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Custom Columns
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ADV 7_1.pdf
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Workshop
Most users are familiar with the prebuilt columns that are available in
the Main HYSYS Environment. This module will introduce the concept
of custom columns. HYSYS allows users to build columns without using
the prebuilt configurations. This is useful for simulating columns that
do not fit into the prebuilt configurations.
Building custom columns allows users to replace reboilers with heat
exchangers; the heat exchangers can then be rated and sized. Likewise,
thermosyphon reboilers can be used in place of generic reboilers.
Learning Objectives
After completing this module, you will be able to:
Build custom columns in HYSYS
Replace generic reboilers with sizable heat exchangers
Prerequisites
Before beginning this module, you should be able to:
Navigate the Main Simulation
Add unit operations to the PFD
Add, and converge, a generic prebuilt column
Process Overview
Column Overview
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Custom Columns
The most common way of adding a column to a simulation is to use the
prebuilt columns that HYSYS offers. There are four prebuilt columns
available:
Absorber - the simplest of all towers, no reboiler or condenser.
Refluxed Absorber - an absorber tower with a condenser on
the top stage that allows for a refluxing stream in the column.
Reboiled Absorber - an absorber tower with a reboiler at its
base, and no condenser at the top.
Distillation Column - an absorber tower with both a
condenser and a reboiler.
Customizing a Column gives the user greater control over the
simulation. For example, replacing the reboiler with a Heat Exchanger
allows the user to use steam as a heating medium and size the
exchanger based on the required duty.
Custom Columns can be built in two ways, either by modifying a
prebuilt column, or by constructing a new column from the beginning.
In this module, a prebuilt column will be modified.
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The Column SubFlowsheet
Whenever a column is added to a HYSYS simulation, a Column
Subflowsheet is created. The Subflowsheet is essentially another layer
in the HYSYS simulation. It is located under the Main layer, and can be
seen by selecting Tools/PFDs in the Main Menu Bar, or by pressing the
hot-key <Crtl><P>. The nature of the layering scheme can be seen in
the displayed list as the Columns PFD is indented under the Main PFD.
Selecting the desired PFD and pressing the View button will open that
particular layer for viewing.
In order to edit the column, i.e. to add and modify operations, it is
necessary to enter the Column Environment. The Column
Environment is accessed through the Column Property Viewer. With
the Column Property Viewer as the active view, press the Column
Environment button. This will take the user into the Column
Environment, allowing them to add and/or modify operations. The
operations can be deleted, modified, replaced, and controlled just like
ordinary unit operations that most users are familiar with when in the
Main Environment.
When in the Column Environment, returning to the Main Environment
is as easy as pressing the Parent Simulation button located on the Main
Menu Bar.
Adding operations to the column is very similar to adding operations in
the Main Environment. The choice of operations is reduced, but the
method of installation is identical.
Parent Simulation button
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Building the Simulation
This module will continue with the column built in the Column Sizing
Module. This column is a depropanizer for use in a gas plant. Any
molecule less volatile than propane leaves the column in the Liquid
Bottom Product and any molecule more volatile than i-butane leaves
the column in the Overhead Vapour Product.
This column was constructed as a generic distillation column. The
condenser is a "Total Reflux" type; this means that there is no liquid
product from the condenser, rather all of the condensed liquid is sent
back into the column to provide a refluxing liquid stream.
The reboiler on this column is also of the generic type. An energy
stream is supplied and the liquid product from the last stage is boiled
up. The vapours return to the column and the liquid leaves the column
as a liquid product.
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Replacing the Reboiler
It is desired to replace the generic reboiler with a shell and tube heat
exchanger. This will allow the user to supply steam to the column as the
energy stream, and size, or rate, the heat exchanger.
1. Before modifying the column, it is necessary to change the
Column Solving Method to Modified HYSIM Inside-Out. The
Solving method is accessed through the Solver page (on the
Parameters tab) of the Column Property View.
2. Press the Run button to reconverge to column.
3. In the Basis Environment, add Water to the list of components.
4. Enter the Column Environment and delete the existing reboiler
and energy stream from the PFD.
Modified HYSIM Inside-Out
is a general purpose solver
that allows Heat Exchangers
and other operations in the
Column Environment.
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5. Because we are replacing a generic reboiler that had no pressure
drop with a heat exchanger that will have a pressure drop, we
need to add a pump to the simulation that will "push" the fluid
through the exchanger. Add a Pump to the Column Environment
with the following information.
6. After the newly created pump, add a Heat Exchanger to the
Columns PFD, with the following information:
7. Define the Steam In stream as saturated at 200
o
C (400
o
F). The
mass flow rate is 1000 kg/hr (2,200 lb/hr).
The pressure of the bottom stage in the column must be set at 320 kPa
(45 psia). In order to solve the column initially, the pressure in the
reboiler was set; however, the reboiler was deleted. Therefore, the
pressure on this stage needs to be fixed.
8. On the Pressures page of the Column Property Viewer within the
Column Environment, set the pressure of the bottom stage
(10_Main TS) to be 320 kPa (45 psia).
In This Cell... Enter...
Name Reboiler Pump
Inlet To Reboiler
Outlet Pump Out
Energy Pump Duty
Delta P (on Parameters page) 75 kPa (11 psi)
In This Cell... Enter...
Name Reboiler
Heat Exchanger Model Weighted
Tube Side Inlet Steam In
Tube Side Outlet Steam Out
Shell Side Inlet Pump Out
Shell Side Outlet Reboiler Out
Tube Side Pressure Drop 25 kPa (4 psi)
Shell Side Pressure Drop 75 kPa (10 psi)
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9. Add a V/L Separator after the Heat Exchanger, with the vapour
product returning to the bottom stage of the column, and the
liquid product leaving the Column Environment as the Bttm
Liquid Product.
10. Ensure that the three active specifications for the column are:
Heavy Key, Light Key, and Heat Balance.
Because the Heat Exchanger was installed in the Column Environment
its specifications appear on the Monitor page along with the
specifications of the column. Heat Exchanger specifications can be
activated and deactivated just like Column specifications; they can also
be added in exactly the same manner as Column specifications.
11. Run the column; after it has converged, answer these questions.
What is the UA of the Heat Exchanger? __________
What is the LMTD for this exchanger? __________
Save your case!
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Connecting Streams Between Flowsheets
1. Open the Main PFD. Notice the streams Steam In and Steam Out
are not visible here. This is because they were created in the
Column Subflowsheet, and have not been connected to the Main
Flowsheet.
2. Streams are connected between the Main and Subflowsheets on
the Connections page. Notice that there are two types of streams
listed here, Internal and External. Internal streams are those
streams that appear only in the Subflowsheet. Steam In and
Steam Out are both internal streams.
3. Internal streams are connected to the Main Flowsheet by typing a
name in the External Stream column. Add the appropriate names
to the External Streams column, and check to make sure that
these streams appear in the Main PFD.
Save your case!
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Optional Exercise
Adjust the Steam Feed Rate
Once both steam streams are installed on the Main PFD, an Adjust
Operation can be installed to ensure that the proper amount of steam is
supplied so that complete condensation of the steam occurs in the
reboiler.
1. The Steam In flow rate was defined in the Column Environment.
Therefore, it is not a specifiable parameter in the Main
Environment. Delete the flow rate of Steam In in the Column
Environment, and enter the same value as a flow rate for Steam
In in the Main Environment.
2. Add an Adjust Unit Operation to the Main PFD. Supply the
following information:
3. Press the Start button to activate the operation, and an error will
appear.
In This Cell... Enter...
Adjusted Variable Steam In - Mass Flow
Target Variable Steam Out - Vapour Fraction
Specified Target Value 0.0
Step Size 10 kg/hr (20 lb/hr)
Maximum Iterations 50
Why does this error occur? ___________________________
What can be done to prevent this from happening?
Remember that the adjusted variable for an Adjust
operation must be specifiable.
Make the necessary corrections to the simulation and
recalculate the Adjust operation.
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4. Calculate the operation, and answer the following question:
Of course, any steam flow rate less than this value will also give
complete condensation, with some subcooling. However, the Adjust
operation stops calculation once the specified target value is reached.
The correct value was calculated because the calculation was started at
a higher vapour fraction value, and the value decreased until a vapour
fraction of zero first appeared. It can be assumed, due to the small step
size, that this flow will lead to complete condensation with little, or no,
subcooling.
What is the required mass flow rate of steam? __________
A subcooled liquid always has
a vapour fraction of zero, and
an superheated vapour has a
vapour fraction of 1.
Save your case!
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