Example: Flash Demo Example

PPT 6

1.

Load the file Start-FlashExample.bkp Simulation is ** water-methanol flash, with

feed of
100 Kmol/hr
(50 Kmol/hr
water and 50 Kmol/hr methanol) at 2 bar and 50 deg C.
Flash block is specified for a vapor fraction
= 0.5, and zero pressure drop.
2.
Run the problem in Aspen Plus and view the flash results very quickly
3.
View menu//**s, to bring up the **s dialogue box
4.
Check the Dynamic box to display the Dynamic **
5.
OK
6.
Click the Dynamic button
to allow dynamic data input
7.
In the Data Browser, under Blocks/Flash, click on the Dynamic to access the dynamic
data forms
8.
Enter the data required for the Vessel tab form , Heat Transfer tab form and the Initial
condition tabs form note that this is optional data for a flash block default is
instantaneous, hence no dynamic data is actually required but flash operation will in
fact be instantaneous (or steady state)
9.
Click the Next button to run the problem
10.
View the Flash block results to show that no extra (dynamic) results are available in
Aspen Plus
11.
File menu/Export to export the Aspen Dynamics file
12.
Select Save as type Flow Driven Simulation to export the Answer-FlashExample dynf
and .appdf files to the workshop directory
13.
File/Save as to save the backup file (good practise) Answer-FlashExample.bkp
in the workshop directory
14.
Exit Aspen Plus there is actually no need to exit Aspen Plus, however, having
windows open is resource limiting and can cause unnecessary crashes in other (Aspen
dynamics) programs
15.
Start Aspen Dynamics by double-clicking on the Aspen dynamics icon or RMB/Open on
the icon.
16.
Describe the 3 main windows (Process Flowsheet, Simulation Explorer, Simulation
Messages),
the
Menu bar, Tools bar and buttons and the Status bar.
17.
Open button to open the example problem from the Workshop directory
18.
View the messages in the Messages window messages
19.
Double-click the Specification status button (inform should always be green for vanilla
file, else bug!) to show the Status window.
20.
Close the Status window
21.
Explain the individual items in the Simulation Explorer under Simulation (Dynamics
library, Flowsheet, Component Lists , Results Archive, Current Snapshots, Solver
Options, Globals table)
22.
Go to Tools/Snapshots to bring up the Snapshot management form.
23.
Explain Initial Specification snapshot loaded with problem
24.
Go to Tools/Use to bring up the Use Current Snapshots dialogue form
25.
Explain Use of snapshots
26.
Make sure the Flowsheet window is highlighted, then Go to the Window on the Menu
bar and set the Flowsheet as Wall**
27.
Double-click on the
VAP stream
to bring up the Results form
28.
Explain default forms and pre-defined forms
29.
Use the New Plot button to bring up an empty generic plot.
30.
Specify a name
for the plot object
31.
Drag and drop the VAP stream methanol mole fraction (variable Zn on the VAP stream
Results table) unto the plot
32.
Highlight the FEED Stream and use RMB on Forms/Manipulate
to bring up the Manipulate table
33.
Drag and drop the FEED stream temperature
(variable T on the FEED stream Manipulate
table) unto the
plot.
34.
Use RMB/Edit to set the time axis range as
0 to 1.0 Hours
35.
Use RMB to set
the Y-axis to a range 0.60 to 0.7
36.
Go to the Run menu and use the Pause At
from the Run menu
to pause the simulation at 0.1 hours
37.
Use the Run button to run the simulation to 0.1 hours
38.
When the simulation pauses, introduce a
FEED stream temperature change (its winter in Boston!) by changing the value of the
temperature variable T to 10 deg C in
the Manipulate table
39.
Set the simulation to pause at time 1.0 hours
40.
Run the simulation to time 1.0 and observe the plot
41.
Switch off auto-naming of blocks from the Tools/Settings/Auto-name tab by ** sure
the box is not checked
42.
Go to the
Simulation Explorer, under the Dynamics library, ControlModels folder,
43.
Drag and drop a PID model unto the flowsheet
44.
Confirm YES to save the current Snapshots to file rename the snapshot as
FlashExample
45.
Enter block ID as TC1
46.
From the Simulation Explorer double-click the archived snapshot (FlashDemo) to show
its contents
47.
Explain precisely where archived snapshots are stored
48.
From the Dynamics/Streams folder select a ControlSignal stream type and drag unto
the flowsheet
49.
Connect the controller input signal (variable TC1.PV) to the VAP stream temperature,
(variable T)
50.
Connect the controller output signal (variable .PV) to the FLASH block duty (variable
QR)
51.
From the menu bar, select
Tools/Snapshots pull up the Snapshot dialogue box and further explain the concept of
Current snapshots (there should be none!) and archived snapshots
52.
From the menu bar, select Tools/Use to bring up the Use form
53.
Click on the Select Results button to show how to access and USE archived
snapshots by selecting the FlashDemo snapshots
54.
Select Dynamic Initialization
55.
Click on
Fixed in the Copy to box to overwrite the existing fixed variables
56.
Click on Copy to initialize the modified flowsheet with the converged results
57.
Bring up the controller TC1 Configure form
58.
Click on Initialize Values to initialize the controller variables
59.
Specify a gain of 10 %/% and an Integral time of 10 minutes
60.
Change the controller action to be Reverse
61.
Set the simulation to pause at 10 hours
62.
Run the problem whilst viewing the plots
63.
File menu/Save as
64.
Select Save as file type and select dynf file type
65.
Enter a name AnswerFinal-FlashExample
66.
Click on Save
67.
File/Exit to exit the Aspen Dynamics application

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Vessels: flash drums, surge tanks and accumulators

There are a variety of places that vessels are used in chemical plants and oil
refineries, e.g.:
Flash drums. Vessels into which flow a mixture of liquid and vapor. The goal
is to separate the vapor and liquid. For design calculations it is normally
assumed that the vapor and liquid are in equilibrium with one another and
that the vessel is adiabatic (no heat lost or gained). One must
simultaneously satisfy a material balance, a heat balance, and
equilibrium. In HYSYS/UniSim, this can be done using either a Separator or
a Tank.
Surge tanks. These are storage tanks between units, and can serve a variety
of purposes. They can dampen fluctuations in flow rate, composition or
 temperature. They can allow one unit to be shut down for maintenance
without shutting down the entire plant. Use a Tank in HYSYS/UniSim.
Accumulators. These are storage tanks following distillation column
condensers. For partial condensers, this flow may be a mixture of vapor and
liquid. The outlet flow may be regulated by a level controller in order to
avoid the tank either flooding (liquid out the top) or going dry (vapor out the
bottom). Use a Separator or Tank in HYSYS/UniSim.

Sizing of vessels
Two classic works are accessible here: Vessels and Vessels2. These are the
basis of the HYSYS vessel sizing utility. There are two methods to access
this. Double click on the vessel icon in your pfd. On Rating Sizing click on Quick
Size. This uses the vessel sizing utility with the default settings of L/D = 3 and 5
minutes liquid residence time. (These are the same as in the heuristics for
process vessels.) Record the volume, diameter and height. Go to Tools,
Utilities, Vessel Sizing. Make any desired changes on Design Sizing and Design
Construction. The results are at Performance Sizing Results. This utility will
also estimate costs, at Design Costing. The "Chemical Engineering Index"
shown at Design Construction and Index & "CE Fab Index" at Design Costing,
Cost Equation Help are the Chemical Engineering Plant Cost Index (CEPCI). To
update to present costs, you change the index on the Design Construction page
to the current CEPCI value in Chemical Engineering magazine.

The following additional information is courtesy of Mohammad Kabir,

Technical Support Consultant at Aspen Technology in 2005:
In the Vessel Sizing utility in HYSYS, the maximum allowable velocity is
estimated based on the steady-state results, using the Souders- Brown
equation. With this velocity known plus other info, an adequate diameter,
height and volume of the separating vessel can then be obtained. To
achieve an equilibrium between different phases, an adequate residence time
for both light liquid and heavy liquid is assumed and it is then achieved by
adjusting the vessel size. The droplet size is not a factor in the equations used
in our Vessel Sizing Utility.
 The Vessel Sizing utility is based on the following references (linked
above):
Evans, Frank L., "Equipment Design Handbook for refineries and
chemical plants - Volume 2", 2nd Edition, p. 154, Gulf Publishing
Company, Houston, Texas, 1980.
Watkins, R.N., "Sizing Separators and Accumulators", Hydrocarbon
Processing, November 1967, p. 253.
LLSD is meant for Liquid level shut down. You can define that value in
HYSYS by yourself. Default calculation method should be found in above
references.