Column Dynamics

Column Dynamics

Instructor:
Eng. Ahmed Deyab Fares
Mobile: 0127549943

1
2004 Aspen Technology. - All Rights Reserved.

Column Dynamics

re
s

Workshop

ey

Learning Objectives

ab

Fa

The Column Dynamics module introduces you to the process for setting
up a distillation column with HYSYS Dynamics. Some of the concepts
you have learned in the previous modules are applied here. However the
distillation column is one of the most complex unit operations in
HYSYS. As such, it deserves special attention. Starting with the Feed
Heater Train, you will expand the Flowsheet by adding the
DePropanizer column.

In this module you will learn to:

Configure a distillation column to meet purity specifications

Prepare the distillation column for dynamic simulation analyses
Develop a control strategy
Test the model

En

g.

Ah

m
ed

Process Overview

E
Columnn
Overview
g.
A
hm
ed
D
ey

ab

Fa

re
s

Column Dynamics

Expanding the DePropanizer Simulation

Flowsheet
Load the simulation case that you created and saved in the
Transitioning from Steady State to Dynamics module (FHT-Dyn1.hsc).
Click the Steady State Mode button to return to Steady State in order to
add a column.
You may get a consistency error when you start the steady state solver.
You need to resolve the error before you continue.

Add a Distillation Column

Distillation Column icon

Add a distillation column to the Flowsheet. Configure the distillation

column with the following information:
In this cell...

Enter...

Connections

HYSYS is equipped with a

distillation column Input
Expert option that allows
you to have properly
configured the column. The
Use Input Expert option can
be accessed from the
Tools-PreferencesSimulation menu

Name

DePropanizer

Number of Stages

24

Inlet Stream

ColFeed

Inlet Stage

12

Condenser Type

Full Reflux

Condenser Energy Stream

Q-Cond

Overhead Vapour Outlet

Propane

Reboiler Energy Stream

Q-Reb

Bottoms Liquid Outlet

C4+

Pressure Profile
Condenser Pressure

1925 kPa (280 psia)

Reboiler Pressure

2070 kPa (300 psia)

Condenser Pressure Drop

0 kPa (0 psi)

Specification
Reflux Ratio

Column Dynamics

re
s

Adding Column Specifications

Open the Column Property view to the Monitor page on the Design
tab. Notice that two specifications are Active, Reflux Ratio and
Overhead Vapour Rate. Make the Overhead Vapour Rate Inactive,
and the Degrees of Freedom goes to 1.

2.

On the Specs page of the Design tab add a new specification with
the following information and make it Active:

Fa

1.

Enter...

Name

Components

3.

Mole Fraction

ey

Spec Value

Condenser
Vapour
0.95

Ethane, Propane

Phase

Column Component Fraction

Lights

Stage
Flow Basis

ab

In this cell...
Column Specification Types

Click the Run button to converge the column.

m
ed

The steady state model of the DePropanizer process is now complete.

All unit operations, material and energy streams are solved.

En

g.

Ah

Save your case as Column_SS.hsc.

Save your case!

Column Dynamics

Preparing for Dynamic Simulation Analyses

Equipment Sizing
On the Rating tab of the Column Property View, you can input the sizing
information for the Distillation Column. The information required to
size a distillation column is the Condenser Volume, the Reboiler Volume
and the Column Tray Section dimensions. Additionally, on the Rating
tab there exists the facility to size other equipment that is in the column
sub-flowsheet.

Vessels
Appropriate vessel sizing is important for dynamic simulation analyses.
The vessel hold-up will affect the system's transient response during
dynamic analyses as you move from one operating regime to the next.
In addition, the vessel size affects the pressure calculations that are
associated with the unit operation.
1.

Input a Condenser Volume of 10 m3 (350 ft3) and Reboiler Volume

of 20 m3 (700 ft3).

Sizing the Column Tray Section

If you do not know the
dimensions of your process
equipment, calculate the
vessel size based on an
appropriate residence time:
10 minutes is typically
a suitable residence for
liquid phase hold ups.
2 minutes is typically a
suitable residence time
for vapour phase hold
ups.

In steady state mode you are free to specify the column pressure profile
as you desire. In fact, we just specified a column pressure drop of 145
kPa (20 psi). In dynamics mode, the column pressure profile is
calculated by the hydraulic calculations on each stage. Thus the
calculated pressure drop on each tray section is a function of the tray
geometry (diameter, weir height, weir length and tray spacing).
The dynamic column pressure profile of each column in your Flowsheet
can be estimated with the Tray Sizing utility. The Tray Sizing utility
performs the hydraulic calculations on each stage of the column. If you
do not know the actual dimensions of your column tray section the tray
section geometry should be used to estimate the size of the tray section
before running dynamically.
7

Column Dynamics

re
s

Some columns may have multiple tray sections. In an effort to balance

model rigour with ease of model development only 1 tray section
geometry is provided on the Rating tab. Averaged tray section
information should be specified on this tab.

ab

Running the Tray Sizing Utility

Fa

If different tray sections are required for more accurate modelling,

multiple tray sections can be configured and linked together.

To run the Tray Sizing utility, do the following:

From the Tools menu, select Utilities and from the Available
Utilities view select Tray Sizing and click the Add Utility button.

2.

Click the Select TS button and choose the tray section to size. In this
case select the DePropanizer Flowsheet and Main TS as the object.
Click the OK button.

3.

Click the Add Section button. This adds the selected tray section to
the utility, allowing the sizing calculations to be performed.

4.

Move to the Performance tab and then select the Results page. The
hydraulic calculations based on the recommended tray geometry
for the column are displayed.

5.

This page also displays the estimated Tray Section Pressure Drop.
Notice the Tray Sizing utility estimates approximately a 10 kPa (1.4
psi) pressure drop through the 24 stages of the column.

ey

1.

m
ed

The HYSYS Dynamics

Assistant is capable of
performing the Tray Sizing
automatically. However, the
process is given here
because the Assistant is
deactivated.

En

g.

Ah

When we initially designed our column in Steady State mode, we

inputted a pressure drop of 145 kPa (20 psi) through the column. The
condenser pressure being specified as operating at 1925 kPa (280 psia)
and the reboiler pressure being specified at 2070 kPa (300 psia).
Additionally, the ColFeed pressure was calculated to be operating at
2000 kPa (290 psia).

Column Dynamics

In dynamic mode, the pressure drop at each stage will be calculated

based on the tray geometry. Moreover, the Condenser, Reboiler and
ColFeed pressures will be based on this dynamic pressure profile. If the
steady state pressure profile does not match the dynamic pressure
profile the column tray pressures and flow rates will oscillate until an
equilibrium pressure profile is established. As the column tries to adjust
to an equilibrium pressure profile, the column can possibly go unstable.
Thus a proper column pressure profile based on the hydraulic
calculations should be entered for the column before moving to
dynamic simulation analysis.

Size the Column Tray Section

1.

From the Results page on the Performance tab of the Tray Sizing
utility, fill in the appropriate tray dimensions in the table below.

In this cell...

Enter...

Rating - Tray Sections

Section Diameter
Weir Height
Weir Length
Tray Spacing
Tray Volume (calculated)

If the Tray Sizing utility

determines more than one
section in the Column, there
are two options:
1. Use the weighted
average dimensions for
the dynamic tray
dimensions.
2. Configure the column
with multiple tray
sections inside the
column sub-flowsheet
and supply the
dimensions as
appropriate.

2.

Open the Column Property view (by double-clicking on the

column).

3.

Enter the values shown in the table above into the appropriate fields
on the Tray Sections page of the Rating tab.

4.

Click on the Parameters tab and select the Profiles page.

5.

Change the pressure of the Condenser and Reboiler as follows:

Condenser Pressure

1925 kPa (280 psia)

Reboiler Pressure

1945 kPa (283 psia)

Save your case as: ClmSize.hsc.

Save your case!

9

Column Dynamics

Fa

Making Pressure Flow and Dynamic

Specifications

re
s

10

Refer to the Rules to Remember Outlined in the Transitioning from

Steady State to Dynamics module.

ab

For your ease of reference, we have included the first seven rules here:
Dynamics Specifications

Pressure Specifications

m
ed

Distillation Columns

Distillation columns with condensers

require an extra specification around the
condenser. Make a flow specification for
the reflux flow.
Use the pressure/flow relationship as
the dynamic specification for a valve.

K value

Use the overall K value as the dynamic

specification for coolers, heaters, and
heat exchangers and LNG exchangers.

Pressure gradients

Be sure to account for pressure gradients

throughout the Flowsheet. Moreover, be
sure to specify reasonable pressure
drops/rises in the Flowsheet. Pressure
differentials are the driving force for flow
through the process Flowsheet.

Ah
g.
En

Place a pressure specification on all

boundary streams (feed/product streams)
within the Flowsheet.

Valves

Tray Sizing

10

Insert a valve on all boundary streams

(feed/product streams) within the
Flowsheet that are not connected to
conductance devices (i.e., heat
exchangers, coolers, heaters)

ey

Boundary Streams

Use the tray sizing utility to estimate the

column geometry and pressure profile.

Dynamic specifications can only be modified when the integrator is stopped. Once
the integrator is started the value of the dynamic specification can be changed (its
value appears in blue), but the choice of dynamic specification can not be
changed.

Column Dynamics

11

Add Valves to the Boundary Feed and Product Streams

1.

In the expanded Flowsheet, two boundary streams have been added

and 1 boundary stream has been removed. The two new boundary
streams are Propane and C4+. The boundary stream that has been
removed is ColFeed.

2.

Remembering Rule one, add a valve to all boundary streams, so add

a valve downstream of the Propane and C4+ streams in the Column
Sub-flowsheet.

3.

Specify a pressure drop of 70 kPa (10 psi) and size the valves as you
did in Module 2.
What Cv value does HYSYS calculate for the Propane valve? _____________
And for the C4+ valve? _______________________________________________

4.

Return to the Main Environment.

5.

Connect the boundary subflowsheet streams Propane Out and C4+

Out to the Main Flowsheet streams Propane and C4+, respectively.
This is done on the Connections page of the Design tab of the
Column Property view.

Make the Appropriate Pressure-Flow Specifications

6.

On the Dynamics tab of streams Propane and C4+ select the

Pressure Specification by checking the checkbox. Again, make sure
only the Pressure Specification is Active. Propane and C4+ are
boundary streams in the main Flowsheet. Remember to deactivate
the Pressure Specification of the ColFeed stream.

11

Column Dynamics

re
s

12

ey

ab

Fa

Figure 1

On the Dynamics tab of the Reflux stream (Column Sub-flowsheet)

make the Molar Flow specification Active.

m
ed

7.

En

g.

Ah

Figure 2

12

Column Dynamics

8.

13

Run the Dynamics Assistant to see if there is something else that

needs to be changed.
What recommendations does the Dynamics Assistant make?
____________________________________________________________________

Dynamic specifications can only be modified when the integrator is

stopped. Once the integrator is started the value of the dynamic
specification can be changed (its value appears in blue), but the choice
of dynamic specification can not be changed.

Save your case as: Clm-Specs.hsc.

Save your case!

Click the Dynamics Mode icon to enter dynamics, and start the
integrator as the model is now ready to run in dynamics. Run the
integrator for a few minutes of integrator time.
Integrator Start icon

13

Column Dynamics

Adding Strip Charts and Controllers

re
s

14

Add the following Controllers to your case for Column Control:

Add the Column Controllers in the Column Environment. Installing

the controllers in the Column Environment eliminates the need for
the controllers to cross the Flowsheet boundary.

Fa

1.

ab

Pressure Control Overhead Condenser

In this cell...

Name

Cond-PC

Process Variable Source

Output Target Object

Condenser, Vessel Pressure

ey

Control Valves should be

sized with a maximum of
twice the Steady-State
value.

Enter...

Connections

C3 Valve

Parameters - Configuration
PV Minimum
PV Maximum
Mode

Direct

Action

m
ed

Kc

1725 kPa (250 psia)

2070 kPa (300 psia)

Auto
2.0

TI

2.0 minutes

SP

1925 kPa (280 psia)

In this cell...

Condenser Level Control

Enter...

Ah

Connections

Dont forget to size the

control valve properly.

Name

Cond-LC

Process Variable Source

Condenser, Liquid Percent Level

Output Target Object

Reflux

En

g.

Parameters - Configuration

14

Action

Direct

PV Minimum

0%

PV Maximum

100%

Mode

Auto

Kc

2.0

TI

10.0 minutes

SP

50%

Column Dynamics

15

Reboiler Duty Control

In this cell...

Enter...

Connections
Name

Tray23-TC

Process Variable Source

Main TS, Stage Temp., Stage 23

Output Target Object

Q-Reb

Parameters - Configuration
Action

Reverse

PV Minimum

100C (200F)

PV Maximum

200C (400F)

Mode

Auto

Kc

2.0

TI

10.0 minutes

SP

140C (270F)
Reboiler Level Control

In this cell...

Enter...

Connections
Name

Reb-LC

Process Variable Source

Reboiler, Liq Percent Level

Output Target Object

C4+ Valve

Parameters - Configuration
Action

Direct

PV Minimum

0%

PV Maximum

100%

Mode

Auto

Kc

2.0

TI

10.0 minutes

SP

50%

Save your case as: Clm-Control.hsc.

Save your case!

15

16

Column Dynamics

re
s

Exercise 1

ColFeed Mass Flow

Condenser Vessel Pressure
C4+ Mass Flow
Propane Mass Flow

Fa

Create a Strip Chart named Column and enter the following variables:

ab

Run the Integrator and watch the variables change over time.
Does the simulation reach a steady state if given enough time?

Exercise 2

ey

____________________________________________________________________

m
ed

Change the Output Variable for the Condenser-LC to Cond-Q, from

Reflux. Make sure that you choose reasonable values for the maximum
and minimum cooling duty. Change the molar flow specification for the
Reflux stream to 1620 kgmole/h (3560 lbmole/hr).
Does this control strategy provide better control over the De-Propanizer?

Ah

____________________________________________________________________
Can you think of another control strategy for the Condenser Liquid level?

En

g.

____________________________________________________________________

16

Column Dynamics

17

Exercise 3
Change the NGL-Feed composition as follows:
Component

Mole Fraction

Ethane

0.01

Propane

0.25

i-Butane

0.08

n-Butane

0.15

i-Pentane

0.07

n-Pentane

0.07

Hexane

0.37

How does this change affect the Propane concentration in the C4+ stream?
____________________________________________________________________
How long does it take for the change to occur?
____________________________________________________________________
Try changing the Tray23-TC set-point in order to return the Propane
concentration back to its original level. Does the temperature have to be
lowered or raised? ___________________________________________________

17

Column Dynamics

En

g.

Ah

m
ed

ey

ab

Fa

re
s

18

18