The University of Sheffield

INTRODUCTION TO

HYSYS

HYSYS is a flow-sheeting package for the design and simulation of processes. Full documentation can be found in the extensive on-line manuals, available via the Start Menu in Windows. In this introduction to the package you will consider some simple systems such as distillation columns, reactors and heat exchangers. There will be three sessions in which you will cover some of the basics. You will then be able to use the package throughout the remainder of your course and beyond. You will also get to use the package in Design Week so this should be considered as grounding in the basics.

EXERCISE 1
Open HYSYS.Plant using the path: Start|Programs|Applications|Engineering|AEA Technology|HYSYS.Plant|HYSYS.Plant Open a New Case (File|New Case) Add a fluids package. The one you choose will depend on the simulation you want to perform. Here we will use Peng Robinson. Select the components for the simulation, e.g. a hydrocarbon separation. Type in Match to find components (SimName used by HYSYS). o Select propane, n-butane, i-butane, n-pentane, i-pentane, and n-hexane. o Input the Parameters (interaction parameters) if required. o Input the Binary coefficients if required (0 = unknown). Use the defaults for now. Return to the simulation Basis Manager. You now need to add Reactions if required. We will set up an equilibrium reaction. First you need to define an Associated Fluids Package. Click Add to FP, then select Basis-1 and Add Set to Fluid Package. Next select Add Comps and then Add This Group of Components. Click Add Rnx. Chose Equilibrium then Add Reaction. Click on the *add comp* cell and chose a component from the dropdown selector ! . o For this example choose n-butane and i-butane with stoichiometry coefficients of +1 and 1.

Dr Peter Styring

Packages

08/03/01

The University of Sheffield If the set up is correct, a green Ready box replaces the red Not Ready. Close down the open windows to get back to the Simulation Basis Manager.

Now the Fluids Package is set up, press Enter Simulation Environment, this takes you into the plant main flowsheet. Take some time to familiarise yourself with the HYSYS simulation environment. Usually holding your cursor above an icon in the floating toolbar will describe the engineering item associated with it.

Back to the simulation.

Select a distillation column: click on the toolbar and again on the main window. There may be a wait of a few seconds while HYSYS retrieves the template. Now select a Material Stream and place it to the left of the column. This will be Stream1. Double click on stream1 and under Worksheet Properties enter the following data: Temperature 30 C Pressure 500 kPa Mass Flow 100 kg/h Click on Worksheet Composition and enter mole fractions for each of the components (use integers for now) and then Normalise to 1. To start with try 1, 2, 4, 1, 1, 1.5 as relative compositions. Close the box down and then double click on the Distillation Column. Define the Inlet Stream as Stream1 and the Inlet Stage as 15_Main TS with a total of 20 stages. The default for the stages is to number down from the top of the column. Set the condenser to total. Set the overhead liquid outlet as stream 2 Set the bottoms outlet as stream 3. Set the reboiler as energy stream q-101 and the condenser energy stream as q-102. Press Next Set the condenser pressure (Pcond) as 400 kPa (4 bar) and the reboiler pressure (Preb) as 450 kPa (4.5 bar). Press Next and Next again Set the Reflux Ratio to 3 and the distillation Liquid Rate to 8 kg/h. You will need to set the materials Flow Basis to Mass. Now press Done. You are now ready to run the simulation. PRESS Run.

If you get any error messages you should try to solve them. They are usually self-explanatory. If really you do have a problem, see a demonstrator.

Dr Peter Styring

Packages

08/03/01

The University of Sheffield

Assuming everything has worked it is time to analyse the simulation data.

Things you should consider after the simulation has converged: What are the compositions of the materials streams leaving the column? What are the temperatures of the two output streams and heat flows at q-101 and q-102? What are the heat flows and power requirements at q-101 and q-102? From the Worksheet you should compare the compositions of the materials streams to establish the efficiency of the separation process. What comes off as liquid and what as vapour? How good is the separation? You should consider how to design a more efficient process by varying the parameters used (temperatures, materials flow, etc). This can be achieved easily and the simulation re-run each time. You should include all the above considerations in your report. Now extend the system by adding a Side Draw. Double-click on the distillation column. On the Design tab select Side Draws. Under tray Selection choose the Vapour radio button and set the vapour draw to 4 (to give materials stream 4). Select a Tray Number from the dropdown menu. Start low, e.g. 10_Main TS, bearing in mind where the input stream enters the column. You will need to define the draw rate on the side draw, start with 2 kg/h and vary this during the course of your simulation. Things you should consider: Re-run the above simulation to see how adding a side draw effects separation. This should again be performed using a range of initial parameters as above. Change the Tray Number and study the effect. Change the Side Draw Rate and again note the effect. Deciding on a final design for the column. Explore the initial parameters used to define the simulation system and their effect on separation. Design a column to maximise: Removal of the heavier fractions (pentanes and hexanes) Separate as efficiently as possible n-butane and i-butane Cost (simple design with low energy requirements) Your Report Use the same formal as in previous sessions (Introduction, Results and Discussion, Conclusions). Enter considerations of initial parameters and discuss the implications in the Results and Discussions section. Justify tour chosen design in the Conclusions section.

Dr Peter Styring

Packages

08/03/01