04 Hysys

Process Engineering Simulation with Aspen HYSYS
Updated: January 26, 2016

Copyright 2016 John Jechura (jjechura@mines.edu)
Process Engineering Simulation

Core chemical engineering doctrine mass & energy balances
Modes
Steady state simulation
Dynamic simulation
Simulation program features

Components / chemical species
Pure component data library
Non-library components
Property models & methods

Thermodynamic models
Physical & transport properties
Chemical reaction models & methods

Unit operation models
Flowsheet capabilities
Recycle loops
Graphical interface
HYSYS as Process Engineering Tool

Owned & marketed by Aspen Tech
Developed by Hyprotech.
Initially DOS-based -- HYSIM
Core calculations for steady state mass & energy balances

Dynamic capabilities as add-on package
Historical orientation towards the oil & gas industry

Components
Extensive pure component database of hydrocarbons
Generate pseudo-components from crude oil assay information
Property models
Consistent with hydrocarbon systems relatively non-ideal mixtures
Capabilities for presence of typical non-hydrocarbons
o
o
Simplified methods for mixtures with water

Acid gas components CO2 & H2S

Towers with pumparounds, side strippers,
Reaction system models

CatCracker, Hydrocracker, Reformer
Composition
Pure component database
Typically use a small number of light hydrocarbons (C1 nC5), CO2, H2S, & H2O
Pseudo/hypothetical components
Narrow boiling point fractions from distillation analysis
Assumption that all components in range will have the same split between vapor &
liquid
Not a good assumption if chemical structure plays a big part in separation or reaction
Correlations to generate average properties for the fraction

Empirical correlations based on boiling point, specific/API gravity, molecular weight
Group contribution methods
Electrolyte mixtures may require explicit definition of ionic species

Pure Components

Pseudo Components from Assay
Refinery Process Modeling

Gerald Kaes
Athens Printing Company., 2000, pg. 32


Split the yield curve into
boiling point ranges
Use the property curves to

generate consistent with
measured data
Use correlations to estimate
unmeasured & unmeasurable

properties
Critical properties
Accentric factor
Binary interaction coefficients




10

11
Property Models & Methods

Typically use an equation of state (EOS) for properties
Consistent properties for vapor, liquid, & transitions between
Thermodynamic properties from the same set of equations
Equilibrium coefficients (fugacity)
Enthalpy
Entropy
Density
Non-ideal behavior from binary interaction coefficients

Major effect on equilibrium coefficients
Very small effect on other properties
May use other properties for other thermodynamic properties

Lee-Kesler for enthalpy
COSTALD for liquid density
12
Property Models & Methods

13
Unit Operation Models

Typical unit operation models
Valve
Separators
Heat exchangers
Pumps
Compressors
Reactors CSTR & plug flow
Towers with & without condenser & reboiler
Without Reboiler
With Reboiler

Without Condensor
Absorber
Reboiled Absorber
With Condensor
Refluxed Absorber
Distillation Column
14
Unit Operation Models for Refining

Complex tower
configurations
Pumparounds
Side draws
Side strippers
Condenser with water
draw
Complex specifications
ASTM temperature spec

15
Typical Overall Efficiencies

Column Service
Simple Absorber/Stripper
Steam Side Stripper
Reboiled Side Stripper
Reboiled Absorber
Deethanizer
Depropanizer
Debutanizer
Alky DeiC4 (reflux)
Alky DeiC4 (no reflux)
Naphtha Splitter
C2 Splitter
C3 Splitter
C4 Splitter
Amine Contactor
Amine Stripper
Crude Distillation
Stripping Zone
st
Flash Zone 1 draw
20 30
57
7 10
20 40
25 35
35 40
38 45
75 90
55 70
25 35
110 130
200 250
70 80
20 24
20 24
35 50
57
Typical Typical No. of

Overall
Theoretical
Efficiency
Trays
20 30
2
34
40 50
65 75
70 80
85 90
85 90
55 65
70 75
95 100
95 100
85 90
45
9 12
45 - 55
50 60
20 30
30
2
37
30
12
nd
7 10
45 50
35
rd
7 10
10 12
50 55
60 70
35
68
50 60
1
12
2
2
13 17
2
23
35
57
1st Draw 2 Draw

nd
Typical No. of
Actual Trays
2 Draw 3 Draw
Top Draw Reflux
Vacuum Column (G.O. Operation)
Stripping
Flash Zone HGO Draw
HGO Section
LGO Section
FCC Main Fractionator
Quench Zone
Quench HGO Draw
HGO LCGO
LCGO Top
24
23
35
35
24 35
57
35
68
7 10
Viscosity
Maxwell
cP
Ave Viscosity of
liquid on plates
0.05
0.10
0.15
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1.50
1.70
104
86
76
63
56
50
46
43
40
38
36
30
28
Drickamer &
Bradford in
Ludwig
Molal Ave
Viscosity of
Feed
98
79
70
60
50
42
36
31
27
23
19
17
7
5
Rules of Thumb for Chemical Engineers, 4th ed.

Carl Branan, Gulf Professional Publishing, 2005
Engineering Data Book, 12th ed.

Gas Processors Association, 2004
Refinery Process Modeling

Gerald Kaes, Athens Printing Company., 2000, pg. 32
16
User Interface
Graphically build the flowsheet by dragging & dropping unit models
Calculations performed automatically as information is entered
Copy & paste capabilities
Pasting in from other locations limited
Aspen Simulation Workbook extends capabilities to put custom interface on top

of simulation

17
HYSYS crude tower example

Available from Aspen Tech web site
http://support.aspentech.com/webteamasp/My/FrameDef.asp?/webteamasp/My/product.asp?id1=26
74&id2=''&id3=all

18
Summary
HYSYS is a capable tool for performing mass & energy balances
Program features make it convenient for petroleum refining applications
Pure component data library & psuedo-components from distillation analyses
Property models & methods
Thermodynamic, physical & transport property models appropriate for petroleum
systems
Chemical reaction models & methods
Specific configurations for complex equipment
Flowsheet capabilities
Graphical interface

19

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Process Engineering Simulation with Aspen HYSYS

Updated: January 26, 2016

Process Engineering Simulation

Simulation program features

Property models & methods

Chemical reaction models & methods

HYSYS as Process Engineering Tool

Core calculations for steady state mass & energy balances

Historical orientation towards the oil & gas industry

Simplified methods for mixtures with water

Unit operation models

Reaction system models

Correlations to generate average properties for the fraction

Electrolyte mixtures may require explicit definition of ionic species

Updated: January 26, 2016

Updated: January 26, 2016

Pseudo Components from Assay

Refinery Process Modeling

Updated: January 26, 2016

Pseudo Components from Assay

Use the property curves to

Use correlations to estimate

unmeasured & unmeasurable

Updated: January 26, 2016

Pseudo Components from Assay

Updated: January 26, 2016

Pseudo Components from Assay

Updated: January 26, 2016

Pseudo Components from Assay

Updated: January 26, 2016

Pseudo Components from Assay

Updated: January 26, 2016

Property Models & Methods

Non-ideal behavior from binary interaction coefficients

May use other properties for other thermodynamic properties

Property Models & Methods

Updated: January 26, 2016

Unit Operation Models

Updated: January 26, 2016

Unit Operation Models for Refining

Updated: January 26, 2016

Typical Overall Efficiencies

Typical Typical No. of

1st Draw 2 Draw

Rules of Thumb for Chemical Engineers, 4th ed.

Engineering Data Book, 12th ed.

Refinery Process Modeling

Aspen Simulation Workbook extends capabilities to put custom interface on top

Updated: January 26, 2016

HYSYS crude tower example

Updated: January 26, 2016

Updated: January 26, 2016

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