Introduction To Process Simulation of Plant Design

@ dr zain, pse-fkkksa, UTM
Page PS-1 Intro to Process Simulation

Introduction to Computer Aided
Process Simulation
At the end of the course participants will be able to:

1. Create a process flowsheet.
2. Simulate an equipment and a process flowsheet.
3. Analyse and operate with simulation results.
4. Troubleshoot simulation problems.

.for continuous and batch process systems.
Intuitive User Interface
Double-Click
Detailed Modeling using Unit
Procedures and Operations
Building a Process Model
Predicting how a process would actually behave
Performing an experiment (on computer)
Incentives:
Highly Cost Effective
Reasonably Accurate
Proactive Approach
Q: What does the word simulate mean?
Some State-Of-The-Art Features:
Material and Energy Balances
What if Scenario Case Study, Sensitivity
Analysis
Equipment Sizing and Costing
Equipment (Performance) Rating
Equipment & Process Optimisation
Dynamic Simulation & Optimisation
Aspen Plus and Derivatives
Hysis
PRO II with Provision
Design II
Super Pro Designer (Batch Process)
.and other in house simulators
C: We have the first five packages mentioned!
Q: Which one are you familiar with?
Aspen Plus
Hysis
Provision
Oil, Gas &
Petrochemicals
Continuous Processes
Design II
Specialty Chemicals
Oleo Chemicals
SS Simulation
Optimisation
Sensitivity Analysis
Dynamic Simulation
Rating
Phys Prop
Batch
Pinch
Economics
Sizing & Costing
Solids
C: We have all the packages mentioned!
Q: Which one are you familiar with?
Water Purification
Wastewater Treatment
Air Pollution Control
BioPro Designer
SuperPro Designer
BatchPro Designer
EnviroPro Designer
Biotechnology
Food Processing
Synthetic
Pharmaceuticals
Specialty Chemicals
AgriChemicals
Established by Intelligen, Inc. (early 90s)
Batch Processes
Design a Process to Recover Methane
from a Gas Stream (i.e. Build a
Process Model to Recover Methane)

Comp Mole % Comp Mole %
Nitrogen 7.91 n-butane 2.44
Methane 73.05 i-pentane 0.69
Ethane 7.68 Pentane 0.82
Propone 5.69 Hexane 0.42
i-butane 0.99 Heptane 0.31
A (typical) gas stream to be processed:
Flowrate 8.0 m
3
/hr
Temperature 120 F
Pressure 602.7 psia
Reactor
Separation &
recycle
Heat exchange
network
Utilities
Process Synthesis
Process Simulation
parameter
optimisation
Process Flowsheeting
structural optimisation
Optimised Design
Material and Energy Balances
(manual & simulation)
Q: Why manual calculations?
Existing
Plant
domain
S1 S2
S3 S4
S5
S6
S7
S10
S9
E1 E2
F1
T1
EX1
C1
V1
S8
FLASH
D
E
M
E
T
H
A
N
I
Z
E
R

COMPRESSOR
EXPANDER
CHILLER
GAS-GAS
EXCHANGER

A Completed Flowsheet
Expander Plant Flowsheet
S1 S2
S3 S4
S5
S6
S7
S10
S9
E1 E2
F1
T1
EX1
C1
V1
S8
FLASH
D
E
M
E
T
H
A
N
I
Z
E
R

COMPRESSOR
EXPANDER
CHILLER
GAS-GAS
EXCHANGER

1. Draw Flowsheet
2. Define Components
3. Select Thermodynamic Option
4. Define Feed Streams
5. Provide Process Conditions
6. Run Simulation, and
dont just take the computers word for it

check the results!!!
S1 S2 S3
S4
E2
CHILLER
FLASH
E1
GAS-GAS
EXCHANGER
Place Module One by One
Expander Plant Flowsheet
Typical Simulator Worksheet
Define Your Components
E.g. N
2

METHANE
ETHANE
PROPANE
I-BUTANE
BUTANE
I-PENTANE

Either enter (type) the components directly or select from list
Component Databank
S1 S2 S3
S4
S5
E2
F1
E1
Simulator
Define Your Feed Streams
S1 S2 S3
S4
S5
E2
F1
E1
Supply stream data; i.e. flowrates, compositions,
and any two of the following
PRESSURE
TEMPERATURE
BUBBLE POINT
DEW POINT

S1 S2 S3
S4
S5
S6
S7
S10
S9
E2
F1
T1
EX1
V1
E1
C1
A
E
C
B
D
Possible Sequence: A-B-C-D-E

S1 S2 S3
S4
S5
S6
S7
S10
S9
E2
F1
T1
EX1
V1
E1
A
B
C
D
E
C1
Possible Sequence: A-B-C-D-E
Select Your Thermodynamics
Calculation Method
Category
Method
Soave-Redlich Kwong
Peng Robinson
Ideal (normally default)
NRTL
Wilson
UNIQUAC
..
For phase equilibrium and thermodynamics property calculations
(e.g. liquid-phase activity and vapour-phase fugacity coefficients, enthalpies..etc)
Equation of State
Liquid Activity
Generalized Correlations
Special Packages
Electrolyte
.
Select Your Thermodynamics
Calculation Method
Relieve everyones nightmares..Chem Eng Thermo
Gaseous Systems, e.g.

Ideal Gas EOS
Generalized EOS
SRK - Non-ideal
Peng Robinson Non-ideal
BWRS Non-Ideal
Liquid Systems

Raoults Law - Ideal
Wilson - Nonideal
NRTL Nonideal
Van Laar Nonideal
UNIFAQ - Nonideal
UNIQUAC - Nonideal

Reference: Walas, Stanley M. (1985) Phase Equipment in Chemical
Engineering. Boston: Butterworth. (TP156.E65)
Provide Process Conditions
N
stages
= 20
X
lk
= 0.99
X
hk
= 0.01
lk = C
3
H
8

hk = C
5
H
12

S1 S2
S3 S4
S5
S6
S7
S8
S10
S9
E1
E2
F1
T1
EX1
C1
V1
P = 1.1 bar
V/F = 0.5

Q: Where to get all the specs from?
S6
S3 S4
S1 S2
S5
S7
S8
S9
E1 E2
F1
T1
EX1
C1
V1
S10

A reminder before we go further
Always perform your simulation for one
equipment followed by another.
Use manual calculations (on selected unit
ops) to make sure the results make sense
The not so good news is..We have just got started!

this is only the tip of the iceberg.
Aspen Plus and Derivatives
PRO II with Provision
Hysim and Hysis
Design II & Super Pro (this module)
.and other in house simulators
But the good news is
If you have seen one simulator.
You have seen them all
Flowsheet description:
A single stage expansion of a light hydrocarbon
stream
Firstly, feed stream is cooled through a feed chiller
(X-1) & any liquid is removed with a vertical separator
(F-2).
The vapor is expanded (E-4) & liquids separated
using a second vertical separator (F-3).
Equipment Tag Specification
Feed chiller X-1 Temp out = -35F
Delta pressure = 10 psi
2 vertical
separator
F-2
F-4
Adiabatic flash
Delta pressure = 0
Expander E-3 Pressure out = 275 psig
Efficiency = 0.80
Component Lbmol/hr Specifications
Methane 6100
T = 90F
P = 980 psig
Ethane 500
Propane 200
N-Butane 100
N-Pentane 100
N-Hexane 70
Thermodynamics methods used:
K-Value = API Soave
Enthalpy = API Soave
Density = Yen Woods (STD)
Feed stream specification:
SOLUTION HAS BEEN REACHED!
Thank You For Your Attention

Over to Dominic Foo
Stream data:

Components Str1
T=25
o
C
P=1 atm
Str2
T=30
o
C
P=1.5 atm
Str3
T=50
o
C
P=1 atm
Water
Ammonia
Acetylene
Oxygen
CO2
4 kmol/hr
2 kmol/hr

3 kmol/hr
7 kmol/hr

11 kmol/hr
0.1 kmol/hr

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@ dr zain, pse-fkkksa, UTM

Page PS-1 Intro to Process Simulation

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