Outline

HYSYS Environment

CHEE 4741 Process and Plant Design I Tutorial 1a: Introduction to Aspen HYSYS

A simple two-part example

A. Donaldson, J. Haelssig, 9/12/2012

A. Donaldson, J. Haelssig, 9/12/2012

HYSYS Environment
Menu bar Toolbar

HYSYS Environment
To start a new case:
File New Case On the Components tab, select the property databank and click on Add (this allows you to add chemicals to your simulation case) On the Fluid Pkgs tab, click add (this allows you to select you fluid package(s) You can add Hypotheticals, Reactions etc. using the appropriate tabs Enter the simulation environment by clicking on Enter Simulation Environment

Status window Status bar

Trace window

A. Donaldson, J. Haelssig, 9/12/2012

A. Donaldson, J. Haelssig, 9/12/2012

HYSYS Environment
Basis Environment Simulation Environment

HYSYS Environment

Flowsheeting Tools

Solver Status Simulation Mode

Object Palette Vessels

Heat Exchangers Fluid Processing PFD Workspace Add Components Add Hypotheticals Add Reactions Simulation Tools Reactors Columns Add Fluid Packages

A. Donaldson, J. Haelssig, 9/12/2012

A. Donaldson, J. Haelssig, 9/12/2012

Example
Acetaldehyde can be produced from ethanol through dehydrogentation on a copper catalyst via the following reaction +

Example: Part 1
Start HYSYS File New Case Under the Components tab, add Ethanol, Acetaldehyde and Hydrogen Under the Fluid Pkgs tab, choose the Wilson activity model Under the Reactions tab, add the reaction as a conversion reaction with a 30% conversion Under Reaction Set, click Add to FP
7 8

Ethanol is pressurized and heated from 25C and 101.325 kPa to 600 kPa and 300C. It is then fed to the isothermal reactor, which operates at a conversion of 30%. The reactor effluent is cooled to 25C and a phase separation is carried out to purge hydrogen. The ethanolacetaldehyde mixture is separated downstream (not included here). Set up the simulation, neglecting pressure drops.
A. Donaldson, J. Haelssig, 9/12/2012

A. Donaldson, J. Haelssig, 9/12/2012

Example: Part 1

Example: Part 1

A. Donaldson, J. Haelssig, 9/12/2012

A. Donaldson, J. Haelssig, 9/12/2012

10

Example: Part 1

Example: Part 1

A. Donaldson, J. Haelssig, 9/12/2012

11

A. Donaldson, J. Haelssig, 9/12/2012

12

Example: Part 1

Example: Part 1
After adding the components, fluid package and reaction, enter the simulation environment by clicking on the Enter Simulation Environment button (ignore the warning about the binary coefficients) To set up the PFD, the following steps must be followed:
1. Create a material stream containing pure ethanol at ambient conditions, use a basis flow rate of 100 kmol/h 2. Add a pump to the flowsheet and specify the pure ethanol stream as the feed to the pump 3. Specify the pump exit stream pressure to be 600 kPa 4. Add a heater to the flowsheet 5. Heat the pressurized stream to 300C (remember to specify 0 pressure drop across the heater)
A. Donaldson, J. Haelssig, 9/12/2012

13

A. Donaldson, J. Haelssig, 9/12/2012

14

Example: Part 1
The flowsheet should now look like

Example: Part 1
6. Click the General Reactors button, then select a Conversion Reactor and add it to the flowsheet 7. Specify the heated and pressurized ethanol stream as the reactor inlet and add two outlet material streams and one energy stream 8. Since the reactor operates isothermally, specify the temperature in one of the outlet streams to be 300C 9. Inside the reactor, click on the Reactions tab and add the Reaction Set to the reactor

25C 101.325 kPa 100 kmol/h

25C 600 kPa 100 kmol/h

300C 600 kPa 100 kmol/h

A. Donaldson, J. Haelssig, 9/12/2012

15

A. Donaldson, J. Haelssig, 9/12/2012

16

Example: Part 1

Example: Part 1
10. All the reaction products should leave the reactor in the vapour phase 11. Add a cooler to the flowsheet and lower the temperature of the product stream to 25C (remember to specify a pressure drop of 0 kPa) 12. You will notice that the stream forms two phases with the vapour being primarily hydrogen 13. Add a vapour-liquid phase separator to the flowsheet to separate the phases

A. Donaldson, J. Haelssig, 9/12/2012

17

A. Donaldson, J. Haelssig, 9/12/2012

18

Example: Part 1
The flowsheet should now look like

Example: Part 1
The final workbook should look like

A. Donaldson, J. Haelssig, 9/12/2012

19

A. Donaldson, J. Haelssig, 9/12/2012

20

Example: Part 2
In analyzing the flowsheet, you should be able to note that a lot of ethanol leaves the system in stream 8, and it would make sense to recover it and recycle it to the process.
1. Add a Component Splitter to the flowsheet and connect stream 8 as its feed. In reality, distillation would be used to separate ethanol and acetaldehyde, but this added complexity is beyond the scope of this tutorial. 2. Add outlet streams to the splitter and specify all outlet pressures to be 600 kPa and all outlet temperatures to be 25C. Specify the split ratios so that ethanol leaves at the bottom and acetaldehyde and hydrogen leave at the top.

Example: Part 2

A. Donaldson, J. Haelssig, 9/12/2012

21

A. Donaldson, J. Haelssig, 9/12/2012

22

Example: Part 2
3. Add a Recycle operation to the flowsheet. Specify stream 10 as the inlet to the recycle and stream 11 as the outlet. 4. Break the connection between stream 2 and E-100 5. Add a Mixer operation to the flowsheet. The Mixer should be specified with streams 11 and 2 as the inlets and 12 as the outlet. 6. Connect stream 12 to the heater E-100

Example: Part 2
The flowsheet should now look like

A. Donaldson, J. Haelssig, 9/12/2012

23

A. Donaldson, J. Haelssig, 9/12/2012

24

Example: Part 2
The final workbook should look like

Example: Part 2
You should note that, with the recycle in place, there is minimal ethanol loss You should also note the energy required by the heater and removed from the reactor and cooler. It is likely that these could be reduced through process heat integration.

A. Donaldson, J. Haelssig, 9/12/2012

25

A. Donaldson, J. Haelssig, 9/12/2012

26