Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

MODUL 1
Basic Principles of The Use of
UniSim Design R451
Objectives:
To understand the basic principles of the use of UniSim Design
R451 simulator:
☻ UniSim’s environment
☻ Engineering unit
☻ Component library
☻ Thermodynamic model
☻ Type of reaction
☻ Simulation Environment
I/1

1.1. UniSim’s Environment

• UniSim: one of simulators that can be used to

simulate unit operation and or integrated-unit
operation both in steady and dynamic mode.

• UniSim  mass and energy balance of process

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

1.1. UniSim’s Environment

new case

Fig. 1.1. Command prompt of UniSim Design R451.

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1.1. UniSim’s Environment

Click New Case

View component library

View Fluid Pkgs

(thermodynamic models)

View Hypotheticals

View Reactions ESE

Fig. 1.2. Simulation Basis Manager.

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

1.2. Engineering Unit

Unit
Variables
EuroSI Field
Vapor fraction unitless unitless
Temperature C F
Pressure bar psia
Flow kgmole/hr lbmole/hr
Mass Flow kg/hr lb/hr
Liquid Volume Flow m3/hr barrel/day
Energy kcal/hr Btu/hr
Molar Density kgmole/m3 lbmole/cuft
Heat Capacity kJ/(kgmole.C) Btu/(lbmole.F)
Entropy kJ/(kgmole.C) Btu/(lbmole.F)
Viscosity cP cP

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1.2. Engineering Unit

click tools at
pull down menu Variables
 preference

Fig. 1.3. Session Preferences

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

1.3. Component Library

• Click New Case

• Click Component at
SBM

Fig. 1.4. List of components Available in UniSim’s’ Library

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1.3. Component Library

Sim Name Write the similar name, e.g. methanol

Click Add Pure

to choose one
component

Fig.1.5.a. Sim Name for choosing one component

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

1.3. Component Library

Full Name/Synonym Write the full name of component

e.g. methane

Click Add Pure

to choose one
component

Fig. 1.5.b. Full Name/Synonym for choosing one component

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1.3. Component Library

Write the formula
e.g. methane: ch4 Formula

Click Add Pure

to choose one
component

Fig.1.5.c. Formula for choosing one component

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

1.4. Thermodynamic Models

Property Package

Click Add

Click Fluid Pkgs at SBM

Fig. 1.6. Thermodynamic models in Fluid Package

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1.4. Thermodynamic Models

6 thermodynamic models in UniSim:

• Equation of State (EOS) Models

• Activity Models
• Chao-Seader Models
• Vapor Pressure Models
• Electrolyte Models
• Miscellaneous (special application) Types.

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

1.4. Thermodynamic Models

Equation of State Models non-polar

RT a
• Peng-Robinson P 
V  b V V  b   bV  b 
Hydrocarbon system with wide range of
pressure and cryogenic system.
RT a
• Soave-Redlich-Kwong (SRK) P  V  b  V V  b
Has been modified by hyprotech so that can be used for hc
system (with pressure up to 5000 psia, and temperature of
above –143 oC
• Kabadi-Danner
modified SRK, and suitable for H2O-hydrocarbon system

Dr. Eng. Y. Deddy Hermawan, Chemical Engineering UPN “Veteran” Yogyakarta I / 13

1.4. Thermodynamic Models

Activity Models polar

yi f i oL i
Ki  
Pi
dimana
xi yi, xi = mol-fraction of vapor and liquid phase
fioL = fugacity of component i at reff. condition
i = Activity coeff. of component i
i = Fugacity coeff. of component i
P = pressure of system

•Van-Laar
•Wilson : alcohol-hydrocarbon system
•NRTL (Non-Random-Two-Liquid)
•Margules
•UNIQUAC (UNIversal Quasi Chemical): polimer

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

1.4. Thermodynamic Models

Chao-Seader Models HC components

 Chao Seader
 Grayson streed : heavy HC with high H2
(hydro-treating unit )

Vapor-Pressure Models
Liquid and vapor are assumed as ideal mixture
Heavy HC at low pressure
Mixture of HC with keton or alcohol
 Antoine, Braun K10, Esso Tabular

Miscellaneous Types
For the special case
 Amine Package, ASME Steam, OLI Electrolyte

Dr. Eng. Y. Deddy Hermawan, Chemical Engineering UPN “Veteran” Yogyakarta I / 15

1.5. Type of Reactions

(1) Conversion,
(2) Equilibrium,
(3) Heterogeneous Catalytic,
(4) Kinetic, dan
(5) Simple Rate

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

1.5. Type of Reactions

Reaction Tab in Simulation Basis Manager

Fig. 1.7. Type of reactions in UniSim

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1.6. Simulation Environment

(1) Process Flow Diagram

(2) Object Palette
(3) Procedure

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

Simulation Procedure
1. Determine Engineering Unit
2. Select Components
3. Select Thermodynamic Model
4. Select Reaction Type (if any) and put in
reactant and product’s parameters
5. Enter Simulation Environment

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1.6. Simulation Environment

Object Palette

Fig. 1.8. Simulation Environment

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

MODUL 2
Ethyl Benzene Process Simulation
with UniSim Design R451
Objectives:
to do the steady state simulation of Ethyl Benzene Plant with
UniSim Design R451.

II / 1

2.1. EB Reactor Process

The basic chemical reaction:

Reaction 1:
Benzene (B) + Ethylene (E)  Ethyl Benzene (EB)

Reaction 2:
Ethyle Benzene (EB) + Ethylene (E)  Diethyl Benzene (DEB)

Reaction 3:
Diethyl Benzene (DEB) + Benzene (B)  2 Ethyl Benzene (EB)

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

2.1. EB Reactor Process

The kinetic equations: where:

69780 Reaction rates are:

R1  C E CB 5.5 x10 e 9
 RT
in kg-mole/sec/m3 (for R1 and R2)
83680 in kg-mole/hour/m3 (for R3)
R2  CE CEB 1x108 e   RT Concentrations are in kg-mole/m3
Activations energies are in kJ/kgmole
62760
R2  C DEB C B 1500 e RT Temperatures are in Kelvin

 Base component of R1 and R2 are Ethylene, and R3 are DEB

 All reactions are in liquid phase
 The reaction section consists of two large CSTR reactors (200
m3) in series.
 Reactor-1 conditions are 160 oC and 9 bar
 Reactor-2 conditions are 173.7 oC and 8 bar
 Benzene to Ethylene Ratio = 2.5

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2.1. EB Reactor Process

Selected Components

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

2.1. EB Reactor Process

Fluid Packages

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2.1. EB Reactor Process

Reaction-1

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

2.1. EB Reactor Process

Reaction-2

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2.1. EB Reactor Process

Reaction-3

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

2.1. EB Reactor Process

Feed Conditions of Reactor-1

Stream RecB FFB FFE inert1
Temperature [oC] 135,1 50 50 50
Pressure [kPa] 900,0 1100 1100 1200
Molar flow [kmole/h] 900,0 700 630,6 5
Mole Fraction:
Nitrogen 0,0003 1
Ethylene 1
Benzene 0,9987 1
Ethyl Benzene (E-BZ) 0,0010
Diethyl Benzene (1,2-E-BZ)

Valves’ Pressure Drop

Valve V1 V2 V3 V4 V5
Press. drop [kPa] 200 200 300 300 100

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2.1. EB Reactor Process

UniSim Reactor-1 Flowsheet

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

2.1. EB Reactor Process

UniSim Workbook with Material Streams of

Reactor-1

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2.1. EB Reactor Process

UniSim Workbook with Compositions of Reactor-1

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

2.1. EB Reactor Process

Feed Conditions of Reactor-2

Stream lR1out inert2 RecDEB
Temperature [oC] 160 50 219,2
Pressure [kPa] 900 1000 800
Molar flow [kmole/h] 1605 3 110
Mole Fraction:
Nitrogen 0,0033 1
Ethylene 0,0000
Benzene 0,6034
Ethyl Benzene (E-BZ) 0,3933 0,001
Diethyl Benzene (1,2-E-BZ) 0,0001 0,999

Valves’ Pressure Drop

Valve V6 V7 V8
Press. drop [kPa] 200 200 330

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2.1. EB Reactor Process

UniSim Flowsheet of Reactor-1 and Reactor-2 in series

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

2.1. EB Reactor Process

UniSim Workbook with Material Streams of

Reactor-1 & Reactor-2 in Series

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2.1. EB Reactor Process

UniSim Workbook with Compositions of Reactor-1

and Reactor-2 in Series

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

2.2. Distillation Process

 Two distillation columns are used for separating E, EB, DEB

 Column-1 specifications: see the steps below
 Column-2 specifications: see the steps below

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2.2. Distillation Process

UniSim Flowsheet of Reactor-1, Reactor-2 and
Distillation Column in series

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

2.2. Distillation Process

Distillation Colum 1 input

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2.2. Distillation Process

Condenser and Reboiler Pressures of

Distillation Colum 1

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

2.2. Distillation Process

Condenser and Reboiler Temperatures of

Distillation Colum 1

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2.2. Distillation Process

Reflux Ratio of Distillation Colum 1

Done

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

2.2. Distillation Process

Run of Distillation Colum 1

Run

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2.2. Distillation Process

Needs one more specification for Running of

Distillation Colum 1

Run

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

2.2. Distillation Process

Column-1 Worksheet

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2.2. Distillation Process

Column-1 Composition

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

Pumps’ Pressure Rise

Pump P1 P2
Press. rise [kPa] 750 880

Valves’ Pressure Drop

Valve V9 V10 V11 V12 V13
Press. drop [kPa] 200 110 300 100 300

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2.2. Distillation Process

UniSim Flowsheet of Reactor-1, Reactor-2 and

Distillation Column in series with Benzene Recycle

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

2.2. Distillation Process

Distillation Colum 2 input

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2.2. Distillation Process

Condenser and Reboiler Pressures of

Distillation Colum 2

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

2.2. Distillation Process

Condenser and Reboiler Temperatures of

Distillation Colum 2

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2.2. Distillation Process

Reflux Ratio of Distillation Colum 2

Done

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

2.2. Distillation Process

Run of Distillation Colum 2

Run

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2.2. Distillation Process

Needs one more specification for Running of

Distillation Colum 2

Run

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

2.2. Distillation Process

Column-2 Worksheet

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2.2. Distillation Process

Column-2 Composition

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

UniSim Flowsheet of Reactor-1, Reactor-2, Column-1 and Column-2 in

series with Benzene and Diethyl Benzene Recycles

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UniSim Workbook with Material Streams of Ethyl Benzene Plant

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

UniSim Workbook with Compositions of Ethyl Benzene Plant

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

MODUL 3
Isobutane Process Simulation
with UniSim Design R451
Objectives:
to do the steady state simulation of Isobutane Plant with
UniSim Design R451.

III / 1

3.1. Isomerization Reactor Process

The basic chemical reaction: nC4  iC4

Reaction rate equation: Notes: Heat of Reaction:
R = lbmol/(jam-ft3),
30000 HR = -3611 Btu/lbmol
R  CnC4 1x10 e  9
 RT
C = lbmol/ft3,
E = Btu/lbmol

Feed conditions:
Reactor conditions:
Stream name rin
Temperature (F) 390 Temperature (F) 390
Pressure (psia) 335.3 Pressure (psia) 335.3

Molar Flow [lbmole/hr] 868.3 Total Volume (ft3) 672

C3 [mole fraction] 0 Length (ft) 18
i-C4 [mole fraction] 0.2584 Pressure drop (psi) 15
n-C4 [mole fraction] 0.7416

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

3.2. Equipments Specifications

Valves and Pump HEs Specifications:
Specifications
Vaporizer Vessel Vol. (ft3) = 1000
Valve P (psi) Duty (Btu/h) = 7.94x106
Furnace Tube Vol. (ft3) = 50
V1 213
Tube P (psi) = 5.1
V2 97.7
Target Temp. (F) = 390
V3 50
Condenser Tube Vol. (ft3) = 50
V4 68.4
Tube P (psi) = 5
V5 90.4
Target Temp. (F) = 120
Pump 305

Dr. Eng. Y. Deddy Hermawan, Chemical Engineering UPN “Veteran” Yogyakarta III / 3

3.3. Column Specifications

Column Conditions Feed Conditions
Number of theoretical tray (bottom to top) 50 Stream name rout
Feed Tray (from bottom) 20 Temperature (F) 431.81
LiqRec Tray (from bottom) 30 Pressure (psia) 320.3
Cond. Press. (psia) 100 Molar Flow [lbmole/hr] 868.3
C3 [mole fraction] 0
Reb. Press. (psia) 103.8
i-C4 [mole fraction] 0.7117
Tray type Sieve
n-C4 [mole fraction] 0.2883
Cond. Temp. (F) 124.6
Reb. Temp. (F) 144.5 Stream name ffb
Spec 1: Distillate rate (lbmole/h) 526 Temperature (F) 90
Spec 2: i-Butane in Top (mole fraction) 0.96 Pressure (psia) 200
Molar Flow [lbmole/hr] 526
C3 [mole fraction] 0.02
i-C4 [mole fraction] 0.25
n-C4 [mole fraction] 0.73
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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

UniSim’s Flowsheet of Isobutane Plant

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UniSim’s Workbook of Isobutane Plant

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Aplikasi UniSim Design R451 pada Pembuatan PFD dan Simulasi Pabrik Kimia

Literatures
1) Hermawan, Y.D., 2013, Modul Praktikum Simulasi
Proses dengan ChemCad, Jurusan Teknik Kimia
UPN “Veteran” Yogyakarta.
2) Luyben, W.L, 2002, Plantwide Dynamic Simulators
in Chemical Processing and Control, Marcel
Dekker, Inc., USA, p. 357 – 374.
3) Luyben, W.L., Tyreus, B.D., and Luyben, M.L.,
1999, Plantwide Process Control, McGraw Hill, New
York, p. 273 – 294.

Dr. Eng. Y. Deddy Hermawan, Chemical Engineering UPN “Veteran” Yogyakarta III / 7

Goodluck

Dr. Eng. Y. Deddy Hermawan, Chemical Engineering UPN “Veteran” Yogyakarta III / 8

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