Aspen Plus Basic Course

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Aspen Plus®Basic CourseChemical Engineering Guy


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Solve this!


Solve this!Change:All T of ReactorsFeed CompositionNo. of Plates in Distl. ColT of Heat ExGas Sep. TCompressor P


And this….


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)


Which companies model? Mainly:

Petrochemical Pharmaceutical Fine chemicals

Other commodities such as:

Sulfuric acids Chlorine/Caustic industry Solvents Coatings Many more…


Other Advantages… Excelent for your curriculum as an engineer

Perfect for analytical/numerical minds

Good for debuging and fixing


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


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...)


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


2. Introduction to Aspen Plus About Aspen Plus ®

Why Aspen Plus ®

Benefits of simulations

Aspen Plus® vs. HYSYS®


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/


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


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!


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


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


Landing Page Start Page

New, Open, Recent Files News Get Started Button (Ribbons) bar


Landing Page - Video 001 Lading Page This is a Free Trial…



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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.


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


Templates Prepared “properties” and

preferences for the user Air Separation Chemical Processes Gas Processing Pharma Refinery (most extensive) Solids

“User” SI or English units


Environment Introduction


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


Typically, once you set your properties, you won’t be using

Properties Environment


Environment - Video 002 Environements & Physical Properties


Simulation Environment


Ribbons/Menu


“Workspace”Streams, Unit

Operations of the Process goes HERE


Navigation Pane


Model PaletteUnit Operation

Blocks


Material/Work/Heat Stream

www.ChemicalEngineeringGuy.comStatus Bar


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)




ASPEN PLUS COURSE

http://www.egpet.net/

http://www.egpet.net/

http://www.cheresources.com/

http://www.cheresources.com/

http://www.eng-tips.com/threadminder.cfm?pid=137

http://www.eng-tips.com/threadminder.cfm?pid=137

http://support.aspentech.com/





Getting Help Using Aspen Help Bar/Button Help Bar/Help Button


Getting Help


Getting Help - Video 004 Getting Help - Help ButtonThis is a Free Trial…



ASPEN PLUS COURSE



4. Physical Properties


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


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


Components Specification

Component (from Databases)*

Molecular Structure...

Polymers

* RequiredAll other folders are studied in other advanced courses


What’s next?


Methods Specifications

Global Property Method Property Methods

Method Name Method Assistant!


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


Methods Method Assistant Process Type Petrochemical


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




ASPEN PLUS COURSE



Methods

Model

Ideal

Equation of State

Classic

Advanced

Activity Coefficient

Binary

Predictive


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

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





ASPEN PLUS COURSE



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


Physical Properties - Video 005 Filling Physical Properties EnvironmentThis is a Free Trial…



ASPEN PLUS COURSE



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!


Awesome!


5. Introduction to Flowsheet


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)


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…


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


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


Process Diagram FINAL DIAGRAM


Material Streams Stream 1. Water

Stream 2. Ethanol

Stream 3. Mixed Product before heating

Stream 4. Mixed Product after heating


Setting Blocks Mixing unit…

Heater unit…


Done! Your Process is Set!

Let’s Run the Simulation!

As follows…


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


Simulation Environmet - Video 006 Filling the Simulation EnvironementThis is a Free Trial…



ASPEN PLUS COURSE



Errors? Debug? Troubleshoot?

No! Perfect!

Continue with Results and Analysis


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


Table of Streams


Results and Analysis - Video 007 Results and AnalysisThis is a Free Trial…



ASPEN PLUS COURSE



6. Unit Operation Models (Basic) Mixers/splitters Separators Exchangers Columns Reactors Pressure Changers

Manipulators * Solids * Solid Separators * User Models * * Not Relevant in this Course



* Not Relevant in this Course

Momentum Heat

Kinetics Mass



* Not Relevant in this Course

Momentum

Mixers/SplittersPressure Change

Heat

Exchangers

Kinetics

Reactors

Mass

SeparatorsColumns


Summary This data is from

Aspen Plus Help Data Sheet


The Unit Operations


Introduction to Unit Operations - Video 008 Introduction to Unit OperationsThis is a Free Trial…



ASPEN PLUS COURSE



Mixers/Splitters Mixer FSplit Ssplit*

*Basic Course does not includes SSplit


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!


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!


Mixers/Splitters Exercise 009 Mixers & Splitters


Separators Fash2 Flash3* Decanter* Sep Sep2*

*Basic Course includes only Flash2 and Sep


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


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”


Separators Exercise 010 Separators This is a Free Trial…



ASPEN PLUS COURSE



Exchangers Heater HeatX* MHeatX* HXFlux*

*Basic Course includes only Heater


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


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


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


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


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


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


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.


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


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


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


Reactors Exercises 013 Reactors This is a Free Trial…



ASPEN PLUS COURSE



Pressure Changers Pump Compr Mcompr* Valve* Pipe* Pipeline*

*Basic Course includes only Pump and Compr


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


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


Pressure Changers Exercises 014 Pressure ChangersThis is a Free Trial…



ASPEN PLUS COURSE



7. Reporting Results BASIC approach

Table Graph Chart Etc…

*** Continue to intermediate for more!


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


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!


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)


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


Case Study I: Solvent Recovery1. Statement2. Building the diagram3. Data Input

Streams Blocks

4. Run Simulation5. Results & Reporting6. Analysis7. Conclusion


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.


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:


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


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?


2. Process Diagram (Case Study I)


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


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


4. Run Simulation (Case Study I) Run the simulation!

Debug required?

Warnings

Errors?


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


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?


Case Study I: Solvent Recovery 016 Case Study I - Solvent RecoveryThis is a Free Trial…



ASPEN PLUS COURSE



Case Study II: Cumene Production1. Statement2. Building the diagram3. Data Input

Streams Blocks



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


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)


2. Process Diagram (Case Study II)


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


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


4. Run Simulation (Case Study II) Run the simulation!

Debug required?

Warnings

Errors?


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


6. Analysis (Case Study II) Recycling:

Non-Recycling


Case Study II: Cumene Production 017 Study Case II - Cumene ProductionThis is a Free Trial…



ASPEN PLUS COURSE



Case Study III: Gas Compression1. Statement2. Building the diagram3. Data Input

Streams Blocks



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


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!


2. Process Diagram (Case Study III)


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


3. Data Input (Case Study III) Mixer:

P = 5 bar Friction loss:

Model as Valve Pressure Drop = 1.5 bar Adiabatic Flash



4. Run Simulation (Case Study III) Run the simulation!

Debug required?

Warnings

Errors?


5. Results & Reporting (Case Study III) Products:

Mass Fraction of all gases Final Temperature Final Pressure

Blocks: Compressor 1 Workload Compressor 2 Workload


6. Analysis (Case Study III) Tempearture increases:

What if, cooling before any compression?

Workload of heater/cooler vs. Compression

Energy optimization?

$$??


Case Study III : Gas Compression 018 Case Study III - Gas CompressionThis is a Free Trial…



ASPEN PLUS COURSE



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)


Case Study IV Problem: Petrochem – (Natural Gas Separation, LP Gas, Pentanes +

Hexaes) Statement Diagram… Compare Results Analysis and Conclusion (send feedback to Contact@Course)


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.


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


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


2. Process Diagram (Case Study IV)


2. Process Diagram (Case Study IV)

Light Distillation Column

Mid-Light Distillation Column

Heavy Distillation ColumnFlash Separator


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)


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)


3. Data Input (Case Study IV) Mixer:

P = 5 bar Friction loss:

Model as Valve Pressure Drop = 1.5 bar Adiabatic Flash



4. Run Simulation (Case Study IV) Run the simulation!

Debug required?

Warnings

Errors?


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


Case Study IV: Results! Download Results at UDEMY!


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!


End of Case Studies


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...)


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


Next Courses! Intermediate + Advance

Continue with the next course Intermediate and Advance!

You will learn…



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



Transient State Steady vs. Unsteady/Transient states Batch modeling

Economy Environment

Safety Environment

Energy Environment



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



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


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

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Reminder :)This is a Free Trial…



ASPEN PLUS COURSE


Aspen Plus Basic Course

Engineering

Transcript of Aspen Plus Basic Course