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TABLE OF CONTENTS :
i. Pump…………………………………………………………………………………………..02
ii. Compressor…………………………………………………………………………………06
iii. Expander……………………………………….…………………………………………...10
iv. Heat exchanger…….…………………………………………………………………….14
v. Flash separator……………………………………………………………………………16
vi. Conversion Reactor……………………………………………………………………..18
vii. Equilibrium Reactor …………………………………………………………………….20
viii. Distillation Columns ……………………………………………………………………22
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PUMP
PROBLEM STATEMENT:
Pumps are used to move liquids. The pump increases the pressure
of liquids. Water at 120 C and 3 bar is fed into pump that has only 10% efficiency. The flow
rate of the water is 100kgmole/hr and its outlet pressure from the pump is 84bar. Using
Peng-Robinson equation of states as a fluid package, determine the outlet temperature of
water.

LEARNING OUTCOMES:
 To solve the single unit by steady state simulation.
 Start HYSYS calculate the parameters of the pump.
 Trend of temperature on pump efficiency.

PRE-REQUISITES:
 Start HYSYS
 Open new file
 Select & Add components
 Add specific fluid Package
 Enter Simulation Environment

SIMULATION SETUP:
 First of all run the software and press Ctrl+N to open the new file.
 Now in the simulation basis manager select the component as water.
 Select the suitable fluid package for your component usually “Peng-Robinson” has
wide range of applicability.
 Enter the simulation environment and open the object pellet by pressing F4 key.
 Now drag the desired equipment in the simulation environment and add and specify
the material streams.
 Insert a material stream for the inlet of pump and specify the properties of water
given in problem statement like temperature, pressure molar flow rate.
 Double click on the pump icon to connect the Inlet and outlet streams to pump.
 By specifying all the properties, open the workbook sheet where we will get the
value of Outlet temperature and the duty of the pump.
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Simulation result:

CONCLUSION:
When the water at 120oC and 3 bar inter in pump, the pump efficiency is 10% then outlet
temperature is 138.1oC at 84 bar pressure. This means that when pump is flowing its
temperature is increased. In this case, the pump was only 10% efficient and it caused
18.1°C in the temperature of the water. The less efficient pump is the greater the
increase in the temperature of the fluid being pumped. This arises because in a low
efficient pump, more energy is needed to pump the liquid to get the same outlet
pressure as compare to more efficient pump. So the extra energy gets transferred to
the fluid.
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COMPRESSOR
PROBLEM STATEMENT:
Compressors are used to move gases. The compressor increases the
pressure of the gases. A mixture of natural gas (C1, C2, C3, i-C4, n-C4, i-C5, n-C5, n-C6, C7+) at
100◦c and 1 bar is fed into a compressor that has only 30% efficiency. The flow rate of the
natural gas is 100kgmole/hr and its outlet pressure from the compressor Is 5 bar. Using
Peng-Robinson equations of state as a fluid package determine the outlet temperature of
natural gas.

LEARNING OUTCOMES:
 To solve the single unit by steady state simulation.
 Start HYSYS calculate the parameters of the compressor.
 Solving the hypothetical components.
 Trend of temperature on compressor efficiency.

PRE-REQUISITES:
 Start HYSYS
 Open new file
 Select & Add components
 Create a hypo-group
 Add specific fluid Package
 Enter Simulation Environment

SIMULATION SETUP:
 First of all run the software and press Ctrl+N to open the new file.
 Now in the simulation basis manager select the component as (C1, C2, C3, i-C4, n-C4, i-
C5, n-C5, n-C6).
 Now add hypo-group component (C7+) and specify its molecular weight and boiling
point and it will estimate the unknowns itself.
 Select the suitable fluid package for your component as “Peng-Robinson” has wide
range of applicability.
 Enter the simulation environment and open the object pellet by pressing F4 key.
 Now drag the desired equipment in the simulation environment and add and specify
the material streams.
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 Insert a material stream for the inlet of Compressor and specify the fractions given in
problem statement like temperature, pressure molar flow rate & composition.
 Now double click on the compressor and design tab will open fill the stream number
and go to parameters and give the efficiency.
 Now see the resultant streams results.

CONCLUSION:
By increasing the efficiency of the compressor the temperatuere of
the stream increases.
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EXPANDER
PROBLEM STATEMENT:
The expender operation is used to decrease the pressure of a high
pressure inlet gas stream to produce an out let stream with low pressure and high velocity.
A mixture of natural gas (methane, ethane, propane) at 25 ◦C and 20 bar is fed into expender
that has only 30% efficiency. The flow rate of natural gas is 100kgmole/hour and its out let
pressure from the compressor is 5bar. Using Peng-Robinson equation of state as a fluid
package, determine the outlet temperature of the natural gas

LEARNING OUTCOMES:
 How to run aspen Hysys to calculate outlet temperature of natural gas by using
efficiency, outlet pressure and the inlet flow conditions.
 Effect on outlet temperature by increasing flow rate of the expander.
 Effect on efficiency of the expander by increasing the outlet temperature.

PRE-REQUISITES:
 Start HYSYS
 Open new file
 Select & Add components
 Add specific fluid Package
 Enter Simulation Environment

SIMULATION SETUP:
 First of all run the software and press Ctrl+N to open the new file.
 Now in the simulation basis manager select the component as (methane, ethane,
and propane).
 Select the suitable fluid package for your component as “Peng-Robinson” has wide
range of applicability.
 Enter the simulation environment and open the object pellet by pressing F4 key.
 Now drag the desired equipment in the simulation environment and add and specify
the material streams.
 Insert a material stream for the inlet of Expander and specify the fractions given in
problem statement like temperature, pressure molar flow rate & composition.
 Now double click on the Expander and design tab will open fill the stream number
and go to parameters and give the efficiency.
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 Now see the resultant streams results.

CONCLUSION:
By increasing the efficiency of the expander the temperature of the stream
goes down.
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HEAT EXCHANGER
PROBLEM STATEMENT:
Hot water at 250oC and 1000psig is used to heat a cold stream of water in a shell and tube
heat exchanger. The inlet temperature and pressure of the cold stream is 25oC and 130psig,
respectively. The outlet temperatures of cold and hot streams are 150 oC and 190oC,
respectively. If the flow rate of hot stream is 100kg/h, determine the flow rate of the cold
stream passing through the exchanger.

LEARNING OUTCOMES:
 Operate a heat exchanger operation in HYSYS to model the heat transfer process

PRE-REQUISITES:
 Start HYSYS
 Select Components
 Define and select a fluid package
 Add and specify material streams

SIMULATION SETUP:
 Create a new simulation on HYSYS by selecting New on the start page.
 Create a component list by adding the given components in the problem statement.
 Now, select a fluid package. For this particular problem select the “Peng-Robinson”
equation of state fluid package.
 Enter the simulation environment and from the palette, select the “Heat exchanger”
symbol and drag it to the main flow sheet.
 Add four material streams from the palette and name them “tube in (Hot stream),
shell in (cold stream), tube out and shell out” and then specify them by giving them
flow rates, temperature, composition and pressure.
 Now specify the pressure difference as “zero”.
 Hence the property window will show a green lit “OK” sign.
 Now results are seen on the flow sheet.
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SIMULATION RESULTS:
 The heat transfer rate increases as the flow rate of the cold stream is increased.
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FLASH SEPARATOR
PROBLEM STATEMENT:
We have stream containing 15% ethane, 20% propane, 60% butane and 5% n-butane at 50oF
and atmospheric pressure and a flow rate of 100lbmole/hr. This stream is to be compressed
to 50 psia and then cooled to 32oF. The resulting vapor and liquid are to be separated as two
product streams. What are the compositions and flow rates of these two streams?

LEARNING OUTCOMES:
 Operate the flash separator in HYSYS to model flash separation process

PRE-REQUISITES:
 Start HYSYS
 Select Components
 Define and select a fluid package
 Add and specify material streams

SIMULATION SETUP:
 Create a new simulation on HYSYS by selecting New on the start page.
 Create a component list by adding the given components in the problem statement.
 Now, select a fluid package. For most problems “Peng-Robinson” equation of state
fluid package is widely used.
 Now enter the simulation environment and from the palette, select the
“Compressor”
 Add material streams to this compressor and specify their properties and name them
as “Gas” at inlet and “comp gas” at outlet of compressor.
 Now, select the “cooler” symbol Also, add material streams to it just like the
compressor but its inlet will be the compressors outlet hence only add one
additional material stream to its outlet named “Cool gas”.
 Select the “separator” symbol and drag it to the main flow sheet. Now add two
streams to the flash separator from the property window and also name the product
streams as “top” and “bottom”. The property window will show green “OK” sign
indicating that the equipment is specified.
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SIMULATION RESULTS:
 The flowrates and compositions of the top and bottom streams are

Components Top Bottom

CONVERSION REACTOR
PROBLEM STATEMENT:
The interest in production of hydrogen form hydrocarbons has grown significantly in the last
decade. Efficient production of hydrogen is enabling technology, directly related to the fuel
cell energy conversion device. The conversion of fuels to hydrogen can be carried out by the
partial oxidation. The partial oxidation method relies on the reaction of the fuel for example
methane with air in order to produce carbon oxides and hydrogen.

CH4+1/2O2→CO+2H2

CH4+O2→CO2+2H2

Develop a model that represents partial oxidation of methane to produce hydrogen.

LEARNING OUTCOMES:
 Simulate conversion reactor and reaction in HYSYS
 Add the reactions and reaction sets
 Attach reaction sets to fluid package

PRE-REQUISITES:
 Navigate the PFD
 Add streams in the PFD or the Workbook
 Add and connect unit operations

SIMULATION SETUP:
 Create a new simulation on HYSYS by selecting New on the start page.
 Create a component list. This list is made by adding the given components in the
problem statement.
 Now, select a fluid package for this particular problem.
 Now, go to the reactions tab below the fluid packages tab and a set will be created.
Add two reactions in this set by clicking on add reactions and select the conversion
reactions.
 Add your components to the reactions according to the given reactions in the
problem and by assigning these components stoichiometric coefficients by using
given chemical equations
 Specify which is of the components is reactant and which is the product.
 Go to the simulation environment and select conversion reactor from the columns
given in the palette.
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 Add two material streams named “Methane” and “Air”. Set their compositions,
flowrates, temperature and pressure.
 Now, Open the conversion reactor property window by clicking on the reactor and
attach the streams to the reactor. Also, name the vapor and liquid outlets
respectively.
 Go to the reactions tab in the property window and select the reaction set as “Set-
1”. The panel under the property window will be green and it will be showing a sign
of “OK” meaning that you’ve run the simulation correctly.
 After completing the whole procedure open the worksheet and take look at
conditions and properties such as outlet stream composition and flowrate.

SIMULATION RESULTS:
 The product stream is entirely vapors as expected from the reactions and they have
a flow rate of 454.6 kgmole/h showing that there is generation due to chemical
reaction.
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EQUILIBRIUM REACTOR
PROBLEM STATEMENT:
The new application of hydrogen as a raw material for fuel cells for mobile power sources
requires that the anode inlet gas have a CO concentration lower than 10-20 ppm.
Otherwise, anode is poisoned and the cell efficiency abruptly drops.

Hence if Hydrogen is produced from Hydrocarbon or Alcohol reforming, purification is

CO+H2O↔CO2+H2

has been employed for 40 years in the industrial process for H2 production from liquid and
gaseous hydrocarbons. The role of the WGS reaction is to increase the yield of H 2 and CO
concentration, which is poison for some catalyst used.

Develop a model which represents WGS reaction.

LEARNING OUTCOMES:
 Simulate equilibrium reactor and reactions in HYSYS
 Re-add the reactions and reaction set
 Attach reaction sets to fluid package
 Print stream and workbook datasheets

PRE-REQUISITES:
 Navigate the PFD
 Add streams in the PFD or the Workbook
 Add and connect unit operations

SIMULATION SETUP:
 Open the previously saved case of conversion reactor in HYSYS.
 Add another component to the component list in it.
 Go to the reaction tab and add another reaction set name it as “Reaction set 2”.
Now, add your components to the reactions according to the given equilibrium
reaction (CO, H2O, H2, CO2) in the problem and by assigning these components
stoichiometric coefficients by using given chemical equations we will specify which is
of the components is reactant and which is the product. This reaction will be named
as “Rxn 3”.
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 Go to the simulation environment and select “equilibrium reactor” from the columns
given in the palette.
 Open the equilibrium reactor property window and attach the streams to the
reactor.
 Go to the reactions tab in the property window and select the reaction set as “Set-
2”.
 After completing the whole procedure open the worksheet conditions and
properties such as outlet stream composition and flowrate.

SIMULATION RESULTS:
 The product stream is entirely vapors as expected from the reactions and they have
a flow rate of 554.6 kgmole/h showing that there is generation due to chemical
reaction.
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DISTILLATION COLUMN
PROBLEM STATEMENT:
Determine whether conventional distillation or extractive distillation with phenol as a
solvent is a more efficient method to separate n-heptane and toluene.

LEARNING OUTCOMES:
 Essentials of extractive distillation
 How to compare design alternative
PRE-REQUISITES:
 Aspen HYSYS V8.0
 Introduction to distillation
SIMULATION SETUP:
 Create a new simulation on HYSYS & Create a component list.
 Now, select a fluid package. For this particular problem select the NRTL package.
 Add two material streams named “n-Heptane” and “Toluene”. Set their
compositions, flow rates, temperature and pressure.
 Open the distillation column property window by clicking on the column and attach
the streams to the column. Also, name the vapor and liquid outlets as n-Heptane and
Toluene respectively. Inlet stream is named Feed and then the numbers of plates are
set to “80”. The feed plate should be designated as the “plate number 69” at the
inlet stage tab. The condenser is run at “full reflux” and the Pressure in both Re-
boiler and condenser is given a value of “1bar”. Condenser duty is named as “Q-
cond”.
 After this, go to the “specs” tab on the left hand side of property window and add 2
component fractions one for each product. Click the component fraction 1 and
change the “target type” to stream and then specify the component as n-Heptane.
Also enter a value of “0.99” to the spec value segment. Set the draw as n-Heptane.
 Now, go to the “Spec summary” tab and unpick all the values except the ones
associated with component fraction 1 & 2. This will make the degree of freedom
zero in the “spec” tab.
 FEED: 1 bar, 50% vapors, 100kgmole/hr (50% n-Heptane, 50% toluene).
 Hence, by setting all these values your system will be converged and Property
window will show a green lit converged sign.
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SIMULATION RESULTS: