aspen plus basic course
TRANSCRIPT
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Aspen Plus®Basic CourseChemical Engineering Guy
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Give it a TRY… Hi there, this is a free overview of the Aspen Plus Course
I hope you like it! There are no VIDEOS in SlideShare You can get those in the Online Course
If you are interested in more learning/practice/lessons/courses go to:
ASPEN PLUS COURSE Get 50% OFF
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Solve this!
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Solve this!Change:All T of ReactorsFeed CompositionNo. of Plates in Distl. ColT of Heat ExGas Sep. TCompressor P
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And this….
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Why Process Modeling/Simulation? Makes us easier/faster work Multiple and Simultaneous Simulations Different Real-Life Scenarios
Change on raw/feed materials scenario Pricing and Costs calculation
Raw Materials Plant Cost Utilities
How it would behave under different conditions High/Low Pressure Humidity Changes Temperature change (cool/warm days/seasons)
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Which companies model? Mainly:
Petrochemical Pharmaceutical Fine chemicals
Other commodities such as:
Sulfuric acids Chlorine/Caustic industry Solvents Coatings Many more…
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Other Advantages… Excelent for your curriculum as an engineer
Perfect for analytical/numerical minds
Good for debuging and fixing
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INDEX1. Course Objectives2. Introduction to Aspen Plus3. User Interface & Getting Help4. Physical Properties5. Introduction to Flowsheet6. Unit Operation Models7. Reporting Results8. Case Studies I, II and III9. Case Study IV10. Conclusion
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1. Course Objectives Basic Modeling of Substances & Processes
General Flowsheet Concepts Basic Requirements to set up a Simulation Setting the adequate Physical Properties Flowsheet “manipulation” Major and Common Unit Operations Workshop Practice Reporting Results (Tables) Technical Stuff (extensions, versions, exporting, saving, etc...)
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1. Course Objectives Course Approach
Theory Practice More Practice Analysis
Course Structure (Intensive) 1st Day 2nd Day
Course Structure (Recommended) 1st
2nd
3rd
4th
5th
6th
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2. Introduction to Aspen Plus About Aspen Plus ®
Why Aspen Plus ®
Benefits of simulations
Aspen Plus® vs. HYSYS®
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About Aspen Plus ®From the website:
“Aspen Plus is the market-leading chemical process optimization software used by the bulk, fine, specialty, & biochemical industries, as well as the
polymers industry for the design, operation, and optimization of safe, profitable manufacturing facilities.”
http://www.aspentech.com/products/engineering/aspen-plus/
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About Aspen Plus ® My version V8.2 and V8.8 (May 2013-2015)
Most recent version V8.8 (May 2015) https://www.aspentech.com/products/Aspen-Plus/V88/
Main differences: Solid Modeling Activated Heat Exchanger Sizing and Rating* Relief Sizing in the Safety Environment Search and Share Models with aspenONE Drive Access Aspen Process Manuals with aspenONE® Exchange
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About Aspen Plus ® Solid Modeling
Solids Modeling for Polymers Particle Size Definition in Reactor Models Contact Dryer Model Conceptual Solids Models Fluidized Bed Reactor Model Spray Dryer Model
NOT included in the BASIC course!
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Aspen Plus® vs. HYSYS® Aspen Plus
Chemical Industry (H2SO4, Polymers, Coatings, etc.) Fine Chemistry (chemical reactions) Non-ideal models (azeotropes, L-V equilibriums, etc.) Electrolytes Equation Oriented Mode
Aspen HYSYS Mainly Petrochemical (upstream/downstream) Hydrocarbon Oriented (Oil Industry) Assays (Mixture of petrochemicals, i.e. petroleum) Refinery Reactors (Catalytic reformer, FCC)
This is a Free Trial…
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3. User Interface & Getting Help Graphic User Interphase (GUI) New File, Existing simulations, Exporting, etc… Extension Getting Help
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New, Open, Save, Export, etc… These exercises will be mentioned as we do Workshops, Practice Scenarios
and Cases It is pretty straight forward really… When opening a New Project Choose a Template and you’re done When saving; use “Save as… Aspen Plus Document” Exporting Files are not included in this Basic Course
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Landing Page Start Page
New, Open, Recent Files News Get Started Button (Ribbons) bar
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Landing Page Start Page
New, Open, Recent Files News Get Started Button (Ribbons) bar
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Landing Page - Video 001 Lading Page This is a Free Trial…
If you are interested in the COURSE, please go to:
You will get 50%OFF for being a SlideShare Fan!
ASPEN PLUS COURSE
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File Extensions One Aspen Plus “Project” may involve:
• Backup file (.bkp)• Embedded backup file (.apmbd) • FORTRAN files ( .dll, .dlopt, .obj, .F )• Equipment design and rating files (.bjt, .edr, etc)• etc.
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File ExtensionsFile Type Extension Format Description
Compound *.apwz Binary Compressed file which contains the model (the BKP or APW file) and external files referenced by the model. You can add
additional files such as supporting documentation to the APWZ file.
Document *.apw Binary File containing simulation input, results and intermediate convergence information
Backup *.bkp ASCII Archive file containing simulation input and results
Template *.apt ASCII Template containing default inputs
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Templates Prepared “properties” and
preferences for the user Air Separation Chemical Processes Gas Processing Pharma Refinery (most extensive) Solids
“User” SI or English units
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Environment Introduction
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Environment Introduction Properties
Physical Properties Thermodynamic Properties Models of Equilibrium Gas models
Simulation Flow Sheet Unit Operations “Blocks” Stream of Mass/Energy “Lines”
Setting the Universe
Setting the Process
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Typically, once you set your properties, you won’t be using
Properties Environment
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Environment - Video 002 Environements & Physical Properties
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Simulation Environment
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Ribbons/Menu
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“Workspace”Streams, Unit
Operations of the Process goes HERE
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Navigation Pane
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Model PaletteUnit Operation
Blocks
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Material/Work/Heat Stream
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Simluation Environment - Video 003 Simulation EvironmentThis is a Free Trial…
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Getting Help Direct Contact
Via Udemy Private Messages/Discussion boards Via e-mail
[email protected] [email protected]
Q&A from Website (Click HERE) Forums & Groups
http://www.egpet.net/ http://www.cheresources.com/ http://www.eng-tips.com/threadminder.cfm?pid=137
LinkedIn Aspen Plus Users Official Aspen Plus User Community Official Aspen Plus User Community (869 users) Official Aspen HYSYS User Community (9,000 users) Aspen HYSYS® Dynamics UsersPrivate Group (1,800 users)
Aspen Tech http://support.aspentech.com ***You got to be registered as a valid Aspen License User(s)
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Getting Help Using Aspen Help Bar/Button Help Bar/Help Button
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Getting Help
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Getting Help
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Getting Help
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Getting Help
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Getting Help - Video 004 Getting Help - Help ButtonThis is a Free Trial…
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4. Physical Properties
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Minimum RequirementsSet up “your” Universe
Setup “General” Components
(H2O, ethanol, butane, etc…) Databank
Methods Property Methods ***(Critical)
Other… (not relevant for this course’s level)
• Chemistry (bp, MW, structure, visc, etc.)
• Gas V,P,T• Ideal• Real (Z, NRTL, VDK)
• Physical Chemistry• Equilibrium L-V• Ideal/Real Solutions• Volatility• Liquid activity• Fugacity
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Setup Specifications
Units (SI, English, bar, etc.) Calculation Options
Convergence Error Maximum Iterations # Errors Automatic Calculations
Unit Set Enthalpy of Formation kJ/mol Heating Value Cal/g Modify “SI” or “English” Reporting Options
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Components Specification
Component (from Databases)*
Molecular Structure...
Polymers
* RequiredAll other folders are studied in other advanced courses
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What’s next?
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What’s next?
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Methods Specifications
Global Property Method Property Methods
Method Name Method Assistant!
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Methods Component Type
Chemical Hydrocarbon Special Chemical (water, amine, sour, electrolyte) Refrigerant
Process Type Chemical, Electrolyte, Environmental, Mineral & Metallurgical Gas Processing, Oil and Gas, Petrochemical, Refining Polymer Power Pharmaceutical
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Methods Method Assistant Process Type Petrochemical
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MethodsType of System Recommended Property MethodTEG Dehydration PR, Glycol PackageSour Water Sour PR, Sour SRKCryogenic / Air Separation PR, PRSV, TSTAtmospheric Towers PR Options, GS, TSTVacuum Towers PR Options, GS, TST, Braun K10, Esso TabularEthylene Towers Lee-Kesler-PlockerHigh H2 Systems PR, ZJ, GS, TSTSteam Systems NBS Steam, ASME Steam, CS, GSChemical Systems Activity Models (NRTL, UNIQUAC,…), PRSVCompression / Light Gases MBWRAmine Systems Amine Pkg, DBR Amine Package, Elec-NRTLElectrolyte Systems Elec-NRTL
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Methods
Model
Ideal
Equation of State
Classic
Advanced
Activity Coefficient
Binary
Predictive
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MethodsEquation of States Activity Coefficients
Good for vapor phase modeling and liquids of low polarity
Preferable for liquid phase
Try to avoid Non-Ideal Liquids Good for non-ideal liquid mixtures
Less binary parameters required Binary parameters required (liquid-liquid)Extrapolation of Data Only valid in Temperature Ranges givenGood for Critical Region (Pc, Tc) Avoid critical regionExamples: – PSRK– PENG-ROB – RK-SOAVE
Examples: – NRTL – UNIQUAC – WILSON – UNIFAC
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Choosing a Property Method – Review
Do you have polar components?
Is the pressure low <10 bar?
Equation of State such as SRK or PENG-ROB…
Advanced Equation of State such as PSRK or PC-SAFT…
Are there any supercritical components?
Activity coefficient model with Henry’s law
Activity coefficient Model (NRTL, UNIQUAC, …)
no
START
no
no
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Exercise 1: Set a Simple Process PART 1 – Physical
Properties A stream of 10 kg/h of ethanol is added to another stream of 50/h kg of water. Both at 25°C and 1 atm. They are mixed. There is no heat exchange with the surroundings (no heat gain/loss) Then we heat it from 25°C to 77°C The streams go out in a single pipe
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Physical Properties - Video 005 Filling Physical Properties EnvironmentThis is a Free Trial…
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Done! You are ready to run the property simulation Aspen will run
Model Methods Compounds
If any compound has a modeling problem, you will receive errors (non-typical)
You are ready to work in the Simulation Environment!
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Awesome!
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5. Introduction to Flowsheet
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5. Introduction to Flowsheet
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Interacting with the Flowsheet Set System/Process
Must have 0 Degrees of Freedom (System is “Fixed”)
Set Input Data in Streams (energy, work and materials)
Set Properties to Unit Operations (Blocks)
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Typical Steps in a Simulation1. Set Physical Properties (Physical Environment)2. Set Process in Flowsheet
Mass Streams (T,P, mass flow, fractions, etc.) Heat/Work Explicit Duties (Q,W) Unit Operations
Mass transfer (Distillation, flashes, etc.) Heat Transfer (Heat Exchanger, single/double HEX, etc.) Momentum Transfer (mixing, transportation of fluids, pumps, compressors, etc.) Reaction Kinetic (Reactor, Equilibrium Reactors, Stoichiometric Reactors, etc.)
3. Run Simulation4. Expect no Errors
If no errors Check solution in Reports If there are errors Check type of error, try to fix if needed, re-run simulation
5. Analysis of Results, Sensitivity Analysis, Optimization, etc…
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Typical Steps in a Simulation1. Set Physical Properties (Physical Environment)2. Set Process in Flowsheet
Mass Streams (T,P, mass flow, fractions, etc.) Heat/Work Explicit Duties (Q,W) Unit Operations
Mass transfer (Distillation, flashes, etc.) Heat Transfer (Heat Exchanger, single/double HEX, etc.) Momentum Transfer (mixing, transportation of fluids, pumps, compressors, etc.) Reaction Kinetic (Reactor, Equilibrium Reactors, Stoichiometric Reactors, etc.)
3. Run Simulation4. Expect no Errors
If no errors Check solution in Reports If there are errors Check type of error, try to fix if needed, re-run simulation
5. Analysis of Results, Sensitivity Analysis, Optimization, etc…
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Typical Steps in a Simulation1. Set Physical Properties (Physical Environment)2. Set Process in Flowsheet
Mass Streams (T,P, mass flow, fractions, etc.) Heat/Work Explicit Duties (Q,W) Unit Operations
Mass transfer (Distillation, flashes, etc.) Heat Transfer (Heat Exchanger, single/double HEX, etc.) Momentum Transfer (mixing, transportation of fluids, pumps, compressors, etc.) Reaction Kinetic (Reactor, Equilibrium Reactors, Stoichiometric Reactors, etc.)
3. Run Simulation4. Expect no Errors
If no errors Check solution in Reports If there are errors Check type of error, try to fix if needed, re-run simulation
5. Analysis of Results, Sensitivity Analysis, Optimization, etc…
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Setting Streams Mass Streams Mainly
All inlet to process (raw material) Intermediate streams (intermediate material) All outlet to process (final products & by-products)
Heat and Work only if Required (direct Duty) 500 kJ must be applied Loss of Heat due to cold temperature is 1054 KJ/s 14 HP Shaft Power Requirement Pump has 12 BHP
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Exercise 1: Set a Simple Process
PART 2 – Flow Sheet A stream of 10 kg/h of ethanol is added to another stream of 50/h kg of water. Both at 25°C and 1 atm. They are mixed. There is no heat exchange with the surroundings (no heat gain/loss) Then we heat it from 25°C to 77°C The streams go out in a single pipe
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Process Diagram FINAL DIAGRAM
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Material Streams Stream 1. Water
Stream 2. Ethanol
Stream 3. Mixed Product before heating
Stream 4. Mixed Product after heating
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Setting Blocks Mixing unit…
Heater unit…
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Done! Your Process is Set!
Let’s Run the Simulation!
As follows…
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Typical Steps in a Simulation1. Set Physical Properties (Physical Environment)2. Set Process in Flowsheet
Mass Streams (T,P, mass flow, fractions, etc.) Heat/Work Explicit Duties (Q,W) Unit Operations
Mass transfer (Distillation, flashes, etc.) Heat Transfer (Heat Exchanger, single/double HEX, etc.) Momentum Transfer (mixing, transportation of fluids, pumps, compressors, etc.) Reaction Kinetic (Reactor, Equilibrium Reactors, Stoichiometric Reactors, etc.)
3. Run Simulation4. Expect no Errors
If no errors Check solution in Reports If there are errors Check type of error, try to fix if needed, re-run simulation
5. Analysis of Results, Sensitivity Analysis, Optimization, etc…
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Next, Run, Purge
1 2 3 4
56
1. Run Complete Simulation
2. Step-by-Step Simulation
3. Stop Simulation
4. Purge/Reinitialize
5. Check Results
6. Next Input
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Simulation Environmet - Video 006 Filling the Simulation EnvironementThis is a Free Trial…
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Typical Steps in a Simulation1. Set Physical Properties (Physical Environment)2. Set Process in Flowsheet
Mass Streams (T,P, mass flow, fractions, etc.) Heat/Work Explicit Duties (Q,W) Unit Operations
Mass transfer (Distillation, flashes, etc.) Heat Transfer (Heat Exchanger, single/double HEX, etc.) Momentum Transfer (mixing, transportation of fluids, pumps, compressors, etc.) Reaction Kinetic (Reactor, Equilibrium Reactors, Stoichiometric Reactors, etc.)
3. Run Simulation4. Expect no Errors
If no errors Check solution in Reports If there are errors Check type of error, try to fix if needed, re-run simulation
5. Analysis of Results, Sensitivity Analysis, Optimization, etc…
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Errors? Debug? Troubleshoot?
No! Perfect!
Continue with Results and Analysis
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Typical Steps in a Simulation1. Set Physical Properties (Physical Environment)2. Set Process in Flowsheet
Mass Streams (T,P, mass flow, fractions, etc.) Heat/Work Explicit Duties (Q,W) Unit Operations
Mass transfer (Distillation, flashes, etc.) Heat Transfer (Heat Exchanger, single/double HEX, etc.) Momentum Transfer (mixing, transportation of fluids, pumps, compressors, etc.) Reaction Kinetic (Reactor, Equilibrium Reactors, Stoichiometric Reactors, etc.)
3. Run Simulation4. Expect no Errors
If no errors Check solution in Reports If there are errors Check type of error, try to fix if needed, re-run simulation
5. Analysis of Results, Sensitivity Analysis, Optimization, etc…
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Final Results & Analysis Solutions Water + Ethanol mix will increase about 3°C due to its “real mixture” Stream Results
Mixture: 60 kg/h; T = 301 K Product: 60 kg/h; T = 301 K
Block Results Mixer Final Temperature = 310.71 K Heater Duty: 12360.66 kJ/h
*** More info in Section 7. Flowsheet Results
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Table of Streams
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Results and Analysis - Video 007 Results and AnalysisThis is a Free Trial…
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6. Unit Operation Models (Basic) Mixers/splitters Separators Exchangers Columns Reactors Pressure Changers
Manipulators * Solids * Solid Separators * User Models * * Not Relevant in this Course
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6. Unit Operation Models (Basic) Mixers/splitters Separators Exchangers Columns Reactors Pressure Changers
* Not Relevant in this Course
Momentum Heat
Kinetics Mass
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6. Unit Operation Models (Basic) Mixers/splitters Separators Exchangers Columns Reactors Pressure Changers
* Not Relevant in this Course
Momentum
Mixers/SplittersPressure Change
Heat
Exchangers
Kinetics
Reactors
Mass
SeparatorsColumns
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Summary This data is from
Aspen Plus Help Data Sheet
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Summary This data is from
Aspen Plus Help Data Sheet
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The Unit Operations
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Introduction to Unit Operations - Video 008 Introduction to Unit OperationsThis is a Free Trial…
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Mixers/Splitters Mixer FSplit Ssplit*
*Basic Course does not includes SSplit
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Mixers/Splitters Mixer Required
One streams inlet (Q,W,M) One stream outlet (Q,W,M)
Useful for In-pipe blending (T-shape) Mixing tanks (Adiabatic Only) Static Mixers
Methods/Conditions Ideal, Adiabatic Mixing
Pressure drop may be added
Either Mass, Q or W!
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Mixers/Splitters FSplit Required
One streams inlet (Q,W,M) One stream outlet (Q,W,M)
Useful for Valves Tanks Back-Mixing Purge/Vents T-Shape Pipe
Methods/Conditions N/A
Either Mass, Q or W!
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Mixers/Splitters Exercise 009 Mixers & Splitters
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Separators Fash2 Flash3* Decanter* Sep Sep2*
*Basic Course includes only Flash2 and Sep
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Separators Flash2 Separates feed into
2 (vapor liquid) or 3 (vapor liquid liquid) using rigorous vapor-liquid or vapor-liquid-liquid equilibrium
Required Inlet (1) Outlet (2)
Recommended Use: Flash drums Evaporators Knock-out drums Single stage separators
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Separators Sep Separates inlet stream components into multiple outlet streams, based on specified
flows or split fractions Required
(1) inlet (1) outlet
Recommended Operations: Component separation operations Distillation Absorption, *** when the details of the separation are unknown or unimportant
Essentially to avoid computation time Not that recommended actually
“Black Box”
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Separators Exercise 010 Separators This is a Free Trial…
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Exchangers Heater HeatX* MHeatX* HXFlux*
*Basic Course includes only Heater
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Exchangers Heater Heater/Cooler Determines thermal and phase conditions of outlet stream Required Streams
(1) Inlet (1) Outlet
Recommended Use Heaters Coolers Condensers Boilers Valves “Pipe” Joints
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Exchangers Heater Calculations:
Bubble or dew point calculations Add or remove any amount of user specified heat duty Match degrees of superheating or subcooling Determine heating or cooling duty required to achieve a certain vapor fraction
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Exchangers Exercises 011 Exchangers This is a Free Trial…
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Columns DSTWU* Distl RadFrac Extract* MultiFrac* SCFrac* PetroFrac* ConSep* BatchSep*
*Basic Course includes only Distl and RadFrac
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Columns Distl Shortcut multicomponent distillation rating model
Number of theoretical stages Reflux ratio Overhead product rate
Determines separation based on reflux ratio, number of stages, and distillate-to-feed ratio Assumes constant mole overflow and constant relative volatilities.
Recommended Operation Columns with one feed and two product streams
**Edmister approach
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Columns RadFrac Rigorous fractionation Performs rigorous rating and design calculations for single columns Operation Recommendations
Ordinary distillation Absorbers/Strippers Extractive and azeotropic distillation Three-phase distillation Reactive distillation
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Columns RadFrac Multistage Vapor-Liquid Calculations:
Ordinary distillation Absorption Reboiled absorption Stripping Reboiled stripping Extractive and azeotropic distillation
RadFrac is suitable for: Two-phase systems Three-phase systems (only in equilibrium mode) Narrow and wide-boiling systems Systems exhibiting strong liquid phase nonideality
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Columns RadFrac Model columns in which two liquid phases and chemical reactions occur
simultaneously, using different reaction kinetics for the two liquid phases. Can model both random and structured packings. Calculation of size and rate columns consisting of trays and/or packings.
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Columns Exercises 012 Columns This is a Free Trial…
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Reactors Balance/Stoichiometry Based
RStoic RYield
Equilibrium Based Requil* Rgibbs*
Kinetic Model Based RCSTR* Rplug* Rbatch*
*Basic Course includes only RStoic and RYield
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Reactors RStoic Stoichiometric reactor Models stoichiometric reactor with specified reaction extent or conversion Models:
Reactors where reaction kinetics are unknown or unimportant but stoichiometry and extent of reaction are known
Reaction kinetics are unknown or unimportant and Stoichiometry and the molar extent or conversion is known for each
reaction Performs:
Product selectivity and heat of reaction calculations Simultaneously or sequentially
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Reactors RYield Yield reactor Models reactor with specified yield Models:
Reactors where stoichiometry and kinetics are unknown or unimportant but a yield distribution is known
Reaction stoichiometry is unknown or unimportant Reaction kinetics are unknown or unimportant Yield distribution is known
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Reactors Exercises 013 Reactors This is a Free Trial…
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Pressure Changers Pump Compr Mcompr* Valve* Pipe* Pipeline*
*Basic Course includes only Pump and Compr
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Pressure Changers Pump Has 1 input and 1 output at least Must be in liquid state or incompressible gas. Otherwise, it must be stated It may also be used as a Turbine Pressure Ratio is allowed Power Requirements are also input/output
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Pressure Changers Compr At least 1 inlet and 1 outlet Excellent for Pressure Increases in gas phase It might be used as a Turbine Performance Curves are also included Pinlet/Poutlet Workload
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Pressure Changers Exercises 014 Pressure ChangersThis is a Free Trial…
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7. Reporting Results BASIC approach
Table Graph Chart Etc…
*** Continue to intermediate for more!
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Table of Data 015 Results P1 015 Results P2 This is a Free Trial…
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Type of Processes Mixing, Splitting Flashing; evaporating Heating/Cooling Evaporation, Condensation Distillation Chemical Reactions Compression; Pressurization; depressurization
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Next Step Now you know how to model the most Basic Unit Operations of Aspen Plus
®
You can model plenty of Common Processes by now!
You should go now:
Case Study I, II, III Apply all the knowledge into one process, step by step.
Case Study IV Apply your knowledge by your own. Compare final results with the template result!
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8. Case Studies I, II and III Lets do a a Workshop! No worries you won’t be alone! We will be analyzing 3 cases:
Case Study I: Solvent Recovery (RadFrac, Mixers) Case Study II: Cumene Production (Rstoic, Flash2, Heater) Case Study III: 3 Gas Pressure (Compressor, Mixer, Valve, Heater)
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Steps in Case Study Solving Statement
Read it carefully, write down all important data. Find data that might be useful Building the diagram
Build the diagram accordingly, “after”, “before” and “then”, “pre” are pretty important words Data Input
Name Streams logically. Add all substances, fractions, masses that are required. Add Blocks, name them accordingly to their functions. Add all data needed
Run Simulation Results Go to results; review there are no warnings, errors. Write a Results Report & Check Results Finally, make an analysis and make your final conclusion
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Case Study I: Solvent Recovery1. Statement2. Building the diagram3. Data Input
Streams Blocks
4. Run Simulation5. Results & Reporting6. Analysis7. Conclusion
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1. Statement (Case Study I) A previous process contains a mixture of solvents which we are required
to recover. We are interested in pure acetone, methanol and water. Source 1 (Process 1) – Contains a 5%-75%-20% water/acetone/methanol mix
350 gal/h are being sub-produced Source 2 (Process 2) – Contains a 5%-35%-60% water/acetone/methanol mix
50 gal/h are being currenty treated in an old storage facility You, as an junior engineer, propose a 2 separaton process: Split acetone (most
volatile); then Split water form methanol. The previous process was not suitable for the separation, it used flash drums.
Instead you propose a distillation column system.
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1. Statement (Case Study I) Since there is no CAPEX left; we are not able to do 2 separate process. The idea is
to mix both stream sources; add water for the methanol/water interaction. You decide to use an old distillation column from a Project which is in standby. It has 40 trays; it owns a kettle reboiler and a total condenser. After calculations
you got that you should start working with a reflux ratio of 1:2 with respect to mass
The D/F ratio should be pretty similar, i.e. 1:1 per mole. Water is fed in the 12 stage and the solvent mix in the 24th
Operation Pressure is about P = 15 psia (it could be optimized) For the methanol-wáter rich bottom product; we require a NEW distillation column. The Senior Engineers recommended the next data:
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1. Statement (Case Study I) Total condenser, Kettle Reboiler, 17 Stages. Similar operater reflux ratios to your
initial column. It must be feed between 9 and 11 stage. Since you are operating at P = 15 psi, opérate at similar pressures Utilities:
Water is available at 15 psia, T = 100 F. Mass balance calculation requires a Vol. Flow rate of 100 gal/h
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1. Statement (Case Study I) Find:
Acetone purity Methanol purity Heat Duty in Reboiler-1 Heat Duty in Condenser-1 Heat Duty in Reboiler-2 Heat Duty in Condenser-2
If methanol prices are $ 1.13 per gallon, how much money we earn per day?
Is this water suitable for drinking?
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2. Process Diagram (Case Study I)
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3. Data Input (Case Study I) Feed:
Water – 100 F; 15 psia; STVol = 100 gal/h Source 1- 100 F; 15 psia; STVol = 350 gal/h. (0.05-0.75-0.20; w,a,m) Source 2- 100 F; 15 psia; STVol = 50 gal/h. (0.05-0.35-0.60; w,a,m)
Distillation Column 1 RadFrac P = 15 psia Equilibrium operated, N-stages = 40, Total Condenser, Total Kettle Reboiler Reflux Ratio = 2 (per mass); D/F Ratio = 1 per mol Water Feed = 12; Solvents Feed = 24
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3. Data Input (Case Study I) Distillation Column 2 RadFrac P = 15 psia Equilibrium operated, N-stages = 17, Total Condenser, Total Kettle Reboiler Reflux Ratio = 2 (per mass); D/F Ratio = 1 per mol Water Feed = 10
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4. Run Simulation (Case Study I) Run the simulation!
Debug required?
Warnings
Errors?
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5. Results & Reporting (Case Study I) Acetone purity Methanol purity Heat Duty in Reboiler-1 Heat Duty in Condenser-1 Heat Duty in Reboiler-2 Heat Duty in Condenser-2
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6. Analysis (Case Study I) Are purities achieved?
How much is recovered % of each material
If methanol prices are $ 1.13 per gallon, how much money we earn per day?
Is this water suitable for drinking?
Is this better tan flashes? Why?
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Case Study I: Solvent Recovery 016 Case Study I - Solvent RecoveryThis is a Free Trial…
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Case Study II: Cumene Production1. Statement2. Building the diagram3. Data Input
Streams Blocks
4. Run Simulation5. Results & Reporting6. Analysis7. Conclusion
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1. Statement (Case Study II) Cumene is typically produced from a benzene + propylene reaction at very low
pressures (vaccum). The plant feedstock is 50%-50% B/P. It is about 80 lbmol/h. It comes from a pump which delivers it at T = 220 F and P = 36 psia The reactor is typically operated with a recycle stream of all volatile material in the
reactor’s outlet. Final Reactors Temerature is not know but tt is imperative to cool down at T = 130
F The sepation is carried out with a flash drum at P = 1 atm (for final product
storage). The flash is operated adiabatically
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1. Statement (Case Study II) Find:
Reactor’s Operation Temperature Heat Duty of Cooler Split Fraction of Separator Flow rate of Recycle Flow rate of product Mol fraction of Cumene in product
Try it without recycle! (Same questions)
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2. Process Diagram (Case Study II)
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3. Data Input (Case Study II) Feed:
P = 36 psi T = 220 F F = 80 lbmol/h X = 0.5 Benzene; 0.5 Propylene
Reactor This is typically done via the reaction of Benzene + Propylene in a Reactor
Use Rstoic Reaction is 1:1 1 90% conversión with respect to Benzene Adibatical; i.e. Q = 0 P = 0 atm
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3. Data Input (Case Study II) Cooler:
T cool = 130 F P final = -0.1 psia (i.e. vacuum)
Flash Drum P = 1 atm (final product) Adiabatical, i.e. Q = 0 Recycle vapors Liquids go to final product
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4. Run Simulation (Case Study II) Run the simulation!
Debug required?
Warnings
Errors?
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5. Results & Reporting (Case Study II) Products:
X fraction of Cumene Mol Flow of Product Stream Recycle Mol flow stream
Blocks: Reactor Temperature Coolers Heat Duty Recycle Split Fraction
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6. Analysis (Case Study II) Recycling:
Non-Recycling
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Case Study II: Cumene Production 017 Study Case II - Cumene ProductionThis is a Free Trial…
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Case Study III: Gas Compression1. Statement2. Building the diagram3. Data Input
Streams Blocks
4. Run Simulation5. Results & Reporting6. Analysis7. Conclusion
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1. Statement (Case Study III) You are in charge of mixing, transport and compressing a mixture of gases used for
a furnace application. They are stored in separate tanks reservoirs. The furnace operates at 5 bar so we need to mix all gases and then transport it to
the furnace. Due to friction losses; we have a 1.5 bar pressure loss from the mixer to the
furnace. Compression is required. The methane gas (essentially natural gas) is stored at 15 bar; ethane gas is at 2
bar and the propane gas is already at 5 bar. Compressors work with the given isentropic and mechanical efficiencies
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1. Statement (Case Study III) Find:
Compressor 1 - Duty Compressor 2 - Duty Final Product Gas Composition Initial Temperature of mixture Final Temperature
Try it with a final heater!
Try it with a cooler before the Compressions!
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2. Process Diagram (Case Study III)
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3. Data Input (Case Study III) Feed:
Methane – 30°C, 15 bar, 155 kg/h Ethane – 25°C, 2 bar, 200 kg/h Propane – 35°C, 5 bar, 120 kg/h
COMP1 Compressor Isentropic Discharge P = 5 bar 95% Isentropic Efficiency 88% Mechanical Efficiency
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3. Data Input (Case Study III) Mixer:
P = 5 bar Friction loss:
Model as Valve Pressure Drop = 1.5 bar Adiabatic Flash
COMP2 Compressor Isentropic Discharge P = 5 bar 90% Isentropic Efficiency 85% Mechanical Efficiency
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4. Run Simulation (Case Study III) Run the simulation!
Debug required?
Warnings
Errors?
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5. Results & Reporting (Case Study III) Products:
Mass Fraction of all gases Final Temperature Final Pressure
Blocks: Compressor 1 Workload Compressor 2 Workload
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6. Analysis (Case Study III) Tempearture increases:
What if, cooling before any compression?
Workload of heater/cooler vs. Compression
Energy optimization?
$$??
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Case Study III : Gas Compression 018 Case Study III - Gas CompressionThis is a Free Trial…
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9. Case Study IV Now its time to practice alone! Make your simulation Compare with the results shown in the Course’s Workshop If there are warning/error shown
Try troubleshooting Send your results to me! @CHEMENG (any contact given before)
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Case Study IV Problem: Petrochem – (Natural Gas Separation, LP Gas, Pentanes +
Hexaes) Statement Diagram… Compare Results Analysis and Conclusion (send feedback to Contact@Course)
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1. Statement (Case Study IV) A Petrochemical Industry requires to Split the next Stream
Tank Status 150F; 800 psia Max. Flow Rate 1000 lbmol/h Composition of petroleum mix:
Try using only 3 distillation columns! A flash drum s convenient for water removal prior to distillation.
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1. Statement (Case Study IV) Find:
Final composition of Natural Gas Line (C1 mainly) Final composition of Light gases (LPG C2-C4) Final composition of Heavy Keys (C5 and C6) Water flow rate from flash drum
Blocks Heat Duty of Boiler + Condenser of each Final Product Pressures
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1. Statement (Case Study IV) Try changing:
Number of stages (trays) Distillate/Feed Ratio Reflux Ratio Pre-coolers and Pre-heater before distillation Pressure drop in columns
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2. Process Diagram (Case Study IV)
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2. Process Diagram (Case Study IV)
Light Distillation Column
Mid-Light Distillation Column
Heavy Distillation ColumnFlash Separator
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3. Data Input (Case Study IV) Feed:
T = 150F; P = 800 psia Max. Flow Rate 1000 lbmol/h
Flash P = 300 psia Q = 0 (adiabatic flashing)
Light Distillation RadFrac P = 150 psia; N = 18; feed = 10 Partial-Vapor Condenser; Kettle Boiler Reflux Ratio = 2 (molar) D/F ratio = 0.5 (mass)
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3. Data Input (Case Study IV) Mid-Light Distillation
RadFrac P = 15 bar psia; N = 25; feed = 12 Partial-Vapor Condenser; Kettle Boiler Reflux Ratio = 8 (mass) D/F ratio = 0.5 (mass)
Heavy Distillation RadFrac P = 250 psi; dP = 15psia; N = 15; feed = 8 Total Condenser; Kettle Boiler Reflux Ratio = 8 (mass) D/F ratio = 0.5 (mass)
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3. Data Input (Case Study IV) Mixer:
P = 5 bar Friction loss:
Model as Valve Pressure Drop = 1.5 bar Adiabatic Flash
COMP2 Compressor Isentropic Discharge P = 5 bar 90% Isentropic Efficiency 85% Mechanical Efficiency
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4. Run Simulation (Case Study IV) Run the simulation!
Debug required?
Warnings
Errors?
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5. Results & Reporting (Case Study IV) Products:
% composition of all products % vapor/liquid in products (should be either 1 or 0)
Blocks: Compressor 1 Workload Distillators:
Heat Duty of Condenser Heat Duty of Reboiler
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Case Study IV: Results! Download Results at UDEMY!
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6. Analysis (Case Study IV) Heat load requirements if previous chilling/cooling Change in % composition due to Reflux Rate and F/D ratio Compare Flashing vs. Not Flashing Chance Flashing conditions (Pressure)
Overall Try to get better results for % compositions of streams!
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End of Case Studies
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10. Conclusion Finally! You made it!
By now you should be able to know:
General Flowsheet Concepts Basic Requirements to set up a Simulation Setting the adequate Physical Properties Flowsheet “manipulation” Major and Common Unit Operations Workshop Practice Reporting Results (Tables) Technical Stuff (extensions, versions, exporting, saving, etc...)
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INDEX (Review)1. Course Objectives2. Introduction to Aspen Plus3. User Interface & Getting Help4. Physical Properties5. Introduction to Flowsheet6. Unit Operation Models7. Reporting Results8. Case Studies I, II and III9. Case Study IV10. Conclusion
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Next Courses! Intermediate + Advance
Continue with the next course Intermediate and Advance!
You will learn…
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Next Courses! Intermediate + Advance
Files: Creating and editing templates Reviewing samples/exercises/previous projects More on extensions and backup, onedrive Exchange, Support and Live chats Continuous training
Physical Properties Environment: More on Methods and how to use them More on substances and YOUR own substances/assays Graphs + Substances Properties charts
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Next Courses! Intermediate + Advance
Transient State Steady vs. Unsteady/Transient states Batch modeling
Economy Environment
Safety Environment
Energy Environment
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Next Courses! Intermediate + Advance
Unit Operations: Rigourous/Detailed Heat Exchange Rigourous/Detailed Distillation; Petroleum Refinery Batch Separation (Columns) MultiFrac and PetroFrac insights Reactors All reactors left (Requil, Rgibbs, RCSTR, Rplug, Rbatch) Modeling for mechanisms and kinetic theory Extraction (liquid-liquid and many others) Manipulators/Calculators dP Valves, Pipes, Pipelines and Piping (drop of pressure, frictions, duty load) Review of Unit Operations with Solids
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Next Courses! Intermediate + Advance
Running Simulations More on Debugging, warnings, and fixing Errors Degrees of Freedom Process simplification
Reporting Results Excel export/import Sensitivity Analysis Charts, Graphs, Tables
Programming tools Fortran coding Manipulator Hierarchy Calculator
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Thank You! It was awesome to share the course!
Hope you like it
Please leave a Review! It really helps other students to find the course easier
If I get students; I get motivated to do MORE material XD
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Reminder :)This is a Free Trial…
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