2 Stage Compression 1

1
2 Stage Compression
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ADV-2 1.pdf
2 2 Stage Compression
2
Workshop
This example demonstrates a typical application of the recycle
operation. Product gas from a glycol dehydration plant enters the
compressor station at 32.35
o
C (90.2
o
F) and 62.35 bar. The gas is to be
delivered at 100 bar, and it is to be compressed in two stages. Each stage
consists of a knockout drum, a compressor, and a cooler. Liquids from
each separator are recycled back to the previous stage, after the
pressure has been reduced.
Learning Objectives
Once you have completed this section, you will be able to:
Use the Recycle operation in HYSYS
Process Overview
4 2 Stage Compression
4
Building the Simulation
Defining the Simulation Basis
For this case, you will be using the Peng Robinson EOS with the
following components: N
2
, CO
2
, H
2
S, C
1
, C
2
, C
3
, i-C
4
, n-C
4
, i-C
5
, n-C
5
,
C
6
, and H
2
O.
Starting the Simulation
Add a new Material stream with the following values:
In This Cell... Enter...
Name Gas from Glycol Plant
Temperature, C 32.35
o
C (90.2
o
F)
Pressure 1725 kPa (250 psia)
Molar Flow 5000 kgmole/h (11,000 lbmole/hr)
Component Mole Fraction
N2 0.0010
CO2 0.0284
H2S 0.0154
C1 0.8989
C2 0.0310
C3 0.0148
i-C4 0.0059
n-C4 0.0030
i-C5 0.0010
n-C5 0.0005
C6 0.0000
H2O 0.0001
2 Stage Compression 5
5
Build the Simulation without the
Recycle Operations.
1. Install a Mixer with the following values:
2. Add a Separator with the information shown below:
3. Add a Compressor with the following values:
In This Cell... Enter...
Connections
Name Mixer 1
Inlet Gas from Glycol Plant
Outlet To LP Sep
Parameters
Pressure Assignment Equalize All
In This Cell... Enter...
Connections
Name LP Sep
Feed To LP Sep
Vapour Outlet LP Sep Vap
Liquid Outlet LP Sep Liq
In This Cell... Enter...
Connections
Name Stage 1 Compressor
Inlet LP Sep Vap
Outlet Stage 1 Out
Energy Stage 1 HP
Parameters
Adiabatic Efficiency 75%
6 2 Stage Compression
6
4. Install a Cooler with the values listed in the following table:
5. Add a Mixer operation to your case.
6. Install a Separator with the following information:
In This Cell... Enter...
Connections
Name Stage 1 Cooler
Inlet Stage 1 Out
Outlet Cooler 1 Out
Energy Stage 1 Q
Parameters
Pressure Drop 70 kPa
Work Sheet
Cooler 1 Out Temperature 50C (125F)
Cooler 1 Out Pressure 80 bar
In This Cell... Enter...
Connections
Name Mixer 2
Inlet Cooler 1 Out
Outlet To IS Sep
Parameters
Pressure Assignment Equalize All
In This Cell... Enter...
Connections
Name IS Sep
Feed To IS Sep
Vapour Outlet IS Sep Vap
Liquid Outlet IS Sep Liq
2 Stage Compression 7
7
7. Add a Valve with the following information.
8. Install a Compressor with the values shown below:
In This Cell... Enter...
Connections
Name LetDown 1
Inlet IS Sep Liq
Outlet LD1 Out
Work Sheet
LD1 Out Pressure 62.35 bar
In This Cell... Enter...
Connections
Name Stage 2
Inlet IS Sep Vap
Outlet Stage 2 Out
Energy Stage 2 HP
Parameters
Adiabatic Efficiency 75%
8 2 Stage Compression
8
9. Install a Cooler operation to the case.
10. Add a Separator with the following values:
11. Install a Valve with the following information:
In This Cell... Enter...
Connections
Name Stage 2 Cooler
Inlet Stage 2 Out
Outlet Cooler 2 Out
Energy Stage 2 Q
Parameters
Pressure Drop 0 kPa
Work Sheet
Cooler 2 Out Temperature 50C (125F)
Cooler 2 Out Pressure 100 bar
In This Cell... Enter...
Connections
Name HP Sep
Feed Cooler 2 Out
Vapour Outlet HP Gas
Liquid Outlet HP Sep Liq
In This Cell... Enter...
Connections
Name LetDown 2
Inlet HP Sep Liq
Outlet LD2 Out
Work Sheet
LD2 Out Pressure 80 bar
2 Stage Compression 9
9
The only operations missing at this point are the Recycles.
Installing the Recycles
A recycle operation is a mathematical unit operation and is installed as
any other. In 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
HYSYS uses the conditions of the assumed stream (outlet)
and solves the flowsheet up to the calculated stream (inlet).
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.
Save your case!
In general, a Recycle operation
is required for material
transfer and not for thermal
recycles.
Always supply a guess or
starting point for the outlet
stream of the Recycle, never
the inlet. A guess close to the
solution will result in a faster
convergence time.
10 2 Stage Compression
10
Notice that both LetDown Valve outlets (also the Recycle Inlets) are
known. This will be a good starting point for the Assumed stream (or
guess of the Recycle).
1. Add the first Recycle by clicking on the Recycle button in the
Object Palette.
Connections Page
2. Supply the Name, Feed and Product information as shown in the
figure:
Recycle Button
2 Stage Compression 11
11
Parameters Tab
Tolerance Page
HYSYS allows you to set the convergence criteria or tolerance for each
of the Recycle variables. In this example, leave everything at the default.
The smaller the tolerance
value, the tighter the
tolerance. Generally it is a
good idea to start with the
default tolerance until you
have a converged solution and
then tighten the tolerance.
12 2 Stage Compression
12
Numerical Page
This page contains the options for the two types of Recycles, Nested
and 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.
Monitor Tab
This page displays convergence information as the calculations are
performed. Any variable that changes between iterations is displayed in
this table.
Worksheet Tab
The Recycle Worksheet page displays the Inlet and Outlet stream
information. 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 already calculated by HYSYS. When the Recycle
was connected, the known Inlet conditions were automatically passed
to the Outlet stream to serve as the starting guess.
2 Stage Compression 13
13
3. Install the second Recycle with the following information:
The final step to solving the flowsheet is to connect the Recycle Outlets
as Inlets to Mixer1 and Mixer2. Once this is done, the flowsheet will
begin solving.
4. Attach RCY 1 Out as a feed to Mixer 1.
5. Attach RCY 2 Out as a feed to Mixer 2.
Optional:
In This Cell... Enter...
Connections
Inlet LD2 Out
Outlet RCY 2 Out
Save your case!
Convert your case to a template
and save!
14 2 Stage Compression
14
Analysing the Results
If you saved your case as a template, close the template and open the
saved case.
Examine the convergence process for the Recycles. Open the Recycle
property view and look at the Convergence tab. How many iterations
did each Recycle need to converge.
Look at the Worksheet tab for each Recycle. How close are the Inlet
and Outlet stream variables?
Are the vapour fractions identical for the Inlet and Outlet?
If the vapour fractions are slightly different, tighten the
composition tolerance (change the tolerance from 10.0 to 1.0).
Does this make any difference?
RCY 1 RCY 2
Inlet Vf
Outlet Vf
2 Stage Compression 15
15
Advanced Modelling
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
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.
Choose a Stable Tear Location
The tear locations can be chosen such that fluctuations in the recycle
stream have a minimal effect. For example, by placing the tear in a
main stream, instead of the physical recycle, the effect of fluctuations
will be reduced. The importance of this factor depends on the
convergence algorithm. It is more significant when successive
substitution is used.
A very poor choice of a tear
stream is a stream with an
Adjust operation controlling
one of its variables.
16 2 Stage Compression
16
Exploring with the Simulation
Exercise 1
A. Where should the Recycle be placed in this flowsheet and why?
Assume that you know the following information:
Temperature and Vapour Fraction of "Cond Out".
Pressure drop and Duty of "Chiller" operation.
Pressure of "Chiller Out" stream.
Pressure drop of "Condenser" Operation.
The Mixer is set to "equalize all."
2 Stage Compression 17
17
Flowsheet 2
Where should the Recycle be placed in this flowsheet and why?
Assume that the Feed is fully defined, Shell and Tube Side pressure drops
are known, as well as the Column Feed temperature.
Flowsheet 3
Where should the Recycle be placed in this flowsheet and why?
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.
18 2 Stage Compression
18
Flowsheet 4
Where should the Recycle be placed in this flowsheet and why?
Assume the Feed is completely defined, and the shell and tube side
pressure drop for E-100 is known.