Getting Started - Aspen HYSYS Shell and Tube Exchanger

©2011 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, OPTIMIZE, and the 7 Best Practices of Engineering Excellence are trademarks of Aspen Technology, Inc. All rightsreserved. All other trademarks are property of their respective owners 11-538-0611

Getting Started — Preliminary Design — AspenHYSYS® Shell & Tube Exchanger Design Utility

A Brief Tutorial (and supplement to training and online documentation)

By Tom Ralston, Product Manager; Steve Noe, Marketing Manager, Aspen Technology, Inc.

About AspenTech

AspenTech is a leading supplier of software that optimizes process manufacturing—for energy, chemicals,

pharmaceuticals, engineering and construction, and other industries that manufacture and produce

products from a chemical process. With integrated aspenONE® solutions, process manufacturers can

implement best practices for optimizing their engineering, manufacturing, and supply chain operations.

As a result, AspenTech customers are better able to increase capacity, improve margins, reduce costs,

and become more energy efficient. To see how the world’s leading process manufacturers rely on

AspenTech to achieve their operational excellence goals, visitwww.aspentech.com.


Getting Started — Preliminary Design —Aspen HYSYS® Shell & Tube Exchanger Design Utility

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1. Business BackgroundConventional workflow employed in the design of heat exchangers introduces both inefficiency and design handicaps. The

design cycle involves several iterations of manual data transfer from process engineer, back and forth to the thermal

expert, to a mechanical expert and possibly a cost estimator.

This manual transfer of data is prone to transcription errors, requiring a labor-intensive data-checking step, often resulting

in project delays. Also, this sequential approach removes the process engineer from the exchanger design process, which

limits visibility and therefore the investigation into multiple process scenarios. The result of this process is that the design

is frequently not optimal.

To overcome these handicaps, AspenTech has introduced an easy-to-use integration between process simulators and heat

exchanger design modeling tools. These enable the use of the Aspen Exchanger Design & Rating (Aspen EDR) product

family — the industry’s most comprehensive suite of programs for heat exchanger design — with the Aspen HYSYS® and

Aspen Plus® simulators. Run time integration with Aspen HYSYS combined with Aspen EDR’s unique capability of

automating the exchanger design to least cost allows process engineers to be actively involved in the equipment design

process. Supervision of engineering decisions by appropriate expert engineers is easily achieved with electronic data

transfer. The entire engineering cycle is simplified through the use of a single integrated framework of programs for all of

the engineering processes. As a result, companies deploying these solutions are able to reduce capital equipment cost,

reduce engineering man-hours, and improve their overall processes.

2. Scope of this DocumentThis document serves as a simple “getting started” guide, taking you through the most common progression of how we

envision the process designer to use this integrated functionality. This guide is not meant to be used as the only reference

source for documentation. We recommend that a range of other resources be called upon to give the new user a

comprehensive view of how to use this capability. This may include:

• Online documentation – which can be accessed through the Aspen HYSYS and Aspen EDR software user screens.

• AspenTech support website (support.aspentech.com), which contains a wide range of knowledge base items with

answers to frequently asked questions.

• AspenTech courseware available in classroom and on-line versions, which provide formal training on process modeling

and heat transfer technology.

• AspenTech business consultants.

• Pre-recorded tutorials and webinars that provide another view of the information contained in this document. You will

be required to enter your AspenTech support id and password (go to the animated tutorial section on the following for

many of these resources: http://support.aspentech.com/webteamasp/My/product.asp?id1=3030&id2=

Aspen%20Shell%20%26%20Tube%20Exchanger&id3=all).

This document covers integration with Aspen HYSYS. This guide assumes that the user has Aspen HYSYS V7.2 and Aspen

EDR® V7.3 installed.

http://support.aspentech.com/webteamasp/My/product.asp?id1=3030&id2=

http://support.aspentech.com/webteamasp/My/product.asp?id1=3030&id2=Aspen%20Shell%20%26%20Tube%20Exchanger&id3=all

http://support.aspentech.com


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3. Problem OverviewProcess engineers need to determine quickly if a process is viable and potentially estimate the cost. Being able to produce

a preliminary design of an exchanger to evaluate its size and weight within the simulator is a very valuable tool. Our

aspenONE integration makes it easy to do this pre-design using the full rigor of the Aspen Exchanger Design & Rating

(EDR) tools. It is also a good starting point if the data can be passed to the thermal specialist who might undertake a full

design. Once the exchanger has been pre-designed (or fully designed), the process engineer can check the full flowsheet

using the geometry and the rigorous calculation of Aspen Shell & Tube Exchanger. Based on the conditions and the geometry

defined, the duty and pressure drops of the heat exchanger are calculated in Aspen HYSYS using the rigorous model.

4. The Step by Step GuideOpen the HYSYS simulation file. Double-click on the icon associated with heat exchanger E-103 to view the details for the

heat exchanger (Figure 1). The original Aspen HYSYS run used the Exchanger Design Endpoint shortcut method for the

HYSYS calculation and the heat and material balance.

We will now use the Aspen Shell & Tube Exchanger rigorous program while still

in the HYSYS run time environment to obtain a preliminary optimized heat

exchanger to least cost. Use the Utilities option from the pull down Tools

command (Figure 2) where we will add the Utility for Shell & Tube Exchanger

(Figure 3).

Click on the View Utility button and the Shell & Tube Design Utility will

appear (Figure 4).

Figure 1. HYSYS PFD – Exchanger E-103Figure 2. Utilities option from the Tools command

Figure 3. Shell & Tube ExchangerUtility Added



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Click on the Select Heat Exchanger button to select heat exchanger E-103 from the list of exchangers (Figure 5).

We will use the Shell & Tube Design Utility to specify desired geometry specific for a crude pre-heat exchanger along with

some process information such as fouling factors and allowable pressure drops. The exchanger type is set to a TEMA style

AET exchanger (Figure 6).

The allowable pressure drop will be set to 0.5 bar on both hot and cold sides. The hot side fouling will be set to 0.000055

C –h-m2/kJ on the hot side and 0.0000833 C-h-m2/kJ on the cold side (Figure 7).

Figure 4. Shell & Tube Exchanger Design Utility

Figure 5. Exchanger E-103 selected

Figure 6. Exchanger Type set to AET Figure 7. Process specifications


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The Bundle section will be used to further define

the desired parameters desired for a crude pre-heat

exchanger. We will select a 90 degree square

pattern to allow for proper cleaning of the bundle

(Figure 8).

In the Design Options window, force the design to 2 passes by setting minimum and maximum tube passes to 2, and limit

the maximum number of exchangers in series and parallel to 2 (Figure 9). We will use the program defaults for any

remaining parameters.

Figure 8. 90 degree – square tube pattern

Figure 9. Minimum & maximum parameters



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Go back to the Exchanger section and click on the RUN button to have the Aspen Shell & Tube Exchanger program design

the preliminary heat exchanger (Figure 10).

Once the Run button becomes active again, you have options for a number of things you can now do with the newly

designed exchanger. You can view the details of this new heat exchanger by clicking on the EDR Results button, and

understand how it will operate within the overall process by clicking Update Design. Click Export to create the Aspen

Exchanger Design and Rating standalone file. The standalone EDR file can then be run with the Aspen Shell & Tube

Exchanger standalone program to fine tune the design or turned over to a thermal expert to develop a final design.

Once the final design is selected, it can be imported back into Aspen HYSYS to simulate how a real exchanger will perform

in your process. This allows the user to get a better understanding of the operation of the heat exchanger and its impact

on the overall process for changes in throughput or crude composition.

5Pauls, Jeff (2010). [Dow]“ImportanceofEconomicAnalysisDuringConceptualDesign.”aspenONEGlobalConference,Boston6Whiteside, James(2005). [ConocoPhillips] “IncreasingProjectPerformanceUsingAspenKbase.”AspenTechWorldwideUserMeeting,Houston

Figure 10. Shell & Tube designs the exchanger


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5. Further ResourcesFor further information on this workflow, or any of the individual products or elements covered briefly in this written

tutorial, please consult:

Public website:

The following web page provides information on Aspen Exchanger Design & Rating:

www.aspentech.com/core/aspen-edr.aspx

Support website:

The support website provides an extensive and growing knowledge base on Aspen Exchanger Design & Rating.

The following knowledge base article provides a getting-started location:

http://support.aspentech.com/webteamasp/KB.asp?ID=130722

Worldwide Headquarters

Aspen Technology, Inc.200Wheeler RoadBurlington, MA 01803United States

phone: +1–781–221–6400fax: +1–781–221–[email protected]

Regional Headquarters

Houston, TX | USAphone: +1–281–584–1000

São Paulo | Brazilphone: +55–11–3443–6261

Reading | United Kingdomphone: +44–(0)–1189–226400

Singapore | Republic of Singaporephone: +65–6395–3900

Manama | Bahrainphone: +973–17–50–3000

For a complete list of offices, please visitwww.aspentech.com/locations

©2011 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, OPTIMIZE, and the 7 Best Practices of Engineering Excellenceare trademarks of Aspen Technology, Inc. All rights reserved. All other trademarks are property of their respective owners 11-538-0611

Getting Started - Aspen HYSYS Shell and Tube Exchanger

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