Process Modeling Using HYSYS With Refinery Focus

Getting Started 1
Getting Started
1
© 2004 AspenTech, Inc. - All Rights Reserved.
1.3.1 Getting Started.pdf
2 Getting Started
Workshop
The Getting Started module introduces you to some of the basic
concepts necessary for creating simulations in HYSYS. You will use
HYSYS to define three gas streams to be used as feeds to a gas plant. In
addition, you will learn how to determine properties of these streams by
using the Phase Envelope and the Property Table utilities.
Learning Objectives
• Define a fluid package (property package, components,
hypotheticals).
• Add streams.
• Understand flash calculations.
• Attach stream utilities.
• Customize the Workbook.
Simulation Basis Manager

HYSYS uses the concept of the fluid package to contain all necessary
information for performing flash and physical property calculations.
This approach allows you to define all information (property package,
components, hypothetical components, interaction parameters,
reactions, tabular data, etc.) inside a single entity.
There are four key advantages to this approach:
• All associated information is defined in a single location, allowing for

easy creation and modification of the information.
• Fluid packages can be stored as completely defined entities for use
in any simulation.
• Component lists can be stored out separately from the Fluid
Packages as completely defined entities for use in any simulation.
• Multiple Fluid Packages can be used in the same simulation.
However, they are all defined inside the common Basis Manager.
2
Getting Started 3
The Simulation Basis Manager is a property view that allows you to

create and manipulate multiple fluid packages or component lists in the
simulation. The opening tab of the Simulation Basis Manager allows for
the creation of component lists which are independent of but can be
associated with the individual fluid packages in the case.
The first tab of the Basis Manager allows you to manage the component
list(s) used in your case. There are a number of buttons available:
Figure 1
Button Description
View Allows you to access the property view for the selected Component
List.
Add Allows you to create a Component List.
Note: Component Lists can be added via the Fluid Package property
view.
Delete Removes the selected Component List from the simulation.
Copy Makes a copy of the selected Component List.
Import Allows you to import a predefined Component List from disk.
Component Lists have the file extension. (.cml)
Export Allows you to export the selected Component List to disk. The exported
Component List can be retrieved into another case, by using the Import
function.
You can use the CTRL B hot key to re-enter the Simulation Basis Manager
from any point in the simulation or click the Basis Environment icon
Basis Environment icon from the tool bar.
3
4 Getting Started
Inside the Current Fluid Packages group, there are a number of buttons:
Figure 2
Button Description
View This is only active when a fluid package exists in the case. It allows you
to view the property view for the selected fluid package.
Add Allows you to create and install a fluid package in the simulation.
Delete Removes the selected Fluid Package from the simulation.
Copy Makes a copy of the selected fluid package. Everything is identical in
the copied version except the name. This is useful for modifying fluid
packages.
Import Allows you to import a predefined fluid package from disk. Fluid
packages have the file extension (.fpk).
Export Allows you to export the selected fluid package to a disk. The exported
fluid package can be retrieved into another case by using the Import
function.
The Fluid Pkgs tab allows you access to the fluid packages/flowsheet
associations list as well as the fluid package definition. As with older
versions, HYSYS allows the user to use multiple fluid packages within a
single simulation by associating the fluid packages with various
flowsheets and linking the flowsheets together. However, beginning with
HYSYS version 3.0 the user no longer requires the use of flowsheets to
employ multiple fluid packages within a single simulation. The user can
now utilize the Stream Cutter operation to incorporate multiple fluid
packages into a single flowsheet.
4
Getting Started 5
Defining the Simulation Basis

Add a Property Package
1. Start a new case by selecting the New Case icon.
2. Go to the Fluid Pkgs tab and create a fluid package by clicking the
Add button.
New Case icon
3. Choose the Peng-Robinson Equation of State model.
Figure 3
4. The fluid package name can be changed in the bottom left corner of
this view. Change the name from the default Basis-1 to Refinery.
5. Click the View button in the Component List Selection section of the
Set Up tab. This will allow you to add components to the
Component List that is now associated with the Refinery fluid
package.
5
6 Getting Started
Add Components
You can select components for your simulation using several different
methods.
To use... Do this...
Match Cell 1. Select one of the three name formats, SimName,
Full Name/Synonym, or Formula by selecting the
corresponding radio button.
You can add a range of 2. Click on the Match cell and enter the name of the
components by highlighting component. As you start to type, the list will
the entire range and clicking change to match what you have entered.
the Add Pure button.
3. Once the desired component is highlighted,
either:
• Click the ENTER key.
• Click the Add Pure button.
• Double-click on the component to add it to your
simulation.
Component List 1. Using the scroll bar for the main component list,
scroll through the list until you find the desired
component.
2. To add the component, either:
• Press the ENTER key.
• Click the Add Pure button.
• Double-click on the component to add it to your
simulation.
Filter 1. Ensure the Match cell is empty, and click the
View Filter button.
2. Select the Use Filter checkbox to display the
various family filters.
3. Select the desired family (i.e., Hydrocarbons)
from the list of Family Filters to display only that
type of component.
4. Use either of the two previous methods to then
select the desired component.
6
Getting Started 7
6. Select the library components C1, C2, C3, i-C4, n-C4, i-C5, n-C5, and
C6.
Figure 4
7. Select the Hypothetical menu item in the Add Component box to

add a hypothetical component to the Fluid Package.
A hypothetical component can be used to model non-library

components, defined mixtures, undefined mixtures, or solids. You will
be using a hypothetical component to model the components that are
heavier than hexane.
When you click the Quick
Create a Hypo Component
button, HYSYS adds a
hydrocarbon class hypo by
default.
If you want to add a hypo
from another class, click the
Hypo Manager button and
then in the view that
appears, click the View
Group button. This will open
the Tabular Hypothetical
Input, where you can add
non-hydrocarbon class
hypotheticals.
7
8 Getting Started
Figure 5
8. In the hypo component view, select the ID tab and type the
Component Name, C7+.
Figure 6
HYSYS always places an ‘*’

after a hypo name so it can
be distinguished from library
components.
Since you do not know the structure of the hypothetical component and
you are modelling a mixture, the Structure Builder will not be used.
8
Getting Started 9
9. Click on the Critical tab. The only property supplied by the lab for
the C7+ component is the Normal Boiling Pt. Enter a value of 110°C
(230°F).
10. Click the Estimate Unknown Props button to estimate all the other
properties and fully define the hypothetical component.
Figure 7
The minimum information

required for defining a hypo
is the Normal Boiling Pt or
the Ideal Liq Density and
Molecular Weight.
11. When the hypo component has been defined, return to the fluid
package by closing the hypo component C7+* view.
12. Add the hypo component to the Selected Components list by

selecting it in the Available Hypo Components list and then clicking
the Add Hypo button.
You can use the Sort List

button to order the
Component List.
9
10 Getting Started
Figure 8
Every hypo you create is part of a Hypo Group. By default, this hypo is
placed in HypoGroup1. You can add additional groups and move hypo
components between groups. This is done on the Hypotheticals tab of
the Simulation Basis Manager.
Compare the properties of C7+ with C7 and C8.
C7+ C7 C8
Normal Boiling Point
Ideal Liquid Density
Molecular Weight
You have now finished defining the fluid package. You can view the
Peng-Robinson binary coefficients for your selected components by
selecting the Binary Coeffs tab.
You will need to add
components C7 and C8 to
the component list in order
to view their properties.
Ensure that you delete them
once this exercise is
finished.
10
Getting Started 11
Exporting Fluid Packages

HYSYS allows you to export fluid packages for use in other simulations.
This functionality allows you to create a single common fluid package
which you may then use in multiple cases.
1. On the Fluid Pkgs tab, highlight the Refinery fluid package.
Figure 9
2. Click the Export button.

3. Enter a unique name (Refinery) for the fluid package and click the
Save button.
HYSYS will automatically add Figure 10

the file extension .fpk when it
saves your fluid package. The
file is automatically saved to
the \HYSYS\paks folder.
11
12 Getting Started
Now that the fluid package has been defined, you can start building the
simulation. Click the Enter Simulation Environment button to begin
building the simulation.
Building the Simulation

When you build the simulation, you will:
• Select a unit set

• Add streams
• Attach utilities
Select a Unit Set

In HYSYS, it is possible to change the unit set used to display the
different variables.
1. From the Tools menu, choose Preferences.

2. Click on the Variables tab.
Figure 11
3. Select either the SI or Field unit set whichever you prefer.
12
Getting Started 13
4. Close this view to return to the simulation.
Changing Units for a Specification

To change the units for a specification, simply type the numerical value
of the specification and press the space bar or click on the unit drop-
down list. Choose the units for the value you are providing. HYSYS will
convert the units back to the default units.
Figure 12
You can scroll through the

unit list by starting to type
the units, by using the arrow
keys, or by using the scroll
bar.
Adding Streams
In HYSYS, there are two types of streams, Material and Energy. Material
streams have a composition and parameters such as temperature,
pressure, and flowrates. They are used to represent process streams.
Energy streams have only one parameter: heat flow. They are used to
represent the duty supplied to or by a unit operation.
13
14 Getting Started
There are a variety of ways to add streams in HYSYS.
To use this... Do this...

Menu Bar • Select Add Stream from the Flowsheet menu.
or
• Press the F11 Hot Key.
The Stream property view opens.
Workbook Open the Workbook and go to the Material Streams tab. Type a
stream name into the **New** cell.
Object Palette From the Flowsheet menu, select Open Object Palette or press
F4 to open the Object Palette. Double-click on the stream icon.
In this case, you will add three streams to represent three different gas
wells. Each stream will be added using a different method of installation.
Adding a Stream from the Menu Bar

To add a stream using the F11 hot key:
1. Press F11. The stream property view appears. If the stream property
view is not displayed, double-click on the newly created stream
(from the PFD) to bring up the property view.
Figure 13
14
Getting Started 15
Highlight the Stream Name cell. Change the stream name by typing in a
new name:
2. Change the stream name to Feed.

3. Enter a molar flow of 100 kgmol/h (220 lbmol/h).
Entering Stream Compositions

There are two different pages for entering stream composition:
On this page... Do this...

Conditions • Double-click on the Molar Flow cell to enter mole
fractions.
or
• Double-click on the Mass Flow cell to enter mass
fractions.
or
• Double-click on the Std Ideal Liquid Volume Flow cell to
enter volume fractions.
The Input Composition for Stream view appears.
Composition Click the Edit button.
The Input Composition for Stream view appears.
4. If the Input Composition for Stream view is not already open,

double-click on the Mass Flow cell.
Figure 14
5. Click the Mole Fractions radio button in the Composition Basis

group to change the basis from mass to mole fractions.
15
16 Getting Started
6. Enter the following compositions.
For this component... Enter this mole fraction...

C1 0.0724
C2 0.1288
If there are <empty> values C3 0.2765
either enter 0 or click the i-C4 0.1895
Normalize button. The
stream is not fully defined n-C4 0.1145
until all composition values i-C5 0.0648
have a numerical input. n-C5 0.0548
C6 0.0329
C7+ 0.0658
7. Click the OK button when all the mole fractions have been entered.
8. Close the Stream property view.
9. Save case as DePentanizer Feed.hsc.
You can use one of several different methods to save a case in HYSYS:
• From the File menu, select Save to save your case with the same
name.
Save icon
• From the File menu, select Save As to save your case in a
different location or with a different name.
• Click the Save icon on the tool bar to save your case with the
same name.
Save your case often to avoid

Save your case!
losing information.
16
Getting Started 17
Flash Calculations
HYSYS can perform three types of flash calculations on streams: P-T, Vf-
Only two of these three P, and Vf-T. Once the composition of the stream and two of either
stream parameters (Vapour
Fraction, Temperature, or temperature, pressure or vapour fraction are known, HYSYS performs a
Pressure) can be supplied. flash calculation on the stream, calculating the third parameter.
If you try to supply temperature, pressure and vapour fraction,

a consistency error will occur.
With the flash capabilities of HYSYS, it is possible to perform dew and

bubble point calculations. By specifying a vapour fraction of 1.0 and
either the pressure or temperature of the stream, HYSYS will calculate
the dew temperature or pressure. To calculate the bubble temperature
or pressure, a vapour fraction of 0.0 and either pressure or temperature
must be entered.
Perform a P-T flash calculation on the stream Feed. Set the pressure to 4000
kPa (580 psia) and the temperature to 100°C (212°F). What is the vapour
fraction?
____________________________________________________________________
Perform a bubble point calculation on the stream Feed. Set the pressure to
4000 kPa (580 psia). What is the dew point temperature?
____________________________________________________________________
Perform a dew point calculation on the stream Feed. Set the pressure to 4000
kPa (580 psia). What is the dew point temperature?
____________________________________________________________________
Attaching Utilities
The utilities available in HYSYS are a set of useful tools that interact with
your process, providing additional information or analysis of streams or
operations. Once installed, the utility becomes part of the flowsheet,
automatically recalculating when conditions change in the stream or
operation to which it is attached.
17
18 Getting Started
As with the majority of objects in HYSYS, there are a number of ways to

attach utilities to streams:
To use the... Do this...

Menu Bar • From the Tools menu, select Utilities.
or
• Press CTRL U.
The Available Utilities view appears.
Stream Property 1. Open the Stream property view.
View 2. On the Attachments tab, click on the Utilities page.
3. Click the Create button.
The Available Utilities view appears.
Next, you will add a utility using each method of installation.
Adding a Utility from the Stream Property View

The Envelope utility (in the Available Utilities list) allows you to examine
The Envelope can only be relationships between selected parameters for any stream of known
calculated on a dry basis composition, including streams with only one component. Vapour-
(any water is ignored).
Liquid Envelopes may be plotted for the following variables:
• Pressure - Temperature
• Pressure - Volume
• Pressure - Enthalpy
• Pressure - Entropy
• Temperature - Volume
• Temperature - Enthalpy
• Temperature - Entropy
An Envelope utility will be added to the stream Feed from the Stream
property view.
1. Open the Stream property view by double-clicking on the stream in

either the Workbook or the PFD.
18
Getting Started 19
2. On the Attachments tab, click Utilities.
Figure 15
3. Click the Create button. The Available Utilities view appears.

4. Select Envelope. Click the Add Utility button. The Envelope Utility
view appears.
5. The Design tab shows the critical and maxima values for the
envelope.
What is the critical temperature and pressure for the stream Feed?
Tc________________________________ Pc________________________________
19
20 Getting Started
6. Switch to the Performance tab to view the envelope.
Figure 16
7. Click on the Table page to view the envelope data in a tabular

format.
Adding a Utility from the Menu Bar

Numerical values can be
copied from HYSYS to
Microsoft Excel using the The Property Table utility allows you to examine property trends over a
copy command, CTRL C, range of conditions in both tabular and graphical formats. The utility
and then the paste
command, CTRL V. calculates dependent variables for user specified independent variable
ranges or values.
A Property Table utility will be added to the stream Feed from the Tools
menu.
1. Press CTRL U. The Available Utilities view appears.

2. Select Property Table.
20
Getting Started 21
3. Click the Add Utility button. The Property Table view appears.
Figure 17
4. Click the Select Stream button and select the stream Feed.
5. Click the OK button to return to the Design tab.
6. Choose Pressure as the first Independent Variable.
7. Change the mode to State.
8. In the State Values matrix, enter values of 500, 1000, 2000, and 3000
kPa. If you are using field units, the values will be 72, 145, 290, 435
psia.
9. Choose Temperature as the second Independent Variable.
10. Change the Lower and Upper Bounds to -50°C (-58°F) and 200°C
(392°F) respectively. Set the Increments value to 5 so each interval is
increased by 50°C (90°F).
21
22 Getting Started
Figure 18
11. Go to the Dep. Prop page.
It is possible to choose multiple dependent properties. In addition, they

may be from different phases or bulk properties.
12. Click on the Add button.

13. Choose Vapour Fraction from the list. Click OK to accept.
14. Click on the Add button again. Select Phase Comp Mole Fraction,
then Liquid Phase, and then n-butane. Click OK to accept.
15. Click the Calculate button to generate the property table.
16. Examine the property table results in either graphical or tabular
format on the Performance tab.
22
Getting Started 23
Figure 19
Analyzing the Results

Stream Property View
Within HYSYS, it is possible to view the properties of the individual
phases for any stream.
1. Open the Stream property view for Feed, and view the Conditions
page.
2. Add a Vapour Fraction of 1.0 and Pressure of 4000 kPa (580 psia).
3. Move the mouse arrow to the left or right side of the view until the
arrow changes to the double-headed resizing arrows.
23
24 Getting Started
4. Press and hold the left mouse button and drag the edge of the view
until all the phases can be seen as shown below.
Figure 20
5. Go to the Properties page. This page contains more detailed

information about the stream.
Figure 21
24
Getting Started 25
Customizing the Workbook

HYSYS allows you to customize the Workbook at several different levels.
You can add additional pages, change the variables which are displayed
on the current pages, or change the format of the values.
In this exercise, a new Workbook tab containing stream properties, Mass

Density, Watson K, and Vap Frac on a Volume Basis will be added.
1. Open the Workbook by clicking the Workbook icon on the tool bar.
2. From the Workbook menu, select Setup. The Setup view appears as
shown below.
Workbook icon
Figure 22
25
26 Getting Started
3. Under the Workbook Tabs group, click the Add button. The new
Object Type view appears.
Figure 23
4. Select Stream and click OK.

5. A new Workbook tab, Streams, will be listed in the Workbook Tabs
group. Ensure that this new tab is highlighted.
6. Highlight the Name cell and change the name to Other Prop.
7. In the Variables group, click the Delete button until all the default
variables are removed.
8. Click the Add button to add a new variable to the tab.
9. From the Variable list, select Mass Density and click OK.
26
Getting Started 27
10. Repeat steps #8 and #9 to add Watson K and Vap Frac on a Volume
Basis as shown below.
Figure 24
11. Exit the view when you are done to return to the Workbook.
12. The Workbook now contains the tab Other Prop. which shows the
values of Mass Density, Watson K, and Vap Fraction on a Volume
Basis as shown below.
Figure 25
27
28 Getting Started
Printing Stream & Workbook Datasheets

In HYSYS you have the ability to print Datasheets for streams,
operations, and Workbooks.
Printing the Workbook Datasheet

1. Open the Workbook.
To print all streams: 2. Right-click (object inspect) the Workbook title bar. The Print
• Customize the Datasheet pop-up menu appears.
Workbook to contain all
the stream data you
want. Figure 26
• Print the Workbook
Specsheet.
3. Select Print Datasheet. The Select Datablock view appears.
Figure 27
28
Getting Started 29
4. From the list, you can choose to print or preview any of the available
datasheets.
Printing an Individual Stream Datasheet

To print the datasheet for an individual stream, object inspect the
stream property view title bar and follow the same procedure as with the
Workbook.
Save your case!
Exploring the Simulation

Exercise 1: Phase Behaviour & Hydrate Prediction
A. Use the Phase Envelope to find the following points of stream Feed:
Critical Point _______________________________________________________

Cricondenbar (maximum pressure) ___________________________________
Bubble Point temperature at 5000 kPa ________________________________
Dew Point temperature at 4000 kPa ___________________________________
Temperature for 50% quality at 5000 kPa ______________________________
Hydrate Formation temperature at 5000 kPa ___________________________
B. Use the Workbook to find the following values:
Bubble Point temperature at 3000 kPa ________________________________

Dew Point temperature at 4500 kPa. __________________________________
Feed temperature for 50% quality (V.F. = 0.5) at 3500 kPa _________________
29
30 Getting Started
30
Propane Refrigeration Loop 1
Propane Refrigeration Loop
1
© 2004 AspenTech, Inc. - All Rights Reserved.
1.3.2 Propane Refrigeration Loop.pdf
2 Propane Refrigeration Loop
Workshop
Refrigeration systems are commonly found in the natural gas processing
industry and in processes related to the petroleum refining,
petrochemical, and chemical industries. Refrigeration is used to cool gas
to meet a hydrocarbon dewpoint specification and to produce a
marketable liquid.
In this module you will construct, run, analyze and manipulate a

propane refrigeration loop simulation. You will convert the completed
simulation to a template, making it available to connect to other
simulations.
Learning Objectives
Once you have completed this module, you will be able to:
• Add and connect operations to build a flowsheet.

• Use the graphical interface to manipulate flowsheets in HYSYS.
• Understand forward-backward information propagation in
HYSYS.
• Convert simulation cases to templates.
Prerequisites
Before beginning this module, you need to know how to:
• Define a fluid package.

• Define streams.
• Navigate the Workbook interface.
2
Process Overview

The first step in building any simulation is defining the fluid package. A
brief recap on how to define a fluid package and install streams is
described below. [For a complete description, see the previous module
(Getting Started)].

1. Create a New Case and add a fluid package.
2. Enter the following values in the specified fluid package view:
On this page... Select...

Property Package Peng Robinson
Components C3
3. Click the Enter Simulation Environment button when you are ready
to start building the simulation.
Installing a Stream
There are several ways to create streams. (For a complete description,
see the previous module.)
• Press F11. The Stream property view appears.
or
• Double-click the Stream icon in the Object Palette.
4
Defining Necessary Streams

Add a stream with the following values.
In this cell... Enter...

Name 1
Vapour Fraction 0.0
Temperature 50°C (120°F)
Composition C3 - 100%
Add a second stream with the following properties:

Name 3
Vapour fraction 1.0
Temperature -20°C (-4°F)
What is the pressure of Stream 1? ______________________________________
Adding Unit Operations to a Flowsheet

As with streams, there are a variety of ways to add unit operations in
HYSYS:
To use the... Do this...

Menu Bar From the Flowsheet menu, select Add Operation
or
Press F12.
The UnitOps view appears.
Workbook Open the Workbook and go to the UnitOps page,
then click the Add UnitOp button.
The UnitOps view appears.
Object Palette From the Flowsheet menu, select Open Object
Palette, or press F4. Double-click the icon of the
unit operation you want to add.
PFD/Object Palette Using the right mouse button, drag ‘n’ drop the icon
from the Object Palette to the PFD.
5
The propane refrigeration loop consists of four operations:
• Valve
• Chiller
• Compressor
• Condenser
In this exercise, you will add each operation using a different method of
installation.
Adding a J-T Valve

The J-T Valve is modelled using the Valve operation in HYSYS. The inlet
to the valve comes from the condenser outlet. The condenser outlet is at
its bubble point.
The valve will be added using the F12 hot key.
1. Press F12. The UnitOps view appears:
You can filter the Available Figure 1

Unit Operations list by
selecting an appropriate
Category. In this case,
Piping Equipment would
filter the list to include the
Valve operation.
2. Select Valve from the Available Unit Operations list.

3. Click the Add button. The Valve property view appears.
6
4. On the Connections page, supply the inlet and outlet connections

as shown below:
Figure 2
Drop-down lists, such as for

the Feed and Product
streams, contain lists of
available streams which can
be connected to the
operation.
Adding a Chiller
The Chiller operation in the propane loop is modeled in HYSYS using a
Heater operation. The outlet of the Chiller will be at its dewpoint.
To add a heater:
1. Open the Workbook and click the Unit Ops tab.

2. Click the Add UnitOp button. The UnitOps view appears.
3. Select Heat Transfer Equipment from the Categories group.
7
4. Select Heater from the Available Unit Operations list as shown

below.
Figure 3
5. Click the Add button, or double click on Heater. The Heater property
view appears.
6. On the Connections page, enter the information as shown below:
Figure 4
7. Go to the Parameters page.
8
8. Enter a Delta P value of 7.0 kPa (1 psi) and a Duty value of 1.00e+06
kJ/h (1.00e+06 Btu/hr) for the Chiller.
Figure 5
The Parameters page will be
common to most unit
operations and contains
parameters such as Delta P,
Duty, and Efficiency.
9. Close the property view.
What is the molar flowrate of propane? ________________________________

What is the pressure drop across the J-T valve? __________________________
What is the temperature of the valve outlet (stream 2)? ___________________
Adding a Compressor
Placing the mouse arrow on The Compressor operation is used to increase the pressure of an inlet
a button in the Object gas stream.
Palette will display a fly-by
description for the button.
To add a compressor:
1. Press F4. The Object Palette appears.

2. Double-click the Compressor icon on the Object Palette. The
Compressor property view appears.
Compressor icon
9
3. On the Connections page, enter the stream information as shown

below:
Figure 6
4. Complete the Parameters page as shown:
Figure 7
10
Adding the Condenser

The Condenser operation completes the propane refrigeration loop. It is
placed between the Compressor and the Valve and is modelled as a
Cooler operation.
Working with a graphical representation, you can build your flowsheet

in the PFD using the mouse to install and connect objects. This
procedure describes how to install and connect the Cooler using the
Object Palette drag ‘n’ drop technique.
Using Drag ‘n’ Drop in the PFD

1. Click the Cooler icon on the Object Palette.
2. Move the cursor to the PFD. The cursor will change to a special
Cooler icon cursor, with a box and a plus (+) symbol attached to it. The box
indicates the size and location of the cooler icon.
3. Click again to “drop” the cooler onto the PFD.
There are two ways to connect the operation to a stream on the PFD:
To connect using the... Do this...

Attach Mode toggle 1. Press the Attach Mode toggle button.
2. Place the cursor over the operation. The
Feed Stream connection point is
highlighted in dark blue.
3. Move the cursor over the stream you
want to connect.
4. Press and hold the left mouse button.
5. Move the cursor to the operation icon
and release the mouse button.
CTRL key 1. Press and hold the CTRL key and pass
the cursor over the operation.
2. Place the cursor over the stream you
want to connect.
3. Press and hold the left mouse button.
4. Move the cursor to the operation icon
and release the mouse button and the
CTRL key.
11
5. From the PFD, connect stream 4 to the Condenser inlet and connect
the Condenser outlet to stream 1.
6. Double-click on the Condenser.
7. On the Parameters page, enter a Delta P of 35 kPa (5 psi).
Figure 8
What is the compressor energy in hp? __________________________________
Save your case!
Manipulating the PFD

The PFD is designed around using the mouse and/or keyboard. There
are a number of instances in which either the mouse or the keyboard
can be used to perform the same function. One very important PFD
function for which the keyboard cannot be used is object inspection.
You can perform many of the tasks and manipulations on the icons in
the PFD by using object inspection. Place the mouse arrow over the icon
you want to inspect and press the right mouse button. An appropriate
menu is produced depending upon the icon selected (Stream,
Operation, Column, or Text Annotation).
12
A list of the objects that you can object inspect are shown in the
following table with the corresponding menus.
Object... Object Inspection Menu...

PFD
Unit Operations
13
Object... Object Inspection Menu...

Streams
Workbook Tables
Unit Operation Tables
Text Annotations
Stream Line
Customize the PFD by performing the following:
1. Add a Title: Propane Refrigeration Loop.

2. Add a Workbook Table for the material streams in the simulation.
3. Add a Table for stream 4.
14
Saving the Simulation as a Template

A template is a complete flowsheet that has been stored to disk with
some additional information included that pertains to attaching the
flowsheet as a sub-flowsheet operation.
Typically, a template is representative of a plant process module or

portion of a process module. The stored template can subsequently be
read from disk and efficiently installed as a complete sub-flowsheet
operation any number of times into any number of different
simulations.
Some of the advantages of using templates are:
• Provides a mechanism by which two or more cases can be linked

together.
• Employs a different property package than the main case to
which it is attached.
• Provides a convenient method for breaking large simulations into
smaller, easily managed components.
• Is created once and can be installed in multiple cases.
Before you convert the case to a template, it needs to be made generic so

it can be used with gas plants of various flowrates. In this case, the
Chiller Duty dictates the flowrate of propane required.
1. From the Simulation menu, select Main Properties. The Simulation

Case view appears as shown below.
15
Figure 9
2. Click the Convert to Template button.

3. Click Yes to convert the simulation case to a template.
4. Answer No to the question “Do you want to save the simulation
case”.
5. Go to the File menu and Save the template as C3Loop.tpl.
Analyzing the Results

This section describes how to retrieve and print unit operation results.
Printing Datasheets for Unit Operations

In HYSYS you can print results through:
To set up the printer, select
Printer Setup from the File
menu, then select either the • The menu bar
Graphic Printer or the • Object inspection of unit operations
Report Printer. This allows
you to set the printer • The Report Manager
configuration, printer, paper,
orientation, and paper size,
and source.
16
Printing Using the Menu Bar

Choose one of the following options from the File menu:
• Print. Lists the available Datasheets for the active unit operation.
You can highlight a Datasheet and either preview or print it.
Figure 10
Choosing the Print

command when the PFD is
the active view will print the
PFD. There are no
datasheets available for the
PFD.
• Print Window Snapshot. Prints a bitmap of the active HYSYS

view.
Printing Using Object Inspection

Object inspect the Title Bar of the unit operation property view and
select Print Datasheet. A list of available Datablocks is displayed for the
object.
17
Printing Using Report Manager

1. Open the Tools menu. Select Reports. The Report Manager view
appears as shown below.
Figure 11
2. Click the Create button to add a new report. The Report Builder view
appears as shown below.
Figure 12
18
3. Click the Insert Datasheet button to add datasheets to your report.

You can add single or multiple unit operation Datasheets to a report.
Figure 13
Adding Unit Operation Data to the Workbook

Each WorkBook has a UnitOps page by default that displays all the unit
operations and their connections in the simulation. You can add
additional pages for specific unit operations to the WorkBook. For
example, you can add a page to the WorkBook to contain only
compressors in the simulation.
Adding a Unit Operation Tab to the WorkBook

1. Open the WorkBook.
2. Open the WorkBook menu. Select Setup. The Setup view appears.
3. Click the Add button in the Workbook Tabs group. The New Object
Type view appears.
19
4. Select Rotating Equipment and expand the list. Select Compressor

as shown.
Figure 14
Double clicking on a title

with a "+" sign will open an
expanded menu.
5. Click OK. A new page, Compressors, containing only compressor

information is added to the WorkBook.
6. Close this view.
Adding Unit Operation Data to the PFD

For each unit operation, you can display a Property Table on the PFD.
The Property Table contains certain default information about the unit
operation.
Adding Unit Operation information to the PFD

1. Open the PFD.
2. Select the unit operation for which you want to add the Property
Remember you can Object Table.
Inspect an object by
selecting it and then clicking
3. Object Inspect the unit operation.
on it with the right mouse 4. Open the Show Table menu.
button.
20
5. After the table has been added, you can move it by selecting it and
dragging it with the mouse.
6. If you Object Inspect the table, you can change its properties and
appearance. You can also specify which variables the table will show.
Advanced Modeling
One of the key design aspects of HYSYS is how Modular Operations are
combined with a Non-Sequential solution algorithm. Not only is
information processed as you supply it, but the results of any
calculation are automatically propagated throughout the flowsheet,
both forwards and backwards. The modular structure of the operations
means that they can calculate in either direction, using information in
an outlet stream to calculate inlet conditions. This design aspect is
illustrated using the Propane Refrigeration Loop.
Figure 15
21
Initially, the only information supplied in the case is the temperature

and vapour fraction for streams 1 and 3 and the composition of stream
1. Since the temperature, vapour fraction, and composition of stream 1
are known, HYSYS will automatically perform a flash calculation and
determine the remaining properties (pressure, intensive enthalpy,
density, etc.) which are independent of flow.
When streams 1 and 2 are attached to the valve J-T, HYSYS first
determines what information is known in either the input or output
stream. It will then assign these values to the other stream. In this case,
since no valve pressure drop was specified, only the composition and
intensive enthalpy of stream 1 will be passed to stream 2.
By attaching stream 2 and 3 to the heater operation, Chiller, the

composition of stream 2 is passed to stream 3 (100% C3). HYSYS can
now perform a flash calculation on stream 3 and determine the
remaining properties which are independent of flow, i.e. Pressure,
enthalpy, etc.
Using the calculated pressure of stream 3 and the specified pressure

drop across the heater, HYSYS back calculates the pressure of stream 2.
Since the pressure, composition and intensive enthalpy of stream 2 are
now known (the valve is isenthalpic) HYSYS can calculate the
temperature of stream 2.
In addition, HYSYS uses the specified heater duty and the intensive
enthalpy of streams 2 and 3 to calculate the flowrate, which is then
passed on to streams 1, 2 and 3.
Next, the Compressor is added to the simulation. Since all of the inlet
information is known, the compressor has only 2 degrees of freedom
remaining. Parameters such as Efficiency, Duty or Outlet Pressure can
satisfy one degree of freedom. The second degree of freedom comes
from the Condenser.
The Condenser connects the Compressor outlet to the Valve inlet (which
is completely defined). The user supplies the Condenser pressure drop,
and HYSYS calculates the inlet pressure, which is also the Compressor
outlet pressure (the second degree of freedom for the Compressor).
22

Exercise 1: Design vs. Rating Scenarios
In the plant, you are unable to accurately measure or calculate the
chiller duty. You do, however, know that the compressor is rated for 250
hp and that it is running at 90% of maximum and 72% efficiency.
What is the chiller duty? ______________________________________________
The Chiller Gas Flow meter has finally been calibrated and you can
determine the chiller duty. It has been decided to increase the chiller
duty to 1.5 MMBTU/hr.
With the compressor running at the same horsepower (250 hp), what is the
best chiller outlet temperature you can achieve (and thus maximize cooling
for the process) while still running the compressor at a reasonable operating
point? ______________________________________________________________
Exercise 2: Refrigerant Composition

Your local propane dealer arrives at your plant selling a 95/5 (mole%)
Propane/Ethane blend.
What effect, if any, does this new composition have on the refrigeration
loop? _______________________________________________________________
Use the base case for comparison:
Base Case: 100% C3 New Case: 5% C2, 95% C3

Flow, kgmole/h
Condenser Q, kJ/h
Compressor Q, hp
23
Challenge: Adding an Economizer

Create a two stage refrigeration loop by adding an Economizer.
What is the net compression in hp? ____________________________________
Figure 16
24
Add the following specifications to the refrigeration loop:
For this Item... Add this specification...

Stream 1 T = 50°C
vf = 0.0
Chiller Pressure Drop = 7 kPa
Q = 1.0 e+06 kJ/h
Stream 3 T = -20°C
vf = 1.0
Stream 4 P = 625 kPa
Mixer Equalize All Pressures
Condenser Pressure Drop = 35 kPa
Save your case!
Convert your case to a template

and save!
25
26
De-pentanizer & De-butanizer 1
De-pentanizer & De-butanizer
1
© 2004 AspenTech, Inc. - All Rights Reserved
1.3.3 De-pentanizer & De-butanizer.pdf
2 De-pentanizer & De-butanizer
Workshop
Separation of light products is typical of Refinery operations. In this
module, two columns will be modeled to separate pentanes and
butanes.
Because the Condenser temperature in the De-butanizer is below zero,

the process stream will need to be cooled. The Propane Refrigeration
Loop from the previous module will be used to cool the process stream,
showing how templates can be linked into HYSYS cases.
Learning Objectives
Once you have completed this section, you will be able to:
• Build columns using the Input Experts

• Use the Spreadsheet
• Link Templates
Prerequisites
Before beginning this module you need to have completed the Getting
Started and the Propane Refrigeration Loop modules.
2
Process Overview
Column Overview
De-pentanizer
De-butanizer
4

For this module you will continue building on the case you worked on in
Module 1 by adding two distillation columns.
1. Open the case you saved at the end of module 1.
Make sure the temperature, pressure and flowrate for Feed stream are
the following:

Pressure 700 kPa (100 psia)
Molar Flow 100 kgmole/h (220 lbmole/h)
Adding the First Column: De-Pentanizer

The De-pentanizer will be modelled with a Distillation column. The
Column is a special type of Sub-Flowsheet, which contains equipment
and streams, and exchanges information with the parent Flowsheet
through the connected streams.
HYSYS has several basic Column templates depending on the type of

equipment your Column requires:
Basic Column Types Description

Absorber Tray Section Only
Liquid-Liquid Extractor Tray Section Only
Reboiled Absorber Tray Section and a bottom stage reboiler
Refluxed Absorber Tray Section and an overhead condenser
Distillation Tray Section with both reboiler and
condenser
There are 12 ideal stages in the De-pentanizer, 10 in the tray section plus
the Reboiler and Condenser.
1. Double-click on the Distillation Column icon in the Object Palette.

Distillation Column icon
The first Input Expert view appears.
5
2. Input the following information into the first input expert page.
In this field... Enter...

Column Name De-Pentanizer
Input Expert is a tool that Inlet Stream Feed
help to ensure all required
information is entered. Once Inlet Stage 5_Main TS
you are familiar with the Condenser Energy Stream Cond1 Q
column view, they can be
Condenser Type Full Reflux
turned off in your preference
file. Overhead Vapour Outlet Ovhd Vap Prod
Reboiler Energy Stream Reb1 Q
Bottoms Liquid Outlet Pentanes+
Figure 1
3. Click the Next button to proceed to the next page.
The Next button is only available when all of the necessary information
has been supplied.
4. Supply the following information to the Pressure Estimates page.

Condenser Pressure 650 kPa (94 psia)
Reboiler Pressure 700 kPa (101 psia)
6
Figure 2
5. Click the Next button to proceed to the next page.

6. On this page, enter the temperature estimates. The Condenser
temperature estimate will be 10°C (50°F), and the reboiler
temperature estimate will be 120°C (248°F).
Temperature estimates are not required for the column to solve but they
will aid in convergence.
Figure 3
7. Click the Next button to continue.
7
8. On the last page supply a value of 2 for the Reflux Ratio.
Figure 4
9. Click the Done button. HYSYS will open the Column Property View
window. Access the Monitor page on the Design tab.
Figure 5
Two specifications must be filled so that the Degrees of Freedom are 0.

You already have specified the Reflux Ratio. In this case you will use the
i-C5 purity instead of the Ovhd Vap Rate.
8
10. You need to deactivate the Ovhd Vap Rate by clicking on the Active
check box. Now only the Reflux Ratio checkbox is checked and the
Degrees of Freedom is 1.
11. To add a specification, click the Add Spec… button.
Figure 6
12. Select Column Component Fraction and click the Add Spec(s)…
button.
13. Provide the following information.

Name iC5 Comp Fraction
Target Type Stream
Draw Pentanes+ @Col1
Basis Mole Fraction
Spec Value 0.27
Components i-Pentane
9
Figure 7
14. When you are done, close the window to go back to the Monitor
page of the Design tab. Check the Active ratio button for the Comp
Fraction iC5 specification.
15. Click the Run button to begin calculations.
Once the column has converged, you can view the results on the
Performance tab.
Figure 8
What is the flowrate of the Pentanes+ stream?___________________________
10
Adding the Second Column: De-Butanizer

The De-butanizer column is also modelled as a distillation column, with
17 stages, 15 trays in the column, plus the reboiler and condenser. The
objective of this column is to produce a bottom product that has a molar
fraction of butanes (both i-C4 and n-C4) of 0.97.
1. Double click on the Distillation Column button on the Object

Palette and enter the following information:

Connections
Name De-butanizer
No. of Stage 15
Feed Stream/Stage Ovhd Vap Prod / 9
Condenser Type Full Reflux
Overhead Vapour Product Light Products
Bottom Product Butanes
Condenser Duty Cond2 Q
Reboiler Duty Reb2 Q
Pressure
Condenser 550 kPa (80 psia)
Reboiler 600 kPa (87 psia)
Temperature Estimates
Condenser -20°C (-4°F)
Reboiler 50°C (122°F)
Specification
Reflux Ratio 2
Component Recovery (i-butane) 0.97
What is the Molar Flow of Light Products stream?________________________

And the flowrate of i-C4 and n-C4 in Light Products? i-C4_____, n-C4_____
What is the molar fraction of butanes in Light Products?__________________
What is the recovery of butanes?_______________________________________
Save your case!
11
Using the Spreadsheet

To answer the previous questions you had to add the fraction of i-C4 and
n-C4 somewhere outside the simulation. HYSYS has a Spreadsheet
operation, which allows you to import stream or operation variables,
perform calculations, and export calculated results.
You are going to create a spreadsheet to calculate the molar fraction

both of pentanes and butanes in their respectively streams and their
recoveries.
1. To install a Spreadsheet and display its property view, double-click

on the Spreadsheet icon in the Object Palette.
2. Click the Add Import button, and the Select Import view will appear.
Spreadsheet icon
3. Choose the Object, Variable, and Variable Specific as shown:
In this field... Select...

Object Feed
Variable Comp Molar Flow
Variable Specifics i-Pentane
Figure 9
Notice that HYSYS assigned the imported variable to Spreadsheet cell

A1, by default. Change this cell location to B1. The reason for doing so
will become apparent on the Spreadsheet tab.
12
4. Before continuing you need to add more rows to the spreadsheet.

Do this by clicking in the Parameters tab and entering 16 in the
Number of Rows field.
5. In many ways, the HYSYS Spreadsheet behaves similarly to
commercial spreadsheets packages; you enter data in the cells, and
calculated results are returned. You can introduce the variables
directly in the spreadsheet. Change to the Spreadsheet tab.
6. Right-click in the cell where you want to import the variable. Do this
in cell D1. The following view will appear:
Figure 10
7. Select Import Variable.

8. Select the Object, Variable, and Variable Specific as shown:
In this field... Select...

Object Feed
Variable Comp Molar Flow
Variable Specifics n-Pentane
9. Enter the following names in the spreadsheet:

A3 PENTANES+
A4 iC5 Frac
A5 nC5 Frac
A6 iC5 Flow
A7 nC5 Flow
A10 iC4 Ovhd Vap Flow
A12 BUTANES
A13 iC4 Frac
A14 nC4 Frac
A15 iC4 Flow
A16 nC4 Flow
D5 Pentane Frac
D7 Pentane Recovery
13

D14 Butane Frac
D16 Butane Recovery
10. Complete the rest of the spreadsheet by importing the following

values into the specified cell.
Cell Object Variable Variable Specifics

B4 Pentanes+ Comp Mole Frac i-Pentane
B5 Pentanes+ Comp Mole Frac n-Pentane
B6 Pentanes+ Comp Molar Flow i-Pentane
B7 Pentanes+ Comp Molar Flow n-Pentane
B10 Ovhd Vap Prod Comp Molar Flow i-Butane
B13 Butanes Comp Mole Frac i-Butane
B14 Butanes Comp Mole Frac n-Butane
B15 Butanes Comp Molar Flow i-Butane
B16 Butanes Comp Molar Flow n-Butane
D10 Ovhd Vap Prod Comp Molar Flow n-Butane
Figure 11
You can move to a cell by clicking it, or by clicking the arrow keys.
The values are those corresponding the variable named to the left.
Import them. Fractions and Flows are in molar basis
14
11. To enter the formulas place the cursor on the cell and write it.
Remember to use a "+" symbol before mathematical operations.
Enter the following formulas
Cell Formula
D5 +b4+b5
D7 +(b6+b7)/(b1+d1)*100
D14 +b13+b14
D16 +(b15+b16)/(b10+d10)*100
Figure 12
Clicking in the Function Help button you can see all the operations that
are available in HYSYS.
Once the cell is completed, you can export the variable to the
simulation. This is done by clicking with the right button in the cell. The
spreadsheet allows you to use your own correlations, for example, for
pressures drop, etc.
What is the pentanes recovery?________________________________________

And that of butanes?__________________________________________________
Save your case!

15
Linking Templates
Once you have completed the recovery fractionation train you can link it
to the Propane Loop Template, and use the Propane Loop to refrigerate
the De-butanizer.
The duty of the Condenser, Cond2 Q, in this module, will be linked to

the duty of the Chiller, Chill-Q in the Propane Refrigeration Loop
template.
1. Double-click on the Sub-Flowsheet icon on the Object Palette.

2. Select the Read an Existing Template button.
3. Open the template file saved in the Propane Refrigeration Loop
Sub-Flowsheet icon module, C3loop.tpl.
4. The Sub-Flowsheet Operation view appears. Click the Sub-
Flowsheet Environment button at the bottom of the view.
5. The PFD of the Propane Refrigeration Loop appears. Double-click
on the energy stream of the Chiller, Chill-Q.
6. Delete the Heat Flow value of the stream by pressing the DELETE key
on the keyboard.
To connect the template
without conflicts, the heat
Figure 13
flow value of Chiller-Q is
deleted in the template prior
to connecting the internal
and external energy stream.
This is to prevent over
specifying the flowsheet; if
the heat flow value of
Chiller-Q is not deleted, a
consistent error will occur as
there are two different heat
flow values for the same
energy stream.
7. Close the Energy stream view. Click the Enter Parent Simulation
Environment icon on the toolbar to return to the Sub-Flowsheet
Operation view.
Enter Parent Simulation
Environment icon
16
8. In the Feed Connections to Sub-Flowsheet group, connect the

External Stream, Cond2 Q, to the Internal Stream Chill Q.
Figure 14
Once the connection is complete, both streams, (Internal and External)

will have the same name and heat flow value, that of the External
stream.
What is the flowrate of propane in the Refrigeration Loop?________________
What is the compressor duty? _________________________________________
17
18 Advanced Modelling
Advanced Modelling
The Column is a special type of SubFlowsheet in HYSYS. SubFlowsheets
contain equipment and streams, and exchange information with the
Parent Flowsheet through the connected streams. From the Main
Environment, the Column appears as a single, multi-feed multi-product
operation. In many cases, you can treat the Column in exactly that
manner.
The Column SubFlowsheet provides a number of advantages:
• Isolation of the Column Solver. The Column Build Environment

allows you to make changes and focus on the Column without the
re-calculation of the entire Flowsheet.
• Optional use of different Fluid Packages. HYSYS allows you to
specify a unique (different from the Main Environment) fluid
package for the Column SubFlowsheet. This may be useful in
instances when a different fluid package is better suited to the
Column (Gas Plant using PR may contain an Amine Contactor
that needs to use the Amines Property Package), or the Column
does not use all of the components used in the Main Flowsheet
and so by decreasing the number of components in the column
you may speed up column convergence.
• Construction of custom templates. In addition to the default
column configurations which are available as templates, you may
define column setups with varying degrees of complexity.
Complex custom columns and multiple columns may be
simulated within a single SubFlowsheet using various
combinations of SubFlowsheet equipment. Custom column
examples include replacement of the standard Condenser with a
Heat Exchanger, or the standard kettle reboiler with a
thermosyphon reboiler.
• Ability to solve multiple towers simultaneously. The Column
SubFlowsheet uses a simultaneous solver whereby all operations
within the SubFlowsheet are solved simultaneously. The
simultaneous solver permits the user to install multiple
interconnected columns within the SubFlowsheet without the
need for Recycle blocks.
The presence of the green "Up Arrow" button in the Button Bar and the
Environment: Name (COL1) indicates that you are in the Column
SubFlowsheet.
It is also written at the right in the Icons bar.
18
Advanced Modelling 19
You can enter the Column SubFlowsheet by clicking the Column

Environment button on the Column Property View. Once inside the
Column Environment you can return to the Parent Environment by
clicking either the Parent Environment button on the Column Runner
view or the Enter Parent Simulation Environment icon in the toolbar.
Enter Parent Simulation

Environment icon
Exploring with the Simulation
Exercise 1
Study the influence of the number of stages on the propane fraction in
bottoms. Increase the number of stages until the propane recovery in
the tower overhead is higher than 0.995.
Exercise 2
What is the Molar Enthalpy for streams Reflux and Boilup?
Reflux___________________________, Boilup____________________________
19
20 Advanced Modelling
20
Oil Characterization 1
Oil Characterization
1
© 2004 AspenTech. All Rights Reserved
1.3.4 Oil Characterization.pdf
2 Oil Characterization
Workshop
The petroleum characterization method in HYSYS will convert
laboratory analyses of condensates, crude oils, petroleum cuts and coal-
tar liquids into a series of discrete hypothetical components. These
petroleum hypocomponents provide the basis for the property package
to predict the remaining thermodynamic and transport properties
necessary for fluid modelling.
HYSYS will produce a complete set of physical and critical properties for
the petroleum hypocomponents with a minimal amount of
information. However, the more information you can supply about the
fluid, the more accurate these properties will be, and the better HYSYS
will predict the fluid's actual behaviour.
In this example, the Oil Characterization option in HYSYS is used to

model a crude oil. The crude is the feed stock to a Pre-heat Train,
followed by the Atmospheric Crude Column, which will be modelled in a
subsequent module.
Learning Objectives
Once you have completed, you will be able to use the Oil
Characterization option in HYSYS.
Prerequisites
Before beginning this module you need to understand the basics of the
Fluid Package (refer to Getting Started).
2

Before you can start the actual characterization process, you will first
learn how to modify the Unit Set which is very useful in a Refinery. For
example, you can work with barrels/day instead of m3/h.
1. Start a new case.
Modifying the Unit Set

HYSYS allows you to have your own set of units. For this case, the unit
for Standard Density will be API_60 instead of kg/m3 as in the SI.
2. From the Tools menu select Preferences, and go to the Variables

tab.
3. Select the SI unit set as the default.
4. You cannot edit the default set, but you can make a copy of it by
clicking the Clone button.
5. Rename the cloned unit set to Refinery.
6. Move the cursor to the Standard Density cell.
7. Select API_60 from the drop-down list.
Figure 1
3
8. Close the Preferences view.

1. On the Fluid Packages tab, click the Import button and select the
fluid package you exported in Module 1: Refinery.
2. Highlight the Refinery Package and click the View button. We are
going to delete the components we do not need: C6 and C7+.
3. Go to the Components tab and highlight n-Hexane and click the
Remove button.
4. Do the same with the C7+.
5. Close this window to return to the Basis Environment.
6. Go to the Oil Manager tab and click the Enter Oil Environment
button. You could also click the Oil Environment icon on the
Basis Environment icon
toolbar. The Oil Characterization view displays.
Oil Environment icon

Oil Characterization
The petroleum characterization in HYSYS accepts different types of
information about the oil. The more information you can supply about
your sample, the more accurate the representation will be.
There are three steps involved in characterizing any oil in HYSYS:
1. Characterize the Assay

2. Generate Hypocomponents
3. Install the Oil in the Flowsheet
The minimum amount of information that HYSYS requires to

characterize an oil is:
• a laboratory distillation curve.

• at least one of the following bulk properties: Molecular Weight,
Density, or Watson K Factor.
4
Characterize the Assay

The assay contains all of the petroleum laboratory data, boiling point
curves, light ends, property curves and bulk properties. HYSYS uses the
supplied Assay data to generate internal TBP, molecular weight, density
and viscosity curves, referred to as Working Curves.
Assay Types
Accurate volatility characteristics are vital when representing a
petroleum fluid in your process simulation. HYSYS accepts the following
standard laboratory analytical assay procedures.
• True Boiling Point (TBP). Performed using a multi-stage batch

fractionation apparatus operated at relatively high reflux ratios.
TBP distillations conducted at atmospheric or vacuum conditions
are accepted by the characterization.
• ASTM D86. Distillation employing batch fractionation but
conducted using non-refluxed Engler flasks. Generally used for
light to medium petroleum fluids. HYSYS can correct for
barometric pressure or cracking effects. You must provide the
data on a liquid volume basis.
• D1160 distillation. Distillation employing batch fractionation but
conducted using non-refluxed Engler flasks. Generally used for
heavier petroleum fluids. Curves can be given at atmospheric
pressure or corrected for vacuum conditions. You must provide
the data on a liquid volume basis.
For all the distillation curves, • D86_D1160. This is a combination of the D86/D1160 distillation
you are required to enter at data types. You can correct for thermal cracking and enable
least five data points. vacuum distillation for sub-atmospheric conditions. You must
provide data on a liquid volume basis.
• ASTM D2887. Simulated distillation analysis from
chromatographic data. Reported only on a weight percent basis
at atmospheric conditions.
• Equilibrium Flash Vaporization (EFV). Involves a series of
experiments at constant atmospheric pressure, where the total
vapour is in equilibrium with the unvaporized liquid.
• Chromatographic Analysis. A gas chromatograph analysis of a
small sample of completely vaporized oil, analysed for paraffin,
aromatic and naphthenic hydrocarbon groups from C6 to C30.
Chromatographic analyses may be entered on a mole, mass or
liquid volume basis.
5
Light Ends
Light Ends are defined as pure components with low boiling points.
Components in the boiling range of C2 to n-C5 are most commonly of
interest.
HYSYS provides three options to account for Light Ends:
• Ignore. HYSYS will characterize the Light Ends portion of your

sample as hypocomponents. This is the least accurate method
and as such, is not recommended.
• Auto Calculate. Select this when you do not have a separate
Light Ends analysis but you want the low boiling portion of your
assay represented by pure components. HYSYS will only use the
pure components you have selected in the Fluid Package.
• Input Composition. Select this when you have a separate Light
Ends assay and your petroleum assay was prepared with the
Light Ends in the sample. HYSYS will provide a form listing the
pure components you selected in the Fluid Package. This is the
most accurate method of representation.
6
Bulk Properties
Bulk Properties for the sample may also be supplied. The bulk
properties are optional if a distillation curve or chromatograph have
been supplied.
• Molecular Weight. This is the Molecular Weight of the bulk

sample. It must be greater than 16.
• Mass Density. The mass density must be between 250 and 2000
kg/m3.
• Watson (UOP) K Factor. This must be between 8 and 15.
• Bulk Viscosity. Given at two reference temperatures, typically
37.7°C and 98.89°C (100°F and 210°F).
• The units for density can be mass density, API or specific gravity,
chosen from the drop down list in the Edit Bar
• The Watson K Factor is an approximate index of paraffinicity.
Physical Property Curves

HYSYS accepts different types of physical property curves
• Molecular Weight Curve

• Density Curve
• Viscosity Curve
Physical property analyses are normally reported from the laboratory

using one of the following two conventions.
• An Independent assay basis, where a common set of assay

fractions is NOT used for both the distillation curve and the
physical property curve.
• A Dependent assay basis, where a common set of assay
fractions is utilized for both the distillation curve and the physical
property curve.
As you supply more information to HYSYS, the accuracy of the

Petroleum Characterization increases. Supplying any or all of the bulk
molecular weight, bulk density, or bulk Watson K factor will increase the
accuracy of your pseudo component properties. You can also supply
laboratory curves for molecular weight, density, and/or viscosity, which
will increase the accuracy further.
7
Adding Assay Data

1. On the Assay tab of the Oil Characterization view, select the Add
button to display the Input Data tab of the Assay view.
2. In the Name cell, change the assay name to Crude.
3. We will use three types of data here. Use the drop-down lists to
select the following in the Assay Definition group box.
For this option... Select...

Bulk Properties Used
Assay Data Type TBP
Light Ends Input Composition
4. Select the Distillation radio button in the Input Data group box.
5. Select the Assay Basis as Liquid Volume (use the drop-down menu).
Click the Edit Assay button; this will allow you to enter the assay
information below.
Assay Percent Temperature

0.0000 -12°C (10.4°F)
4.000 32°C (90°F)
9.000 74°C (165°F)
14.00 116°C (241°F)
20.00 154°C (310°F)
30.00 224°C (435°F)
40.00 273°C (523°F)
50.00 327°C (620°F)
60.00 393°C (740°F)
70.00 450°C (842°F)
76.00 490°C (914°F)
80.00 516°C (961°F)
8
6. Select the Light Ends radio button and enter the data given below:
Light Ends Composition

Methane 0.0065
Ethane 0.0225
Propane 0.3200
i-Butane 0.2400
n-Butane 1.7500
i-Pentane 1.6500
n-Pentane 2.2500
You need to enter the light components in the Fluid Package for them to
be available to the Oil Manager.
7. Select the Bulk Props radio button to enter the Bulk information.
8. In the Standard Density cell, enter an API Gravity of 29 for the crude.
9. Once you have entered all of the data, click the Calculate button.
The status message at the bottom of the Assay view will display
Assay Was Calculated.
Once the Assay is calculated, the working curves are displayed on the
Plots and Working tabs. The working curves are regressed and
extrapolated from the Assay input. From the user-supplied data, HYSYS
generates curves for NBP, molecular weight, mass density, and viscosity.
These working curves are used in determining the properties of the
hypocomponents generated in the Blend step.
10. Close the view and return to the Oil Characterization view. You
should still be on the Assay tab of the view. Notice that all of the
buttons on the view are now accessible.
Hypocomponent Generation/Blending the Oil

The Cut/Blend characterization in HYSYS splits the internal working
curves for one or more assays into hypocomponents. The Blend tab of
the Oil Characterization view provides two functions, Cutting the Oil
into Hypocomponents and Blending two or more Assays into one set of
hypocomponents.
9
Cut Ranges
You have three choices for the Cut Option Selection:
• Auto Cut. HYSYS cuts the assay based on internal values
Range Cuts
37.78 - 425°C (100 - 797°F) 28 (4 per 37.78°C/100°F)
425 - 650°C(797 - 1202°F) 8 (2 per 37.78°C/100°F)
650 - 871°C(1202 - 1600°F) 4 (1 per 37.78°C/100°F)
• User Points. You specify the number of hypocomponents

required. HYSYS proportions the cuts according to an internal
weighting scheme.
Cutpoint Range Internal Weighting

IBP - 425°C(IBP - 797°F) 4 per 37.78°C/100°F
425 - 650°C(797 - 1202°F) 2 per 37.78°C/100°F
650°C - FBP(1202°F - FBP) 1 per 37.78°C/100°F
• User Ranges. You specify the boiling point ranges and the
number of cuts per range.
Cutting the Assay

Once the Assay has been calculated, you can cut the Assay into
individual hypocomponents.
1. Move to the Cut/Blend tab of the Oil Characterization view. Select

the Add button to create a new Blend.
2. In the Name cell, change the name from the default, Blend-1 to
Crude.
3. From the list of Available Assays (there should only be one), select
Crude and click the Add button. This will add the Assay to the Oil
Flow Information table and a Blend (Cut) will automatically be
calculated. The Blend is calculated using the default Cut Option,
Auto Cut.
4. Instead of using the default Auto Cut option, change the Cut Option
Selection to User Ranges. Select 20 cuts for a Cut Point temperature
of 425°C (800°F), 5 cuts at 620°C (1150°F), and 2 cuts for the range
up to 720°C (1328°F).
10
5. Click the Submit button to accept the ranges and cut the oil.
Figure 2
The results of the calculation can be viewed on the Tables tab of the
Blend view.
Go to the composite plot tab to verify the calculated curve matches the
input one.
Installing the Oil in the Flowsheet

The final step of the characterization is to transfer the hypocomponent
information into the Flowsheet.
1. Close the Blend view, and move to the Install Oil tab of the Oil
Characterization view.
2. The Blend, Crude, appears in the Oil Install Information group.
11
3. In the Stream Name column, enter the name Raw Crude to which
the oil composition will be transferred.
Figure 3
HYSYS will assign the composition of your calculated Oil and Light Ends
into this stream, completing the characterization process.
Return to the Basis Environment by clicking the Return to Basis

Environment button.
When you return to the Basis Environment, the hypocomponents that

you have generated in the Oil Characterization are placed in the current
fluid package. You can view the fluid package and examine the
individual hypothetical components which make up your oil.
Hypotheticals are named according to the blend group to which they
belong and to their normal boiling point. For example, a component
named NBP[0]118* was generated by the first blend in the case and has a
boiling point of 118°F.
Save your case!
12
Answer the following questions:
What are the two lowest boiling points for the hypocomponents? _________
What are the Ideal Liquid Density for those hypocomponents? ___________

Exercise 1
HYSYS allows you to introduce a Sulphur Curve as a User Property. This
is done in the Oil Environment. Go to the User Property tab of the Oil
Characterization and click the Add button. All the default options will be
used in this case except for the Mixing Basis fields. Sulphur is quoted on
a weight basis, so select Mass Fraction from the drop-down list. Click on
the Edit component user property values button located at the bottom
of the User Property view. The User Property Value appears. Enter a
value of 0 in the User Property Value cell for all the light products (C1,
C2, C3, i-C4, n-C4, i-C5, and n-C5). Click Submit when finished.
You can also provide a descriptive Name for the property, such as
Sulphur.
13
Now that you have created it, you can return to the Assay Property view,
User Curves tab, and add it to your Assay. The view displayed should
look like this:
Figure 4
Click the Edit button to enter the sulphur curve data.
Assay (%) Sulphur Value

16 0.083
27 0.212
36 1.122
52 2.786
64 2.806
72 3.481
85 4.984
90 5.646
Click the Calculate button on the Assay view. You can now print the new
plots, especially that of the sulphur, to analyse them.
Tip: Go to the Blend tab,
and then to the Composite
Plot.
Save your case!
14

Exercise 2: Heavy Oils Characterization
Heavy oils are traditionally defined as those whose specific gravity is
lower than 20 API and viscosity is higher than 1000 cP. In the past,
commercialization and transportation of heavy oils has not been very
profitable, but recently developed technologies are now making them
much more attractive.
One of the inherent practical difficulties of heavy oils is their high

viscosities. Transportation of heavy oil for instance is difficult due to the
high energy losses and pressure drops generated by the large friction
effects.
In order to facilitate their transport, an attractive option could be to mix

the heavy oil with a lighter one––often termed a “diluent”. This way the
Another way to transport resulting mixture’s density and viscosity could become much more
heavy oil would be to
operate at elevated
appropriate for the transportation and further commercialisation of the
temperatures however this oil.
can have adverse effects
like increasing the solubility
of the water in the crude oil,
If we have a good representation of both the heavy oil and the diluent(s)
as well, some materials may in our simulation it is possible to model different scenarios and quickly
lose mechanical strength at evaluate them. HYSYS can thus be an invaluable tool in helping us to
elevated temperatures.
make the best decision!
In this example, we will use our existing crude from the previous
exercise (Raw Crude) as a diluent and mix it with a heavy oil of 15 API, in
order to see what the new calculated properties of the resulting mixture
are. In characterizing the heavy oil, we have its bulk density (15 API), a
TBP curve, and will also use viscosity curves provided by the lab.
Remember: API density is
inversely proportional to
Specific Gravity so the lower
141.5
it is, the higher the density API gravity ( degrees ) = ---------------------------------------------------------------
- – 131.5
value. 60
Specific Gravity at ----------
60F
15
How HYSYS Calculates Oil Viscosity

HYSYS automatically selects the model best suited for predicting the
phase viscosities of the system under study. The model selected is from
one of the three available in HYSYS: a modification of the NBS method
(Ely and Hanley) for vapours and light hydrocarbons, Twu's model for
Adapted from HYSYS 3.2 heavy hydrocarbons, or a modification of the Letsou-Stiel correlation for
Simulation Basis Guide - non-ideal liquids.
Appendix A.5 Physical and
Transport Properties.
When supplied viscosity assays are used to regress the parameters used
in the viscosity correlations. The parameters (known as shape factors)
are specific to each hypothetical component.
Average crude oils (including water and acid gases) are well represented
by the modified NBS method, however the Twu method is found to do a
better job of predicting the viscosities of heavier hydrocarbons
(NBP>155oF).
The method used for the mixed oil stream will depend on its
composition (NBP).
Exercise
For a proper characterization of a heavy oil it is crucial to know its bulk
density and its viscosity at two different temperatures; providing the
Watson K factor is also recommended.
Physical Property curves can improve the accuracy of your oil

characterization, particularly when combined with bulk property data.
The hypothetical component physical properties will be correlated so
that the property curves are matched. If the user does not supply
property curves HYSYS Oil Manager must generate its own internal
curves for density and viscosity using API recommended correlations
and known bulk property data.
16
Physical Property Curves

Physical property curves are normally reported from the laboratory
using one of the following two conventions:
Adapted from HYSYS 3.2 • An Independent assay basis, where different sample assays are
Simulation Basis Guide - done––one for the distillation curve, and a different one for each
Characterization Assays of the physical property curves. The assay fractions will likely be
different for each curve.
• A Dependent assay basis, where a common set of assay
fractions is used for both the distillation curve and the physical
property curves.
Calculated hypothetical component physical properties are average

values for the given boiling point range, and hence are midpoint values.
Distillation data reports the temperature when the last drop of liquid
boils off for a given assay range and therefore distillation is an endpoint
property. Since all dependent input property curves are reported on the
same endpoint basis as the distillation curve, they are converted by
HYSYS to a midpoint basis. Independent property curves are not altered
in any manner as they are already defined on a midpoint basis.
As with distillation curves, there is no limit to the number of data points

you provide. The order in which you input the points is not important,
as HYSYS sorts the input data. A minimum of five data points is required
to define a property curve in HYSYS. It is not necessary that each
property curve point have a corresponding distillation value.
Using bulk properties. If a bulk molecular weight or mass density is

going to be supplied, then the corresponding Molecular Weight or
Density working curve generated from your input is smoothed to ensure
a match with the bulk property. If you do not enter bulk properties, then
they are calculated from the unsmoothed working curves.
1. Enter the Assay data for the Heavy Oil.
From the existing case, go to the Oil Environment and add a new Assay
with the following data:
• S. Joaquin Crude
• Standard density 15.3 API
• Viscosity @ 70 F 2040 cSt
• Viscosity @ 100 F 337 cSt
17
TBP Kinematic Viscosity Kinematic Viscosity

T (C) @ 100 F @ 210 F
%LV
0.408 0.447 0.446 0.326
0.446 70
1.59 0.631 0.854 0.343
0.854 100
2.38 1.03 2.444 0.430
2.444 150
5.18 1.85 4.824 0.592
4.824 190
5.81 3.89 10.004 0.860
10.004 235
9.09 9.01 15.814 1.340
15.814 280
40.4 144 24.904 2.250
24.904 343
65.304 20.3
65.304 565
2. Create a new blend for the heavy oil.
There are two methods for blending oils in HYSYS:
• If the 2 oils are blended within Oil Manager only 1 set of hypo
components is created, representing the blended mixture.
• However, when different crudes are coming from very different
sources, it is a good idea to blend them separately (creating two
different blends) and mix them in the Simulation Environment
instead. The reason for this is that in blending the crudes within
Oil Manager, HYSYS must generate a set of common
hypocomponents that can well predict the properties both of the
source oils––not necessarily a reasonable expectation for very
different crudes.
The S Joaquin Crude in this case differs greatly from the "Raw Crude" we
created earlier in this module (both in NBP and in physical properties).
For this reason the user is encouraged to create another blend, instead
of creating a common set of hypocomponents from the two crudes.
Optional Exercise
Test this out yourself––after completing this exercise in full, create a new
blend in the Oil Manager that is a mix of both assays. Then compare the
properties of this blend with the those of the mixed stream created in
Step #6 below.
18
3. Validate the generated pseudo/hypo components:
After you've created the blend, go to the Composite Plot tab and
compare the generated curves with the input data. (You can change the
scale of the graph in order to have a better view of the viscosity by right
clicking on the plot).
4. Install the S Joaquin oil in the PFD. Go to the Install tab of the Oil
Manager and enter the stream name "S Joaquin".
5. Enter the Simulation Environment and view the S Joaquin stream.
What is the current API density of the SJoaquin stream at1 bar and 60 F?
____________________________________________________________________
You can see the importance of using the bulk density in the
characterization of the oil: go back to the Oil Environment and delete
the value that is entered there.
Go back to the Simulation Environment.
What is the calculated SJoaquin density? _______________________________

And the Raw Crude one? ______________________________________________
Restore the value 15 API for the bulk density of the heavy oil assay in the
Oil Environment before continuing.
6. Mix the Heavy Oil and Diluent:
As mentioned, to make a crude lighter for transporting by pipeline,

Heavy Oil is mixed with a diluent such as naphtha or a lighter crude oil.
We want to transport 600000 Kg/h of San Joaquin Crude but in this

example our transportation system will only accept crudes starting from
21 API. We have studied several scenarios and the best one seems to be
mixing the heavy Oil with another one, the Raw Crude.
What is the minimum quantity of Raw Crude we need to add? (Hint: Use an
Adjust) _____________________________________________________________
Is the viscosity of the mixed stream better for transportation now? _______
19
Save this case for your records and load the one we created prior to the
Exploring the Simulation exercise. The rest of the course materials are
built using the lighter "Raw Crude" stream as the oil source.
20
Pre-Heat Train 1
Pre-Heat Train
1
1.3.5 Pre-Heat Train.pdf
2 Pre-Heat Train
Workshop
In this module you will continue to develop your ability to create HYSYS
simulations. Here, we will continue with the HYSYS case that was started
in the previous module.
Typically, after some preheating the first unit that a crude oil will pass
through is the desalter. This unit is responsible for removing salt, grit,
and other impurities from the oil. This unit is normally placed along the
Pre-Heat Train, needed to recover energy from products and to raise the
temperature of the oil stream before it enters the Atmospheric Crude
Column. In this module, you will learn how to build a Heat Exchanger in
HYSYS.
Logical operations and the Databook are also introduced in this module.
Learning Objectives
• Install and converge Heat Exchangers.

• Understand Logical Operations (Balances and Adjusts).
• Use the Case Study tool to perform case studies on your
simulation.
Prerequisites
Before beginning this section you need to complete the Oil
Characterization module.
2
Process Overview
4 Pre-Heat Train

For this module you will continue building on the case you worked on in
the previous module by adding a Heater Exchanger, a Desalter, two
simple Heaters and a Pre-Flash Separator, to complete a simple pre-heat
train.
1. Open the case you saved at the end of the previous module (Oil
Characterization).
Only the composition is known for stream Raw Crude. Add the following
data to it:

To add components to the
mass Flow 6e+05 kg/h (1.3e+06 lb/hr)
simulation, you must enter
the Basis Environment by
clicking the Basis
Environment icon.
Adding a Stream
You need to add a Water stream. Before adding it, you need to add Water
to the Fluid Package. Afterwards, create a material stream called Water,
at 15°C and a mass flow rate of 21600 kg/h (100% water). If you are using
Enter Basis Environment
icon field units it is 59°F and 47600 lb/hr.
Adding a Mixer
A mixer is added to combine the raw crude with water to represent the
oil sample entering the refinery. Downstream the free water is knocked
out with the three - phase separator.
Mixer icon
Add a Mixer with the following values:

Connections
Name Mixer
Inlets Raw Crude
Water
Outlets To Heater
4
Pre-Heat Train 5

Parameters
Pressure Assignment Equalize All
Adding a Heater
The Pre-Heat Train consists of various heat exchangers. A heater will be
added to account for them and raise the temperature to 65°C (149°F).
Heater icon
Add a Heater, we will use a Shell and Tube Heat Exchanger later.
1. Complete the first view with the following names.

Connections
Name Simple Heater 1
Inlet To Heater
Energy H1 Q
Outlet To Heat Exchanger
Fluid Package Refinery
Figure 1
2. Enter a Delta P of 50 kPa (7.25 psi) in the Parameters view.

3. In the worksheet specify a temperature of 65°C (150°F) for stream To
Heat Exchanger.
5
6 Pre-Heat Train
Adding a Stream
Before adding the Heat Exchanger, we need to define the Pumparound
stream, which will exchange heat with the Raw Crude.
1. Add a Material Stream.

2. Change the stream name to Hot Pumparound.
At this stage, we don’t know the pumparound composition. As a starting

point, we are going to use the same composition as the Raw Crude. Of
course, later, when we build the Crude Tower, we will change it to the
actual stream.
3. Click the Define from Other Stream button on the bottom of the
Hot Pump Around Stream view.
4. Highlight Raw Crude in the Available streams list.
5. Uncheck all the Copy Stream Conditions boxes except for
Composition. You will be specifying your own conditions in the next
step.
Figure 2
6. Click the OK button to return to the previous menu and enter the
following values in the Hot Pump Around stream: Temperature 180
C, Pressure 200 kPa and Std Ideal Liq Vol Flow of 175 m3/h. (356°F,
30 psia and 2.6e+04 barrel/day if you are using field units).
6
Pre-Heat Train 7
Adding the Heat Exchanger

A Heater Exchanger is added to continue heating the crude stream. A
shell and tube heat exchanger will be used to preheat the crude with the
Pumparound, which is at 180°C (356°F).
The Heat Exchanger performs two-sided energy and material balance

calculations. The Heat Exchanger is capable of solving for temperatures,
pressures, heat flows (including heat loss and heat leak), material stream
flows and UA.
1. Double-click on the Heat Exchanger icon in the Object Palette.

2. On the Connections page, enter the following information.
Heat Exchanger icon In this cell... Enter...

Connections
Name Heat Exchanger
Tube Side Inlet To Heat Exchanger
Tube Side Outlet To Desalter
Shell Side Inlet Hot Pumparound
Shell Side Outlet Cold Pumparound
Figure 3
7
8 Pre-Heat Train
3. Switch to the Parameters page. Complete the page as shown in the

following figure. The pressure drops for the Tube and Shell sides, in
field units, will be 35 kPa (5 psi) and 5 kPa (0.7 psi), respectively.
Figure 4
The Exchanger Design models are defined as follows:
• Weighted. The heating curves are broken into intervals, which

then exchange energy individually. An LMTD and UA are
calculated for each interval in the heat curve and summed to
calculate the overall exchanger UA. The Weighted method is
available only for Counter-Current exchangers.
• Endpoint. A single LMTD and UA are calculated from the inlet
and outlet conditions. For simple problems where there is no
phase change and Cp is relatively constant, this option may be
sufficient.
4. Choose Exchanger Design (Weighted) in the Heat Exchanger Model.
5. Go to the Specs page.
In order to solve the Heat Exchanger, unknown parameters (flows,

temperatures) are manipulated by the solver. Each parameter
specification will reduce the degrees of freedom by one. The number of
constraints (specifications) must equal the number of unknown
variables. When this is the case, the degrees of freedom will be equal to
zero, and a solution will be calculated.
8
Pre-Heat Train 9
Two specifications are needed for this exchanger:
• Heat Balance = 0. This is a Duty Error specification and is

needed to ensure that the heat equation balances. This is a
default specification that is always added by HYSYS so you do
not need to supply it.
• Min Approach = 30°C (54°F). This is the minimum temperature
difference between the hot and the cold stream.
You can have multiple Estimate specifications. The Heat Exchanger will
only use the Active specifications for convergence.
6. You will first need to deactivate the UA specification. To do this,

remove the X from the Active checkbox for the UA specification so
that the view is the same as below.
Figure 5
7. To add a specification, click the Add button, the Exchanger

Specification view displays.
8. Provide the following information using the drop-down list to
specify the Type and Pass:

Name Temp Approach
Type Min Approach
Pass Overall
Spec Value 30°C (54°F)
9
10 Pre-Heat Train
When you change the type of specification, the view will change
accordingly. Once all the information has been provided, the view will
be as below. Close the Temp Approach window.
Figure 6
The completed heat exchanger Specs page should look like this:
Figure 7
10
Pre-Heat Train 11
Adding the Desalter

The Three-Phase Separator divides the vessel feed into vapour, light
liquid and heavy liquid (Aqueous) phases.
1. Add a Three-Phase Separator with the following information.

Three-Phase icon Connections
Name Desalter
Inlet To Desalter
Vapour Ovhd Vapour
Light Liquid Crude
Heavy Liquid Desalter Water
Figure 8
What is the Molar Flow rate of Crude?__________________________________

What is the Molar Flow rate of Desalter Water?__________________________
11
12 Pre-Heat Train
Finishing the Simulation

You need to add the last three units before the crude enters the
Atmospheric Column: two heaters and a Preflash separator to reduce
the light components in the feed. Since you already know how to use
shell and tube heat exchangers, we will simulate these heaters in a
simplified mode.
Adding the First Heater

Add a Heater with the following values:

Connections
Name Simple Heater 2
Inlet Crude
Outlet To Preflash
Energy H2 Q
Parameters
Delta P 375 kPa (54 psi)
Worksheet
To Preflash Temperature 175°C (347°F)
The Delta P represents the result of the pressure drop along the various
heaters.
Adding the Pre Flash

Click on the Separator icon from the Object Palette.

Separator icon Connections
Name Pre-Flash
Inlets To Preflash
Vapour Outlet Light Prod
Liquid Outlet Bttm Liq
12
Pre-Heat Train 13
Adding the Last Heater

Add a Heater with the following values:

Connections
Name Furnace
Inlet Bttm Liq
Outlet ATM Feed
Energy H3 Q
Parameters
Delta P 250 kPa (36 psi)
Worksheet
ATM Feed Temperature 400°C (752°F)
Save your case!
Adding the Balance

The Balance operation provides a general-purpose heat and material
balance facility. There are different Balances available in HYSYS.
• Mole. An overall balance is performed where only the molar flow

of each component is conserved. Outlet streams will have the
same molar flow rate and composition as the inlet stream, but will
contain no vapour fraction, temperature, or pressure values.
• Mass. An overall balance is performed where only the mass flow
is conserved. The outlet stream will contain no composition,
vapour fraction, temperature, or pressure.
• Heat. An overall balance is performed where only the heat flow is
conserved.
• Mole and Heat. An overall balance is performed where the heat
and molar flow is conserved.
13
14 Pre-Heat Train
Look at the Vapour Fraction for stream To Desalter. The feed to the
Desalter has to be liquid, in this case it is, but it could change with the
pressure. The stream parameters are calculated so there is no way you
can force the stream to calculate a bubble point. Adding a Mole Balance
allows you to create a second steam with the same molar flowrate and
composition as To Desalter, but no vapour fraction, temperature or
pressure.
1. Double-click on the Balance icon in the Object Palette.

2. Add the following information

Connections
Balance icon Name Bubble Point
Inlet Streams To Desalter
Outlet Streams Bubble Temperature
Parameters
Balance Type Mole
3. Specify a Pressure of 915 kPa (133 psia) for the stream Bubble
Temperature.
4. Set the Vapour Fraction to calculate the bubble point temperature.
Up to what Temperature can the Feed be heated in the Pre-heat Train so that
it remains liquid?____________________________________________________
Adding the Adjust

The Adjust operation is a Logical Operation: a mathematical operation
rather than a physical operation. It will vary the value of one stream
variable (the independent variable) to meet a required value or
specification (the depend variable) in other stream of operation.
We are going to use this tool to optimize the heating-train, by specifying

the Flowrate of Light Prod in the Pre-Flash, which depends on the
temperature of the feed stream.
The Adjusted Variable must always be a user specified value.
14
Pre-Heat Train 15
1. Double-click on the Adjust icon in the Object Palette; the Adjust

property view displays.
Figure 9
Adjust icon
2. Click the Select Var… button in the Adjusted Variable group to open
the Variable Navigator.
3. From the Object List select To Preflash. From the Variable List,
which is now visible, select Temperature.
Figure 10
Always work left to right in the Variable Navigator. Don't forget you can
use the Object Filter on the right-hand side when the Object list is large.
15
16 Pre-Heat Train
4. Click the OK button to accept the variable and return to the Adjust
property view.
5. Click the Select Var button in the Target Variable group.
6. Select Light Prod Molar Flow as the target Variable.
Figure 11
7. Enter a value of 200 kgmole/h (440 lbmole/hr) in the Specified

Target Value box.
8. The completed Connections tab is shown below.
Figure 12
16
Pre-Heat Train 17
9. Switch to the Parameters tab, and leave the parameters at the

default values. Note the Tolerance and step Size values. When
considering step sizes, use larger rather than smaller sizes. The
Secant method works best once the solution has been bracketed
and by using a larger step size, you are more likely to bracket the
solution quickly.
When adjusting certain variables, it is usually a good idea to provide a

minimum or maximum that corresponds to a physical boundary, such
as zero for pressure or flow.
10. Click the Start button to begin calculations.

11. To view the progress of the Adjust go to the Monitor page.
Figure 13
Note how the Secant method works.
What is the To Preflash Temperature to achieve the Light Prod Flow

specification?________________________________________________________
17
18 Pre-Heat Train
Using the Case Study

The Case Study tool allows you to monitor the steady state response of
key process variables to changes in your process. You select
independent variables to change and dependent variables to monitor.
HYSYS varies the independent variables one at a time, and with each
change, the dependent variables are calculated.
Instead of using the Adjust to find a feed temperature to achieve a

required flowrate you can use the Case Study to examine a range of
temperatures and flow.
Before installing the Case Study, the Adjust has to be turned off so that it
does not conflict with the Case Study.
Any Unit Operation can be temporarily removed from the calculations

by selecting the Ignore check box.
1. Open the Adjust property view.

2. Check the Ignored checkbox.
3. Close the Adjust property view.
4. From the Tools menu select Databook, or use the CTRL D hot key, to
open the Databook.
Both the independent and the dependent variables are added to the
Databook from the Variables tab.
Figure 14
18
Pre-Heat Train 19
5. On the Variables tab, click the Insert button to open the Variable
Navigator.
6. Select the Object as To Preflash and choose Temperature as the first
variable.
7. Click the Add button to add the variable. This will leave you in the
Variable Navigator to add the second variable.
8. Select Light Prod - Molar Flow and click the Add button.
9. Close the view to return to the Databook.
10. In the Databook, switch to the Case Studies tab.
11. Click the Add button to add a new Case Study.
12. Select To Preflash Temperature as the Independent Variable and
Light Prod - Molar Flow as the Dependent Variable.
Only user supplied variables can be selected as Independent Variables.
Figure 15
13. Click the View button to setup the Case Study.
19
20 Pre-Heat Train
14. Enter values for Low Bound, High Bound, and Step Size of 150°C
(300°F), 250°C (482°F) and 10°C (18°F) respectively.
Figure 16
15. Click the Start button to begin de calculations.
What is the influence of temperature in Light Prod flowrate?______________
Once you have finished the Case Study, activate the Adjust operation by
unchecking the Ignored box.
20
Pre-Heat Train 21

Exercise 1
When you added the Balance, a new stream was created, and then you
introduced a value of 915 kPa for the pressure, because it was that of To
Desalter stream. But the pressure in the To Desalter stream could
change, and consequently the bubble point. There is a tool in HYSYS,
which allows you to set the pressure of Bubble Temperature as a
function of To Desalter pressure. It is a Logical Unit Operation called Set.
The Set is a steady-state operation used to set the value of a specific

Process Variable (PV) in relation to another PV. The relationship is
between the same PV in two like objects; for instance, the temperature
Set icon
of two streams, or the UA of two exchangers.
In this case we want it to be the same, but in other cases, it could be

useful to use a linear dependency.
Try to use this option to set the Bubble Temperature pressure.
Exercise 2
You are very concerned about the behaviour of the Pre-flash. You want
to achieve a good separation of the light components. Although you
adjusted the temperature to the required flowrate, usually this value of
the molar flow is not known, and the specification is a desired molar
Use a spreadsheet to create fraction of light products in the stream entering the Atmospheric
this new variable.
Column.
Use the Adjust to achieve a molar fraction of light products (C1, C2, C3,
i-C4, n-C4, i-C5, n-C5 and Water) in the Bttm Liq of 0.12.
Save your case!

What is the required temperature?_____________________________________
21
22 Pre-Heat Train
22
Atmospheric Crude Column 1
Atmospheric Crude Column

1.3.6 Atmospheric Crude Column.pdf
2 Atmospheric Crude Column
Workshop
Atmospheric Crude Columns are one of the most important pieces of
equipment in the petroleum refining industry. Typically located after the
Desalter and the Crude Furnace, the Atmospheric Tower serves to distil
the crude oil into several different cuts. These include naphtha,
kerosene, light diesel, heavy diesel and AGO.
In this module, you will construct, run, analyse and manipulate an

Atmospheric Crude Column simulation. You will begin by building a
simple column and continue by adding side operations to the column.
Learning Objectives
After completing this module, you will be able to:
• Build and converge an Atmospheric Crude Column.

• Use HYSYS to analyse and predict the behaviour of a simulated
column.
• Add side operations to a column to improve operation and
efficiency.
• Add cut point specifications to increase side product quality and
quantity.
Prerequisites
Before beginning this module you will need to know how to:
• Add streams and unit operations.

• Characterize and install a crude oil.
2
Process Overview
Column Overview
Expanding the Flowsheet

Load your Pre-Heat Train case from the Pre-Heat Train module.
Column Product Specs

Before beginning the construction of a crude column it is useful to know
the quantity of products that you can expect to get out of the column.
HYSYS can present this information in a graphical format.
1. Return to the Basis Environment, enter the Oil Manager then enter
Oil Environment view.
2. Under the Cut/Blend tab, select the default crude blend and click
the View button.
The Distribution Plots tab
displays a bar chart
3. Go to the Tables tab. This is where the information is displayed.
depicting how an assay 4. Using the Oil Distributions Table Type and the Straight Run cut
would be roughly distributed
in a fractionation column.
option, complete the following table:
Component Volume % Volume in bbl.

Lt St Run
Naphtha
Kerosene
Diesel (Light & Heavy)
AGO
Residue
TOTAL 100% 100,000 bbl
5
Adding the Column Steam Feed

1. Add a material stream named Btm Steam. Add the following
temperature, pressure and flow rate to the steam stream:

Name Bttm Steam
Vapour Fraction 1
The composition of H2O for Pressure 1380 kPa (200 psia)
all steam streams is 1.0 Temperature 3400 kg/h (7500 lb/hr)
Mass Fraction.
Add the Atmospheric Crude Column

The Atmospheric Column will be simulated as a Refluxed Absorber.
1. Select the Refluxed Absorber icon.

2. The Input Expert is now displayed. Input the data as shown
Refluxed Absorber icon In this cell... Enter...

Column Name Atmos Tower
# Stages 29
Inlet Stream ATM Feed
Inlet Stage 28_Main TS
Bottom Stage Inlet Btm Steam
Stage Numbering Top Down
Condenser Energy Stream Cond Duty
Condenser Partial
Ovhd Outlets Off Gas
Naphtha
Condenser Partial
Bottoms Liquid Outlet Atm Residue
3. Check the Water Draw checkbox and name the stream Waste Water.
The Water Draw checkbox

must be checked to prevent
two liquid phases being
formed in the column.
6
Figure 1
Crude Columns always

require a water stream off
the condenser.
4. Move to the next page of the Input Expert. Enter the following data:

Condenser Pressure 140.0 kPa (20.31 psia)
Condenser Pressure Drop 60.00 kPa (8.7 psi)
Bottom Stage Pressure 230.0 kPa (33.36 psia)
Figure 2
Always provide a pressure

for the stage 1 in a crude
column. The column may
not converge without it.
7
5. Move to the next page of the Input Expert. Enter the following data:
Figure 3
Active specifications are

those values that are fixed.
Inactive specifications (or
Estimates) are those values
that the program can adjust
in order to converge the
column.
6. Move to the next screen of the Input Expert. Enter 0 kgmole/h in the
Vapour Rate field as shown.
Figure 4
7. After clicking Done, you are placed on the Column Property View.
Move to the Design tab and open the Monitor page.
What is the current Degrees of Freedom? _______________________________
8
8. Specify a Distillate Rate of 150 m3/h (22,500 bbl/day). In order to set

a volumetric flowrate for this specification, you must open its
property view and change the flowrate type. Double-click on the
In order to specify a volume specification’s name and change the flow basis to Volume.
flow rate specification, you will
have to change the flow rate 9. For this column to solve we need to activate the Vap Prod Rate
basis of this specification. specification with a flow rate of 0. This means that the condenser
will operate as a total condenser.
10. For the column to converge, the Degrees of Freedom must be 0. This
can be done by deactivating the default spec of Reflux Ratio.
11. Click the Run button to converge the column.
What is the flow rate of:

Naptha? _______________________ Residue? __________________________
Wastewater?____________________ Off-Gas?___________________________
Adding the Side Strippers and the Pump Arounds

Side Strippers are added to the column in order to improve the quality of
the three main products (Kerosene, Diesel, and AGO). There are two
types of side strippers available in HYSYS: Reboiled and Steam Stripped.
We will install one reboiled side stripper and two steam stripped.
Pump Arounds help to improve the column’s efficiency. They operate by

drawing a liquid stream from one stage cooling it, and pumping it into a
higher stage. In effect, this process adds to the reflux between these two
stages.
The first side operation of each type will be added using the side ops
input expert. This tool is design to simplify the process for adding side
operations to columns.
1. On the Side Ops tab, click the Side Ops Input Expert button.
2. The Side Ops Input Expert is really five experts in one interface. The
first page of the input expert is for adding reboiled side strippers,
and the other pages are for different side operations.
When entering the stream
names, do not enter the 3. In this part of the module, a steam stripped side stripper is the
"@COL1" this term is added operation that we want to install. Click the Next button once to
automatically by HYSYS.
move to the appropriate input expert for this type of operation.
9
4. Click the Add Side Stripper button, and complete the view with the
following connections:

Name AGO SS
Return Stage 21_Main TS
Draw Stage 22_Main TS
Steam Feed AGO Steam
Draw Product AGO Prod
Figure 5
5. Click the Install button. HYSYS will now add the side stripper and
associated streams to the simulation.
6. The next side operation that we will add is the pump around for the
AGO section of the column. Again, this operation will be added by
using the input expert for pump around operations.
7. Click the Next button twice to get to the appropriate input expert.
8. Click the Add Pump Around button to add the operation. Define it
with the information shown below.

Name AGO PA
Return Stage 21_Main TS
Draw Stage 22_Main TS
10
Figure 6
9. Click the Install button to add this operation to the simulation.

10. Close the Side Ops Input Expert view, and return to the Monitor
page of the Design tab. Here, the specifications that will govern the
operation of the two side operations that were added in the previous
steps will be added. In total, the side operations contribute three
degrees of freedom to the column; therefore, three active
specifications will be required before the column will be able to
solve.
11. The three specifications that we need to add are:
• AGO SS Product Flow
• AGO PA Rate
• AGO PA Duty
12. HYSYS automatically creates four specifications when the side
operations are added via the input expert. We only have to set the
specified value for the specifications and select which ones we need
as active. Set the following values for the various specifications.
• AGO SS Prod Flow = 30 m3/h (4500 bbl/day) - Note: change flow
basis to volume before setting the value.
• AGO PA Rate = 200 m 3/h (30 000 bbl/day)
• AGO PA Duty = -3.7E7 kJ/h (-3.5E7 Btu/hr)
11
13. On the Work Sheet tab, enter the following information for the AGO
Steam stream:

Remember that the Temperature 150°C (300°F)
composition of steam
streams is always 100%
water. Mass Flow 1150 kg/h (2500 lb/hr)
After making substantial 14. Return to the Design tab and Monitor page. Ensure that the Degrees
changes to a column’s of Freedom is 0.
design, it may be necessary
to reset the specified values 15. Click the Run button to converge the column.
before the column will
converge. Simply click the
Reset icon.
Save your case!
Adding the Diesel Side-Ops

The remaining side operations (two side strippers and two pump
arounds) will be added without using the input expert.
1. In the Column Environment, on the Side-Ops tab, select Side

Stripper and click the Add button. Enter the following information:

Name Diesel SS
Return Stage 16
Draw Stage 17
Flow Basis Volume (select this radio button)
Product Stream Diesel Prod
Draw Spec 130 m3/h (19,250 bbl/d)
Configuration Steam Stripped
Steam Feed Diesel Steam
2. Click the Install button when you are finished and close the view
after.
12
3. On the Side Ops tab, select Pump Arounds and click the Add button.
Enter the following information:

Name Diesel PA
Return Stage 16
Draw Stage 17
4. Click the Install button, and you will be moved to the second part of
the installation process. Under the first active and second active
specs, add the following information to complete the specifications
for this pump around.

Diesel PA_Rate (PA), Flow Rate 200 m3/h (30,000 bbl/d) Note: the
flow basis must be changed to
volume.
The specification type for Diesel PA_Duty (PA), Duty -3.7e7 kJ/h (-3.5e7 Btu/hr) Note: the
the second active spec must specification type must be changed
be changed to Duty instead to Duty instead of the default dT.
of the default dT. The active
spec can be changed by
double-clicking the name of 5. On the Work Sheet tab, enter the following information for the
the spec. Diesel Steam stream:

Mass Flow 1350 kg/h (3000 lb/hr)
Composition 100% H2O
6. Return to the Design tab and Monitor page. Ensure that the Degrees
of Freedom is 0.
13
Adding the Kerosene Side-Ops

Again the Side-Ops installation procedure can be repeated to install the
Side-Ops for the Kerosene product.
1. Add another Side Stripper with the following information:

Name Kerosene SS
Draw Stage 9
Return Stage 8
Prod Stream Kerosene Prod
Prod Rate 62 m3/h (9300 bbl/d)
Configuration Reboiled
Boil Up Ratio 0.75
The boilup ratio is the ratio
of the vapour to the liquid
leaving the reboiler. 2. Add a third Pump Around with the following information:

Name Kerosene PA
Draw Stage 9
Return Stage 8
Flow Rate 330 m3/h (50,000 bbl/d)
Duty -4.5e7 kJ/h (-4.2e7 Btu/hr)
3. Return to the Design tab and Monitor page. Ensure the Degrees of
Freedom is 0.
What is the flow rate of Naphtha?______________ Residue?_______________
Save your case!
14
Adding an Energy Stream to the Column

In modelling this column, a refluxed absorber was chosen, which does
not have a reboiler at its base. However, a side exchanger can be
simulated on Stage 28 by attaching an energy stream to the bottom of
the column and specifying a duty or another parameter.
1. On the PFD in the parent environment, create a new Energy stream

with the name Trim Duty. Do not specify a duty for this stream.
2. Double-click on the Column and click on the Connections page on
Energy Stream icon (Red) the Design tab. In the Inlet Streams group, add the Trim Duty stream
in a new External Stream cell, and specify stage 28 as its feed stage.
Adding an Energy stream that is not fully defined creates one degree of
freedom for the column. Therefore, we need to add another
specification to the column in order for it to solve.
3. Go to the Monitor page and click the Add Spec button in the
Specification group.
4. Choose Column Liquid Flow from the list that appears. Click the
Add Spec button.
5. Enter the data as shown (if using Field units, the flow value will be
3500 bbl/d) and make the specification Active.
Figure 7
The Net Liquid Flow spec is

used to represent the
overflash. A typical rate of
the overflash specification is
3.5 LV% of the crude rate:
(660 m3/hr* 3.5% = 23 m3/
hr).
6. Change the Kerosene SS BoilUp Ratio specification to an Estimate

only. This specification could conflict with the one that was just
created. However, we still need a way to define the Kerosene SS
Reboiler. A duty specification will be used for this purpose.
15
7. Add a Column Duty specification with the information as shown

(7.5e6 Btu/hr), and make the specification Active:
Figure 8
8. Return to the Monitor page and ensure that the Degrees of Freedom
= 0. Click Run to converge the column.
Remember that in module 4, when we characterized the oil, we included

Any User Property can be the sulfur curve. To see how much sulfur contains any stream there’s a
used as a Column utility called User Property.
specification
Attach it to Diesel Prod stream.
What is the Sulfur content of the Diesel Product?

____________________________________________________________________
Save your case!
16

Maximizing the Naphtha Product
The column is now solved using product flow rate specifications. These
flow rate values were obtained from the Distribution Plot in the Oil
Manager (remember the exercise on page 5 of this module). Flow rate
specifications are probably the easiest to understand conceptually;
A good clue that the however, they are also the most inflexible way of defining the column.
material and/or heat
balance is failing is when the If the crude flow rate were to change substantially, for example, the
equilibrium error goes to
zero while the heat/
column may fail to converge because the material balance would not
specification error fails to compute.
converge.
As another example, it is desired to maximize the production of a
particular cut, such as Kerosene. One could simply increase the
Kerosene flow rate spec but this may produce a negative consequence as
the quality of the product may be reduced.
Therefore, another method of defining the streams may be better in

these cases. One of the most common ways of doing this is to use Cut
Point specifications to define the product streams.
The Distribution Plot page in the Oil Manager (under the Blend view)
shows the cut points that were used to generate that plot. In order to
maximize the proportion of Kerosene the Cut Point range is widened
slightly.
For example, it is desired to maximize the production of Naphtha. Since

the flow rate of Naphtha is related to the flow rate of Kerosene, both of
these streams will be defined in terms of cut point values.
Before we maximize the production of the various products, the base

case needs to be defined. Use the BP Curves utility to complete the
17
following table:
Flow D86 CutPoint Temperatures, °C

3
m /h (bbl/d) 5% 95%
Naphtha 150 (22, 500)
Kerosene 62 (9, 300)
Diesel 130 (19, 250)
AGO 30 (4, 500)
To maximize the products, you will need to add Cut Point specifications
to replace the product flow specifications.
Save your case!
Exercise 1
Maximize the Production of Full Range Naphtha
To maximize the production of Naphtha, it is necessary to increase its 95
vol% cutpoint temperature. At the same time, the Kerosene’s 5 vol%
cutpoint temperature will show a corresponding increase as the lighter
Kerosene components are transferred into the Naphtha product
(becoming the heavier Naphtha components). By changing the flow rate
specifications for both the Naphtha and Kerosene products to ASTM
D86 95% vol% cutpoints, we can maximize the production of a full range
Naphtha from the column.
Product Specifications Flow, m3/h (bbl/d)

Naphtha 95% D86 Naphtha
190°C (375°F)
You will need to make the
Kerosene 95% D86 Kerosene
Naphtha and Kerosene flow
245°C (470°F)
specifications Inactive and
the Cut Point specification Diesel Flow 130 m3/h (19500 bbl/d)
Active. AGO Flow 30 m3/h (5000 bbl/d)
18
Exercise 2
Maximize the Production of a Full Range Kerosene
To maximize the production of Kerosene, its boiling point range has to
be expanded. The ASTM D86 95 vol% cutpoint for Naphtha should be
lowered to 162°C (325°F), the base case value, and the 95 vol% of
Kerosene raised to 275°C (525°F). Change the Diesel product flowrate
specification to an ASTM D86 95 vol% cutpoint specification of 330°C
(625°F).

162°C (325°F)
275°C (525°F)
Diesel 95% D86 Diesel
330°C (625°F)
AGO Flow 30 m3/h (5000 bbl/d)
19
Exercise 3
Maximize the Production of a Full Range Diesel
The production of Diesel can be maximized in a similar manner to
maximizing Kerosene. The ASTM D86 95 vol% for Naphtha is 162°C
(325°F). The Kerosene ASTM D86 95 vol% is lowered to 220°C (430°F).
The ASTM 95 vol% Diesel specification should be increased to 360°C
(675°F). Since the AGO flowrate will have to change, its flowrate
specification should be changed to an ASTM D86 95 vol% cutpoint
specification of 415°C (780°F).

162°C (325°F)
220°C (430°F)
Diesel 95% D86 Diesel
360°C (675°F)
AGO 95% D86 AGO
415°C (780°F)
20
Vacuum Tower 1
Vacuum Tower

1.3.7 Vacuum Tower.pdf
2 Vacuum Tower
Workshop
Vacuum Towers are commonly used in the refining industry to further
process the bottoms product of the Atmospheric Column. The Vacuum
Tower distills the atmospheric bottoms product under reduced pressure,
enabling further separation of the petroleum fractions.
Learning Objectives
• Install a Vacuum Tower in HYSYS, with Side Draws and Pump

arounds.
• Perform Tray Sizing and Rating calculations.
Prerequisites
Before beginning this section, you need to know how to:
• Add Unit Operations to the PFD.

• Add specifications to a column.
• Add side operations such as Pump arounds to a column.
2
Process Overview
Column Overview
Vacuum Tower 5

The Vacuum Tower is a Column operation, with the configuration of an
Absorber with Pump Arounds. For this module you will continue
building on the case you worked on in the previous module (The
Atmospheric Crude Column). The bottoms product from the
Atmospheric Crude Column must be heated and its pressure must be
reduced prior to using it as the Feed stream to the Vacuum Tower. A
Heater will be installed upstream of the Vacuum Tower to perform both
of these tasks.
Add a Heater
The Atmospheric Crude Column should be converged using the Product
Flow specifications, not the Cut Point specifications.
Add a Heater operation and enter the following information:.

Connections
Name Vac Heater
Inlet Atm Residue
Outlet Vac Feed
Energy Vac Duty
Worksheet
Temperature, Vac Feed 395°C (740°F)
Pressure, Vac Feed 15 kPa (2 psia)
Add the Steam Stream

Add a stream with the following data

Name Vac Steam
5
6 Vacuum Tower

Mass Flow 1800 kg/h (4000 lb/hr)
Composition 100% H 2O
Add the Vacuum Tower

1. Add an Absorber Column and enter the following information:

Name Vacuum Tower
Stages 9
Top Stage Reflux Pump around (radio button)
Pump-around draw stage 2
Optional Inlet Streams Vac Feed/8
Bottom Stage Feed Vac Steam
Ovhd Vapour Outlet Vacuum Ovhd
Bottoms Liquid Vacuum Residue
2. Under the Optional Side Draws group add the following data:
Name Type Stage

LVGO L 2
HVGO L 6
Each side draw adds one degree of freedom and so requires one
specification.
3. Click the Next button to move to the Pressure Profile page, and
enter the following values:

Top Stage Pressure 11 kPa (1.6 psia)
Bottom Stage Pressure 13 kPa (1.8 psia)
6
Vacuum Tower 7
4. Click the Next button to move to the Temperature Estimates page,

and enter the following values and click the Done button.

Top Stage Temp 120°C (250°F)
Bottom Stage Temperature 370°C (700°F)
PA Rate 275 m3/h (41510 barrel/day)
5. On the Specs page of the Design tab, add the following draw rate
specifications.
• The draw rate for the Vacuum Ovhd is 2600 kg/h (5732 lb/hr)
• The draw rate for the LVGO is 32 m3/h (4800 bbl/d)
• The draw rate for the HVGO is 90 m3/h (13,700 bbl/d)
Ensure these specs and the top PA Rate spec is active and change the
default name to PA_1 Rate (Pa). Do the same for TopStagePA_Duty (Pa)
by changing the default name to PA_1 Duty(Pa).
6. Go to the Side Ops tab and click the Side Ops Input Expert button.
7. Click Next three times to move to the Pump-Around Input Expert
view.
8. Change the default name TopStagePA to PA 1.
9. Click the Return button to go back to the Column properties view.
Save your case!

10. Run the column.
1. What is the molar flow rate of Vacuum Residue?_____________________

2. What is the actual volume flow rate of Vacuum Ovhd? _______________
3. What is the Duty of PA 1? __________________________________________
7
8 Vacuum Tower
Add the Pump Arounds

Add two Pump Arounds to the column with the following information:
After making substantial changes to a column, it may be necessary to

click the Reset button before the Run button You may want to converge
the column after adding each Pump Around.
Pump Around 2
Name PA 2
Return Stage 5
Draw Stage 6
Rate 265 m3/h (40,000 bbl/d)
Pump Around 3
Name PA 3
Return Stage 8
Draw Stage 9
Rate 330 m3/h (50,000 bbl/d)
Return to the Design tab, Monitor page. Check that the Degrees of
Freedom is equal to zero. Make sure that the PA_1 Duty specification is
not active. Click the Run button to converge the column.
1. What is the flow rate of Vacuum Residue now? ______________________

2. What is the flow rate of Vacuum Ovhd now? _________________________
3. Did these values change from before? _______________________________
4. Why were the Pump Arounds added then? ___________________________
8
Vacuum Tower 9
We have converged this column using an Overhead Gas Flow Rate.
Perhaps a better specification to try is a top temperature. Change the

overhead vapour product rate specification to the top temperature
specification by adding a Column Temperature spec and name it
Temperature. Select 1_TS-1 as the stage and enter a spec value of 120°C
(250°F). Remember to deactivate the Vacuum Ovhd spec before you run
the column.
What is the new Overhead Gas Flow? _________________________________
Save your case!
Tray Sizing
In the second part of this module, you will learn how to size columns.
While HYSYS is able to size and rate tray sections, the values that it
provides are only a rough estimation and should be treated as such.
There are two ways of performing this design:
• Design Mode
• Rating Mode
Use of the tray sizing utility requires a converged column.
Column Sizing in Design Mode

In design mode, HYSYS allows you to perform a design sizing based on
the vapour and liquid traffic in the tower. Available design specifications
for trayed and packed sections include the type of tower internals,
maximum allowable pressure drop, and maximum allowable flooding.
1. Select Tools / Utilities from the Main Menu bar, or press the hot key
9
10 Vacuum Tower
CTRL U.
2. Select Tray Sizing from the list of available utilities and click the Add
Utility button.
3. Click the Select TS button, and select Vacuum Tower as the
Flowsheet and TS-1 as the Object.
HYSYS allows users to select Tray Sections and not entire columns so
Side Strippers may be sized independently from the Main Column.
4. Click the Add Section button. In the Setup Section group, change
the Internals from Valve (default value) to Packed.
HYSYS will calculate the dimensions of the column using present values
for the column internals and for the various parameters.
5. On the Specs tab you can select the tower internals. Change the
Packing Type to Ballast Rings (Plastic, random) 1_inch.
6. On the Performance tab, a summary of the calculations is
presented. Choose the Packed radio button to see the detailed
calculation.
1. What is the Vac Column diameter? _________________________________

2. What is the HETP? ________________________________________________
3. What is the pressure drop? _________________________________________
4. What is the total section height? ____________________________________
Column Sizing in Rating Mode

In rating mode, HYSYS allows you to perform rating calculations based
on a specified tower diameter and fixed tray configuration. If desired,
some of the tray dimensions may be left unspecified and HYSYS will
automatically calculate design values for them.
1. On the Specs page, set the Mode to Rating.

2. Enter a diameter of 5 m (16.4 ft) to calculate the pressure drop.
What is the Section Delta P? _________________________________________
10
Vacuum Tower 11

In this exercise, the effect of packing type on column operation is
investigated. HYSYS uses the vapour and liquid traffic results from the
converged column and will report information such as flooding and
pressure drop.
Obtain the flow parameters and pressure drops for a column that uses
the different packing as given in the table below.
1 Ballast Rings Metal (1 inch)

2 Pall Rings Plastic (1 inch)
3 Ballast Rings Metal (1.5 inches)
The following requirements must be met for optimal column operation.
• Maximum % Flood = 85
1. On the Specs page, set the Mode to Rating.

2. Set the diameter to 5.5 m (18 ft).
3. For each case, change the packing and note the results on the
Design tab Specs page.
4. Complete this table with the information provided by HYSYS.
Case # 1 2 3
Flooding (%)
Total delta P (kPa)
Save your case!
11
12 Vacuum Tower
12
Heat Integration 1
Heat Integration

1.3.8 Heat Integration.pdf
2 Heat Integration
Workshop
Process streams at high temperature contain energy that can be
recovered. Heat integration is nowadays indispensable to reduce
product cost. In this module we will learn how to simulate this
integration,
In this workshop, you will use the recycle operation to recover heat from
the Atmospheric Crude Column and used to pre-heat the raw crude.
Learning objectives
• Export Pumparounds.
• Use the Recycle operation in HYSYS.
Prerequisites
Before beginning this module you should have completed the Vacuum
Tower modules.
2
Process Overview
4 Heat Integration

In this module we will continue working on the previous module. Open
the case you saved at the end of the Vacuum Tower.
Using the Kerosene Pumparound in the Heat Exchanger

Up until now, we have been using a fictitious pumparound to preheat
the raw crude. Now we are going to use the real Kerosene pumparound.
Before you begin this section answer the following questions:
1. What is the heat flow in the Kerosene Pumparound? __________________

2. What is the duty of the Heat Exchanger? ______________________________
3. What is the temperature of stream To Desalter? ________________________
1. Export the Kerosene Pumparound. To do this, check the Export

checkbox in the Pump Arounds page of the Side Ops Tab of the
Atmosphere Column.
Figure 1
4
Heat Integration 5
2. In the main PFD you can check that the Kerosene_PA Draw and
Kerosene_PA Return streams appear.
It is important to remember that these streams are completely

calculated by the Column. By using them in the Heat Exchanger the
Duty is fixed, because it is calculated by the Column. For this reason, it
is necessary to delete the specs in the Heat Exchanger. Go to the
Property View Page and delete the Shell drop pressure (in the
Parameters page) and the Temp Approach specification (in the Specs
page).
3. Delete the Hot Pumparound and Cold Pumparound streams.

4. Connect the Kerosene_PA Draw and the Kerosene_PA Return to the
shell sides of the Heat Exchanger. You can either do this in the
Connections tab or with the Attach Mode icon.
Attach Mode icon You can see that the process remains yellow and no calculation is
performed. This is because HYSYS has no starting point. We need to
install a Recycle Operation.
Installing the Recycles

A recycle operation is a mathematical unit operation and is installed as
any other. It has an inlet (calculated) stream and an outlet (assumed)
stream. The operation is called/calculated whenever changes to the
inlet stream fall outside of the converged tolerance.
The Recycle installs a theoretical block in the process stream. The feed
into the block is termed the calculated recycle stream, and the product
is the assumed recycle stream. The following steps take place during the
convergence process
In general, a Recycle
operation is required for • HYSYS uses the conditions of the assumed stream (outlet) and
material transfer and not for solves the flowsheet up to the calculated stream (inlet).
thermal recycles. • HYSYS then compares the values of the calculated stream to
those in the assumed stream.
• Based on the difference between the values, HYSYS modifies the
values in the calculated stream and passes the modified values to
the assumed stream.
• The calculation process repeats until the values in the calculated
stream match those in the assumed stream within specified
tolerances.
5
6 Heat Integration
As it is only a mathematical unit it doesn't have to be placed where the

physical recycle is. Moreover, in some cases a better placement can be
chosen to reduce the number of recycles, which means less calculation
time and more accuracy.
Always supply a guess or
starting point for the outlet Another important recommendation is to choose a tear location such
stream of the Recycle, never
the inlet. A guess close to that specifying the assumed stream will define as many streams
the solution will result in a downstream as possible, for example, downstream of gathering points
faster convergence time.
(mixers) or upstream of distribution points (tees, separators, and
columns)
You are going to add the Recycle operation just before the Column. This
way, HYSYS will start calculations at this point, and once the Kerosene
Pump Around is determined it will continue with the Heat Exchanger,
up to the ATM Feed once again, where it will compare values.
1. Click on the Break the Connection icon for the ATM Feed with the
Atmosphere Column.
Break Connection icon
2. Add the Recycle by double-clicking on the Recycle icon in the Object
Palette.
3. Select ATM Feed as the inlet stream to the recycle. Enter ATM Feed 2
as the outlet from the recycle.
Recycle icon
Figure 2
The smaller the tolerance

value, the tighter the
tolerance. Generally it is a
good idea to start with the
default tolerance until you On the Parameters tab, you can see the tolerance sensitivities. HYSYS
have a converged solution
and then tighten the
allows you to set the convergence criteria or tolerance for each of the
tolerance. Recycle variables. In this example, leave everything at the default.
6
Heat Integration 7
On the Numerical page, you can see the options for the two types of
Recycle, Nested or Simultaneous.
• Nested. This type of recycle gets called whenever it is

encountered during calculations. Use this type if you have a
single Recycle or if you have multiple recycles which are not
connected.
• Simultaneous. All recycles set at Simultaneous will be called at
the same time. Use this option if your Flowsheet has multiple
inter-connected recycles.
In this case, we will use Nested Recycles.
Figure 3
In the Monitor tab, convergence information is displayed as the

calculations are performed. Any variable that changes between
iterations is displayed in this table.
In the Worksheet tab information about the Inlet and Outlet stream is
displayed, as usual. In this instance, notice that the Inlet and Outlet
streams have the same values. This is because before we installed the
Recycle, the Inlet stream was known. When the Recycle was connected,
the known Inlet conditions were automatically passed to the Outlet
stream to serve as the starting guess.
4. Connect the ATM Feed 2 back to the Atmosphere Column.

Remember to attach it in the 28th stage.
5. Go to the main PFD and see how the recycle is built.
7
8 Heat Integration
6. As a starting point, you are going to define the ATM Feed 2 as the
Raw Crude but at 400 ºC (752 ºF). Use the Define from Other Stream
option in the Stream Property View.
7. Run the column.
It may be useful to ignore
the Adjust while converging In the Monitor Page from the Design Tab of the Property view Column
both columns.
you can see how HYSYS is calculating each loop.
What is the new temperature for stream To Desalter? _____________________

What is the Duty of the Heat Exchanger? ________________________________
Save your case!
Exploring with the simulation

Exercise 1
Trying to recover as much heat as possible use the AGO Pumparound to
heat the raw crude just at the entrance of the pre-heat train (Simple
Heater 1). Since it is a Simplified Heater and not a two-side Heat
Exchanger, you only need to externalize the AGO_Q-Cooler stream
Complete the following table before doing it to appreciate the changes

later
Simple Heater 1 Duty
AGO PA_Duty
AGO PA_ Draw Flow
AGO PA_Draw Temperature
AGO PA_Return Temperature
8
Heat Integration 9
Notice two important things:
• For energy streams no Recycle is needed.

• You need to deactivate the AGO PA_Duty (Pa) before connecting
the AGO PA_Q-Cooler with the Simple Heater; in this case the
Pump Around Duty will be fixed as a function of the Outlet
Temperature, which is specified (65°C, 150°F).
1. Go to the Design tab on the Monitor page of the column. Deactivate

the AGO PA Duty spec. The column status will change to
unconverged.
2. Go to the Connections page and click on the <<Stream>> cell beside
the AGO PA_Q-cooler stream in the Outlets Streams table.
3. From the drop-down menu, choose H1Q. This will connect the duty
from the Simple Heater to the AGO Pumparound cooler. The stream
name in the column will change to H1Q.
What is the new AGO Pumparound Duty? ______________________________

What are the new temperatures for the pumparound streams:
Pumparound Draw? _________________________________________________
Pumparound Return? ________________________________________________
Save your case!
9
10 Heat Integration
Advanced Modelling: Deep in the Recycles

Exercise 1
As we have said, because the Recycle operation is a mathematical
representation of a physical process, its location in a simulation is a
particularly important one. The location of the tear stream can often
determine success or failure to converge a recycle. In this part of the
module we will insist in a few recommendations.
Choose a Tear Location to Minimize the Number of Recycles

Reducing the number of locations where the iterative process is required
will save on the total convergence time. Choosing the location of the
Recycle will depend on the flowsheet topology. Attempt to choose a
point such that specifying the assumed stream will define as many
streams downstream as possible. It generally occurs downstream of
gathering points (mixers) and upstream of distribution points (tees,
separators, and columns).
Choose a Tear Location to Minimize the Number of Recycle

Variables
Variables include vapour fraction, temperature, pressure, flow, enthalpy
and composition. Choose the tear stream so that as many variables as
possible are fixed, thus effectively eliminating them as variables and
increasing convergence stability. Good choices for these locations are at
separator inlets, compressor after cooler outlets and trim heater outlets.
10
Heat Integration 11
Choose a Stable Tear Location

The tear locations can be chosen such that fluctuations in the recycle
A very poor choice of a tear stream have a minimal effect. For example, by placing the tear in a main
stream is a stream with an stream, instead of the physical recycle, the effect of fluctuations will be
Adjust operation controlling
reduced. The importance of this factor depends on the convergence
one of its variables.
algorithm. It is more significant when successive substitution is used.
Exercise 2: Recycles
1. Where should the Recycle be placed in this flowsheet and why?
Figure 4
Figure 5
Assume that the Feed is

fully defined, Shell and Tube
Side pressure drops are
known, as well as the
Column Feed temperature.
11
12 Heat Integration
Figure 6
Assume the Feed is

completely defined, shell
and tube side pressure
drops for E-100 and E-101,
and the temperatures of
streams 3 and 4 are known.
Figure 7
Assume the Feed is

completely defined, and the
shell and tube side pressure
drop for E-100 is known.
12
Rating Heat Exchangers 1
Rating Heat Exchangers

1.3.9 Rating Heat Exchangers.pdf
2 Rating Heat Exchangers
Workshop
A heat exchanger is a vessel that transfers heat energy from one process
stream to another. Until now, we have not considered the physical
parameters of the heat exchangers we have modeled. In this module we
will be entering this additional information regarding our shell and tube
heat exchanger and allowing HYSYS to determine whether or not it will
suit our needs.
Learning Objectives
In this workshop you will learn how to:
• Use the Heat Exchanger Dynamic Rating Method in HYSYS for

heat exchanger design.
• Determine if an existing heat exchanger will meet the process
specifications.
Prerequisites
We ignore the adjust so that
Before beginning this workshop you need to have completed the
it doesn’t interfere with out previous modules.
calculations.
2
Process Overview
First Part
Process Overview
Second Part

We will be modifying the heat exchanger modeled in the Heat
Integration module. Open the case saved at the end of module and
ignore the Adjust operation.
Modeling Heat Exchangers

In this workshop, we will examine a heat exchanger from the Pre-Heat
Train. Heat exchangers are modelled in HYSYS using one of three
configurations:
• Shell and Tube

• Cooler/Heater
• Liquified Natural Gas (LNG) exchanger
The Cooler/Heater operations are single-sided unit operations where

only one process stream passes through the operation. The LNG
Exchanger allows for multiple (more than two) process streams.
A shell and tube heat exchanger is a two-sided unit operation that

permits two process streams to exchange heat.
In this module, a shell and tube exchanger of given dimensions will be

rated to see if it will meet the requirements of the process.
5
Heat Exchanger Calculations

The calculations performed by the Heat Exchanger are based on energy
balances for the hot and cold fluids. The following general relation
defines the heat balance of an exchanger.
(1)
(M (H –H ) –Q ) – (M (H – H ) –Q ) = Balan ceError
cold out in cold leak hot in out hot loss
where: M = Fluid mass flow rate
H = Enthalpy
Q leak = Heat Leak
Q loss = Heat Loss
The Balance Error is a Heat Exchanger Specification which, for most

applications, will equal zero. The subscripts "hot" and "cold" designate
the hot and cold fluids, while "in" and "out" refer to the inlet and outlet.
The Heat Exchanger duty may also be defined in terms of the overall
heat transfer coefficient, the area available for heat exchange and the log
mean temperature difference:
Q = UA ( LM TD )F = M ( H – H ) –Q = M (H –H ) –Q
(2)
t hot in out hot loss cold out in cold leak
where: U = Overall heat transfer coefficient
A = Surface area available for heat transfer
LMTD = Log mean temperature difference
Ft = LMTD correction factor
6
Log Mean Temperature Difference (LMTD)

The LMTD is calculated in terms of the temperature approaches
(terminal temperature differences) in the exchanger using the following
equation:
∆T – ∆T (3)
1 2
LMTD = -------------------------------------
Ln ( ∆T ⁄ ∆T )
1 2
where: ∆T 1 = T hot ,out – T col d,in
∆T 2 = T hot ,in – T cold ,out
The LMTD can be either terminal or weighted. This means that it can be
calculate over the exchanger as a whole (terminal) or over sections of the
exchanger (weighted). The need for this type of calculation is shown on
the next page.
The following plot is a heat loss curve for a single phase stream. It
compares the temperatures of the process streams with the heat flow
over the entire length of the exchanger. For single phase streams, these
plots are linear.
Figure 1
7
The following curve represents a superheated vapour being cooled and

then condensed. Note that it is not linear because of the condensation
that takes places inside the exchanger.
Figure 2
If the LMTD is calculated using the hot fluid temperatures at points A

and C, the result would be incorrect because the heat transfer is not
constant over the length of the exchanger. To calculate the weighted
LMTD:
1. Break the heat loss curve into regions at point B.

2. Calculate the terminal LMTD for each region.
3. Sum all of the LMTDs to find the overall LMTD.
HYSYS will do this automatically if the Heat Exchanger model is chosen

as Weighted. Therefore, if condensation or vaporization is expected to
occur in the exchanger, it is important that Weighted is chosen as the
model.
Available Heat Exchanger Models

There are five shell and tube heat exchanger models available in HYSYS.
The End Point and Weighted models can be used for material and
energy balance for any two-sided heat exchangers. They can also be
used for shell and tube exchanger’s material and energy balance. Steady-
State Rating model is used for rating in steady-state mode as well as in
dynamic simulation.
8
The basics of each model:
• End Point Model. This model is based on Q = UAFt(LMTD). The

main assumptions behind this model are the overall heat transfer
coefficient U is constant the specific heats of the streams at both
exchanger sides are constant. The heat curves of both shell and
tube side are linear. The heat exchanger geometry is not taken
into account in this model.
• Weighted Model. This model is particular powerful in dealing
with non-linear heat curve problems such as phase change of
pure components in one or both heat exchanger sides. The heat
curves are divided into a number of intervals and energy balance
is performed in each interval. This model can only be used for
energy and material balance. The heat exchanger geometry is
not taken into account in this model.
• Steady State Rating Model. This model makes the same
assumptions as the End Point Model. It simply an extension of the
End Point model which incorporates a rating calculation. If
detailed geometry information is provided, the exchanger can be
rated using this model. For linear or nearly linear heat curve
problems, this model is a good choice because it is much faster
than the dynamic rating-detailed model.
• Dynamic Basic Model. The Basic Model is based on Q =
UAFt(LMTD) and makes the same assumptions as the End Point
model. This model was originally developed for dynamic mode
but was extended for rating in steady state. This model is
somewhat oversimplified in that geometry configurations are not
taken into account. Therefore, this model has limited functionality.
When using this model, both pressure drops and the overall UA
must be specified.
• Dynamic Detailed Model. The Detailed Model divides the entire
heat exchanger into a number of heat zones. In each heat zone
there is a shell hold-up and one or more tube hold-ups, according
to the number of tube passes per shell pass. It is a good
counterpart to the Weighted Model. The Dynamic Detailed Model
is used both in steady state and in dynamic operation and is
designed to solve any linear and non-linear heat curve problems.
Heat Exchanger Rating

Providing detailed heat exchanger to a HYSYS heat exchanger with the
Shell and Tube inlet streams fully defined, HYSYS can calculate the
conditions of the outlet streams. HYSYS iterates on the outlet
temperatures until the heat balance is satisfied. Pressure drops are
determined from the geometry.
9
We need to break the Kerosene_PA return connection to the Heat

Exchanger.
When using the Rating mode the Duty can not be fixed, that means that
the Streams entering the Heat Exchanger can not be fixed by the
Column, as they are when exporting the Pump Around.
1. Break the connection of the Kerosene_PA Return stream to the Heat

Exchanger.
2. Go to the Property View of the Heat Exchanger and complete the
Outlet Shell with a stream called Kerosene Out.
3. Go to the Parameters tab. See that the pressure drop from the shell
side has been deleted. Remove the one from the tubes because,
rating a Heat Exchanger, HYSYS, uses its own correlation to calculate
this value.
4. The Rating option can be chosen by selecting Dynamic Rating from
the Heat Exchanger Model drop-down menu on the Parameters
page on the Design tab. Note that once this model is chosen, all
information on this page disappears. This is because with this type
of model the required information must be specified elsewhere.
Figure 3
Some of the physical design specifications of an exchanger must be

supplied on the Sizing page of the Rating tab.
10
The Rating tab has the following aspect.
Figure 4
The radio button selection in the Sizing Data group will dictate the type
of information shown at any given moment. Each parameter will be
defined later on in this module.
The radio buttons in the Sizing Data group include;
• Overall. Required information about the entire exchanger. Most

of the information entered here is used only in dynamic
simulations.
• Shell. Required information concerning the shell side of the
exchanger. All variables must be specified.
• Tube. Required information concerning the tube side of the
exchanger. All variables must be specified.
The TEMA Type is selected as part of the Overall sizing data. There are
three drop-down lists which allow you to specify the geometry of the
front end stationary head type, the shell type and the rear end head type
for the exchanger. The following tables provide brief descriptions for
each designated TEMA Type letter. Drawings of the various TEMA types
can be found on page 11-4 of Perry's Chemical Engineers Handbook,
Sixth Edition.
11
TEMA - Front End Stationary Head Types

TEMA Types Description
A Channel and Removable Cover
B Bonnet (Integral Cover)
C Channel Integral with TubeSheet and Removable
Cover (removable tube bundle only)
N Channel Integral with TubeSheet and Removable
Cover
D Special High Pressure Closure
TEMA - Shell Types

TEMA Description
E One Pass Shell
F Two Pass Shell with Longitudinal Baffle
G Split Flow
H Double Split Flow
J Divided Flow
K Kettle Type Reboiler
X Cross Flow
TEMA - Rear End Head Types

TEMA Types Description
L Fixed TubeSheet like "A" Stationary Head
M Fixed TubeSheet like "B" Stationary Head
N Fixed Tubesheet like "N" Stationary Head
P Outside Packed Floating Head
S Floating Head with Backing Device
T Pull Through Floating Head
U U-Tube Bundle
W Externally Sealed Floating TubeSheet
12
Rating Parameters
Brief explanations are provided below for each Simple Rating parameter.
The parameters are categorized according to the radio buttons in the
Sizing Data group box. Most of these parameters are only available when
the mode is chosen as Detailed as opposed to Basic.
Overall Information:
• Tube Volume per Shell. The volume inside the tubes, used only
in dynamic simulations
• Shell Volume per Shell. The volume inside the shell, used only
in dynamic simulations
• Heat Trans. Area per Shell. The total area available for heat
transfer, calculated from the specified geometry.
• Elevation. The height of the base of the exchanger, used only in
dynamic simulations.
• Tube Passes per Shell. The number of tube passes per shell.
• Orientation. The orientation of the exchanger, used only in
dynamic simulations.
• Number of Shells in Series. The number of shells in series.
• Number of Shells in Parallel. The number of shells in parallel.
• TEMA Type. Described earlier.
Shell Side Required Information:

• Shell Diameter. Can be specified or calculated from inputted
geometry.
• Number of Tubes per Shell. The number of tubes in one shell
• Tube Pitch. The shortest centre to centre distance between 2
tubes
• Tube Layout Angle. A choice between four different
configurations.
• Shell Fouling. The fouling factor on the shell side.
• Baffle Type. A choice of single, double, triple, or grid.
• Baffle Orientation. A choice between horizontal or vertical.
• Baffle Cut (% Area). The percent of the cross-sectional profile
unobstructed by the baffle.
• Baffle Spacing. The distance between adjacent baffles.
13
Tube Side Required Information:

• Tube OD. The outside diameter of the tubes.
• Tube ID. The inside diameter of the tubes.
• Tube Thickness. Usually calculated from the two numbers
inputted above.
• Tube Length. The tube length per shell (one side for a U-tube).
• Tube Fouling. The tube side fouling factor.
• Tube Thermal Conductivity. The thermal conductivity of the
tubes, used in determined the overall heat transfer coefficient, U.
• Tube Wall Cp, and Tube Wall Density. Two physical properties
of the tube material, used only in dynamics.
If you want HYSYS to use general correlations to determine the shell and
tube side pressure drops and heat transfer coefficients, select the
Detailed model on the Parameters page. This will allow HYSYS to
calculate the desired terms.
The Rating model in HYSYS uses generalized correlations for heat

transfer coefficients and pressure drop. These correlations are suitable
for approximate results in most cases but may not be valid for every
exchanger. For more accuracy, a rigorous model may be required.
Please contact your Hyprotech representative for a list of available third
party heat exchanger packages that are compatible with HYSYS through
OLE Extensibility.
We are going to use some of the values provided by HYSYS by default

and change others.
5. Introduce the following data where it corresponds:

Tube Passes per Shell 1
OD (mm) 25
ID (mm) 21
Tube Pitch (mm) 30
Baffle Type Double
6. Go to the Parameters tab and check the Detailed radio button. Note
that the data needed for the simulation changes.
14
Make sure that both pressure drop cells are empty, as we said before,
HYSYS calculates the values.
What is the new temperature of stream To Desalter? ______________________
Compare the Kerosene Out stream with the Kerosene_PA Return.
Kerosene Out Kerosene_PA Return

Temperature
Pressure
Completing the heat integration

From the previous exercise, we know that the Kerosene Out and the
Kerosene_PA Return streams have different values, this is because one is
calculated by the Heat Exchanger and the other by the Column,
respectively. To complete the heat integration and close the loop you
need to break the Pump around, since, as said before in Heat Exchange
rating, the outlet streams can not be fixed.
Once you've broken the Pumparound, the data in the Kerosene Streams
will be deleted, it's a good idea to keep the values of Kerosene_PA Return
to provide the Outlet Recycle stream with a starting point. Create a
stream called Kerosene_PA Return Copy and defined it from
Kerosene_PA Return.
1. Go to the Atmosphere Column Property View.

2. Enter the Column Environment.
3. Delete the Kerosene SS Cooler. You will be asked if you want to
delete all elements associated with the Pump Around. Answer NO.
You are also asked if you wish to delete the Kerosene Pa_Rate(Pa)
since it is not required any more. Answer YES.
4. Return to the Main Property View. Answer YES to deleting the
Kerosene PA_Q Cooler.
5. You need to change the specifications for running the column later.
Move to the Monitor page, and click in the Kerosene_PA Duty(Pa)
check box to deactivate it.
6. Add a Kerosene PA_Draw Flow spec of 300 m3/h (45,000 barrels/
day)
15
7. Add a Recycle unit and connect the Kerosene Out as the Inlet stream
and the Kerosene_PA Return as the Outlet.
8. In the Numerical page of the Parameters tab, change the Maximum
Iterations to 20.
9. You need to provide the Outlet Recycle stream with an initial guess,
so that all the streams entering the Column are defined, define it
from the Kerosene_PA Return Copy you previously created.
10. Run the Atmosphere column.
What is the Total NL-Solver Iterations? _________________________________

This data is shown in the window in the right down corner.
Exercise 1
In the previous module, we learned where to place Recycles. It is also
important to minimize the number of recycles used in the flowsheet.
Tip: A helpful way of doing
this is to place the Recycle
mentally in different Look at your simulation and decide where to place a single recycle to
locations and imagine the converge the case.
HYSYS calculation
sequence.
How many iterations did you need? ___________________________________
16
Exercise 2
You are asked to find a heat exchanger to replace the existing one.
However, since you are on a very restricted budget, you can only
consider used equipment. A heat exchanger has been found in a nearby
plant. If the critical process parameter is to maintain the To Desalter
temperature of at least 85°C (185°F), can this heat exchanger be used?
The TEMA definition of this exchanger is A.E.L. The dimensions are

given here:
Tube length (m) 5
Number of Tubes 150
Baffle Type single
All other parameters are the HYSYS default values
What is the temperature of To Desalter using this exchanger? _____________
Previous experience has shown you that after about six months in
operation, the exchanger becomes fouled and the fouling factor for both
shell-side and tube-side is 0.0001°C-h-m2/kJ.
What will the temperature of To Desalter be after 6 months of service? ______

Will this exchanger be adequate after 6 months of service? _______________
17
18
Crude Column Optimization 1
Crude Column Optimization
© 2004 AspenTech. All Rights Reserved.

1.3 Crude Column Optimization.pdf
2 Crude Column Optimization
Workshop
A crude column with pump arounds and side-strippers can converge in
a few seconds using a wide variety of product quality specifications.
However, the complexity of the model and intrinsic interaction between
variables can make it very difficult to use the model alone as a decision-
making tool.
For example, in a typical oil refinery, the operation must be adjusted so

that different feed stocks can be processed to yield products with tight
quality specifications, while meeting a desired economic performance.
How does one use the model to choose the best operating conditions?
HYSYS includes additional modelling and decision support tools that

can be used to enhance the usability of your models. In this module, you
will use the HYSYS optimization tool available in HYSYS.RTO to
investigate the debottlenecking and optimization of a crude column.
Learning Objectives
After completing this module, you will be able to use the Derivative
Utility to:
• Define Process Constraints and Variables.

• Define the Objective Function.
• Run the Optimizer and check the results.
Prerequisites
Before beginning this module you will need to know how to:
• Create and modify active specifications in the column.

• Create utilities and select variables through the HYSYS Object
browser.
2
Process Overview
Description of the Problem

In the Atmospheric Crude Column module we defined and converged
the tower based on a predetermined set of performance criteria. The
profit of this column operation is dependent on the price of its various
products and on its operation costs (e.g., energy and steam). It should be
possible to operate the column with better performance: maximizing
the profit from the column while keeping the product quality
constraints within specified limits. However, the number of variables to
manipulate and the number of constraints to be met makes the
optimization problem impossible to do manually. Consequently, the
help of an optimization algorithm is needed. Let us examine the
variables involved:
Price Revenue
3
Revenues ($/m ) ($/h)
Naphtha 14.00 2100
Kerosene 12.00 743
Diesel 10.00 1300
AGO 6.00 180
Residue 2.00 580
Costs ($/MM kJ)
Condenser 0.12 15
Flash zone duty 3.00 287
Profits (approximately) 4600
From the cost and revenues table above, we can determine that it would
be most desirable to get the maximum quantity of Naphtha possible,
since it is the highest value product, and of course, concurrently
minimise the energy consumption. This is not a simple task because the
market requires that product quality standards be taken into account.
The following table shows these standards:
Product Specification type Minimum (°C) Maximum (°C)

Naphtha D86 / 5% 40.00 50.00
Naphtha D86 / 95% 160.00 180.00
Kerosene D86 / 5% 170.00 190.00
Kerosene D86 / 95% 240.00 260.00
Diesel Pour point -15.00 5.00
4
Diesel Flash point 90.00 110.00

AGO Pour point 0.00 20.00
AGO Flash point 130.00 150.00
What will happen to the Naphtha product's distillation curve if we extract a

very high quantity of this product?
More components from the heavier Kerosene range will go to the

Naphtha extraction and consequently the distillation curve (i.e., D86
95% will be higher and thus will overpass the maximum value needed
to meet quality requirements).
Expanding the Flowsheet

1. Load the simulation case from the Atmospheric Crude Column
module. You can use the case you created, or load pre-made case
Crude6.hsc from your Solution Cases folder.
In this module, we will optimize the performance of the atmospheric

crude column based on the product quality specifications.
Changing the Units

As you know, HYSYS allows you to create your own set of units. If a
desired unit can not be selected from the database, we can define our
own unit by specifying an appropriate conversion factor.
In this case, the prices for the Energy values are given in MMKJ/h and,
since this unit is not available in the HYSYS unit library, we will need to
define it.
1. From the Tools menu, select Preferences.

2. Go to the Variables tab and select the Units page.
If the Refinery unit set is

3. Select the Refinery package that we defined in the Oil
missing, use a clone of the Characterization module.
SI unit set.
4. Move the cursor to the Energy cell and click on the Add button.
5
5. Complete the view as shown below.
Figure 1

Column Product Specs
In this case, we will converge the column using simple specifications
(e.g., flowrates and duties) since the optimizer will need to run the
column many times (and simple specifications enhance convergence).
We will make sure Cut Point quality specifications are selected as
estimates but are not active.
1. Open the Column Property View.

2. Change the Temperature of the feed to 320°C.
3. Click the Design tab and click the Monitor page.
6
4. Enter the Kerosene flowrate as 62 m3/h. The specifications on your

Monitor page should appear as shown:
Figure 2
The Column property view should display a “Converged” status.
Save your case!
7
Derivative Utility
The Derivative Utility is used to hold all the data used for defining the
HYSYS Optimizer variables, constraints, and the Objective Function.
The first step in setting up an optimization problem is creating a

Derivative Utility. The Derivative Utility is responsible for gathering all
necessary information for the optimizer. Notice that several different
Derivative Utilities can be added to the same simulation, that is, the
same simulation model can be used in the analysis of several different
scenarios.
To install a Derivative Utility:
1. From the Tools menu, select Utilities.

2. Click Derivative Utility in the list box on the right.
3. Click on the Add Utility button. The Derivative Utility property view
appears as shown:
Figure 3
8
Selection of Unit Operation(s)

The first step in the implementation of the Derivative Utility is the
selection of the unit operations to be considered.
4. Click the Operation button.
We will use only the distillation column as the desired unit operation.
Using this mode will optimize variables pertaining to the Atmospheric
Crude Tower unit operation.
5. Add the Atmos Tower to the Scope Objects list as shown:
Figure 4
6. Click Accept List.
Installing Optimization Variables from the Utility

The next step is to define the variables that we would like to optimize in
our case. The Optimization variables will be product flowrates, steam
flowrates, and energy values.
The needed optimization objects for the utility (in the case of the
Derivative Utility: Optimization Variables, Constraints, and Objective
Function variables) can be added directly from this view. In the
Derivative Utility Configuration group, there is a drop-down list on the
right side of the group.
9
The drop-down list contains three options:
• Process Constraints: ProcCons

• Optimization Variables: OptVars
State Variables are on/off • Objective Function: ObjFunc
variables which are not • State Variables: StateVars
being used in this case.
Figure 5
7. Select OptVars and click the Add button to the left of the drop-down
list. The selection view is displayed:
Figure 6
8. By making the selection as shown, an Optimization Variable is

created (Bttm Steam Mass Flow) and is added into the utility. By
default, the new object is given the next available name. However,
you can edit the name of the object directly from the utility view by
highlighting the name in the Object Name column and typing a new
string.
10
Figure 7
The Object Name column lets you modify the name of the created
variables. In addition, the Attached Object and attached Property
columns are also displayed in the view, as well as the variable's current
value.
The Master and Runtime radio buttons toggle the display between all
objects and those being considered for the current evaluation. The
properties can be filtered into the following:
• All. All properties.

• Input. Properties requiring user input.
• Output Calculated and outputted values.
• Results. Solution results.
Required Input for Variables

The input for optimization variables are:
• Optimize flag
• Minimum
• Maximum
• Range (optional)
• Global Minimum
From the list of variables, if • Global Maximum
you uncheck the “Optimize
flag” check box for certain
variables, the Master list will
The Global inputs are appropriate only for real time applications and
still show you all the can be set at the same values as the minimum and maximum.
variables (selected and non-
selected) whereas the
Runtime list shows only the
The Optimize flag works in conjunction with Runtime and Master lists.
selected ones. When the optimization problem is being set up, this flag is evaluated for
11
each variable. If the flag is false, then the variable is not exposed to the
Optimizer and the value remains at its starting value for the length of the
solution. With this, you can easily switch between optimization
problems by turning variables and constraints on and off. The value for
the variable Range is used in the calculation of a perturbation (= range x
perturbation factor). If none is provided, the span (maximum -
minimum) is used for the calculations.
Adding Variables
We need to add all of the optimization variables in the same way. Notice
that only those variables shown as blue in the simulation (input values)
can be selected since they must be available for updating during the
optimization. In this example, those variables that are specified as
Active specs in the column will need to be accessed through this
derivative utility.
9. Click the Add button with the OptVars option selected in the drop-
down list.
10. Add the steam flowrates. Since the specified value (blue) in this case
is in the stream itself, you will be able to access it through this object
directly as you did with the Bttm Stream Flowrate.
Figure 8
This displays how to access

a column Active
specification through the
Object ANavigator.
12
11. Repeat the steps in order to complete the list of Optimization

variables as follows:
Figure 9
Make sure that all values from the Current Value column are in blue,
since they’ll be changed later by the optimizer.
12. Select the Input view from the Variables tree on the left.
13. Complete the minimum and maximum values for each of the
variables.
Minimum Maximum
Minimum and maximum
values are the boundaries Flowrates Steam (kg/h)
for the variables in the
700 AGO Steam Flow 1600
optimization; this is the valid
range for the optimization. 2000 Bttm Steam Flowrate 4800
800 Diesel Steam Flow 1900
Flowrates Products
0 Off Gas Flowrate (kgmole/h) 10
110 Naphtha Flowrate (m3/h) 190
46 Kero Flowrate (m3/h) 80
104 Diesel Flowrate (m3/h) 156
20 AGO Flowrate (m3/h) 40
13
Minimum Maximum
Energy (MMKJ/h)
-33 Kero PA Duty -60
-25 Diesel PA Duty -50
-25 AGO PA Duty -50
Pump Around Draw Rates (m3/h)
240 Kero PA Flowrate 400
150 Diesel PA Flowrate 250
150 AGO PA Flowrate 250
Additional Specs
6 Kero Reb Duty (MMKJ/h) 10
17 Liq Flow Stg 27 (m3/h) 30
Save your case!

HYSYS SQP Optimizer is able to solve constrained optimization
problems. In the presented case, we want the product quality to remain
inside certain values. We can set this need as constraints in an
optimization problem.
Required Input for Constraints

The required inputs for constraints are as follows:
• Use flag
• Minimum
• Maximum
• Scale
All constraints are treated by the Optimizer as ranged constraints (i.e.,

the value of the constraint should lie between the minimum and
maximum at solution, within the prescribed Scale tolerance). The scale
can be considered as an approach, or as the boundary around the
minimum and maximum values that defines whether the constraint is
active, or violated. This information is reported during and after the
solution as the status of the constraint.
14
14. Click on the Add button with the ProcCons option activated in the
drop-down list as shown:
Figure 10
We could add the distillation points from the Boiling point Curves utility,
but that would take more time than if we took the values from the
Column’s Monitor page (they will save calculation time).
Use a descriptive name as 15. Add the required Distillation Points on the Monitor page of the
this will make it easier to find Column Property view if they are not already there.
with the Object Navigator.
Figure 11
The products must meet the following quality specifications:
Product Specification type Minimum (°C) Maximum (°C)

Naphtha D86 / 5% 40.00 50.00
Naphtha D86 / 95% 160.00 180.00
Kerosene D86 / 5% 170.00 190.00
Kerosene D86 / 95% 240.00 260.00
Diesel Pour point -15.00 5.00
Diesel Flash point 90.00 110.00
AGO Pour point 0.00 20.00
AGO Flash point 130.00 150.00
15
16. Repeat the steps in order to complete the whole list of Constraint
variables as displayed in the previous table.
17. For the heavy streams, we will include Flash Point and Pour Point
specifications by selecting them from the column.
18. Go to the Monitor page.
19. Click the Add Spec button.
We can also view these
properties with the 20. Click the Add Spec button again and select Cold Properties.
corresponding utility but it
will be better to gather all Figure 12
the information within the
Monitor page.
21. Remember to take into account the equipment limitation

constraints.
Equipment Min Duty (MM kJ/h) Max Duty (MM kJ/h)

Condenser 105.00 125.00
Flash Zone 70.00 90.00
16
22. Add two new process constraints for the Energy streams (you can
select these directly from the stream).
Figure 13
If any current value

exceeds the boundaries, Your view should appear as shown:
the optimizer will put it
within the limits.
Figure 14
17
Is there any constraint variable currently beyond the specified Minimum

and Maximum boundaries? _________________________________________
Objective Function Variables

Objective Function variables are installed individually which facilitates
the calculation of the gradient during the course of Jacobian
evaluations. Alternatively, an Objective Function can be built in a
spreadsheet operation, with a single cell representing the results, and
having a single Objective Function object attached to this result cell.
All the variables with a cost associated may be listed into the
Constraints/Objective Function tab. The HYSYS SQP optimizer will only
minimize the Objective Function. For this reason the revenues have to
be expressed as negative, and the cost values positive.
Thus, every single variable will have, as a result, its current value
multiplied by the associated cost/revenue. The Jacobian will minimize
the individual values that will end in a total minimum (the sum of all the
values from the list).
Price
3
Revenues ($/m )
Naphtha 14.00
Kerosene 12.00
Diesel 10.00
AGO 6.00
Residue 2.00
Costs ($/MM kJ)
Condenser 0.12
Flash zone duty 3.00
Profits
18
23. To add Objective Function variables, click on the Add button with
the ObjFunc option selected.
Figure 15
24. For this problem, individual objective function objects are installed
as shown below. Select the Naphtha product Volume Flowrate
(because the price is in $/m3).
Figure 16
19
Figure 17
Which would be the formula of the global Objective Function?
Naphtha flowrate * price Naphtha + Kero flowrate * price Kero +

Diesel flowrate * price Diesel + AGO flowrate * price AGO + Residue
flowrate * price Residue - Condenser Heat Flow * cost Energy
Condenser - Flash Zone Heat Flow * cost Energy
And its value? ________________________________
Save your case!
20
Optimizer
The Optimizer interface is used to collect all of the derivative utilities
within the current simulation case and provide them to the
optimization algorithm. The Optimizer is invoked by pressing F5 or by
opening the Simulation menu and selecting Optimizer.
Remember that we can use several utilities in the same case.
1. On the Configuration tab, select Hyprotech SQP as the optimization

algorithm.
2. After all the information is configured (leave the defaults), the
model can be run. Click the Hyprotech SQP tab and click the Start
button to run the Optimizer.
Figure 18
To examine the results on the variables and constraints, open the

appropriate Derivative Utility and view the Results page.
21
Examining the Results

Go to the Optimizer Property View (press F5).
Did the model find a solution? ________________________________________

What is the Objective Function value? __________________________________
Have we improved it? ________________________________________________
Go to the Derivative Utility and select the Results option, in the

Constraints/Objective Function tab.
Was any constraint violated? _________________________________________

And active? _________________________________________________________
An active constraint means the variable is in one of its boundaries.

Since Naphtha is the more valuable product, increasing the flowrate
should also increase the profit. We can do so by relaxing the constraints,
however, we are constrained to the quality specifications.
Change the D86 95% Temperature value to 185°C.
What is the new Objective Function? ___________________________________

What are the active specifications? _____________________________________
Did the profit increase after these changes were made? ___________________
22

Process Modeling Using HYSYS With Refinery Focus

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Getting Started 1

Simulation Basis Manager

There are four key advantages to this approach:

• All associated information is defined in a single location, allowing for

The Simulation Basis Manager is a property view that allows you to

Defining the Simulation Basis

7. Select the Hypothetical menu item in the Add Component box to

A hypothetical component can be used to model non-library

HYSYS always places an ‘*’

The minimum information

12. Add the hypo component to the Selected Components list by

You can use the Sort List

Compare the properties of C7+ with C7 and C8.

Normal Boiling Point

Ideal Liquid Density

Exporting Fluid Packages

1. On the Fluid Pkgs tab, highlight the Refinery fluid package.

2. Click the Export button.

HYSYS will automatically add Figure 10

Building the Simulation

• Select a unit set

Select a Unit Set

1. From the Tools menu, choose Preferences.

3. Select either the SI or Field unit set whichever you prefer.

4. Close this view to return to the simulation.

Changing Units for a Specification

You can scroll through the

There are a variety of ways to add streams in HYSYS.

To use this... Do this...

Adding a Stream from the Menu Bar

2. Change the stream name to Feed.

Entering Stream Compositions

On this page... Do this...

4. If the Input Composition for Stream view is not already open,

5. Click the Mole Fractions radio button in the Composition Basis

6. Enter the following compositions.

For this component... Enter this mole fraction...

Save your case often to avoid

If you try to supply temperature, pressure and vapour fraction,

With the flash capabilities of HYSYS, it is possible to perform dew and

As with the majority of objects in HYSYS, there are a number of ways to

To use the... Do this...

Next, you will add a utility using each method of installation.

Adding a Utility from the Stream Property View

1. Open the Stream property view by double-clicking on the stream in

2. On the Attachments tab, click Utilities.

3. Click the Create button. The Available Utilities view appears.

6. Switch to the Performance tab to view the envelope.

7. Click on the Table page to view the envelope data in a tabular

Adding a Utility from the Menu Bar

1. Press CTRL U. The Available Utilities view appears.

11. Go to the Dep. Prop page.

It is possible to choose multiple dependent properties. In addition, they

12. Click on the Add button.

Analyzing the Results

5. Go to the Properties page. This page contains more detailed

Customizing the Workbook

In this exercise, a new Workbook tab containing stream properties, Mass

4. Select Stream and click OK.

Printing Stream & Workbook Datasheets

Printing the Workbook Datasheet

3. Select Print Datasheet. The Select Datablock view appears.

Printing an Individual Stream Datasheet

Save your case!