
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Jump Start: Activated Energy Analysis in Aspen Plus and Aspen HYSYS
The utilities are listed with the hot utilities at the top of the table and the cold utilities listed at the bottom. This table
displays information about the actual and target consumption and savings potential for each utility. The energy cost
savings in both absolute and relative terms are also listed for each utility, along with the approach temperature, which
can be customized by entering a value into the table. Additionally, there is a column with a Status for each utility. This
column indicates if the utilities are sufficient to calculate the heating and cooling target.
The Carbon Emissions tab displays a table with more detailed information about the carbon emissions of each utility in
the process, as shown in Figure 7.
Figure 7. Carbon Emissions tab displays detailed carbon emission information for activated energy analysis.
It displays the information about the actual and target carbon emissions and savings potential associated with each
utility. Additionally, the carbon emission cost savings in both absolute and relative terms are listed for each utility used in
the process.
The Exchangers tab on the Activated Energy Analysis form, shown in Figure 8 displays all the heat exchangers being
analyzed in the process, including heaters, coolers, and process-process heat exchangers.
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Jump Start: Activated Energy Analysis in Aspen Plus and Aspen HYSYS
Figure 8. Exchangers tab displays detailed exchanger information for activated energy analysis.
This form displays the key information of the exchangers on the flowsheet. Hovering the mouse over the Hot Side Fluid
and Cold Side Fluid text will display the hot side process pinch and cold side process pinch temperatures, respectively.
The energy inefficiency of the process can be viewed through the recoverable duty column which gives the duty for each
exchanger. This information is pertinent when deciding design change solutions later in the workflow.
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Jump Start: Activated Energy Analysis in Aspen Plus and Aspen HYSYS
Note: For Aspen Plus users, only utilities defined in the Utilities Object Manager will be considered in the targeting
process for utility switching. For Aspen HYSYS users, all utilities defined in the Process Utilities Manager will be
considered. Undesired utilities need to be removed from the Process Utilities Manager in Aspen HYSYS if they are
unavailable for selection.
This table shows a listing of the heat exchangers included in the heat integration, each exchangers duty, temperatures,
area, heat transfer coefficients, and hot and cold fluids. In version 8.4 or higher of Activated Energy Analysis, a column
titled Ideas for Changes appears. In this column, if a light bulb appears, Activated Energy Analysis has detected a simple
design change (i.e. changing the temperature of a heat exchanger inlet stream) that could lead to more efficient energy
usage in the process. Additionally, heat transfer coefficients obtained from rigorous Aspen Exchanger Design and Rating
models can be used to improve the accuracy of the heat exchangers being used in the heat integration model. See the
Obtaining Heat Transfer Coefficients from the Activated EDR section later in this guide to learn more.
Figure 9. The Design Changes tab specifying the number of retrofit solutions suggested.
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Revamp solutions are generated by clicking the Find Design Changes button which will launch the 3 types of design
solutions to be produced, resulting in Figure 10.
Figure 10.Selecting the Find Design Changes button will produce the available retrofit solutions.
Once the retrofit analysis is complete, the table in the Final Design Changes tab is populated with retrofit solutions. The
three types of retrofit options explored in more detail are:
1. Modify Exchangers: This retrofit option will modify existing exchangers by adding surface areas to save energy. This
option will produce one solution. The top gird shows the summary of this retrofit solution.
2. Add Exchangers: This retrofit option will add a new heat exchanger to the existing heat exchanger network, one at a
time. Users can select 1-5 solutions to be produced. The second grid in Figure 10 shows the possible solutions for this
retrofit option, with each row representing a different solution or proposed heat exchanger to be added.
3. Relocate Exchangers: This retrofit option will relocate one existing heat exchanger to a different location within the
process. Users can select 1-5 solutions to be produced. The third grid in Figure 10 shows the possible solutions for this
retrofit option, with each row representing a different solution or proposed heat exchanger to be added.
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Jump Start: Activated Energy Analysis in Aspen Plus and Aspen HYSYS
The desired retrofit option can be chosen by clicking the hyperlink of the solution type, which will launch the details of the
Energy Analysis Environment, as shown in Figure 11.
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Jump Start: Activated Energy Analysis in Aspen Plus and Aspen HYSYS
After instituting the second revamp solution, the scenario form will update. Figure 13 shows a scenario in which the
process has added a new heat exchanger followed by the addition of a second heat exchanger.
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Jump Start: Activated Energy Analysis in Aspen Plus and Aspen HYSYS
The top table in Figure 13 now includes four rows that display the specs for the base case design, the initial revamp, the
process after two revamps, and the target. This table can be used to track energy savings as more revamps are included.
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Jump Start: Activated Energy Analysis in Aspen Plus and Aspen HYSYS
After running Activated Energy Analysis to obtain a revamp solution, such as the heat exchanger addition case shown
in Figure 15, use the Location of Heat Exchanger column in the design change table to determine where the new heat
exchanger model should be placed on the flowsheet.
Then, using the Heat Exchanger Details table found on the same form, locate the new load for the heat exchangers
in the process. Highlighted in Figure 16, Design Load represents the new heat exchanger duties after adding a revamp
scenario, while the base load was the load that existed for the initial simulation.
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Jump Start: Activated Energy Analysis in Aspen Plus and Aspen HYSYS
Add a heat exchanger model to the flowsheet using the model palette in either Aspen HYSYS or Aspen Plus. Then,
connect the appropriate streams as shown in Figure 15. Figure 17 shows the crude preheat train with the new heat
exchanger addition. The shell side of the heat exchanger has been attached to the stream PA_3_1, which previously was
a feed to E-113, and the tube side of the heat exchanger has been attached to the stream crude46, which was previously
a feed to E-106.
Figure 17. Crude preheat train flowsheet in Aspen HYSYS with heat exchanger addition
The updated duties for the heat exchangers listed in the table in Figure 16 were then input to all the corresponding heat
exchanger models. After converging the simulation with the new heat exchanger duties, the flowsheet is then indicative of
the revamp solution. The Activated Energy Analysis panel will update with new saving potentials if opened after updating
the flowsheet.
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The Result Comparison form allows for the quick comparison of revamp solutions for a given heat integration project.
Figure 19. Details option to open HEN diagram and composite curves
Aspen Energy Analyzer then opens directly to the heat exchanger network diagram. An example HEN diagram is shown in
Figure 20.
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At the bottom of the Aspen Energy Analyzer program, a tab labeled Performance is selected. To access the composite
curves for the heat integration, select the Targets tab adjacent to the Performance tab.
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Figure 21. Accessing composite curves and example composite curves chart
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Simulation values and default values remain the same unless heat exchangers are sized using Activated EDR. To do this,
return to the Simulation environment, and click the blank area of the EDR Exchanger Feasibility panel from the Activation
dashboard, as shown in Figure 25.
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The Exchanger Summary Table will appear showing the heat exchangers and their status as either rigorous or available to
convert, as shown in Figure 26. Click a Convert to Rigorous button next to a heat exchanger to make it a rigorous model.
After a heat exchanger has been sized, return to the Saving Potential form in the Energy Analysis environment, and
choose Simulation on the dropdown. The heat transfer coefficient and heat exchanger area should change to the values
obtained from rigorous sizing.
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(For more information on using Activated EDR or in Aspen HYSYS and Aspen Plus, refer to the Activated EDR webpage,
available here.
As shown, sorting this table to only show streams below the pinch reduces the table to that in Figure 28.
Figure 28. Reduced heat exchanger details table sorted below the pinch
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Conclusions
Activated Energy Analysis is a tool capable of calculating process energy reliance and greenhouse gas emission, as well as
reducing these values through more cost effective utility selection and process revamp. Located within Aspen HYSYS and
Aspen Plus, Activated Energy Analysis allows users to generate changes and then implement them directly to simulation
to view performance. Activated Energy Analysis, when used in conjunction with the other members of the Activated
Analysis family, becomes an even more powerful process optimization tool. Activated Analysis can be implemented to
new processes or existing ones to dramatically improve performance.
As a reminder, it is free for current AspenTech customers to upgrade to the latest version of the aspenONE
Engineering suite. Simply contact AspenTech support via http://support.aspentech.com to do so.
Additional Resources
Public Website:
http://www.aspentech.com/products/aspen-hysys.aspx
http://www.aspentech.com/products/aspen-plus.aspx
http://www.aspentech.com/Products/Activated-Energy-Analysis/
http://www.aspentech.com/products/aspen-hx-net.aspx
Supporting Documents:
Activated Energy Analysis Demo File in Aspen HYSYS - Crude Preheat Train
Activated Energy Analysis Demo File in Aspen Plus - Ethylene Separation Process
Online Training:
http://www.aspentech.com/products/aspen-online-training
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About AspenTech
AspenTech is a leading supplier of software that optimizes process manufacturingfor energy,
chemicals, engineering and construction, and other industries that manufacture and produce products
from a chemical process. With integrated aspenONE solutions, process manufacturers can implement
best practices for optimizing their engineering, manufacturing, and supply chain operations. As a result,
AspenTech customers are better able to increase capacity, improve margins, reduce costs, and become
more energy efficient. To see how the worlds leading process manufacturers rely on AspenTech to
achieve their operational excellence goals, visit www.aspentech.com.
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