CHEN 4520 Process Synthesis Fall 2006

Simple HYSYS
TM
Simulation or the Pro!uction o Toluene

Toluene is pro!uce! rom n"heptane #y !ehy!ro$enation o%er a Cr2&' catalyst a#sor#e!
on (l2&')
n"heptane is heate! rom 65 to *00
o
F in a superheater an! then e! to a catalytic reactor+
,hich operates isothermally an! con%erts -5mol. o n"heptane to toluene/ 0ts eluent is
coole! to 65
o
F an! e! to a separator/ (ssumin$ that all o the units operate at
atmospheric pressure+ use HYSYS to !etermine the species lo, rates in e%ery stream/
The lash %essel remo%es hy!ro$en rom the reactor eluent/ ( !istillation column ,oul!
normally #e installe! to reco%er toluene rom the li1ui! pro!uct/
Metho! o Solution
-/ Start+ Pro$rams+ (spenTech+ (spen En$ineerin$ Suite+ (spen HYSYS 2004/2+
(spen HYSYS 2004/2 2enter3
2/ File+ Ne,+ Case
'/ 4e must a!! a lui! property pac5a$e so the simulator 5no,s the physical
properties o the components/ 6o to the 7Flui! P5$8 Ta#/ 4e ,ill use the Pen$
9o#inson 2P93 Property Pac5a$e 2(!!+ Pen$ 9o#inson+ (ll Types+ E1uation o
State+ HYSYS &ption+ Smooth :i1ui! ;ensity+ mo!iy H2 Tc an! Pc+ Clic5 <ie, or
Components :ist " - Selection3/
4/ =n!er the Component :ist Selection clic5 <ie,/ 6o to the #o> Match an! clic5
7ormula8 ra!io #utton/ 4e nee! to enter the components or the mi>ture/ Enter
the ' components/ Type 7n"heptane8+ select 7a!! pure8/ Type 7toulene8+ select
7a!! pure8 or toluene/ Type 7H28+ select 7a!! pure8 or hy!ro$en/ You ,ill see
each o the components a!!e! to the 7Selecte! Component :ist8/ Close #y clic5in$
the 2>3 in the upper ri$ht han! corner o the ta#/ 6o to Home <ie, #y clic5in$ on
the las5 icon in the upper let si!e/
5/ Clic5 9eactions Ta# 279eactions83/
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CHEN 4520 Process Synthesis Fall 2006
6/ 0n the 79>n Components8 6roup on the let+ #e sure that all components are sho,n/
?/ The 79eaction Sets8 $roup ,ill sho, one reaction set as !eault 26lo#al 9>n Set3/
;ou#le clic5 to select this reaction set/ 0n the 7Name8 #o>+ erase the e>istin$ name
26lo#al 9>n Set3 an! chan$e it to 7Simple Toluene8/ Close this ,in!o,/
*/ Hi$hli$ht the reaction set 2Simple Toluene3 an! clic5 the 7(!! 9>n8 @utton/ (
pop"up ,in!o, ,ith 5 reaction cate$ories ,ill appear/ Choose 7Con%ersion8 an!
press the 7(!! 9eaction8 #utton/
A/ &n the ollo,in$ pop"up ,in!o,+ enter the reactants an! pro!ucts/ To !o this+ clic5
on the component cell an! rom the !rop !o,n menu at the top select your
component an! enter the stoichiometric coeicients/ The si$ns or the
stoichiometric coeicients are ne$ati%e or reactants an! positi%e or pro!ucts/ 0n
this case+ n"heptane shoul! #e "-+ toluene shoul! #e -+ an! hy!ro$en is 4/
-0/ Clic5 the 7@asis8 ta#/ Select n"heptane as the @ase Component ,ith a con%ersion
o -5. 2Co3 an! an o%erall reaction phase/ The reaction shoul! no, #e $reen
in!icatin$ that it is rea!y/ Clic5 close 2B3/
--/ &nce the reactions ha%e #een associate! ,ith a reactions set+ the reaction set nee!s
to #e associate! ,ith a Flui! Pac5a$e/ To associate a reaction set ,ith a Flui!
Pac5a$e+ clic5 the 7(!! to FP8 #utton on the ri$ht/ Clic5 on the 7@asis"- NC) '
PP)Pen$ 9o#inson8/ Clic5 the 7(!! Set to Flui! Pac5a$e8/
-2/ Clic5 7Enter to Simulation En%ironment8/
-'/ Clic5 on the 7Heater8 in the palette #o>+ mo%e to the lo, sheet an! clic5 a$ain to
place the 7Heater8 on the lo, sheet/ ;ou#le clic5 the heater an! name it
7Superheater8/ Enter the inlet as 7Fee!8+ the outlet is 79"Fee!8+ an! the !uty is
7Sup";uty8/ =n!er the paprameters enter a Cero pressure !rop/ Clic5 7Close8 2B3/
-4/ ;ou#le clic5 the Fee! stream an! enter a temperature o 65
o
F+ pressure o - atm
an! a molar lo, rate o -00 l#moleDhr/ Clic5 e!it un!er compositions an! enter -
or the mole raction o n"heptane an! 0 or toluene an! hy!ro$en/
-5/ Clic5 on the 7Con%ersion 9eactor8 in the palette #o> un!er $eneral reactors+
mo%e to the lo, sheet an! clic5 a$ain to place the 7Con%ersion 9eactor8 on the
lo, sheet/ ;ou#le clic5 the reactor an! name it 7Catalytic 9eactor8/ Enter the
inlet as 79"Fee!8+ the %apor outlet is 79"Pro!8+ the li1ui! outlet is 7None8+ an! the
!uty is 79";uty8/ =n!er the reactions ta# a!! the reaction set usin$ the !rop !o,n
menu an! select 7Simple Toluene8/ The reactor shoul! sol%e an! turn $reen or
rea!y/ Clic5 7Close8 2B3/
-6/ (!! a cooler to re!uce the eluent temperature o the reactor pro!ucts to 65
o
F
,ith the pressure !rop o Cero/ Name the cooler 7Cooler8+ the !uty stream 7C"
;uty8+ an! the outlet stream 7S"Fee!8/
-?/ 0nsert a separator an! name it 7Flash <essel8/ (lso+ name the %apor outlet 7<apor8
an! the li1ui! outlet 7:i1ui!8/
-*/ (t this point the pro#lem shoul! #e completely sol%e! an! your ,or5#oo5 shoul!
loo5 li5e the one sho,n #elo,/ Sa%e an! print ,ith the Materials+ Composition+ an!
Ener$y 4or5#oo5s/
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CHEN 4520 Process Synthesis Fall 2006
Since the heatin$ an! coolin$ !uties re1uire! #y the superheater an! the cooler are
compara#le+ ,e can a!! a ee!Dpro!uct heat e>chan$er to re!uce the utility loa! an!
thus process costs/
-A/ Chan$e the name o the superheater ee! stream to 7Pre"Heat8/
20/ Chan$e the name o the Catalytic 9eactor eluent stream to 79"Pro!-8 an!
speciy a temperature o *00
o
F/
2-/ Chan$e the name o the cooler ee! stream to 79"Pro!28/ ;elete 9"Pro!/
22/ 0nstall the pre"heater usin$ a heat e>chan$er an! name it 7Pre"Heater8 ,ith tu#e
si!e inlet an! outlet streams Fee! an! Pre"Heat+ 9"Pro!- an! 9"Pro!2 as the shell
si!e inlet an! outlet an! no pressure !rop/
2'/ Clic5 on Parameters un!er the ;esi$n ta# an! chan$e the heat e>chan$er mo!el to
E>chan$er ;esi$n 24ei$hte!3/ No, chan$e the num#er o inter%als or #oth
streams rom 5 to '0/ &n the 4or5sheet ta# chan$e the Pre"Heat temperature to
600
o
F/
24/ This pro#lem shoul! no, #e sol%e! ,ith a Superheater !uty o -/4'>-0
6
@tuDhr/
2Note) 0 it is not sol%e!+ you may nee! to re"enter the Fee! temperature o 65
o
F/3
Sa%e an! print ,ith the Materials+ Composition+ an! Ener$y 4or5#oo5s/ Your
,or5#oo5 shoul! no, loo5 li5e the one sho,n #elo,/
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CHEN 4520 Process Synthesis Fall 2006
No, ,e ,ant to in%esti$ate the eect o Pre"Heat temperature on the Superheater !uty+
,hich is accomplishe! #y usin$ the HYSYS Databook/
25/ Clic5 Tools+ ;ata#oo5+ an! un!er the <aria#le ta# clic5 0nsert/ Select Pre"Heat
,ith temperature an! a!!E Sup";uty ,ith Heat Flo, an! a!!E an! Pre"Heater ,ith
=(+ a!!+ an! close/
26/ &n the ;ata 9ecor!er Ta# clic5 (!! in the (%aila#le Scenarios #o> an! Scenario
- shoul! appear/ Chec5 all o the ra!io #o>es to inclu!e Pre"Heat+ Sup";uty+ an!
Pre"Heater/
2?/ =n!er the Case Stu!ies #o> a$ain clic5 a!! or Case Stu!y - to appear/ Chec5 the
!epen!ent 2!ep3 ra!io #o>es or Sup";uty an! Pre"Heater an! the in!epen!ent 2in!3
ra!io #o> or the Pre"Heat temperature/ Clic5 <ie, un!er the (%aila#le Case
Stu!ies #o>+ enter a temperature ran$e o 0 to 600
o
F ,ith a step siCe o 20
o
F+ an!
clic5 Start/ Close so that youFre #ac5 to the ;ata#oo5 an! clic5 9esults ,ith the
$raph ra!io #utton selecte!/
2*/ 9i$ht clic5 an! print this plot/ 0n ' or 4 sentences+ e%aluate the results o the
;ata#oo5 in%esti$ation/

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