Hysys 7.3 Manual

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(1)This electronic HYSYS v7.3 manual is a condensed version of your purchased HYSYS v7.3 manual. It contains mostly those pages that have web links. Use the bookmarks to the left to go to a specific page.. Chemical Process Simulation and the Aspen HYSYS Software. Michael E. Hanyak, Jr.. Department of Chemical Engineering Bucknell University Lewisburg, PA 17837. This electronic HYSYS v7.3 manual is a condensed version of your purchased HYSYS v7.3 manual. It contains mostly those pages that have web links. Use the bookmarks to the left to go to a specific page..

(2) Copyright © 1998 to 2012 by Michael E. Hanyak, Jr. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means—electronic, mechanical, photocopying, recording, scanning or otherwise—without the prior written permission of the Publisher, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act. Request to the Publisher for permission should be sent to the address below.. Dr. Michael E. Hanyak, Jr., Publisher Chemical Engineering Department Bucknell University Lewisburg, PA 17837 Email:. [email protected].

(3) I dedicated this book to my wife—Martha Jane—for her love, understanding, and English prowess..

(4) About the Author Michael E. Hanyak, Jr. is Professor Emeritus of Chemical Engineering at Bucknell University in Lewisburg, PA. He received his B.S. from The Pennsylvania State University in 1966, M.S. from Carnegie Mellon in 1968, and his Ph.D. in Chemical Engineering from the University of Pennsylvania in 1976. From 1967-1970, he worked as a senior chemical engineer at Air Products, Inc. in Allentown, PA, where he developed process simulation software for cryogenic systems. He served as Professor of Chemical Engineering at Bucknell University from 1974 to 2010. His teaching and research interests included computer-aided engineering and design, instructional design, pedagogical software tools, and the electronic classroom. With undergraduate and M.S. graduate students, he has developed a thermodynamic software system (BUTS), a linear equation system solver (BLESS), a formative assessment system for teamwork (TEAM 360), and an electronic learning system for engineering problem solving (eLEAPS), of which the last three are an integral part of the freshman introductory course and senior design course in Bucknell’s curriculum for chemical engineering majors. His two manuscripts— Companion in Chemical Engineering (CinChE): An Instructional Supplement and Chemical Process Simulation and the Aspen HYSYS Software— support a team-oriented and problembased-learning environment for the introductory course in chemical engineering. The CinChE manual presents a novel application of a problem solving strategy that enhances students’ higherorder thinking skills of analysis, synthesis, and evaluation. The HYSYS manual is a self-paced instructional document that teaches students how to use effectively a process simulator. With grants from the Air Products Foundation, the General Electric Fund, and the National Science Foundation, Professor Hanyak provided leadership with groups of engineering faculty in pioneering the electronic classroom and active learning in the chemical engineering department and the engineering college at Bucknell University. As an outreach since 2003, he and his colleagues have annually presented summer workshops at Bucknell Univeristy on active learning, cooperative learning, and problem-based learning to nearly 300 engineering faculty from the U.S. and abroad. In 1983, Professor Hanyak served on the original committee that formulated the Writing Program at Bucknell University. He has integrated teamwork, writing, oral communication, and professionalism in the freshman course on stoichiometry, the junior unit operations laboratory, and the two senior design courses, using a fictitious consultant company, the Bison Engineering and Evaluation Firm (BEEF, Inc.). He has authored two BEEF company handbooks to support this integration. As department chairman from 1998-2002, Professor Hanyak supervised the migration to the first outcome-based format for the successful ABET accreditation in 2002, automated the course scheduling process, and spearheaded the electronic assessment of courses in the Chemical Engineering Department. For his love of teaching and non-traditional research in support of that teaching, he received the Lindback Award for Distinguished Teaching from Bucknell University in 2002. He has been a member of the American Institute of Chemical Engineers and the American Society for Engineering Education (ASEE). He is the recipient of the 2011 CACHE Award given by the Chemical Engineering Division of ASEE for significant contributions in the development of computer aids for chemical engineering education. iv.

(5) Preface This document entitled Chemical Process Simulation and the Aspen HYSYS Software is a selfpaced instructional manual that aids students in learning how to use a chemical process simulator and how a process simulator models material balances, phase equilibria, and energy balances for chemical process units. A student’s learning is driven by the development of the material and energy requirements for a specific chemical process flowsheet; that is, the toluene alkylation with methanol to produce styrene monomer. This semester-long, problem-based learning activity is intended to be a student-based independent study, with about two-hour support provided once a week by a student teaching assistant to answer any questions. Your feedback is welcomed in order to improve the next version of this instructional manual. Please direct your feedback to the email address [email protected]. This HYSYS manual can be used with most textbooks for the introductory course on chemical engineering, like Elementary Principles of Chemical Processes [Felder and Rousseau, 2005], Basic Principles and Calculations in Chemical Engineering [Himmelblau and Riggs, 2004], or Introduction to Chemical Processes: Principles, Analysis, Synthesis [Murphy, 2007]. It can also be used as a refresher for chemical engineering seniors in their process engineering design course. Because the HYSYS manuscript was compiled using the Adobe Acrobat® system for document processing, it contains many web links. In the Acrobat Reader® version of this instructional manual (the .pdf file), you can access the web links that appear in many of the tutorials and simulation problems of the paper copy. You are encouraged to view electronically the “.pdf” version while you read the paper copy of this instructional manual. Type the following web link to access it: http://www.departments.bucknell.edu/chem_eng/cheg200/HYSYS_Manual/a_blueHYSYS.pdf. The web links access HYSYS “.hsc” files, “.pdf” documents, “.docx” files, and “.xlsx” files that appear in many of the chapters. You can view but not copy or print content within the “.pdf” version of this HYSYS manual. Errata for this version of the HYSYS manual are available at the following web link: http://www.departments.bucknell.edu/chem_eng/cheg200/HYSYS_Manual/a_errataHYSYS.pdf. Downloading the “.hsc”, “.pdf”, “.docx”, and “.xlsx” files from within the electronic version of the HYSYS manual using Internet Explorer®, Firefox® or Safari® should work smoothly. The HYSYS manual contains four chapters. Chapter 1 provides an overview of the problem assignment to make styrene monomer from methanol and toluene. Chapter 2 presents ten tutorials to introduce the student to the HYSYS simulation software—tutorial conventions, HYSYS interface, simulation file creation, heater operation, conversion reactor, process flow diagram (PDF) manipulation tools, Gibbs equilibrium reactor, plug flow reactor, printing capabilities, and spreadsheet programming. The first six of these tutorials can be completed in a two-week period for the introductory chemical engineering course. The other four are intended for the senior-level design course. Chapter 3 provides five single-unit assignments—process stream, pump, cooler, mixer/tee, and reactor—to develop the student’s abilities and confidence to simulate individual process units using HYSYS. These five assignments can be completed over a three-week period. Chapter 4 contains seven assignments—reactor section, cooling/decanting section, methanol recycle purification section, toluene recycle purification section, feed preparation section, recycle mixing/preheating section, and product purification section—to develop the process material and energy requirements for the styrene monomer flowsheet. These seven assignments can be completed over a seven-week period. The HYSYS manual also contains fourteen appendices in support of the four chapters for the steadystate simulation of a continuous process represented by a process flow diagram (PFD). Appendix A describes how to solve a batch example process within the Aspen HYSYS software using a spreadsheet v.

(6) operator. Appendix B provides an overview of the steady-state simulation modules for the material and energy balances of some standard unit operations that are detailed in the next ten appendices. Appendix B also provides the conceptual and mathematical models for a process stream divider, often called a TEE. Appendices C to L present the mathematical models and some of their mathematical algorithms for ten standard steady-state process units—process stream, stream mixer, pump, valve, heater/cooler, chemical reactor, two-phase separator, three-phase separator, component splitter, and simple distillation. Appendix N contains the economic model and its HYSYS spreadsheet to determine the net profit for the styrene monomer flowsheet. Finally, Appendix N contains the bibliography for the preface, four chapters, and thirteen appendices. Some of the important web links that appeared in the chapters are also provided in the bibliography. During the 1980’s, a paradigm shift started to take place from the traditional lecture-based deductive approach in the classroom (i.e., sage on the stage) to the student-centered inductive approach (i.e., coach on the side) that incorporates one or more of the following learning techniques—active learning, collaborative learning, cooperative learning, and problem-based learning [Prince, 2004 and Prince and Felder, 2006]. Although the HYSYS manual has been designed for a problem-based learning environment, it can easily be used in other active learning scenarios. Hanyak and Raymond [2009] present the design and application of a team-based cooperative learning environment for the introductory course in chemical engineering, where student learning is driven by solving process unit problems and is supported by the CinChE manual [Hanyak, 2011]. As a self-study activity, how would students determine the material and energy requirements to make styrene monomer from toluene and methanol using Aspen HYSYS? Students work individually to complete the tutorials and exercises in this HYSYS manual according to the schedule given next: Topics. ½-Week Project P0. HY.3. F&R: Ch. 4. HY.4, HY.5. F&R: Ch. 6. SM.1, SM.2. { done as a team }. F&R: Chs. 4, 6. SM.3. F&R: Chs. 7-8. SM.4, SM.5. F&R: Ch. 9. SM.6, SM.7. { done as a team }. Energy and Energy Balances (no reactions). 2-Week Project P5. HY.1, HY.2. { done as a team }. Exam II Review, Exam II on Friday. 2-Week Project P4. F&R: Ch. 4. { done as a team }. Chemical Phase Equilibrium. 1-Week Project Ex3. 2.4, 2.5, 2.6. F&R: Chs. 5, 4. Material Balances, Recycle Processes. 2-Week Project P3. F&R: Chs. 2, 3 CinChE: Ch. 3. { done as a team }. Equations of State, Exam I on Friday. 2-Week Project P2. 2.1, 2.2, 2.3. { done as a team }. Material Balances (with and without rxn’s). 1-Week Project Ex2. CinChE: Ch. 1 HYSYS: Ap. C. { done as a team }. Process Variables; Exp. Data Curve Fitting Project Problems; Thermophysical Properties. 2-Week Project P1. HYSYS Section. { done independently }. Problem-Solving Methodology HYSYS Simulation and Process Streams. 1-Week Project Ex1. Source. { done as a team }. Material/Energy Balances (with reactions) Final Exam, Week of Finals. F&R - the Felder and Rousseau textbook; CinChE – Companion in Chem. Eng. by Hanyak. vi.

(7) where in the “Source” column, “CinChE” is Companion in Chemical Engineering: A Instructional Supplement [Hanyak, 2011], “HYSYS” is this Aspen HYSYS manual, and “F&R” is the Felder and Rousseau textbook [2005]. The “HYSYS Section” column identifies the tutorials and exercises in this HYSYS manual. Obviously, the above schedule table is for the introductory chemical engineering course on material balances, phase equilibra, and energy balances. In this course, students must develop their lowerorder thinking skills—knowledge, comprehension, and application—and their higher-order thinking skills—analysis, synthesis, and evaluation—in Bloom’s cognitive taxonomy [1956], in order to become effective problem solvers and to guard against blindly using the Aspen HYSYS software as a black box. The traditional lecture-based format tends to focus on the lower-order thinking skills and usually does not provide a formal emphasis on the higher-order thinking skills. In a problem-based learning environment, student teams that are required to follow the tenets of cooperative learning [Johnson, et al., 1998] can develop both their lower-order and higher-order thinking skills, as demonstrated by Hanyak and Raymond [2009] using team-based projects. In a team-based learning environment, the creative problem-solving methodology emphasized in CinChE [Hanyak, 2011] provides a general framework in which to solve any type of well-defined engineering problem involving material balances, phase equilibria, and energy balances. It is a systems strategy that heavily uses the mental processes of decomposition, chunking, and pattern matching, and it is specifically designed to enhance students’ higher-order thinking skills of analysis, synthesis, and evaluation. In applying this methodology, team members learn how to develop a conceptual model (a diagram), formulate a mathematical model with its assumptions, create a mathematical algorithm, do the numerical solution, conduct heuristic observations, and develop the formal documentation for a problem. In conjunction with the CinChE problem-solving methodology, Projects P0 and Ex1 in the above table are designed as one-week projects that essentially introduce the students to the Aspen HYSYS interface using tutorials from Chapter 2 of this instructional manual. Projects Ex2 and Ex3 occur during an exam week and provide the students with further challenges on using the HYSYS simulator. Projects P1 to P5 are each two weeks in duration. A two-week project of assigned analysis problems on material balances, phase equilibria, or energy balances can drive the learning on how individual process units are modeled and solved. The number of manually-solved analysis problems in a project is equal to the number of members in a team (e.g., four problems for a four-member team). The CinChE problem-solving methodology not only guides the students in solving the analysis problems, it also serves as the critical framework in which to foster communication and teamwork skills using the five tenets of cooperative learning [Johnson, et al., 1998]. As team members are working to solve the analysis problems, they are also independently completing the assigned HYSYS problems (identified in the “HYSYS Section” column of the above table) and documenting their solutions in their technical journals. Once all team members have completed the HYSYS tutorials or problems, they gather as a team to answer the questions posed at the end of each HYSYS problem. While the self-study HYSYS problems serve to help students learn how to use a process simulator, the manuallysolved analysis problems provide the knowledge base of what happens within the black box. In Chapter 4 of this HYSYS manual, Problems SM.1 to SM.7 require the students to develop the process flow diagram to make styrene monomer from toluene and methanol. Each member of a team begins with the process reactor unit for a specifically-assigned temperature, molar conversion, and yield. Subsequent assignments increase the complexity of the flowsheet by adding process units, one by one, until the complete flowsheet is simulated in Aspen HYSYS. The team’s objective is to determine the operating temperature for the reactor, so that the net profit is maximized without considering federal taxes. vii.

(8) I would like to thank the General Electric Fund for sponsoring during the summers of 1998 and 1999, under its Faculty for the Future program in the area of undergraduate research, the development of this problem-based learning material on computer-aided chemical process simulation. Jessica Keith (Class of 1998) and Cynthia Caputo (Class of 1999), undergraduate research students in chemical engineering at Bucknell University, deserve special thanks for their contributions to this courseware development project during the summers of 1998 and 1999. Jessica provided initial drafts of Chapters 2, 3, and 4. She also wrote the first draft of the appendices on process simulation modules. Cynthia worked on enhancing the process simulation modules using the MathType software, a mathematical equation editor. Dr. William J. Snyder’s encouragement throughout this project and his idea for the batch problem in Appendix A are very much appreciated. Finally, I thank the Bucknell chemical engineer majors (nearly 400 of them) for their patience, understanding, and feedback while developing this manuscript. Their feedback has been invaluable and has helped to enhance the final document. Michael E. Hanyak, Jr.. viii.

(9) Table of Contents About the Author ........................................................................................................................... iv Preface ............................................................................................................................................. v 1. Styrene Monomer Production ................................................................................................ 1-1 Introduction ...................................................................................................................... 1-1 Chemical Flowsheet Description ........................................................................................ 1-2 Flowsheet General Assumptions ........................................................................................ 1-4 Flowsheet Thermodynamic Data ....................................................................................... 1-4 Flowsheet Design Variables ............................................................................................... 1-5 Flowsheet Design Specifications ......................................................................................... 1-6 Flowsheet Economic Analysis ............................................................................................ 1-6 Flowsheet Development Strategy ....................................................................................... 1-7 Your Professional Challenge.............................................................................................. 1-8. 2. HYSYS Simulation Tutorials 2.1. 2.2. 2.3. Process Flowsheet Overview.......................................................................................... 2-1 Tutorial Conventions ...................................................................................................... 2-2 A. Keywords for Mouse Actions ......................................................................................... 2-2 B. Text Formatting ........................................................................................................... 2-2 C. Interactive Process Modeling ......................................................................................... 2-3 D. HYSYS at Your University ............................................................................................ 2-4 E. Your Default HYSYS Preferences .................................................................................. 2-7 Introduction to the HYSYS Interface ........................................................................... 2-8 A. Retrieve a pre-defined simulation file.............................................................................. 2-8 B. Open a pre-defined simulation file in HYSYS .................................................................. 2-9 C. Manipulate stream specifications ..................................................................................2-10 D. Change global preferences ............................................................................................2-12 E. Add variables to the workbook......................................................................................2-13 F. Add a second the fluid package .....................................................................................2-15 G. Program a spreadsheet operation ..................................................................................2-16 H. Document your simulation session .................................................................................2-19 I. Close the simulation case ..............................................................................................2-20 Simulation File Creation................................................................................................2-21 A. Start the HYSYS program ............................................................................................2-21 B. Create a simulation basis ..............................................................................................2-22 C. Find component physical properties ..............................................................................2-23 D. Create a process stream ...............................................................................................2-24 E. Copy and delete a process stream ..................................................................................2-26 ix.

(10) F. Specify alternative stream conditions ............................................................................2-28 G. Document your simulation session .................................................................................2-32 H. Close the simulation case ..............................................................................................2-33. 2.4. 2.5. 2.6. 2.7. Heater and Case Study ..................................................................................................2-34 A. Retrieve a pre-defined simulation file.............................................................................2-34 B. Open a pre-defined simulation file in HYSYS .................................................................2-35 C. Add a heater operation ................................................................................................2-36 D. Specify the heater outlet condition .................................................................................2-38 E. Perform a case study ....................................................................................................2-39 F. Document your simulation session .................................................................................2-42 G. Close the simulation case ..............................................................................................2-43 Conversion Reactor and Reactions ...............................................................................2-44 A. Retrieve a pre-defined simulation file.............................................................................2-44 B. Open a pre-defined simulation file in HYSYS .................................................................2-45 C. Add a reaction to the fluid package ...............................................................................2-46 D. Add a reactor to the flowsheet .......................................................................................2-49 E. Specify the reactor outlet conditions ..............................................................................2-51 F. Document your simulation session .................................................................................2-53 G. Close the simulation case ..............................................................................................2-54 PFD Manipulation Tools ...............................................................................................2-55 A. Retrieve a pre-defined simulation file.............................................................................2-55 B. Open a pre-defined simulation file in HYSYS .................................................................2-56 C. Zoom flowsheet in and out ............................................................................................2-57 D. Orient some PFD icons .................................................................................................2-58 E. Move some icon labels ..................................................................................................2-59 F. View some operating conditions.....................................................................................2-60 G. Add some documentation text .......................................................................................2-61 H. Connect and disconnect PFD objects .............................................................................2-63 I. Copy a PFD to a Word document ..................................................................................2-68 J. Document your simulation session .................................................................................2-70 K. Close the simulation case ..............................................................................................2-71 Gibbs Equilibrium Reactor ...........................................................................................2-72 A. Retrieve a pre-defined simulation file.............................................................................2-72 B. Open a pre-defined simulation file in HYSYS .................................................................2-73 C. Copy a reactor feed stream ...........................................................................................2-74 D. Add a Gibbs reactor to the flowsheet .............................................................................2-75 E. Specify the reactor outlet conditions ..............................................................................2-77 F. Analyze results for the Gibbs equilibrium reactor............................................................2-79 G. Document your simulation session .................................................................................2-82 H. Close the simulation case ..............................................................................................2-83 x.

(11) 2.8. Kinetic Model and a Plug Flow Reactor ......................................................................2-84 A. Retrieve a pre-defined simulation file.............................................................................2-84 B. Open a pre-defined simulation file in HYSYS .................................................................2-85 C. Copy a reactor feed stream ...........................................................................................2-86 D. Add a plug flow reactor to the flowsheet.........................................................................2-87 E. Add a kinetic reaction set to the fluid package ................................................................2-89 F. Specify reactor parameters and outlet conditions.............................................................2-92 G. Analyze results for the plug flow reactor ........................................................................2-95 H. Document your simulation session .................................................................................2-96 I. Close the simulation case ...............................................................................................2-98 2.9 HYSYS Printing Capabilities ........................................................................................2-99 A. Retrieve a pre-defined simulation file.............................................................................2-99 B. Open a pre-defined simulation file in HYSYS ............................................................... 2-100 C. Print the PFD and a process unit window ..................................................................... 2-100 D. Print the reactor datasheets ........................................................................................ 2-102 E. Print the case study plot ............................................................................................. 2-103 F. Create a case report ................................................................................................... 2-103 G. Document your simulation session ............................................................................... 2-105 H. Close the simulation case ............................................................................................ 2-106 2.10 HYSYS Spreadsheet Programming ............................................................................ 2-107 A. Retrieve a pre-defined simulation file........................................................................... 2-111 B. Open a pre-defined simulation file in HYSYS ............................................................... 2-112 C. Examine the process flow diagram .............................................................................. 2-113 D. Complete the spreadsheet operator.............................................................................. 2-113 E. Compare the simulation results ................................................................................... 2-116 F. Document your simulation session ............................................................................... 2-117 G. Close the simulation case ............................................................................................ 2-118 3. Process Unit Exercises HY.1 HY.2 HY.3 HY.4 HY.5. Overview ....................................................................................................................... 3-1 Process Stream Simulation .......................................................................................... 3-2 Pump Simulation .......................................................................................................... 3-4 Heater/Cooler Simulation ............................................................................................ 3-6 Mixer/Tee Simulation .................................................................................................. 3-9 Reactor Simulation......................................................................................................3-12. 4. Flowsheet Development Exercises Overview ....................................................................................................................... 4-1 SM.1 Styrene Monomer Reaction Section ........................................................................... 4-3 SM.2 Reactor Effluent Cooling/Decanting Section ............................................................. 4-5 xi.

(12) SM.3 SM.4 SM.5 SM.6 SM.7. Methanol Recycle Purification Section ...................................................................... 4-8 Toluene Recycle Purification Section ........................................................................4-13 Toluene/Methanol Feed Preparation Section ...........................................................4-17 Recycle Mixing and Preheating Section ....................................................................4-19 Styrene Monomer Purification Section .....................................................................4-23. Appendix A. Example Batch Simulation in HYSYS .............................................................. A-1 Appendix B. HYSYS Steady-State Simulation Modules ......................................................... B-1 Process Module Format ............................................................................................... B-1 Stream Tee Module ......................................................................................................B-3 Appendix C. Process Stream Module ....................................................................................... C-1 Appendix D. Stream Mixer Module ......................................................................................... D-1 Appendix E. Pump Module........................................................................................................ E-1 Appendix F. Valve Module ........................................................................................................ F-1 Appendix G. Heater/Cooler Module ........................................................................................ G-1 Appendix H. Chemical Reactor Module .................................................................................. H-1 Appendix I. Two-Phase Separator Module .............................................................................. I-1 Appendix J. Three-Phase Separator Module ...........................................................................J-1 Appendix K. Component Splitter Module ............................................................................... K-1 Appendix L. Simple Distillation Module .................................................................................. L-1 Appendix M. Styrene Net Profit Analysis ................................................................................ M-1 Appendix N. Bibliography ........................................................................................................ N-1. xii.

(13) Chapter 1 Styrene Monomer Production.

(14) Chapter 1 Styrene Monomer Production.

(15) Chapter 1. Page 1-1. Styrene Monomer Production. Introduction Welcome to the Internship Program in the Process Engineering Department of BEEF, Inc., the Bison Engineering and Evaluation Firm. As a new provisional engineer in this program, you will learn how to develop a chemical process and determine its process requirements for material and energy using the process simulator called Aspen HYSYS®. BEEF is a consultant company that solves chemical processing problems for governmental institutions and industrial companies. Since our clients lack the technical expertise, they hire us to recommend and implement solutions to their chemical processing problems. Solving a client’s problem is a complex activity involving many departments in our company. Our department’s focus is to develop, on paper, a large-scale solution, called a process design, for a chemical processing problem. We accomplish this design by synthesizing a process flowsheet, solving its material and energy balances, sizing and costing its equipment, and determining its profitability. Basically, we determine the feasibility of the process design, that is, is it feasible to build and run this process design. Finally, BEEF communicates a process design to our client in the form of a technical report. Hawbawg Chemical Company has hired us to investigate the feasibility of manufacturing styrene monomer from the raw materials of toluene and methanol. They have completed a royalty deal with Exelus, Inc. to use their proprietary one-step process with a newly-developed catalyst. Styrene monomer is an intermediate material used to make such consumer plastic products as polystyrene packaging and film, cushioning materials, radio and television sets, and toys. About 90% of the styrene monomer marketed in the United States currently uses a two-step process beginning with benzene and ethylene. First, benzene is alkylated with ethylene to form ethylbenzene. After purification, the ethylbenzene is catalytically dehydrogenated to produce styrene. The dehydrogenation step is endothermic and requires a large quantity of steam mixed with the ethylbenzene to maintain the desired reaction temperature, to depress coking of the catalyst, and to dilute the reaction concentration to enhance the reaction equilibrium. However, the Exelus process will produce styrene monomer from toluene and methanol in one step, and steam addition is not required. Some byproduct ethylbenzene is also produced which can be sold to conventional styrene producers. The new catalyst discovered by Exelus might give Hawbawg the opportunity to develop a new, low-cost route to styrene monomer. As a first step in our feasibility study for Hawbawg, your team is assigned the tasks to develop the flowsheet and determine its process requirements for material and energy that maximizes the net profit. The chemical process for converting toluene and methanol to styrene monomer is globally depicted in the diagram below. byproduct. toluene. flowsheet methanol. ?. styrene monomer wastes. You must synthesize the process flowsheet, where the chemical reactor is the heart of that flowsheet. This flowsheet will be composed of process units (such as reactors, heaters, coolers, pumps, and distillation columns) that are connected by process streams, and it will conceptually shows the flow of material and energy from the raw materials to the products. Before you look at this flowsheet in detail, you should click here to complete.

(16) Chapter 1. Page 1-2. Styrene Monomer Production. an interactive demonstration on the construction of a simple flowsheet to produce styrene monomer from toluene and methanol. This interactive demo takes about two and half hours to complete. You can stop the demo at any time. When you restart it, you can begin where you had left off. The interactive demo illustrates the basic concepts that you will be learning about in this HYSYS manual on chemical process simulation.. Chemical Flowsheet Description The senior chemical engineers in our Process Engineering Department have formulated several possible process flowsheet designs that could produce styrene monomer. They applied design rules of thumb (a.k.a. heuristic rules) to determine those formulations. In Chapter 4 of this HYSYS manual, you will be introduced to some of those heuristic rules as you build the process flow diagram (PFD) one process unit at a time starting with the chemical reactor and using the Aspen HYSYS® software. Our senior chemical engineers have recommended an initial chemical process design without energy integration to convert toluene and methanol to styrene monomer, as depicted in the following block flowsheet: Q. WS. heater toluene. toluene recycle H2 fuel. pump. Q. Q. decanter. column. organic furnace. reactor. Q. WS. cooler. methanol aqueous. column. methanol recycle heater. ethylbenzene. column. pump. styrene monomer waste water. This flowsheet is an adaption of the one presented in the 1985 American Institute of Chemical Engineers Student Contest Problem [AIChE, 1984]. A flowsheet is a collection of blocks, circles, and arrowed lines. The blocks and circles represent process units, such as reactors, heaters, coolers, pumps, and distillation columns. The solid arrowed lines are process streams (i.e., chemical material flowing in pipes) that are assumed to have uniform temperature, pressure, flow rate, and composition (as a first approximation, these four variables do not vary along the length of a pipe). These four quantities are referred to as the process state of a stream. The dashed arrowed lines represent energy streams of heat ( Q ) and work ( WS ). Usually, they are draw as solid lines but were drawn as dashed ones above, in order to distinguish them from material streams. Basically, the block flowsheet conceptually shows the flow of material and energy from the raw materials (toluene and methanol) to the product (styrene monomer), by-product (ethylbenzene), and wastes (H2 and water)..

(17) Chapter 1. Page 1-3. Styrene Monomer Production. Although it is not shown in the above flowsheet, toluene and methanol at 25°C and 1 atm are first compressed and heated to saturated vapors at 460 kPa. The toluene and methanol recycles are also compressed and heated to saturated vapors at 460 kPa. Then, the two vapor feeds of pure toluene and methanol entering the above flowsheet are mixed with the toluene and methanol recycles to form the process stream to the furnace. The process stream leaving the mixer operation is superheated in a fired furnace to around 465 to 540°C and then fed to the catalytic reactor where the following vapor-phase reactions take place: C7H8. +. toluene. C7H8 toluene. CH3OH. →. methanol. +. CH3OH methanol. C8H8. +. styrene. →. C8H10 ethylbenzene. H2O water. +. +. H2 hydrogen. H2O water. As a first approximation, you can assume that other byproduct formation and polymerization of styrene monomer are negligible and that the catalyst does not coke or deactivate with time. The reactor is assumed to operate adiabatically; that is, it is well insulated and no heat is transferred to the surroundings. In the above block flowsheet, the process stream leaving the reactor is condensed with cooling tower water and cooled to 38°C, forming three phases—vapor, organic, and aqueous—in a decanter. The vapor stream from the decanter contains mostly hydrogen, and it could be used as a fuel. The aqueous stream contains primarily methanol and water, and it is sent to a methanol distillation column. This column’s product stream is the recycled methanol, while its bottoms stream is wastewater, which is eventually discharged at 25°C and 1 atm. The organic stream from the decanter contains mostly toluene, ethylbenzene, and styrene monomer. It is sent to a toluene distillation column. This column’s product stream is the recycled toluene stream containing some methanol, while its bottoms stream contains mostly ethylbenzene and styrene monomer, which are sent to the styrene distillation column. In the styrene column, the product stream is mostly ethylbenzene, and the bottoms stream is mostly crude styrene monomer. Although not shown in the above flowsheet, both of these streams must be cooled to 25°C and 1 atm before each enters a separate storage tank. In the above styrene monomer flowsheet, the process operates on a continuous basis; that is, material is continually flowing into and out of each process unit. The Aspen HYSYS® simulator is designed specifically for a continuous process of multiple process units. It is not designed to handle batch, semi-batch, or semi-continuous process units. In a batch operation, no material is flowing into or out of the process unit like a batch chemical reactor. The batch reactor is charged with materials, the reaction takes place in the reactor container, and at the end of the reaction the material is removed. In a semi-batch process, at least one chemical compound either enters or leaves the process unit, while all other chemical compounds remain within the process unit. In a semi-continuous process, at least one chemical compound enters and leaves the process unit, while all other chemical compounds are processed as batch or semibatch operations. Using the spreadsheet module in Aspen HYSYS®, you can program the solution to the material and energy balances for a batch, semi-batch, or semi-continuous process unit. Appendix A presents an example batch problem for expanding a gas mixture in a cylindrical tank system, a typical problem that you will encounter in the junior-level chemical engineering thermodynamics course. It also describes how to use the HYSYS spreadsheet module to complete the numerical solution to this batch example problem. Before examining Appendix A, you should complete Tutorials 2.1, 2.2, and 2.3 in Chapter 2 of this HYSYS manual..

(18) Chapter 1. Page 1-4. Styrene Monomer Production. Flowsheet General Assumptions Our client, Hawbawg Chemical Company, expects the plant capacity to be 250,000 metric tons per year of crude styrene monomer with an onstream time of 8,320 hours per year. For a preliminary design study, our senior chemical engineers have provided a list of process simulation assumptions to determine the material and energy requirements for the above process flowsheet as follows: • • • •. Impurities in purchased methanol and toluene are negligible. Yield losses in the chemical reactor due to trace byproducts can be ignored. The catalyst in the chemical reactor does not coke or deactivate with time The chemical reactor is well insulated, and thus no heat is transferred to the surroundings.. • • • •. Mostly methanol partitions into both the organic and aqueous phases of the decanter. Except for methanol, negligible organics will partition into the decanter aqueous phase. Negligible water will partition into the decanter organic phase. The off-gas from the decanter will be given a credit as fuel at its lower heating value.. • • •. The methanol is to be recycled as a saturated vapor at 460 kPa. The toluene/methanol mixture is to be recycled as a saturated vapor at 460 kPa. Water, ethylbenzene and styrene monomer recycled to the reactor feed are at small enough concentrations to pass through as inert compounds.. Flowsheet Thermodynamic Data In your process simulations of the above flowsheet, all necessary thermodynamic calculations for thermophysical properties (such as density and molar enthalpy) and for phase equilibria (such as vapor-liquid or vapor® liquid-liquid) can be done using an equation of state. In the Aspen HYSYS simulator, the Peng-Robinson Stryjek-Vera (PRSV) equation of state is recommended by our senior chemical engineers for the analysis of the manufacture of styrene monomer from toluene and methanol. The PRSV equation is an improvement on the Peng-Robinson (PR) equation of state, and it extends the application of the PR method to moderately non-ideal systems. The physical properties of the six chemical compounds associated with the above flowsheet are summarized below. Their values were extracted from the Aspen HYSYS® databank. Property CAS Registry Number Molecular Weight Normal Boiling Point at 1 atm, °C Critical Temperature, °C Critical Absolute Pressure, kPa Critical Volume, m3/kgmol Acentric Factor ΔHf at 25°C and 1 atm, kJ/kgmol. Hydrogen. Methanol. Water. Toluene. Ethylbenzene. Styrene Monomer. 1333-74-0 2.0160 -252.60 -230.86 1925.55 0.0515 -0.1201 0. 67-56-1 32.0419 64.65 239.45 7376.45 0.1270 0.5570 -201,290. 7732-18-5 18.0151 100.00 374.15 22,120.00 0.0571 0.3440 -241,000. 108-88-3 92.1408 110.65 318.65 4100.04 0.3160 0.2596 50,029. 100-41-4 106.17 136.20 343.95 3607.12 0.3740 0.3010 29,809. 100-42-5 104.152 145.16 362.85 3840.00 0.3520 0.2971 147,400. These thermodynamic data are used in the PRSV equation of state to calculate such thermophysical properties as mass density and molar enthalpy of a mixture of chemical compounds..

(19) Chapter 1. Page 1-5. Styrene Monomer Production. Flowsheet Design Variables In a chemical process simulation, design variables are those variables that you have the freedom to set their values. Our Research and Development Department has conducted some pilot-plant studies on the adiabatic reactor performance of making styrene monomer from methanol and toluene using the newlydeveloped catalyst from Exelus, Inc. In this study, stoichiometric feed (i.e., equal moles of toluene and methanol) to the reactor resulted in the following performance data for the formation of styrene monomer (the product) and ethylbenzene (the byproduct) at a reactor inlet pressure of 400 kPa: X - molar conversion. Y - molar yield. X*Y. X*(1 – Y). Member Symbol. Inlet T, °C. TL reacted TL fed. SM formed TL reacted. SM formed TL fed. EB formed TL fed. α ♠ ♥ ♣ ♦ ω. 465 480 495 510 525 540. 0.649 0.679 0.709 0.759 0.819 0.879. 0.909 0.869 0.829 0.779 0.719 0.659. 0.5899 0.5901 0.5878 0.5913 0.5889 0.5793. 0.0591 0.0889 0.1212 0.1677 0.2301 0.2997. TL is toluene, SM is styrene monomer, and EB is ethylbenzene. An Excel version of this table is available by clicking here. In Chapter 4 of this HYSYS manual, you will complete the process simulation of the above flowsheet for an assigned inlet temperature to the chemical reactor. The first column in the above table identifies a team member symbol that will be assigned to you by your project supervisor. That assigned symbol indicates the inlet temperature that you will use in your HYSYS process simulations of Chapter 4. For a HYSYS distillation column simulation, the feed, distillate, and bottoms streams are to be saturated liquids. Nominal atmospheric distillations will operate at 135 kPa top tray pressure and 125 kPa condenser outlet pressure. Avoid column operating pressures above nominal atmospheric. Allow 5 kPa pressure drop between the top of the column and the condenser outlet for a vacuum distillation column. Based on some heuristic rules in engineering practice [Woods, 2007, Ch. 2], the following pressure drops thru process units caused by frictional losses may be assumed: Fired heater Reactor Heat exchangers* (shell and tube sides) Condensers under vacuum Other major equipment Distillation Trays: 1.0 kPa per theoretical stage for pressure columns 0.5 kPa per theoretical stage for vacuum columns. 60 kPa 70 kPa 10 kPa 5 kPa 10 kPa. *Includes condensers, vaporizers, interchangers and all other exchangers except condensers operated under vacuum.. For pumps and compressors, the adiabatic efficiency can be assumed to be 75%. The combined mechanical and electrical efficiency for this type of equipment is approximately 90%..

(20) Chapter 1. Page 1-6. Styrene Monomer Production. Flowsheet Design Specifications Design specifications set limits on the values of important calculated variables in a chemical process flowsheet simulation for the stated simulation assumptions and design variables. As recommended by Hawbawg, some design specifications for toluene, methanol, ethylbenzene (EB), styrene monomer (SM), and water in the aromatic and wastewater streams are as follows: Recycle Methanol Recycle Toluene EB Byproduct Crude SM Product Wastewater. No specified limit on toluene. No specified limit on methanol. 4 wt % ethylbenzene maximum. 5 wt % maximum for sum of EB and SM. 0.8 wt % toluene maximum. 3 wt % SM maximum. 300 ppm EB maximum. (ppm is parts per million by weight) Governmental standards on all pollutants. The Environmental Protection Agency (EPA) standards for water pollution are given as the maximum parts per million (ppm on mass basis). These standards are: 80 ppm for toluene, 60 ppm for methanol, 108 ppm for ethylbenzene, and 108 ppm for styrene monomer. With respect to any distillation column that contains styrene monomer, do not exceed 145°C in that column with more than 50 mass% styrene monomer in the bottoms stream, in order to minimize polymerization of the styrene monomer (i.e., solid formation of a polymer).. Flowsheet Economic Analysis For a preliminary design study, the economic viability of manufacturing styrene monomer from toluene and methanol can be determined by maximizing the net profit. The net yearly profit for the styrene flowsheet can be approximated as follows: net profit. =. product sales. +. byproduct sales. +. fuel credit. −. cost of raw materials. −. annualized capital cost. −. utility costs. where each term is $ per year. The annualized capital cost for purchasing the equipment is estimated to be (product sales + byproduct sales)/6 in $/yr. The other terms in this net profit equation can be determined once the material and energy requirements for the above flowsheet are calculated for a specific reactor inlet temperature using Aspen HYSYS®. Appendix M provides details on how to determine these other terms. In Chapter 4 of this HYSYS manual, your team members will determine their net profit for their assigned reactor inlet temperature. Your team will then plot sales (which include the fuel credit), costs, and net profit versus the reactor inlet temperatures to determine that operating temperature that maximizes the net profit. In this plot, you can expect to see the net profit curve exhibit a maximum value either within the range of reactor temperatures or at an end point of the range. That point at which the maximum profit occurs is the “best” temperature at which to operate the adiabatic reactor. Although economics are important in determining the viability of a process flowsheet, other factors such as efficiency, health, safety, reliability, aesthetics, ethics, and social impact are also important. You will study these other factors in the senior-level process engineering course of the chemical engineering curriculum. For this introductory course on chemical engineering, our focus for flowsheet viability will just be the net profit. For the economic analysis of other engineering problems, minimizing the costs can be the objective. Click here to review a simple tank problem that is based on minimizing costs..

(21) Chapter 1. Page 1-7. Styrene Monomer Production. For the preliminary economic analysis of the above process flowsheet to make styrene monomer from toluene and methanol, the economic data in the table below are to be used to determine the net profit. These economic data are tentative and appropriate only for a preliminary economic evaluation. Raw Materials: Methanol $ 350/metric ton = Toluene $ 650/metric ton = Product Values: Crude Styrene Product $1,540/metric ton = Ethylbenzene Byproduct $ 970/metric ton = Credits: Off-gas from three-phase separator $ 8.53/M kilojoules Utilities: Natural Gas* $12.10/M kilojoules Steam from HP Steam: 6 bar, 158.8°C, saturated vapor $30.29/K kilograms 11 bar, 184.1°C, saturated vapor $30.59/K kilograms 42 bar, 253.2°C, saturated vapor $30.97/K kilograms Cooling Water $ 0.03/K liters Average inlet temperature 31°C Average outlet temperature 41°C maximum Electricity $0.06/kW·h *Assume 90% efficiency for the fired heater fuel usage. The symbols K and M mean a thousand and million, respectively.. $0.35/kg $0.65/kg $1.54/kg $0.97/kg. All of these data are for 2009 and apply to the Houston Gulf Coast area, where the plant will be located.. Flowsheet Development Strategy Using the above assumptions and data, you and your teammates will be analyzing the above styrene monomer flowsheet extensively in this introductory course as a semester-long project using the Aspen HYSYS® process simulator. The goal of the project is for your team to determine the “best” process requirements for material, equilibrium, and energy based on economics. This project is designed as an independent study to sharpen your life-long learning skills. The chapters in this HYSYS manual will guide you as you do this independent study. The development of any process flowsheet is a very complex activity. Engineers handle complexity by a divide and conquer strategy. In this HYSYS manual, Chapters 2, 3, and 4 are the sub-parts of a strategy to develop the flowsheet for the production of styrene monomer from toluene and methanol. These chapters accomplish the following: •. Chapter 2 introduces you to the Aspen HYSYS® process simulation software. Tutorials 2.1 to 2.6 in this chapter provide you with detailed instructions on how to use HYSYS in the Windows environment, in order to do some standard process simulation calculations in the introductory chemical engineering course. Tutorials 2.7 to 2.10 are intended for the senior-level design course in the chemical engineering curriculum.. •. Chapter 3 provides five assignments in which you can develop your abilities and confidence to simulate individual process units using Aspen HYSYS®. These assignments focus on a process stream, pump, heater, mixer/tee, and reactor. Once.

(22) Chapter 1. Styrene Monomer Production. Page 1-8. you’ve completed the assignments, you will have a mathematical understanding of how HYSYS does its calculations for each process unit. •. Chapter 4 contains seven assignments to develop the styrene monomer flowsheet. Each member of your team will begin with the reactor section at an assigned operating temperature and increase the complexity of the flowsheet by adding sections, one by one, until the complete flowsheet is simulated in Aspen HYSYS®. While doing these assignments, you will learn about some heuristic rules that provide guidance on selecting process unit operations in the flowsheet and determining their operating conditions.. You will complete the tutorials of Chapter 2 and the assignments of Chapters 3 and 4 over a 14-week period. Once these tasks are completed, you will have finished the first step in a feasibility study on the production of styrene monomer from toluene and methanol; that is, the development of its flowsheet and processing requirements for material and energy. While completing the tasks of Chapters 2, 3, and 4, you will need to access additional information, which you can find in the appendices. Appendices B to L contain simulation modules for various continuous process unit operations. Each appendix or module provides a mathematical explanation of how Aspen HYSYS does its calculations for that continuous process unit. A module includes a module description, a conceptual model, model assumptions, a mathematical model, example mathematical algorithms, and several HYSYS simulation algorithms. You will need to consult these appendices while doing your assigned tasks in Chapters 3 and 4.. Your Professional Challenge As a new provisional engineer in BEEF, Inc., your professional challenge of developing the styrene monomer flowsheet using Aspen HYSYS® is formable. To complete this challenge, you must develop your critical thinking skills as a problem solver and document your progress in your technical journal. As reported by Halpern [1989, pp. 29-30], critical thinking has two essential components—the mental skills as well as a healthy attitude. As a provisional engineer, you must develop your critical thinking skills by learning the strategies to apply the CinChE problem-solving methodology [Hanyak, 2011] and to simulate the process requirements for a chemical process flowsheet using Aspen HYSYS®. Also, you must develop a critical thinking attitude; that is, you must be willing to plan, be flexible in your thinking, be persistent and not lazy, and be willing to self-correct. You cannot become a critical problem solver without this sort of attitude. As reported further by Halpern [1989, p. xvii], developing your critical thinking skills requires you to be an active learner that completes reading assignments on time, drafts segments of a problem solution in a timely manner, raises questions when needed, documents the solution in a professional manner, and enjoys what you are doing. You begin your journey in applying the self-paced materials in this HYSYS manual. So, please get comfortable, prepare for some hard work, and enjoy this instructional manual on the Aspen HYSYS® simulator. It should be a cinch! BEEF, Inc. hired you as a new employee, because you possess the talent to become a critical problem solver and professional documenter. Welcome to our company, and good luck in your team's development of the styrene monomer flowsheet. Remember our company’s two mottos, “Engineering is 10 % Inspiration and 90 % Perspiration” and “Results not Excuses.”.

(23) Chapter 2 HYSYS Simulation Tutorials.

(24) Chapter 2 HYSYS Simulation Tutorials.

(25) Chapter 2. Page 2-1. HYSYS Simulation Tutorials. Process Flowsheet Overview As stated in Chapter 1, a fundamental aspect of chemical engineering is the design of chemical processes. A chemical process transforms raw materials into products through a series of process units connected by process streams. A process unit or unit operation is equipment that physically and/or chemically changes the chemical compounds passing through it. Increasing temperature, decreasing pressure, and mixing are some examples of physical changes, while chemical reactions cause changes in chemical compounds. Process units are connected by material process streams that carry the chemical compounds at a certain process state—temperature, pressure, flow rate, and composition. Energy streams connected to process units supply the needed energy for an operation or remove energy released in an operation. A schematic diagram called a process flow diagram (PFD) and often referred to as a flowsheet represents a chemical process. A flowsheet shows all process units and streams and how they are connected, as illustrated in Figure 2.1 below. 25°C 3095 kPa 330 kgmol/h 64.8 mol% benzene 33.5 mol% propylene 1.7 mol% propane 0.0 mol% cumene. Q=?. S1. E1 heater. Q=?. S2 350°C 3075 kPa. R1 reactor. S3 350°C 3025 kPa. Figure 2.1. A Simple Process Flowsheet. The arrow lines labeled S1, S2, and S3 are material streams, while the other two arrow lines are energy streams. The two circles labeled E1 and R1 are process units. For the flowsheet in Figure 2.1, the simulation problem is “what heat duty in kJ/h is required to raise the temperature of Stream S1 from 25 to 350°C” and “how much energy in kJ/h is required to operate the reactor at an isothermal condition (i.e., at constant temperature)”? A simulation of a chemical process does the material and energy balances on all of the process units. This information can then be used to see how to manipulate the process to maximize net profit, maximize product rate, minimize energy use, etc. Aspen HYSYS® is a computer program that simulates chemical processes. Using a computer for a process simulation takes a fraction of the time it takes to do it by hand. The speed of a computer simulation allows the user to observe quickly the effect of changes in a simulation. For example, using HYSYS, you can easily compare the amount of product produced using different ratios of starting materials. Doing this comparison with hand calculations would be a long and tedious task and subject to human calculation errors. In this chapter, you will learn how to use HYSYS within the Windows 7 operating system to do some process simulation calculations. You will also gain a better understanding of some chemical process units and how their material and energy balances are solved. This chapter presents ten tutorials to introduce you to steady-state process simulation. They are: (1) tutorial conventions, (2) introduction to the HYSYS interface, (3) simulation file creation, (4) heater and case study, (5) conversion reactor and reactions, (6) process flow diagram (PFD) fundamentals, (7) Gibbs equilibrium reactor, (8) kinetic model in a plug flow reactor, (9) HYSYS printing capabilities, and (10) HYSYS spreadsheet programming. Tutorials 1 to 6 are designed to be used in the introductory course on chemical engineering, often called the stoichiometry or material and energy balance course. Tutorials 7 to 10 are intended for the senior-level process engineering or design course..

(26) Chapter 2. HYSYS Simulation Tutorial 2.1. Page 2-2. Tutorial Conventions Since HYSYS is totally interactive, it provides virtually unlimited flexibility in solving any simulation problem. Please keep in mind that the approaches used in solving each example problem presented in this tutorial chapter may only be one of many approaches. You should feel free to explore other alternatives by consulting the “Help” facility in the Aspen HYSYS® software. This tutorial presents general convention adopted for this chapter. It focuses on terminology used to describe mouse actions and on formatting conventions for text in this chapter. The tutorial also presents general comments on interactive process modeling, the HYSYS way. Finally, you initialize HYSYS for your use at your university.. A. Keywords for Mouse Actions As you read through various procedures in this HYSYS manual, you will be given instructions on performing specific functions or commands. Instead of repeating certain phrases for mouse instructions, we will use a keyword to imply a longer instructional phrase: •. The keywords select, choose, pick, press, or click mean to position the cursor on the object or button of interest, and press the primary mouse button once.. •. The keyword double-click means to position the cursor on the object of interest, and press the primary mouse button twice quickly in succession.. •. The phrase click and drag means to position the cursor on the object of interest, press and hold the primary mouse button, move the cursor to a new location, and release the primary mouse button.. •. The keyword object inspect means to position the cursor on the object of interest, and press the secondary mouse button once.. •. The keyword enter means to position the cursor in an input cell, press the primary mouse button once, type the required information, and then press the <Enter> key on the keyboard.. For a standard two-button mouse, the primary mouse button is on the left, while the secondary one is on the right, provided you have not changed the mouse settings within the Windows 7 operating system.. B. Text Formatting A number of text formatting conventions are also used throughout this chapter. They help to quickly identify menu commands, buttons, keys on the keyboard, windows or views, areas within windows, radio buttons and check boxes in window areas, material and energy stream names, unit operation names, and HYSYS unit operation types. These conventions are as follows: •. When you are asked to invoke a HYSYS menu command, the command is identified by bold lettering. For example, File indicates the File menu item, while Tools/Preferences… means the Preferences option within the Tools menu..

(27) Chapter 2. HYSYS Simulation Tutorial 2.1. Page 2-3. •. When you are asked to press a HYSYS button, the button is identified by bold, italicized lettering. For example, Close identifies the Close button within a particular window (i.e., a viewing area on the screen).. •. When you are asked to press a key or keys to perform a certain function, keyboard commands are identified by bold lettering, enclosed by angle brackets. For example, <F1> identifies the F1 key on the keyboard. A combination of keys like <CTRL><Alt><Delete> is to be pressed simultaneously.. •. The name of a HYSYS view (or window) is indicated by bold lettering; e.g., Session Preferences.. •. The name of a Group or Area within a view is identified by bold lettering; e.g., Initial Build Home View.. •. The name of Radio Buttons and Check Boxes are identified by bold lettering; e.g. Default or User Supplied.. •. Material and energy stream names are identified by bold lettering; e.g., S1, Column Feed, and Condenser Duty.. •. Unit operation names are identified by bold lettering; e.g., Flash Separator or Atmospheric Tower. Note that blank spaces are acceptable in the names of streams and unit operations.. •. HYSYS unit operation types are identified by bold, uppercase lettering; e.g., HEAT EXCHANGER, SEPARATOR, and DISTILLATION COLUMN.. •. When you are asked to provide keyboard input, it will be indicated by bold lettering; e.g., “Enter 100 for the stream temperature”.. C. Interactive Process Modeling The role of process simulation in this instructional manual is to improve your chemical process understanding so that you can make the best process decision. A flowsheet solution in the Aspen HYSYS system is an interactive simulation, unlike the Aspen PLUS system which is a batch simulation. The HYSYS solution not only makes the most efficient use of your simulation time, but by building the process model interactively—with immediate access to results—you gain the most complete understanding of your process simulation. The HYSYS software uses the power of Object-Oriented Design, together with an Event-Driven Graphical Environment, to deliver a completely interactive simulation environment where: •. calculations begin automatically whenever you supply new information, and. •. access to the information you need is in no way restricted.. At any time, even as calculations are proceeding, you can access information from any location in HYSYS. Each location is always instantly updated with the most current information, whether specified by you or.

(28) Chapter 2. HYSYS Simulation Tutorial 2.1. Page 2-4. calculated by HYSYS. This interactive calculation environment is similar to what occurs in a spreadsheet program like Microsoft Excel. In an Aspen PLUS batch simulation, the process information is placed in an input file, that file is then submitted for processing to the process simulator, the results from the simulation are set to a file, and then the results file is viewed to observe any errors or the calculated results. If errors have occurred or the calculated results are not reasonable, then the batch simulation must be restarted by updating the input file. Given the power and flexibility designed into HYSYS, many ways exists to accomplish the same task. The tutorials of this chapter have been designed to show you one way to do each HYSYS task, primarily for simplicity and speed. Other ways do exist, and you can consult the Help facility in the Aspen HYSYS® software to investigate those ways.. D. HYSYS at Your University Before you proceed to learn how to do process simulations, you want to configure some HYSYS preferences and save them as a file for later use. To configure the HYSYS software, proceed as follows: 1. Press keys <CTRL><Alt><Delete> and then login using your account name and password.. To access the Windows 7 desktop on a computer that is connected to the network at your university.. Click the yellow Windows Explorer icon in the bottom taskbar of the Windows 7 desktop.. To display the Favorites, Libraries, and Computer resources available on your logged-into computer.. Under Computer resources, double click your account name and then double click on your private area.. To open your private folder on the network file server at your university. At Bucknell University, your private area is in partition (\\netspace)(U:).. Object inspect your private folder [i.e., position the cursor on the object and press the secondary (usually right) mouse button once]. Select New/Folder and. To create a new folder in your private area on the network file server at your university. You will use your private aspen_hysys folder to store your HYSYS preferences for later use in this manual.. name your new folder aspen_hysys.. 2. Access the electronic version of this HYSYS manual using a web browser like Internet Explorer, Firefox, or Safari. Then, go to this page in that electronic manual.. See the Preface section in this HYSYS manual to obtain the web address for the electronic version, which you must type into the web browser.. Note that . Since you will access this web address often, you should bookmark it in the web browser.. Click here to download the logo image file beef_logo_256.bmp and select the Save button in the File Download window. Then, navigate to your private aspen_hysys folder and click the Save button in the Save As window. If necessary, click the Close button to exit the Download Complete window. If the Paint program opens instead of the File Download window, select the File/Save As... option, navigate to your private aspen_hysys folder and click the Save button in the Save As. To store a copy of our company’s logo image (which has been pre-made for you) into your private area on the network file server at your university..

(29) Chapter 2. HYSYS Simulation Tutorial 2.2. Page 2-8. Introduction to the HYSYS Interface You will download the existing file t2.02_intro.hsc and then conduct a process simulation in HYSYS using that file. This HYSYS file simulates a material stream containing benzene, propylene, propane, and cumene. It also uses the Peng-Robinson-Stryjeck-Vera (PRSV) fluid package to calculate the thermophysical properties of the stream, such as mass density, molar volume, and molar enthalpy. The conceptual diagram for this stream is: TS1 = 25 C PS1 = 175 kPa nS1 = 200 kgmol / h zS1, BZ = 0.500. S1. zS1, PY = 0.015 zS1, PR = 0.015 zS1,CU = 0.470. The process state of Stream S1 is its temperature, pressure, flow rate, and composition (in this case mole fractions). The material state of Stream S1 is just its temperature, pressure, and composition. Knowing the material state, many properties of the stream can be determined by HYSYS, such as mass density, molar volume, molar enthalpy, surface tension, and viscosity. Process stream states are used to determine the material and energy requirements for process unit operations found in a process flow diagram (or flowsheet). Note that the process state is the material state plus the flow rate. You will practice HYSYS navigation fundamentals and some basic HYSYS capabilities in nine sections— retrieve a pre-defined simulation file, open a pre-defined simulation file in HYSYS, manipulate stream specifications, change global preferences, add variables to the workbook, add a second fluid package, program a spreadsheet operation, document your simulation session, and close the simulation case. To proceed, you must have completed the tasks in Tutorial 2.1.. A. Retrieve a pre-defined simulation file. A HYSYS file has been created for you to start the simulation. It is called t2.02_intro.hsc. This section explains how to download this pre-defined simulation file, and then save it to either the Windows desktop on your logged-in computer or your private area on the network file server at your university. Proceed as follows: 1. Access the electronic version of this HYSYS manual using a web browser like Internet Explorer, Firefox, or Safari. Then, go to this page in that electronic manual. Click here to download the simulation file t2.02_intro.hsc and then select the Save button in the File Download window. 2. Navigate to a folder in your private area on the network file server at your university. or. See the Preface section in this HYSYS manual to obtain the web address for the electronic version, which you would type into the web browser or which you would select from your bookmark list. To begin the process of retrieving the pre-defined HYSYS file for this tutorial simulation. To store the simulation in one of your private folders as a file on the network file server. or.

(30) Chapter 2. HYSYS Simulation Tutorial 2.3. Page 2-21. Simulation File Creation In Tutorial 2.2 for the “Introduction to the HYSYS Interface,” you practiced basic HYSYS skills using an existing simulation file t2.02_intro.hsc. Now you will learn how to create and save a simulation file similar to t2.02_intro.hsc. The creation of this file is divided into eight sectionsstart the HYSYS program, create a simulation basis, find component physical properties, create a process stream, copy and delete a process stream, specify alternative stream conditions, document your simulation session, and close the simulation case. To proceed, you must be familiar with the material in Tutorial 2.2.. A. Start the HYSYS program. After you start the HYSYS program, you need to complete a task before you begin your simulation work. That is, you must load your default HYSYS preferences to overwrite the global preference settings last stored in the computer user area for your login account. Proceed as follows: 1. Choose Aspen HYSYS thru the Start menu on the Windows desktop. Click the middle Maximize Window icon  in the upper-right part of the HYSYS desktop. 2. Choose Tools/Preferences… from the menu bar.. To access the Aspen HYSYS process simulation program. To expand the HYSYS desktop window to fit the full area of the monitor screen. To display the Session Preferences window with tabbed preference views.. Click the Load Preference Set … button in the lower right of the Session Preferences window.. To begin the process of loading your default preferences to overwrite the global preferences in the HYSYS program.. Navigate to your private aspen_hysys folder on the network file server at your university.. To locate the folder containing your default preferences stored in file Aspen HYSYS V7.prf.. Double-click on the file Aspen HYSYS V7, or Select this file and click the Open button.. To load your default preferences into the HYSYS program on the computer you are sitting at.. 3. Choose Tools/Preferences… from the menu bar.. To display again the Session Preferences window with tabbed preference views.. Select the Variables/Units page.. To display the Units preference page.. Select my-fps in the Available Unit Sets area.. To make it the chosen unit set, if available.. Click Delete in the Available Unit Sets area.. To delete this cloned set of units, if it is available.. Select SI in the Available Unit Sets area.. To make it the chosen unit set for this session.. Click the Close or X button.. To return to the HYSYS desktop window..

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