Module 3 - Basic Equipment

Supported by:

Aspen HYSYS Training

Module 3: Basic Equipments in HYSYS

Tutor:M. Ersharry Yunashtanto

Zayyanatun ZulfaIkha MuliawatiMada Harahap

1. Mixer

2. Tee (Flow Splitter)

3. Separator

4. Pump

5. Compressor

6. Expander

7. Valve

BASIC EQUIPMENTS IN HYSYS

8.Cooler

9. Heater

10. Heat Exchanger

11. Reactor CSTR

12. Reactor PFR

13. Distilation Column

1. Mixer

Unit Function

• To Mix/Combine

two/multiple feed streams

as one product stream

Important Design

Parameter

• Automatic Pressure

Assignment

• Equalize All

• Set Outlet to Lowest

Inlet

Objective of Unit

• To calculate the final properties of

mixed fluid (using flash calculation)

OPEN EXERCISE 3.1

1. Mixer (Cont’d)A. Set Outlet to Lowest Inlet

1. Mixer (Cont’d)B. Equalize All

2. Tee (Flow Splitter)

Unit Function

• To divide one feed

stream into

two/multiple

product streams

Important Design

Parameter

• Flow Ratio

• Flow ratio (Fr) for

each stream

0 ≤ Fr ≤ 1

Objective of Unit

• To get multiple product streams

with same operating condition (P&T)

and composition as feed stream

3. Separator

2-Phase Separator

3-Phase Separator

Why do we need Separation ???

Disperse Phase can have undesirable effects, i.e:

1. Steam which has a little moisture entrained in it can leave undesirable silica deposits on superheater tube

2. Water carried over into turbine from a boiler can erode the blades.

3. Gas carried under into pump from a vessel can erode the impeller.

3. SeparatorSeparation in HYSYS

1. HYSYS use P-H flash to determine Products:P : lowest Feed Pressure – Delta Pressure

2-Phase Separator

3-Phase Separator

H: Sum of Feed Enthalphy ± Duty

3. Separator

Important Design

Parameter

• Delta P (Pressure Drop)

• Inlet

• Vapor Outlet

By Default: Delta P = 0Actual : Delta P > 0

3. Separator

Unit Function

• To separate multiphase feed stream/streams into several “single”

phase product stream (vapor, light liquid, heavy liquid)

BY DEFAULT:

Separator Unit in HYSYS

PERFECT SEPARATION

ACTUAL:NO PERFECT SEPARATION

IF REQUIRED

Separator Unit in HYSYS can model IMPERFECT SEPARATION

4. Pump

Basic Theory:

1. Objective of pump : Transfer/move liquid from source to destination (higher head)Circulate liquid around a system

2. Pumping System CharacteristicTotal Head = Static Head + Friction HeadPump Performance CurvePump Operating Point- Duty Point: rate of flow at certain head- Pump Operating Point : intersection of pump curve and system curve

System head

Flow

Static head

Frictionhead

Systemcurve

Flow

Head

Statichead

Pump performance curve

System curve

Pump operating point

4. Pump

Unit Function

• To increase the head of inlet liquid

stream

Objective of Unit

• To calculate one of these unknown data:

• Pressure

• Temperature

• Pump Horse Power

• Pump Efficiency

4. Pump

Important Design

Parameter

• Delta P

• Adiabatic Efficiency

• Duty (Pump Horse Power)

4. Pump

Check this box to use the pump curve

Flow

Head

Statichead

Pump performance curve

System curve

Pump operating point

Pump Curve Head Vs. FlowCommonly, this curve is provided by vendor

5. CompressorIdeal Work is calculated for mechanically reversible process

Along a particular compression path

Adiabatic Compressor- Follow Isentropic compression

path from inlet pressure to outlet pressure

Polytropic Compressor- Compression path is also adiabatic or isothermal

Actual Work and ΔH is determined from Wrev and Efficiency

T &/ or P is determined from ΔH

5. Compressor

Unit Function

• To increase the head of inlet gas

stream by adding Work.

Objective of Unit

• To calculate one of these unknown data:

• Pressure

• Temperature

• Compressor Horse Power

• Compressor Efficiency

5. Compressor

Important Design Parameter

• Compressor Efficiency:

• Adiabatic Efficiency

• Polytropic Efficiency

• Duty

• Operating Mode

• Centrifugal

• Reciprocating

5. Compressor

Compressor Curve Commonly, this curve is provided by vendor, consists of: flow rate, pressure head , & efficiency To choose Adiabatic/ Polytropic as Efficiency Basis

To enable the curve

Click to add the curve

Click to activate the curve

5. Compressor

Optional if only 1 curve availableInput flow, head, & efficiency data

Choose the Unit

For Single Curve, the combination of input data will solve:

- Inlet pressure & flow- Inlet pressure & duty- Inlet and Outlet Pressure- Inlet and efficiency

6. Expander

Unit Function

• To decrease the pressure of inlet gas with

higher pressure into produced work

Objective of Unit

• To calculate the Work produced

Application

• As model for Turbine & Turbo Expander

6. Expander

Important Design Parameter

• Expander Efficiency:

• Adiabatic Efficiency

• Polytropic Efficiency

Expander : liquid, Turbine : gas

7. Valve

Unit Function

• To drop the pressure of the

inlet which has higher

pressure

Objective of Unit

• To calculate one of these unknown

conditions:

• Outlet T or Outlet P

• Inlet T or Inlet P

7. Valve

Important Design

Parameter

• Delta P

• Specified by user.

8. Cooler

Heat Duty

Theory

8. Cooler

Unit Function

• To cool down the temperature of inlet

stream

Objective of Unit

• To calculate one of these unknown data:

• Outlet Temperature

• Cooler Duty

Cooler is one-sided Heat Exchanger,Q is removed (-)

8. Cooler

Important Design

Parameter

• Delta P

• By Default=0 or

• Specified by user.

• Duty

8. Cooler

Heat Duty

Theory

9. Heater

Unit Function

• To heat up the temperature of inlet

stream

Objective of Unit

• To calculate one of these unknown data:

• Outlet Temperature

• Heater Duty

Heater is one-sided Heat ExchangerQ is added (+)

9. Heater

Important Design

Parameter

• Delta P

• By Default=0 or

• Specified by user.

• Duty

10. Heat ExchangerTheory

1. Type of HE based on flow direction

10. Heat Exchanger

2. Energy Balance

Duty which increase the temperature

Duty which decreasethe temperature

3. Heat Exchanger Duty

10. Heat Exchanger

Unit Function

• To transfer the energy from warmer

fluid to colder fluid

Objective of Unit

• To increase the energy efficiency of the

overall facility

10. Heat Exchanger

Basic Equation:[Mcold x ΔHcold – Qleak]- (Mhot x ΔHhot – Qloss]

= Balance Error = 0 (Typically)

Heat Exchanger has two sided:- Hot Side - Cold Side

10. Heat Exchanger

Important Design Parameter

• Heat Transfer model

• End Point

• Weighted Point

• Steady State Rating

• Dynamic Rating

• Delta P

• On Shell & Tube Side

• Overall Heat Transfer Coeff. Area (UA)

• Heat Exchange Geometry

• Tube

• Shell

10. Heat Exchanger

Parameter to be specified:- Temperature/ Delta Temp.- Minimum Appro. Temp.- UA- LMTD- Duty- Duty Ratio- Flow

Ada contoh kasus error

10. Heat Exchanger

Heat Exchanger Requires Recycle Operations:

1. Start with unconnected heater & cooler

2. Connect heater and cooler with one single energy stream

3. Replace heater and cooler with Unit Heat Exchaner

4. Use Recycle Block if the calculation seems difficult to be matched.

Distillation

• Distillation process use 40% of energy in a chemical plant.

• The traditional approach for solving distillation columns uses the concept of equilibrium or theoretical stages. This concept assumes the vapor and liquid phases leaving any stage are in thermodynamic equilibrium with each other.

Principle

Minimum number of tray

Parameter adjustment

Design of Distillation Column

Obtain:

• Operating pressure

Obtain:

• Initial value of number of tray

• Initial value of feed stage

Optimization

• Design a distillation column to get propene in top stream with purity 96%

(mole).

Study Case

Components Mass Flow (kg/h)

Ethane 4.1

Propane 4000.4

Propene 131.8

n-Butane 10498.2

Conditions Value

Temperature (C) 38

Vapour Fraction 0

Fluid Package Peng-Robinson

• Function : used when there is a reaction occurs in the process

simulation

• There are 6 type of reactors provided by hysys: 1. General reactors consist of : Gibbs Reactor, Equilibrium

Reactor, Conversion reactor, Yield Shift Reactor 2. Continuous Stirred Tank Reactor (CSTR) 3. Plug Flow Reactor (PFR)

• Before begin the simulation it is important to describe the

reaction on the hysys simulation basis manager.

11. Reactor

Type of Reactor

Can be used when we do not know the reaction sets

Can be used for modelling conversion reactions

Can be used for modelling equlibrium reactions

can be used for complex reactors where no model is available

CSTR Reactor

The CSTR is a vessel in which Kinetic, Heterogeneous Catalytic and Simple Rate reactions can be performed. The conversion in the reactor depends on the rate expression of the reactions associated with the reaction type.

PFR Reactor

The PFR can modelled Kinetic, Heterogeneous Catalytic and Simple Rate reactions.

Example Using Reactor in Simulation

How to Add Reaction Set

Choose Reaction type

Input component involved in reaction

Input stoichiometric coefficient

Add Reaction to Fluid Package

How to Add Reactor (1st method)

How to Add Reactor (2nd method)

click Double click

Reactor Designs Tab

Reactor Reactions Tab (To Add Rxn set to Reactor)

Click to select Rxn and Rxn Set

REACTOR EXERCISE

Problem Description: One possible way to produce acetone is by dehydrogenation of Isopropyl Alcohol (IPA). The Reaction mechanism is as follow: With Reaction Rate: By Using PFR as reactor, with design condition given as below, determine the acetone product flowrate.

Type of reaction: Heterogeneous Catalytic Reaction

Basis of reaction: Vapor Phase, IPA

Pressure drop in the PFR is assumed to be zero

OPEN FILE: IPA- REACTION EXERCISE-STARTER.HSC

REACTOR EXERCISE ANSWER

Thank You

M. Ersharry Yunashtanto Zayyanatun Zulfa

Ikha Muliawati Mada Harahap

Referensi

1. Separation. http://lhd52.files.wordpress.com/2011/09/group-6-separation-operations.pdf

2. HYSYS Design Tutorial for CHEE470. http://m.chemeng.queensu.ca/courses/CHEE470/documents/HYSYSTutorial.pdf

3. HYSYS Tutorial Che 3G4. http://jpkc.tongji.edu.cn/jpkc/hgyl/second/site/Hysys.pdf

4. http://www.departments.bucknell.edu/chem_eng/cheg200/HYSYS_Manual/a_BlueHYSYS.pdf

5. Dr. Istadi, ST, MT. Perancangan Process Kimia (Chemical PRocess Design). http://tekim.undip.ac.id/staf/istadi/files/2009/05/presentasi_perancangan_proses_kimia_1.pdf

6. Tutorial Apps. http://www.uam.es/personal_pdi/ciencias/vferro/documentacion/doc/Hysys%203.2/Doc/HYSYS/TutApps.pdf

7. Peter Griffith. www.thermopedia.com/Vapor-Liquid Separation

• Aspen Hysys Unit Operation Guide, Aspen Technology, 2011 • Turton, R., Bailie, R. C., Whiting, W. B., Shaeiwitz, J. A., &

Bhattacharyya, D. (2012). Analysis,Synthesis, and Design of Chemical Processes. Pearson Education, Inc.

REFERENCES