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Process Simulation and Control Using Aspen

Process Simulation and control using ASPEN

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Process Simulation and Control Using Aspen

Process Simulation and control using ASPEN

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astern

PROCESS SIMULATION
AND CONTROL USING

METHANOl

BUTENES

RDCOLUMN CCS

AMIYA K. JANA
This
Thispage
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Rs. 295.00

PROCESS SIMULATION AND CONTROL USING ASPEN

Amiya K. Jana

@ 2009 by PHI Learning Pnvate Limited, New Delhi. All rights reserved. No part of this book may
be reproduced In any form, by mimeograph or any other means, without permission in writing from
the publisher.

ISBN-978-81-203-3659-9

The export rights of this book are vested solely with the publisher.

Published by Asoke K. Ghosh, PHI Learning Private Limited, M-97, Connaught Circus,
New Delhi-110001 and Printed by Jay Print Pack Private Limited, New Delhi-110015.
Rs. 295.00

PROCESS SIMULATION AND CONTROL USING ASPEN

Amiya K. Jana

ISBN-978-81-203-3659-9

The export rights of this book are vested solely with the publisher.

Published by Asoke K. Ghosh, PHI Learning Private Limited, M-97, Connaught Circus,
New Delhi-110001 and Printed by Jay Print Pack Private Limited, New Delhi-110015.
This
Thispage
pageintentionally
intentionallyleft
leftblank
blank

Rs. 295.00

PROCESS SIMULATION AND CONTROL USING ASPEN

Amiya K. Jana

ISBN-978-81-203-3659-9

The export rights of this book are vested solely with the publisher.

Rs. 295.00

PROCESS SIMULATION AND CONTROL USING ASPEN

Amiya K. Jana

ISBN-978-81-203-3659-9

The export rights of this book are vested solely with the publisher.

Published by Asoke K. Ghosh, PHI Learning Private Limited, M-97, Connaught Circus,
New Delhi-110001 and Printed by Jay Print Pack Private Limited, New Delhi-110015.
Contents

Preface vii
Acknowledgements ix

Part I Steady State Simulation and Optimization

using Aspen Plus
1 . Introduction and Stepwise Aspen Plus Simulation:
Flash Drum Examples 3-53
1 1 . Aspen: An Introduction 3
1 2 Getting Started with Aspen Plus Simulation
. 4
1 3 Stepwise Aspen Plus Simulation of Flash Drums
. 7
13 1
. .
Built-in Flash Drum Models 7
13 2 Simulation nf a Flash nmm , , , _
8
1 33
. .
Computation of Bubble Point Temperature 28
1 3
. 4 Computation of Dew Point Temperature
. 35
1 3 5 T-xy and P-xy Diagrams of a Binary Mixture
. . 42
Summary and Conclusions 50
Prnhlpms , , , ,
50

Reference 53

2 , Aspen Plus Simulation of Reactor Models 54-106

2 1 .
Built-in Rpartor Models 54
2 2 Aspen Plus Simulation of a RStoic Model
. 55
2 3 Aspen Plus Simulation of a RCSTR Model
. 65
2 4 Aspen Plus Simulation of a RPlug Model
. 78
25 Aspen Plus Simulation of a RPlug Model using LHHW Kinetics
.
93
Summary and Conclusions 104
Prohlpms 704

Reference 106
v

Copyrighted maierlal
VI CONTENTS

3 . Aspen Plus Sinmlation of Distillation Models 107-185

3 1 Rnilt-in nistillntinn Mndols 107
32 . Aspen Plus Simulation of the Binary Distillation Columns 108
3 2 1 Simulation of a DSTWTT Mnripl IQfl
3 9. 9 Simulation of a RaHFrnr MoHpI 122
3 . 3 Aspen Plus Simulation of the Multicomponcnt Distillation Columns 136
3 3 1
.
Simnlnt.ion of a RaHFrar MoHpI 13fi
332
. .
Simulation of a PetroFrac Model 148
3 . 4 Simulation and Analysis of an Absorption Column 164
3 .
5 Optimization using Aspen Plus 178
Summary and Conclusions 181
Problems l2

f
Part II Chemical Plant Simulation using Aspen Plus
4 . Aspen Plus Simulation of Chemical Plants 189-226
4 1 TntrnHnrtion
4 . 2 Aspen Plus Simulation of a Distillation Train 189
4 . 3 Aspen Plus Simulation of a Vinyl Chloride Monomer (VCM)
Production Unit 203
Summary and Conclusions 220
Prnhlpms ; , -
220

References 226

Part III Dynamics and Control using Aspen Dynamics

5 . Dynamics and Control of Flow-driven Processes 229-284
5J Tnt.roHiirt.ion 229
52 . Dynamics and Control of a Continuous Stirred
Tank Reactor (CSTR) 230
5 . 3 Dynamics and Control of a Binary Distillation Column 255
Summary and Conclusions 279
Prnhlpms , , ,..
279
References 284

6 . Dynamics and Control of Pressure-driven Processes 285-313

il Tnt.rndnrtinn 285
f

6 2 . Dynamics and Control of a Reactive Distillation (RD) Column 286

Summary and Conclusions 310
Problems 31J
References 313

Index 315-317

Copyrlghled maierlal
r

Preface

"
The future success of the chemical process industries mostly depends on the ability to
design and operate complex, highly interconnected plants that are profitable and that
"
meet quality, safety, environmental and other standards To achieve this goal, the software
.

tools for process simulation and optimization are increasingly being used in industry.
By developing a computer program, it may be manageable to solve a model structure
of a chemical process with a small number of equations. But as the complexity of a plant
integrated with several process units increases, the solution becomes a challenge. Under
this circumstance, in recent years, we motivate to use the process flowsheet simulator to
solve the problems faster and more reliably. In this book, the Aspen software package
has been used for steady state simulation, process optimization, dynamics and closed-
loop control.
To improve the design, operability, safety, and productivity of a chemical process
with minimizing capital and operating costs, the engineers concerned must have a solid
knowledge of the process behaviour. The process dynamics can be predicted by solving
the mathematical model equations. Within a short time period, this can be achieved
quite accurately and eficiently by using Aspen lowsheet simulator. This software tool is
f

not only useful for plant simulation but can also automatically generate several control
structures, suitable for the used process flow diagram. In addition, the control parameters,
including the constraints imposed on the controlled as well as manipulated variables.
are also provided by Aspen to start the simulation run. However, we have the option to
modify or even replace them.
This well organized book is divided into three parts. Part I (Steady State Simulation
and Optimization using Aspen Plus ) includes three chapters. Chapter 1 presents the
introductory concepts with solving the lash chambers. The computation of bubble point
f

and dew point temperatures is also focused. Chapters 2 and 3 are devoted to simulation
of several reactor models and separating column models, respectively.
Part II (Chemical Plant Simulation using Aspen Plus ) consists of only one chapter
(Chapter 4). It addresses the steady state simulation of large chemical plants. Several
individual processes are interconnected to form the chemical plants. The Aspen Plus
simulator is used in both Part I and Part II.
vii

Copyrighted maierlal
viii PREFACE

The Aspen Dynamics package is employed in Part III (Dynamics and Control using
Aspen Dynamics ) that comprises Chapters 5 and 6. Chapter 5 is concerned with the
dynamics and control of low-driven chemical processes. In the closed-loop control study ,

f
the servo as well as regulatory tests have been conducted. Dynamics and control of
pressure-driven processes have been discussed in Chapter 6.
The target readers for this book are undergraduate and postgraduate students of
chemical engineering. It will be also helpful to research scientists and practising engineers.

Amiya K. -Jana

Copyrighted maierlal
Acknowledgements

It is a great pleasure to acknowledge the valuable contributions provided by many of my

well-wishers. 1 wish to express my heartfelt gratitude and indebtedness to Prof. A.N.
Samanta, Prof. S. Ganguly and Prof. S. Ray, Department of Chemical Engineering, IIT
Kharagpur. I am also grateful to Prof. D. Mukherjee, Head, Department of Chemical
Engineering, IIT Kharagpur. My special thanks go to all of my colleagues for having
created a stimulating atmosphere of academic excellence. The chemical engineering
students at IIT Kharagpur also provided valuable suggestions that helped to improve
the presentations of this material.
I am greatly indebted to the editorial staff of PHI Learning Private Limited, for their
constant encouragement and unstinted efforts in bringing the book in its present form.
No list would be complete without expressing my thanks to two most important people
in my life-my mother and my wife. I have received their consistent encouragement and
support throughout the development of this manuscript.
Any further comments and suggestions for improvement of the book would be
gratefully acknowledged.

rial
Part I

Steady State Simulation and

Optimization using Aspen Plus

Copyrigf
This
Thispage
pageintentionally
intentionallyleft
leftblank
blank

Rs. 295.00

PROCESS SIMULATION AND CONTROL USING ASPEN

Amiya K. Jana

ISBN-978-81-203-3659-9

The export rights of this book are vested solely with the publisher.

Published by Asoke K. Ghosh, PHI Learning Private Limited, M-97, Connaught Circus,
New Delhi-110001 and Printed by Jay Print Pack Private Limited, New Delhi-110015.
CHAPTER
i
Introduction and Stepwise
Aspen Plus Simulation:
Flash Drum Examples

11
. ASPEN: AN INTRODUCTION

By developing a computer program, it may be manageable to solve a model structure of

a chemical process with a small number of equations. However, as the complexity of a
plant integrated with several process units increases, solving a large equation set
becomes a challenge. In this situation, we usually use the process lowsheet simulator,
f

such as Aspen Plus (AspenTech). ChemCad (Chemstations), HYSYS (Hyprotech)

and PRO/II (SimSci-Esscor). In 2002, Hyprotech was acquired by AspenTech.
However, most widely used commercial process simulation software is the Aspen
software.
During the 1970s, the researchers have developed a novel technology at the
Massachusetts Institute of Technology (MIT) with United States Department of Energy
funding. The undertaking, known as the Advanced System for Process Engineering
(ASPEN) Project, was originally intended to design nonlinear simulation software
that could aid in the development of synthetic fuels. In 1981, AspenTech, a publicly
traded company, was founded to commercialize the simulation software package.
AspenTech went public in October 1994 and has acquired 19 industry-leading companies
as part of its mission to offer a complete, integrated solution to the process industries
(http://www.aspentech.eom/corporate/careers/faqs.cfm#whenAT).
The sophisticated Aspen software tool can simulate large processes with a high
degree of accuracy. It has a model library that includes mixers, splitters, phase
separators, heat exchangers, distillation columns, reactors, pressure changers,
manipulators, etc. By interconnecting several unit operations, we are able to develop a
process low diagram (PFD) for a complete plant. To solve the model structure of either
f

Copynghled material
4 PROCESS SIMULATION AND CONTROL USING ASPEN

a single unit or a chemical plant, required Fortran codes are built-in in the Aspen
simulator. Additionally, we can also use our own subroutine in the Aspen package.
The Aspen simulation package has a large experimental databank for
thermodynamic and physical parameters. Therefore, we need to give limited input data
for solving even a process plant having a large number of units with avoiding human
errors and spending a minimum time.
Aspen simulator has been developed for the simulation of a wide variety of
processes, such as chemical and petrochemical, petroleum refining, polymer, and coal-
based processes. Previously, this flowsheet simulator was used with limited
applications. Nowadays, different Aspen packages are available for simulations with
promising performance. Briefly, some of them are presented below.
Aspen Plus-This process simulation tool is mainly used for steady state simulation of
chemicals, petrochemicals and petroleum industries. It is also used for performance
monitoring, design, optimization and business planning.
Aspen Dynamics-This powerful tool is extensively used for dynamics study and closed-
loop control of several process industries. Remember that Aspen Dynamics is integrated
with Aspen Plus.
Aspen BatchCAD-This simulator is typically used for batch processing, reactions and
distillations. It allows us to derive reaction and kinetic information from experimental
data to create a process simulation.
Aspen Chromatography-This is a dynamic simulation software package used for both
batch chromatography and chromatographic simulated moving bed processes.
Aspen Properties-It is useful for thermophysical properties calculation.
Aspen Polymers Plus-It is a modelling tool for steady state and dynamic simulation,
and optimization of polymer processes. This package is available within Aspen Plus or
Aspen Properties rather than via an external menu.
Aspen HYSYS-This process modelling package is typically used for steady state
simulation, performance monitoring, design, optimization and business planning for
petroleum refining, and oil and gas industries.
It is clear that Aspen simulates the performance of the designed process. A solid
understanding of the underlying chemical engineering principles is needed to supply
reasonable values of input parameters and to analyze the results obtained. For example, a
user must have good idea of the distillation column behaviour before attempting to use
Aspen for simulating that column. In addition to the process flow diagram, required input
information to simulate a process are: setup, components properties, streams and blocks.
,

12 . GETTING STARTED WITH ASPEN PLUS SIMULATION

Aspen Plus is a user-friendly steady state process flowsheet simulator. It is extensively

used both in the educational arena and industry to predict the behaviour of a process
by using material balance equations, equilibrium relationships, reaction kinetics, etc.
Using Aspen Plus, which is a part of Aspen software package, we will mainly perform
in this book the steady state simulation and optimization. For process dynamics and
INTRODUCTION AND STEPWISE ASPEN PLUS SIMULATION 5

closed-loop control, Aspen Dynamics (formerly DynaPLUS) will be used in several

subsequent chapters. The standard Aspen notation is used throughout this book. For
example, distillation column stages are counted from the top of the column: the
condenser is Stage 1 and the reboiler is the last stage.
As we start Aspen Plus rom the Start menu or by double-clicking the Aspen Plus

f
icon on our desktop, the Aspen Plus Startup dialog appears. There are three choices
and we can create our work from scratch using a Blank Simulation, start from a
Template or Open an Existing Simulation. Let us select the Blank Simulation option
and click OK (see Figure 1.1).

MM 'Ml I I-

FIGURE 1.1

The simulation engine of Aspen Plus is independent rom its Graphical User
f

Interface (GUI). We can create our simulations using the GUI at one computer and run
them connecting to the simulation engine at another computer. Here, we will use the
'
simulation engine at Local PC'. Default values are OK.
Hit OK in the Connect to Engine dialog (Figure 1.2). Notice that this step is specific
to the installation.
The next screen shows a blank Process Flowsheet Window. The irst step in
f

developing a simulation is to create the process lowsheet. Process flowsheet is simply

defined as a blueprint of a plant or part of it. It includes all input streams, unit
operations, streams that interconnect the unit operations and the output streams.
Several process units are listed by category at the bottom of the main window in a
toolbar known as the Model Library. If we want to know about a model, we can use the
Help menu from the menu bar. In the following, different useful items are highlighted
briefly (Figure 1.3).

Copyrighted material
6 PROCESS SIMULATION AND CONTROL USING ASPEN

Connect to Engine

Serve« type Local PC

Liter Into

Node name:

Uset name

Password

Working dfedory:

Q Save as Default Cormeciion

OK Exit Help

FIGURE 1.2

A*<>r rv l u» s*iitiil-('

N> t* « » (MU To* »ir' nxntM Ibary wnty Hit

aKlftl-l-yl N l -!| .) |H| [ j?| *\

r|ttRt..|:>|.>l rr
Al/lniAiAioj-MMBSF ZlF

Next button

Data Browser button Solver Settings button

Material STREAMS icon

Status bar

H / lfcMM/5«iln«t | Sipiram | H«rfEKtwgvt | Calm | Rmovi | PmtutOnoi | MrauMeti | Sat* | UmtUoM j

Model Library toolbar
s 1 mhb rsiK sscn
PatntMrtH'l

FIGURE 1.3

Copyrighted material
INTRODUCTION AND STKPWISK ASPEN PI.US SIMULATION 7

To develop a lowsheet, irst choose a unit operation available in the Model Library.

f
Proprietary models can also be included in the lowsheet window using User Models

f
option. Excel workbook or Fortran subroutine is required to define the user model. In
the subsequent step, using Material STREAMS icon, connect the inlet and outlet streams
with the process. A process is called as a block in Aspen terminology. Notice that clicking
on Material STREAMS, when we move the cursor into the lowsheet area red and blue

f
arrows appear around the model block. These arrows indicate places to attach streams
to the block. Red arrows indicate required streams and blue arrows are optional.
When the lowsheet is completed, the status message changes from Flowsheet Not
f

Complete to Required Input Incomplete. After providing all required input data using
input forms, the status bar shows Required Input Complete and then only the simulation
results are obtained. In the Data Browsery we have to enter information at locations
where there are red semicircles. When one has finished a section, a blue checkmark
appears. In subsection 1.3.2. a simple problem has been solved, presenting a detailed
stepwise simulation procedure in Aspen Plus. In addition, three more problems have
also been discussed with their solution approaches subsequently.

13
.
STEPWISE ASPEN PLUS SIMULATION OF FLASH DRUMS

1 3 1 Built-in Flash Drum Models

. .

In the Model Library, there are ive built-in separators. A brief description of these
f

models is given below.

Flash 2: It is used for equilibrium calculations of two-phase (vapour-liquid) and three-
phase (vapour-liquid-liquid) systems. In addition to inlet stream(s), this separator can
include three product streams: one liquid stream, one vapour stream and an optional
water decant stream. It can be used to model evaporators, lash chambers and other
f

single-stage separation columns.

Flash 3: It is used for equilibrium calculations of a three-phase (vapour-liquid-liquid)
system. This separator can handle maximum three outlet streams: two liquid streams
and one vapour stream. It can be used to model single-stage separation columns.
Decanter: It is typically used for liquid-liquid distribution coeficient calculations of a
f

two-phase (liquid-liquid) system. This separator includes two outlet liquid streams along
with inlet stream(s). It can be used as the separation columns. If there is any tendency
of vapour formation with two liquid phases, it is recommended to use Flash3 instead of
Decanter.

Sep 1: It is a multi-outlet component separator since two or more outlet streams can
be produced rom this process unit. It can be used as the component separation columns.
f

Sep 2: It is a two-outlet component separator since two outlet streams can be

withdrawn from this process unit. It is also used as the component separation columns.
At this point it is important to mention that for additional information regarding a
built-in model, select that model icon in the Model Library toolbar and then press Fl
on the keyboard.
8 PROCESS SIMULATION AND CONTROL USING ASPEN

132 . .
Simulation of a Flash Drum

Problem statement

A 100 kmol/hr feed consisting of 10, 20, 30, and 40 mole% of propane, c-butane,

r
n-pentane and n-hexane, respectively, enters a lash chamber at 15 psia and 50oF.
,

f
The lash drum (Flash2) is shown in Figure 1.4 and it operates at 100 psia and 200oF.
f

Applying the SYSOP0 property method, compute the composition of the exit streams.

3 -

FLASH

FIGURE 1.4 A lowsheet of a lash drum.

f
Simulation approach
From the desktop, select Start button followed by Programs, AspenTech, Aspen
Engineering Suite, Aspen Plus Version and Aspen Plus User Interface. Then choose
Template option in the Aspen Plus Startup dialog (Figure 1.5).

I 1- l-MHM*

FIGURE 1.5

As the next window appears after hitting OK in the above screen, select General
with English Units (Figure 1.6).

Copyrighted material
INTRODUCTION AND STEPVV1SE ASPEN PLUSIM SIMULATION 9

-Hi 1

1 #

;1
L -
'
. I

i.-

I i -

FIGURE 1.6

Then click OK. Again, hit OK when the Aspen Plus engine window pops up and
subsequently, proceed to create the lowsheet.
f

Creating flowsheet
Select the Separators tab from the Model Library toolbar. As discussed earlier, there
are ive built-in models. Among them, select Flash2 and place this model in the window.
f

Now the Process Flowsheet Window includes the lash drum as shown in Figure 1.7. By
f

default, the separator is named as Bl.

nia*lHl mU JM ??1
-
a-i-m * -ai-o "d 3 I l-l SI Hi bl'
r

- I --i

0 9 «=>. 8 - C . 1

FIGURE 1.7

Copyrlghled
10 PROCESS SIMULATION AND CONTROL USING ASPEN1

To add the input and output streams with the block, click on Streams section (lower
left-hand comer). There are three different stream categories (Material, Heat and Work),
as shown in Figure 1.8.

, l , 1 Ma I J--

XQ.o Q lr
- -

FIGURE 1.8

Block Bl includes three red arrows and one blue arrow as we approach the block
after selecting the Material STREAMS icon. Now we need to connect the streams with
the lash chamber using red arrows and the blue arrow is optional. The connection
f

procedure is presented in Figure 1.9.

-
i- - rl ...iil il a ! 1
rmfT -1 "| LV I .(Bit
-
( - 11 iwl

-
- - I

. III MM .- . I -.

FIGURE 1.9

Copyrighled mateial
r
INTRODUCTION AND STFPWISK ASPEN PLUS SIMULATION 11

Clicking on Material STREAMS, move the mouse pointer over the red arrow at the
inlet of the lash chamber. Click once when the arrow is highlighted and move the

f
cursor so that the stream is in the position we want. Then click once more. We should
see a stream labelled 1 entering the drum as a feed stream. Next, click the red arrow
coming out at the bottom of the unit and drag the stream away and click. This stream
is marked as 2. The same approach has been followed to add the product stream at the
top as Stream 3. Now the lowsheet looks like Figure 1.10. Note that in the present

f
case, only the red arrows have been utilized.

.. . ,

-
a
0
.

-
Of.
.
<o-e-a.o.ir-

FIGURE 1.10

We can rename the stream(s) and block(s). To do that highlight the object we want
to rename and click the right mouse button. Select Rename Block and then give a new
name, as shown in Figure 1.11 for Block Bl.

a
-
«
r

0 %

' '

0 O-P-f c
.
a

FIGURE 1.11

Copynghied material
12 PROCESS SIMULATION AND CONTROL USING ASPEN

Alternatively, highlight the object, press Ctrl + M on the keyboard, change the
name, and finally hit Enter or OK. After renaming Stream 1 to F, Stream 2 to L,
Stream 3 to V and Block Bl to FLASH, the lowsheet inally resembles Figure 1.12.

f
~

- -

c-Q-
0
a-=

Si . , S

jjH* - <*- i -ja- -- md.n -fw »

FIGURE 1.12

In order to inspect completeness for the entire process lowsheet, look at the status
f

indicator. If the message includes Flowsheet Not Complete, click on Material STREAMS.
If any red arrow(s) still exists in the lowsheet window, it indicates that the process is
f

not precisely connected with the stream(s). Then we need to try again for proper
connection. To ind out why the connectivity is not complete, hit the Next button on the
f

Data Browser toolbar. However, if we made a mistake and want to remove a stream
(or block) from the lowsheet, highlight it. right click on it. hit Delete Stream (or Delete
f

Block), and inally click OK.

Anyway, suppose that the lowsheet connectivity is complete. Accordingly, the status
f

message changes rom Flowsheet Not Complete to Required Input Incomplete.

We have defined the unit operation to be simulated and set up the streams into
and out of the process. Next we need to enter the rest of the information using several
input forms required to complete the simulation. Within Aspen Plus, the easiest way to
ind the next step is to use one of the followings:
f

1 .
click the Next button
2 ind Next in the Tools menu
f

3 . use shortcut key F4

As a consequence. Figure 1.13 appears.

Copynghied material
INTRODUCTION AND STKPWISK ASPEN PLUS SIMULATION 13

r|nf? . .

l ..|..h nr .! -wi i - M
3

a-c

o
- m

(mu, im ml '

FIGURE 1.13

Configuring settings
As we click OiC on the message. Aspen Plus opens the Data Browser window containing
the Data Browser menu tree and Setup/Specifications/Global sheet.
Alternatively, clicking on Solver Settings and then choosing Setup /Specifications in
the left pane of the Data Browser window, we can also obtain this screen (Figure 1.14).

-JUS.'

; I*
.
. >i . ->

rr.Fi F

OQ-o-O-it-

FIGURE 1.14
14 PROCESS SIMUIvVTION AND CONTROL USING ASPEN

Although optional, it is a good practice to ill up the above form for our project giving

f
the Title (Flash Calculations) and keeping the other items unchanged (Figure 1.15).

. !

3af* I 3 ri-i - »i ji .1 H
-

."
y

*
-
(0-eo.o-1

FIGURE 1.15

In the next step (Figure 1.16), we may provide the Aspen Plus accounting information
(required at some installations). In this regard, a sample copy is given with the followings:
User name: AKJANA
Account number: 1
Project ID: ANYTHING
Project name: AS YOU WISH

\ r i-i i-f si

.
iO-Oo.Q.I.
m -

FIGURE 1.16

Copyrighted material
INTRODUCTION AND STEPWISE ASPEN PLUS SIMULATION 15

We may wish to have streams results summarized with mole ractions or some other basis

f
that is not set by default. For this, we can use the Report Options under Setup folder. In the
subsequent step, select Stream sheet and then choose Mole raction basis,

f
... - rJtW

. . --

g
'
""
t -

IZZi U-.-J7-- i
-
* '
i
*

.
(O-eo-e-T-
FIGURE 1.17

As illed out, the form shown in Figure 1.17, inal results related to all inlet and
f

product streams will be shown additionally in terms of mole raction. Remember that all
f

values in the inal results sheet should be given in the British unit as chosen it previously.
f

Specifying components
Clicking on Next button or double-clicking on Components in the column at the left side
and then selecting Specifications, we get the following opening screen (Figure 1.18).

iff i ijLJH .

.
(0-8-o.o.ir.
. * -

FIGURE 1.18

Copynghi
16 PROCESS SIMULATION AND CONTROL USING ASPEN1"

Next, we need to fill up the table as suggested in Figure 1 18. A Component ID is .

essentially an alias for a component It is enough to enter the formulas or names of the .

components as their IDs Based on these component IDs, Aspen Plus fills out the Type .
,

Component name and Formula columns But sometimes Aspen Plus does not find an .

exact match in its library. Like in the present simulation, we have the following screen ,

(Figure 1.19) after inserting chemical formulas of the components in the Component ID
column.

3513
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"
-
Heai Etclianflet! | Coturr j Reacloit | Prenue Changers Manpiiaioo | Sobdi | U;ei Modets
"

Sep
-c. Sep2
FotMefcj preMFI . C:\ ..aFolde(5\A!penP1ui 11,

FIGURE 1.19

Obviously, only for Component ID C3H8, Aspen Plus provided the Component name
(PROPANE) and Formula (C3H8). This simulator does not recognize the other three
components by their IDs. Therefore, we have to search in the following way
(Figure 1.20) to obtain their names and formulas. Click on a component ID (say, N-C4H10),
then hit Find button.
Now, we have to give a hint with Component name or formula (butane) and then
hit Enter or Find now button (Figure 1.21). Apart from component name or formula,
we can also search a component by giving component class or molecular weight (range)
or boiling point (range) or CAS (Chemical Abstracts Service) number. Click on Advanced
button in the following screen to get these options.
INTRODUCTION AND STKPWISE ASPEN PLUS SIMULATION 17

23 t-n "T. T«rf« WbI ifrvy Wwk-' h*>

i r- u.ivi»rT
»j <<||*i -| »| Qlral h»|
7 1
HmmaftmU

. / .'r -.r,,
Careen r
>i cm}: DMNMeMI
M«HU DBIWVWBM

*lf-Con«»
"

| M«fryCa«p«

it
_
j immmm

I COTvOcttins
-
tOCirr.0»ilicr»
3>!>!ic:- BBS wowre >:...<-» ..r .j -

irw, i«Hei
O M<4>

U k4
UmriKitrmx Sapaiataii | Han
Hm> Eichtnsan | COni
-

CH
m 6 o
mo. cm n
-

» st-t

FIGURE 1.20

MWflll III I I

aKlftl-l l'Tl S!J "SI -I I Hl wj ll itL

f
I F--IHH>nr i i -i 'Ipi i m\ .i-i

i 35Ji

e?*-'aTtyr ' u'tt

WMM
' Mirr? 1X414
' I'tM* |M.| fiiM
tOD O* *MM2
.
*
J 1 'ttrVM r tuhtn 114 2n -VJ J-' SrM O-' '
C4M»4 runrn
PURE 11
J
. I

Si K

FIGURE 1.21
18 PROCESS SIMULATION AND CONTROL USING ASPEN

Aspen Plus suggests a number of possibilities. Among them, select a suitable

component name (N-BUTANE) and then click on Add. Automatically, the Component
name and Formula for Component ID N-C4H10 enter into their respective columns.
For last two components, we follow the same approach. When all the components are
completely defined, the illed component input form looks like Figure 1.22.

- u m m: vr
f rai-«-l«»|««i|-4| *»-| »"l
,
.) i"! -I vj
"
ttl
I r- I " i I I M -leal : ! !
let >.-
Si - ~

j s- I

n tt-

FIGURE 1.22

The Type is a specification of how Aspen calculates the thermodynamic properties.

For luid processing of organic chemicals, it is usually suitable to use 'Conventional*
f

option. Notice that if we make a mistake adding a component, right click on the row
and then hit Delete Row or Clear.

Specifying property method

Press Next button or choose Properties I Specifications from the Data Browser. Then if
we click on the down arrow under Base method option, a list of choices appears. Set the
SYSOPO' method as shown in Figure 1.23.
A Property method defines the methods and models used to describe pure component
and mixture behaviour. The chemical plant simulation requires property data. A wide
variety of methods are available in Aspen Plus package for computing the properties.
Each Process type has a list of recommended property methods. Therefore, the Process
type narrows down the choices for base property methods. If there is any confusion, we
'
may select All' option as Process type.

Specifying stream information

In the list on the left, double click on Streams folder or simply use Next button. Inside
that folder, there are three subfolders, one for each stream. Click on inlet stream F, and
enter the temperature, pressure, low rate and mole fractions. No need to provide any
f

data for product streams L and V because those data are asked to compute in the present
problem (see Figure 1.24).

This property method assumes ideal behaviour for vapour as well as liquid phase.

C ll
INTRODUCTION AND STEI'WISK ASPEN PLUS SIMULATION 19

cina

Tiers r
"

i
0 samii (Ham
UVUM .
-
par-

-
AFU
r
I t4 -I - I . - |M

Co
f> . FBI

P j mi«D»

-
a-
HO-e-o-i-it. !

FIGURE 1.23

Ha 'ssH I

0]t*lMI _

rmr i~i-..t>-rv
f5~

Im«7V= 31
nns Dt
f, .rilll
, ri.ttn it:
-

I JIU-*"- I'M- . *

.1. -.. .11. : ...

h o e czd- @ - it.

FIGURE 1.24

Specifying block information

Hitting Next button or selecting Blocks/FLASH in the column at the left side, we get
the block input form. After inserting the operating temperature and pressure, one
obtains Figure 1.25.
20 PROCESS SIMULATION AND CONTROL USING ASPRN

U3SE
Toob Ron Piol Lfciaiy Wmdow Help

~
did -J a M
D - I I 'I -isil I lai alS*l
~

i :r .- u>i"i-

UNIFAC Gioup 3 /Sp«c>rioalion>{ Floih.Ophwn | ErJ

_
) UN1FAC G<oup
.
__
J
Cl 0ot ,
-
_
J A sJyBJ
PMP>SMi
-

gp-n=-3
O K>OE5I<iN
0 tMCPMAL
(#> TXPOftT -
i
O VIE

* .
ilj Advanced
JQ
-
Lifl >=
-

Input

EO varial

IS FLASH
| Be

Conv Op«noj
i EO Conv Option*
O Setup
DMOBasK

49 DMOAdv

Input CompteK

[1 Mbcwt/SpBtsit Sopjuato.. j HmI Exciwigsi t Columni | FtMclnt | Pfonuio Chonoe

:
STREAMS
H 0 - 9 -CD-
'
Fl«h2 FlaihS Deca/Kei Sep 5ep2

FIGURE 1.25

Now the Status message (Required Input Complete) implies that all necessary
information have been inserted adequately. Moreover, all the icons on the left are blue.
It reveals that all the menus are completely filled out. If any menu is still red, carefully
enter the required information to make it blue.

Running the simulation

Click on Next button and get the following screen (see Figure 1 26). To run the .

simulation, press OK on the message. We can also perform the simulation selecting
Run from the Run pulldown menu or using shortcut key F5 .

r Zl I - * I .IPI . I > in rnim

Tl SJ b li"" 1 1 ] all*- -l±j cjJ _

Cl ~-T

3
£=1

8 ! 7.1 CarrvOpllam
33 to Conv Option*

.TfUAMt ' FWttJ SgM L -«o>i S p "fJ

FIGURE 1.26

The Control Panel, as shown in Figure 1.27, shows the progress of the simulation.
It presents all warnings, errors, and status messages.
jNIRODUCTlON AND STEPW1SE ASPEN PLUS SIMULATION 4 21

Q rtm eai vw« DM* roota Lih..i..

,
QhrjAj*i j-j an .| ihi .j M
I 1"! _=J 3?) H -iroh L_jih
3 I
- "

3 r "

3 r

. loch:

Pt.iofva and Po«U<**» Soipti

p" l t*«i * *S'«- f" '.. i ' r..:.

Command Lr» |
AI bkK+» h«v» bean .

STREAMS
0
FU>»K3
6 -ciD
Fl<nH3 D«canl- Sup S»p2

FIGURE 1.27
Viewing results
Hitting ATex button and then clicking OK, the Run Status screen appears irst (see Figure 1.28).

f
yil l .i.l.lJIII«.II..IIHIII.I.IMItMIIIIH.HI II.Wl'ltlll.Ml.llltHW
-

I I Ffe Edt VKm Data Tools Rvxi Mot Lbtoty Window htetp

ItflHI -I v| daHal
-

3 m I _iJ_iMi_L
B Ru-i Slatut 3 sQg r
S i Streams

QU RaMiU Swranarv
-

Run Statu*
Streams
Convergence

Atpen Plui Vetswn prrr

Lite [fLash CALCULATIONS
"

Dale and lime [JUNE 5. 2007 1 23621 Pm

Uminam» [AOMIN IS TRATOB
S*»\D |TEAM_EAT
Machnelypo [WIN32 Hott iCONTROLLAB

Use << and >> robiowie testitt

MBW./Scfcie.. S* . ) H»al E-changst | CcWa | Be«clor. e Chang** i Man« j Sobd. | U>«Mo4* |

(0-9 o 8 .

FIGURE 1.28

From the Data Browser, choose Results Summary /Streams and get the following
1 29).
screen that includes the inal results of the given problem (see Figure .
f

We can
Save the work by choosing File/Save As/...from the menu list on the top.
name the ile whatever we want. Note that an Aspen Plus Backup ile (*.bkp) takes
f
f

much less space than a normal Aspen Plus Documents ile ( .apw).
f
22 PROCESS SIMULATION AND CONTROL USING ASPEN

1j Fto '. ,-V . - Took Run P

: JSbd JMSj-d HIP jsJ . j . i

I I
» J/l Block*

£1 fo. * r
"

3 5l<»amT»blf[

r rjj 1 - 3
50 0 2000 200 0
i f. nr i ion oo ion on

Vapo* Froc 0016 0 000 1 000

Mote Flow cmot/hi 220 462 1 Tf 971 42 492

f
Mas* Ftow b/h. 15906 41* 13312.698 2593 716
v. l:...- Flow culler 1039 561 382.439 3008 065

lE.Hh»lpy MMBtu/hi 16 583 1243? 2 236

Mole Flow bmolVIv

C3H8 22 046 9 275 12 771

NC4H10 44092 30124 13 969

66139 56 242 9 896

N.C6H14 eeies 82 329 5856

(V Mixw pMto! SoiMralof* { Heal Enchangon | Column* | Re»cto.. \ P-eume Chongeij \ Mo puMw* | So§*. | Um. Models )

STREAMS
HO 0 cd ' FVwh2
" ""
Flaih3 D>came> 3ep Sep2
For H*te, press Fi C.\- .g Pol<tou\Ajper. PK» 11,1 ! NUM i - .
.
.. Av,4,>:-

*
Start}} Aspen Pkn - Simulatl_

FIGURE 1.29

If we click on Stream Table button, the results table takes a place in the Process
Flowsheet Window, as shown in Figure 1.30.

Fie Edt View Data Tocfc Run Ffevaheet Librvy Whdow Help

1 global j |£e.| . I lai

F L V

Temptntuit F 50 0 200 0 200.0

Pttiiun pri 15 00 100 00 100.00

V*poi Fnc 0 018

.
0 000 1000

HoUFtow cnoVhi 220462 177 971 42 492

f
r

ctu 15906 414 13312 698 2593 716

f
f

VokuntFlw 1639 561 382439 3008 065

EnlhJpy MMBtu/hi -
16583 -
12.499 -
2236

Hole Flw

C3H8 22 046 9 275

-
12 771

H-C4H10 44 092 30 124 13569

K-C5H12 66139 56 242 9996

H-C6H14 88 185 82.329 5 856

Mok Trie

C3K8 0 100
.
0053 0 301

HX4HI0 0 200
.
0 169
.
0329

H-C5H12 OJOO 0 316 0233

H-C6H14 0 400 0 463 0 138

Mm/Spitlan Sflprntms { Heat Eicchangeit { Cdum | Reactori | PrMtue Chmgeii j Mmpdalai | Soldi j Use. Models j
D-»
<0-8-o
-

C:V.oF<*lefs\A»penMu»n.l

?1 1

FIGURE 1.30
INTRODUCTION AND STKPWISK ASPKN PI.US,M SIMUI.ATION 23

Viewing input summary

To obtain the input information, press Ctrl + Alt + I on the keyboard or select Input
Summary rom the View pulldown menu. The supervisor may ask to include the results,
f

shown in Figure 1.30, along with the input summary in the inal report on the present

f
project (see Figure 1.31).

Fl» Ml ft >W He»

linput swimtrf crvaccd bv upen Plus "el. U.l tt tiiMtiS rrf jun a, 2007 ~
; Dlr»ctory CtSproarur 11 TBc\Aspanrai:n\WDrklng Polaei ' j' iveft Plus 11.1 tllnnm*

mMPuis
DPLUS RCSULTS-ON

TITLE 'PlHh Calculations '

IN-UNir» lii.

DEC-STRESS CONVtlt ALl

CCOUNI-tKEO KC0UNT>1 PROJECT-ID»*MtTHING 4

ff>0)6C'OU WISH 0SE('-H**S-"«J/f«'

DGKRIPriON '
General Sl*u1al1e*< w<th English unl s :
F, dsI, Ib/hf, lEf«ol/»». oiu/hr, eirft/hr,
Propariy Haihooi wona
eln* M*l» for Incur: NOll
"

i r j - report : '. . Mola *lo»

PUBCII / AQUCOUS / SOLIDS / UttROANIC / t

tOASPENPCO

PROP-IOURCES CUBEll / MJUCOUS / SOCIOl / INC>Ra»"IC

CJm8 C3h8 /
N-camo caxio-z /

N-cenW CftHH-l
"lOWSHEET
bicc> flash ih-e aut-v l

PROPERTIES SY5OP0

SUOSTRCAH -EO TEWB.lo. PBE5-11, »MLE-PLOB-i00. -ktcVr>->

xe-fb»c ana o.i / w
.* kio o.j / n-cihi? o. t / »
N-c6nl4 0 .4

- - plash Flash;
kabah rtwp- ao. "sr.-ic-j .

FIGURE 1.31

Creating report file

To create a detailed report of the work we have done, including input summary, stream
information, etc., select Export (Ctrl + E) from the File dropdown menu. Then save the
work as a report ile (e.g. C/Program Files/AspenTech/Working Folders/Aspen Plus
,
f

Version/ Flash.rep). Subsequently, we may open the saved report ile (Flash.rep) going
f

through My Computer with using a program, such as the Microsoft Office Word or
WordPad or Notepad. A report ile for the present problem is opened below.
f

ASPEN PLUS IS A TRADEMARK OF HOTLINE:

ASPEN TECHNOLOGY. INC. U.S.A. 888/996-7001
TEN CANAL PARK EUROPE (32) 2/724-0100
CAMBRIDGE. MASSACHUSETTS 02141
617/949-1000
24 PROCESS SIMULATION AND CONTROL USING ASPEN

PLATFORM: WIN32 JUNE 10, 2007

VERSION: 11.1 Build 192 SUNDAY
INSTALLATION: TEAM EAT _
11:23:23 A.M .

ASPEN PLUS PLAT: WIN32 VER: 11.1 06/10/2007 PAGE I

FLASH CALCULATIONS

ASPEN PLUS (R) IS A PROPRIETARY PRODUCT OF ASPEN TECHNOLOGY, INC.

(ASPENTECH), AND MAY BE USED ONLY UNDER AGREEMENT WITH ASPENTECH.
RESTRICTED RIGHTS LEGEND: USE, REPRODUCTION, OR DISCLOSURE BY THE
U S GOVERNMENT IS SUBJECT TO RESTRICTIONS SET FORTH IN
. .

(i) FAR 52.227-14, Alt. Ill, (ii) FAR 52.227-19, (iii) DEARS
252.227-7013(c)(l)(ii), or (iv) THE ACCOMPANYING LICENSE AGREEMENT,
AS APPLICABLE. FOR PURPOSES OF THE FAR, THIS SOFTWARE SHALL BE DEEMED
TO BE "UNPUBLISHED" AND LICENSED WITH DISCLOSURE PROHIBITIONS.
CONTRACTOR/SUBCONTRACTOR: ASPEN TECHNOLOGY, INC. TEN CANAL PARK,
CAMBRIDGE, MA 02141.

TABLE OF CONTENTS

RUN CONTROL SECTION 1

RUN CONTROL INFORMATION 1
DESCRIPTION 1

FLOWSHEET SECTION 2
FLOWSHEET CONNECTIVITY BY STREAMS 2
FLOWSHEET CONNECTIVITY BY BLOCKS 2
COMPUTATIONAL SEQUENCE 2
OVERALL FLOWSHEET BALANCE 2

PHYSICAL PROPERTIES SECTION 3

COMPONENTS 3

U-O-S BLOCK SECTION 4

BLOCK: FLASH MODEL: FLASH2 4

STREAM SECTION 5
F L V 5

PROBLEM STATUS SECTION 6

BLOCK STATUS 6

ASPEN PLUS PLAT: WIN32 VER: 11.1 06/10/2007 PAGE 1

FLASH CALCULATIONS
RUN CONTROL SECTION
RUN CONTROL INFORMATION

THIS COPY OF ASPEN PLUS LICENSED TO

TYPE OF RUN: NEW

INPUT FILE NAME: _

1437xbh.inm

OUTPUT PROBLEM DATA FILE NAME: _

1437xbh VERSION NO. 1
INTRODUCTION AND STEPWISE ASPEN PLUS SIMULATION 25

LOCATED IN:
PDF SIZE USED FOR INPUT TRANSLATION:
NUMBER OF FILE RECORDS (PSIZE) = 0
NUMBER OF IN-CORE RECORDS - 256
PSIZE NEEDED FOR SIMULATION - 256

CALLING PROGRAM NAME: apmain

LOCATED IN: C:\PROGRA~ I\ASPENT~-1 \ASPENP~1.1 \Engine\xeq

SIMULATION REQUESTED FOR ENTIRE FLOWSHEET

DESCRIPTION

GENERAL SIMULATION WITH ENGLISH UNITS : F, PSI, LB/HR, LBMOL/HR,

BTU/HR, CUFT/HR. PROPERTY METHOD: NONE FLOW BASIS FOR INPUT: MOLE
STREAM REPORT COMPOSITION: MOLE FLOW

ASPEN PLUS PLAT: WIN32 VER: 11.1 06/10/2007 PAGE 2

FLASH CALCULATIONS
FLOWSHEET SECTION

FLOWSHEET CONNECTIVITY BY STREAMS

STREAM SOURCE DEST STREAM SOURCE DEST

F FLASH V FLASH
L FLASH

FLOWSHEET CONNECTIVITY BY BLOCKS

BLOCK INLETS OUTLETS

FLASH F V L

COMPUTATIONAL SEQUENCE

SEQUENCE USED WAS:

FLASH

OVERALL FLOWSHEET BALANCE

MASS AND ENERGY BALANCE

IN OUT RELATIVE DIFF.

CONVENTIONAL COMPONENTS (LBMOL/HR)
C3H8 22.0462 22.0462 0 101867E-09
.

N-C4H10 44.0925 44.0925 0 326964E-10

N-C5H12 66.1387 66.1387 -

0 113614E-10
.

N-C6H14 88.1849 88.1849 -

0 332941E-10
.
26 PROCESS SIMULATION AND CONTROL USING ASPEN

TOTAL BALANCE
MOLE( LBMOL/HR) 220.462 220.462 0.000000E+00
MASS(LB/HR) 15906.4 15906.4 -0.782159E-11
ENTHALPY(BTU/HR) -0.165833E+08 -0.147349E+08-0.111463

ASPEN PLUS PLAT: WIN32 VER: 11.1 06/10/2007 PAGE 3

FLASH CALCULATIONS
PHYSICAL PROPERTIES SECTION

COMPONENTS

ID TYPE FORMULA NAME OR ALIAS REPORT NAME

C3H8 C C3H8 C3H8 C3H8
N-C4H10 C C4H10-1 C4H10-1 N-C4H10
N-C5H12 C C5H12-1 C5H12-1 N-C5H12
N-C6H14 C C6H14-1 C6H14-1 N-C6H14

ASPEN PLUS PLAT: WIN32 VER: 11.1 06/10/2007 PAGE 4

FLASH CALCULATIONS
U-O-S BLOCK SECTION

BLOCK: FLASH MODEL: FLASH2

INLET STREAM: F
OUTLET VAPOR STREAM: V
OUTLET LIQUID STREAM: L
PROPERTY OPTION SET: SYSOP0 IDEAL LIQUID / IDEAL GAS

***
MASS AND ENERGY BALANCE ***

IN OUT RELATIVE DIFF.

TOTAL BALANCE
MOLE(LBMOL/HR) 220.462 220.462 0 000000E+00
.

MASS(LB/HR) 15906.4 15906.4 -

0 782136E-11
.

ENTHALPY(BTU/HR) -0.165833E+08 -0.147349E+08 -0.111463

INPUT DATA

TWO PHASE TP FLASH

SPECIFIED TEMPERATURE F 200.000
SPECIFIED PRESSURE PSI 100.000
MAXIMUM NO. ITERATIONS 30
CONVERGENCE TOLERANCE 0 000100000
.

***
RESULTS ***

OUTLET TEMPERATURE F 200.00

INTRODUCTION AND STEPWISE ASPEN PLUS SIMULATION 27

OUTLET PRESSURE PSI 100.00

HEAT DUTY BTU/HR 0 18484E+07
.

VAPOR FRACTION 0 19274

V-L PHASE EQUILIBRIUM:

COMP F{I) X(I) Yd) K(I)

C3H8 0 10000
.
0 52117E-01
.
0 30055
.
5 7668
.

N-C4H10 0 20000
.
0 16926
.
0 32874
.
1 9422
.

N-C5H12 0 30000
.
0 31602
.
0 23290
.
0 73697
.

N-C6H14 0 40000
.
0 46260
.
0 13781
.
0 29790
.

ASPEN PLUS PLAT: WIN32 VER: 11.1 06/10/2007 PAGE 5

FLASH CALCULATIONS
STREAM SECTION
F L V

STREAM ID L V
FROM : FLASH FLASH
TO FLASH

SUBSTREAM: MIXED
PHASE: MIXED LIQUID VAPOR
COMPONENTS: LBMOL/HR
C3H8 22.0462 9 2754
.
12.7709
N-C4H10 44 0925
.
30.1237 13.9688
N-C5H12 66 1387
.
56.2424 9 8963
.

N-C6H14 88 1849
.
82.3291 5 8558
.

COMPONENTS: MOLE FRAC

C3H8 0.1000 5 2117-02
.
0 3005
.

N-C4H10 0 2000
.
0 1693
.
0 3287
.

N-C5H12 0 3000
.
0 3160
.
0 2329
.

N-C6H14 0 4000
.
0 4626
.
0 1378
.

TOTAL FLOW:
LBMOL/HR 220.4623 177.9706 42.4917
LB/HR 1.5906+04 1 3313+04
. 2593.7158
CUFT/HR 1839.5613 382.4385 3008.0650
STATE VARIABLES:
TEMP F 50.0000 200.0000 200.0000
PRES PSI 15.0000 100.0000 100.0000
VFRAC 1.8002-02 0 0 .
1 0000
.

LFRAC 0.9820 1 0000

.
0 0
.

S FRAC 0.0 00 .
0 0
.
28 PROCESS SIMULATION AND CONTROL USING ASPEN1

ENTHALPY:
BTU/LBMOL -7.5221+04 -7.0232+04 -5.2612+04
BTU/LB -1042.5543 -938.9019 -861.9118
BTU/HR -1.6583+07 -1.2499+07 -2.2356+06
ENTROPY:
BTU/LBMOL-R -130.1235 -123.3349 -87.8846
1 4398
BTU/LB-R -1.8035 -1.6488 -

DENSITY:
LBMOL/CUFT 0.1198 0.4654 1.4126 02 -

LB/CUFT 8.6469 34.8100 0.8623

AVG MW 72.1503 74.8028 61.0406

ASPEN PLUS PLAT: WIN32 VER: 11.1 06/10/2007 PAGE 6

FLASH CALCULATIONS
PROBLEM STATUS SECTION

BLOCK STATUS

**************
********************************************************

* *

*
Calculations were completed normally *
* *

*
All Unit Operation blocks were completed normally *
* *

*
All streams were lashed normally *
f

* *

************************************************************************:!:;!=

13
. .
3 Computation of Bubble Point Temperature
Problem statement

Compute the bubble point temperature at 18 bar of the following hydrocarbon mixture
(see Table 1.1) using the RK-Soave property method.
TABLE 1.1

Component Mole fraction

Ci 0 05
.

c2 0 1
.

C3 0 15
.

i-Ci 0 1
.

n-Ci 02
.

i-C5 0 25
.

n-C5 0 15
.

Assume the mixture inlet temperature of 250C, pressure of 5 bar and low rate of
f

120 kmol/hr.
S,MULA' noN 29
Simulation approach
After starting the Aspen Plus simulator, the Aspen Plus Stnrt v i
Among the three choices, select Template option and then S
,.,

e F Tl 3
L L J.-i..'i- I iM BlMtt i ~| S!| -j j jj g j

t ,J;'&9'lr.lrtoi\Ait«r.leI:MV l,1gffj ,Asinwi

Ptft.,..- "" TTrTtrtilVfnrt.i0ritliiiV>iWnrfca 11
C 'Pi09'*T>F'f'''-!CW"lecl-AW1>t»>jFc«eii'A Mr!rt,: n
:

H !i j

FIGURE 1.32

When the next window pops up (see Figure 1.33) ,

select General with Metric Units
and then hit OK.

3 -II ...d..ji:;L: i 1 1 raliH

FIGURE 1.33

In the next ,
press OK in the Connect to Engine dialog. Once Aspen Plus connects to
the simulation engine, we are ready to begin entering the process system.
30 PROCESS SIMULATION AND CONTROL USING ASPEN

Creating flowsheet
Using the Flash2 separator available in the equipment Model Library, develop the
following process low diagram (see Figure 1.34) in the Flowsheet Window by connecting

f
the input and output streams with the lash drum. Recall that red arrows are required

f
ports and blue arrows are optional ports. To continue the simulation, we need to click
either on Next button or Solver Settings as discussed earlier. Note that whenever we
have doubts on what to do next, the simplest way is to click the Next button.

rjafn ..|-|..|. {k jl .15)1 I gl *w

0
o

mm 1
o-e-oi-ir-
_
2£

£S-| »... >

FIGURE 1.34

Configuring settings
From the Data Browser, choose Setup I Specifications. The Title of the present problem
is given as 'Bubble Point Calculations'. Other items in the following sheet remain
untouched (see Figure 1.35). However, we can also change those items (e.g., Units of
measurement. Input mode, etc).

3 -.1 ,b. i -. m -\u

gag i 3 abi 3 »l alai

ij
, u m
it »
« "'E E3

FIGURE 1.35
INTKODUCTION AND STHPWISE ASFKN PLUSIM SIMULVTION 31

In the next, the Aspen Plus accounting information are given (see Figure 1.36).

rt* tm ttw imt 'i** Hot its* igi«]

_ .
.

P|a»IBI -I -I rW ralt-Htl l-al l 3J . I I"! J?J 21 j J Si

i.
-

r
-

i h.i> rsr f I _ti>|g| - I ' m

t.-'l(.

.
I i Us*-**,

11 -

-
< O Q <=>. @ . 4 .
KM a IV- II I MM »»»»» !r.i-».
i
FIGURE 1.36

Specifying components
Click on TVex button or choose Components /Specifications in the list on the left. Then
define all components and obtain the following window (see Figure 1.37).

rfc r« mm Ma took " pw ia»»v »w««fc- t««.

PisgLBJ .1.1 H»l SI aKifcKl-ai i H II JhJ ! jcj m

_
1 J
-
I-I"I> i j . i i xapji i iw 'H
tgj <«irM »i cuari n.i
r

/ -. ii.- MMM

9 BmiMM VMM

r -
.

L 11 d i it .jf
*

I
'

X . 4 i
.. .

l.w..-->., s-m

1
l

H 0 8 cd. g - f .
t

[ li itin ci «ri<«i im-i n I >o< >....-_i- ... i

FIGURE 1.37

Copyrlqhted material
32 PROCESS SIMULATION AND CONTROL USING ASPEN

Specifying property method

Hit Next button or select Properties / Specifications in the column at the left side. In
Property method, scroll down to get RK-Soave. This equation of state model is chosen
for thermodynamic property predictions for the hydrocarbon mixture (see Figure 1.38).

.
=1 3 JLi Si Mi bl
-

8
i 3;
F-3

. Q-S-o-'g-'ii
D

FIGURE 1.38

Hitting ATex/ button twice, we have the following picture (see Figure 1.39). The binary
parameters are tabulated below. When we close this window or cbck OK on the message.
it implies that we approve the parameter values. However, we have the opportunity to
edit or enter the parameter values in the table. In blank spaces of the table, zeros are
there. It does not reveal that the ideal mixture assumption is used because many
thermodynamic models predict non-ideal behaviour with parameter values of zero.

T£msxS\zi zl 2 '-I H 21 61
3 .ifLdB&teMMI)

n
m
TTD
-3

:
3

MIX

« MM I *

FIGURE 1.39
INTRODUCTION AND STEPWISR ASI-KNJ>LU
sim 33
Specifying stream information
Click OK. Alternatively, use the Data Browser menu tree to navigate to the Streams/1/
Input/Specifications sheet. Then insert all specifications for Stream 1 as shown in Figure 1 40

J &1
J . 1 1,, I*
~

n 1 1 i 1 igi
la El »l aUl

JO
tcxnpojitior.
3 71 n
pr

(5
1 tdvaoced
f

rr s;; -
J
~

r i Rpioftt

& Setup

Q| OMOAdv s,. p-It ,111,. . l-v ...:...>, --r.-nlV-- H-lp

L55s?P Bos-:

[i hWs/Sphleu Ssp falais j He Esdw ers j Columns | Reaclw: [ Piessine Changers j Manipulators : Solids j UferModefi

Matenal

STREAMS Flash2 Fla h3 Dncanie. Sep 5ep2

Fo. Help, p C:V gFfWe'slflspanPbjs 11.1 MJM P* wrwl In*/

J Start j j A»pen plu, - Skmdab- Aspen Phjj Smxjlatton 2. . j

FIGURE 1.40

Specifying block information

Hit Afot or select Blocks/BUBBLE from the Data Browser. After getting the blank input
r

form, enter the required inputs (Pressure = 18 bar and Vapour fraction = 0) for block
BUBBLE (see Figure 1.41).
-
al>l

3 *i I *! «iEi
"

si - r
/Speatifotnni FlathOcdoni ' Er**rrr«nl

i Pr<*8rUw

J/) Prcpertr Metro

CJ 2
~J 1
-

1
.

_
)

9 ***

-
a-»

STREAMS
0 0 Qfl
Ri ? fWJ Ete i S<c S Bi

FIGURE 1.41
34 PROCESS SIMULATION AND CONTROL USING ASPEN
Running the simulation
Press Next button and then hit OK to run the simulation The following Control Panel .

demonstrates the status of our simulation work (see Figure 1 42). .

laillUJLIIIlllBIl
i f** t-t Vwi- Data Toofi Bun Lfciafy WVidwv/ Meto
JDlugB] atfij J-j ral-rlatl-l-qi l «ii [=5 _
d .
IjjJ -J SI afl e-i

f
i 3 - i i -i tim mi
41 - I "I JiJ S i l <| jjB] | IMI
ss 3 r i r

Inieriijpi DMO Sotver

J NoEOFwm
.

j
i - r-. - and Po:iiotve SckXi

Command Lr* f

STREAMS
'
o o
flathZ Flail-.3 Decade.
e - it -
Sep Sepg
C:\...oFoW«"\A«>enPtuj 1

r «* (W Oi/fc &<$ 7:52 P

FIGURE 1.42

Viewing results
Clearly, Figure 1.42 includes the Status message: Results Available. As the simulation
calculations completed, click on Solver Settings and then double-chck on Blocks to obtain
the following screen (see Figure 1.43).

-
-

| ne c >' v«v. 0*a Toob Ain PM Lferarv Wmdcw Hcto

J _
l l-l-PT
-
j j b I 3 ±tti iiJfXi 32>J jaal n i
33 Set-*

O Setup

i SOU. | U-Moa* |

-
CM
<o 9 e i
1 n A?
. FWi3 Dac«4«> Sap -

| ,Md«fl« .»-.. .

FIGURE 1.43
INTKODUCTION AND STKPWISK ASI'KN PLUS SIMULATION 35

Choosing Blocks/BUBBLE/Results in the column at the left side, we get the

following results summary for the present problem (see Figure 1.44).

JaflHI Ml *1
mi

WMllwilfc ii»»i»y

NM1 »»»

IB 3(v«««iP»*Jl

ra f O Cor- OBban*
V

O 1
tmt

| SOU. | UnMaM |

.
j 0 - 6 -o- f. r.
111,1 ' MM *r

FIGURE 1.44

From the results sheet, we obtain the bubble point temperature = 42.75411960C.

13
. 4
. Computation of Dew Point Temperature
Problem statement

Compute the dew point temperature at 1.5 bar of the hydrocarbon mixture, shown in
Table 1.2, using the RK-Soavc property method.
TABLE 1.2

Component Mole fraction

Ci 0 05
.

C2 0 1
.

Ca 0 15
.

<-c4 0 1
.

n-CA 0 2
.

M3a 0 25
.

(>
,
0 15
.

Assume the mixture inlet temperature of 250C, pressure of 5 bar and low rate of
f

120 kmol/hr.
36 PROCESS SIMULATION AND CONTROL USING ASPEN
Simulation approach
As we start Aspen Plus rom the Start menu or by double-clicking the Aspen Plus icon on

f
our desktop theAspe?i Plus Startup dialog appears (see Figure 1.45). Select Template option
,
.

Id *J 1PJ M _j.
l LJ...l-:i.::.l JAI
_.
"

-
I/I I J J_J_J_:J..J gj
-
J

1 empWis

i C VProffwnFdc-. sptnTeehWA/oikaigFolitei'/Jiipen Plus 11

C ogfam F,lt; Vi.ipenTBeh\W0il<ing Folded r\A;i>-n Plo: 11

For Help, prws Fl

ft? Start] j £

FIGURE 1.45

As Aspen Plus presents the window after clicking OK as shown Figure 1.45, choose
General with Metric Units. Then press OK (see Figure 1.46).

MB
i i i

Peisonalj Bsfmeiy Stmolahons

Ail SefWabon wth Engt:h Umt: K..
<, PetuJeuin >«ihEris(
Au Sep*aiion wih Molrie Uriitl Pe'io jum
Ajp*! SU F haimacouiKiJ: Ml
9l3f* SimJalK I Ptiarniaceijlical;
"

ChetrocalsWhEngkrtiUnH Polymei: wiinEr

Chemcali w(h McKk; Umt PoWe*! "el'
ElecnoMe; wuh Engliih U i5 gi Pyiionie<alugi' iviih
Elect'O eiwiihMen-cUnj P>Kime'aluigy wiUn
Ga: Pioceisng wth EnpM) Unn: Sefids wthEnghhl
ProcesniQ w*h Metric UrJ Sc*di«*hMetf« U
General v*lhEnak;hU i gSpecialj- Chemcal

H>«oii«talurQi' wuf. Engii:i Urn

P l,t
ggMydrometaOuTK. wJh Mel
-
., .-
_

Flowsheei

Daneel

For M*, pre»» PI

Start j Aip PV«

FIGURE 1.46
INTRODUCTION AND STEPWISE ASPEN PLUS SIMULATION 37

Subsequently, dick OK when the Aspen Plus engine window pops up.
Creating flowsheet
In the next, we obtain a blank Process Flowsheet Window. Then we start to develop
the process lowsheet by adding the Flash2 separator from the Model Library
f

toolbar and joining the inlet and product streams by the help of Material STREAMS
(Figure 1.47).

gjffc i« Dm > Ha-w- Ifca* . .iffi J

-
H c-

0 St*

-
CD c

± if

itftLWfS n>rJ f* i c-*. -3 s«.-

mt| » -i>w. |>-icj- i.«tanwr|| - # i

FIGURE 1.47

Now the process low diagram is complete. The Status bar in the bottom right of
f

the above window (see Figure 1.47) reveals Required Input Incomplete indicating that
input data are required to continue the simulation.

Configuring settings
Hitting Next button and then clicking OK, we get the setup input form. The present
'
problem is titled as Dew Point Calculations' (see Figure 1.48).
In Figure 1.49, the Aspen Plus accounting information are provided.

Specifying components
Here we have to enter all the components we are using in the simulation. In the list on
the left, choose Components /Specifications and ill up the table following the procedure
f

explained earlier (see Figure 1.50).

Copyrighted malenal
38 PROCESS SIMULATION AND CONTROL USING ASPEN1

,J9J »i

J U
- LT _l_LJ__rv 3 I I _lL
v ...
S«up
</Gh*»l| OeKtw»ion | ilccojnlh.0 ] DiagrwHiei |
© SprtlfttaMoo,

.
J J 3
Blocks
-

I
CorVrwoente
L

* Fl- vsh cting Options VM phaiei [

-
J
*
_
J MjdH ArWyjo Tooli r l>«(iee waleicalculatrani
'
Vj EO Cont"Jur«i n
* Results

Text lo appeal on eorh page Ihe FTporl He See Help

STREAMS S
0 o 8 I Scp2
tilCTh2 Flath3 Decaniei Sap _

Fo He*i, prats Fl C:\ .,gFo«ders\AspwiPlu5 11.1 MUM ?«qu)

FIGURE 1.48

Mi
Fie E* View Data Tools Run Plot Lfcrary Window Help

al-f-jfeKI-glH N>i -I . | \*\ m\m ..:/;| [

Lit 3 >'H r *\*m\i-
-

r
|0 Specfeno
h j/j Setup /GlobalI ./Descnption /Arc Diapnoslici
Specifications
SiroJatron Options : Aspen Plus accounitng ioifnation
r

Stieam Class '

bfe Subsbeams
j U set name: jAKJANA
Accouil luffnber:
S 1 3 Units-Sets
Q Custom Unrts I PtqedID ANYTHING
0 Report Options j Project name: jAS YDU UKEi
*:
| Components
+ Properties
I Streams
_
iJ Blocks
Si Reactions
+ Convergence
+ FtowsheeSng Options
* Mate'Analysts Tools
*
.
ifl Cor/iguration
Q] RtsJts Sunmary

Project n .

Input Canvtete

H 0 -0 -0
C < Flash? FImKI DmcmIm

fcHelc, press Fl <;\...gFl*fcrs\Asii<nHu!U.l NUM . isquiWlicuHftafToiete

FIGURE 1.49
INTRODUCTION AND STEPWISE ASPEN PLUS SIMULATION 39

i--rr - i-!>-i' it

» «

.
Jj I 111

t r

SlJ "" -l ""H

-
I »~ I

-
Q*
.
<o-8o.i.ii:

FIGURE 1.50

Specifying property method

From the Data Browser, select Properties /Specifications to obtain a blank property input
form. From the Property method pulldown menu, select RK-Soave (see Figure 1.51).

! Ut Wfw CMC* loak Hut fw tArarr wMsb* m»*.

a-i iM-ai f j t) -I |h| -j

]aBf«l -I «lfa-3>>lQl l!gJ

=1
IMXooc Cfcc* »i c*iiBMr opto* SHI
r . -.

-I

i
-
1 .i

WnmW 1 » * » | Haaf.ctaran I fi pi. | Hull

4 'P- .

» Mart!: A-a.-r* J 13 tiB AH

FIGURE 1.51

Copyrighted material
40 PROCESS SIMULATION AND CONTROL USING ASPEN

Specifying stream information

In the column at the left side choose Streams/1. As a result, a stream input form opens ,

Entering all required information one obtains the screen as shown in Figure 1.52 , .

D1<|H| SIS Mi Iik£lJl<Jij Sd 2J j-LiiLl ±1 3 .

_
L r
_
-
- If Pi j i ! jjbl bj

II
-

WO[>l ili
<:< 'i
ptseu i t«um [Met. »]:
fin f hr*"" .] ik
BrTH>l
. its til
_
j Cfctt/ » runt

, .~J>
_

a .

Micw illii
"

V Mwct tdm S«p«»loc I He«E*£h>wi | OA*** | nMcton 1 P.e»»«Chan*"

-
jO 8 0-8 C
* «-«| I AvenPfcn-SknutotL-

FIGURE 1.52

Specifying block information

The inal area that requires input is the Blocks tab. In the list on the left, double-click
f

on Blocks and then select DEW. Filling up the input form, we have Figure 1.53.

too** Otn Wo» Library wmdcwi

Btali
r
: ,. uh.|! rv I 3 /-\ 1 -i -Igil I Ji

3
"

3 FlMhOpooru I Em

30
3n
" -

ANWIJ-1
ANCMIJ-I
3
BnSBIJ-1

0XTrI>l

I Group

Input CcntfM*

STREAMS
<0 Q cd

FIGURE 1.53
INTRODUCTION AND STEPWISK ASPEN PLUS 3!MUU\TION 41

Running the simulation

Running the simulation, the following progress report is obtained (see Figure 1.54).

-
j r-H'-hrr
- II . t .! -1031 I - ! !

HI 3
3 ,

mi r . .1:

' !« I MM WWII | CMm I l-MI I -- II in I - I I Mi I IM MB

IIKMM
D -

o-e-oi-it-
-I*. MM'I (Will

FIGURE 1.54

Viewing results
First click on Solver Settings. From the Data Browser, choose Blocks/DEW/Results
(see Figure 1.55) to get the dew point temperature = 22.19453840C.

i' r ui>.i.rf
-

i* I- *

.MM

-
I
a -.

MM*
MM*
JVM -

hum
.
(O-e-o-i-it-
1 im*f n u t- w ' i

FIGURE 1.55
42 PROCESS SIMULATION AND CONTROL USING ASPEN
13
. .
5 T-xy and P-xy Diagrams of a Binary Mixture
Problem statement

A binary mixture consisting of 60 mole% ethanol and 40 mole% water, is introduced

into a lash chamber (Flash2) with a flow rate of 120 kmol/hr at 3 bar and 250C
f

(a) Produce T-xy plot at a constant pressure (1.013 bar)

(b) Produce xy plot based on the data obtained in part (a)
(c) Produce P-xy plot at a constant temperature (90oC)
Use the Wilson activity coefficient model as a property method.

Simulation approach
As usual, start Aspen Plus and select Template. Click OK to get the next screen and
choose General with Metric Units. Then again hit OK. In the subsequent step, click OK
in the Connect to Engine window to obtain a blank Process Flowsheet Window.

Creating flowsheet
From the equipment Model Library at the bottom of the Aspen Plus process lowsheet

f
window, select the Separators tab and insert the Flash2 separator. Then connect the
separation unit with the incoming and outgoing streams. The complete process is shown
in Figure 1.56.

CD o

0
-
o

STfSAMS
9-o

FIGURE 1.56

Configuring settings
After clicking on Solver Settings, select Setup /Specifications in the list on the left. The
Title of the present problem is given as TXY and PXY Diagrams'. Subsequently, the
'

Aspen Plus accounting information are also provided [see Figures 1.57(a) and (b)].
INTKOIHTTION AND STKI'WISK ASl'liN I'l.l'S ' SIMULATION 43

S!fll>l*l<H !ti 3 -i l-l.TJ S -I 1U

r 1 1 i .1 ..b; : . IP «|J»I
-

: 5! r-

CO . j .

FIGURE 1.57(a)

213

I -IE' - ;« 1

1
gjg j i 3 <iF-i] >>j aal -I

?3
3 <o'»-

-
CH
oeo.@.
«t Mi(.i,tra5»«-i

FIGURE 1.57(b)

Specifying components
Hitting Next button and defining the components (ethanol and water) in the input
form, one obtains Figure 1.58.

Specifying property method

The user input under the Properties tab is probably the most critical input required to
run a successful simulation. Clicking Next button we obtain the property input form.
,

For this problem, choose the Wilson model by scrolling down (see Figure 1.59).
44 PROCESS SIMULATION AND CONTROL USING ASPEN1

i £«* Vlaw cyta Icob Biji n-j

iL !
r j .Lj.inr
__

L
- - , _

l L
1© Specfrahon:
'
v
Selertionj PtMeum | NoneonvtrMnal | Oat nki {

ComponnHID
_
J Sot rr s
iTHANOl

lltr-ComOS
f

) HerryCofroi

.
_
J P nwt

Strrars

£i« Warn* I Um Drtned ! R><

.
Jj _
CwTy Ocunj
-

21 EC Ccti. 0«JOftt
_

Matewl
STREAMS 1 lwW Sep
f

For Heb, piKsFI NUM P HPClroxlrvm- -f

At pen Prut - SlniulatL-

FIGURE 1.58

Vww Oats Toote Run Plot Ltifa Wmbow net

3
"

3M t r
© 5wj(aC»i Opt mm Gtobalj Flow!heel Seciooi j Heleie.-ced j
Streain Class
-
j Substra4fn» ' c . meihodi i moddi
w-y rr lhod fwiUSDN
_

*
Ljfl Un*s-S«s P.oc«i two P

Vl
©
Components
Report OcKnns Base method
Henry component
| WILSON
i 1 Modty piopeity models

1 Asia//Blend

=3
~

"
3
.
_
lj petfo Cha< actof cation Wale, solubtty j 3
P ss-jdoeoinporients
ACw-Comp* Electic le cal ula'lor.oplnni
| I Menry Comp* "

3
UWIFAC (Vo
__
j Comp-Ofoupi
.
_
y ConxHJsts

Ptopertes
SpeclTKatton*
.
_
V) Pf«5<rrty Method*
* Estmalion
.
_
J Molecular Structure
» Paramateri
'

i Data

*
33 Prop-Set)
. Advanced

Input Complete

Por Hefc., pren PI MUM Reoui-i dlnp-jt lnco.Tcl

.
-

J| Aspen Plu. - SKthiIoII.. 3 s pm

FIGURE 1.59

Once the base property method has been selected and we click the Next button, a
window pops up asking whether to continue to the next step or to modify the properties
(see Figure 1.60).
INTRODUCTION AND STEPWiSK ASPEN PLUS SIMULATION 45

Required Properties Input Complete i

Go to the Next requiied step, or supply
additional properties information,

Go to Next required input step

'
Modify required property specifications

E nter property parameters

Enter raw properly data

OK Cancel

FIGURE 1.60

Specifying stream information

The next window includes a stream input form. Specifying temperature, pressure, low

f
rate and components mole fraction, one obtains Figure 1.61 as shown.

PlflftlM<M! 31 jUjU-=J S i£l Ed

I -

.
- --r- :

it
3
m
If -

."HI
ft -nvm i iia"

m m» wa«

nr
-
a -

o-e-o-i-ir-

FIGURE 1.61

(a) Creating T-xy plot: Selecting ToolslAnalysis I Property I Binary, we have

Figure 1.62.

Copyrighled material
46 PROCESS SIMULATION AND CONTROL USING ASPEN

Q ru r« v«h> Ma TnA =.». itrvy wrdw h i

ni lMl -I U ini »ff)
j . i I 'I -IflPJ J - Jill mm

ffTIwioL

J BSg I

[ iii.r-ini< iiiiuuTiJi I imiimim I c | n- .. | p.«m.o-«-. i m**-. i | u«.m~ i

P jT H il 3 s*»h

FIGURE 1.62

We must note that this option can be used to generate T-xy, P-xy or Gibbs energy of
'
mixing diagrams. Select Txy for the present problem. We aim to do an analysis on the
mixture of ethanol and water; so select these components accordingly. The user has the
'

option of specifying, which component will be used for the x-axis (which component s
mole raction will be diagrammed). The default is whichever component is indicated as
f

component 1. Make sure that we are creating the diagram for the mole raction of ethanol.
Entering required information Figure 1.62 takes the following form (see Figure 1.63).
, f

O lot* Pun lAf»y Wnion teto

rsKlfel i Kl tj ! |n| jl! M

.-
IJ l-M- r» 3
"

[WATER
His-1

lUj- "> ru.,

jEIKWDL

MM >>«».l Vox x.- o..

FIGURE 1.63

Click on Go and get the T-xy plot at a constant pressure (1 013 . bar) as shown in
Figure 1.64. Although the Status bar shows Required Input Incomplete ,
but there is no
problem to get the plot based on the given information.
INTRODUCTION AND STEPWISE ASPEN PLUS1 M SIMUL.\TION 47

OltflBI lai Mel »l r3ii-|ii<H»!l 2 5J Ji) M

i r-i-i-i>nr I -"IBI I' g 21!!

FIGURE 1.64

It should be noted that if we move the T-xy plot slightly or close it, we ind

f
Figure 1.65 having a databank. Some of these values have been used to make the
plot (Figure 1.64).

n3K|fc!»|-qM!!H 3i
-

i i i .i .m- i m\

Mil* I MMI

rwrrc

Wtfm
: : -

<o e-o-e-a;
«Mp»iM.i lM«4Ml-

FIGURE 1.65

Copyrighted material
46 PROCESS SIMULATION AND CONTROL USING ASPEN

ru tut M* I** BiW H>«>> Vrt Ji-

.
r
"

-
:;
- i Mf n: j i i 'i mo; i i"i SM
. .

' ri«h2 fLwM C'mjtj- 'if

REAMS
j tRLAMb
f-

FIGURE 1.62

We must note that this option can be used to generate T-xy, P-xy or Gibbs energy of
mixing diagrams. Select Txy' for the present problem. We aim to do an analysis on the
'

mixture of ethanol and water; so select these components accordingly. The user has the
'

option of specifying, which component will be used for the x-axis (which component s
mole fraction will be diagrammed). The default is whichever component is indicated as
component 1. Make sure that we are creating the diagram for the mole fraction of ethanol.
Entering required information. Figure 1.62 takes the following form (see Figure 1.63).

M il SI M SI

2 |W*TER 3

fETHANOL
3
(\oflm<y cmms

-
o-

FIGURE 1.63

Clicking on Go button, we have the following P-xy plot |see Figure 1.68(a)|
at a constant temperature (90oC) and respective databank produced (Figure 1.68(b)|.

I I- I-I.-IkU-

L *
-
i

1 1 1 DM

- .
. ..
.

FIGURE 1.68(a)

3/11 '' IBi.-l ' I

uoitnuc I0IH I0T* I0T« UOUO UOUD UOUO

ETWMOl mti K ni QAMHt cum
IIMM01 - TF- walla
[
i ma UHlil urci
T5HJ J
UMH 171 KB
-

on nr*' iSKs? - 7.4':.,, tWK i-

B n 1 IPIIJ THS rraei Siwr- SW?H )i

B na raro nryn TflfT
f

B I ...
11 n?
TWB ! 11 sarm
A ij " nBsw
"

Wii
"

B .
'
ams IWB T7ZB5 ITFii
r

[2 rssi ess ms www

S an nnss SWHHT"-- nan
r

moo n
B [B TIPl fSiiTE IfifiBT
f

1 n no OBfl nrarc aaw awn a-

« nw na! 61 1
.

HD-*
HO-Q-o-i-iI-
Ikvil .H«i) Ohm Sh> !»!
IU MM

FIGURE 1.68(b)

Copyrighled material
50 PROCESS SIMULATION AND CONTROL USING ASPEN
Notice that the plot window can be edited by ight clicking on that window and

r
selecting Properties In the properties window, the user can modify the title axis scale
.

,
,

font colour of the plot, etc. Alternatively, double-click on the different elements of the
,

plot and modify them as we like to improve the presentation and clarity .

SUMMARY AND CONCLUSIONS

In this chapter a brief introduction of the Aspen simulator is presented first. It is well
,

recognized that the Aspen software is an extremely powerful simulation tool in which , ,

a large number of parameter values are stored in the databank and the calculations are
pre-programmed. At the preliminary stage of this software course, this chapter may
help to accustom with several items and stepwise simulation procedures. Here four ,

simple problems (flash calculation, bubble point calculation, dew point calculation and
T-xy as well as P-xy plot generation) have been solved showing all simulation steps .

PROBLEMS |
1 . 1 A liquid mixture, consisting of 60 mole% benzene and 40 mole% toluene, is fed
with a low rate of 100 kmol/hr at 3 bar and 250C to a flash chamber (Flash2)
f

operated at 1.2 atm and 100oC Applying the SYSOP0 method, compute the
.

amounts of liquid and vapour products and their compositions.

1 2 A liquid mixture, consisting of 60 mole% benzene, 30 mole% toluene and
.

10 mole% o-xylene, is lashed at 1 atm and 110oC. The feed mixture with a low
f

f
rate of 100 kmol/hr enters the lash drum (Flash2) at 1 atm and 80oC Using the .
f

SYSOP0 property method,

(a) Compute the amounts of liquid and vapour outlets and their compositions
(b) Repeat the calculation at 1.5 atm and 120oC (operating conditions)
1
. 3 A hydrocarbon mixture with the composition, shown in Table 1.3, is fed to a
lash drum at 50oF and 20 psia.
f

TABLE 1.3

Component Flow rate (lb moiyhr)

i-C4 12
n -C4(LK) 448
i-C 5(HK) 36

Ce 23
C7 39.1
272.2
c9 31

876.3

The lash chamber (Flash2) operates at 180oF and 80 psia. Applying the SYSOP0
f

thermodynamic model, determine the amounts of liquid and vapour products

and their compositions.
INTRODUCTION AND STEPWISK ASPEN PLUS SIMULATION 51

1 . 4 Find the bubble point and dew point temperatures of a mixture of 0.4 mole fraction
toluene and 0.6 mole fraction rso-butanol at 101.3 kPa. Assume ideal mixture
and inlet temperature of 50oC, pressure of 1.5 atm, and low rate of 100 kmol/hr.

f
1 5 Find the bubble point and dew point temperatures and corresponding vapour
.

and liquid compositions for a mixture of 33 mole% n-hexane, 33 mole% n-heptane

and 34 mole% n-octane at 1 atm pressure. The feed mixture with a low rate of

f
100 kmol/hr enters at 50oC and 1 atm. Consider ideality in both liquid and vapour
phases.
1 6 Compute the bubble point and dew point temperatures of a solution of
.

hydrocarbons with the following composition at 345 kN/m2(see Table 1.4).

TABLE 1.4

Component Mole fraction

c3 0 05
.

n-C4 0 25
.

n-C5 04
.

Ce 03
.

The ideal solution with a low rate of 100 kmol/hr enters at 50oC and 1 atm.
f

1 . 7 Calculate the bubble point pressure at 40oC of the following hydrocarbon stream
(see Table 1.5).

TABLE 1.6

Component Mole fraction

c, 0 05 .

c2 0 1 .

Ca 0 15 .

i-C4 0 1 .

n-C4 02 .

i-Cs 0 15 .

n-C5 0 15 .

c6 0 1 .

Use the SRK thermodynamic model and consider the inlet temperature of 30oC,
pressure of 4.5 bar and low rate of 100 kmol/hr.
f

1 .
8 A binary mixture, consisting of 50 mole% ethanol and 50 mole% 1-propanol, is
fed to a lash drum (Flash2) with a low rate of 120 kmol/hr at 3.5 bar and 30oC.
f

(a) Produce T-xy plot at a constant pressure (1.013 bar)

(b) Produce P-xy plot at a constant temperature (750C)
(c) Produce xy plot based on the data obtained in part (b)
Consider the RK-Soave thermodynamic model as a base property method.
1 .
9 A ternary mixture with the following component-wise low rates is introduced
f

into a decanter model run at 341.1 K and 308.9 kPa. To identify the second
liquid phase, select n-pentane as a key component (see Table 1.6).
52 PROCESS SIMULATION AND CONTROL USING ASPEN

TABLE 1.6

Component Flow rate (kmol/hr)

n -pentane 10
ethanol 3
water 75 .

Applying the NRTL property method simulate the decanter block to compute
,

the flow rates of two product streams .

1 .
10 A ternary mixture having the following low rates is fed to a separator (Sep2) at

f
50oC and 5 bar (see Table 1.7).

TABLE 1.7

Component Flow rate (kmol/hr)

n -pentane 33.623
ethanol 0 476
.

water 3 705
.

To solve the present problem using Aspen Plus, the following specifications are
provided along with a T/F ratio of 0.905478 (see Table 1.8 and Figure 1.69).
TABLE 1.8

Component Split fraction in stream T

n -pentane 0 999.

ethanol 09 .

water (calculated by Aspen)

B -O

FIGURE 1.69 A flowsheet of a separator.

Applying the SRK property method, simulate the lowsheet, shown in Figure 1.69,
f

and determine the product compositions.

1 . 11 Repeat the above problem with replacing the separator Sep2 by Sep and using
split fraction of water 0.4 in Stream T.
1 12 A dryer, as specified in Figure 1.70, operates at 200oF and 1 atm. Apply the
.

SOLIDS base property method and simulate the dryer model (Flash2) to compute
the recovery of water in the top product.
INTRODUCTION AND STKPWISE ASPEN PLUS SIMULATION 53

Wet

Temperature = 75DC
Pressure = 1 aim AiROur;

Flow rates
S(02 = 800 Ib/hr
H20 = 5 Ib/hr WET

Air
Temperature = 200oC
AIR
0
Pressure = 1 atm

Flow rates = 50 Ibmol/hr

dry; O
N2 = 80 mole% DRYER
O, b 20 mole%

FIGURE 1.70 A lowsheet of a dryer

f
REFERENCE

AspenTech Official Site, When was the Company Founded?, http://www.aspentech.com/

corporate/careers/faqs.cfm#whenAT.
C H A PT E R 2
Aspen Plus Simulation
of Reactor Models

2 1
.
BUILT-IN REACTOR MODELS

In the Aspen Plus model library, seven built-in reactor models are available. They
are RStoic, RYield, REquil, RGibbs, RCSTR, RPlug and RBatch. The stoichiometric
reactor, RStoic, is used when the stoichiometry is known but the reaction kinetics is
either unknown or unimportant. The yield reactor, RYield, is employed in those cases
where both the reactions-kinetics and stoichiometry-are unknown but the product
yields Eire known to us. For single-phase chemical equilibrium or simultaneous phase
and chemical equilibrium calculations, we choose either REquil or RGibbs. REquil model
solves stoichiometric chemical and phase equilibrium equations. On the other hand,
RGibbs solves its model by minimizing Gibbs free energy, subject to atom balance
constraints. RCSTR, RPlug and RBatch are rigorous models of continuous stirred tank
reactor (CSTR), plug low reactor (PER) and batch (or semi-batch) reactor respectively.
,
f

Eor these three reactor models, kinetics is known. RPlug and RBatch handle rate-
based kinetic reactions, whereas RCSTR simultaneously handles equilibrium and rate-
based reactions. It should be noted that the rigorous models in Aspen Plus can use
built-in Power law or Langmuir-Hinshelwood-Hougen-Watson (LHHW) or user defined
kinetics. The user can define the reaction kinetics in Fortran subroutine or in excel
worksheet.
One of the most important things to remember when using a computer simulation
program, in any application, is that incorrect input data or programming can lead to
solutions that are correct based on the program's specifications but unrealistic with
" "

regard to real-life applications. For this reason, a good knowledge is must on the reaction
engineering. In the following, we will simulate several reactor models using the Aspen
Plus software package. Apart from these solved examples, interested reader may
simulate the reactor models given in the exercise at the end of this chapter.

54
ASPEN PLUS SIMULATION OF REACTOR MODELS 55

22
.
ASPEN PLUS SIMULATION OF A RStolc MODEL

Problem statement

Styrene is produced by dehydrogenation of ethylbenzene. Here we consider an

irreversible reaction given as:

CgHs-C2H5 -> CgHs-CH - CH2 + H2

ethylbenzene styrene hydrogen

Pure ethylbenzene enters the RStoic reactor with a low rate of 100 kmol/hr at 260oC

f
and 1.5 bar. The reactor operates at 250oC and 1.2 bar. We can use the fractional
conversion of ethylbenzene equals 0.8. Using the Peng-Robinson thermodynamic method,
simulate the reactor model.

Simulation approach
As we start Aspen Plus from the Start menu or by double-clicking the Aspen Plus icon
on our desktop, first the Aspen Plus Startup dialog appears (see Figure 2.1). Choose
Template option and then click OK.

iaj _1_J __J *j rv.Mft, I-Hid 3 I I l-J±]-J _J

_
J

FIGURE 2.1

As the next window pops up (see Figure 2.2), select General with Metric Units and
hit OK button.

Copyrighted materia
56 4 PROCESS SIMULATION AND CONTROL USING ASPEN

jzj

I M I I I lAl I I I- I

[5'.f»**-«i "v.* (Ma

j" *-** /.r, . - - ( 'to-.
JV--- *.j m . , _
j
'
jJ. mo; Mil E-v v 'Mi 3 'th B«M
W
r . jw*-N«ta»et« SkwtrM

.
j .j--jc-r; ] f.-S- -.r 3 C j n-V; j «' if!: VV.

FIGURE 2.2

Here we use the simulation engine at 'Local PC. Click OK when the Connect to
Engine dialog is displayed (see Figure 2.3). Note that this step is specific to the installation .

Connect to Engine

Server type: Local PC

User Info

Node name :

User name:

Password:

Working directory:

O Save as Default Connection

OK Exit Help

FIGURE 2.3

Creating flowsheet
We are now ready to develop the process low diagram. Select the Reactors tab from
f

the Model Library toolbar, then choose RStoic icon and inally place this unit in the
f

blank Process Flowsheet Window. In order to connect the feed and efluent streams
f
MODELS 57

with the reactor block, click on Material STREAMS tab in th 1

As we move the cursor, now a crosshair, onto the proces lnw s fui , COriier -

two red arrows and one blue arrow. Remember that red aarr0WSfare 're(luired

f
rrow
blue arrows are optional ports. ts and
Click once on the starting point, expand the feed li ne and click a~Hn tv f a
stream is labelled as 1. Addmg the outlet stream to the reactort tJXwa WW
-

n
y' UIiaiiy
we make the image as shown in Figure 2.4.

I .lal I Ml

= 03-
-
Q a

i . i . S -O-M-i
o
-

a Ri astt. tb pfvjj

FIGURE 2.4

After renaming Stream 1 to F, Stream 2 to P and Block Bl to REACTOR, the

lowsheet looks like Figure 2.5.
f

» l«IVl
-

'
. r- C«J Kf! Pin tr-Kl«- LI'-TV iWoc,-. i
'
c*
f

DltflBI «BI Id iff! GN-|e>IM<iM h-I "I I IH -i

Eh-

at rsms acs'R

FIGURE 2.5

Obviously, the Sia s md/cator in the bottom right of the mam window h changed
the message rom Flowsheet Not Complete to Required Input /ncom ff . fsimulation.
lete the ation
to enter th* remaining data using several input forms required to comp
f
58 PROCESS SIMULATION AND CONTROL USING ASPEN

Configuring settings
Hitting Next icon and clicking OK on the message sheet displayed we get the setup input ,

form. First the title of the present problem is given as 'Simulation of the RStoic Reactor'
In the next, the Aspen Plus accounting information (required at some installations)
are provided.
User name: AKJANA
Account number: 5
Project ID: ANYTHING
Project name: YOUR CHOICE
Finally, select Report Options under Setup folder choose 'Mole' as well as 'Mass' ,

fraction item under Stream tab (see Figure 2.6(a) (b) and (c)). ,

MM ±S
_
i r- i - i- i jv
_
-
i « i iai
UMsi

[jjttiEjjft
L- - .1

J .
lU -

I- S . S . § -Q-M-O-
B.BM Bi u.
.
'-.C--- KC TIi PFtjj Rfem.

FIGURE 2.6(a)

Jl-T - i I- fV I -M I lal fifj

FIGURE 2.6(b)
ASPEN PLUS SIMULATION OF REACTOR MODEI S 59

Mil

: r-i-hi r» ! .|gi
.
i ip' h-i
,

Dm dm
r _ utM

-
it

I i i I M>l Umomm I
-
O
-

'
tifc waw «
f

FIGURE 2.6(c)

Specifying components
In the Data Browser window, choose Components /Specifications to obtain the component
input form. Now ill out the table for three components, ethylbenzene, styrene and
f

hydrogen (see Figure 2.7). If Aspen Plus does not recognize the components by their
IDs as defined by the user, use the Find button to search them. Select the components
from the lists and then Add them. A detailed procedure is presented in Chapter 1.

I?! 1 -1-

i "" TH III

sr-l© 8 18 0IIU

FIGURE 2.7

fd materic
60 PROCESS SIMULATION AND CONTROL USING ASPEN

Specifying property method

Choosing Properties /Specifications in the column at the left side one obtains the ,

property input form. Use the Peng-Robinson thermodynamic package by selecting PENG -

ROB under the Base method tab (see Figure 2 8). .

ol lBj _
J_ J w] KW«>|<H m -1 H JpJjJ J

r
"

3
""

"
3
J * ew Proc*li«t 1 3
f

3
"

U **-

STREAMS RSldc fn'«M BE RSbte RCSTR iPH) BB*

3M| #
'

FIGURE 2.8

Specifying stream information

The Streams IFIInput I Specifications sheet appears with the Data Browser menu tree in
the left pane. Entering the values for state variables (temperature, pressure and total
low) and composition (mole raction), we inally have the following screen (see Figure 2.9).
f

DZSMSSEGSSSD
: i* Hot Utorr Wrdo* H-fc
f

I r I -1 "I T» ' I -Ml I . 131

A|>Mdiedtio<n| FWiOwonTl
|/M1XED

o'***
t

Ware 2mu«
3
~

"
3
p3" 3
(i a ****** 3

1 'wr-S-

0
D
1
J -
' ur

ttBUH,
m
eS
'
i q
-1 - Bli. - BO f""
su
SSiS :
r

. ,.JCT»J .

FIGURE 2.9
ASPEN PLUS SIMULATION OF REACTOR MODELS 61

information
Specifying block
From the Data Browser, select Blocks/REACTOR. Specifying operating conditions for
the reactor model, the form looks like Figure 2.10.

Efb »|-.| ..IB q .>| ol,,! |

F tc. PCStB To Mvg- .

l Qactg Mom. I » Vsm"

FIGURE 2.10

Specifying reaction information

In the next, either hit Next button or Reactions tab under Blocks /REACTOR Chck iVeiy, .

to choose the reactants and products using the dropdown list input the stoichiometric ,

coefBcients and specify the fractional conversion In the Aspen Plus simulator, coefficients .

should be negative for reactants and positive for products (see Figure 2 11). .

** b* bo "e*

> '-'

RiACTQR

Wt<it BCSTR BtVn

FIGURE 2.11
62 PROCESS SIMULATION AND CONTROL USING ASPEN

Running the simulation

In Figure 2.12 Status message includes Required Input Complete. It implies that all
,

required input information have been inserted by the user. There are a few ways to
run the simulation. We could select either the Next button in the toolbar which will tell
us that all of the required inputs are complete and ask if we would like to run the
simulation. We can also run the simulation by selecting the Run button in the toolbar
(this is the button with a block arrow pointing to the right). Alternatively, we can go to
Run on the menu bar and select 'Run' (F5).

MM.|8W«'!i ,l|Hllir

DMll
I M ill
Elfb Imeicbah
""

A«s8V.'Bend /Sp«£tfeahont /Re- , 1 Contujlion | HMHiResclion | Setacli«ly | PSO | EowmrtAm |

Rcadicxs

RxnNo Specilicaiun type Stochiotneby

IttrCanpi ETHYL-01 > STYREHE . KrtiflOGEN

UNIFAC Group* <l 1 -

I Comp-GroLps
' Con-.p-Lis's

*
1 1 Cperty Methods
S tstrfi ficn At tequfed npd u ocmpHe Y j can rui the MnuMlon nitw. w
t

':
Jj Moiecua- Sbuctm iiu can erttr more input To er4er more f-pj. Bated Cared th«n
> p ParameJers seled t e ooUont yoj mM tnyn Ihe Dais poldOAT-, menu
D a Rui ir-e sirxilatiwi now?

S Advanced
&reanS
_

Jfl :

(1 EOVsraH« P Rwchom occu r ien«

CJ P
3 Bocks
. RECTOR

Inpu C«nplete

[H " Mnwii/SpWer; Hea<Ev.-. i9Pt; J.,, Rucloi Chsnga, | M<n>M>t ( 5c«> j U»Mo*b |
-
CH
'
STREAMS RStdc RYieW
F-
r H«o press F1
, ,

Stall *
'

Aww.RaocDdr | « Awr.Mcd I
-

.
Boot
_

FIGURE 2.12

Viewing results
As we click OK on the above message the Control Panel appears showing the progress ,

of the simulation. After the simulation is run and converged we notice that the Results ,

Summary tab on the Data Browser window has a blue checkmark Clicking on that tab .

will open up the Run Status. If the simulation has converged it should state ,

"
Calculations were completed normally" (see Figure 2 13). .

Pressing Next button and then OK, we get the Run Status screen In the subsequent .

step, select Results Summary /Streams in the list on the left and obtain the final results
(see Figure 2.14). Save the work done by choosing File/Save As/...in the menu list on
the top.
If we click on Stream Table knob just above the results table, the results are recorded
in the Process Flowsheet Window, as shown in Figure 2.15
ASPEN PLUS SIMULATION OF REACTOR MODELS 63

'
>k r« An [Mi Tot \r Um <.>«. MO

tnut iulmtiu imi." un nn i< nt ecu iiuti

ui tmrrrxz nm a tmh tmis us . unm

um wen* Mat- unic

- - -
-
CH
s ' w*. mw< n* w> ii>*j

FIGURE 2.13

-
T I M -I -lei

I I

- "

3» 3 "-'-I
J
-
a)
55T:
-

t« " <w
"

is*" .
, i i.

M», iMm

l>ii l«U

Man'*
m
cna

inpp BUB

Waw' VI | **** | H»«U .

incMA
m- @ . i . e u m u
' irw« wto* MMt ac» S

"- I r

FIGURE 2.14
64 PROCESS SIMULATION AND CONTROL USING ASPEN

Ffc Edt Vfew 0«a Into tjn nowheri Lfc fy VAk w Het

f
'
-

lup I , IT _
LiiE| | |a|

EES;: gIBl«l|Oi. £lal«l|'rj. .aaJj'lL

STREAMS 1 BSinc
, S 0 U 31U
BEoii HGMis RCSTB BPItg RBaM.
\ s FoWen JJswn Ru» H 1 HUM lfloAi Artahie

f
FIGURE 2.15

Viewing input summary

For input information, press Ctrl + Alt + I on the keyboard or select Input Summary
rom the View pulldown menu (see Figure 2.16).
f

CBSES
Fie £* Forw* >Atw

input Sugary created by Aspen Plus K«1. 11.1 at 12:U:CM Thu jul 5, 300?
Oirecrory C: Proqr-5R Pi les'AspenTech .norfcing Pol ders'.Aspen Plus 11.1 Fllep
'

e Ci Users-.akjana.AppMtaMocal Terep -ape906.tK}

title 'SlmUllon of the iStolc Reactor"

IN-UNITS KET VOLU> E-FLOS<- cuB hr ENTMLPV-Fl.O-'»lkcal/hr' A

HCAT-TRAHS-C- kcal/hr-sqn-K" PRESSURE"bar TEMPERATURE-C &

VOLUHE-CUIT OELTA-T-C HEAD-neter httLE-DENSin'- cisol/cuni'
'

&
f

fASS-DENSITV-
'
kg.'CUH" W)LE-£NTHALP- kcal,'noV t,
t-ASS-EWTM .P- kcal/kg' HE*T-MMkcal t'OLE-CONC-'mol .
T
'
&
POBOP-bar

OCF-STREAt'S COMVEN AIL

DESCRIPTIOH "
General SlHllailoi) mith Metric units :
C, bar, kg/hr, knclhr. MMKcal/hr, c\m/hr.
property Method: Mone

Flow basis for Input: Kole

Stream report cooposltlon: Kole flow

ROP-SOURCES PUBEll - AQUEOUS / SOLIDS f INORGANIC

COMPONENTS
ETHYL-01 C8H10-4 /
STVRENE C8H8 ,'
HVOfiOGEN H2

PBOPERTIFS PENG-ROB

5THCAH F
SUBSTBEAf KIXEO TCHP-J60. PRE5-1.S MOLE-FLOW-100.
W>LE-FMC ETHYL-01 1.

'
B i I vjnwi-* |- la»«Jtol | lto.»,-s || -WEME1 :« jpCittU

FIGURE 2.16
- y wkjusu,jO t
f 65
DO

If one may wish to generate a report ile (* rep) or the nrp f u,

f
instructions as presented in Chapter 1 P eSent Problem, follow the

f
.

2.
3 ASPEN PLUS SIMULATION OF A RCSTR MODEL
Problem statement

The hydrogenation of aniline produces cyclohexylamine in a CSTR accord f

following reaction: ' accor(lirig to the
C6H5NH2 + 3H2 CeHnNHa
aniline hydrogen cyclohexylamine
The reactor operates at 40 bar and 120oC , and its volume is 1200 t3 (75% liquid) For

f
the liquid-phase reaction, the inlet streams have the specifications shown in Table 2 1
, . .

TABLE 2.1

Reactant Temperature (0C) Pressure (bar) Flow rate (kmol/hr)

Pure aniline 43 41 45
Pure hydrogen 230 41 160

Fake reaction kinetics data for the Arrhenius law are given as:
Pre-exponential factor = 5 x 105 m3/kmol s
Activation energy = 20,000 Btu/lbmol
[CJ basis = Molarity
Use the SYSOP0 base property method in the simulation. The reaction is irst-order in f
aniline and hydrogen. The reaction rate constant is defined with respect to aniline.
Simulate the CSTR model and compute the component mole fractions in both the liquid
as well as vapour product.

Simulation approach
Start with the General with Metric Units Template, as shown in Figures 2.17(a) and (b).
Click OK in the above screen. When the Connect to Engine dialog appears, again
hit OK knob to obtain a blank Process Flowsheet Window.
Creating flowsheet
Select the Reactors tab from the Model Litwy
models available. Among them, choose RCSTR P cetheit process
t
in tn low magr
them,
Adding inlet and product streams and renaming
f

look like Figure 2.18.

"
PROCESS SIMULATION AND CONTROL USING ASPEN

Q|a|B| JJ J_J
_
nMfel I 1 :1 si 21 __1_L.J ni M M ®l

A1 ] c 8lor+. SmuWen

r OMUsnE.ulr.lSim.jl.j'i-

Aap«n Plus « Vf # i VSJ6

FIGURE 2.17(a)

g *apen IP= Strean Prx&hts

mnz Lines.

MMtajJ-V arvtr
nitpwi wi mmi ,

I Beetle, «|fa Enshh ijrit Propetty I lhod; None

|aklnt«ill wth Medic IMi
Bow oss crinpiif 'tee
t

Procws g fAs Unfa Strtom eaai

cwrpcttEfi: Mote low

SpNtft/Chmic*

SUrti
'

FIGURE 2.17(b)
ASPEN PLUS1" SIMUIATION OF REACTOR MODELS 67

h W ..> 3a Hi* .<-»-» MMa

o|rf|y|giai _
lg|g rj|twi<H;j 3 I ("l jajgj

-
I}-

tmuHt 1 Igj gMij gM Wii. .Hi ->

FIGURE 2.18

Configuring settings
Hit Afe button and then OK and get the setup input form. The present project is titled
as '

Simulation of the RCSTR Reactor' and the accounting information are given as
'

AKJANA/6/ANYTHING/YOUR CHOICE* (see Figures 2.19(a) and (b)).

Jim _iJ ! El &iMiid 3 I i"l 3 I

- II -». w . t -.-.
f

FIGURE 2.19(a)
68 PROCESS SIMULATION AND CONTROL USING ASPEN1 M

' Fie E« On TmH PU Lfrvy Wilder- *k>

0 Spiicfcii

l li«< MBW
.

.
jfl IM-SHi
O CuHsflUnli Rovci ID
f

kfUCdRfMi

STREAMS
'

RSioc RYwId
. 11 -y-Bo
REgnl RGMw RCSTfl RWjg REafch

O * $3 17 1'.

FIGURE 2.19(b)

In the subsequent step, choose Setup/Report Options / Stream rom the Data Browser f
'
window and select Mole' as well as 'Mass' fraction basis (see Figure 2.20).

B* E* Mxr CM* Todi tr PW Uorv AWow h«b

i ajJJ iBJ J al-rlfeKKI I n>i ij J |h| a| 1 M

Cereal | Ftowiho* | Bbcf Ali j Roperty j AW |

0 SkW* Qnl
turn U be ndmM r, iiMm itpoii
t

.
Jfl Ml S«t»
P MtJa P Mcta TFF [gENJ T]
! r Uau P Mm |S Standard fa0cdm>i

P S.>- .:abh t
P Componerti t h (wo o-. 01 H itDon
-
t

f " M- Sc-.. | S».n | HME

StfltW
(Bill
BV fvuc RE.M- RGte. RCS1R RPI m j,
f

1 " -

FIGURE 2 20 .
ASPEN PLUS SIMULATION OP REACTOR MODELS -f 69

Specifying components
The example reaction system includes three components. They are aniline, hydrogen
and cyclohexylamine. Defining all these species in the component input form, one obtains
Figure 2.21.
V nt Eik 4n eu To* FU. Pla Uh
f

3 Mdiilfs-3ij bj rl
~

AMIUNE C6H7I11

WyMOGEN K1T1R0G H

CYCLO H EWLAMICSH13W -01

Ffesctons
Eire V/cw) UtwCMnd Rtttdei:

' ""'""
D in

I I Sotd. | U«>M«Mt t

Ml
RSac Brttj tEqai RGfcb) lCStft RFtifl Rflaieh
r

FIGURE 2.21

Specifying property method

We know that a property method is a bank of methods and models used to compute
physical properties. For the sample reactor model, select SYSOP0 base property method
(see Figure 2.22) after clicking on Next icon in the above screen.

Fk eu VW* D«» liA Fj, li -f V,Wfe/. hefc

i
I 3

urvac

_
j F rm

Aipcn rim - Sani

si* | .>j3l*J<>TtQ('«W -i.d"°°«*''",l''fi'

FIGURE 2.22
70 PROCESS SIMULATION AND CONTROL USING ASPEN

Specifying stream information

As we hit Next followed by OK, a stream input form appears. For Stream A (pure
aniline) and Stream H (pure hydrogen), values of state variables and composition are
inserted in the following two forms, shown in Figures 2.23(a) and (b).
m mr.i
.

ffe * '-Am D«i T«ol« An Fix Uc**y Wnfe* 'k

mm >. Ittieiwj nH-clalsKM!sJ 31 ! HiJ21«) »)

J
-

3 i«*f

_
j PiAiW

Strunu

fj EOVar-ittai

SIBEAMS BGMw BCSTH

FIGURE 2.23(a)

:: St Edi Mw* 0«« To* An a* ifc,. whd*. Htfc

10
3 Owerti

i Jy MIXED
~

3
3 :iu*f..
-

3
-

O UMFACQtsun 3

« Zj EMMbn

ra; ToW IT

BCSIB «fl, m»

FIGURE 2.23(b)

Specifying block information

In the next, there is a block input form. Providing required information for the CSTR
block, we have the screen as shown in Figure 2.24.
ASPEN PI-US SIMULATION OF REACTOR MODEIiJ 71

lim -Vii.l.-l!,! II I M --- B .

' i -I
.
E« Sm 'mm Lbw> MrtM 4a .. f

d « « |.if.|.iu«-.| ne i
9 - .

'- I' I.. -I

p=-31 -r-3
'

i -

ff .
j .
.
J
- 1,--.

I
1

F 3
~
J

Si-
__-__
iir

ITXUK
r |®- 9 . S . 9 Q U O Mm fJte >-. -'« »-

FIGURE 2.24

Product streams have been defined with their phases (see Figure 2.25).

Ifflll

I r-M-|r |T ' I .ICI I Ml

I.
li:
.
I
-

0 -p uj

» llji lli! i j I t XMUtavn I UMa III Hi | tmmammu | » mi I Ma I iMHwk j

-
o-

I1XJM
m 0 . 8 . o y JE D IMMI Ptmt hm. unit TVl ggg

0»>W a< - <

FIGURE 2.25

Press Afexf button or click on Reactions and get the window (as shown in Figure 2.26).

Copyrighted material
72 PROCESS SIMULATION AND CONTROL USING ASPEN"

I UtatCSTRflCCTn i

f
«b Ed* ««» DKB Tooit tr Pta IJfewy Wirvis Hdp

f
e|ej rgklaKKM "I ! I"l J JJ J ®l

f
_

JJ
-

i 1 i HT I leal; I M Hi
, Setup

Solsd .e ion Mlt lo be nciideii n ihs

Arabia i««clw wU i SriBctedttwc'cn'-
rWft af Studio

MvanMd

a h
.
11 L

Bocta
-
C5TR
e s-up

(J EOVsnai>«
O EOhpu -
O Sp«c GfWJpt
Pott
leschon E3 ID
Peaili
-

[1 " MiMMiyS{«ter9 | S«p«aU»i ] He*E hangefi j Coluwij Heoclou j Preiwe Changeii ] MfloipUaloft | Sf** | UiwH&Wi |
-

a->
Mated \
STREAMS REeril RGtb! iCSTR RPbg
f

C \ l FtAJerj'Aweo Piu) 11 i HUM

i Ofttce Woni j f-toggft Pcwergjrt . l . j MjCe toX>< frofett f [

FIGURE 2.26

Right click on Available reaction sets, hit New button, then either accept default
name R-l or give a name as we want for the reaction set and inally click on OK f .

Subsequently, select POWERLAW in the Enter Type list and hit OK to get the screen
as shown in Figure 2.27.

Ffc &» w tWa Toe fU Fte Ubnr, Vttyfcw Hdp

MHl
r .-l-i- PT -.1 M- I Ml jW
.
/Spccft hm j/S««atm/Ba ljont] PSD j CwvwMAm [
£j Pwwt/Henccs S dect (sacbcn tw to t« ndudsd r nwdel
LJ
"

1 Mdecwer Su-me
J : -
_ j Data

i V) tco-S*:
f

Jfl H
'

i o l

csrn
O '

9 Sp«Gto*i
H SbeenRMub ,

<0 s s s o O
LJ.

FIGURE 2.27
ASPEN PLUS SIMULATION OF REACTOR MODELS 73

Specifying reaction information

Hitting Next knob, we obtain the screen, shown in Figure 2.28.
ul.i
** cm <%* fw » -.>=- **

S .

* | SiMMt | HewE h-vjpr | a m- Rm om { Praiiu,Charge.! | H««a«» | I UmiH<mM |

STfttAKS RStoc f.W

i - s - § .©.mo-
RtajJ RGttK lCSTR RPl RBWtf,
f

FIGURE 2.28

As we click on New; button a form is displayed as shown in Figure 2.29. In this

form, we need to enter the stoichiometric coefficient as well as exponent for all
components. The exponents represent the order of the reaction with respect to each
component. Note that there are two types of reactions [kinetic (rate-controlled reactions)
and equilibrium] permitted under Power law reaction ID .

DlilBj J J eiej l nrMfcl-NM '»!

_ _
1 I H -I l?l 1 ®|
f

I f~ l-.l. li IT ! -lEI I |gl

Caw 1 CMtft 1 f.t * Cow«rt Co o* *

[ r.i.-' |
_

M. | |

j
-

hB- 0 . i . 0 1 1
iifitw4i f.4M Bf»J Km wifl

t j A J» " .» 1 »*r**:««w«i-Lij<* * -*,»1 1 i ' . || 5-i - «ft ' 11"

FIGURE 2.29
74 PROCESS SIMULATION AND CONTROL USING ASPENT

As stated, the reaction

C6H5NH2 + 3H2 C6HnNH2

is irst-order in aniline and hydrogen. Also, the reaction rate constant is defined with
f

respect to aniline. Accordingly, we may use the following information to specify the
reaction (see Table 2.2).
TABLE 2.2

Component Coefficient Exponent

aniline -
1 1
3 1
hydrogen -

1 0
cyclohexylamine

Recall that in Aspen Plus terminology, coefficients must be negative for reactants
and positive for products. As we ill up the form, it looks like Figure 2.30.
f

illtiliiii ESS
'

aj} f*, Fe>

.
iw tup Tcotr

BoacMrNo.: |7i 3 Reaction type: 3

RuctMi - Product!

Comnonent Coeficient Enponent 1 CompafieW Coelficient Ej<ponent

ANILINE 1 j ; CYCLO-01 1
-

IYDR0GEN .
3
j *
* 1 i

Ctote

Bock,

y Reactiom
r J Chemolry
B Peacuons Edt Delete
t R-I
f

1 Convefgcnce
fj Rowaheetng Onions
1
.r
Reojrad tipul hcowMe
IT Mam pKen | Sepaators | HeatEndiangen | Cokams Haachm | PtenueOiaven ] SoUt UnModeb

KWariel
STREAMS RSIoic RYieU
1.0 .y-U-U-
HMj RStb. RCStfl BPIm Rieldi
"

ForHefc weMfl . !C\i,fi*ta.vW«iHi.111 , HUH

ReuMtnO
« « b3

FIGURE 2.30

If we do not specify the exponent for a species, Aspen Plus takes a default value of
zero. In Figure 2.31, the resulting relation is displayed in the stoichiometry sheet.
In the subsequent step (see Figure 2.32), we move on to Kinetic tab.
ASPEN PLUS SIMULATION OF REACTOR MODELS 75

PHPI Liasigl -

.
if?:.
3aft l"-" JSldilJP BiiJfllalfil
-

.
j am

I» j 0-.
- 1 <

) - .IW I I I Ihmt

<o- y i Q on o
"
KiMWiingwr r ~ » !

FIGURE 2.31

Irl |x|

IM .Q C3WA\*\<M H
* "I I"! -I vl -I 9|
r .

3alt: »l*l <<Jp »| Gh-t ml

- 1.-.,.

' jfl
- I 3
9
9 .
t into mn*&*B**n*
f

t .

3
.
jfl .
.
-
*
P '
* jfl

.m* Vm m t> mam >ew*

r .
-
. KIT

FIGURE 2.32
76 PROCESS SIMULATION AND CONTROL USING SPEN]
basis. Accordingly, the
'
'Molarity
As directed in the problem statement, we use
Power law is expressed as:
n
E n 1
r= k exp (2.1)
[T0; R

where r is the rate of reaction, K the reaction rate constant (kinetic factor in Aspen
Plus terminology), k the pre-exponential or frequency factor, T the temperature m degree
K Tn the datum temperature in degree K, n the temperature exponent S the activation
energy R the universal gas constant, C the molarity in kmol/m a the concentration ,

exponent, i the component index, and 0 the product operator.

If To is ignored, the Power law expression has the following form:
E
r= kTnexp n(G) (2.2)
RT

where,
E
K = kTn exp (2.3)
RT

In most of our simple cases, the reaction rate constant is represented by the Arrhenius
law, that is
E N
K - k exp (2.4)
RT)
Notice that when the Arrhenius formula is used we put zero for n and nothing for T0
,

in the Aspen Plus window. Also, the units of the pre-exponential factor are identical to
those of the rate constant and vary depending on the order of the reaction As we .

know, the dimensions of the rate constant for an nth order reaction are:
(time)-1 (concentration)1-'1
Next come back to the problem The kinetic data are required to provide in the above
.

sheet. Here we use the Arrhenius law to represent the reaction rate constant. It is
important to mention that the pre-exponential factor must be specified in SI unit. For
the example CSTR problem ,
the pre-exponential factor and activation energy are given
as 5 x 105 m3/kmol s and 20 000 Btu/lbmol respectively (see Figure 2.33).
,

Running the simulation

In the window shown in Figure 2 33, the Status bar clearly indicates that all required
.

mputs are now complete Hitting Next

knob and clicking on OK we have the foUowing

Control Panel (see Figure 2 34).

.
ASPEN PLUS SIMULATION OF REACTOR MODELS 77

mam
.. ._ - -J »«. Pte Un* OMn m,

QMIHI -I .1 gJ al-i-|«>ll<l-| n.| | M

I r l-'l-'l-JV .
l .lalr : I: Ml
"

ANIUNE . 3 HYDROGEN -i CYaO-Cl

f LMMMto twite

s csm
3

ll ; US

a-i
*

Kdlarai."
stream

farHsfe.pnMn

| igiM afc. .| gdifcT,«fi .. | g a»»ita 11 .aroe. || S fSTI- « 45.}

,
«.s
C

t
FIGURE 2.33

:
Ffc Dm Taofai Run Lfesry Wirdiw KHp

DMB| al M -H x?! nklaKI I I »>| IS -I H g|-|3| @|;

JJ 1 1- i,JV
,
-Hal
-
iLWjilSla)
5
@ CSTPJ

oxputatich carsB rsi

Bi«ck.- csra uc tai. rcstr

fV . j Sep«a(«> i HwlE-changer. [ Cokm* Hb«1o« | Pte eChsr rt | M npuWw: | StJd; 1 UiwModel: |

MitoJ
SIflEAMS RStM fffxM REquJ RCiibOi BC5TR B Jg tSalch
f

fo K o .. .
.-

FIGURE 2.34

Viewing results
In the next select Solver Settings, choose igsuto Summary/Sf ms in the list on the
f

left and finally get the results shown in Figure 2.35 in a tabulated form.
78 PROCESS SIMULATION AND CONTROL USING ASPEN1

B» Ebl V«- D*. TMi. Hun fW ijt MiiM m J4J«J

I f I I i PT ! .leal I - Ml tM

" I i I i i I I i

3 '-" l

il il -

am nil 1
1000 0541

0«5

0J30 0 001
MUM nooo
-

mmmi tso 601

'
1
ITTre 0«J

sm DOM MPPM

0 98)

nr » | HuiE«w> ! C<jwi l-ctet. | FYB.M.Change.. i | UisrWodeU |

R&tac RVWd
i -1 .QMi-O'
SEgJ HQtei RCSIR RPfaa RftWi

o* j 3 ecofQB.c .jjJ Hereto P yP j Jatwlpd | .Ei wprf [{ AwenPkw-S « 1*35

FIGURE 2.35

Save the simulation work in a folder giving a suitable file name.

2 . 4 ASPEN PLUS SIMULATION OF A RPlug MODEL

Problem statement

The combination of two benzene molecules forms one molecule of diphenyl and one of
hydrogen (Fogler, 2005). The elementary reversible vapour-phase reaction occurs in a
plug low reactor (PER).
f

2CqHq <-> C12H40 + H2

benzene diphenyl hydrogen
The forward and reverse reaction rate constants are defined with respect to benzene.
The vaporized benzene (pure) with a low rate of 0.02 Ibmol/hr enters the reactor at
f

1250oF and 15 Psi. The data for the Arrhenius law are given below .

Forward reaction: A; = 3.2 x lO-6 kmol/s . m3 . (N/m2)2

E = 30200 cal/mol

Reverse reaction: k = 1.0x lO-5 kmol/s . m3 . (N/m2)2

E = 30200 cal/mol

[C,] basis = Partial pressure

The reactor length is 36 in and diameter is 0.6 in. It operates at inlet temperature.
Applying the SYSOP0 thermodynamic model,
(a) compute the component mole fraction in the product stream, and
(b) produce a plot ofreactor molar composition (mole raction) vs i-eactor length' (in).
'
f
ASPEN PLUS SIMULATION OF REACTOR MODEI S 79

Simulation approach
Select Aspen Plus User Interface. When the Aspen Plus window pops up, choose
Template and click on OK (see Figure 2.36).

i -

...
.

...

iwmmmlt mm

FIGURE 2.36

In the next step (see Figure 2.37), select General with English Units and hit OK button.

1 V-

I
-

- -

FIGURE 2.37

Click O/C when the Aspen Plus engine window appears.

Copyrighted material
TM
80 PROCESS SIMULATION AND CONTROL USING ASPEN

Creating flowsheet
In the Model Library, select the Reactors tab. Expanding the RPlug icon, the following
screen is obtained (see Figure 2.38).

li,-1?:- ?-- IM
-

Uj _

SIftEAMS
jS's - s - § o
'
RStoc lY»fc) W»J RCte RCSTR RBtfd<
f

FIGURE 2.38

Inserting the left bottom symbol in the Process Flowsheet Window adding the feed and ,

product streams, and renaming the block as well as streams, finally we see Figure 2.39.
Be £* *> &M ro* tj> Uonn WnSo* H*
f

r|ttF..U|-. -nr Nsi|--..| -MBi IN

>|[T><rr| h~o

,
I* -****** | f«M». t hmI- mw | c*-« iu««« I rM..1,o, _
i 1 '

S'W
iS- SSI Gj
-

' BS*» FTiMd tc nstfa. HCSTB lfy ,

q.
Tftj T
f

FIGURE 2 39 .
ASPEN PLUS SIMULATION OF REACTOR MODELS 81

Configuring settings
At this moment, we are sure that the process low diagram is drawn correctly . The Status

f
message directs us to provide the input information. Hitting Next knob and clicking on
OK, we obtain a form for setup specifications. First we input the Title of the present
nroject (Simulation of the RPlug Model), followed by the accounting information
(AKJANA/7/ANYTHING/AS YOU WANT) and Report Options [see Figures 2.40(a) to (c)] .

3Sifr-~3 m si I >>i liai g

f
ISrolWoneilheHPVjgMocW

Vdd|*MMC |

-
o->

SIKAMS '
HSteic tVM
i s u -= u
myt RG|te. RC?tR Rptq RBtuh
t

FIGURE 2.40(A)

UaTSil
> nt Mm OKk TMIp An W L±>»v WWo* H*p

arsi
aiobdj-/Deicnmn >/Acciwnlina| 0>agr>o«(«ci {

[T MMi- pdim I Smmnc I HulE«chv4«i | Cot-mi. lo«'«" | Pimm«C»W

SIRLWi
hB- 1 -1 - 8 Q
l5ia R.'* RfrMl RGfaU; W Iff Hf''-.
O
f

"
U
gMdiM-AiMf But " I
__ '
.

FIGURE 2.40(b)
82 PROCESS SIMULATION AND CONTROL USING ASPEN

dmbl Melm mbhjsM«!] 21 g

r m«i
» r SM

K C twwrH »4i , »« flow W 'IK

»O-S-0 y

FIGURE 2.40(c)

Specifying components
From the Data Browser, select Specifications under the Components folder. As we provide
the chemical formula of the components in the Component ID column, the other columns
of the table are automatically filled up (see Figure 2.41).

< Fit E* Htw D«i Tat* tji RsT Ihwf fntotr Hife
f

IMM FvmU,

cia<io

_
j «r<rCwwi

SET
"

r* rg '. Bin
k«W iooxi Id* -J

d
rvJ.cnttm
'

Mwl «*h OIR

FIGURE 2.41

Specifying property method

In the list on the left, choose Properties /Specifications to obtain the property input
form. Then choose SYSOPO by scrolling down (see Figure 2.42).
ASPEN PLUS SIMULATION OF REACTOR MODELS 83

tmum

3 1 I

is I
I
3
d
"~
r.
I 3

. » r

ETREAfce tStac FTV dd SEtMl RCSTS RPljg lgateh

FIGURE 2.42

Specifying stream information

In the left pane of the Data Browser window select Streams IF and enter the values ,

for all state variables and composition as shown in Figure 2 43. .

_
i r _ .

{y MIXED 3
State vsmUm
" " "

3 3r 3
|12SJ |f 3

1-5 |p. d H2
UH**C i3rtu»
Toid lwr (m.,- 3
f

|0 02 jbmot/N 3

Miinii

Tdat IT

Hoi 'jmvUf t.

i-1 . § . § u-i j
'

i* Rfrfi be j note ncsm npijg m»a

FIGURE 2.43
84 PROCESS SIMULATION AND CONTROL USING ASPEN

Specifying block information

In the next, select PFR by opening the Blocks folder The reactor is specified in the .

window, shown in Figure 2.44 .

i Wl tl P*l Lb try Wn

f
f
Jill IMMM
'

r-.i:i i nr

*
-
J Ntw QuwclWMldn
'
3

J/j Prcf n«

-
J

> -a f
aock-

_
J Readx
_
J C -wssxe

I Sold* { UnrMixM. j

BE** ftGMn

FIGURE 2.44

Open the Configuration sheet and enter the reactor dimensions in the next form
(see Figure 2.45).

F«* Edt tm 043 Tuafc flun fVK tbwy Wndm H* Ma

DlcglBl 1 M iteial *l uW\&\**\<\vi n>| Hi ! |Mi H i?i :H

_
j . /- itarj

DwtmUt 06 . -J

S _
j PAttwn

?»cp(rtif Veered

a :

| Sohk | Um> Modab |

a §is q-u
'
RStot Rrail lE<M Wite' BCS'R Bp
f

HUM

FIGURE 2.45
ASPEN PLUS SIMULATION OF REACTOR MODELS 85

T the subsequent step, we define a reaction set for the simulation. The default name
R-l has been accepted. Then select Power law kinetics and obtain the picture, shown in
Figure 2.46.
' r
M *" D*« ** "rw*

I 22
'

SIR£>M$
H®-1 j . I y
' HStac fiW RCqU RGtti RCSTR iB
a BB*J>
f

FIGURE 2.46

Specifying reaction information

Hitting Afof button and clicking on New we have the following forms (see Figures 2.47(a) ,
r

and (b)) for reaction number 1 (2C6H6 -> C12H10 + H2). Since the reaction rate constants
are defined with respect to benzene we convert the stoichiometric coefficient of benzene
,

to unity for both the reactions Obviously the reactions are second-order.
.
,

Jala_jj iiei wj nHM'.teM ».| m .| |h| .| pi ®|

1 r..l..|,.l it . 1 .ibi- 1 / ial

Rmmm

I1-I'

v R 1

-
o -

-
0 S 0 1J
-
a .a # 1

FIGURE 2.47(a)
86 PROCESS SIMULATION AND CONTROL USING ASPEN
HI »l

D|tf|y| I I <«l aHM-KM

l ! |h| -i ~ij j

J _2=J

j i
. :

3-1-0 o =u RE R6ife RnSTR

f ue HB**
'

j y- Bi-KOT- W j K Mmrst* Moiod j r jj Aver. Plu< - 5M " ij.} 30» '

FIGURE 2.47(b)

As mentioned previously, when we do not specify the exponent for a component ,

Aspen Plus uses a default value of zero. As the message on the screen, shown in
Figure 2.47(b) reveals, it is true that the forward reaction rate does not depend on the
product components. After completing the irst reaction, select 'New' rom the Reaction
f

f
No. list. Enter '2; for the reverse reaction QHe C H + H2) and click OK (see Figure 2 48). .

3| |B| JJ Mgl jgl nklaNUI I n-i 3

_
_
LliiJ El J
-

l -

.
. ff alaltfrfi
-

.1 ilBl: I si
f

«|-

r a
1

Oeate a nm Redcton No .

R-t

i'R£aUS nS>« tMM

BCtM
Cir.-,.;
tI"..-..,
Gbb. RCSTf
n -.n
t RFVp IS
f

Fa-Htfc mm FI " "~

'-
-
--- II *p»f\«-a»i «

FIGURE 2 48 .

Subsequently provide the stoichiometric coeficients along with ex

the screen, ponents, and get
f

shown in Figure 2 49. .

ASPEN PLUS SIMUIATION OF REACTOR MODELS 87
iViirtiT.r

433
1 n-i 1.1 nr -

i ,ieii
. i mi *m
i; i
71

am*. | CJk-< | [(on '

CI.X'6 > wi [1
. 1
. 1

J _i5Lj

jjWM REaJ gg»] HCs lt nawcft

FIGURE 2.49

Hit A exf knob and obtain two stoichiometric relations as shown in Figure 2 50. .

-
.

y. To* An fV Lirwy (fntjrw Mai

DMBI 1
-
i-nr .1 w - i
-

3>>J qLJniJ

HmNo Stuctimttry

: Kn«c

_
j MHnnd

, I Sehdt I Ui*M«Jrt )

u E .11
,.

61 bio's
*
c

' fif.ioc ff/ id

1r§
he j* new- tCMn lrv Rn»th
f

c v e (BiiTffiirr ft* n-i " "

FIGURE 2.50

In the simulation of the present problem we use partial pressure basis (applicable ,

for vapour only) and therefore, the Power law expression has the following form:
,

( f >
n
E ri 1
r = k exp (2.5)
R To ,

where , P represents the partial pressure (N/m2). If fo is not specified, the above equation
18 replaced by:
88 PROCESS SIMULATION AND CONTROL USING ASPEN

r= kTn exp mPif1 2 6)

RT, .

For the prescribed reactions, values of the pre-exponential factor and activation energy
are provided in the two forms, shown in Figures 51(a) and (b). To apply the Arrhenius
2 .

law, we put zero for temperature exponent n and left the box, allotted for datum
temperature T0, empty.
i»f.i

I r mi r» ! .isi; I - IB!
as
±1
"

[i) cfwe-. sciwio. 3

1 d
E §
ill

* ai F
* a ?
Si Bacfa
i PR

0 R-1

StflEfiMS RSI fteM REqui Rtjfco RCSTFI RPVJ5 RBVch

f
r

FIGURE 2.51(a)

». Ea »«, 0«, r i, a .
.

i '

r u>i-«i» rr 'i-.joii
-

HMfcl"" »|-»l «l|Ii 3 >>l Dj J n.|

(31 50*10. 5m; . C6M6

a i
KiMtel«daNUT/T>>|"*'(E<n|m'l/TB|

i a *******

I Mill

SfBtMK ' BStet R>wto

8 i 0
Rt fjfl ,
a
"
11 Lin i

FIGURE 2 51(b) .
ASPKN PLUS SIMULATION OF REACTOR MODELS 89

Running the simulation

Hitting Afet button and running the simulation, we obtain the Control Panel (Figure 2.52)
r

showing the progress of the present simulation.

_
i r-i I ! f»
_
'
-i-igi 1 w aisd

(0 9 S 8 O = UM t<< Of*

FIGURE 2.52

(a) Viewing results: Click on Solver Settings knob, choose Results Summary/
Streams in the column at the left side and inally obtain the results for all
f

streams, shown in Figure 2.53.

I r-i-i -rf7 'i -Hi i in i*l

" J
a S d
IUWi 1 -m
- -
tm-1
" "

TW no-
4 1-
- -
*m sub-
-
aaraocc- ve- im
(stcsss: -
rwm 1
L
ROT Ml
Mr
-

oi
TWI
M

I - I M»l

inuA mm mm mik --

-I * I-

FIGURE 2.53

C ll
90 PROCESS SIMULATION AND CONTROL USING ASPEN

(b) Producing a plot of mole fraction vs length: Use the Data Browser menu
tree to navigate to the Blocks IPFRI Profiles sheet (see Figure 2.54).
MJi HillLlim-WPMlMli -. ..l»1.T71.
»in: «.
Fte &*l
Wi V*t
V*» C#»
C#» Toe*
roe* H i
Hji PW
pw L*f«7
Ltmv > "«

Dloi|y| I -.1 EtelBl «d H H I"! li U

.
ifl - P.OC..I Sbe«. I
it Pt >wt«
t aa 9»um
f

-
e v.
-

a pf

_
pn F z
Utt Sutra.
far-
bt !S iHo
f] nwdb IS TZZf&VS
"

; 15 r?55 sSiTFW
.
4
s !5 00001 u*?
-

m
a 9fM- p« Z' 5

A m RNdm lb i55S
-

QniMgra i* 15

IS last 1 [ri!DK4IIt

f
g LSiQFM,
it. j

I Maroiato-s | So** ) UtaHvkk |

C :., a fciJen'j'jsei Pin v

FIGURE 2.54

In the next, select Plot Wizard from the Plot pulldown menu Alternatively, press .

Ctrl+Alt+W on the keyboard and obtain Figure 2 55. .

a S5
I
: PlOCCUtilMnKtXEflM

1 a t
f

Wercome ta Aspen Plus Plat WU.rdl

;

9 EM IJ
if/ t** Ocw

jlE
E

t Fa* ;
f

ii
24 IE
ir
-

9 a EOCor-Ortcm ;

fj LSSOPBu -
L J J

51 REAMS
1
1 HSbe
i . i y=o
HVMJ REcU ROttx

FIGURE 2 55 .

Click on Next icon and get a variety of plots (see Figure 2 56). .
ASI'KN PLUS SIMULATION OF REACTOR MODELS 91

pi-eniajaaisi =i r. -i ht a3f j

a 3fif* I 3 4321 iiB1 3iil 3t J Id

t
---

I
a tfmm

i
9 -
? - m N
1
-

n 1
17 f
R
-

n
ri
n 1
(
< H
1

J I i

iTmao -
Nftj mfc < w
- " -

ind* .. -_;=_
f

FIGURE 2.56

Among the available options, select one plot type that is titled as 'Composition' and
press Next button (see Figure 2.57).

r-l |..l'fT
-

- 'i-lci 1

fi ita.l
3 i±d «JP-3a -''ail -i -

.
a - i r
-
io -
-
j
-
m -
a Bin
3S

v- I i-*

-
3 '-
4
'

{© 9 . i 0 Q -O-
'
w > mm "tj~ mm m> mm J
FIGURE 2.57

Again click on Next and get the form, shown in Figure 2.58.
92 PROCESS SIMULATION AND CONTROL USING ASPEN1

I mim 1?! r3l-<-lfcl<.UM "-I H _jLH jd JEl

V) - , PlOCBU SUUM j I I

i
.
iJ PHI f''V.I fi

,. -1
I
5r .

i
.

i {
CIS-
t
ri t
!
_

Cvitl 'Sack ir i

-
CH
STREWS RYaM
si y
TlSitd mt*» SCS?fl BWug
u BflWch

1« j- 9 -B- «M

FIGURE 2.58

Check whether the information displayed in the window, shown in Figure 2.58 are ,

ok or not. Hitting Finish knob. Figure 2.59 is obtained by plotting 'reactor molar
'
composition (mole fraction) as ordinate against 'reactor length' (in) as abscissa.

t- <\<- Dtfa Tooa Put trv . Wnsmr H(*>

Dl lHl am oivj ipi al-nal-KI I"»! Its I M .l lal yj

Block PFfi Cemmin

| Xnxan. | Sou | u>Mod> |

STROIMS RS'jc HTot)

si u=u
Qg RGtfc, tCSIR tFy
f

111 *
'

.
" ' 8M,

FIGURE 2.59

Note that the plot window can be edited by right clicking on that window and
selecting Properties In the properties window
.
,
the user can modify the title, axis scale,
font and colour of the plot Alternatively, double-click on the different elements of the
.

plot and modify them as we like to improve the presentation and clarity.
ASPEN PLUS SIMULATION OK KKACTOR MOOEI 93

2.
5 ASPEN PLUS SIMULATION OF A RPlug MODEL USING LHHW
KINETICS

Problem statement

In acetic anhydride manufacturing, the cracking of acetone produces ketene and methane
according to the following irreversible vapour-phase reaction:
CH3COCH3 -> CH2CO + CH4
acetone ketene methane

This reaction is irst-order with respect to acetone. Pure acetone feed with a low
f

f
rate of 130 kmol/hr enters a PFR at 7250C and 1.5 atm. The kinetic data for the Aspen
Plus simulation are given below.
k = 1.1 s"1
E = 28.5 x 107 J/kmol
n=0

T0 = 980 K
The unit of pre-exponential factor clearly indicates the |C 1 basis. To use the Langmuir-
,

Hinshelwood-Hougen-Watson (LHHW) kinetic model, set zero for all coeficients under Term 1

f
and that for all coeficients except A under Term 2. Take a very large negative value for
f

coeficient A. The sample adiabatic PFR is 3 m in length and 0.6 m in diameter. Applying
f

the SYSOP0 base method, compute the component mole fraction in the product stream.

Simulation approach
As we select Aspen Plus User Interface, first the Aspen Plus Startup window appears,
as shown in Figure 2.60. Choose Template option and press OK.

2I=flHJ-J-Lag Pl-W i-H=J Tl I I I 'IW *l

1 -I

**mmm*mH MM

FIGURE 2.60
94 PROCESS SIMULATION AND CONTROL USING ASPEN

In the next, select General with Metric Units and again hit OK button (see Figure 2.61) .

pea

An IPE a-wm tcpwl*

f
<*-Sxar
'

Penmen
Mair>

'
"
11 'C*
'

FIGURE 2.61

As the Connect to Engine dialog pops up ,

click OK.

Creating flowsheet
From the Model Library toolbar we have selected RPlug reactor and developed the
,

process low diagram as displayed in Figure 2.62 .

He & 3an Tocfc fir FW mI Jy»r, WnSe* Htfc

Qi lHI aiai |a| yj nl-i-iaKKi i w.| 3 _

i ii<j
_
j 3 _j
_
_
|
rlttF-I l- l PT I Mi I igl

s,flt
H8- S . 8 - <SSL QU U
zzz rsr izf
M awif- ~ -

FIGURE 2.62
ASPEN PLUS"1 SIMULATION OK REACTOR MODELS 95

Configuring settings
In the list on the left, choose Setup /Specifications. For the present problem, we wish to
'
give the Title as Simulation of the PFR'. and accounting information as 'AKJANA/8/
ANYTHING/AS WE LIKE'. In addition, choose 'Mole' and 'Mass' fraction basis for the
streams under Report Options [see Figures 2.63(a), (b) and (c)l.

' i LU.

-
Ml o . § 6 onu
m»t «>>.

FIGURE 2.63(a)

I'HIM ' - XM -i..

FIGURE 2.63(b)

Gopyngt-
96 PROCESS SIMULATION AND CONTROL USING ASPEN1

ttn fci VV* CMi teds FLn Pw lirat, VAmtow 3ip

o|a!|ai I I tfeiel t?! phlftltl l'-l n) _L_L!iJ iJ 21 j2J
i r- i-i pt | -|m i - imi

Cor i j now***- I etod. /StaM»| p'««"y i I

ti-n» o hi NAKtad W

t
FkMbM hi--- 'i
P Hde PM* TFf, IGEN M.
3
T Mm. P

P Cwowit nih IWO ib- «I'KUjn

SI REAMS PStoc frriii REqal t6tU RCSIR RFV) BSatc

efHeb pcufl CV lFoldenXAaDerPlB 1- 1 NUH : -r irt- t.- r tr.-arpt-i

r
f

FIGURE 2.63(c)

Specifying components
Select Specifications under Components folder in the Data Browser window As we .

out the Component ID column Aspen Plus provides the rest of the information in ,

component input form shown in Figure 2.64. ,

le EJI Wen On tim» t* Put Utray Vfrifcw o«

1 f -
i i-i- r» jiAm \ m
"

3 M£ i J nJ -3 »l Qj -.1 «*!
3 S-L*

O SfamOM*
Tim
tCEIO-JE
SottTSe )3<roi
itENE KEIENE bHJO
$ a«pm)<i seths -pn
»

|1
i Bk«k>

stficwi wiac f .
-
8 . 1 -y-lE-U
Pfcu
'

ns tu ncsTp
f

FIGURE 2.64

Specifying property method

Hit Afot button and in property method (see Figure 2.65), scroll down to get SYSOPO
r
ASPEN PLUS SIMULATION OF REACTOR MODEI.S 97

JtUI

l r Ll_L_F
_ _
-iCI I ! !

9 "w-cwr.

I 3

j» -

. la
mr'iiir

.
(0- 0 I t»*
: I jn U- ia ).

FIGURE 2.65

Specifying stream information

In the left pane of the Data Browser window, select Streams IF. Inputting the values
for temperature, pressure, total low and mole fraction, we have the picture as displayed
f

in Figure 2.66.

I.UH
-
;

I
, ,

3 i--- 3
I '
-
.

r
I--... --

I '- -
3
figs?
I'* 3

g M

f|7
. »
-
1 i iT

I- 0 . i . 8 OMU
»»«« gjfc «ani ggi

FIGURE 2.66

Copyrighted material
98 PROCESS SIMULATION AND CONTROL USING ASPEN

Specifying block information

In the subsequent step (see Figure 2.67), select PFR under Blocks folder. Specify the
reactor as an adiabatic one.

i ffc Ed» We* Oto Ta* Rn Rot lisrary VAnJo* He* 313
OUIHI I I itelal i?l rsK NKiH »'| 3 _
UjiJ _J -il SI

aft I 3 »hJiii(s £i»i

i KSS 3 ulwCcr/gi/Wcr. |wRtK(nni| Pitt*** j

_
J AM H
.
_
J y c
-
9MM
-
Jfl F

O BUM*:
3;-* Ctro'
~

| | = 41111)
Mta

O EOrw -J

STREAMS RVaM
.
8 i US IJ
BEqut RGhta BCSTfl SPlup HBatet
f

. .

C ' g Foktect- apen FVi il l : HUM fW Ki rtsi muc s

60* r;;a«cfefZ-M!S j - jj.
tii
'

ftoM } }LladuTtfi5- j .'debt AgttK Pr |{

. Plus - S .
« 1107
f

FIGURE 2.67

In the Configuration sheet reactor length as well as diameter are given (see Figure 2.68).
,

Rfe E« 'rim 'tieo An PW

QNB| _ u ie|jg] n|-<-|fcN M Hi a »l |n| .la l i|

I 3

36 a SM
3i
t

StMrtl "

.
J6 f 3
rj f
& tdta
f

PnAn
f EOVw-b*.
a EOmpJ -
0
D

SWMlttf I HtHEttl

D-* iisi (
-

StflE*MS RSlac frtM

i -1 -o-n-o-
M*A RBto PCSTR

FIGURE 2.68

In the next we define a reaction set for the present simulation The default name
, .

R-l is ok Then select LHHW kinetics and obtain the screen exhibited in Figure 2.69.
.

,
ASPEN PUJSTM SIMULATION OF REACTOR MODELS 99

1 W-l-K-l..

-
a .

(@- 0 g g u a u
1 . - WW -G- Hi-' WS.

FIGURE 2.69

Specifying reaction information

Press Nex/ knob and then click on New. Under Reactants, select 'ACETONE' from the
Component dropdown menu and set the coefficient to -1. Similarly under Products,
select KETENE' and 'METHANE', and set both coefficients to 1 (see Figure 2.70).
'

i r.:i..i-u rr . mi-*ifc|

d «- 1 d
*.Ml' -

t 2 roK-. i
.

I*
-

in«Mt
Q -

-
<@ S 8 § Q»0 *a>. 'mh gi»

FIGURE 2.70
100 PROCESS SIMULATION ANnjWQlOLUSING ASPEN'

Hitting on Next and clicking Kinetic button, we get Aeldn ics input form. A littl e

description is given below to understand the use of LHHW kmetxc model m Aspen
simulator.
The LHHW rate expression is represented by:
(kinetic factor) (driving force)
r = (2 1)
(adsorption expression) .

The kinetic factor (reaction rate constant) has the following form:
'
n
E \ 1 >
K = k exp (2.8)
R k
T To)

If Tq is ignored, Eq. (2.3) replaces the above expression. Note that all the notations
used in Eq. (2.8) have been defined earlier.
The driving force is expressed by:
f N A
n c?

and the adsorption is modelled as:

M
N
nc"J
Li=i
where,
In (Ki) =Ai + Bi/T + Ci IniT) + D.T (2.9)
Here, m is the adsorption expression exponent M the number of terms in the adsorption
,

expression, N the number of components a the concentration exponent,, K2, K, the

equilibrium constants [Eq (2.9)], A,, it, Q,
.
the coefficients and I Notice that the
f

concentration term C used in the above discussion is dependent on the [CJ basis Say .

for example when [CJ basis is selected as molarity the concentration term represents
,
,

the component molar concentration (kmol/m3); similarly when [CJ basis is partial
pressure, the concentration term represents the component partial pressure (N/m2).
Providing required data we have the illed kinetic sheet shown in Figure 2.71.
,
f

Click on Driving Force to obtain a blank form as shown in Figure 2.72.

Select 'Term 1' and then 'Molarity' as [CJ basis Under Concentration exponents for .

reactants,
set acetone exponent to 1. Similarly for products set ketene and methane ,

exponents to 0 Also enter zero for all four driving force constants as mentioned in the
.

problem statement (see Figure 2 73). .

In the subsequent step (see Figure 2.74), select Term 2' rom the pulldown Enter
f

term menu Since the given reaction is irst-order with respect to acetone
.

and there is
f

no second term enter zero for all exponents and coefficients Owing to
,
the method .

Aspen Plus uses to specify a reaction, we should insert a very large negative value for
coetticient A (say ,
-106) to make Term 2 essentially zero [see Eq (2 9)1 Finally click ,

on Next icon .
n- .
ASPEN PLUS SIMULATION OF REACTOR MODELS 101

f t* 0m Om Ta«i .av* VMw

-
L T -
I I 'i r-i -I -lei I !«!

3
-~ .

.
j ii w
, 3

j9
O 'm<iaii '

-
i
*
Zj i am i(t/T«f
lUlllll cuM.
:
f

J
.
Zj
a *-
.
j f
. .
- i

D -.

Ml
-

fF II | IWBMM | MlMnpn | Man W I | .W.w.Oa n | Mwwl-i | MB | IMMM |

ItWMn om. ggjl gjj MM. WWI

1IWJ'

<5 l-B

FIGURE 2.71

I Mk | - --

WB. B'Mt 'CM Wto. "lac*-

FIGURE 2.72
102 PROCESS SIMULATION AND CONTROL USING ASPEN

1
j
-

[-EETEEXSC

Idlbsw I
j
_
'.D- o-xr'

-
I

. p eis ep

f
.
1

BEoJ AG**!

FIGURE 2.73

Rwcaigthsai jVapm
3
Hi
ErteHtrm [l«rm2
.
a
_
j
t(*clartr
Expowii
0
) .

lJ Q
u

_
) Data

a
.

SbMM
F
. p

r'. u co(W,c»1t A tewrddning low J«m Ln(ccr.;fanl

.
21 - i f/fT
PFS - Ml T SeeHfle .
t

lj Omttry

G
j Ci ytw tyw »fival«n enerw 'a t«
.
Jn poww law wpittWin

j
_

u l»

Mom
STRCAHS
BE(M RSfca RCSTR
f

FUin HUM

llQi<to; wcwrtw l j ig ito w J

FIGURE 2.74

Running the simulation

The Stoins bar displays a message of Required Input Complete in the bottom ight
r

comer of the window shown in Figure 2 74. Subsequently run the simulation and obtain .
,

the status report as displayed in Figure 2 75

ASPEN PLUS SIMUUVTION OF REACTOR MODELS 103

_
j r i
_
- -
i-i'
'
nr -i \ m -sw

i --»- tii

»**"' I
'
II I -*« -- I . *"l »->

£r <@ 6 S 0 O H U
IIIMH HlK «* Mm ".iril A* Mar

FIGURE 2.75

Viewing results
Pressing Solver Settings knob and selecting i?esw/ s Summary /Streams, we obtain the
final results as reported in Figure 2.76.

i i-liisialiil:

"
1 1 I -i

1 3
r[.- , .... el
_

fami ST
____ -

iffan ur
r

rzw

'
i
BTTiW I'M

Tivi
'

M- Q . S . § U S U Wii TM- l»-

FIGURE 2.76

Copynghied material
104 PROCESS SIMULATION AND CONTROL USING ASPF.N

SUMMARY AND CONCLUSIONS |

This chapter presents the simulation of several reactor models. Here, we have considered
a variety of chemical reactions in the Aspen Plus simulator. Probably the most useful
kinetic models. Power law and Langmuir-Hinshelwood-Hougen-Watson (LHHW). have
been used in the solved examples. A number of problems are given in the exercise for
extensive practice.

PROBLEMS |
2 . 1 Ethyl acetate is produced in an esterification reaction between acetic acid and
ethyl alcohol.
acetic acid + ethyl alcohol <-> ethyl acetate + water
The feed mixture, consisting of 52.5 mole% acetic acid, 45 mole% ethyl alcohol
and 2.5 mole% water, enters the RCSTR model with a low rate of 400 kmol/hr at

f
750C and 1.1 atm. The reactor operates at 70oC and 1 atm. Both the reactions
are first-order with respect to each of the reactants (i.e., overall second-order). For
these liquid-phase reactions, the kinetic data for the Arrhenius law are given below:
Forward reaction: k = 2.0 x 108 m3/kmol - s
E= 6 0 x 107 J/kmol
.

Reverse reaction: k = 5.0 x 107 m3/kmol . s

E= 6 0 x 107 J/kmol
.

[C,l basis = Molarity

Perform the Aspen Plus simulation using the NRTL thermodynamic model and
reactor volume of 0.15 m3 .

2 . 2 Repeat the above problem replacing RCSTR model by RStoic model with 80%
conversion of ethyl alcohol.
2 3 Simulate the reactor (Problem 2.1) for the case of an RGibbs model.
.

2 . 4 An input stream, consisting of 90 aole% di-tert-huty\ peroxide, 5 mole% ethane

and 5 mole% acetone, is introduced in a CSTR at 10 atm and 1250C and a low
f

rate of 0.2 kmol/hr. The following elementary irreversible vapour-phase reaction

is performed isothermally with no pressure drop.
(CH3)3COOC(CH3)3 C2H6 + 2CH3COCH3
Fake kinetic data for the Arrhenius formula are given as:
k = 1.67 x 104 kmol/m3 s (N/m2)
£ = 85 x 103 kJ/kmol

LCJ basis = Partial pressure

The reactor operates at 50oC and its volume is 6 m3. Using the SYSOP0
thermodynamic method, simulate the CSTR model and compute the component
mole fractions in the product stream.
ASPEN PLUS SIMULATION OK REACTOR MODELS 105

2 . 5 A feed stream, consisting of di-tert-buty\ peroxide, ethane and acetone, enters a

RYield model at 10 atm and 1250C. The reactor operates at 10 atm and 50oC.
Use the SYSOP0 property method and assume the following component-wise
low rates in the feed and product streams (see Table 2.3).
f

TABLE 2.3

Component Feed flow rate (kg/hr) Product flow rate (kg/hr)

di-tert-hntyl peroxide 26.321 1 949
.

ethane 0 301
.
5 314
.

acetone 0 581
.
19.94

Simulate the RYield reactor and compare the results (mole fractions in the
product) with those obtained for Problem 2.4.
2 6 As stated in Problem 2.1, the reaction between acetic acid and ethanol gives
.

ethyl acetate and water.

CH3COOH + C2H5OH (-> CH3COOC2H5 + H20
The inlet stream, consisting of 50 mole% acetic acid, 45 mole% ethanol and
5 mole% water, is fed to a REquil model with a flow rate of 400 kmol/hr at 750C
and 1.1 atm. The reactor operates at 80oC and 1 atm. Using the NRTL property
method, simulate the reactor model and report the compositions of the product
streams.
2 . 7 Ethylene is produced by cracking of ethane in a plug low reactor. The irreversible
f

elementary vapour-phase reaction is given as:

C2H6 - C2H4 + Hg
ethane ethylene hydrogen
Pure ethane feed is introduced with a low rate of 750 kmol/hr at 800CC and
f

55 atm. The reactor is operated isothermally at inlet temperature. The kinetic

data for the LHHW model are given below (Fogler, 2005).
k = 0.072 s"1
£ = 82 x 103 cal/mol

Tq = 1000 K
|C,] basis = Molarity
The reactor length is 3 m and diameter is 0.8 m. Using the SYSOP0
thermodynamic model, simulate the reactor.
2 8 Repeat the above problem replacing the PFR by a stoichiometric reactor with
.

80% conversion of ethane. If require, make the necessary assumptions.

2 9 In acetic anhydride manufacturing, the cracking of acetone occurs and produces
.

ketene and methane according to the following irreversible vapour-phase reaction:

CH3COCH3 i CHoCO + CH3

1
106 PROCESS SIMULATION AND CONTROL USING ASPEN

In the CSTR model, ketene is decomposed producing carbon monoxide and

ethylene gas. '
K
CH2CO-> CO + 0.5 C2H4
where,
15
, .

'
-
rk = K
26586
K= exp 22.8- mol/lit s . atm15
T

25589
K' = exp 19.62- mol/lit . s

[C,] basis = Partial pressure

Here, -rA is the rate of disappearance of acetone (A), -rk the rate of disappearance
'
of ketene ik), PA the partial pressure of A, and K and K the reaction rate
constants. Pure acetone feed with a flow rate of 130 kmol/hr enters the reactor
at 7250C and 1.5 atm. The reactor with a volume of 1 . 4 m3 operates at 700oC
and 1.5 atm. Applying the SYSOPO base method compute the component mole
,

fractions in the product stream .

REFERENCE |
Fogler ,
H. Scott (2005), Elements of Chemical Reaction Engineering Prentice-Hall of India
,

3rd ed.. New Delhi .

CHAPTER

Aspen Plus Simulation of

Distillation Models

31
.
BUILT-IN DISTILLATION MODELS

An Aspen simulation package has nine built-in unit operation models for the separating
column. In the Aspen terminology, these packages are named as DSTWU, Distl, RadFrac.
Extract. MultiFrac, SCFrac, PetroFrac, RateFrac and BatchFrac. Under these categories,
several model configurations are available. Note that Extract model is used for liquid-
liquid extraction. Among the built-in column models, DSTWU, Distl and SCFrac
represent the shortcut distillation and the rest of the distillation models perform igorous

r
calculations.
DSTWU model uses Winn-Underwood-Gilliland method for a single-feed two-product
fractionating column having either a partial or total condenser. It estimates minimum
number of stages using Winn method and minimum reflux ratio using Underwood
method. Moreover, it determines the actual reflux ratio for the specified number of
stages or the actual number of stages for the specified reflux ratio, depending on which
is entered using Gilliland correlation. It also calculates the optimal feed tray and reboiler
as well as condenser duty. Remember that this model assumes constant molar overflow
and relative volatilities.
Distl model includes a single feed and two products, and assumes constant molar
overflow and relative volatilities. It uses Edmister approach to calculate product
composition. We need to specify a number of stages, e.g. feed location, reflux ratio,
pressure profile and distillate to feed iD/F) ratio. Actually, when all the data are
provided, we can use this column model to verify the product results.
RadFrac is a rigorous fractionating column model that can handle any number of
feeds as well as side draws. It has a wide variety of appUcations, such as absorption,
stripping, ordinary distillation, extractive and azeotropic distillation, reactive distillation, etc.
MultiFrac is usually employed for any number of fractionating columns and any
number of connections between the columns or within the columns. It has the ability to
simulate the distillation columns integrated with flash towers, feed furnaces, side
107

Copyrighted material
108 PROCESS SIMUKATION AND CONTROL USING ASPEN

strippers, pumparrounds, etc. This rigorous column model can be used as an alternative
of PetroFrac, especially when the configuration is beyond the capabilities of PetroFrac .

As mentioned earlier, SCFrac is a shortcut column model. It simulates a distillation

unit connected with a single feed, multiple products and one optional stripping steam .

It is used to model refinery columns, such as atmospheric distillation unit (ADU) and
vacuum distillation unit (VDU).
PetroFrac is commonly employed to fractionate a petroleum feed. This rigorous model
simulates the refinery columns, such as ADU, VDU, luidized-bed catalytic cracking (FCC)

f
fractionator, etc., equipped with a feed furnace, side strippers, pumparounds and so on.
RateFrac is a rate-based nonequilibrium column model employed to simulate all
types of vapour-liquid separation operations, such as absorption, desorption and
distillation. It simulates single and interlinked columns with tray type as well as packed
type arrangement.
BatchFrac is a rigorous model used for simulating the batch distillation columns. It
also includes the reactions occurred in any stage of the separator. BatchFrac model
does not consider column hydraulics, and there is negligible vapour holdup and constant
liquid holdup.
It is worthy to mention that for detailed information regarding any built-in Aspen
Plus model, select that model icon in the Model Library toolbar and press Fl.
In this chapter, we will simulate different distillation models, including a petroleum
refining column, using the Aspen Plus software. Moreover, an absorption column will
be analyzed. In addition to the steady state simulation the process optimization will
,

also be covered in the present study.

3 .2 ASPEN PLUS SIMULATION OF THE BINARY DISTILLATION

COLUMNS

32 1
. . Simulation of a DSTWU Model

Problem statement

A feed stream, consisting of 60 mole% ethane and 40 mole% ethylene enters a DSTWU
,

column having a low rate of 200 Ibmol/hr at 750F and 15 psia This feed is required to
.
f

fractionate in a distillation column capable of recovering at least 99 6% of the light key

component in the distillate and 99 9% of the heavy key component in the bottoms. The
.

sample process operates at 300 psia with zero tray-to-tray pressure drop The pressure
.

in the reboiler as well as condenser is also 300 psia In the simulation, use total
.

30 theoretical stages (including condenser and reboiler) and a total condenser Applying .

the RK-Soave property method simulate the column and calculate the minimum reflux
,

ratio, actual reflux ratio minimum number of stages actual number of stages, and
,
,

feed location.

Simulation approach
From the desktop select Start button and then click on Programs, AspenTech, Aspen
,
,

Engineering Suite Aspen Plus Version and Aspen Plus User Interface. Then choose
,

Template option in the Aspen Plus Startup dialog and hit OK (see Figure 3 1). .
ASPEN PLUS SIMULATION OF DISTILLATION MODKUS 109

Q\a\m -I -I |r| <ri q-r-mi .l-Kl!d 2) I I l gj J -

I ' l-l-l I- 1 1 I
-
I ! 1-1

FIGURE 3.1

Select General with English Units as the next window appears (see Figure 3.2).

.
4./
MM
-
Hi . -

...

mm ...

__
l

FIGURE 3.2

C aterial
110 PROCESS SIMULATION AND CONTROL USING ASPEN

Again press OK to see the Connect to Engine dialog (see Figure 3.3). Here we choose
T,ocal PC by scrolling down. Hit OK knob and move on to develop the process low diagram

f
.

Connect to Engine a
Server type:

User Info

Node name:

User name:

Password:

Working directory:

Save as Default Connection

( OK 1 Exit Help

FIGURE 3.3

Creating flowsheet
As we select Columns tab in the bottom Model Library toolbar (Figure 3 4), Aspen Plus .

shows all built-in column models.

«a 6t Mr- 0*s locii Rfi Rewhart Ltrary Wxto- H«fc>

Model Library toolbar

StftEAMS 1 DiTVU Ci-J R»fEjJikI M tfug Sffru PWtrf.te Rurf- Bwctfi -

FIGURE 3.4
ASPEN PLUS SIMULATION OK DISTILLATION MODELS 111

In the next, select DSTWU icon to represent the short-cut distillation process.
Once we have selected the icon, place the icon on the lowsheet by clicking with the

f
cross-hair somewhere on the lowsheet background. When inished, click on K | symbol

f
or ight-click on the lowsheet background. By default, the column is named as Bl
r

f
(see Figure 3.5).

i\n 'amiami I
Hi tM Dn <oaa 'hr nrann lw -«

Dfagyai aial id g] aififci K!--! "i i |m| ! v\ *\

r|rrFf,.|..|..h HT 'MPl I Bl -fW

UJ -
iT
_

-
CH
"SAW. ' DIIMI Out "*l<m 1M MtfMi IW l*. ..
i c-.i C- a'aMAcwi a IM AM ru- MMC*

FIGURE 3.5

In the screen, shown in Figure 3.5. only the block is displayed; there are no incoming
and outgoing streams connected with the block. Therefore, the Status message in the
bottom right of the window includes Flowsheet Not Complete. Interestingly, after
connecting all required streams with the unit, this message sometime may also be
retained. This happens because of improper flowsheet connectivity.
To add a single feed stream and two product outlets (distillate and bottom), click on
Material STREAMS tab in the lower left-hand corner. As we move the cursor
(a crosshair) onto the process lowsheet, suddenly three red arrows and one blue arrow
f

appear around the block. These arrows indicate places to attach streams to the block.
As we know, red arrows are required ports and blue arrows are optional ports. Click
once on the connection point between the feed stream and the DSTWU block, enlarge
the feed line and finally click again. By default, this stream is labelled as 1. In the
similar fashion, we can add the two product streams, namely 2 and 3, to the distillation
unit (see Figure 3.6).

Copyrighted malarial
112 PROCESS SIMULATION AND CONTROL USING ASPEN

He EA V«* data Tooti Rr. FtowtfiM Ut-av Wtxfaw H«to

rlRFi-|...httt lT 1 irol I - lal 1

0 -

STREAMS ' DSTWU Dntl Rrfisc EntisO Mutftw; SCFiac PeOoFi Ratrf.ac BWchFiac

Book flOflCfcrJ-
r

FIGURE 3.6

After renaming Stream 1 to F, Stream 2 to D, Stream 3 to B and Block Bl to

DSTWU, the lowsheet finally looks like Figure 3.7.
f

fte EiJI «ew OKa Tocti f**i fte«h«i Uxsy Wndm. H-t

MiBl alal lei 1 ni-rlftl Nkl H li! -

0 O

E -

STREAMS
'
DSVM Rrf(»e E**d MtAffc SCfttc PMcfiae RjuF.ic Eatctfr
.. , - ~r IR Wfc. . nR*!!! MUM TW*o
'

Vn co- I Qw i W l- O il W l UN T * || A -a .
f

FIGURE 3.7
ASPEN PLUS SIMULATION OF DISTILLATION MODELS 113

Now the Status bar in the window, shown in Figure 3.7, says Required Input
Incomplete indicating that the lowsheet is complete and the input specifications are

f
required to provide using available input forms for running the Aspen simulator.

Configuring settings
Recall that within the Aspen simulation software, the simplest way to find the next
step is to use one of the following equivalent commands:

(a) press the Next button

(b) ind 'Next' in the Tools menu
f

(c) use shortcut key F4

and obtain Figure 3.8.

mF-M-i-i nr 'i -ici \-\m

0 -

c-Q-

D«pr, rce rout to**'

3 I

HmnnUBmt | VwMdi | HMUOwpn fil | Rmckb | Pmj0««Bi | Mar«i«Mn | iota | UwMolM

STRUMS ' DSrwU Pit Wi we 1*1 tOit WtwT Warfwe jtjjjg

| *,0-H-» Wot I tJO t ttoM I <]OmH»1 Mnw |aj<i»Otto»»« || AvxfV S~ Ql'f. t*9t

FIGURE 3.8

Hitting OK on the above message, we obtain the setup input form. Alternatively,
select Solver Settings knob and choose Setup /Specifications in the list on the left
(see Figure 3.9).
Although optional, it is a good practice to ill out the above form with a title and to
f

provide the accounting information subsequently. The present project is titled as

'
Simulation of a Shortcut Distillation Column' (see Figure 3.10).
114 PROCESS SIMULATION AND CONTROL USING ASPEN
Sid
oltflBl A t Nel fl rahclfc l lwl n J 21 JiJilJ zJ 2l J ©1

t
L r i-i
_ _
rv 'I -ipi i w

I "'M'.

'
SintMC WIMAJ Cxi Brf.K MiJtfue 5Ct'«c Pk. i tttrfii Brf.»f«:
f

FIGURE 3.9

3Mbl JMlJiilF Bid LJ

_
J W«w

i (Mi

" -

I 3
= 3 EOCsn.C«n

'*
,
7 '*"' I ""I 1 -TO- I Mrow<w I Sold: t UtvUaMt (

FIGURE 3 10 .

In the next (see Figure 3 11) the Aspen Plus accounting information (required
.

some installations) are given in the following way.

User name: AKJANA
Account number: 9
Project ID: ANY ID
Project name: YOU CHOOSE
ASPEN PLUS'" SIMUI-ATION OF DISTILLATION MODELS 115

.
l\ I r",

9 -

3f
a) -.
a mi

) MB I - - - I

1 nlVI M (M* <M»_ fMa WlB Ir- .

FIGURE 3.11

We may wish to have stream results summarized with mole fractions and/or some
other basis that is not set by default. For this, we can use Report Options under Setup
folder. In the subsequent step, open Stream sheet and then choose 'Mole' fraction basis.
In this regard, a sample copy is shown in Figure 3.12. although this is not essential for
the present problem.

i-d 3-J-itiiJa.ii

0 -»

P <* ' i PBS .* luiTi 3

1 .«*>*>

FIGURE 3.12
116 PROCESS SIMULATION AND CONTRQLUSING ASPEN

Specifying components
Use the Data Browser menu tree to navigate to the Components/Specifications/
Selection sheet (see Figure 3.13).

«t W DM T«ii t*. PW tto¥ i HHP

.
-

. :

f
. .

1 J

ComiKifun" WTO FamO)

Caww*iD

.
5 Drill-id!

Uyr-End Pmpoti

rHudocariiMW

ti aeehi

iO II SiiKi ait to tr rMneved Itom dsiatw* J. erte< C<m(rt<*fK Haw « f om-ia SteHdp
O ,

[if Mtw SpUen | S«p»*« | HealEttJiWBen Cohmnt } lwcto« 1 P-essueO owt | MwpuWWi | Sate | UraM«W. j
f

STREAMS 1 OSTWJ Drti ErtaO Mutfac

U *
- PatftFi ? Rahjiac BalchFrae
r

Sr«*,B«.ft
-

r:siHa-Ai>i,ivini1

FIGURE 3.13

In the window, shown in Figure 3.13, the table has four columns; they are under
the headings oi Component ID, Type, Component name and Formula. Among them, the
Type is a specification of how an Aspen software calculates the thermodynamic
properties. For fluid processing of organic chemicals, it is generally suitable to use
Conventional optiom Remember that component ID column should be illed out by the
f

user. A Component ID is essentially an alias for a component It is sufficient to use the .

chemical formulas or names of the components as their IDs On the basis of these .

component IDs, Aspen Plus may spontaneously ill up the Type Component name and
f T haPPen' * that AsPen Plu« to ind an eXaCt
,
f

mateh in A«Pen Plus does not recognize the components by

lt}lhrATyin °*er words

0 0 Search the components Select the components rom
'

T86 fj!?
f

Subsectiri 3 detaiIs See the solution aPProach '

IDs
(see lfir COmPonent hane and ethylene, as thefr
3.14). ThefootherT
6 0f
(see Figure three columns have been automatically filled out. i

Specifying property method

tZSlTjiT j11'1!!?68 I?0118 meth0ds *** mod to compute the phy

0ht th? Pr0Perty input f0rm er hit Next icon or choos
e

Pron l i2cations in the left pane of the Data Browser window

Propernes/Specif .
'

.
Set RK-Soave
property method by scrolling down (see Figure 3.15).
ASPEN PLUS SIMULATION OK DISTILLATION MODELS 117

..i-j ;
3 .

FIGURE 3.14

3S3
Plata l I wi Qb3Mslllid5d 3
I r-l I..|-f7 .: .id ! '« -It
zsjti D»ld -3l alig|g|
» BS aJ
9 -

i ! r
-

FIGURE 3.15

Specifying stream information

The Streams /F/Input / Specifications sheet appears with the Data Browser menu tree
in the left pane (see Figure 3.16). Here, we have to provide the values for all state
variables (temperature, pressure and total flow) and composition (component mole
fractions).

Copyrighted material
118 PROCESS SIMULATION ANnCO TROLJ-JSING ASPEN'

Ffe til '. Tut. Teal, r-m FW limy Wr« H

i r - I .i-l rv . j J-Igl M.
mm m

.
J PltKTMM 21
-

a) enjr,h«»caa r f THWIE
|pmtu«
-
-
:

RK£6'J1 ;
l
nrtxu i

ri UNKK Owe-
rj um(KO j>(
m i

1
111' if

1 MJflK SCFlK PWoF E.- --" B-r*f,»-

5TR£JWS 1 DSTWU - < -

FIGURE 3.16

Filling out the form, shown in Figure 3.16, with the data given in the problem
statement, one obtains the data, shown in Figure 3.17.

.
He Ed! Vc« ata Took e> FM Ltrary M*km -i*
t

3Mi
.
J/) sT»*r. M«hoC ] EOOpbora |

Conmotnon
-

g , - .-
| Mole f-*: 3r
h Corrconan
2
-

|Pini«o IS
RXSBU-1
[is 04

RKTKUI

Q E*anM*To-is

1J «.

.
_
j «.w

lew [T

ll _

-
o ~*

SIB6W6 : bStWU
i
J- «
.
! »2l

FIGURE 3 17 .

Specifying block information

ia wDianKtblock in Sfn t under Blocks folder. As a result.
put form is displayed (see Figure 3.18).
f
ASPEN PLUS SIMULATION OF DISTILLATION MODELS 119

FIGURE 3.18

Under Column specifications option, here we enter the number of stages that is 30.
It is fairly true that we can alternatively specify the reflux ratio when the number of
stages is asked to compute. Note that ethylene is the light key and naturally ethane is
the heavy key. As mentioned in the problem statement, recovery of the light key
component in the distillate (= moles of light key in the distillate/moles of light key in
the feed) is 0.996 and recovery of the heavy key component in the distillate (= moles of
heavy key in the distillate/moles of heavy key in the feed) is 0.001. In addition, the
pressure of the total condenser and reboiler is given as 300 psia. Entering all these
information, one obtains the result, shown in Figure 3.19.

i f -
l-l t' -

1 I
f

--
|

-o -

FIGURE 3.19

CopynghlGd material
120 PROCESS SIMULATION AND CONTROL USING ASPKN'

Running the simulation

The Status message includes Required Input Complete indicating that we are in a positio n
to run the simulation. Simply press Next button and receive a message regarding th e
present status (see Figure 3.20).

iT TTJ
f

[30 jgi i Cm*

Jj UkifIC Gkc ioW I ]300

f
KiHictoipooert
.
s*.
Com [ETMYLEHE
Smm

itjucioMtiTCienpu Totftw- xnpu «fccCwM t*n

t
flBMy: [0 0C1
E0V»Mblw
_

33 Dsmni
a -
Q Be-* C-pua-i
Mb

STRWMS

FIGURE 3.20

Click OK on the above message and obtain the Control Panel window that shows
the progress of the simulation (see Figure 3 21). .

F»» Efe «« £to T«* An iMy -AWto* H*

]aj®iJ i£ll w| KHIMKI h>\ 0 >Nh| *i lacal

*bs atrsitrro rkx sot iabli taw

-
EH

HUM

it -. I
f

FIGURE 3.21
ASPEN PLUS SIMU1.ATI0N OF DISTILLATION MgggUj 121
Hitting Next followed by OK, we have the Run Status screen (see Figure 3.22).

_
i r -i
_
rr .i.ipi i ibi
-

.
f

HMtf
mutt WIWW (M fMF(« iMMO *fik SOik i*rfi«
f

HH-'Ifci '*. .

FIGURE 3.22

Viewing results
In the next, select Blocks/DSTWU/Results rom the Data Browser. In the following
f

(Figure 3.23), we get the answers as:

Minimum reflux ratio = 7.724
Actual reflux ratio = 8.751

Minimum number of stages = 33.943

Actual number of stages = 67.887
Feed location = 40.417

Save the work by choosing File I Save As /... in the menu list on the top. We can name the
ile whatever we like. Remember that a backup ile (*.bkp) takes much less space than
f

a normal Aspen Plus documents ile (*.apw).

Viewing input summary

If we wish to have the input information, press Ctrl + Alt + I on the keyboard or select
Input Summary from the View pulldown menu (see Figure 3.24).

Copyrtghtod material
122 PROCESS SIMULATION AND CONTROL USING ASPEN

dim
-
-
i 'j-i
.

I r..|-M= IT -i .iai, I ibi

i a SH

r
-

1S?497652

»3*J12.;3 Br.il.
-

ifM IM|NMM f

0399
HE IP

STREAMS DSmj OaK Hrf.K F M HJtfiflC SCR PeMFmc Wtfwc BteW,*

sti| s
'

_
I Oa j-WWtW Awcn PIl» - Static Q G9«

FIGURE 3.23

'
lalxt
i Edi Font \kB '

irpuc SuwMry creic«d by Aspen Plus Bel. 11 .

1 at 10:15:40 Tho Jol 12, 2007
Directory c:\Pr09ran f nes'.Aspenrechvworklng foIi
working FoldersVupen plus 11.1 .
Fllenw c :\users\4kjana\AppMt«\Local\Te«p- ap6336. trt
~

[TITLE 'SinulatiorL of 3 Shortcut Cist Illation column'

I-UNITS EPXC

Ikf-STREjWS COMVEW ALL

bescfiiPTiON -
Central simulation with Eoallih units :
F. psl, Ib/hr Ibool/hr, Btu/hr. coft/hr.
,

property Method: nort

Flow basis for Input: Mole

Strea* report composition: HoU flow

PSOP-SDUSCES PUHEll

C0KPOMEKTS
ETHANE C2H5 /
ElKfLEKE C2H>

PROPERTIES Pk-SOAVE

PROP-OATA RirSKD-l
IH-W.ITS ENC
PROP-LIST BKSKI3
BPVAL ETHANE ETHYLENE . OlOOMOfriJO
BPVAL ETMYLENE ETHANE .0100000000

iTREW F
S085TRE»t fIXEO TEKP"' 5. PRES-1S t«0LE-FLOW-200 .
.

M016-FRAC ETHANE 0.6 - ETWlENt 0 4 ,

-
»± | <1A
.

.1I.». |Hn««»|.« | Mj ynn | |

FIGURE 3.24

Creating report file

To create a detailed report on the complete work we have done including input ,

summary, stream information, etc., select Export rom the File pulldown menu. Then
f

save the work as a report ile (e.g., C/Program Files/AspenTech/Working Folders/Aspen

Plus Version/ DSTWU.rep). In the next, open the saved report file (DSTWU.rep) goingd
through My Computer and inally using a program, such as the Microsoft Office Wor
f

or WordPad or Notepad. For the present problem, the inal report is shown below.
f
ASPEN PLUS SIMULATION OF DISTILLATION MODELS 123

ASPEN PLUS IS A TRADEMARK OF HOTLINE:

ASPEN TECHNOLOGY, INC. U S A 888/996-7001
. . .

TEN CANAL PARK EUROPE (32) 2/724-0100

CAMBRIDGE, MASSACHUSETTS 02141
617/949-1000

PLATFORM: WIN32 JULY 12. 2007

VERSION: 11.1 Buiid 192 THURSDAY
INSTALLATION: TEAM EAT .
12:07:22 P.M.

ASPEN PLUS PLAT: WIN32 VER: 11.1 07/12/2007 PAGE I

SIMULATION OF A SHORTCUT DISTILLATION COLUMN

ASPEN PLUS (R) IS A PROPRIETARY PRODUCT OF ASPEN TECHNOLOGY. INC.

(ASPENTECH). AND MAYBE USED ONLY UNDERAGREEMENT WITH ASPENTECH
RESTRICTED RIGHTS LEGEND: USE, REPRODUCTION. OR DISCLOSURE BY THE
U S GOVERNMENT IS SUBJECT TO RESTRICTIONS SET FORTH IN
. .

(i) FAR 52.227-14. Alt. Ill, (ii) FAR 52.227-19. (iii) DEARS
252.227-7013(cMl)(ii). or (iv) THE ACCOMPANYING LICENSE AGREEMENT,
AS APPLICABLE. FOR PURPOSES OF THE FAR, THIS SOFTWARE SHALL BE DEEMED
TO BE "UNPUBLISHED" AND LICENSED WITH DISCLOSURE PROHIBITIONS.
CONTRACTOR/SUBCONTRACTOR; ASPEN TECHNOLOGY. INC. TEN CANAL PARK.
CAMBRIDGE. MA 02141.

TABLE OF CONTENTS

RUN CONTROL SECTION

RUN CONTROL INFORMATION
DESCRIPTION

FLOWSHEET SECTION 2
FLOWSHEET CONNECTIVITY BY STREAMS 2
FLOWSHEET CONNECTIVITY BY BLOCKS.. 2
COMPUTATIONAL SEQUENCE 2
OVERALL FLOWSHEET BALANCE 2

PHYSICAL PROPERTIES SECTION 3

COMPONENTS 3

U-O-S BLOCK SECTION i

BLOCK: DSTWU MODEL: DSTWU 4

STREAM SECTION 5
EOF 5

PRORT.RM STATUS RfTnTION

ninr,K STATUS

ASPEN PLUS PLAT-WIN32 VER- 11 1 07/19/9007 PAGF/1

SIMULATION OF A SHORTniTT DISTTT.T.ATION COLUMN
RUN CONTROL SECTION
124 PROCESS SIMULATION AND CONTROL USING ASPEN

RUN CONTROL INFORMATION

THIS COPY OF ASPEN PLUS LICENSED TO

TYPE OF RUN: NEW

INPUT FILE NAME: _

00341ji.inm

OUTPUT PROBLEM DATA FILE NAME: _

00341ji VERSION NO.
1

LOCATED IN:

PDF SIZE USED FOR INPUT TRANSLATION:

NUMBER OF FILE RECORDS (PSIZE) = 0
NUMBER OF IN-CORE RECORDS = 256
PSIZE NEEDED FOR SIMULATION = 256

CALLING PROGRAM NAME: apmain

LOCATED IN: C:\PROGRA~l\ASPENT~l\ASPENP-l l\Engine\xeq
.

SIMULATION REQUESTED FOR ENTIRE FLOWSHEET

DESCRIPTION

GENERAL SIMULATION WITH ENGLISH UNITS : F PSI, LB/HR, LBMOL/HR,

BTU/HR, CUFT/HR. PROPERTY METHOD: NONE FLOW BASIS FOR INPUT: MOLE
STREAM REPORT COMPOSITION: MOLE FLOW

ASPEN PLUS PLAT: WIN32 VER: 11.1 07/12/2007 PAGE 2

SIMULATION OF A SHORTCUT DISTILLATION COLUMN
FLOWSHEET SECTION

FLOWSHEET CONNECTIVITY BY STREAMS

STREAM SOURCE DEST STREAM SOURCE BEST

F DSTWU D DSTWU
B DSTWU

FLOWSHEET CONNECTIVITY BY BLOCKS

BLOCK INLETS OUTLETS

DSTWU F DB

COMPUTATIONAL SEQUENCE

SEQUENCE USED WAS:

DSTWU
ASPEN PLUS SIMUIAT10N OF DISTILLATION MODELS 125

OVERALL FLOWSHEET BALANCE

MASS AND ENERGY BALANCE

IN OUT RELATIVE DIFF.

CONVENTIONAL COMPONENTS (LBMOIVHR)
ETHANE 120.000 120.000 0 000000E+00
.

ETHYLENE 80.0000 80.0000 0 000000E+00

TOTAL BALANCE
MOLE( LBMOIVHR) 200.000 200.000 0 000000E+00
.

MASS(LB/HR) 5852.66 5852.66 -0 155399E-15

ENTHALPY(BTU/HR) -0.252753E+07 -0.363687E+07 0 305025

ASPEN PLUS PLAT: WIN32 VER: 11.1 07/12/2007 PAGE

SIMULATION OF A SHORTCUT DISTILLATION COLUMN
PHYSICAL PROPERTIES SECTION

COMPONENTS

ID TYPE FORMULA NAME OR ALIAS REPORT NAME

ETHANE C C2H6 C2H6 ETHANE
ETHYLENE C C2H4 C2H4 ETHYLENE

ASPEN PLUS PLAT: WIN32 VER: 11.1 07/12/2007 PAGE 4

SIMULATION OF A SHORTCUT DISTILLATION COLUMN
U-O-S BLOCK SECTION

BLOCK: DSTWU MODEL: DSTWU

INLET STREAM: F
CONDENSER OUTLET: D
REBOILER OUTLET: B
PROPERTY OPTION SET: RK-SOAVE STANDARD RKS EQUATION OF STATE

MASS AND ENERGY BALANCE

IN OUT RELATIVE DIFF.

TOTAL BALANCE
MOLE( LBMOIVHR) 200.000 200.000 0 000000E+00
.

MASS( LB/HR) 5852.66 5852.66 -

0 155399E-15
.

ENTHALPY(BTU/HR) -0.252753E+07 -0.363687E+07 0.305025

* * INPUT DATA *** .

HEAVY KEY COMPONENT ETHANE
RECOVERY FOR HEAVY KEY 0.00100000
LIGHT KEY COMPONENT ETHYLENE
RECOVERY FOR LIGHT KEY 0.99600
TOP STAGE PRESSURE (PSI) 300.000
BOTTOM STAGE PRESSURE (PSI) 300.000
1"
126 PROCESS SIMULATION AND CONTROL USING ASPEN

NO. OF EQUILIBRIUM STAGES 30.0000

DISTILLATE VAPOUR FRACTION 00
.

* RESULTS *

DISTILLATE TEMP. (F) -18.3114

BOTTOM TEMP. (F) 20.4654
MINIMUM REFLUX RATIO 7.72431
ACTUAL REFLUX RATIO 8.75092
MINIMUM STAGES 33.9434
ACTUAL EQUILIBRIUM STAGES 67.8868
NUMBER OF ACTUAL STAGES ABOVE FEED 39.4169
DIST. VS FEED 0.39900
CONDENSER COOLING REQUIRED (BTU/HR) 3,034,310.
NET CONDENSER DUTY (BTU/HR) -3,034,310.
REBOILER HEATING REQUIRED (BTU/HR) 1,924,980.
NET REBOILER DUTY (BTU/HR) 1,924,980.

ASPEN PLUS PLAT: WIN32 VER: 11.1 07/12/2007 PAGE

SIMULATION OF A SHORTCUT DISTILLATION COLUMN
STREAM SECTION

BDF

STREAM ID B D F
FROM: DSTWU DSTWU
TO : DSTWU

SUBSTREAM: MIXED
PHASE: LIQUID LIQUID VAPOUR
COMPONENTS: LBMOL/HR
ETHANE 119.8800 0 1200
. 120.0000
ETHYLENE 0 3200
. 79.6800 80.0000
COMPONENTS: MOLE FRAC
ETHANE 0 9973
. 1 5038-03
. 0 6000
.

ETHYLENE 2 6622-03
. 0 9985
. 0 4000
.

TOTAL FLOW:
LBMOL/HR 120.2000 79.8000 200.0000
LB/HR 3613.7256 2238.9320 5852.6576
CUFT/HR 140.3489 82.0590 7 5963+04
.

STATE VARIABLES:
TEMP (F) 20.4654 -

18.3114 75.0000
PRES (PSI) 300.0000 300.0000 15.0000
VFRAC 00 00
.
. 1 0000
.

LFRAC 1 0000
. 1 0000
. 00
.

SFRAC 00 00
.
. 00
.

ENTHALPY:
BTU/LBMOL -
4 1532+04
.
1 6983+04
.
-
1 2638+04
.
ASPEN PLUS SIMULATION OF DISTILLATION MODELS 127

BTU/LB -
1381.4403 605.3231 -
431.8608
BTU/HR - 4 9921+06
.
1 3553+06
.
-
2 5275+06
.

ENTROPY:
BTU/T.RMOL-R -
58.6713 -
30.5758 -
28.8269
BTU/LB-R -
1 9515
.
-
1 0898
.
-
0 9851
.

DENSITY:
LBMOiyCUFT 0 8564
.
0 9725
.
2 6329-03
.

LB/CUFT 25.7482 27.2844 7 7046-02

AVGMW 30.0643 28.0568 29.2633

ASPEN PLUS PLAT: WIN32 VER: 11.1 07/12/2007 PAGE 6

SIMULATION OF A SHORTCUT DISTILLATION COLUMN
PROBLEM STATUS SECTION

BLOCK STATUS

* *

*
Calculations were completed normally *
*
All Unit Operation blocks were completed normally *
« *

*
All streams were lashed normally *
f

« #

322
. . Simulation of a RadFrac Model

Problem statement

We will continue the above problem with few modifications. A hydrocarbon stream,
consisting of 60 mole% ethane and 40 mole% ethylene, enters a RadFrac column having
a low rate of 200 Ibmol/hr at 750F and 15 psia. The distillation process that has total
f

68 theoretical stages (including condenser and reboiler) and a total condenser operates
at 300 psia with zero pressure drop throughout. The distillate rate, reflux ratio and
feed tray location are given as 79.8 Ibmol/hr, 8.75 (mole basis) and 41 (above-stage),
respectively. Consider the RK-Soave property method.
(a) Simulate the column and compute the compositions of top as well as bottom
products.
(b) Is there any discrepancy in product compositions obtained rom RadFrac and
f

DSTWU columns? If yes, what is the main reason?

Note: In the comparative study (for part b), consider total 68 theoretical stages (including
condenser and reboiler) keeping other entered data unchanged for the DSTWU column
(see Subsection 3.2.1).

Simulation approach
(a) Start with the General with English Units Template, as shown in Figures 3.25(a)
and 3.25(b).
128 PROCESS SIMULATION AND CONTROL USING ASPEN

I I

FIGURE 3.25(a)

Click OiiTin the screen, shown in Figure 3.25(b). When the Connect to Engine dialog
pops up, again press OK button to obtain a blank Process Flowsheet Window.

FIGURE 3.25(b)

Creating flowsheet
Among the built-in columns in the Model Library of Aspen Simulator select RadFrac
,

and place it in the lowsheet window Connecting feed, distillate and bottom product
f

streams with the distillation column ,

and changing the default names of the block and
all streams, inally we get Figure 3 26.
.
f
ASPEN PLUS SIMULATION OF DISTILLATION MODELS 129

r|gf7-| .|..|' pr .
1 -tCi i iw IH

t 13 0

sne»fi muu am im mj** ujw

- J r- -
<

FIGURE 3.26

Configuring settings
In the subsequent step, simply hit Afet button followed by OK to open a setup input
r

form. These two windows, shown in Figures 3.27(a) and (b), include the Global and
Accounting information for the present project.

. % fa M» Dm tM» * imh n m n*

9 i"-
- . I - 11 - I
9

i ii
-
3 >- w.

0 -

ITOf Mr. '

MIUU Da oM IM*a «0<a Narfw ..McfiAB
t

FIGURE 3.27(a)

Copyrighted material
130 PROCESS SIMULATION AND CONTROL USING ASPEN

JaglHl :| Mftl yJ nWkfoKM 1 til .]J_nJ juJ 1 1 ill

Skv

iwi-s«i

O MET US YOU UKE

O METCfiAR
l METCMGCM
f

f> 5V-C6AH

Sttwrnf

v a
*
Flo»*e«bftg Opbon*
t1 a MoM ,1-! Took
f
-

4 Gfl

i 2Jil

STREAMS DSTWU Dim Rrft«c E- ad Muffnc SCFfac PaBcfiae Ratftac Batetfrac

farHaip.pMn

| .si) Chapter 3 ttowJWcri | 4]Q>«pMf2-lto«rfi Wtrt H A xn Pkj. - SM«i . fi'"

FIGURE 3.27(b)

In the Setup/Report Options / Stream sheet select ,

ole' as well as 'Mass' fraction
basis as shown in Figure 3.28.

. : ib b« on To* n« u»v nvhw Hdp

r Uhv R 1 >IB3|- . { lal

0 Becwrt Opdcro UMbl'1 -I -3>>JialajNil
i G«mi4 I Ftatt««t j Btaek Vsi»m} Proper j ADA |

; H«MtebancUWinsD««nMpwl
Ffaubwit FiMjonbMa ShWDfamM -

j f? Mote P Moio ; tff- [geTTe

r mm ' P S»S Iff Si«ndsd(BOoctant
'

T SUHovcAjw r SUi viAm ; r WUaPBcoUw)

i jjj Bock. _ 1 P SoK-rewatfwwKw*
K ConpoAMvAweftMoftKlnn

Wo«tWu.iartwiw*

MOM

* tWSrten | S Mtatt | HMEwhangm

SIRCMC <i-t-o:-§-iv-(i..#.c-r-
' DSTMl
DSTMJ ag Arf E*ao. SCf >1>rf l .ac e IK
f

FIGURE 3.28
ASPEN PLUS SIMULATION OF DISTILLATION MODELS 131

Specifying components
In the list on the left, choose Components /Specifications to define the components.
Using the component names, ethane and ethylene, as their IDs, we obtain the illed

f
table as shown in Figure 3.29.

=W 54 » :«> T FV« itun Wrs-

r-i-i-i
-
i .w
-
i -igi *m

3a !«
Mn*

;lrM*N£ cats
. IHYUNC

O si

o ,.
-

Pttfnc R«rfW:: B«ct#.*;

FIGURE 3.29

Specifying property method

From the Data Browser select Specifications under Properties folder and then set RK-
,

Soave base method to compute the physical properties (see Figure 3 30). .

' Fit CM

0|<*|H| - ;
>I>'.|--|T »MBJ|v
.
mrai J «J|a.

3
B«i«»a(tw6 fflr.SOAVt
.
- - r 1 J

OwoCTylO j

IJ .

5T««)J ' OSTWU

FIGURE 3.30
132 PROCESS SIMULATION AND CONTROL USING ASPEN

Specifying stream information

Use the Data Browser menu tree to navigate to the Streams /F/Input / Specifications
sheet. Inserting the given values for the feed stream, Figure 3.31 is obtained.
r itfi>t|
-

3EfSiF -q l-li Fi-Hid QUIH

3 |m* dr

it ,

(200 jbrt*.

1 Hm(t jr r: CMlma | FtMcicn | RMMfOungett | Htrie-Mm \ SiteJ UtftKoM |

Ejiki Mulfia: SCFlK FmfiK PmfiiK 901*:

FIGURE 3.31

Specifying block information

In the left pane of the Data Browser window select Blocks/RADFRAC/Setup. Fill up ,

the Configuration sheet as shown in Figure 3 32. .

Sa To* Rn Pa tfea/ WMw Help

I r.-.|-.i-l fT Nv i 11] isN

3
g BO VMbki

a «*

H*o4erHcuv*i
7]F 1 ?98 (trrotA,

O Dwt i

Ha
-

FIGURE 3.32
ASPEN PLUS SIMULATION OF DISTILLATION MODELS 133

Under Setup subfolder, the filled Streams sheet looks like Figure 3.33.

i 'to
. 1 « «!«.;

> | | MB I M»» |

it r
-

FIGURE 3.33

In the next, simply input 300 psi under Stage 1/Condenser pressure. Aspen simulator
assumes that the column operates isobarically if no additional pressure information is
provided (see Figure 3.34).

IB I' W tl*)

i:.,ir.ir.ii.0.ii'.fi..#.s .j-.

FIGURE 3.34

Running the simulation

To run the simulation, hit Next and then OK to observe the progress of the simulation
in the Control Panel window, shown in Figure 3.35.
134 PROCESS SIMULATION AND CONTROL USING ASPEN

n* E# M«m Dal* Toch t* Utrvy WMdaw M*.

f
I l"l "li-dail 4;|
l i-.i T ai Jfilp
~

_.
iJ -

- * Hao«Miafl input «p«cl<tCiti.4B* ...

Ml JSTftllVtO fSON 3 Or tABLt IAELE tIAJa - KJWSTD

owpotatiom owata ro> tmi jiowshmt;

-
>C«lcaJ.«ttQn» t»«in . . .

Block: aAcrajkC «<mui raofsac

IS LOHM THM( JTXGJ 1 MKMVM D.7Oi«*07 (H/SSW1

Coif/«cg*nfi» iearttlOK*:
f

01 KL IL Sce/Tol
ill Eo.oas
a i j U.m
J 13 7.oc«a
4 1 « i.73*fr
5
.
.
i : i o.i6a»7i-ai

lli>ra»l

STREAMS PSTWU Dirf Radfw , lAaci MUtfxic; SCFuw fahoFrac Ratrffac Batetfrac __
_

FIGURE 3.35

Viewing results
Click on Solver Settings followed by Results Summary and Streams, we have the table,
shown in Figure 3.36, accompanying the results of all individual streams. Save the
work in a folder as a ile.
f

j He Ed) Urn Curt TooU Ron Plot Ifinry WndoM l-<*

JjlJ 121 1 1*1

_
da)
3Mbl ±l±l«jPi-H JMaljjj

3 Sii.i»I«e|

J CcnvOotcm
1 i i
" 1

l»316 8 078 7*1154

J982 13i5 752(1
|e.fr«:
t

OS* Um 0517
"

TTfhUNE QOQi 0995 0383

ComOnta

tiHiilt 11371! 120«(«

CTHYIENC 0498 73512 man)

EIHAHE 0 336 bou oeao

EIHYUNE 00M 03»

- cx.magttgicffTr-wi

FIGURE 3.36
ASPEN PLUS SIMULATION OF DISTILLATION MODELS 135

Viewing input summary

Select Input Summary rom the View dropdown menu to obtain all input information

f
of the present problem (see Figure 3.37).

ire«.i uiu-y itHin bv up*- »lia .>. It.I « ll.'S'l* Sal ).i 11, 00'
Olr.ciory I Pro m (tin -Oin! .s't-t .ic.r Hut II. 1

Tin* 'SII»l1»T("i . UlM'M ts'w*

I-IIUVI CVfllD ILL

.ccolvi.ii>o xcow-io .Mie'-io-un 10 t

cavit 'i-. ill- - '- i-.'iM' .. :, ;

a. B»«. fV*r> ll-al Kr. Hh.Vt , c H.O,

Ml> 'w live ">!.

'nrari (oiMitilax: Mil flo"

Miiauas main unimi yxio- ikkmiu 4

tiHu« ei-» -
rmkM C!"

W'OITl Ultll'l

HWii ill wii:i

CfWuM EIMK .oio»Xo<»:

MCKMI VMB VMIK fi "IWl, ««ll "iw-.'OC.

1 . ..

FIGURE 3.37

Results of the RadFrac column

TABLE 3.1

Composition (mole fraction)

Component B D

ethane 0 996
.
0 004
.

ethylene 0 004
.
0 99G
.

Results of the DSTWU column

TABLE 3.2

Composition (mole raction)

Component B D

ethane 0 997
.
0 002
.

ethylene 0 003
.
0 998
.

From Tables 3.1 and 3.2, it is obvious that there is a little difference between the
product compositions. However, the main reason behind this fact is that the RadFrac
performs rigorous calculations, whereas the DSTWU is a shortcut model. Another
possibility is the round-off error associated in the reflux ratio and feed tray position.

Copyrighled malarial
'
136 PROCESS SIMULATION AND CONTROL USING ASPEN

3 .
3 ASPEN PLUS SIMULATION OF THE MULTICOMPONENT
DISTILLATION COLUMNS

33
.
1
.
Simulation of a RadFrac Model
Problem statement

A multicomponent distillation column, specified in Figure 3.38, has total 20 stages

(including condenser and reboiler) with 60% Murphree efficiency. A hydrocarbon feed
mixture enters above tray 10 of the RadFrac column. Apply the Peng-Robinson
correlation and consider 120 psia pressure throughout the column.
(a) Simulate the model and calculate the product compositions, and
(b) Produce a Temperature' (0F) vs. 'Stage' plot.

Feed Specifications <

Vapour Distillate Specifications
Flow rate = 100 Ibmol/hr
Flow rate = 50 Ibmol/hr
Temperature = 120F Reflux rate = 125 Ibmol/hr
Pressure = 120 psia
Component Mole%

C3 5
/-C 15
4
n-C4 20
' C5-
25
A?-C5 35

FIGURE 3.38 A flowsheet of a distillation column .

Simulation approach
(a) As we start Aspen Plus from the Start menu or by double-clicking the Aspen
Plus icon on our desktop the Aspen Plus Startup dialog appears (see Figure 3 39).
,
.

Select Template option .

FIGURE 3.39
VSI'KN I'll 'S SIMl'LATION OF DISTOIATIOM MHHKl.S 137

As Aspen Plus presents the window after clicking OK in Figure 3.39, choose General
with English Units. Then hit OK (see Figure 3.40).

FIGURE 3.40

Click OK when the Aspen Plus engine window is displayed (see Figure 3.40).
Remember that this step is specific to the installation.

Creating flowsheet
At present, we have a blank Process Flowsheet Window. So, we start to develop the
process low diagram by adding a RadFrac column from the Model Library toolbar and
f

drawing the inlet and product streams by the help of Material STREAMS.
Now the process lowsheet is complete. The Status bar in the bottom ight of the
f

screen, shown in Figure 3.41, displays a message of Required Input Incomplete indicating
that input data are required to enter to continue the simulation.

Configuring settings
Hitting Next knob and then clicking OK, we get the setup input form. In Figures 3.42(a)
'

and (b), the Title of the problem ( Simulation of a Multicomponent Column') followed
by the Aspen Plus accounting information (AKJANA/ll/ANY ID/FINE) are provided.
Include the additional items in Report Options/Stream sheet under Setup folder
(see Figure 3.43).

C aterial
PROCESS SIMULATION AND CONTROL USING ASPEN

fi, 6* v«« rwa To* IVi rk**M ll»»v wn~ H

-
CM

STREAMS ' DSm) Diiii Kvfiec E«liacl Muffiac SCFw PelroFiK Hattfims BUchFrac
'

FsrIMs.miFI i cv Rto*>wn»'ii.i ihim

| Chacte3 Wo«<!»W ,[ ]Oi«tcl-lto«tlW.. | Met* Acicla ftcfewl I IMS

FIGURE 3.41

|a<xl
-

* Mi D». To* fo» PW litra unto* H*

D|ia|B| |«8| >g| aklaKKM n.| -Ti| ,±jHj | _

mTb fJ Mil iilpi-3 »l oi l H

a aj s«i»

© StvamOast til« :: !|S«wiabor at a MJHcoffponent Colwrr

UiHiflm »««« GMMri
=c ia LWl.-S<h
f

O RepalCptom
d
Conmneti
OuQtitanAt |ENG
Prao«t« CONVEN Si
d
rj Rearforj d
Uu...... '
< 1 J
d
r UwfreswAtcataJabm
_
J RaKliSurray

. SetHat,

F M"! ''ll'n ' j40**** I

r
H**£***«"" C«fc«Ba | Raactan | nat«MCIWisin ! ManBii*w i S«U> | UawHaMi )

FIGURE 3.42(a)
ASPEN PLUS SIMULATION OF DISTILLATION MODELS 139

illJIBI I ! c(PJ S fJ- >l»l !-H 3 'I 1*1 i| TJ j J

f
_

I f - l -I-1 fV -1 -iC! i m\ MM
o--

1-1

Hi-a li im MMa wr« -w. t-

FIGURE 3.42(b)

.
i -iff] i 1*1 -iti

- I
5

r .

'" '''' aim

FIGURE 3.43

Specifying components
In the left pane of the Data Browser window, select Components /Specifications. Filling
out the Component ID column, we obtain the table as shown in Figure 3.44.

Copynghied material
140 PROCESS SIMULATION AND CONTROL USING ASPEN

mas. :?j 'I

m Do* lock Br. PU Lbtwy Moo- HHp

±J-" - l-l hPT 1 lai .

N
1© ?(«c -

it SmJalicn 0*:<-i
f
PROPANE Convert onal fflOPWIE
SOBUfll S06UTAHE C4H10-2
CuBjn Uh*l
0 Papc"
wet* MEmtlBUIiJIt. 9UZ-3
JPCItTWIE

L J-J 6-<J Pro»l»i

r
M CJ NtaOhMcMMMn

Prtcaties

far Help p-eai M

FIGURE 3.44

Specifying property method

In order to define the base property method press Next icon or select Properties/ ,

Specifications in the column at the left side (Figure 3 45). From the Property method .

pulldown menu, select PENG-ROB. This equation of state model is chosen for
thermodynamic property predictions .

das
Ffe E* W Pa W

0|e?|B|
I W
si «lStl
Jt Specficabom

PiopBly method: t modHt

lhUS«s
Ptoctislypw. F
[PEHG-ROe
r
-

tw-waioi method j -
f

htufaoampemrti

Qj H-f»)rC<mpj
; . unif«:qw*>! : ChcntbylD j

O GLOBAL

1 (3 Enmaw

1 -ij PramMwi

F
-
CH
STREAMS Pflefnc P fwt B#etf.K
t

FIGURE 3.45
ASPEN PLUS SIMULATION OF DISTILLATION MODELS 141

Specifying stream information

In the next, use the Data Browser menu tree to navigate to the Streams /F/Input /
Specifications sheet. Entering the values of all state variables and component mole
fractions, we get this picture (see Figure 3.46).

. ....

I rH-H-F " -IB I'll IW

Ml II- P=!J 3

I2S I-
~

3
f» k 3 ,

& -

3
I 3

' 'U*w 5? !?- Mftg «!-

Ei -*. -~ »
-P-- M= 'O--------

FIGURE 3.46

Specifying block information

Open the Configuration sheet choosing Blocks /RADFRAC in the list on the left. In the
problem statement, the information on number of stages, condenser type, vapour
distillate low rate and reflux rate are given (see Figure 3.47).
f

r£Z3_
3=

: 3

. mam

ea
t

. rauv s-.rv, Ma Cm mm «. .*>>

FIGURE 3.47
142 4 PROCESS SIMULATION AND CONTROL USING ASPEN

In the subsequent step, specify the feed tray location in the Streams sheet as shown
in Figure 3.48.

fl. Ml D«i T«* t* PW Uom* VMcm N*

f
I

.
31 P«p 3«.
Q
flow

i rj dv
20 Um4

S .
t . .
9 , '
0- RADFRAC

Hi j j lndxra
f

* Cj T3<*

SinDWS ! OSTW OiW t K tmt MJJ.tc Sgte fWuc Hwfi»e B*<(W-<«

FIGURE 3.48

Enter the coliunn pressure of 120 psi and get Figure 3 49 .

as shown in the screen.

-1*1 xl

5* pfboi
: f--3

Cj b**<**t
Ci 'jruJACCw
Cj uwff«&o
t cj «~*

E ( J Vt. j xr-

* CJ .
cj w

_ CJ earfiMngCkUn
f

!-
f*M* Mfr

FIGURE 3.49

The Blocks/RADFRAC/Efficiencies/Options sheet appears with the Data Browser

menu tree in the left pane To input the Murphree eficiency value for all trays (excluding
.
f

the condenser and reboiler) we have the screen, shown in Figure 3.50 irst. ,
f
ASPEN PLUS SIMULATION OF DISTILLATION MODELS 143

T He S« <- Ma Tn t* Ft* Un, WMdw 4*

f
wal _U a|t1«>hNIH!£l 2l jiiiiii J ©i
r.>i..i..|. fT -

I .W I - W jgfel
'

o
Method

« Set*

Jj
0
:j
9
0

p llhMWHcu
Trr. Smg

»
0
0 Gsmaigra
®
0
T' 4
"
1

STf&WS Km) Dha Hvfttc Eiftact Httfrac SCF»ac PdtoFiac Ra<eFt«c :

SalcbFiK

Aspen Phis - 9b.. /- AOeb« ooba j « l: i fM 1S<6

FIGURE 3.50 t

Press the knob to open the Vapour-Liquid sheet (see Figure 3 51). .

tj He &t Uew Teob Rji Pie! liw/ VAvfcw heb

±Jr~--l h.b HT _ij_iM_J_Ua| M!d

HafaiEn. d±i±li5lPi BidoLaliid
3 yOphOW VoptM-UqilU j 1
O '
-

a '
a
Slartrg Endng

*
-
RSOfRAC

O a.

_
j P*> Sir.)

5-
/Cx- iele

flT <**tmm I I He»L£»-J«wn 1 *-". | Re«a». | l> i«ei>w | Meroiae,. ) Sol* 1 UwHoA*
-
a-»
MeMTiel '
. . -' 5 SEi . n. .... Dj.kT.

FIGURE 3.51

Assume the rectifying along with the stripping zone as Section 1 and fill up the
table , shown in Figure 3.52.
144 -f PROCESS SIMULATION AND CONTROL USING ASPEN1

mmmamm
RU> &H \Aew Dats Tec*

i r-i y i nr am i m

.
-
J <

'
joc*w. St«V9
Ugp
1 19
PAOFRAC
* 1

Mm CM

C vientm hi

Pock Sa j

EMMm

Report
User Suooj-

LiJ_

f -r.
STREAM?

NUM o

Mobetuot* It

FIGURE 3.52

Running the simulation

Hit Afcci button followed by OK and observe the progress of the simulation in
Control Panel window as shown in Figure 3.53.

Fte E* Vtew 0«e To . Run Jbnrf VHvhw

±Jjij
< Loading SlmXat cn Jngtn* lS:61r33 i
D RADFRAC

»;rDC«8»ing Input .p»cif tc»ti =Ti« .

, . .

IHTOUUTTflH
eitJAfly PUJutfOTiRS paru can* set d roa hoo«l SEParrD
mie muivn from scf tasli . xuu kms - lsptste

slock: tirraxc maids a*cnuc

« esM

1 2195
.

c ;j*4t

Jsasll

f " M«ii<$«aM> II S.O.*..

M«.iJSra»> SeMJtJ. II IMiM
H«<£«»«w
vr- fill
CM I| (Won
Rajrtai || IWnCh n ||
Pa-nOwvn MnuM i

"
V J

STREAMS
'
OSIVAJ
OSTWU Dfl« Rrfwc MJf« iCfiK FWrfnc R ft*: gaafwe

J'j jT«-tfc, i- *

FIGURE 3.53
ASPEN PLUS SINfULATION OF DISTILLATION MODELS 145

Viewing results
Click on Solver Settings knob and then choose Results Summary /Streams to obtain the
product compositions (see Figure 3.54).

r-i .i.i>fv jci

rl 3'-f 13 "--l
9
_
J
IM Mi
mmf ~
" "

Hi 1 T» TBH
"
«.>* TOB 1 l» . "
J
»*».
-
sin 1
"

rtai-'
-
1|
1 !
Will ue in

TariT ' «« IM

lb i«»
i.«
"
aoni IJH- TIB TM
ntn 1 . a l<» III
Tf«5B 1

f» n hi 1 i I wr mi "in 1 « » hihi I "i |

|
-

<u« eWj M M« C-» Mta ti>« rmt» Km*~

. rw » -.«»«* I- .> '..

FIGURE 3.54

It is a good habit to save the work done at least at this moment. If we wish to see
the tabulated results with the process low diagram in a single sheet, simply hit Stream
f

Table button just above the results table (see Figure 3.55).

JMMI .til _!.) a nH-|»l%l<M ») r I i-l .IglJi £j

lisf i -
i -id urn

«-C3-

FIGURE 3.55
146 PROCESS SIMULATION AND CONTROL USING ASPEN

Viewing input summary

As stated previously, to obtain the input information, press Ctrl+Alt+I or select Input
Summary from the View pulldown menu (see Figure 3.56).

imut Su«Hry' cr«««d by Ajp«r Clul R«l. 11-1 it VMM Sun )ul IS, 2007
; Dlr«tory c froqriM fil« .AipefiT«ch\**ork1ng Folders Aspen Plus 11.1
. Fileniw C userj ijjn* *ppOjt« local T*<Bp -*pt>a cn,

tiuC
"

SlBuUllor of a IMdCtCMpMM Colo o

Is-unITS CNG

EXF-STREWS CONVIN ALL

" "

ACCOUMT-INFO ACCOUHT-ll PROJECT-IO-AHY ID PRO JECT-NWI- FINE

USE R - HAf E " AK J AH*

OtStRIPTION
C»n»ral Slaulation wtth English units ;
f, psl. Ib-tv. Itaol/hr. Btu hr. cuft/hr.
property method: none
fIoh basis for Input: Nola
Strcan report cowposlclon: t»ol« fl«

'
AOUEOUS / 50LIOS / INOBGANIC , A

PROP-SOURCES POREll .
aflUEOUS ,' SOLIDS / INORGANIC
CWPOWMTS
PROPAXE ClHS ,'
ISO»U-0l C4HI0-Z ,'
N-«VT-01 CAMlO-l /
2-t«ET-01 CiMl2-2 /
N-PEN-&1 C5H12-1

rSHCET
BLOCK RAOFR.AC IN-F OVT-OV B

PROPERTIES PEMG-ROB

> -DATA PRKIJ-1

IN-UH1TS CPKt
PROP-LiyT PRKI)
BPVAL PROPAME ISOSU-01 -7.BOOOOOOE-3
BPVAL PROPAhE N-BUT-01 3.300000001-3
BPVAL PROPANE 2-MET-01 .0111000000

. ol #
'.
f> " o* t QwpW M I JO IW l lhAJT M- [ wnfta 5 } > AtWwAort* || -APF7EAJ > 1 17a>
t
t

FIGURE 3.56

(b) First, choose Blocks /RADFRAC /Profiles in the column at the left side
Accordingly, we have the stage-wise data as shown in Figure 3 57. .

mm J >>j am w
3fl *«- rmi I c 1

Vapofto.

F oawnd
r *j
Tiit
1 asoU 1 "

B
--
o
t
t

3 aj i
'
9TIJ3K?SI 20 i 171 385017

T- t c I 195 3*a»6 20 j
f

20 i
liJnuiiJlii i
;oo 3ra 20 i

201354309 ia i

9 anwsssi }»
lit
n 121) ;: -
.
.
- i
llJ ||
:iT:;nr-si

fir I HME | Mh | M.UoM |

STntAMS jgwc tW-« H«rf.>i *mtr»C J

FIGURE 3.57
ASPEN PLUS"" SIMULATION OF DISTILLATION MODELS 147

In the next, select Plot Wizard rom the Plot dropdown menu or press Ctrl + Alt + W

f
on the keyboard to get Figure 3.58.

I ... '.
1H|_U*1«*) nKW*haMH n I |h| .131.31 _
j

71 .1
. «-
Cj owl-

Welcome to Aspen P!b» net Wlzwdl

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r

a 'mm
ijte>

!tDM5
I Until-
1

15"
-
CH

MnrtJ D,> tuf<tc MJfac Sg-«c P trf.tc Ralrfrac Bl£tfi»c

FIGURE 3.58

Click on Next button in the Plot Wizard Step 1 dialog and get a variety of plot types ,

shown in Figure 3 59. .

i"l pi a)|

ift
~

g «JI" d»| olaii n>i

3 IPFQ | CwvoMora j KVAjW j

To bvn MbM a (W lypo )>ou wh lo omniU

.
Q?1!* OowfMto fV**! Mva

'
H4W
,
i
( smvm*

J 51 OK
_
J T.w Sot,
naa
j
_
wFodo FkMntln CCCOTHI CQCQS H) Hv4m > BM
J
- s- j seisa

«2J!4

Wti*1
1 Join*
1

60 - .

JP""
Pi"
-
CH
'
m& tS» so.. w« ac.-A»»H.MI NU«
f
f

iQVjre 1740

FIGURE 3.59
148 PROCESS SIMULATION AND CONTROL USING ASPEN

Select the plot type under the heading of Temp and press Finish button to obtain a
'
plot of Temperature (0F) vs. 'Stage' (see Figure 3.60).

rinwii-ii

I I J s < i io u £ 15 i« k w tr tt is-a

: it

FIGURE 3.60

Recall that the above plot window can be edited by ight clicking on that window
r

and selecting Properties. Then the user can easily modify the title, axis scale, font and
colour of the plot.

332
. .
Simulation of a PetroFrac Model

Problem statement

An artificial petroleum refining column (PRC), shown in Figure 3.61, consists of a feed
furnace and a distillation tower. The tower has two pumparound circuits, a partial
condenser and three side strippers. The furnace (single stage lash type) operates at
f

25 psia and provides a fractional overflash of 40% (StdVol basis) in the tower. The
outlet stream of the furnace goes to the tower on Stage 22. The tower has 26 stages
with a Murphree stage eficiency equal to 90%. A steam stream, STEAM, is introduced
f

at the bottom of the ractionator (26th stage with on-stage convention). There are another
f

three steam streams, STM1, STM2 and STM3, used in the side strippers. The condenser
runs at 15.7 psia with a pressure drop of 5 psi. The tower pressure drop is equal to
4 psi. The distillate rate is 10000 bbl/day and the distillate vapour fraction in the
condenser is 0.2 (StdVol basis).

Copyrighted malarial
ASPEN PLUS SIMULATION OF EHSTILLATIQM MODELS 149

LIGHTS <

WATER

STMl

sir,-

STM2

BOT

FIGURE 3.61 A lowsheet of a petroleum refining column.

A hydrocarbon mixture with the following component-wise low rates enters the

f
furnace at 1170F and 44.7 psia (see Table 3.3).
TABLE 3.3

Component Flow rate (bbl/day)

Ci 3
c2 65
C3 575
i-C4 1820
«-c4 7500
i-C5 30000
n-C5 42000

H2O 250

In Table 3.4, two pumparound circuits and three side strippers are specified.
TABLE 3.4

Loeatum Specifications
Pumparound Draw stage Return stage Flow rate Heat duty
(drawoff type) (bbl/day) (MMBtu/hr)

1 (partial) 8 6 49000 -

40 (for cooling)
2 (partial) 1 12 1000 -
17 (for cooling)
Location

Stripper No. of Stripper Draw Return Stripping Bottom product

stages product stage stage steam flow rate (bbl/day)
1 5 SID1 6 5 STMl 11000
2 4 SID2 12 11 STM2 15000
3 3 SID3 19 18 STM3 8000
1
150 PROCESS SIMULATION AND CONTROL USING ASPEN

Four steam streams used in the column model are described in Table 3.5.
TABLE 3.5

Specifications 1

Steam stream Location Temperature (0F) Pressure (psia) Flow rate (lb/hr)
STEAM Main tower 350 50 11500
STM1 SID1 stripper 350 50 4000
STM2 SID2 stripper 350 50 1500
STM3 SID3 stripper 350 50 1000

Considering the 'BK10' base method under 'REFINERT process type, simulate the
PetroFrac column and report the low rates (bbl/day) of all product streams.
f

Simulation approach
Select Aspen Plus User Interface. When the Aspen Plus Startup dialog appears ,

choose Template and click on OK (see Figure 3.62).

I I I I I I It

Cioata a Utm SmMan Using

A+ f Blank Smiiabon

A+ Temptale

OpendnEwiingSimulatior

e*r\ADU BOOK apw

DAeoolAChaptesVAOU OWN xm
D:V0ook\Chap(«sViDU t*{>
.

0«
I

| Adobe Ao-dia P,d«»« I Chace.s W \ 4]Q*i** 2 HmcHW || Av Pka

FIGURE 3.62

As the next window pops up (see Figure 3.63), select Petroleum with English Units
and press OK knob .
ASPEN PLUS SIMULATION OF DISTILLATION MODELS 151

mm
'Mm.
1

linn v-

.
..

L-
EJ J-J

.
. ..

FIGURE 3.63

Click OK when the Connect to Engine dialog appears. The next screen presents a
blank process lowsheet.
f

Creating flowsheet
Select the Columns tab from the Model Library toolbar. As we expand the PetroFrac
block icon, a variety of models is displayed as shown in Figure 3.64. Select a model
icon and press Fl to know more about that.

rinF. I- I-h HI I .Ml I lal iN

J? if" IT
[1 it Jb Jt
& ir if
ir .
# lb
t ir Op
f

tr ffc* c
J 1 -

4
. | turn* t
i> B p a .

# I .
-

W 11 1

FIGURE 3.64
152 PROCKSS SIMULATION AND CONTROL USING ASPEN

As the distillation tower described in the problem statement, it is appropriate to

choose CDUIOF PetroFrac model. Then place it in the flowsheet window. Adding all
incoming and outgoing streams and renaming the streams as well as block, the process
low diagram takes the shape as shown in Figure 3.65.
f

L'Mi- 111" A KM* 1W mm m 31* 1Mb -jM«.

FIGURE 3.65

Configuring settings
Click Next to continue the simulation (see Figure 3.66). In the Title field, enter
'

Simulation of a Petroleum Refining Column'. Open the Accounting sheet keeping

untouched the other global defaults set by Aspen Plus.

r
k
<UbM
-

.
<i.i-?-ir-Q-ii'-i?--i
.
»»No M - -o- Ut- W»
i.-r
W.

FIGURE 3.66

Copyrlghtf
ASPEN PLUS SIMULATION OF DISTILLATION MODELS 153

In the form, shown in Figure 3.67, the Aspen Plus accounting information are included.

I'M MI | i l"!
1 1 F
-

9 -i*--- I 1 ,1'5-l-Mi-' 3 »\ Q| .i -1

-
9 M Mjri '-c
s
»1 9i<>>

. I"- 1

ITBUM :-1TMj ba 1m .kMnc tOM MXai Mai

FIGURE 3.67

Specifying components
In the subsequent step, use the Data Browser menu tree to navigate to the Components /
Specifications sheet. Filling out the component input form, we have Figure 3.68.

U> ZlgjFi 3 >id <AP-Bid Lj'i

aTJ*
3 gr 1 i -i;
..

1 7
-

3
T
,
- -
it! T KJETTH tSruT
-

r? f

Lj i-r

tntUM ' wraij a- B i. wo., ip i tw.. *****

FIGURE 3.68
154 PROCESS SIMULATION AND CONTROL USING ASPEN

Specifying property method

We know that the thermodynamic models calculate the properties, such as vapour
liquid equilibrium coefficient, enthalpy and density. In the list on the left shown " ,

Figure 3.69, choose Properties/Specifications to open the property input form In th 6 .

Process type ield, select 'REFINERY

and in the Base method ield, select 'BKlO' (Brau

f
K-10 method).

Ea Tc<* tr HO th*> .v v t

f
NBI I I a>|e| ¥?! nlt'lftKKI I >»l ~l i I "I -I *\ I J
I f i i I fV .|:-liS|-. I .:M
1 >hl -3idPy!!il
-

ficwtw |Bfni;tFf.

I 3

3
< i-j :

1 aj c v-lu

STRUMS KTVM OM ikfiK PtftaPut RatoFiv 8«=rfi«

FIGURE 3.69

Specifying stream information

Next the Streams /FEED /Input/Specifications sheet appears with the Data Browser
menu tree in the left pane Entering the feed data, Figure 3.70 is obtained.
.

D|tfiB| _
iJ e|jgJ njKjfti i-g -i ».i { |h| Miigj .} _
j

Pn zi bJiiif
-

3 »J QN h

n
|
n
b
iei
cs nm

!3J no
i 0.1

w,
1 ED-**

rv
-

D -

""!««' wwi » ., m,,, s , « t«,« i i*

FIGURE 3.70
ASPEN PLUS SIMULATION OF DISTILLATION MODELS 155

As we hit Next icon, an input form for Stream STEAM opens up. After illing out, it

f
looks like Figure 3.71 .

* t* V«« D*» T«w fVn PW Marwt VMem

M-i rv -

[ft HuTorCoew 3 | EOOptan |

1*0 |r
. F/traBy

£ Mol(Qior Stioam
i: FtranKn
ict
d ia 1
d H

11500
: g ST
E S
S LGHTS
3 SE>1
3 O SlOS
* a
"

Total NlSOO

itiputCMeM*
fV MMd iAw. } SwoWort 1 HutEttharpei' Columw j Rwawt j h w O* | M*v niE | S<*t> | U«Modes |

'
STREAMS DSIWU
ntnjl r. .1 Raifitc EntlKl MJtf . SCfiac t)_-.r...
Pt fwFrac njj
Bat
-

efiae
._

Bwctjj..
b
fiac
;
NUVI cj/Ki i Tote

O
- S . * AwnWM t'

FIGURE 3.71

In Figures 3,72(a) (b) and (c), three illed input forms are shown for STM1, STM2
,
f

and STM3 streams ,

' itf csk Wew Dm Tooli H i PW Ibtw,

JMI mi
dSfb GPET.r-j Ol l fZi T] Q|.M N>J
"

9
| EOOptm )
j'Aijean n*n*
: I
J to
_

| Ma:-. Flow dl*'

N |f d
.

_
y t- tr-, Minodi
C1
.
_
j d C2
ISO [p.. d -O
_
J 0*3 C4
d - ICI
- 1

cs
NC5
1 J H20

fEEL

tniii

kM Cans,..

i fM-I-8-If'(S'#'C'4
"
-
'

SWUM MTMI
'
MM* (renFI

FIGURE 3.72(a)
156 PROCKSS SIMULATION AND CONTROL USING ASPEN

O tn Ua J9J»J
S3 2J 1 SI
_
LiJ pr 1 1 1 jaj «iM
») LJ| | N.|
-

1
EOfJi eini
ApecMicotioo<| FtHhOtfHIni ) 1
l/j Cm<p<mIi BkfcibMmnaiq) fTMIXuT 3 J
31 [mmTfIcm 31"1"'
\m |i zJ 1 '.(.-'/r 1 V**

u,,
.
MdMculitSniaM r "

zl -
DA
id

'
Mam 1
ItfalltoM |SUwl id
| |l.H/dv zj cs
»j Steaon
. BIT
. ns 1. J ; m
_
,
.
JH FEED
. LIGHTS

f _
j sin
.
_
, sm
. srew
.
S s '
-

_
stm:
O kvol
RnuU

STREAMS <1 neTiini

DSTWU r
OisH
,.
-

i .
Duc.
Rwftw. c ,_i
Exlud u. c.u
MiAFiac crc.v
SCFisc c .rX,
Pe'.cfi f4v«Fi»: 84ictfi«

Aspen Plus -S

FIGURE 3.72(b)

at:
Rs £c* We* Dae Tc s Fiwi FU : lAray VNVid&B
"

3M 5 [ g rg \ \ u j | n>|
~

/S(»cifiwrtton»j FlaihOpwn: | EOOfton: |

SLtsdeamr me jyMIXED 3 I
| Frcc et
~

3 K'**-
|3» 1- Vdue

:t
|p, ,. d
|SD If. zi
--

3fl C4
ISidvcJ d riC4

901
1 d CS
£ J BIS
1 J
-

HA-i
i
a FEED
S ij LN5HTS
s _
j sm
g i SID2
._

j 5103
_

> jfl ST = AM

J! STMi
s STM 3 lad fuccT
© lt*xJ
P,
ED A

Llj-_

-
a-»
Rrfrac EJiaci MJf c SCF.« (W.k RaFw

FIGURE 3.72(c)

Specifying block information

From the Data Browser, open Blocks /PRC/Setup /Configuration sheet and ill 11 up
f

(see Figure 3.73).

ASPEN PLUS SIMULATION OF DISTILLATION MODELS 157

Tmi "<»«. 3« tJT P« Ufco* A5«to- HMn

j .
TiU-J.J 1'
_
!l:'Mii,

Sehjoteta'i
o
P«rN*V o, Ligud

* a f-" Uiidtihu«E

3\-ur
S EOT

UGHTS
K BDI
i jj so;
g £j 903
>: M STEAM
STVl
M STM2

WATER

1
J
Ki vjij hGOFWw- ~
4 Main colunn 81

"
Mod
' MTi.ni iv-.o . '.r. ri-e- n. f... K. t-- nJ. ii-...
SWE-MS I OSrwU DitB BrfrK E-trwt HMik SCfitc P fix. (WeF.se B<(j*F(»(,
fs-.net, wean
'

a«i a ' ... OvWtjrt pan Pk - SaJTt" '

FIGURE 3.73

As we press Next icon, the Blocks /PRC/Setup /Streams sheet appears as shown in
Figure 3.74.

'
Fie Edt W C*s T>-A PW Uxsy Wrec* Hefe -
f

jtHGRETRC <<j|Ai 3 j
5 JCcriifjiter, ystiasnej Steam |vn«*tue|wCariMnnn)vFijin«ca{
feed me*"!
31** Conwibon
5 TEAM 26

FEED 22 Funaco

Hwse FMw B«m Fkw IWt

-
j (w
eoi
_

ttSHTS Vapd
Fieewatei

DIS

Jfl STBI
.
nw

i, as*!

| wWi | HeMEohongeii Cotuan) j Rmumi | Pre;iu9 Cltaroa! | ManpUstco | Soldi j liieiModd! |

< ..sFtabe '.'fire-iPijjll 1

'
a*

FIGURE 3.74

n Figure 3.75, the pressure sheet shows the condenser pressure along with the top
as well as bottom stage pressure of the distillation tower.
As given in the problem statement enter 0.2 in the Distillate vapour fraction field ,

naer the heading of Condenser specification (see Figure 3.76).

158 PROCESS SIMULATION AND CONTROL USING ASPEN

rl«l-l

9 -

F P 3
-

17-

- 3 'no r
.
_j imi
< o «
*
a S'
.
zj m
-
3 iTm

Himdl ' in
.

I-Wav. nruu M law Mhr VI» AbA.

M
.

-I « - - o-
'

FIGURE 3.75

i r-i-i. i-- rir -

i -'ci i « -i-i
3gifh - 1 l-l »l 31-1 "'1
a -

I ] 3

T _

UXTI
w

itfl

I 1-11 I H»«e l»l «i f «H I r> I rMMOM«M I MI I M* I IMOMa |

-
£>*
Haas
i .r.
M/w IOib NWw lau«<a

£S-1 IW I " .mm

FIGURE 3.76

In the next step (see Figure 3.77), the feed furnace is specified by selecting the type
of furnace and giving the values of pressure and ractional overflash.
f

Copyrighted material
ASPEN PLUS SIMULATION OF DISTILLATION MODELS 159

tUiiLH
MM
.
_
!3 J J
_

J *«nmr. I yS«Mi| Staw | yC d et Awm.)

- zi

| SoUt | UiaMotJtt }

.
R£*MS
.
L/ST-mj _
D*L R«*mc E*«» Mrffue StTuc PeboFiK R ef>*e £!5n«C

FIGURE 3.77

In the left pane of the Data Browser window select Blocks I PRC I Efficiencies and ,

provide 90% Murphree tray efficiency (see Figure 3.78).

My| 1 1 las! « dvifelsKM »j -| 1 IH_JS)_J ®l

; i nr 1 IOI 1 la! iMSil
Fb |r..-,rr,F:-.| H | «||..
_
4 'W*!

Sertgr. Enlnq

fir1

Kjrf.sr SOW NWfwt Rvrfiy gjjtjftg

-
a - . ii i HUH P-j. JtothLy?**-

FIGURE 3.78

The three windows shown in Figure 3.79(a), (b) and (c), specify the side strippers
,

tj d on the given input data.

160 PROCESS SIMULATION AND CONTROL USING ASPEN

(Buck PUT (INMroftm;) Slriivm SI - IWofttmwI

tU F-» I Took f\vi -V.' Ubrary- Yfrdon Heto

I IB] I SI MM

_
] Mi 3 ]0pUlrtalF«di | Uqud Retail j P'i
J
_

id Seho
'

ll 3 r 3
a Stj m "

_
J 60T a
-

J DiS
-

FEED
- "

TT-
-
ICHTS
S'ipgng iearr, f 3
r
3
~

SIDl
_
l SlMm lo bo«om pioduct tslw |Wion»l| f
Jj SID! "

j SO] r 3
jfl STEW
STM1 Flow jptcrfcahwi
5TH2
fiofioftTpoduct 1
a STHi
'
- -
EC
_
j , .

PBC
O Scbc

.
ii 3-;
.
il 53
O Healer Co
4ir*«ol:fa!)o«,nctbng(ebo Reboto itprttdtK m Ihe bdlofn sage
-
,1

STREAMS DSTWU Dirt RadFiac ENttact MiAfrac SCfiac P*

Penoffdc Balefiac Saictiftx

Cv lFoWon.afljenFVsll I rij.rM |)|mI hcOT»c

« "
.
.
I; 13:01

FIGURE 3.79(a)

Rt Edl Unr Dtfa Tooh Run PW Lfcary WfxJw

EBB
r

Dl lyj J J clej w) QKlfeKl l i n.| 3 >l J

_ _

h i - IBI iSlti
as'
* forced
| OpbanalFeedt j Rerun
, rj ot Setup
t

U 015
.
Jfl fEEt
NUTlb8(0(tl«(|ei [* 3 3
Siropeiixoduol 1 102 0v«<hMdretuK |n 3
.
j 5DI
-
.
H 5:02 Slnpomgirwdun
: a SiO) I* Stiipoiij *te*fi |STM2 jj
.
STEAM
.
5TM1
Sieamtobollampiodi 1 It .

.
Ji sTMi r Rebcisfduy
.
!r,«
S 23 WATER OpboMt tebo<e. heal ihwmt
ij Brxki t " (. produd 3 3
i|
Srrf/oJ 15000
'

I P i»»wid» -1
-

St r.
*
Si
*
A S-2
> .
S-3

O ttw* Stwca
f
r

0 -

rj CoodMer Hcurv

iwifiii iiHi W
KMancdu dw. JSt
3SA tinM) Sb»«r S2
HutEichanoeii Cokanu | Raadai | Pnuuactrogni I MawMon | SdUs | UmMcxMi

STREAMS OSTWU 0ml RadFtsc Erf/acl Mtt ffK

MJfi«: SCFuc PmoFiic R«rfi« e«ttfi«c:
C\ gFoUmVANMnAjill 1
'

- I » i.2l " Jj£lS | jJOaa»2 HcmrtlW |'T A»«i,P«»<fcii.H)J || HO

FIGURE 3.79(b)
ASPEN PLUS SIMULATION OF DISTILLATION MODELS 161

as-3

-
a GOT
! U ns
FEED
3
n l "

3 tJv*f>»adi«t«n fie -J
f

-
u UCHTS
. Zj SOI
S«DJ

nB
SOS
5TBW
STM1
1 iV) snc
r Rttolodur)' .
r

*
- j STM3
.
j WATtP
_

n
- FX. 4

1) Jj .....

WaCwwH M Mar cou-t. jwja ;aji,

[V M«m/5c*Mt. I S tHten I H»«E*ch«n9M Cok-ni j n. on [ f Miw*CKangtrt ] HmvMm | SoUi | Model. |

STREAMS DSTWU
'

fvHtki fn .

FIGURE 3.79(c)

Although the Status bar says Required Input Complete, we have to specify the two
pumparound circuits connected with the main fractionator. Select Blocks/PRC/
Pumparounds in the list on the left. Click on New as the object manager appears. We
may accept the default Pumparound ID T-l Then specify the first pumparound circuit
'
.

(see Figure 3.80).

H* Es* VW D«j Toob Rwi Pa Jsrvy Vintom net

Ql -l H

_
J ra» «
-
1) Sdukw
_ j

J W.srtrt
OHRltfMM
_

-
J «*

lj LXirTS

1, 5103
U s-o: 31-ur
STEAM
STM1
jfl snc
ino
j MHTSH
taw
$ fK

Jj "MV

HBEAMS
-
hfin: ' OStWU
OSIWU Dail if.*: ErtM HJ*.* SCfi*c P«ofr*c H«rf'*c
f
r

FIGURE 3.80
"'
162 PROCESS SIMULATION AND CONTHOL USING ASI'KN

Select again Blocks/PRC/Pumparounds to reopen the pumparounds object manager.

By the same way, ill out the form for second pumparound circuit, shown in Figure 3.81.

f
|»'|H| |
i r n I F .
i
. .. p rr-T n U -1 q -.| ul 1 n.|
-
J i
-
J -

| :
.
f" -
hm*lm
7
'
-
I t:
.

_
j w;
.
V) REE
_

_
j SiOl (..m 1... . d
.

.
1
,
"0-
L-
Sfll 1 -.-. d
f

J Beck*

Jfl ' T - OS
-
Jfl PI

h
_
i

_
J

FIGURE 3.81

Running the simulation

Hit Next icon and click OiTto run the simulation .
The Control Panel window is presented
in Figure 3.82.

...
J rj_iUV 11 Im; i ibi i i

S Was Jui M, lOC''*

.
Fr nxtcj input i(Mift«Hiau

oawjimiftp oawa rca the n-wsasir .

1 1 O.tlMl

STP£Am D5TWI] Cfl ifiac m.HiF.k SCf.w Fy.rfnc i a.- g w,

f
r

FIGURE 3.82
ASPEN PLUS SIMULATION OF DISTILLATION MODELS 163

Viewing results
From the Data Browser, choose Results Summary /Streams and obtain the table, shown
in Figure 3.83, that includes the low rates (bbl/day) of all product streams. Save the

f
work done.

l.;,ft-i

-
o-

FIGURE 3.83

To obtain the input information (see Figure 3.84), select Input Summary from the
View pulldown menu.

ITU UMilMly of 1 1

. fv irtm no- Ha. »»t.

titmm . uve. : * lid. flaa

Cl CM
ut c*<ao ;
Ml . ««0-|

"Co

ncc* «c >uo s'*! t.ii:o»T» lu

w c*Ti" iroa >tw «oj

FIGURE 3.84

Copyrighted material
164 PROCESS SIMULATION AND CONTROL USING ASPEN

34
.
SIMULATION AND ANALYSIS OF AN ABSORPTION COLUMN
Problem statement
A hydrocarbon vapour enters an absorption column below the bottom stage and the
absorbent enters above the top stage. The column operates at 75 psia with no pressure
drop and it has four equilibrium stages. The absorber is specified in Figure 3.85.
GAS-PDT
Absorbent

Pure n-C10
Temperature = 90oF
Pressure = 75 psia
Flow rate = 1000 Ibmol/hr

ABSORBENT

oAo-rttu

Gas Feed

Temperature = 90oF
Pressure = 75 psia

Component Flow rate

LIQ-PDT
(Ibmol/hr)
280
c2 150
C3 240
n-C 170
4

n-C 150
5

FIGURE 3.85 A Tlowsheet of an absorption column.

Apply the Peng-Robinson equation of state model in the simulation.

(a) Simulate the absorber model (ABSBR2 under RadFrac) and compute the product
compositions.
(b) Perform the sensitivity analysis by examining the effect of absorbent low rate
f

on the exiting C3 concentration in the top product .

(GAS-PDT). 3
Simulation approach
(a) Double-click Aspen Plus User Interface icon on the desktop. When Aspen Plus
window pops up, select General with English Units Template as shown m
Figures 3.86(a) and (b).
ASPEN PLUS SIMULATION OF DISTILLATION MODELS 165

; .
b
,
_£l a AHM -< r-J 3 ! I I Jgl-J _!

1 r OMn»E«F«Sai>H>

0 J.<* *h«MW«U»0

V
..

FIGURE 3.86(a)

oi W U J )ig| J2hm_L_kld 2J_LLJ_ia_i

_ - _

FIGURE 3.86(b)

Click OK when the Connect to Engine dialog is displayed and proceed to develop
the process low diagram .
f

Creating flowsheet
Select the Columns tab from the bottom toolbar Among the available RadFrac models,.

select ABSBR2 and then place it on the lowsheet by clicking with the cross hair
f

somewhere
the inlet andon the lowsheet background Right-click to de-select the block. Connecting
.
f

outlet streams and changing the all default labels we have Figure d.»/. ,
166 PROCESS SIMULATION AND CONTROL USING ASPEN

F dl
- Vto* tJ«8 Tccto Btr low wl liw/ Wn<*»«

J1IM J_L-LJI .1 .tel. I IBI «g]*!j

O 1 «8 'H
-

O 1 :-AS'Ee: f

STREAMS S OSTWU CwU Ratfiac E»»[»c> MtlaP.ac SCfiv: PfUcfrac Raiefiae Batctfrac

; Slwl] S J " Botk j 4] Aapen_ Mo«by Mct | - Cha r3 Hritirft j jUwtdTwro Hwcao )[ Aapen PVj« . Soul « j

FIGURE 3.87

Configuring settings
In the subsequent step, hit Next symbol and ill up the three setup input forms as shown
f

in Figures 3.88(a), (b) and (c).

Re E(k Mm D« Tooii Pur. Pid Lbra>y Wfida- H >

n| |H| J JMg|jgl nsMfeKNM H j

_ _ SI
~

_
L r i-i-I- PT
_
-

5**
© Spectftcj«k>n«
Q SmitMlcnOiMni
ISmJabon ot «i Abtoiba

R«#iiVPO 3
OuWtBttlt |ENG r "

: Stio«m dan |cOW>/HH 3

Ftowbesw [ 1

DM C

STREAMS OST'VU QaU RxF.ac E«kI M F.oc P»tof.ac R<Mfi«c

FIGURE 3.88(a)
ASPEN PLUS SIMULATION OF DISTILLATION MODELS 167

* -

FIGURE 3.88(b)

Tig-
IS
sir
-
:

FIGURE 3.88(c)

Specifying components
From the Data Browser, choose Components/Specifications. In the input form, shown
in Figure 3.89, all components are defined.

Specifying property method

In the list on the left, shown in Figure 3.90. select Properties /Specifications to obtain
the property input form. Set PENG-ROB property method.

Copyrighted malarial
168 PROCKSS SIMULATION AND CONTROL USING ASPEN11

& .
! -m I W W

'
I "

5!ES
ii
-

11 LI

-
D -

FIGURE 3.89

. > --

-
D-
W W >»«.» M«» -il> «-»»

FIGURE 3.90

Specifying stream information

In the next data entry step, press Next button and click on OK. Enter the feed
information for both the gas stream and absorbent in two forms as shown in
Figures 3.91(a) and (b).

Specifying block information

Use the Data Browser menu tree to navigate to the Blocks/ABSORBER/Setup/Confi-
guration sheet (see Figure 3.92).
ASPEN PLUS SIMULATION OF DISTILLATION MODELS 169

' r i i i- rv i ie:
-
m aia
i

3 nr

IS 3 .
,

IV
H3-

FIGURE 3.91(a)

7laLJlllrr-3»)aU;
"

I E0O«Mr« |

: 1 EC?*- >]
I .

tea
r L

"
'

> fi '

£J T-r1

FIGURE 3.91(b)

ouiul .1 ! ami 01 al-rtcloKlyl » ! 3 I MilBj} 3

«i -fe!
SfEf

P 3 ,

j\ r
-

Li ir

FIGURE 3.92
170 PROCESS SIMULATION AND CONTROL USING ASPEN

Select the Streams tab to specify stream location. Under Convention, there are two
feeding options: On-Stage and Above-Stage. In the present problem, the top stage is
the first stage and the bottom stage is the fourth one. Therefore the absorbent is fed
above Stage 1 and the gas feed is introduced above Stage 5 (see Figure 3.93).
-
He &k Vfe* CW* Tec* Fin fa u , Wi-do- Up
Mai -I..[ **m *?! oMfel M *'l :2l_J_liiJjdElj*J.£iJ
i r 1.14- nr -i i iai

PtoimiI >/!:cnjcnni| 1 I

sws. Com*

WOfiBEH
5

| .

SfBEAMS : Djrf f&F-K E-iKa W-if.s: SCF P ff-t -

. fistf.ic B«c»f >

FIGURE 3.93

In the next step (see Figure 3 94), select Pressure tab to specify the pressure profile
.

across the absorption column In this case, the column is operated isobarically at
.

75 psia. Under Top stage / Condenser pressure enter 75 psi. Aspen software assumes ,

that the column operates isobarically if no additional information is provided.

E« tca a(s "m« Rji ta Jay, 7fr»e«

7]
fop ' Ccmkraii pftlfJI*

* l (t*Sf EEC
f

E AflSOftSER

[V I - I . ..MT-UJ-W: 1 W J

0 0- R . t Pnrf.>: tiufnt Bwtfat

| tjHA.MTMa We {j < n -S ' o. **** tr j - Mil

FIGURE 3.94
ASPEN PLUS"' SIMULATION OF DISTILLATION MODELS 171

Running the simulation

Hit Next foUowed by OK to run the simulation. The Control Panel window is shown in
Figure 3.95.
-
Ft. E« V*- OA TMh 4*

ci»1H| *U M*} _
aMai H'"I n . I M .| i?i m £

r
-
J T-l l-l' F*
-
'I .IBI I laai «M

mjihTiiiiTiii liiriSij

StPEAMi [ .11VU C«« RadF.-a- Mjfffac SCFr«c Prttofra- RatsF Bt&f'* .

FIGURE 3.95

Viewing results
Choosing Results Summary /Streams in the left pane of the Data Browser window ,
we
get the results as shown in Figure 3.96.

fit SX .Vn t« 1 It.-. a»> P« UrVf

loHal am
_
Lr_ia_ J rr _
.
i
la .
1 *LiJ «)W
~

3 aaad
I
j|r d
'

Jll .
d
a aria HBB
ei Mm
»> ...
NC4 tuoiyi liH IMHB

TiB iSidV) H9913

S Ntll) isnutu
-

a-1 *l)4s
r

C1 ozn jw- O0M

H 0152 0J<* 6020

' -

C) «»2 01* US'-

RG dm 0012 cioo

mM OlOD
|
tcio 1000 np oca .
1

-
a-
'
_V ~, 26... r-j .., iESfad
sifiEtw' e '' j Dr.« ri.j,3, Ml<, '* SSfigB f,v'r'a- SftS
f
f

f -. kM- j.

I a-w a i e ss i iaajgLg
t

FIGURE 3.96
172 PROCESS SIMULATION AND CONTROL USING ASPEN

(b) In the sensitivity analysis we will manipulate the absorbent low rate and ,

f
examine its effect on the exiting propane concentration In the column at the .

left side, double-click on Model Analysis Tools folder and then select Sensitivity .

As the Object manager is displayed, choose New. On the next window shown in ,

Figure 3.97, Aspen prompts us for an ID. Enter 'C3' as ID, and click OK .

- t* idl .tea
f

1 MM Wl nMfcl-si-JI-i el r I L'iiliJJSll -1
_
i r L m rv
_ _
d |B|
1

.
_ , w
-
:.-
.
_
]

I C mrtn
I C-.**

i j Sohh | Utti

FIGURE 3.97

In the next step (see Figure 3.98), select New under Define tab. Then we are
'
prompted to enter a variable name. Enter C3' and press OK. Subsequently, the following
information are required to provide:

II I I ! . fT . 1 .lEI ,
1 |B|

1 |

StaM l&i-iTOI

- > -
J .

4...,'. ., | MW. I H«,[Jw U>mm | aca>. | Bbu.Ow I M-MO, | U* I <lm*M I

n OITWU Cm R«fCMtt HJf*c «Tac IW'k n 'tc c 't -

FIGURE 3.98
ASPEN PLUS*" SIMULATION OF DISTILLATION MODELS 173

Type: Mole-Frac
Stream: GAS-PDT
Substream: MIXED
Component: C3
Hit Next and select the Vary tab (see Figure 3.99) The manipulated variable iis
specified with the following data:

Type: Mole-Flow
Stream: ABSORBEN
Substream: MIXED
Component: NC10
Overall range
Lower: 500

Upper: 1500
Increment: 50

> Ht aa Vfem Csa Too» fu\ Pa {tar, >Vhd» >Mi 1*1 "i
-

i i»l.li:M;ii A
_
L r _

danElEMo -i «[|ai "~

* 1>>I ! 1 *»1
/Dorr yvacj |«T«ulaM| TaUgr OMMbn I Oaard |
.
_
j On, Ogmrm VsxMtruitei 3

Tor
Cjcpona 3 Low |M0
Upo» [Two
Ina fsT
Hercxljbrti
u«e Tea*
Lm1 I
-

-
Train,
Ure2 |
U C3 LntJ P
'

» - -
MM

.
_
j D»Ff

23 r tttji

MM
UKJAHS ' CrtTVU FVlrfnc lKrfnc BWrt/'K
f

FIGURE 3.99

In the subsequent step (see Figure 3 100), . select the Tabulate tab. This screen is
used by Aspen to set up tables. Insert T under Column No. Then right click on the
adjacent cell under Tabulated variable or expression. Select Variable List and drag and
drop the variable name (C3) into the cell. We may also directly type 03' in the cell. '

Then run the simulation and get the screen, shown in Figure 3.101.
174 PROCESS SlMULVriON AND CONTROL USING ASPEN

'
» (. <« . Mi Im* * uam mmm M*

sfgl.. j»[di<)P Zl JiUjd

-
10 > Cfton*
'> -

et " .
ft . .- u~

4 "
s

-
D -

'
DSTWU CMI Mrfe wjftK KTm hmfm *ml~ Mo o
t

< w -m Ik

FIGURE 3.100

1 .
I'ICI I 111 !?1»!J
AM
ir
- Qc>

> nn
I :mii

In Tm.
t trv
I Mil
t Mai

lil/TU
'» «»«
K ua
MtM
i uut

'
MIMU Om IW<k Umo >w i« IOai DMTw taXw

FIGURE 3.101
\SPEN PLUS SIMULATION OF DISTIUJVTION MODELS 175

From the Data Browser, select Model Analysis Tools/Sensitivity/C3/Results to

display the tabulated data (see Figure 3.102).

5 -

- I » - " . - I rijo- - 11; .--

FIGURE 3.102

In order to represent the results graphically, highlight a column in the table and
select X-Axis Variable (Ctrl + Alt + X) from the Plot pulldown menu. By the similar
way. select Y Axis Variable (Ctrl + Alt + Y) for the next column. Then select Display
Plot (Ctrl + Alt + P) from the Plot menu and obtain Figure 3.103.

J T
-
I-1 l- iv i-g I i»< siW

I --. I - l - I

J
FIGURE 3 103
176 PROCKSS SIMULATION AND CONTROL USING ASPEN

(c) In the left pane of the Data Browser window {see Figure 3.104), open
Flowsheeting Options folder and then select Design Spec. We need to provide
this design spec a name in the same manner that we did for the sensitivity
analysis. Press New, enter DSC3* and click on OK. '

38
2i£B_uaas -'-i ~ _u-j.ii2a

3 ~--

5=.

o
-

_ AH .> Mfc. lw Mto W. W«

FIGURE 3.104

Select ihTettJ under Define tab. Then enter 'CS' as a variable name and press OK. In
the next step (see Figure 3.105), the following information are required to input:
Type: Mole-Frac
Stream: GAS-PDT
Substream: MIXED
Component: C3

.
.
K-MJ-B-M-iM-f-

FIGURE 3.105

Copyrlghiod material
ASPEN PLUS1M SIMULATION OF DISTILLATION MODELS 177

In the subsequent step (see Figure 3.106), select the Spec tab. Design specification
data are noted below:
Spec: C3
Target: 0.15
Tolerance: 0.001

;Ti=E4Mi DSTVU Dag R»Jf>: Erftaci M frac SCF»c PihoF-JC flyrf.K cj'ctfix
f

FIGURE 3.106

Finally (see Figure 3 107), select the Vary tab and enter the following information:
.

> 4. Lfc Ar- Cm« to-Ji Hpi Ptoi Ubr, AWtow »H>

MHj_U jff) nkiaiaKiH n.| P >|'l"l I ~l 1 il

_
j r iii nr
_
imi i ibi i i

' X
.

U
' -

i
_
/-,

6
3 "
-

- J r
0 r r
0
Q ! M6
'
>

r-s.

_
i >

I -' - Tan, I > fi-

-
?
:

1
| HmMH I r>MMf'CM«M | Mr iW I SOW: | UwMaW- |

»gj ' I a

FIGURE 3.107
178 PROCESS SIMULATION AND CONTROL USING ASPKN"

Type: Mole-Flow
Stream: ABSORBEN
Substream: MIXED
Component: NC10
Manipulated variable limits
Lower: 500

Upper: 1500
As we run the simulation, we get the screen, shown in Figure 3.108.

&k 'Aw U«j Tw, fu. w**«.

el w| Mii*MaJi£)!id r -
I I "I 311 <M
j lai

Slock: ISSOAfilS USFUC

K. K. XL Ici Ir.
1 t 1
I 1 1 C.1K31

Lhtt i.e. sicwr- iMunuii i

i - l-.j.J. Hbi Ik/TcI 0 IS9ft«3
f

ML IL ttt/To)
i i » c.aui*

3TH£*«S ! OSTWU Dan Brfrac Um* UtffiK SOHk ttfwe RaUfwc Badftic
f
f
r

ail * J " . »t
'

FIGURE 3.108

As we choose Streams subfolder under Results Summary folder in the list on the left
(see Figure 3.109), we get the absorbent low rate of 1179.467 Ibmol/hr to keep 15 mole
f

of C3 in the gas product. This answer we can also obtain from the sensitivity plot.

35. OPTIMIZATION USING ASPEN PLUS

It is well known that Aspen Plus is capable to optimize a function Here, we will continue .

the above absorption problem (Section 3 4) for optimization. In the present study, we .

wish to maximize C3 mole fraction in the gas product (GAS-PDT) with respect to
absorbent inlet temperature (lower limit = 50oF and upper limit = 300oF) .

Simulation approach
First solve part (a) of the previous absorption problem It means, ill up the input
f

forms for setup components, properties, streams and blocks. In the next, simulate tne
,

optimization problem as described in the following .

ASPEN PLUS SIMULATION OF DISTILLATION MODELS 179

t -r
4

« -

.
'
)
M
"

TM H
lit
KB
r
r
,

_
1 1
-
- Si.- - JUBJ -
-

i>'«

IT iMT 1
.
sna-fSBRI- - tc

U wra-; wim
M .» i .«<-'.

rr owi t-rr* M Im* o»« '

FIGURE 3.109

In the column at the left side (see Figure 3.110), choose Model Analysis Tools/
Optimization. As the Object manager is displayed, hit New button and accept the default
ID 0-1' Press OK and then New. Entenng variable name 'CS'. again click OK Provide
the following information to maximize C3 mole fraction in the gas product.

I'M*
N t)

FIGURE 3.110
180 PROCESS SIMULATION ANT) CONTROL USING ASPEN1

Hit Next knob twice and get the screen, shown in Figure 3.111.
T-Birry m.v.-.T'-iB

_
LilJ Jl]35l £vj:

3 <<J[ --7]2>J DijdHd

i0C.-.~. Osbcn
-

-
ii

dp
a

-
iJ

At o i

ir Hitut/SpEttm j
f

STREAMS h!BM f 5&M S£p»

0 ' ioc*< p!9.

FIGURE 3.111

Right-click in the empty cell with selecting Maximize option. Then select Variable
List and drag and drop the variable name (C3) into the cell (see Figure 3 112). We can .

also simply type C3 in the field.

E* fwe ~ada Z,r. \Jutr, Wrtie* Hnb

CbiKtive tundnn -

HQ OfWlc*
s 2u eSci
[5) Rma

S ij 01

U .. ..
i'r

FIGURE 3.112

'
In the subsequent step select the Vary tab. Under Variable number, as we choose
,

New', automatically the number T appears FillinR out the form, we have the window .

as shown in Figure 3 .
113.
ASPEN PLUS'" SIMULATION OF DISTILLATION MODELS 181

!5)| I \£\ j l

21 Cw

_
j rw-m
fi nw aw i
f

D -

FIGURE 3.113

Pressing iVex symbol and running the simulation we get the answer (see Figure 3 114). , .

The maximum C3 mole raction of 0.259 is obtained at absorbent inlet temperature of 179 80F . .
f

In vi>* C*i Kn fa ttnja,,

J 1 i i fir i bi
-
-
. 1 ibi

j 'Jr-.rr.
3 T i

>,
K1.«pu 75 00

noco 10*

foosaoo HH
USC0 £»-
wv.- lUHjU
"

MMB Lit 5»SS7

4*m
'

. t
f

Wfa>
'
'
c? mm 1?. *

Ti PIVB
170(00 i»S3

FIGURE 3.114

SUMMARY AND CONCLUSIONS |

At the beginning of this chapter a brief of all built-in column models of Aspen software
,

has been presented Several separating columns, including a petroleum refining column
.

and an absorber have been simulated using Aspen Plus. The process optimization has
,

also been discussed with an example. The present study covers both the binary as well
as multicomponent systems Interested readers may try to simulate the models given
.

in the exercise .
182 PROCESS SIMULATION AND CONTROL USING ASPKN

PROBLEMS|
3 . 1 A feed mixture, consisting of 60 mole% ethanol and 40 niole% water, is to be
separated by using a DSTWU model having a low rate of 100 kmol/hr at 40oC

f
and 1 atm so as to recover at least 85% of the light key component in the liquid
distillate and 80% of the heavy key component in the bottoms. The column
operates at 1 atm with no pressure drop throughout. In the simulation, consider
the reflux ratio of 1.5 and a total condenser. Applying the Wilson property method,
simulate the column and ind out the minimum number of stages, actual number
of stages, and feed position. f
3 . 2 A feed stream, consisting of 50 mole% ethane and 50 mole% ethylene. enters a
Distl column having a low rate of 200 Ibmol/hr at 750F and 15 psia. This separator
f

runs at 300 psia with no tray-to-tray pressure drop. The pressure in the reboiler
as well as condenser is also 300 psia. The feed enters the model at 6th stage and
the column has total 15 theoretical stages (including condenser and reboiler)
and a total condenser. If the reflux ratio is 7 and the distillate to feed ratio is
08
compute the mole fraction of ethane in both the product streams with applying
. .

the RK-Soave equation of state model.

3 3 A feed mixture specified in Figure 3.115 is to be distilled by a rigorous RadFrac
.

model (FRACT2). The column consists of total 24 equilibrium stages (including

condenser and reboiler) with a stage pressure drop of 2 kPa. Consider the
condenser (total) pressure of 125 kPa and the top stage (Stage no. 2) pressure of
130 kPa. The distillate low rate is 120 kmol/hr and the reflux ratio (mole basis)
f

is 2. A side product (vapour) is withdrawn from 14th stage. Applying the Soave-
Redlich-Kwong (SRK) property method, simulate the column model and report
the product compositions.

Feed

Temperature = 110nF
Pressure = 175 kPa
Dj O
Feed stage = 10 (above stage)
Component Flow rate Sj cC.
(Ibmol/hr)
benzene 250
toluene 80
diphenyl 10 B\ $

FIGURE 3.115 A flowsheet of a distillation column.

3 .
4 A reboiled stripper is to be employed to remove mainly propane and lighter
components from a feed stream, shown in Figure 3.116. It has total 6 stages
(including condenser and reboiler) and no condenser. The bottoms rate is
100 Ibmol/hr and the column pressure is 150 psia throughout. Using the Peng-
Robinson thermodynamic method, simulate the RadFrac model (STRIP2) and
ind out the product compositions.
f

Copyrighted material
ASPEN PLUS SIMULATION OF DISTILLATION MODELS 183

Feed

Temperature = 40oF D -
Pressure = 300 psia
Feed stage = 1 (above stage)

Component Flow rate

(Ibmol/hr)
c, 60

c2 75
c3 150
n-C 175
4
n-C5 60
n-C 35
s

FIGURE 3.116 A flowsheet of a stripping column.

3 . 5 A feed mixture of cyclopentane and cyclohexane is to be separated employing a
liquid-liquid extraction unit at 250C and 1 atm with the use of methanol as a
solvent. The schematic diagram of the process with feed specifications is given
in Figure 3.17. The process unit, having toted ive stages, is operated adiabatically.
f

Applying the UNIQUAC property method, simulate the extraction model (ICON1)
and note down the product compositions.

Feed

Temperature = 30oC
Pressure = 1 atm
Feed stage = 1

Component Flow rate

(Ibmol/hr)
cyclopentane 250
cyclohexane 750
FEED EXTRACT

Solvent - SOLVENT-
RAFFINAT
'

Temperature - 30DC
Pressure = 1 atm
Feed stage = 5

Component Flow rate

(Ibmol/hr)
methanol 1000

FIGURE 3.117 A lowsheet of an extraction column.

3 . 6 A gas consisting of 40 mole% ammonia, 60 mole% air at 20CC, 25 psia, flowing at

the rate 120 kmol/hr, is to be scrubbed counter-currently with water (pure) entering
at 60oC and 30 psia at a rate 100 kmol/hr. The column operates at 1 atm throughout
and it has four stages. Using the UNIFAC thermodynamic model, (a) simulate the
RadFrac absorber (ABSBR2) and determine the exiting ammonia concentration in
the gas product, (b) Perform the sensitivity analysis by examining the effect of
absorbent low rate on the exiting ammonia concentration in the top product.
f

Copyrlghled malarial
184 PROCESS SIMULATION AND CONTROL USING ASPEN

3 .
7 An artificial petroleum refining column (PRC) shown in Figure 3.118 consists of
a feed furnace and a fractionation tower. The tower includes one pumparound
circuit, a partial condenser and one side stripper. The furnace (single stage flash
type) operates at 20 psia and provides a fractional overflash of 50% (StdVol basis)
in the tower. The outlet stream of the furnace enters the tower on stage 18 .

The column has total 20 stages. A steam stream, STEAM, is fed at the bottom
of the fractionator (20th stage with on-stage convention). There is another steam
stream, STEM1, used in the side stripper. The condenser runs at 15 psia with a
pressure drop of 5 psi. The tower pressure drop is equal to 5 psi. The distillate
rate is 12000 bbl/day and the distillate vapour fraction in the condenser is 0.25
(StdVol basis). The liquid product, SID1, is withdrawn from 5th stage with a
flow rate of 2000 bbl/day.
A hydrocarbon mixture with the given component-wise low rates (Table 3.6)

f
enters the furnace at 120oF and 45 psia.

LIGHTS

WATER

IS o
-

SID1

STEM1 -O

FEED
SID2 C>

STEM
BOT O

FIGURE 3.118 A flowsheet of a petroleum refining column

TABLE 3.6

Component Flow rate (bbl/day)

10
c2 100
C 600
3

1800
n-C 7500
4

30000
1-0, 42000

nrCt 250
H 0 250
2
ASHEN PLUS SIMULATION OF DISTILLATION MODELS 185

The pomp around circuit (for cooling) and the side stnpper are specified with the
following information (see Table 3.7).
TABLE 3.7

Location Specifications
i

Pumparound Draw Return Flaw rate Temperature

idrauoff type) stage stage (bbl/day) feF,

I (partial) 8 6 40000 20

Location

Stnpper No. of Stnpper Draw Return Stripping Bottom product

stages product stage stage steam flow rate (bbl/day;
1 5 SID1 12 10 STEM1 15000

Two steam streams, used in the column model, are described in Table 3.8.

TABLE 3

Specifications
Steam stream Location Temperature (8F) Pressure (psia) Flow rate Ob/hr)
STEAM Main tower 350 50 12000

STEM! Stnpper 350 50 5000

Selecting the PENG-ROB base method under RE FINE RV process type simulate ,

the model using a PetroFrac column and report the flow rates (bbl/day > of all
product streams.
This
Thispage
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Rs. 295.00

PROCESS SIMULATION AND CONTROL USING ASPEN

Amiya K. Jana

ISBN-978-81-203-3659-9

The export rights of this book are vested solely with the publisher.

Published by Asoke K. Ghosh, PHI Learning Private Limited, M-97, Connaught Circus,
New Delhi-110001 and Printed by Jay Print Pack Private Limited, New Delhi-110015.
Part II

Chemical Plant Simulation

using Aspen Plus
This
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pageintentionally
intentionallyleft
leftblank
blank

Rs. 295.00

PROCESS SIMULATION AND CONTROL USING ASPEN

Amiya K. Jana

ISBN-978-81-203-3659-9

The export rights of this book are vested solely with the publisher.

Published by Asoke K. Ghosh, PHI Learning Private Limited, M-97, Connaught Circus,
New Delhi-110001 and Printed by Jay Print Pack Private Limited, New Delhi-110015.
Aspen Plus Simulation of
Chemical Plants

4 1 .
INTRODUCTION

In the last three chapters, we have studied in detail the simulation of individual
processes, such as flash drum, dryer, chemical reactor, distillation column including
petroleum refining process, absorber, stripper and liquid-liquid extraction unit, using
Aspen Plus software. Here, by a 'chemical plant' we mean a chemical process
integrated with several single process units. The chemical process industries usually
include flash chamber, mixer, splitter, heat exchanger, pump, compressor, reactor,
fractionator, ilter and so on. It is easy to simulate even a large chemical plant by the
f

use of Aspen software package.

In the present chapter, the simulation of two chemical process flowsheets is
discussed. They are a distillation train and a vinyl chloride monomer (VCM)
manufacturing unit. After thoroughly reading this chapter and simulating the solved
examples in hand, we will be able to use Aspen Plus flowsheet simulator for solving a
wide variety of chemical plants. To improve the flowsheet simulation skills, it is
recommended to solve the problems given in the exercise.

4 2 . ASPEN PLUS SIMULATION OF A DISTILLATION TRAIN

Problem statement

A hydrocarbon stream H is supplied at 50C and 2.5 atm. The pump Pi discharges the
feed F at 10 atm. In Table 4.1 the component-wise low rates are tabulated for stream H.
f

The schematic representation of the complete process integrated with a pump and
ive DSTWU column models (Cl, C2, C3, C4 and C5) is shown in Figure 4.1.
f

189

Copyrk
190 PROCESS SIMULATION AND CONTROL USING ASPEN

TABLE 4.1

Component F/ouj rate (kmol/hr)

10
35
50
130
200
180
200
n-C.
5

pi C1 C2 C3 C4 cs

FIGURE 4.1 A lowsheet of a distillation train.

For Aspen Plus simulation of the distillation train, required information are given
in Table 4.2.

TABLE 4.2

Column Condenser Reboiler

(abbreviation) pressure (aim) pressure (atm)
Deethanizer (CD 9 9
Depropanizer (C2) 5 6
Deisobutanizer (03) 4 4
Debutanizer (04) 3 3
Deisopentanizer (05) 2 2

All distillation models have total 20 theoretical stages (including condenser and
reboiler) and a total condenser. For the light key (LK) and heavy key (HK), we expect
99.9% and 0.1% recovery, respectively, in the distillate of all columns. Using the Peng-
Robinson property method, simulate the distillation train and report the compositions
of all distillation products.

Simulation approach
From the desktop, select Start button followed by Programs, AspenTech, Aspen
Engineering Suite, Aspen Plus Version and finally Aspen Plus User Interface. Then
choose Template option in the Aspen Plus Startup dialog (see Figure 4.2).

Copyrighled malarial
\SI'KN PWB SIMULATION OP CHKMK \l PLANTS 191

hmbj_lj__bJ'ii mmLii-jd .3 J.i.'isim i. :

In ro..-

AM n i.tu.

1 1"
-
.' I 1 «

FIGURE 4.2

As wo hit OK button, the following window appears (sec Figure 13). Based on the
units used in the problem statement we select General with Metric Uliits,
,

in-i
.

1»

1- . l-.

<- r< mil I-'

.- J - .

.
I J I"-
_

I
'

FIGURE 4 3
192 PROCESS SIMULATION AND CONTROL USING ASPEN
'

Press OK and obtain the Connect to Engine dialog. Select Local PC as Server type
and click OK. Actually, this step is specific to our installation (see Figure 4.4).

Connect to Engine

Server type:

User Info

Node name:

User name;

Password;

Working directory:

Save as Delaull Connection

OK ] ExB Help

FIGURE 4.4

Creating flowsheet
The next screen represents a Process Flowsheet Window. Add a pump by selecting the
Pressure Changers tab from the Model Library toolbar. Moreover, in the library, select
the Columns tab and then choose DSTWU model to include five such columns
consecutively on the flowsheet. Notice that to incorporate a block click on the ,

appropriate icon and then place the block on the process lowsheet by clicking with the
f

cross hairs somewhere on the lowsheet background. Right click to de-select the block.
f

Now we need to interconnect the blocks and add the inlet as well as outlet streams.
Select Material STREAMS on the left of the toolbar at the bottom In the next, as we .

move the cursor to the process lowsheet window several red and blue arrows appear
,
f

around the blocks. The red arrows indicate required streams and the blue arrows are
optional. In the previous chapters, we have learned how to connect the feed and product
streams with a single block.
Let us observe Figure 4.5 to know how to interconnect the two blocks by a stream.
Here, irst we wish to interconnect the pump PI with the column Cl using the feed
f

stream F. Right-click with highlighting feed block select Reconnect Destination and
,

then move the cursor to click on an arrow that is fed to the column Cl.

m o
-

QD-o
SOD-*

r ]-o

PI Cl

FIGURE 4.5
ASPEN PLUS SIMU1.ATION OF CHEMICAL PLANTS 193

We can select Reconnect Source instead of Reconnect Destination if we modify

Figure 4.5 to Figure 4.6.
j3L D1

B1 c>

FIGURE 4.6

By the same way, interconnect remaining blocks. Renaming all blocks as well as
incoming and outgoing streams, finally we have the screen shown in Figure 4.7. To
rename a particular stream (or block), irst select it, then right-click, next select Rename
f

Stream (or Rename Block) and inally enter the appropriate name.
f

Re E« Vto» On Took tin Uban Whfen Help

H _J iU _l J

5","*,s Oirwu o ai
, SCfuc PMiofioc BMefiai Boictfuc
C |iFold».mo»IVilH HUM fw»llr»J

FIGURE 4.7

The status indicator in the bottom right of the window, shown in Figure 4.7, says
Required Input Incomplete indicating that the process flowsheet is complete and input
data are required to enter for running the simulation.
194 PROCESS SIMULATION AND CONTROL USING ASPEN

Configuring settings
As we hit Next icon and then click on OK, the following window pops up (see Figure 4.8).
Remember that in the Data Browser, we need to enter information using data input
forms at locations where there are red semicircles. As we inish a section, a blue

f
checkmark appears.

» r- -i'iv
-

life ,

FIGURE 4.8

It is always a good practice to represent a simulation problem with entering a title.

In the Tattle field, enter 'Simulation of a Distillation Train'. Note that we may change
the input/output data units under Units of measurement (see Figure 4.9).

I r i-l I 17 -i.gi i «(i

V-H

-
id* ~ ' . -

figur: m 9

The next window (see Figure 4.10) includes the Aspen Plus accounting information ,

as given below, required at some installations.

ASPEN PLUS SIMULATION OF CHEMICAL PLANTS 195

User name: AKJANA

Account number: IIT-KGP
Project ID CHEMICAL
Project name: DT

-
o- i S *
MM -

FIGURE 4.10

If we want the streams results summary sheet to display mole fractions select ,

Report Options under Setup folder to the left Under the Stream tab select 'Mole' as ,

Fraction basis (see Figure 4 11) .

n fT7

-
- .
i i
-

*- . -

-
»

u>U>i

.
2}' I -
n .
- .« <

FIGURE 4.11
196 PROCESS SIMULATION AND CONTROL USING ASPEN

Specifying components
In the subsequent step, use the Data Browser menu tree to navigate to the Components/
Specifications sheet. It is shown in Chapter 1 how to define components in the component
input form. Here, we have this table as shown in Figure 4.12.

ffc E* p. tw To R»

i r l-l .l- fT >i -"Pi I iai

g :.r.: Fopui

C2
CJ

IU
cs
.

*
!S
*

_
j wy tm
1: - . .

_
J O pOa**
.

i i r
id

5 -.
_
| > M<MVnt«« -J

FIGURE 4.12

Specifying property method

In the list on the left , choose Properties/Specifications to obtain the property input form.
A property method includes the models and methods to calculate the physical properties,
such as vapour-liquid equilibrium coeficient enthalpy and density. For the example
f

plant, set PENG-ROB base property method by scrolling down (Figure 4 13). .

5* C*, T** P« U , Wnajt. tt*

I 3

J DM
.
3

FIGURE 4.13
ASPEN PLUS SIMULATION OF CHEMICAL PLANTS -f 197

Note that there is no compulsion to use only a single thermodynamic property

method for all processes in a chemical plant. Aspen software provides an option to
choose different property methods for different processes. To do so select Block Options! ,

Properties under a particular model of Blocks folder in the list on the left and then
choose the suitable property method.

Specifying stream Information

The Streams/H/Input/Specifications sheet appears with the Data Browser menu tree in the
left pane. Entering the given data for stream H, we obtain the sheet as shown in Figure 4.14.

j T-i i-i r>

-
'
i-w I'M -

3
"

3 j. a. -j],. ,. j

ti»» .rtl.m '-if

2j twi- m*.

' ". : ww. r w sit.

FIGURE 4.14

Specifying block information

As we hit Next button the block input form appears. The deethanizer column is specified
,

with the given data as shown in Figure 4.15.

arn<tv*\
* & V- tm, r , m

31i£iai _U iB| 51 nl-mi!<l

.
_
1 "

: ; £

it:

6 :

imua h** m tfl

FIGURE 4.15
198 PROCKSS SIMULATION AND CONTROL USING ASPEN

Subsequently, the filled input forms are shown in Figures 4.16(a), (b), (c) and (d)
for other four DSTWU columns.

fir. Prt Ubfwy WMM

-
LT-

ap u**
t

neb*.

»>y ctnponent Condentei ipertcalun!

Ct«p fo
1 F
-

Rww jo O
T

O St*: G<t<-C-.

r>n»m

] .JtdiJ Trim

FIGURE 4.16(a)

J iiiJ JZi J
_

_
iJ~_
|0 IrcU 3Mt I HJilJ -3 U
_
j V- n CdaimxtOebor* j Convagervt
.
) .an d Ptuiite

i pi
a Wumbe.
- tjf
j
Reba» fT
_

.
U B3 r Reftw .aha
*
6-
-
_
1
.
U K
I J W
Ccrrp fic<
_

.
0 02 3]
_1 M
'

-
_
j W
j _, D£

Reow (0 CO)
S M Cl

jfi : .

tco- It* cm
f

RMI
t

P»u

I I Sob* I UMModrt t

k
Km-

Fv H* cm F"

FIGURE 4.16(b)
ASPEN PLUS SIMULATION OF CHEMICAL PLANTS 199

Si ioj _U 51 riKifci- l-M 3) _J_JjiJ ji) 5j

i _
J «
(7 ll**c»*

*
Zl r i »>-
S H
-

J '
-

J -
-

1 «

I HMtKfaan | Colm | Rucmt | Pimm*!

-
CH
MM
M- FSptr SSpM
C iFMiStavPUtn NUN fi«w*Jkci41

FIGURE 4.16(c)

Pta Jrav

fiimii
f

CondEnia f

u «
_
J w
_
J .
-

- I

f" HMra/lrfi-"nan || f[«*jit

Mraeon || Hn.f
.
Him rp., | Coupni | RmcV<. | Prwtti.Ch»»n | tWiMi t Set* | UtpUM* |
-
CM
Hp
flflUMS ' U** V , *

C a(t«J r tI> HUN ,««rJKmvwa u

FIGURE 4 16(d) .

Click on Afet and specify the pump (PI) outlet by providing the discharge pressure
r

of 10 atm (see Figure 4.17).

200 PROCESS SIMULATION AND CONTROL USING ASPEN

FU Jtnry Wndov. I Ms

HA
L TJ i i
-
J2J

r Preci.ie "iciMie

r Pt«tiu>«(Mo
"

I I 3
) <Jfti«mr* (kthnjs condhoni

Saiw

ij»t SutrciJine

£0 MM

Sw&wjm -1

j <Ch« 'il-IA=r'Ari j 1 JAcw | -J U- q Tern} Atpei> Pk» - Simi

FIGURE 4.17

The status bar in the window, shown in Figure 4.17, includes a message of Required
Input Complete; it reveals that to run the simulator, sufficient data have been provided.
But there is no such restriction that we cannot specify the process with more input
information. Again, as we click on Next, Aspen Plus shows a message under the heading
of Required Input Complete as shown in Figure 4.18.

J T -
1-1. I pr H jsn l -iai

/Specifcaliooij CflcOalKr. OsHjw ] flaihOphor.t

wni
f

D>38
(? Ptmp
0 EWSK
j Rtcnc
"

"
3
3
P Result
_
J

ro-jcertrterma'eincxJ To no'rr roi ed»i ijncd »

Al Mea ' c fx :- Hm - * Osu .>: -- (Mnu.
Ptnp.

I W ci
-
ai c;
j a o
.
ai «
.
a pi

EOCorwOpten

-
Q -

iM
. 9 -m *

FIGURE 4.18
ASPEN PLUS"' SIMULATION OF CHEMICAL PLANTS 201

Notice that if there are no red semicircles in the left it can be said that the data ,

entry for running the Aspen simulator is complete.

Running the simulation
As we approve the simulation run, the Control Panel, displayed in Figure 4 19, .
shows
the progress of the flowsheet simulation in addition to a message o[ Results Available .

.
1

B a
B O
B w
Z '
93 us states; ~. Jt mu tjxll huz - jjtkt:

n a = c» n

z. =i3»i arc:

lice* a Bsmi: csrta

fi" -

. " v. ex. -vOS

FIGURE 4.19

Viewing results
Choose Results Summary /Streams in the column at the left side and obtain the
compositions of all distillation products as shown in Figure 4.20.
We may save the work by choosing File/Save As/...using the menu list on the top.
W< tan give a name of the ile whatever we like. Note that if we click on Stream Table,
f

the results summary table is incorporated in the Process Flowsheet Window, as shown
in Figure 4 21.
.

Viewing input summary

If we wish to have the systematic input information, press Ctrl + Alt + I on the keyboard
or select Input Summary from the View pulldown menu (see Figure 4*22).
In order to create a report file (*.rep) for the present problem, we may follow the
approach presented in Chapter 1 It is worthy to mention that the report file contains
.

all necessary information on the solved Aspen Plus problem including given process ,

data and computed results

202 PROCESS SIMULATION AND CONTROL USING ASPEN

3 >bJ.'<IP~~3»l-i g|

C- « 1 J .
~
J Cv CMn
Wit T a!
o . B -

am
"

TW
"

nrw
9 - l
Tia HH
"

i.r.T
e - - - -

n TTEB 1 m mid

" 1 '
e tUi sm 1 TOTB 1 nuif 1m muff
- ~ ~ " -

B nn- TW Mi
" '-

IB ttd- rw- rfq|p !. 11 nnu Tifi- BM 1

1
Hm
.
- -

RD UB ' Wi 1 UK TW
"
-

.
4 2j
TS ~

a TBS
"

713 us 1 TB 1
r

S
" ____ ,

BB TRC -
IMl
"

irK. iv -.

MM. ' | U.I

tmufi *M ««

FIGURE 4.20

i MIBlJBI
-

WPT |-3i-«Hil%l-g|w| -?i ! M .jiyial

r|st7,|-|..|j fV .| .|E| Bj «i|fc|

1
.r
lOmm* I " I Ho I

FIGURE 4.21

Copyhghied malarial
ASPEN PLUS SIMULATION OF CHEMICAL PLANTS 203

rrrvJ |t«i1«t<«i of a DUinUtlon TrtU

MCW-aetrr i<ol( -OtNSrrr- tuol' c-ji

voilM-CM otir*-!

for Inpm: Ho1«

Stream report ct xnltiwi: «o1t fli

SOLIDS 1MMCAMIC

W-SDUKCS Wll / -QOWWS SOLIDS INOtMMC

CI C2M I
( 1 ClHt
1C4 C4H10-2 i
' ' C4N10-1 /
IC1 CSH12-; '
ici cvai-i /
MCt CftfU-1

LCMMKT
1LOW C» I«l-e4 O'JT-O) Bl
.LOCK C4 IWt} O'.n-.oi M
ukk ci in-c; out-03 el

FIGURE 4.22

43
. ASPEN PLUS SIMULATION OF A VINYL CHLORIDE MONOMER
(VCM) PRODUCTION UNIT
Problem statement

The process low diagram for Aspen Plus simulation of the vinyl chloride monomer
f

manufacturing plant is shown in Figure 4 23. The lowsheet has been developed based .
f

on the VCM production technology reported in a book by Seider et al (1998). .

O-fcmi

O-feu

BB 66 B7

F10

[purge]-o

FIGURE 4.23 A flowsheet of a vinyl chloride monomer production unit .

204 PROCESS SIMULATION AND CONTROL IISINO ASRKN

Pure ethylene, stored as a gas at 70oF and 1000 psia, with a flow rate of 20 tons/hr ,

and pure chlorine, stored as a liquid at 70oF and 150 psia, with a flow rate of 50 tons/hr
enter the mixer block Bl operated at 2 atm. The mixer outlet Fl then goes to the
reactor B2 run at 363 K and 1.5 atm. In this stoichiometric reactor (RStoic), the following
chlorination reaction occurs with 98% conversion of ethylene to 1, 2-dichloroethane:
C2H4 + Cl2 -> C2H4C12
ethylene chlorine dichloroethane
In the next, mixer B3 operated at 1.4 atm allows the mixing of the recycled stream
F12 with the reactor product F2. The outlet stream F3 is then condensed fully to liquid
phase in block B4 at 298 K before being pumped to an evaporator. The pump B5 has
discharged the liquid at 26 atm. The evaporator B6 performs the phase change operation
and then the vapour temperature is increased in the same unit to 515 K. In the
subsequent step, stream F6 is introduced in the reactor B7 (RStoic) in which the
following pyrolysis reaction occurs:
C2H4C12 -> C2H3C1 + HC1
dichloroethane VCM hydrogen chloride
The dichloroethane is converted to VCM and it takes place spontaneously at 773 K
and 25 atm with 65% conversion. To reduce carbon deposition in the heat exchanger,
the hot vapour stream leaving the reactor is quenched in block B8 yielding a saturated
vapour stream at 443 K. Quencher effluent stream F8 is condensed to liquid phase in
block B9 at 279 K and then fed to a DSTWU column B10 as stream F9. In the next ,

Stream F10 is introduced in another DSTWU column Bll. The first column mainly
separates HC1 from other components, while the second column purifies VCM from the
rests. Both the distillation columns have 10 theoretical stages (including condenser
and reboiler) and a total condenser along with the specifications shown in Table 4.3.
,

TABLE 4.3

% Recovery of LK/HK in distillate Pressure (atm)

Block Light key (LK) Heavy key (HK) Condenser Reboiler

B10 99.9% of HC1 0.1% of VCM 20 22

Bll 99.9% of VCM 0.1% of dichloroethane 75 .
8

Finally block B12 (FSplit) splits stream Fll to ensure the recycling of 99.999% of
Fll as F12 stream to mixer B3. A purge stream is introduced to prevent accumulation
of unreacted components.
Using the POLYSRK property method simulate the complete plant to compute the
,

composition of all streams.

Simulation approach
To start Aspen Plus package select Aspen Plus User Interface under Programs. When
,

the Aspen Plus window pops up choose Template and click on OK. In the next, select
,

Polymers with Metric Units (see Figure 4.24) and press OK button.
ASPEN PLUS SIMULATION OF CHEMICAL PLANTS 205

- . . r .ii.-i.*. Ti 3 . i i .rj 3 a
i : ; : I -i

-
:

HZ]

FIGURE 4.24

Click OA" when the Aspen Plus engine window appears to obtain a blank Process
Flowsheet Window.

Creating flowsheet
We can develop the process low diagram (see Figure 4.25) by incorporating the following
f

IpF -I- I I- IT MCI I m ti

ED
413

? 4f

FIGURE 4.25
206 PROCESS SIMULATION AND CONTROL USING ASPEN

built-in process units available in the Aspen Plus Model Library:

two mixers (Bl and B3)
two Stoic' type reactors (B2 and B7)
four 'Heater1 type heat exchangers (B4, B6, B8 and B9)
1

one Tump type pressure changer (B5)

two T TWIT type columns (BIO and BID
'

one TSplit type splitter (B12)

All the blocks and streams are renamed according to the problem definition.
The status message directs us to provide the input information required to run the
complete Aspen Plus simulation program. In the subsequent sections, we will ill up

f
several input forms one by one.

Configuring settings
After creating the lowsheet for the VCM manufacturing unit hit Next button followed ,
f

by OK to open the Setup /Specifications / Global sheet. In the following the irst screen ,

f
,

shown in Figure 4.26(a), includes the Title of the present project as Simulation of a
VCM Production Unit' and the next screen displayed in Figure 4.26(b), shows the ,

Aspen Plus accounting information as given below .

User name: AKJANA

Account number: SAY X
Project ID: ANYTHING
Project name: AS YOU LIKE

t* Edl ««. Dal* TotU f*jr. linry Wndw Help

DNBi L JMjaj jg| dvlfeM M n>i -j -1 |h| a| -4 M a|

_ -

O irouldars fwiT 3
Input mods

v Sf>ec/>awrn
Sueam das:
31
Flovbuc 3
it Jj Pew Oiar»a*fo
3

r Um see

£1 Cvre-ljdi
it; O Parw

> r j Mntof 4t "i Tents -J

5Tft£*MS
ssft.

FIGURE 4.26(a)
ASPEN PLUS SIMUI.ATION OF CHEMICAL PLANTS 207

Qi BI _
LJ *j«J .] r5h-|ftl»N|w| mj rj J_iilj _J J
I r -i-1-i Fir -
t lei, I i«l MhJ

Mi*

FIGURE 4.26(b)

We wish to have streams results summarized with mass fraction basis that is not
set by default. Accordingly, we choose Mass' fraction basis in the Report Options/
'

Stream sheet under Setup folder (see Figure 4.27).

«. Ea '<W Tm> V< tat,

- AWl- -*k

DIQ*IHI
'

J .
1 - M|
11 >id illF-Z]»J iJ _

OKI o U rciM r. fMaitcV

P Hbi

P Ir-imi .«! no >» j tKW,

I .1

FIGURE 4 27
208 PROCESS SIMULATION AND CONTROL USING ASPEN

Specifying components
The components that are involved in the monomer manufacturing process are ethylene
(C2H4), chlorine (CI2), 1,2-dichloroethane (C2H4C12), vinyl chloride (C2H:iCl} and hydrogen
chloride (HC1). In order to get a blank component input form, choose Components/
Speciftcatiojis in the left pane of the Data Browser window. Defining all species in the
Selection sheet, we have Figure 4.28.

1 (ComponaO Spooftoiioni . Dal a Bnnrasr) ma

Data Tods fkn Plot Library Window Hdp

510*101 _
Tii.J J
JT _1_M.

_
Setjr
Selection] Pelidftum | Noraiorivenliona! j-/Dalabanl s |
Soedicatona
0 Smjiaion Options Define comp«*nli
Q Slrean- Class Componerit ID Type Comconent name Foirtiula

::h4 Conventtonal ETHYLENE C2H4

J/) UrUs-S«S
CL2 Conventional IHLORINE ri;
( Custom Unrts
Q Report C ions C2H4CL2 Conventional 1 2-DICHL0R0ET r :h4
.
.
Cemporwrti Conventional VINYL-CHLORIDE C2H3CL

HCI Conventional HYDROGEN CHLC HCI

Lg l-End Propert.es >

*
Jj Petrc Cha cterzatoi
FieudoccmocneiTts

I t-'enf - Comps
iMFJCGrtupi
'

1 Conp-Groops
.
J/] Comp-Ltsts
_
j Fo ert
PfOpefti«

| Stocks
'

1 Reaoons ElecWEatd UsetDelmed

I Corv-ergence
'

1 Flowsheeling Oplons
'

j Modd -ViaSyas Toots

EOCorrfgurabon

z1
if Miyeu/Splittets | Sepaialoi Heat Exchargeti ] Columns ) Reactots ) Ptestute Changei: ] Manpulatots j SoWs ) Usei Modeit ]
f

Matei.at
STREAMS ' »m FSpS SSpK
ForHe*j.pn»j Fl C\. gFtAlfla\Aip«nPliji 11 1 NUM fiML«<! tTua netwowK
'.
ami s - jjChapter4 1*00 | Oiapler I - Mero | T) Uidii Teimi I* | Aspen f\j» - VCM [| Aspen Plus « 9 C . '656
FIGURE 4.28

Specifying property method

In the subsequent step choose Properties/Specifications to set the property method.
,

As mentioned in the problem statement accordingly select POLYSRK base method ,

under POLYMER process type (see Figure 4.29).

Specifying stream information

From the Data Browser ,
choose Streams folder and see the name of all input, output
and intermediate streams. However, we have to provide information for only two input
streams, C2H4 and CL2 which are fed to the mixer block Bl. Figures 4.30(a) and (b),

show the filled stream input forms.

ASPEN PLUS SlMULVnON OF CHEMICAL PLANTS 209

IM tp ... .' i ~ . .

f
CirftUl .-I i c|g| ni-«-|fcl%l-3M ml I M "I ?l -I _
Li

in fHMM
f

a
o

VtBUKi
- -

. - M

FIGURE 4.29

|i*lB|
-
J L
"

3 "! M -1 ""1
10 Ci . I

|-«i.pr. 3 pw=-3P -3
IB 1 - f
fS5
ED
- "

iPin

.
-

d
1

.
_
j
. "
-
U "

.
3 U
5 "
-
"
. 3 .-
"
hi -

iTKMI 1 o rh. im
t

9
-

FIGURE 4.30(a)
ASPEN PLUS SlMULVnON OF CHEMICAL PLANTS 209

IM tp ... .' i ~ . .

f
CirftUl .-I i c|g| ni-«-|fcl%l-3M ml I M "I ?l -I _
Li

in fHMM
f

a
o

VtBUKi
- -

. - M

FIGURE 4.29

|i*lB|
-
J L
"

3 "! M -1 ""1
10 Ci . I

|-«i.pr. 3 pw=-3P -3
IB 1 - f
fS5
ED
- "

iPin

.
-

d
1

.
_
j
. "
-
U "

.
3 U
5 "
-
"
. 3 .-
"
hi -

iTKMI 1 o rh. im
t

9
-

FIGURE 4.30(a)
'

210 PROCESS SIMULATION AND CONTROL USING ASI KN

n. on Pirn Stn.l*>on 1 [SlrBM C.L3 WATEBIAL) kyU IMa towwrl -

t
t

Data Tools Ruti rlol

_
i rj _

3 ©[15 1st Z LJiiii"' jziJuUijiJ

_
Conv-Ultl 3 /Specilicalioni| Flash Oplor.i | | EO Option. |
SiMnamnaiM p MlxtD 3
Q SptdfKationl Slate vaftaWe-. Compojitioo
.

*
Pnpoty Mdhodi
Estimalcfi
d
Mo cJat Sttxicl'jie 1" F .
J ComponenI Va>je
t j Pafanrten cm
_

j Data jpntttn d CL2

j
_

_
j Mt* iso P« d 1 J-DOl
PnapSel)
C2HXL
*
Jj y danced
J/J Streams Total How Ma;-. d HCL
-

C2H« 1 kgAr d
© IhdJ
RajuJs
d EO Vanables
-

(a CL2
0 Inpul
Rtsuls
Cf EO Vanables
.
_
j D1
.
_
j 02
.
J
Total IST
_

.
_
J "
t . , F3
t

S F4
. 1 F!

ill ' "

twulCompiete

Material
STREAMS 1 FSpia SS|*
FocHeto orevin C:\ gFoWere'-AspoiPlusIt 1
: NUM Rt»ju«ed ir<x£ TTC0ncJ«»t
3*1 S i Chaptera Aipen Plus - Smjali

FIGURE 4.30(b)

Specifying block information

Unlike stream information , we need to input required data for all blocks of the process
low diagram. As stated earlier the lowsheet of the VCM plant consists of two mixers, ,
f

two reactors, four heat exchangers one pump, two distillation columns and one splitter. ,

Although discussed during the Aspen Plus simulation of different single process units
in the preceding chapters, we must remember the following points when we ill up the
f

block input forms.

To simulate a mixer model, at least provide the pressure data and valid phases.
In the simulation of the reactor model coefficients should be negative for ,

reactants and positive for products .

In the Vapour fraction ield of a heater model put 0 to indicate bubble point
f

and 1 to indicate dew point. For subcooled liquid and superheated vapour, use
Flash specifications.
The windows, shown in Figures 4.31(a) to 4.31(n) display the block-wise information
using the input forms.
ASPEN PLUS SIMULATION OF CHEMICAL PLANTS T

f* e* d*»
'

** * *****

ol lBj _
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JCh«»<-MCT I <j-J-.wMr1 Watt | JiJ-'jrwnii-M || Ptpm Plus J«p Plui-SOI ( « §: >i

- ISM

FIGURE 4.31(a)

Took R i ta ubrs) Mndw, etp

a|tf|y| | I hi .tifssi il
i-nr mei. lai im
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i sir i..e. -i oi i .
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fF "n..-,./ ,i i,,, ] s jo, | H«>E.a«nj«1 | CAm. |

-
C3-

'Si* w»

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ail /-

FIGURE 4.31(b)
1"
212 PROCKSS SIMULATION AND CONTROL USING ASPKN

jag|y| I I ie|ll8| fj aMfkltKH H 2J-Liil)-2J iil -I J

t
f
Read arts

Compwienl
C2H4 i C2H4d2
12 i *

3
3

H Heck Ooi"-.!!!

r lMCtors occu «teiiot

Spec Group)
Si p

[i Hiwit/Spttlef* j iepatalow ] HealE«hsrwi | Column) | Beattot) ] Ptftsauro Chanijers j ManpjIalMi [ SoWs | UwMwtei?

STREAMS M t. FSpS SSpH

forHab press F1

jChapiy* Mcr: | --J;OacW I - IActi | -gjUxfJ Te M jj /open Pita Ag - MCg | » Q g Sffl

FIGURE 4.31(c)

Aapen Pk> CH4 SeC 4

_ _
.
3 - [Bocfc B3 (dtxer) anner]
t

He b* Das

DMHj LjM®l l nhl NK i n>| 3 I IMB J

_
LJ~- I -1 i PT -I isi I ; m

3 jb [MET <<|
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-

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TtmpnaJue eiSmala Convtrjance paiamwlwi
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Site CMC

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amte
t

youwrheofenure AtwoUe i OjW p.enue K value > 0 Ptaw/e *«, rW 0 Ga yrj; Oj!*. p,. -* lo- 3h
'

MCorwca

STREAMS
PorHato-MiFl
Hea a. Heat.- MHaaC
-
Hwar.
~
HXFV* HrRCvlST J
4 UtoT jj Japw-J ctCTT:»3<
O

FIGURE 4.31(d)
ASPEN PLUS SIMULATION OF CHEMICAL PLANTS 213

i. j** On Toe* Urvt MMMt M r

aH|_iJ *1H r3ifH>|».KI | H II I l"l 'I jiil

0 c.-"
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wkfimitm

F -tefc p m W C v. g ' i .-; F\s 1 M

W II A««»iPk«- . (ao t .-'CT ( «q wj ;.
-
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FIGURE 4.31(e)

Ei* /«* C-a« Too* flji Ra Llw, /, r-v. 'v-t

Mil ! I gj rj|-claKI<l~i -| I [m] J jj | J

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:> t- .,
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FIGURE 4.31(f)
214 * PROCESS SIMULATION AND CONTROL USING ASPEN

< : E* «»« Ml T-)C<5 Run Pic' Uw> H*

I :!lJ.JS.J
_
Lr i i i nr -Lm 71

Raail
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.
Reactws j Pie-jyjie Char eis ] Mawpife!«; ] SoWs j User Modei:

STREAMS ' Mm FSpB 5Sp5!

J[ Aspen Plus - . -py, v'CH [

FIGURE 4.31(g)

Ems
'

dMb| I -J Mil j J uhl NNM j j liEi J _

J
m mm
t Selup aTSl"" d±L lilJ
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3 optics
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d EO y*i*i«

l SpccGnjjw
f

£
STREAMS.
.
{>.< %} Mm FS,* JsJ

J| or ty. veil | - J «

FIGURE 4.31(h)
ASPEN PLUS SIMULATION OF CHEMICAL PLANTS 215

I r J- IT

(7-3

MOT j :«*«fl,

HO.
«
*

I 3

Sort "t n New T 1 ' ' Oelele

'
STREAMS Mm, FSct SSpt
an* on.Fl C-gFoMws axrPusIl 1 HUM
f

" 1 . . | - jChootw -'-o; j jdaotgl Ffeo j j Ussft Twrs W |[ Aapen Plus o. Fus '.CM | « 3C:&7
t

FIGURE 4.31(i)

DloSlBi i I iakliiWi-ai r i -i -| |wi'"4lfifrSi

i r i h LJT hlsl 1 lal Sfiel
t

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r c-... ._

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[» Mao./Sclii.,, | j
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FIGURE 4.31(j)
216 PROCESS SIMULATION AND CONTROL USING ASPEN
-a
.
t:
-
Took Ru' PM Lbrv> Wlr

hJ J J
j r L _
_
IT l lal I lal ggj

FtothrpecAcMione
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0 Sf«C Cir<XM
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i Pwi
"
i
[i Hbeii/SpMtwt | .
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cvy:.. | HeatEicch)ng»: | Ct-Unrj j ReflCioi)

STREAMS FSpM
"

=«. help prwi Fl NUM

Book | AapcnPlu. 2038

FIGURE 4.31(k)

Fie Edl 4ew Dots Toott F>in Plot U«*v Wmdcw Hdp

us
i r i -1 i - pt i m i

Hanres *|
i
Resotr ~

1" 3 '>«fcme'
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bd mill 3
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| ScMi ) LiMrHodM |

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SIR£AMS ' M-t ts,*

FIGURE 4.31(1)
ASPKN PLUSIM SIMUI.VriON OF CHEMIC-VI PL\NTS 217

uMiei | i ibj I nhlit Hhi J

I >I = |h| I J
i r -i i i nr - i -m \ m

'
t-- i- F

f
1

O Si*. 3 .

f
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1
Me

" «ba> | 'JC c-i Wot | ' .O tf o | 1 -Jl»r. w [I /ton*. ««

FIGURE 4.31(m)

i gr>i
..

'
Hi h* (te "t» fVr ty, ttai Widn >

1
re

FIGURE 4 31(n)
'

218 PROCESS SIMULATION AND CONTROL USING ASPEN 1 M

Running the simulation

As we press Next button, Aspen Plus displays a message as shown in Figure 4.32. Since
the data entry is fully complete, the simulator seeks user permission to run the program.

Dltfiui j | ricl gj n\'(\%\**\<W\ H I >! |h| ] v| gj

i r i-i f i: nr mei i iai

2]s}T g g H gj <iJi" jj uJ_J ij
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5 N" * -
URGE

V) B11

raijc«rBf<tir:)r»ir>J Tc-BrtfBior* .nom *xei \:tr.

Rj in if.- rcn'

a
Rw-ij 01t 1 1

t*
f

SbMM BenA

lonnt/SplilUK |

STREAMS 1 Mew SSpi -

I rjOap:a4 t rjstfi Ware j jjte«". tata MgM A>pm Ptu. - Sn-AW

FIGURE 4.32

As we hit O-K button on the message the Control Panel window appears as displayed ,

in Figure 4.33. It usually shows errors warnings, convergence status, etc. ,

gaBSBEsai
*) £ Cm IceM umj WrDo* m» 4uS

J £
'

» .» %w,cj - lilSSEi

FIGURE 4.33
ASPEN PLUS SIMULATION OF CHEMICAL PLANTS 219

Viewing results
Choose Results Summary /Streams in the column at the left side and rearrange the table to
get the results in the form as shown in Figure 4.34 Save the work positively at this moment. .

_ _
r -i i I'-f -
i HOI
jaTS i »M«Hr- ..|.|_.|n.|

il 1
. .

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1
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1
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00 «siT?s iDrtUo ICQOCOO

49 Q0 M 00 30
-

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IMHM * 004!% KUOEBE )<UCCQ nStWi i

1 <«U< I UVMMW ]

Hmmt AMkw Kffo MTHM5T

FIGURE 4.34

Viewing input summary

To obtain the input information of the present project, select Input Summary rom the
f
View dropdown menu (see Figure 4 35). .

UK* e: umeI o«t.».'

sntew CiiM

."
n -ncw cl2 y>. ctorn'tr*

UOC. BiO MT,«j

FIGURE 4.35
220 PROCESS SIMULATION AND CONTROL USING ASPEN

SUMMARY AND CONCLUSIONS |

In the previous chapters, we have studied the steady state simulation of a large variety of
individual process units using Aspen Plus package. In the present chapter, several chemical
processes have been assembled to develop the chemical plants and those plants have
been simulated subsequently. The solved examples include a distillation train and a vinyl
chloride monomer unit. In the second example, the loop is closed by a recycle stream,
whether in the irst unit, there is no such complicacy. However, the straightforward
f

approach to simulate a lowsheet is that after developing the process low diagram in the
f

f
lowsheet window of Aspen Plus, we can simply use Next button for data entry. As we
f

receive the message of Required Inpu t Completey we can move on to run the simulation.
In the next two chapters, we will study the process dynamics and closed-loop control of
low-driven as well as pressure-driven processes using Aspen Dynamics package.
f

PROBLEMS|
4 . 1 A hydrocarbon stream with component-wise low rates, shown in Table 4.4, enters
f
the isentropic compressor at 120oF and 1 atm. The compressor has discharged the
vapour stream at 3 atm.
TABLE 4.4

Component Flow rate (kmol/hr)

10
95
150
n -C4 25
/i-C3 10
n-C 100
6

The complete process lowsheet for lashing and stripping operation is shown in
f

Figure 4.36. The lash drum (Flash2) runs at 1250F and 2.8 atm. The stripper
f

(STRIP2) has total 6 stages (including condenser and reboiler) and bottoms to
feed ratio (mole basis) is 0.8. The feed stream to the stripper is introduced above
the top stage and the pressure throughout the column is 2 atm.

V24

I 0 1

COMPRESS FLASH STHiPPER

FIGURE 4.36 A flowsheet for flashing and stripping operation .

CopyHghlod material
ASPEN PLUS SIMUIJUION OF CHKMICAL PLANTS 221

Using the UNIQUAC property method, simulate the plant to compute the product
compositions and flow rates.
4
.
2 A ternary mixture, as shown in Table 4.5, is fed as stream H at 100oF and 290
psia to a pump Pi employed to increase 20 psi pressure.
TABU 4.5

Component Flow rale (Ibmol/hn

500

300

"
r 11, 10

The stripper (STRIP2) has total 100 stages (including condenser and reboilen
with a reboiler duty of 107 Btu/hr Stream F enters above 70th stage and Stream
R) mien above 1st stage. The top stage pressure of the stripper is 280 psia
with a stage pressure drop of 0.5 psi The intercolumn pump P2 has increased
25 psi pressure The RECT column has total 120 stages (including condenser
and reboileri with a reflux ratio (mole basis) of 10 and a bottoms to feed ratio
'mole basis) of 0.6. Stream Dl enters below 120th stage. In the simulation,
consider condenser pressure of 275 psia with a pressure drop of 5 psi and a
stage pressure drop of 0.1 psi (see Figure 4.37).

0
-
0

PI 8TRIP2 ' w"

FIGURE 4 37
.
A flowsheet of a propylene-propane mixture separation process

Applying the RK-Soavc thormodynamit mod* I

(a; simulate the above propylene propane mixer Beparation plant and report the
product compositions, and
(by perform the seneitivity aaalysifl to observe the effect of the second column
eficiency varied rom 20'/. to 10091 on the propylene mole fraction in the
f

distillate
222 PROCESS SIMULATION AND CONTROL USING ASPEN

4 . 3 The hydrogenation of aniline produces cyclohexylamine in a CSTR according to

the following reaction:
CgHgNH;, + 3H2 -) CgHnNHs
aniline hydrogen cyclohexylamine
To simulate the aniline hydrogenation process using Aspen Plus, we develop the
process flow diagram as exhibited in Figure 4.38.

FA
S-o
C>-I ANILINE

El
PUMP

CD-
-

C>-| HYDROGEN I-I

CSTR

COMPRESS

FIGURE 4.38 A flowsheet for aniline hydrogenation.

The reactor model (RCSTR) operates at 580 psia and 2480F, and its volume is
1200 t3 (75% liquid). For the liquid-phase reaction, the inlet streams have the
f

specifications, shown in Table 4.6.

TABLE 4.6

Stream Temperature Pressure Flow rate

(0F) (psia) (Ibmol/hr)
ANILINE (pure aniline) 95 100 150

HYDROGEN (pure hydrogen) 12 100 600

Both pump and compressor (isentropic) have discharged the fluids at 585 psia.
Data for the Arrhenius law are given as:
Pre-exponential factor = 5x 105 m3/kmol . s
Activation energy = 20,000 Btu/lbmol
[CJ basis = Molarity
Use the SYSOPO base property method in the simulation. The reaction is irst-
f

order in aniline and hydrogen. The reaction rate constant is defined with respect
to aniline. Simulate the process and compute the component mole fractions in
the liquid product and the vent stream.
4 . 4 The process flow diagram for an azeotropic distillation process is shown in
Figure 4.39. The technique involves separating close boiling components
(acetic acid and water) by adding a third component (vinyl acetate), called an

Copyrighted material
ASPEN PLUS SIMULATION OF CHEMICAL PLANTS 223

entrainer, to form a minimum boiling azeotrope which carries the water overhead
and leaves dry product (acetic acid) in the bottom. The overhead vapour is
condensed and then separated in the decanter into two liquid phases: the organic
phase and aqueous phase.
DECANTER

1 VA-RICHh
DIST
VA

1 FEEDf

HW-RICHh

RADFRAC

FIGURE 4.39 A flowsheet of an azeotropic distillation process .

A feed stream, namely FEED, enters above 15th stage of the azeotropic distillation
column at 330oF and 90 psia in addition to the low rates, shown in Table 4.7.
f

TABLE 4.7

Component Flow rate (Ibmol/hr)

acetic acid 2700
water 500

The entrainer, VA (vinyl acetate), with a low rate of 455 Ibmol/hr enters above
f

12th stage of the column at 200oF and 100 psia. The azeotropic column (RadFrac)
has the following specifications:
Number of stages (including condenser and reboiler): 55
Condenser type: total
Valid phases: vapour-liquid-liquid
Reflux ratio (mole basis): 4
Bottoms rate: 2700 Ibmol/hr
Condenser pressure: 66 psia
Column pressure drop: 12 psi
Key component in the second liquid-phase: water
Stages to be tested for two liquid-phases: 1 to 55
The specifications for the decanter model are noted below:
Pressure: 50 psia
Temperature: 110oC
Key component in the second liquid-phase: water
Using the NRTL RK thermodynamic model simulate the process to compute the
-

component-wise product low rates.

f
224 PROCESS SIMULATION AND CONTROL USING ASPEN

4 . 5 A hydrocarbon stream H is at 50C and 2.5 atm. The pump has discharged the
liquid feed F at 5 atm. The component-wise low rates are shown in Table 4.8 for

f
stream H.
TABLE 4.8

Component Flow rate (kmol/hr)

C3 50
i-C, 130
n-C 200
4

c5 180
n-C5 200

n-C 5
6

In Figure 4.40 the schematic representation of a hydrocarbon separation process

integrated with a Pump, three DSTWU columns (Cl, C2 and C3) and two RadFrac
(RECT) columns (CR1 and CR2) is shown.

DRl DR2

CR2

CRT
BR2|-0

BRI
G1

PUMP
h
C2
C3

B3 | C1 B2}<>

FIGURE 4.40 A flowsheet of a hydrocarbon separation process .

AH DSTWU fractionators have total 20 stages (including condenser and

reboiler) and two RECT models have 10 stages (including condenser and reboiler)
with no reboiler. The specifications, shown in Tables 4.9(a) and (b) are required
,

for simulating the process.

«PEN PLUS SIMULXTION OF CHKMICAL PLANTS 225

TABLE 4.9(a)

* Recovery of LK/HK in distillate Pressure (atm)

Block Lighi key Heavy kev Condenser (type) Reboiler

IK (HK)

Cl 99 of r»-C4 1% of i-CB 4 (partial condenser with 4

all vapour distillate)
C2 99* of t-C4 21 of n-C4 1 5 (total condenser)
.
15 .

C3 99* of 1-C5 4* of n-C5 3 (total condenser) 3

TABLE 4.9(b)

Block Condenser Distillate to feed ratio Pressure

(type) (mole basis) (atm)

CR1 Partial vapour 02 .

CR2 Total 05 .
15

Applying the Peng-Robinson property method, simulate the separation process

to compute the flow rates and compositions of all product streams.
4 6 An inlet Stream H supplied at SOT and 300 psia is compressed to 4000 psia by
.

the use of an isentropic compressor Bl. Stream H has component-wise flow rates,
shown m Table 4.10.
TABLE 4.10

Component Flow rate (Ibmol/hr)

mtrogen 100
hydrogen 300
ammonia 0
carbon dioxide 1

A low diagram for the ammonia process (Finlayson 2006) is shown in Figure 4.41.
,
f

B '

m-<
H-

0 H"

ED-0

Bl B2 B3 84

FIGURE 4 41 A lowsheet of an ammonia process

f
226 PROCESS SIMULATION AND CONTROL USING ASPEN

Stream Fl is mixed with the recycle stream F8 in a mixer block B2 operated at

4000 psia. Before introducing into the reactor, the mixer efluent F2 is heated in

f
block B3 to 900oF at 4000 psia. Note that the reactor (RGibbs) B4 runs at 900oF
and 3970 psia. In the next, the reactor outlet F4 is cooled in a heat exchanger
B5 operated at 80oF and 3970 psia. The flash drum (FIash2) B6 produces Streams
Bl and F6 at 80oF and 3970 psia. In the subsequent step, Stream F6 enters the
splitter (FSplit) B7 and 0.01% of it is used as purge. Finally, an isentropic
compressor B8 has discharged Stream F8 to the mixer block B2 at 4000 psia.
Using the NRTL thermodynamic model and the Newton's iteration method (from
the Data Browser, choose Convergence/Conu Options), simulate the ammonia
process to compute the component-wise low rates and compositions of all streams.

f
REFERENCES |
Finlayson, B.A. (2006), Introduction to Chemical Engineering Computing, 1st ed., Wiley
Interscience, New Jersey.
Seider, W.D., J.D. Seider and D.R. Lewin (1998), Process Design Principles: Synthesis,
Analysis, and Evaluation, 1st ed., John Wiley & Sons, New York.

Copyrighted maierlal
Part III

Dynamics and Control

1
using Aspen Dynamics
CHAPTER

Dynamics and Control of

Flow-driven Processes

51
.
INTRODUCTION

Dynamic -imulation of a chemical process greatly helps to understand the transient

behaviour Aspen Dynamics , which is tightly integrated with Aspen Plus is widely,

used or process design and control. This powerful simulator can automatically initialize
f

the dynamic simulation using the steady state esults of the Aspen Plus simulation .
r

Interestingly, when the ile containing the lowsheet is opened in Aspen Dynamics the ,
f

default control structures are already installed on some loops Usually, level, pressure
.

and temperature controllers are included where appropriate However these default ,

control schemes can be modified or even eplaced with other suitable control loops
r

available in Aspen Dynamic- package Note that there is a scope to include some
additional controllers for the used process Moreover this simulation tool provides a
,

graphical environment to show the process response.

To convert a steady state simulation into a dynamic simulation there are several
,

items that should be taken care of For example the size of all equipments must be
,

specified and the control structures must be devised For steady state simulation using
Aspen Plus the size of the equipment is not needed, except for eactors. On the other
,
r

hand ,
for dynamic simulation using Aspen Dynamics, the inventories of material
contained in all the piece* of equipment affect the dynamic response Therefore, the
.

physical dimensions of all process units must be known.

When the steady state Aspen Plus simulation is exported into Aspen Dynamics, we
need to choose either simpler low-driven dynamic simulation or more rigorous pressure-
f

driven dynamic simulation Pres ure-driven simulations include pumps and compressors
-
.

where needed to provide the required pressure drop for material low Control valves
f

must be installed where needed and their pressure drops selected For flow-driven
,

simulations , however, no such arrangements are required.

229
230 PROCESS SIMULATION AND CONTROL USING ASPEN

In the present chapter, we wish to study the dynamics and control of the low-

f
driven processes. For this intention, we choose a reactor (RCSTR) as well as a distillation
column (RadFrac) example rom the model library of Aspen simulator.

f
52 .
DYNAMICS AND CONTROL OF A CONTINUOUS STIRRED TANK
REACTOR (CSTR)
Problem statement

Ethyl acetate is produced in an esteriication reaction between acetic acid and ethyl alcohol.

f
acetic acid + ethyl alcohol ethyl acetate + water
A feed mixture, consisting of 52.5 mole% acetic acid, 45 mole% ethyl alcohol and
2 5 mole% water, enters the RCSTR model with a low rate of 400 kmol/hr at 750C and
.

f
1 .
1 atm. The reactor, as shown in Figure 5.1, operates at 70oC and 1 atm.

FIGURE 5.1 A flowsheet of a CSTR

Both the reactions are first-order with respect to each of the reactants {i.e., overall
second-order). For these liquid-phase reactions, the kinetic data for the Arrhenius law
are given below:
Forward reaction: A = 2.0 x 108 m3/kmol s
S = 6.0 x 107 J/kmol
Reverse reaction: k = 5.0 x 107 m3/kmol . s
£ = 6.0 x 107 J/kmol

Composition basis = Molarity

Here, k is the pre-exponential factor and E represents the activation energy. The reactor
geometry data are reported below.
Vessel type: vertical
Head type: lat
f

Diameter: 0,45711 m
Volume: 0.15 m3

(a) Simulate the reactor model using the SYSOP0 thermodynamic model to compute
the product compositions.

Copyrighied malerial
)YNAMICS AND CONTROL OF PI.OW-DHrVKN PROCKSSKS 231

(b) Report the default controllers tuning parameters and control actions used, and
constraints imposed on variables.
(c) Investigate the servo performance of the default liquid level and temperature
control algorithms and discuss the effect of loop interaction.
(d) Show the regulatory behaviour of both the controllers in presence of disturbance
in feed temperature.

Simulation approach
(a) To open the Aspen Plus Startup dialog box. click the desktop Start button, then
point to Programs, AspenTech, Aspen Engineering Suite, Aspen Plus Version
'
and then click the Aspen Plus User Interface. Let s select the option with
Template and then click OK (see Figure 5.2).

aWHl 1 I M*l oKlfcl MwiH -| I I I -I J

L .H ! -i I i

o-tt rt m mots; am -

bHft mm 1 ; :_ tm

FIGURE 5.2

As the next window appears (see Figure 5.3), it is appropriate to select General
with Metric Units and hit OK button.
Here we use the simulation engine at 'Local PC When the Connect to Engine dialog
pops up (see Figure 5.4), press OK. Note that this step is specific to the installation.

Creating flowsheet
The process low diagram, shown in Figure 5.5, includes a reactor, namely RCSTR,
f

with an incoming FEED stream and an outgoing PRODUCT stream.

Copyrlghiod material
232 PROCESS SIMULATION AND CONTROL USING ASPEN

Nil Zl ,
iJ_l
_
J J
I I 1 1

I Rk Separato'-r wth Engi<h Uhb

I Air 5«paraK> ntfi Meirc 'Jnti PelroleuT v-th r-lefr

r
.

.
3*3pe IPE S!fe»T Property kit Fhafnieceul cals hI Caenerai SmJalion vrth
fBark Smutatcn L Fhamaceuticala Mettle iJnts
r

H Polymefs Mh Engis C ba'>gyhr anoMr,

2Chemical3w<h English ijnts .

t
MMKca(/W cum/nr
i3 Chemicals w<h Heine Unrts Polymer wrO". Mibfe
j BMMMM »**> BfSlW> UnJs f. P,TT>fr«*atu / /.-eh Property Method Nooe
i S cl VM **h MeMc Lints £jj P>n)fr«(arur3y /. (h
FtewbwfoTB xi Mole
i jGas Process iMi English UrAa So!'*;-fh EngWi I

r
yScWswlh fAetrcU. Strearr report
,
G*n*rai wth English IJhta La Specia*/ QmiOk ccmpoabon Hole flow

"
£2 Specialty ChemV;a*s
d m alkjgy EntfishUnfts
dumelallurgy Mih Metnc Unfis Run Type

1 2] [Rwsheel 3

111
Fot Help prws Fl
,

Start I r- j j]Ch lei-5-Migiiio(IW | aw 2 - MCTtcB W . | - Aijob«/taoei Pro(ett . | Aepoi Pka

FIGURE 5.3

Connect to Engine

Server type: Local PC

User Info

Node name:

User name:

PassiAiord:

Working directory:

n Save as Default Connection

OK Exit Help

FIGURE 5.4
PVNAMICS AND CONTROL OF FLO\V DRl\-EN PROCESSES 233

M rn,-» 1
.
« I I ---

-
- -;

e i i i ysa
'

.*» MB Mtet acsT» ie«o-

-
-
.
i

FIGURE 5.5

Configuring settings
Hitting Next button, we get Global sheet of the Specifications form under Setup folder
in the left pane of the Data Browser window. Enter the Title of the present problem-
Dynamic Simulation of a CSTR'. change the Input mode from 'Steady-State' to "Dynamic"
"

and leave the remaining items at their defaults. The window looks like Figure 5.6.
? ).!
,

81 V
.,

* a

jLr
~

i
3 I 1 !-! -'in: q >!i.

4
-

Km "ttm "CT on

js- b

FIGURE 5.6
234 PROCESS SIMULATION AND CONTROL USING ASPEN

In the next window, as shown in Figure 5.7, the Aspen Plus accounting information
required at some installations are provided.

Hi _l 3 J J
_
j r _
I I I [»" -
I M I M

/GbUI] /OWbMoP -/AtcountIngj Di mn'ci |

O r-.i* - - 1. PVil i . tr. I . " .

Accouxlrurbar

lnoMtCflinpi<»
[V Hm>iA(«m j $etur*» j --v . I C(*ftm RMEton | PreiMeChange | Marv ai j Sokb | UwMoiw |

STREAMS RSttK nvdd REtwl RGbb. RCSTR RPKi Rewch

For **> cr-u Ft C \ a FoMan'Aoen »us 11 NOM RwpM b ot ntr --

FIGURE 5.7

In the subsequent step (see Figure 5.8), select Stream sheet with opening the Report
Options form under Setup folder and include Mole fraction item.

.
tfe E* V1e» 0*4 '<xk Rn tM Ufmy WMoh -.
f

1 hi .JSlal _J
i r-1 i i nr i -m \ |a! «|».|
-

3 »| j ,| H.|

P Gtf«<a(e»ii»xlsrJ*Mn-feKirt
am'o br rcUM r lDcmti itpvt
t

iWhua Fi«cMntt*m
P Malt P Mole TIT fGEfTM
0 RVMlOIMm
r Urn* r Mm.

.
_
l -r. - - -.

.
Jj

-
CH

ffaM tt PQbt. RCSTR HPhg ftfiad.

- s -

FIGURE 5.8
DVN VMICS AND CONTROL OF FLOW-DRIVEN PROCESSES 235

Specifying components
In the Data Browser window, choose Components /Specifications to obtain the component
input form. Filling out the table with the components (acetic acid, ethanol, ethyl acetate and
wateri involved in the present reaction system, the screen looks like Figure 5.9.

MM - . -

E-sC

aun
i 1

I
I*

cmt : fstnc f/wa

8 § O w&mh ai:s Tft
O
Re3''>
f

, ,,.

.
* - -« MUM

FIGURE 5.9

Specifying property method

Choosing Properties /Specifications in the column at the left side, one obtains the
property input form. As shown in Figure 5.10, we use the SYSOPO base property method.
i.|jrrxl

'
-

KW -U MSI *) nKI*M-aH 1 3)

9 «-.*«

. 2

HflUwj Wfae fft*

I 8 y Ki)
t COM, hc IP
t

FIGURE 5.10
236 PROCESS SIMULATION AND CONTROL USING ASPEN

Specifying stream information

Use the Data Browser menu tree to navigate to the Streams/FEED I Input I Specifications
sheet. Specifying the FEED stream by its temperature, pressure, flow rate and
composition, we have this window, shown in Figure 5.11.

oj -
u l-w
-

-
3 ****
* 1
-

- 3
3 (.-. j| 3
T 3
('- * z
h -

i= 3 -
.
3
pr (n -%\
I J

I "in

> > Mat l«

FIGURE 5.11

Specifying block information

In the list on the left, choose Blocks IRCSTRI Specifications to obtain the block input
form. It is illed with the given data as shown in Figure 5.12.
f

-
o -

# l-s-g-Q-m-g-
-

. j
'
T*4m ! . » Iff ..-*-. |.;a .l»-. |<j w> r

FIGURE 5.12
DYNAMICS AND CONTROL OF FLOW-DRIVEN PROCESSES 237

In the next step (Figure 5.13), select RCSTR I Dynamic! Vessel sheet under Blocks
folder and enter the reactor geometry data.
LMf ***** -**

JUIBI U _
51 nMi>H<H 3 I H .-J JJ -1 J
i r i i i fv i lei I Pi 3>M

. i

STftfAMS WSw fr-ipd Wgu* HGfcbi RCSIfl RPfc i BBwt*

C gUdms iw Pk* 111 MJU %

FIGURE 5.13

The forward reaction as well as the backward reaction is represented with their
stoichiometric coeficients and exponents in two sheets shown in Figures 5.14(a) and (b). ,
f

J l-i I IT .1 .IBI I IBI .

J
"
ti »i nl i « !

EAC

_
l ***

gff Vftrtc:

-
CH-
.
1-0 LIZ U

FIGURE 5.14(a)
238 PROCESS SIMULATION AND CONTROL USING ASPEN

Mai 1J Mfli MJ ahlahNN 1 Jl .! I"i _J El M M

f
_

i r i i i nr i m I issi
71 f. .1 I .1 I .<lr:- 7i »i nl «i uf\
-

UMFAC Grows;
Reaction No fyT
Readmit Pto<k«<t

Compgnert EKpononi Cofr wrKf*

'
.
'
v- i- .
rv
-

1 V
-

J 0"

Prop Sett

3 -"EEC
j PRODUCT
_

3 Becks
.
J/j 3CSTR

_
j Ow stry
-
Resctcr:
w R-l
J t eti e

ll -

STREAMS lSloe RYidd REqul RGbtu FiCSTR March

FIGURE 5.14(b)

The power law data for both the reactions provided in the problem statement are
entered in the two Kinetic sheets shown in Figures 5.15(a) and (b)

, nt Edt '.' en Can Toot Pir. fU Lfeery Wrxto-. He*

ar -i MM <<||AI 3 »l o\s
~

/Sto-Jwnwy *Kinebc| : - |
'

; | He«yG)mt>s
UfUF Grauo*
}l) AA- EAL-) EAC . VATER d
iwc Cte, | . -J
J/i Zcrvij&
f

| PIBpctfN r«*c(actor.)jr/To/'e-(E »'/I'l/ro)

;
"

;
i "
k. 200000000
[ W
.
.
. a P«* en i E::
_
l 0** To-
I
(qi«w.

> ) FEED
£ PRODUCT
.
1 SCSTR
y Reacscoi
_
J Ow-wy-
-

nn miiii

SIRtAHS

J- 90

FIGURE 5.15(a)
DYNAMICS AND CONTROL OF FLOW-DRIVEN PROCESSES 239

-.- 1 3

I I

r
.
«

f " If Till I | MME->w. I C3k-s RMcMn | Ck . | I

HD->

st e
-'

py.>- pew «ac cstr

FIGURE 5.15(b)

The status indicator in the above window reveals by the message Required Input
Complete that no more input specifications are required to run the simulation .

Running steady state simulation

As we click on Next button to continue the simulation the Required Input Complete ,

dialog box appears Hitting OK on the message, we are displayed the Control Panel
.

where the simulation messages during the run are recorded (see Figure 5.16).
- ?!

- MM

iT*0»r. Kmm . Pif

i i Q
W ji
D
| -ii?»i u -J- I .ic- .i-a.-i. || .n, am, .. .. -_ |. «ij

FIGURE 5.16
240 PROCESS SIMULATION AND CONTROL USING ASPEN

Viewing steady state results

In the next, select Solver Settings, choose Results Summary /Streams in the list on the
left and inally get the steady state results as shown in Figure 5 17. .
f

.md.m.x. 1 - |Ftei.*« Sumn»r Sreano - DUit Browser)

'
.

f Fte &» »ew D*> Todj Run Lbraiy WMow Htjp

Setup
1 I I 1
Omponeras

Streams
3 foumi r
" ~

as Bocks
Displw 3 Stie«mTatile|
Reacts

3fl Ccr.v«gefK«
'

1 Conv Options
41 d1 d
£0 Conv Options Volume Flow cumyhi 24.497 24 01S
O S«up Enthalpy MMkcal/hi .
35035 35 951
o 0M0 Bsslc
o OMOAdv Mole Flow km*hi
o lSSQP Base M 2ia0CB 87110
0 LSSQP Ad*
EAl 180.000 57110
Tear
EAC 122,890
1 Convei ence
Conv Ortef WATER mooo 132.890
Q| Sequence id* fan
Rowsheetng Ctouons
AA 0 525 0 218
Model Analvsis Too .

EO CcHguration EAL 0 450

.
0 143
.

P«Rit5 Summaiy EAC 0 307

Q Run Status WATER 0 025 0 332

Q Streams . .

Convetgence

Jdll
Results Avaisse

STREAMS ' RSIok: RYieM

.
1 . S -U-E-U-
REqui RGibbs RCSTR RPlug RBalch i
RofHeb.ptessFl C;\ .gFolde<s\A9penPlu3l1 1 : NUM

| j£]Oaiaer5-McmsollW..| 4]Cha(»er2-Wt!roseilW...|| Aspen flu. - SIimSI.. Adohe olal Pntesai |« iS?t}); 1545
t

FIGURE 5.17

(b) Exporting dynamic simulation: In the subsequent stage (see Figure 5.18),
we wish to carry out the simulation dynamically. Accordingly, at this moment,
we have to follow the sequential steps noted below:
Click on Export from the pulldown File menu or simply press Ctrl+E on the
keyboard.
Open the Drive and then Folder where we want to save the work as a ile.
f

Type 'ChS S RCSTR' in the File name ield.

Choose 'Flow Driven Dyn Simulation (*.dynf & *dyn.appdf)' rom the options
f

available in the Save as type box.

Finally, hit Save button.
Also, save the work done as a backup ile (e.g., Ch5_5.2_RCSTR.bkp). We may use
f

the same folder within which the exported dynamic simulation ile is saved. Originally
f

many iles are saved along with the backup or dynamic ile. Anyway, we are now ready
f

to run Aspen Dynamics and we may quit Aspen Plus.

DYNAMICS AND CONTROL OF FLOW-DRIVEN PROCESSES 241

3 ±ljili<JF; »l jlalH
. I I I

.
1 , 1
-

9 Ljii=v.
Tt*-

CJ Omwrngnt **, MW
Can***

I Pc««-««r«; Ctt '-* M

| M«W .V*** Tn»» -

EAL

WATER
SrniatTi r irTi i -o/r «Caned |

Jjj

8 . S -O'll-O-
cvi
| 0>»l»5-rfco...| *]am2-«*n,. \.*]Mll<m,-lic..\\ <»«,PIU.-C , '; eJu t |'« igsj

t
f
FIGURE 5.18

Starting Aspen Dynamics

As we click the Start button
point to Programs, then AspenTech, then Aspen Engineering
,

Suite, then Aspen Dynamics Version and then click on Aspen Dynamics a blank dynamic ,

simulation window appears as shown in Figure 5.19 .

f*e Eat Tood ftowtfiMl Rr. VMoh Hcb

D H SQ W |Sl»dySl.lc j-J
3
r «-Jt c ioos j a, k it

It- Lfcr- f,:.»

Jaw
.

FIGURE 5.19
242 PROCESS SIMULATION AND CONTROL USING ASPEN

Opening existing simulation

To open the low-driven dynamic ile, select Open rom the File dropdown menu or
f

f
press Ctrl+O on the keyboard. In the Open dialog box, locate the drive, then folder and
inally the ile 'Ch5 52 . RCSTR' (see Figure 5.20).
f

_ _

ij is H *»Q IS

UIMl
r »-
-

SSmJatn
> Ft OinMITKt

l-llff. |.|9. HT» H

.
Chi 5i
_ _
CSTR !; Ch5 EJ BCSTB
i _ ,

£l Hi

5 *«» ICM .
U f
.
. ITS | CWn |

Opin
B i -r

FIGURE 5.20

As we press Open button, the process lowsheet consisting of the automatically

inserted level (LCI) and temperature (TC2) controllers appears (see Figure 5.21).

fte &* Urn Twh HswhMt «jn Wr4» tft

-
Li

Tt MM [MM :"
u
'
i
t- - - - .
-Ill
f

. .

. ..
..

Li I
m
lad *>.

FIGURE 5.21
DYNAMICS AND CONTROL OF FLOW DRIven PROCESSES
-

243

Details of the two control loops, to be used inally, are given below

f
.

Loop 1
Controller: LCI
Type of controller: proportional (P) only
Controlled variable: reactor liquid level
Manipulated variable: product flow rate
Controller action: direct

Loop 2
Controller: TC2
Type of Controller: proportional integral (PI)
Controlled variable: reactor temperature
Manipulated variable: heat duty (cooling operation)
Controller action: reverse

Note that the direct acting control system increases the output signal as the input
signal to the controller increases. On the other hand, as the input signal to the control
structure increases, the output signal from the controller must decrease for the case of
reverse acting control strategy. The direct acting control law has negative gain and
increase/increase (or decrease/decrease) term is commonly used to represent it For the .

reverse action, increase/decrease (or decrease/increase) term is used and controller gain
has positive sign.
The reactor flowsheet includes two (LCI and TC2) single-input/single-output (SISO)
control loops. Therefore we can say that this is a multi-input/multi-output (MIMO) or
,

simply a multivariable closed-loop system .

In Aspen terminology the process variable or controlled variable is denoted by PV,

the set point is represented by SP and the controller output or control variable or
manipulated variable is abbreviated by OP .

For the example CSTR system level and temperature controllers are automatically
,

implemented when the Aspen Dynamics simulation is created The default values for
.

SP , PV and OP are computed from the steady state simulation. To achieve better closed-
loop process response the Aspen-generated control structures can be modified or even
,

replaced by the suitable control schemes available in the control library of Aspen
software .
In addition, the default values for controller tuning parameters, such as gain,
integral time derivative time and so on, can also be changed.
,
,

Most of the control strategies are easily tuned by simply using heuristics. As
suggested by Luyben (2004) all liquid levels should use P-only controllers with a gain
,

of 2. All flow controllers should use a gain of 0.5 and an integral time of 0.3 minute
'
also enable iltering with a ilter time of 0.1 minute). The author also mentioned that
f

the default values in Aspen Dynamics for most pressure controllers seem to work
reasonably well But temperature controllers often need some adjustments.
.

Viewing default values of variables

In Aspen Dynamics, the steady state values of process variable and controller output
ar displayed in a table At this stage the set point value, displayed in table, shown in
.

,
244 PROCKSS SIMULATION AND CONTROL USING ASPEN

Figure 5.22, is same with the value of process variable. To show the results table of
loop I, highlight the controller block LCI, press the ight mouse button, go to Forms

r
and then select Results.

'
-
i .mi m i -- w*

ffes

El &
m £

- (M M Has M ! ! i lull aw M-M

11 ..1 in

FIGURE 5.22

We can have the same information in a faceplate, shown in Figure 5.23, simply by
double-clicking on the block LCI. But as a difference, the units are not mentioned here
with the values of SP. PV and OP.

.
. ;i J
-
.

W ,1V- 3
>

IP
mar

urn

FIGURE 5.23

Gopyngt-
DYNAMICS AND CONTROL OF FLOW DRIVEN PROCESSES -

245

Similarly, we have the results table, shown in Figure 5 24 for the temperature loop 2. .
,

E3B i«ra
-

r g <: |.v» J Ji i K >ft l|

-
frol-

r-O-

SiBulaticn resd? tor soJuiion

8 equadons were not elininated because they had i
*
"
(jtal ol 109 equations (29 5'/,) verc sUaiMted
ilation has 36J variablea 2(,0 equations and 91

FIGURE 5.24

Modifying controller tuning properties

First we need to open the sheet that contains the controller tuning information. To do
so for the level controller, highlight the controller block LCI, press the right mouse
button, point to Forms and then select Configure (see Figure 5.25).

|iirjf;j>,l'l. fi S I PPQ UCI l-Q

r,.-:n .

rwutlolis'm* bo .tiHinatad be aus* they had residuals over J»-00?

oi IH equ»ii2rii (5 J weie elmir.sted

'
.

LMien has HI *ui»tUi ito equiitjdni ar.d 'ifie

O j ct
-

Ij JOgggj j j Jctf Voty P-Vet || l Aspen gh f* J - * ,stM

FIGURE 5.25
246 PROCESS SIMULATION AND CONTROL USING ASPEN"1

Alternatively, to obtain the Configure dialog box, irst double-click on the controller

f
block LCI and then click on Configure symbol (yellow colour) in the faceplate as shown
in Figure 5.26.

ll(i*H«a IS {Dyn.mlc 3 mvo t: tin a 13

r tt .t ghF* J «i a 'a i' 3

C SsD-
U 1
.

3
«liBtn»ted becAutA t . hsd residuals ouer le-OUS

Istion has J63 vortabies HO equations and 969 non-zeros

FIGURE 5.26

By the similar way, we obtain the tuning data sheet, shown in Figure 5.27, for the
temperature controller TC2.

Bf H » Q <& If {Dynamic 3 »»« «« CB'JetiHDaia

o i

u
a» F f.A

(MMM |a FT-3
£3
r Dmo>

d5.

FIGURE 5.27
DYNAMICS AND CONTROL OF FLOW-DRIVEN PROCESSES 247

Note that the default Operator set point value is the steady state value of the process
variable (PV). The reactor liquid level is the PV for loop 1 and reactor temperature for
loop 2. Bias signal is the output rom the controller when the error (= SP-PV) is zero.

f
From the results tables shown earlier, it is obvious that the error is zero for both loops.
Therefore, Aspen Dynamics has set the value of OP as the bias value.
The proportional integral (PI) control methodology is automatically installed with
default values for the controller gain (= 10 %/%), integral time (= 60000 minutes) and
derivative time (= 0 minute) to monitor the reactor level. However, as mentioned
previously, the proportional-only controller with a gain of 2 is sufficient to effectively
control the liquid level. Remember that to make the integral action inactive, we can
use a very large value, for example 105 minutes (even the default value of 6 x 104
minutes may also be accepted), for the integral term. For loop 1, the controller action
should be Direct' as set by default (see Figure 5.28).
'

Baa
Ffc MM Took Af) Wltttm H*

|DynBfnic ]
"

U 7f 3 ii t i*
f

BLOCKSfTCn Co mv

Op**to» ie* part. jO 314029 K

r : i

Bw |21083 6171
Gat

jiooooo d
L

m m ConOofc* «aon -
-
-

- -
-

t cj
f
f

Integrftting tro. 62 43 to 62 44
Integrating tr » 62 44 to 6? 45
Mograt ing fro* 62 45 to 62 46
Step 3074 Tiw 6 2504«+001 step size- 5 OOOOe-002 step facto 1 5000e+000 accepted

j
wm -.

1* Wggg [ ' Adotoc Vroe P.o<mc

FIGURE 5.28

In loop 2 , we prefer to employ the proportional integral controller to monitoriven.

the
reactor temperature. In data sheet, shown in Figure 5.29, the default values are g
The TC2 is truly a reverse acting controller. However, we may adjust the values of
controller tuning parameters (gain and integral time) during the closed-loop study if
the control performance is not satisfactory.
Modifying ranges for process variables and controller outputs
In the Configure dialog box, hit the Ranges tab and get Figure 5.30 for level control loop.
248 PROCESS SIMULATION AND CONTROL USING ASPENIM

iDynamlc ii m * 93 O ci rj a

f
r ft -jt G,.t| 3 iL Si i 'i

f
5

luwng 1 R«v" 1 FHwng | 0H>« LCI

Ope>«ioi ;a>pan p 1

Mi
G«n h
tmegral dm --

w-lPRoSucrt-H .
,
.

['' . v- tme I

C.>**i Chwi
r Died

Revwte

IfWiataeVabei | Htto

0|>e"i Lbra So ve*

OpBoni

m
alftulation ready for solution 3
equations were not eliMinated because they had residuals ever le-OOS
k total ol 109 equations (29 S'-i) were eliminated
Simulation has 363 variables 260 equations and 968 non-zeros

Rea*- Rea V a Iocs

Oiaplm UChajtef S -MoMsflW j Mobe Pootm PrrfrnJ [ .
-

lAjpenOrn-c.

FIGURE 5.29

t ts -n Dyn-wwca Ch5_5 2_HCSlH.dyrf

f
f

Be Wew Tao* Run Wndow Help

Q SniMoh

a Bi.ocKsnrncorfKi

Piocott voiabie

Ranjsmawwm (l 8280M (m

o
TC3

Rang* m»«num |l2167 2343 |

P Cfetorang«

Ct>0>n btT»y
.us S- Ktr
Ootore

Simulation ready lor xoluiion 3

equations were not eliminated because the? had residuals o*t
i total of 109 equations (29 S'O were elminated
"

mulaiion has 36} rarimbles 260 equations and 989 nae~:ero«

M ty«m>ce«a
I UCh e'

FIGURE 5.30
DYNAMICS AND CONTROL OF FLOW DRIVEN PROCESSES -

249

As shown in Figure 5.30, the default ranges for both the process and output variables
are too large (± 100% of the steady state values) It may be practical to consider the .

following constraints.
Process variable
Range minimum: 0.6855 m (25% subtracted from steady state value of PV)
Range maximum: 1.1425 m (25% added with steady state value of PV)
Output
Range minimum: 15812.7 kg/hr (25% subtracted from steady state value of OP)
Range maximum: 26354.5 kg/hr (25% added with steady state value of OP)
Entering these upper and lower bounds, we have the window, shown in Figure 5.31,
for the level controller.

Ul«l
ftv Ut» Wnd?* He«

di*h - a <e [d s 3 » .i h « oaga eslaiimm :

f
r t 7t eiloos J ,w ii 5V s-: ;
t

h
jl M253G h PBODUCT)-C|>

Oulf/

S firty. BUMMM
|1SBI27

91
l-wtions <"-ie nol elikinst«d Ivrrsuse they had residuals over le-OOS
h total ol 109 equations '29 S;| vete .Uaiaat«d
StTOlation has H'i v«ri*&lM 260 aqtrnttoM end 989 iior-:eros

Vital iV«nw:*00(

FIGURE 5.31

Again the typical ranges for the temperature control loop are noted here.
Process variable
Range minimum: 52 50C (25% subtracted)
.

Range maximum: 87 50C (25% added).

Output

Range minimum: 1 1447 MMkcal/hr (25% subtracted)

Range maximum: 0 6868 MMkcal/hr (25% added)

The corresponding Aspen Dynamics window is shown in Figure 5 32. It is worthy to .

mention that the negative value of heat duty reveals the cooling operation (heat removal).
250 PROCESS SIMULATION AND CONTROL USING ASPEN

o *y .a m w |n,..mic

, .

,r ..- j 1 1«t5) |MMlS3R

'
9

Editing Siaulacion

Validation coBplete

urrent snapihois havo been saved to 11 le (r-pAflOOO anp

i - I
i

FIGURE 5.32

Both the control algorithms are completely specified above. In the next, the controller
performance will be examined in terms of set point tracking (servo) and disturbance
rejection (regulatory).
(c) Starting the Run: Before running the program, we must be accustomed with
some frequently used items of the toolbar as described in Figure 5.33.

Step Re-start Simulation

c 601 lacJt R» Wnto

. IMJSI

Run Pause Rewind to a saved Snapshot

FIGURE 5.33
DYNAMICS AND CONTROL OF FLOW DRIVEN PROCESSES -

251

We wish to carry out the simulation for a certain time, say 5 hours To ix up this .

f
time period, select Pause At from the Run pulldown menu or simply press Ctrl+F5 on
the keyboard. Then select Pause at time, type 5 in the ield or whatever we want and

f
click on OK (see Figure 5.34).

yrr&ntmsmfmsssi : .
,,. 1.1

a uai
,

, s - MA

c; |W)-

1 « 1 : O -

jj j ' (fnci cil C-

tC5tR
f

S i 1
.

i ;;;.-,;"',:::/;;:,:'m;.;:'::;f iv,i:
,
J

FIGURE 5.34

Viewing servo performance of LC1

As we double-click on LCI block in the lowsheet, first the faceplate appears. In the
f

next, press on Configure and Plot symbols in the faceplate. Alternatively, to open the
faceplate Configure dialog box and ResultsPlot dialog box, first select LCI block, then
.

choose Forms and subsequently press one-by-one on faceplate Configure and ResultsPlot, ,

respectively Judiciously arrange all three items within the Aspen

.
Dynamics window
(see Figure 5 35) so that we can properly observe them together.
.

Eiaagi ' 'i Baaaa wpw-

! .

r nit a«(o» 1] i * "t

< {MB

n mm MUUI

ma : -

.
ja_!J
nMm I fmg, | <
! r.j J
-

>.,,
pi KJS» ,

|r~ 1"
l
~

1
-

,
1 «, 1

I ogji I at.
t

FIGURE 5.35
252 4- PROCESS SIMULATION AND CONTROL USING ASPEN

First make sure that all the items in the Configure dialog box and faceplate are
correct. In order to execute the dynamic closed-loop simulation click on Run button in ,

the toolbar. During the simulation run, give a step change in the set point value of
reactor liquid level from 0.914029 to 1.1 metre at time = 1 5 hours. Typing the new set .

point value in the faceplate, press Enter button on the keyboard so that the Operator
set point value in the Configure dialog box also changes automatically to 1 1 . meter
Note that the new set point must be within the specified ranges of PV In Figure 5 36 ,

the servo performance of the level controller is depicted for 5 hours as selected earlier
Obviously, the plot also includes the manipulated input profile .

Coopoient Lots
} Dagncsl'cs
*
SS

OPgHi 1210356171 "

t'POC I
IT
o JDJ*]
t

Tuning ] langes | Ftong | Olhw

Owralw set pewit p 1

Twmg paramtf er,

|21083.61 RCSIR

1 C; Plot 8LOCKSCLCl-l Reia»«Plol

: lrJe.;tdlme: limtjo |
m

I" l d
-

De<iv alive time: "»

If5 11
'

Cpndolei adkm
: Direct
-
( Reveise
||
:o» 4 97
-
obi 4

0 0.5 1 15 2 25 3 35 4 45 5 1 5000e*ODO. MDCepted

Run coaplete Time Hours

Paused

FIGURE 5.36

Figure 5.36 represents an excellent set point tracking performance of the level
controller (P-only). Obviously, the LCI provides process responses with almost no
deviation from the desired set point value and with very fast approach to reach the
target liquid level.
Notice that the above plot can be edited by right clicking on that plot and selecting
Properties option or by clicking on that plot and pressing Alt+Enter on the keyboard.
In the properties window, user can modify the title, axis scale, font and colour of the
plot. Alternatively, double-click on the different elements of the plot and modify them
as we like to improve the clarity and overall presentation.
Now, we will discuss the interaction of two control loops. When we introduce a set
point step change in the reactor liquid level, the LCI scheme attempts to compensatell
for the changes through the manipulation of the efluent low rate. This, in turn, wi
f

t
disturb the reactor temperature and loop 2 will compensate by manipulating the hea
DYNAMICS AND CONTROL OF FLOW DRIVEN PROCESSES
-

253

removal of the CSTR appropriately. Thus we can say that loop 1 affects loop 2. In Figure 5.37,
Aspen Dynamics window demonstrates the loop interaction under the same set point
step change (0.914029 to 1.1 metre at time = 1.5 hours) as considered previously .

PS
~

rKjTj F= E],. ;- %

o
.

BEDS
1 - 3

J _JSS_J

FIGURE 5.37

Viewing servo performance of TC2

As described in Figure 5.38, open the faceplate along with Configure dialog box and a
blank plot sheet. Before starting the simulation run, carefully check all entries in the
faceplate as well as Configure dialog box. In the next, choose Initialization run mode in
the toolbar and then run the program once. After completion, go back to Dynamic
mode from Initialization mode (see Figure 5.38).

ehj
f

FIGURE 5.38

Now we wish to conduct the servo performance study for the TC2 controller with two
consecutive set point step (pulse input) changes in reactor temperature (70 -) 750C at
time = 1 2 hours and then 75 -> 70oC at time = 3 hours).
.
254 PROCESS SIMULATION AND CONTROL USING AS PEN

Clearly, the proportional integral controller with default tuning parameters values
shows a high-quality temperature tracking performance. As stated if the performance ,

of any controller is not satisfactory, we have the option to tune the parameters simply
by trial-and-error method.
If we introduce a set point change in the reactor temperature the TC2 controller ,

takes necessary action with adjusting the heat duty to compensate for the changes .

But interestingly, the liquid level remains undisturbed. Figure 5.38 confirms this fact .

At this point we can conclude that loop 1 affects loop 2, but loop 2 does not affect loop 1 .

Actually here the interaction is in a single direction.

(d) Viewing regulatory performance of LCI and TC2: To perform the
regulatory study, we need to introduce at least a single change in the input
disturbance. However, here we consider two subsequent step changes in the
feed temperature. Initially, the feed temperature changes from 75 to 80oC at
time = 2 hours and then the temperature (80oC) returns to 750C after 1.2 hours .

To change the feed temperature twice as prescribed above, irst we need to open

f
the feed data sheet by double-clicking on the FEED block in the process flowsheet
(see Figure 5.39).

-
Ch55.2 BC5rRd»rf
_

Bt TooB Rui Van** Hefc

Alllms

jDynamcs o -

; SyiieriLbrjry
,

Q Table STHEAMSfFEED") Re«*« KH

Description Value linrt*

F Tolnl noSe ItoW

fm T JalfTiaaa Bow 210836
T 75 0 .

P Press U'e bai

vf Milar *api>f tricion oo
n Mrls! >(ihftlp> - 87 5«7I
Rho 16 3267
MM Mohii msight 52708
mn
uebnictan 0t25
ZrfEAC Ucte rrocton

Lkie Iradton

Solver Componert
tXlOTrl LMs
f

OUgnogucs GMmIc
ntegrating fra» 4 96 to 4 97 1
Integrating fro« 4 97 to 4 98
Integrating fro« 4 99 to 4 99
Integrating fro* 4 99 to S
Step 361 Time- 5 0422e+0O0. step size- S 0000e-002. step tactor* 1 S000»*000 accepted
Run complete at 16 45 29
il I

| Jaae S Xerox* Wort || 'U Met* K bm PxAatr j

FIGURE 5.39

In the subsequent step, run the program with Initialization run mode. As it is
inished, go back to Dynamic mode. Then, open the plot sheets for both the controllers.
f

The regulatory behaviour is illustrated in Figure 5.40 giving changes in feed temperature
DYNAMICS AND CONTROL OF FLOW-DRIVEN PROCESSES 255

are not
in the feed data sheet. For brevity, the faceplate and configure dialog box
included in the Aspen Dynamics window, shown in Figure 5.40.

2 a ts 7 I Dynamic

3
-

r u loo? s

scripts ] VUue | Unrrt

r RM -WOO - Mf
-

Ot* :iC£3=
-
-

trx*'*-** C fi

U
| _

p Pre»vc j11158 tr

j nr.urT
-

Ml
in

'1 r fidcn 0 *2f ijnctVnc-l

Mofen-tdian |0.B imMV-nc*
a

53 a

T mpeiatuie loop

-
i
; So

1
3
0 05 1 1= 2 25 3 35 4 45 5
Time Hems 000e+000. accepted

FIGURE 5.40

It is obvious that the reactor liquid level remains unchanged with a change in feed
temperature since there is no interaction involved On the other hand, the reactor .

temperature is disturbed However the TC2 controller provides satisfactory disturbance

.
,

rejection performance under this situation.

So far we have studied mainly the closed-loop behaviour of a reactor system coupled
with Aspen-generated control schemes. We did not include any additional controller with
the CSTR model In Section 5.3 we consider a distillation example to elaborate this point.
.

5 3 DYNAMICS AND CONTROL OF A BINARY DISTILLATION COLUMN

Problem statement
A partially vaporized binary mixture of benzene and toluene enters a RadFrac
distillation model as displayed in Figure 5 41. .

he column has total 25 theoretical stages (including condenser and reboiler) and
operates at a pressure in the reflux drum of 18 psia and reboiler of 21 psia. The
ow rate is 285 Ibmol/hr and reflux ratio is 2 2 (mole basis) .
.
256 PROCESS SIMULATION AND CONTROL USING ASPEN

Feed Specifications

Flow rate = 600 Ibmol/hr TOP o

Temperature = 225° F
Pressure = 21 psia FEED

Feed stage = 13 (above stage)

Component Mole %
BOTTOM
benzene 45
toluene 55

FIGURE 5.41 A flowsheet of a distillation column .

In Table 5.1, the reflux drum and the base of the column (the 'sump' in Aspen
terminology) are specified. It is fair to use an aspect ratio (length to diameter ratio) of
2 (Luyben, 2004).
TABLE 5.1

Item Vessel type Head type Height / Length (ft) Diameter (ft)

Reflux drum horizontal elliptical 5 25.

Sump -

elliptical 5 25.

The column diameter is 5 ft. Use default values for other tray hydraulic parameters
(e.g., tray spacing, weir height and weir length to column diameter ratio). Consider log-
mean temperature difference (LMTD) assumptions for the total condenser. Actually the ,

LMTD is calculated using the temperatures of process luid and coolant In the simulation. .
f

assume constant reboiler heat duty and apply the UNIFAC base property method.
(a)Simulate the column model to obtain the products mole fractions.
(b)Keeping the default level and pressure control algorithms unaltered, inspect
the servo as well as regulatory performance of a proportional integral (PI1
controller that is required to insert to control the benzene composition in the
distillate by manipulating the reflux low rate.
f

(0 Devising an another PI control scheme to maintain the benzene composition in

the bottom product with the adjustment of heat input to the reboiler, observe
the interaction effect between the top and bottom composition loops.

Simulation approach
(a) Select Aspen Plus User Interface and when the Aspen Plus window pops up.
choose Template and press OK. In the subsequent step, select General with
English Units and hit OK button. To open the process lowsheet window, click
f

OK when the Aspen Plus engine window appears.

Creating flowsheet
From the Model Library toolbar, select the Columns tab. Place the RadFrac model on
the lowsheet window and add the feed as well as two product streams. Renaming all
f

the streams along with distillation block, we have Figure 5.42.

DYNAMICH AND rnNTKOI, OP KI-OW DIUVKN I'lfOCKHHKH 257

.
imaimAJmm lAdftiauugj*) ji.ojjiIzJII

o: 6 -i

'
twin TmT

FIGURE 5,42

Configuring settings
Ah we hit Nt'xf followed by OK button, the ROtUp input Corni appcarH (h«m* Kitfun! .43).
The diHtillation problem Is tilled oh: 'Cl0S6d-l00p Performanct; of a DihI illation ('olumn'
Iniportuntly, une tin- 'Dynanne' input noxle

mltiMI

lit I:: | n

NiMH
I
(
(

FIGURE 6 43
258 PROCESS SIMULATION AND CONTKOI, IISINC ASPEN

Figure 5.44 includes the Aspen I'lus (iccon/ilin infornuition We can fill up the
.

Accounting sheet with any name, number and ID.

'
-
i '1
t t vW o**

f
mm jj ai LiinsMibd ad j ..ijj-j -j ai i i

jJgjJT; j Mil illR"ZI uL..]

O Ma
o - J-.

f> 1 " .
!(. [Ilflll,

I - MCM
fToirTiTTT
I

_
J M.>i*t 4» M 1><»

1 DSTWU DHH nwJFp £.ii*;i MJ/tac SCr-oc

Pei(iJ t»c Piefi« BvcWi

a -1* prt-M 11 C - 0 :s*Kt5-/Jeei". (Vfl !1 I HUM (leoulcillnM

Uvain . I -l|a. n/ ' Hi'W.O | ' } rhjiHg fi tVio«imVcrt [[ Aapcn fits »?t>8 111'

FIGURE 5.44

We like to see the composition of all incoming and outgoing streams in mole raction

f
basis in the inal results table. Accordingly, we use Stream sheet under the Report
f

Options of Setup folder (see Figure 5.45).

rif F* Mix Otfa fir F*<3 l±rtv Wtwjo- Hrfc

i MHl iJM«l _
BMSLSfcalgl "'I "'I I I "I "I ~l g
""

JJ I I I FV . _
LLM_Lia|
"

FlipdrtOplta 351
bnnil | rbwihWI | BM ./SIiiimi| Piorniy [ ADA |
0 S*-*. ",
'
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.

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O -

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. J 1

FIGURE 5.45
DYNAMICS \NI) CONTUOI, OK I'l.OW DRIVKN ('UOCICSSKS 259

Specifying components
'

From (In- Data Brow.scr, hoIoc! ( oniponcnta/Speeipcctions to open the componont input
'

lorm In ill'' lahlc. shown in l- i mc S 1 (> Ihc Ivvo species are dclincd .

UM M» fVA I** Unfti

h d .Igil I lal -iW

0 H""

Qp
him nl

ni.urm rrniioii mo
Itarimi Ophor*

I Ml/ tC Qrm)«

ml
Mi

Wiwii d b rit»i».; li. i Muifi« ..ti eMtoi 0«oN>i«>

FIGURE 5.46

Specifying property method

,, >(. li'i on Hm- Nil
choose Properties/Specifications and gel the property Inpul form.
.

in Aspen simulation a property method originall} Includes several models for calculating
,

the physical properties For the distillation example, set the UNIPAC base method b>
scrolling down (see Figure 5.47).
Specifying stream Information
,"
next, (.pen Streama IFEED IInput ISpecifications sheel Entering the given
Values lor all State variables and teed eompo ion Ihe slream mpnl lorm looks like
.

Figure 6 'IH

Specifying block information

,"
lefl pane ol the Data Browser window select Blocks IRADFRACI Setup to open ,

Configuration sheet and then insorl the required datn (see Figure 5.49)
260 . PROCESS SIMULATION AND CONTROL USING ASPEN

> He E* Wew Oati Tooli t FW Ut»ry Window H>

f
JjiJ J J
_
LJ~- I I I Jje
HU I J±hJill -ZliiJuLJgij
Relerenced |
0 Slream Oae* Piowxtyrwthocbt moded
B | S<i)*ww
PtocMt IVP*
Picwtymethod juNiFftr Tj
Q Cutlom OMi B«e meitwd jufJIFAC r Modlv P<ope<iy rmdett
O Repwt Opicna Heniy corrvcuwitt [
'

PelTOteum cflloHston option* 3

Fiw-watm method 3
~

b t-end Pfop«i«i W«le< »otut*y 3

P»e<rfoc«npOfi«rt9
3
Etecddyte c ciisbon option:
; O MrCorpi Chamtiiy ID r
17 . : .

_
Potjma

B l Property Method!
f

.
_
j EHi Un
9 CD Wotecd» Slftjcti«

a
LJNIFAC wlh AedKrh-Kwof.g elation d tlate and Henty't law
Qt | Prap-S«ts
£ r j Adveoced
hpot Complete

[it* MbMi/Splilleri j Sepstfon | HhI Exchangees Cohaint { Readou | Piettue Changeft | Manptiatori | Sokh | UteiModrt |

STREAMS DSTVAJ Di'.H FladFiac E act Mijfrac SCf<ac FelioFisc fWeFrac BaichFrac
C \ d Fitfcn'Asien dd IM HUM

| .'- JOMptef -Mgoicft W j 0 «S-Hcto W j ) tjMftJ Twig-Mcn:«< |j tmpmn Pka

FIGURE 5.47

-
fi- ?d( [Ula T04I1 Run not tibrary Wride)v< HH'

d|b;|h| l l Nel ¥?! akiahl-gl i n.|

la]
3 J*J <<J( i 3 >>J Q|aJ n J
"

O Report Ot*or< 3 ClI.C FlsshOplioBt I I EOOpiw: I

-
ConpaTerts
Speofcebont Siij!li«mf»m» )yMIXED
Asw'Bend
"

$ JJ Peiro Owaclefuabon
Lghl-End Prcpofto
3 |M*f 3
I d
'

Pteudocorvowta 225
CotrpGrem Vofcje

SEN2ENE 015
HonyCcrrps d TOLUENE 055
UNIFAC Gtohm
I p.. d
) Comp-Groupi
> Compel
d
_

B _
) Potywi lanlltow [Mote
-

.J/) Prtceft ee |600 d

*
Property M«hod9
Cj E«mal»3n 1 J
.
_
j Wcc iaf Sbucture
W p»wwet«
'

,
i Data
_
J MM*
-
Ji Pr -Sett
$ MvarvceC

.
_
| BOTTOM !oUI F
-

Jl) FEED
o

EOVMMu

STREAMS 1 DSTVA)
FoH* PMF1
Book

FIGURE 5.48
DYNAMICS AND CONTROL OK KLOW-DKiVEN PROCESSES 261

cz:

'-
a
Mr

a
3
9

-
ap>
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FIGURE 5.49

In the subsequent step (see Figure 5.50), fill up Streams sheet with informing t\
location 113th tray (above stage)!.

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FIGURE 5.50
262 PROCESS SIMULATION AND CONTROL USINKi ASPEN

In Figure 5.51, the column pressure profile is defined.

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FIGURE 5.51

Entering heat transfer data for condenser and reboiler

Next select Dynamic under RADFRAC of Blocks folder. There are three heat transfer
options: constant duty, constant medium temperature and LMTD. As mentioned in the
problem statement, the condenser heat duty depends on the log-mean temperature
differential between the process luid and the coolant. The coolant inlet temperature is
f

set constant. Here the temperature approach represents the difference between the
process temperature and the coolant outlet temperature at the initial steady state
Note that among the heat transfer specifications the coolant inlet temperature and ,

temperature approach may vary during a dynamic simulation whereas the specific ,

heat capacity of the coolant is ixed during a dynamic run (see Figure 5.52).
f

For the reboiler , it is fair to use constant heat duty computed in the Aspen Plus
simulation. However , the reboiler duty may be changed at dynamic state either by
manually or automatically with employing a controller (see Figure 5.53).
Entering geometry data for reflux drum and sump
The reflux drum and sump are specified in Figures 5.54(a) and (b) with their given
geometry data. The information on vessel orientation, head type, length (or height)
and diameter are used to compute the vessel holdup .
DYNAMICS AND CONTROL OF FLOW DmVKN PROCKSSP S -

263

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FIGURE 5.53
264 4- PROCESS SIMULATION AND CONTROL USING ASPEN

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FIGURE 5.54(b)
DYNAMICS AND CONTROL OF FLOW-DRIVEN PROCESSES 265

Entering tray geometry

The example column has total 25 stages-Stage 1 being the condenser and Stage 25
the reboiler. We already have inserted the necessary information for stages 1 and
25. Now, we need to inform the simulator the tray geometry specifications for stages
2 through 24. Note that the tray holdups are computed using these geometry data
(see Figure 5.55).

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FIGURE 5.55

Running steady state simulation and viewing results

Hit Afecf button and press OK to run the steady state simulation. Finally, the result."
table , shown in Figure 5 56, is obtained. At this time, we should save the work.
.

(b) Exporting dynamic simulation: For process dynamics study, we wish to

export the steady state Aspen Plus simulation into flow-driven Aspen Dynamics
simulation giving a ile name of'Ch5 53
.
RadFrac'. Then close the Aspen Plus
f

_ _

window .
266 PROCESS SIMULATION AND CONTROL USING ASPEN

E* Vtev Data To R« Ubr*v Window Help

1 ±Lil <iJF 3«1 ,

Setup
1 1
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Convergence .

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-
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.
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f

FIGURE 5.56

Starting Aspen Dynamics

Open a blank dynamic simulation window for the example column, following a similar
procedure as previously shown for the CSTR problem. In the next, simply open the
flow-driven dynamic ile 'Ch5 5 3 RadFrac.dynf. As a result, the Aspen Dynamics .
f

_ _

window appears (see Figure 5.57) accompanying with the closed-loop process low
f

diagram. The flowsheet actually includes the three default control schemes LCI, PC2
and LC3 to monitor the reflux drum liquid level, top stage pressure and column base
liquid level, respectively.
In the present discussion, we do not want to change anything of the three
automatically inserted control strategies. All data, including timing parameters, ranges,
bias values and controller actions, remain untouched. A little detail of these control
structures is given below.
Loop 1
Controller: LCI
Type of controUer: P-only (since integral time is very large (60000 minutes))
Controlled variable: liquid level in the reflux drum
Manipulated variable: distillate low rate
f

Controller action: direct

DYNAMICS AND CONTROL OF FLOW-DRIVEN PROCESSES 267

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Siaulation ready for solution

7 equations were not eliminated because they had residuals over le -
005
3
A total of S32 equations (38 b'/.) were eiinmated
Sinulation has 1991 variables. 1484 equations and 6219 non-zeros

IBjnsilcal 0.(10
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FIGURE 5.57

Loop 2
Controller: PC2
Type of Controller: PI
Controlled variable: top stage pressure
Manipulated variable: coolant inflow rate
Controller action: direct
Loop 3{
Controller: LC3
Type of controller: P-only
Controlled variable: liquid level in the column base
Manipulated variable: bottoms low rate
f

Controller action: direct

Adding a new PI controller for top composition loop

Now we wish to include a proportional integral (PI) law to control the benzene
composition in the top distillation product by manipulating the reflux rate. In the top
left of the window the Dynamics library is included within Simulation folder of Ml
Items pane Click on expand (+) button of Dynamics subfolder. Consequently, the expand
,

button changes to collapse (-) button as shown in Figure 5.58.

268 PROCESS SIMULATION AND CONTROL USING ASPEN

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ar s _

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FIGURE 5.58

Again hit expand button next to the ControlModels icon Then select PID controller .

drag it to the low diagram and drop the control block near to the top product stream .
f

Renaming the top composition controller as CCT we have Figure 5.59. ,

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FIGURE 5.59

Connecting controller with process variable (Controlled variable)

Ixpand Stream Types under Dynamics subfolder and hold down the mouse button ow
-
on
he ControlSignal icon. As we drag it onto the lowsheet window, many blue an
appear around the process diagram. Interestingly, when we f l I Z S
f

wiih holding the ControlSignal icon over a port, the name of that P
.

*ame *
on the
Anyway, move the pointer and release the mouse buttonselect 0fe g wo
the dastillate compos.tio
OutputSignal originated rom TOP (stream) block. To
f
CONTROL OF FLOW
DRTV rPPn cc 269
of benzene as controUed variable, choose 'STREAMSCTOP") ZnCBENyFTWv
raction' by description in the Select the Control Variable 4 bo Fi 5 6of
f

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FIGURE 5.60

As we press 0/!l button, the cursor becomes a solid black arrow representing the
input signal to the controller. To transmit this signal to the CCT block, connect the
black arrow with a port marked InputSignal. Since this signal conveys the process
variable (PV) information to the CCT controller select 'CCT.PV by name with 'Process ,

variable
'
by description in the Select the Control Variable dialog box (see Figure 5.61).
-
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ri
.

FIGURE 5.61
270 PROCESS SIMULATION AND CONTROL USING ASPEN

Hit OK button and obtain Figure 5.62. Obviously the CCT controller is partially ,

configured. To complete the top composition loop, the controller output should be
connected with the manipulated variable to pass on the signal .

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ing Simulation

ent snapshots have been saved to file snpAOOlO snp

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Ready Jl ocal Dynamic at 0 00
f

FIGURE 5.62

Connecting controller with control variable (Manipulated variable)

Again hold the ControlSignal icon, drag it onto the process lowsheet and drop it on
f

the blue outgoing arrow marked OutputSignal from the CCT block. As Select the
Control Variable dialog box appears (see Figure 5.63), choose 'CCT.OP' by name and
press OK.
Immediately, a solid black arrow representing the controller output signal is
automatically generated. Move the mouse pointer to reflux stream and make a
connection to InputSignal2 port. To use the reflux low rate as control variable, select
f

'
BLOCKSC'RADFRAC). Reflux.FmR' in the dialog box and click OK (see Figure 5.64).
Now the binary distillation column is coupled with four control schemes, LCI,
PC2, LC3 and CCT, and the closed-loop process looks like Figure 5.65. The subsequent
discussion includes the modification of different tuning properties of the CCT
controller.
DYNAMICS AND CONTROL OK FLOW DRIVKn PROCESSES -

271

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272 PROCESS SIMULATION AND CONTROL USING ASPEN

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FIGURE 5.65

Modifying controller tuning properties

First we wish to see the default tuning properties. So double-click on the CCT block and ,

then hit Configure symbol in the faceplate to open the Configure dialog box (see Figure 5.66).

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FIGURE 5.66
DYNAMICS AND CONTROL OF FLOW-DRIVEN PROCESSES 273

Obviously, some of the default values set by Aspen Dynamics are not acceptable.
For example, the operator set point value of process variable (benzene composition in
distillate) should not be greater than L Secondly, the CCT controller action must be
Reverse'. In addition, the value of control variable (reflux flow rate) at steady state is
'

usually used as bias value.

We have two options in our hand to correct the default values. Either manually
we can do it or Aspen Dynamics can automatically initialize the values of set point ,

process variable, control variable, bias and ranges. Note that the controller action is
changed only manually. It is wise to initialize the values by the help of Aspen Dynamics .

For this, press Initialize Values button in the Configure dialog box and use 'Reverse'
controller action. It is obvious in the window, shown in Figure 5.67, that the values of
SP, PV and OP in the faceplate change automatically to their steady state values. If
this approach fails to initialize the simulation of controller model with the steady state
data, check and replace, if necessary, the values of PV and OP with their steady state
values by double clicking on signal transmission lines (input to the controller and output
from the controller).

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FIGURE 5.67

Modifying ranges for process variable and controller output

we hit the Ranges tab, the Configure dialog box (see Figure 5.68) shows the default
ranges imposed on process variable and controller output.
274 PROCESS SIMULATION AND CONTROL USING ASPEN

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FIGURE 5.68

However, here we use the typical variable ranges, shown in Figure 5.69 .

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FIGURE 5.69
DYNAMICS AND CONTROL OF FLOW DRIVEN PROCESSES
-
275

Process variable
Range minimum: 0.85
Range maximum: 10
Output
Range minimum: 10000 Ib/hr
Range maximum: 120000 Ib/hr
It is important to mention that it is a good idea to carry out Initialization as well
as Dynamic run after each new change in the control scheme so that any error in
controller installation can be detected individually.
We have now completed all required control specifications for the top composition
loop In the ongoing study, we prefer to conduct the simulation experiment to observe
the designed controller performance continuously for 5 hours. As done for the previous
CSTR problem, similarly either simply press Ctrl+F5 on the keyboard or select Pause
At rom the Run menu and put 5 hours as Pause at time.
f

In the next, we will inspect the CCT controller performance first dealing with the
servo problem followed by the regulatory problem.

Viewing servo performance of CCT

As we double-click on the CCT controller block in the lowsheet window the faceplate
f

appears. Then open the Configure as well as ResultsPlot dialog box The second one is
.

basically a blank graph sheet that presents the variations of process variable set point
,

and controller output with respect to time.

Before running the program make sure that all the items in the Configure dialog box
,

and faceplate are correct. In the next hit Run button to start the dynamic simulation. The
,

plots, shown in Figure 5 70, illustrate the servo behaviour of the PI control algorithm with
a step increase (0 9437 - 0 97 at time = 1.51 hours) followed by a step decrease
.

(0 97 - 0 9 at time = 3 hours) in the set point value of the distillate composition of benzene.
.

To achieve an improved closed-loop performance we have used the values of proportional

gain of 10 %/% and integral time of 10 minutes. These values have been chosen based
on a pulse input test in the distillate composition of benzene and using the trial-and-
error approach It should be kept in mind that the objective at this point is not to come
up with the best control structure or the optimum controller tuning. We only need a
control scheme and tunings that provide a reasonably good tracking performance to
drive the simulation to a new steady state.
Remember that to edit the plots, shown in Figure 5 70, double-click on different
elements of the plots and modify them as we like.
Viewing regulatory performance of CCT
In order to investigate the regulatory performance of the CCT controller, we give a step
input change in the feed pressure (21 -» 23 psia) at time = 1.48 hours and that in the feed
temperature (225 -» 230oF) at time = 3 hours. The PI controller tuning set provides good
disturbance rejection performance (see Figure 5.71) although the tuning parameter values
.
gain and integral time) have been chosen based on a pulse set point input change.
276 PROCESS SIMULATION AND CONTROL USfNG AST'EN

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FIGURE 5.71

(c) Adding a new PI controller for bottom composition loop: We have to

devise another PI control scheme to monitor the bottoms composition of benzene
by adjusting the heat input to the reboiler. As developed, the CCT controller
for the top loop, similarly we can configure the CCB controller for the bottom
loop as shown in Figure 5.72.
DYNAMICS AND CONTROL OF FLOW-DRIVEN PROCESSES 277

I.:IM

.
:

1
s
.

41 . .
! m
.

lm< uuuk.'* w-> Ml X-M i.. I.im mmttfll M*

FIGURE 5.72

We have chosen the following tuning properties (see Figure 5.73):

Gain = 10 %/%
Integral time = 10 minutes
Controller action: Direct

dub .a % » |M*«.. r 3 . . nvm awocigi

r :: f - >. »- »

1 55 i; 7T i: '».»«
'w. i .
-

f v ..

c MM
-

.TIM mmm lia»

EkMIMi tl A I.. li.c...

| "1 .MtMlM lftj« WMtlOM m4 M3» mm-two*

FIGURE 5.73
278 . PROCESS SIMULATION AND CONTROL USING ASPEN

In addition, the used constraints are reported below:

Process variable

Range minimum: 0.0

Range maximum: 0.1
Output
Range minimum: 6000000 Btu/hr
Range maximum: 18000000 Btu/hr

Viewing interaction effect between two composition loops

To observe the effect of interaction between two composition loops, the set point value
of bottoms composition of benzene has been changed twice. The simulation result is
depicted in Figure 5.74 for a step increase (0.0033 -> 0.0045 at time = 1.5 hours) followed
by a step decrease (0.0045 -> 0.0025 at time = 3 hours).

EC MS*}
-

He Mew Toots en Window net

| Dynamic h « CBS'S aiaocsH

9 -
=inj l
"
_

r Tt (0 05 3 i£ i « W 1* 3

LCI
>o-

%j am {33-0
SP| 100025
PV; I00O25 LCJ >a-j
--

0PHH |12117835,; >o- CCT

BOTTOM K>
Tunuvj | Ranges | Ffenr ] Olha

Opetatot set poi* (0 0025 jbmol/bfrol

Turwtg paameten

S«t. [l1613W7r jBtu/W 63

Gart [To I.
s.
Iniegrafww. flO f i
Owwabvetimei [o
-

11
Cortiolw action -
Drad > £
i
r Reverte S?
1
-

If r
0 0 5 1 1 5 2 2 5 3 3 = 4 45
,
5 i 2 2.5 3 13
Time Hours Time Hours

TEE
eed
t

FIGURE 5.74

Clearly, the CCB controller shows satisfactory set point tracking performance
against a pulse input change It is observed rom Figure 5.74 that owing to strong
.
f

interaction between the two composition loops of the distillation column the set point ,

changes in bottom loop affect the top product composition Similarly, when any set .

point change is introduced in the top composition loop, the bottom product composition
will also be affected.
DYNAMICS IND CONTROL OF FLOW-DRIN KN I'HOrKSSKS 279

SUMMARY AND CONCLUSIONS |

This chapter has investigated the closed-loop process dynamic characteristics using
Aspen Dynamic- package. To observ e the controller performance in terms of set point
tracking and disturbance rejection, a CSTR in addition to a distillation column have
been illustrated The default control strategies have been tested for the reactor example,
whereas the two additional composition control loops have been included along with
the default control laws for the distillation example. Several simulation experiments
have been executed for both the processes under flow-driven dynamic simulation. Note
that Chapter 6 presents the dynamic simulation and control of more rigorous pressure-
driven dynamic process.

PROBLEMS|
5 1 A feed mixture of benzene and toluene is fed to a flash drum (Flash2). The
.

separator operates at 1.2 atm and 100oC For dynamic simulation, required feed
.

specifications are provided in Figure 5.75.

Feed

Temperature = 25°C
Pressure = 3 bar
FLASH
Flow rate = 100 kmol/hr
>o
PI
Component Mole fraction

benzene 06
.

toluene 04
.

FIGURE 5.75 A flowsheet of a flash drum.

'
a) Use the SYSOP0 property method to compute the amounts of liquid and
vapour products and their compositions .

.
b) As shown in Figure 5 75, employ a PI control scheme to monitor the
.

temperature in the flash drum by manipulating the heat duty .

(d) Report the tuning parameters obtained by trial-and-error method, controller

action and ranges imposed .

5 2 A vapour mixture of toluene, methane and hydrogen is heated using a shell and
.

tube heat exchanger (HeatX) The superheated steam is used as a heating medium.
.

Complete specifications required for closed-loop dynamic simulation are shown in

Figure 5 76.
.
280 PROCRSS SIMULATION AND CONTROL USING ASPEN

Hot Stream Out

Pressure = 14 psia
Cold Stream In

Temperature = 2780F I
HOT-OUT
Pressure = 500 psia
Cold Stream Out
Component Flow rate
(kmol/hr) ICOLD-INf j cold-out hoi Temperature = HOOT
Pressure = 498 psia
toluene 200
Dead time pi
methane 2300
HOT-INK >AT
hydrogen 1000 >o

ii
Hot Stream In

Temperature = 1160oF
Pressure = 14.7 psia
Flow rate = 5110 kmol/hr

FIGURE 5.76 A flowsheet of a heat exchanger.

(a) Simulate the heat exchanger model using the shortcut method, counter-
current low direction and NRTL-RK property method.
f

(b) Include a PI control structure to observe the set point (cold stream outlet
temperature) tracking performance and the manipulated input (steam inflow
rate) profile. In the closed-loop simulation experiment, assume that the
temperature sensor takes 1 minute time (dead time) to measure the controlled
variable. Report the used tuning properties.
(c) Examine the regulatory performance by introducing + 10% and subsequently
-

10% step changes in the inlet temperature of the cold stream.

5 3 Device a cascade control scheme for the above heat exchanger and investigate
.

the controller performance.

5 4 A liquid mixer model with a typical ratio controller (Seborg et al. 2003) is shown
.

in Figure 5.77. The low rates for both the disturbance or wild stream (Fw) and
f

the manipulated stream (FE) are measured, and the measured ratio, R = FE/Fw m ,

is calculated. The output of the ratio element is sent to a ratio controller (PI) that
compares the calculated ratio Rm to the desired ratio Rd (set point) and adjusts
the manipulated low rate accordingly.
f

Input 2

Ratio
>o
PI
> | POT >

Input 1

FIGURE 5.77 A flowsheet of a mixer

DYNAMICS AND CONTROL OF KLOW-DRIVKN PROCESSES 281

The input data are shown in Table 5.2 for simulation.

TABLE 5.2

Stream Temperature CO Pressure (aim) Flow rate (kmol/hr) Composition

E 50 1 Pe = 100 pure ethanol
W 60 1 = 150 pure water

Process variable at steady state = 0.667 (FE/FW = 100/150)

Controller output at steady state = 100 kmol/hr
Proportional gain = 4 %/%
Integral time = 20 minutes
Controller action = reverse
(a) Appljang the SYSOPO base property method, simulate the mixer model
operated at 1 atm.
(b) Using the given controller properties and default ranges, report the
ratio controller performance with two consecutive set point step changes
(0.667 -> 0.72 0.65) in the ratio.

Hint: Double-click on Input 1 transmission line and ill up Tables 5.3(a) and (b).
f
TABLE 5.3(a)

Value Spec
*,
>STREAMS("E ) Fcn("ETHANOL")
.
100.0 Free

<Ratio.Input! 100.0 Free

Similar table for Input 2 is obtained as:

TABLE 5.3(b)

Value Spec
w
>STREAMS("W ) Fcn("WATER").
150.0 Free

<Ratio.Input2 150.0 Free

In the next, double-click on Ratio element and get Table 5.4.

TABLE 5.4

Description Value Units

Inputl Input signal 1 100.0 kmol/hr

Input2 Input signal 2 150.0 kmol/hr

Output Output signal, Inputl/lnput2 0 667

Use Initialize Values button and incorporate the given tuning properties before
running the program.
282 PROCESS SIMULATION AND CONTROL USING ASI'RN""

5 , 5 A reboiled stripper is used to remove mainly propane and lighter species from a
feed stream, shown in Figure 5.78. It has total 6 stages (including condenser
and reboiler) and no condenser.
The bottoms rate is 100 Ibmol/hr and the column top stage pressure is 150 psia
with a column pressure drop of 8 psi. The diameter of the stripper (Stages 1 to
5) is 6.5 ft. The reboiler heat duty is assumed constant, although it changes at
dynamic state. The sump has elliptical head with a height of 5 ft and diameter
of 2.5 ft.
For the closed-loop simulation, use the following data:
Dead time = 2 minutes
Magnitude of noise (standard deviation) = 0.01 Ibmol/lbmol
Proportional gain of PI = 1 %/%
Integral time of PI = 20 minutes
Controller action = Reverse

PCI
Feed

Temperature = 40oF
Pressure = 160 psia
Feed stage = 1 (above stage)
Dead time Noise Pi
Component Flow rate
(Ibmol/hr) >o
c, 60

c2 75

C3 150
n-C4 175
n-C 60
5

n-C 35
8

FIGURE 5.78 A flowsheet of a stripping column .

(a) Using the Peng-Robinson thermodynamic method simulate the RadFrac ,

(STRIP2) model and compute the product compositions.

(b) Keeping the default controllers (PCI and LC2) unaltered configure a ,
'

composition control scheme (PI) coupling with a 'Dead time' and 'Noise _

elements to maintain the propane mole fraction in the distillate by

manipulating the reboiler heat duty as shown in Figure 5 79. Use the given .

closed-loop data and execute the dynamic simulations to test the developed
composition controller performance .

5 .
6 Ethylene is produced by cracking of ethane in a stoichiometric reactor. The
irreversible elementary vapour-phase reaction is given as .

C2H6 -i C2H4 + H2
ethane ethylene hydrogen
Pure ethane feed enters the reactor model shown in Figure 5.79, with a low
,
f

rate of 750 kmol/hr at 800oC and 5 5 atm. The reactor operates at inlet
.

temperature and pressure with 80% conversion of ethane .

DYNAMICS AND CONTROL OF FTOW-DRIVKN PROCESSES 283

> M >o

FIGURE 5.79 A lowsheet of a reactor

f
U) Using the SYSOPO thermodynamic method, simulate the reactor model.
(b) Develop a control loop as configured in the low diagram to maintain the

f
desired reactor temperature by the adjustment of heat duty. Considering the
measurement lag of 1 minute, inspect the servo as well as regulatory control
performance. Report the tuning properties used to achieve a satisfactory
closed-loop performance.
5 . 7 A binary feed mixture consisting of methylcyclohexane fMCH) and toluene is
introduced above tray number 14 of a RadFrac distillation model, shown in
Figure 5.80.

O 1 phenol [

O 1 FEED h

FIGURE 5.80 A lowsheet of a distillation column

It is dificult to separate this close-boiling system (MCH-toluene) by simple binary

distillation Therefore, phenol is used as an extractant and introduced above

tray number 7 of the column The two input streams have the following
.

specifications shown in Table 5.5.

TABLE 5.5

Stream Temperature (*C) Pressure 'bar) Flow rate Mole fraction

PHENOL 105 14
.
100 nrVhr 10
.

FEED 105 14
.
181.44 kmol/hr 0 5/0.5
.

(MCH/toluene)

The column has 22 theoretical stages (including condenser and reboiler) with a
total condenser The distillate rate and reflux ratio are given as 90.72 kmol/hr
.

and 8 (mole basisrespectively. The pressure profile is defined with Stage 1

pressure of 1 10316 bar and Stage 22 pressure of 1 39274 .
bar. Use LMTD
assumptions for the condenser The reboiler heat duty is assumed constant. The
reflux drum and sump are specified in Table 5.6.
284 PROCESS SIMULATION AND CONTROL USING ASPEN

TABLE 5.6

Item Vessel type Head type Height /Length Diameter

(m) (m)
Reflux drum horizontal elliptical 15
. 0 75
.

Sump -
elliptical 15
. 0 75
.

The column diameter and tray spacing are given as 2 m and 0.6 m respectively,
,

(a) Simulate the distillation column using the UNIFAC property method to
compute the composition of MCH in the distillate and that of phenol in the
bottom product.
(b) In addition to the default level and pressure controllers, insert a PID structure
to control the MCH composition in the top product by manipulating the flow
rate of PHENOL stream.
(c) Produce the plots to show the closed-loop control responses, and report the
tuning parameters, control actions and operating ranges for controlled as
well as manipulated variables used.

REFERENCES|
Luyben, W.L., (2004), "Use of Dynamic Simulation to Converge Complex Process
Flowsheets", Chemical Engineering Education, pp. 142-149.
Seborg, D.E., T.F. Edgar and D.A. Mellichamp, (2003), Process Dynamics and Control,
2nd ed., John Wiley & Sons, Inc.
CHAPTER
6
Dynamics and Control of
Pressure-driven Processes

61 .
INTRODUCTION

To know the transient characteristics of a complicated chemical plant, we need a dynamic

process simulator. It is well-recognized that Aspen Dynamics is such an efficient
flowsheet simulator used for dynamic process simulation. As we have seen in Chapter 5,
Aspen Dynamics simulator can be employed to design a process as well as its associated
control strategies.
Aspen Dynamics extends an Aspen Plus steady-state model into a dynamic process
model. If the steady state Aspen Plus simulation is exported to Aspen Dynamics, there
is a necessity to choose either flow-driven dynamic simulation or pressure-driven
dynamic simulation In a rigorous pressure-driven simulation, pumps and compressors
.

are inserted where needed, to provide the required pressure drop for material low.
,
f
Control valves are installed where needed, and their pressure drops selected. For good
,

control , the pressure drop across a control valve should be greater than 0.1 bar. The
luid that lows through a valve should normally be liquid-only or vapour-only because
f

the two-phase low through a control valve is unusual .

It should be pointed out that for a pressure-driven case, we must not insert a valve
in the suction of a pump or at the discharge of a compressor (compressor speed or its
equivalent compressor work is manipulated). The control valves are positioned on the
luid streams such that the controllers can manipulate the valve positions.
f

The simple low-driven dynamic simulations have been discussed in detail in the
f

previous chapter. Therefore ,

here we are intended to study the pressure-driven
simulation .
A reactive or catalytic distillation column is exampled for the rigorous
pressure-driven Aspen Dynamics simulation as well as control.

285
286 PROCESS SIMULATION AND CONTROL USING ASPEN

6 . 2 DYNAMICS AND CONTROL OF A REACTIVE DISTILLATION (RD)

COLUMN

Problem statement

The methyl tertiary butyl ether (MTBE) column configuration (Jacobs and Krishna,
1993) chosen for the simulation is shown in Figure 6.1.

Pure methanol (MeOH) feed

(liquid)

Temperature = 320 K
Pressure = 1 aim
Flow rate = 711.30 kmol/hr
Jy tCl-fpisT-Q
Feed stage = 10 (above-stage) 0| METHANOL Ft
CV2

PUMP

Butenes feed (vapour) CH butenes]-1

Temperature = 350 K 1-H l-IbotI-<>

Pressure = 1 aim CV3

Flow rale = 1965.18 kmol/hr RDCOLUUN

Feed stage = 11 (above-stage)

COMPRESS
Component Mol fracl

/so-butene (IB) 0 36
.

n -butene (NB) 0 64
.

FIGURE 6.1 A lowsheet for the production of MTBE.

The RD column (RadFrac) consists of 17 theoretical stages, including a total condenser

and a partial reboiler. Reactive stages are located in the middle of the column, Stage 4
down to and including Stage 11. In Aspen terminology, the numbering of the stages is
top downward; the condenser is Stage 1 and the reboiler is the last stage.
MTBE is produced by reaction of IB and MeOH:
(CH3)2C = CHa + CH3OH «-»(CHgk COCH3
IB MeOH MTBE

The liquid-phase reaction is catalyzed by a strong acidic macroreticular ion exchange

resin, for example Amberlyst 15. and n-butene does not take part in the reaction (inert).
The forward and backward rate laws (Seader and Henley, 1998; Rehfinger and Hoffmann,
1990) are derived in terms of mole fractions, instead of activities (products of activity
coefficient and mole fraction):

'
9244(M
-
.
IB
Forward rate: rf= 3 67 x 1012 exp
.

RT xMeOH ,

-
134454> VMTB!'
Backward rate: r,, = 2 67 . x 1017 exp
RT
DYNAMICS AND CONTROL OF PRESSURE-DRIVEN PROCESSES 287

Here, z represents the liquid-phase mole fraction. The pre-exponential factors,

including the activation energy (kJ/kmol), are given in SI units. The catalyst is provided
only for reactive stages (8 stages total), with 204.1 kg of catalyst per stage (Seader and
Henley. 1998). The used catalyst is a strong-acid ion-exchange resin with 4.9 equivalents
of acid groups per kg of catalyst. So, the equivalents per stage are 1000 or 8000 for the
8 stages. In some references, the equivalents per stage are directly given.
The column, starting from Stages 2 to 16, is packed with 'MELLAPAK' (vendor:
SULZER) having a size of 250Y. Use 'Simple packing' hydraulics and the height
equivalent to a theoretical plate (HETP) may be considered as 1 m. The distillation
column diameter is 6 m. Stage 1 (condenser) pressure is 11 atm with a column pressure
drop of 0.5 atm. The reflux ratio is set to 7 (mole basis) and the bottoms low rate is

f
640.8 kmol/hr. In the MTBE synthesis process, it is desirable to obtain a bottom product
containing high-purity MTBE and a distillate containing high-purity NB. In Table 6.1
the reflux drum and the sump (the next-to-last stage in the column) are specified.
TABLE 6.1

Item Vessel type Head type Height/Length (m) Diameter (m)

Reflux drum horizontal elliptical 2 1

Sump -
elliptical 22 .
1 1 .

The pump delivers the liquid stream POUT at 11.7 atm. The compressor (isentropic)
has discharged the vapour feed FV at 11.5 atm. The three control valves (adiabatic
lash) CV1, CV2 and CV3 have the outlet pressures of 11.5 atm, 10.8 atm and 11.3 atm
f

respectively. Using the UNIFAC base property method,

(a) simulate the process lowsheet to obtain the distillation product summary, and
f

(b) develop the control configurations to achieve the desired product purity under
disturbance input.

Simulation approach
(a) Start the Aspen program by double-clicking the Aspen Plus User Interface icon
on the desktop. Then select Template option and press Oif (see Figure 6.2).

: aM

FIGURE 6.2

Copyrighted material
1
288 PROCESS SIMULATION AND CONTROL USING ASPEN"

We choose General with Metric Units option and hit OK button (see Figure 6.3).

016*11 _
L I _!_) *d U-i-lfcl I M 3 I I I J jU J J
l l I I l I HI J J J
_ _ ,
J U ali

mi in -
I
.

>.. I

0*. I ,.J h
1

r -

P.*

FIGURE 6.3

When the Connect to Engine window appears, use the default Server type (Local PC).

Creating flowsheet
The process low diagram includes a feed pump a feed compressor, a distillation column ,
f

and three control valves. The complete process lowsheet drawn in an Aspen window
f

should somewhat resemble the one shown in Figure 6 4 Recall that Aspen has a tool . .

in the toolbar that automatically takes the user through the required data input in a
stepwise fashion. The blue Next button does this.

-
o-
" if - *x

FIGURE 6.4
DYNAMICS AND CONTROL OF PRKSSIIRE-DRI\T N PROCESSES ,
289

Configuring settings
At the beginning of data entry, ill up Global sheet followed by Accounting sheet under

f
Specifications of Setup folder. Moreover, select 'Mole' fraction along with 'Std.liq.volume'
low basis in Stream sheet under Report Options [see Figures 6.5(a) ,
(b) and (c)].
f

& -

Sim

Pi bw
HUB .
|
MMH .

fMM,

r 3 EC

ir S

FIGURE 6.5(a)

:.
>-B| *ifi »] atmnn-at .! 3 I 1"! jiJ 3
-
T i-l h r* .1 -IE; : II

- a*-=- = -
aa-2-

FIGURE 6.5(b)
290 PROCESS SIMULATION AND CONTROL USING ASPEN

j r
_ _
I I -I 1 ,
;
| .imi I M MgJ
nafhi >bJiiiF-a Jj
0
P lr<Ul«il>«tmd«.CTvtlci.i

FV>-.bM> fmctmUm SUWlflHllH

CtiHomUtii f7 Mod P Mod Iff [.''.>. 3
Optioni
r mwi r mm
P S-dlQrt***. r Stdklvcim. r ...m ..
.

P Conconni 2«o Hnw or hKbm

_
j RosrMru

[V . | ., , v . | --vr. w | CdUHM | RtKicni Pimtw*ClMngnt | MwdMrt | Scfcc | UiaMotWi |

f
STREAMS Pmp Conif MCow fV»
FaH«te . (wun gFoUeiiVwenButllV HUM FUntiwIlrpj r cWc

FIGURE 6.5(c)

Specifying components
The components involved in the example system are MeOH (CH40) IB (C4H8-5), NB ,

(C4H8-1) and MTBE (C5H120-D2). Within the parentheses, the chemical formulas
used in Aspen terminology are mentioned (see Figxire 6.6).

fh I* v** Date 1Mb Rui Pw itnuy Wndew

Iglg) _U *le) £1 aRI&Kl l-l n.| |

I r M I IT I W! I [a) -«l»«l
3MS

MEOH KTHANOL Hti

h EQWmfMi
NB i-BUIEHE C4HB'1

MIBE

.
_ J PwoCh.

.
J Con
. - . PA

J Si 35! I u'*

|» tdMAriMi | SwMka. ) KMEKtw«p> | 4 . | iMcm Pimm Ounv" | |

i »tr»iiiiin

FIGURE 6.6
DYNAMICS AND CONTROL OF PRESSURE-DRIVEN PROCESSES 291

Specifying property method

The user input under the Properties tab is probably the most critical input required to
run a successful simulation. This has been discussed in much greater detail in the
previous chapters. This key input is the Base method found in Global sheet under
Specifications option. Set UNIFAC for the present project (see Figure 6 7). .

1 d 1 J
1 3
'1 J 1 J
1 d 1 3
I J
1 J
1 r

tfclj l f | HatfE**** i CAM | iuuc- * -Ol«inii j 1 id* | UhWoMt |

FIGURE 6.7

Specifying stream information

Under the Streams tab, we have used Specifications sheets to input the data for both
the feed streams, BUTENES and METHANOL [see Figures 6.8(a) and (b)].

«k U DM I*M <k/. m lMm> Vnfc. rtw

a r i j-j-i ..if; 3 ») qU I
9 S3HS 1I
wo
I
-

ass
.

.
1

FIGURE 6.8(a)
292 PROCESS SIMULATION AND CONTROL USING ASPEN

E« V*. D«j 1b.

i r m i nr i ei i m mi
-

DgrfcR FH »| |..|[Tr
) mum* i i

HPS 3
la !.
J r: -.
"lur

1
il Pi9
mibe

i
'

SJIENIS

1 E0v«
.

_
j
j Fl
_

*
li FV
-

ICIHMBI

Res*;

Evripn | C<A«n | fUicioa IWttraCkw«m | > ,,...-. | c«bk | UisModn |

iKall-V HUM RtMndkwJfraOk

FIGURE 6.8(b)

Specifying block information

In Figures 6.9(a) to (d), irst the feed compressor details are giver.. Subsequently, the
f

three control valves, CVl, CV2 and CV3, are specified.

_
i r- I -1 I- IT
_
I lal I la
afbRTr H JulF 321) QLJ!!!!
-

fir-.

q hm 3
J tUIENES

1
S PI
J POUI
_

COMffltSi
Q Salup

f COVmUk
i tO Ira'
f

I iaomMt | He Ertw vi | Coimi | neclait Ple»i»« Ch»»«< | MmWcn | Stdf ) U « «(«** |

-
CH

. ; MM

FIGURE 6.9(a)
DYNAMICS AND CONTROL OF PRESSURE-DRIVEN PROCESSES

Ffc {« Am l "** If* fV LtMV r Or.

ir LUJV _
'I'N Mai gH
0
-
a, n
A. F\
-
ij M(t>«nOL
.
ai n
.
ii w

0
a
a
a
a Bo.* O(*ora

3 MmnMtatm p
s t'J in"
Spk BMW
_
J
Pm

w
Iflpul
Btae« Ophorj

tP .»rtNei
9 IQlfVJ

a snear O-.ji

5TREAKS Mm fSi* SSc*

f o Mtfc sen R D4M* AOMiM]

.
MUM

A.per. flu, t.Pbl

FIGURE 6.9(b)

Ed| Pfc, Liv y K- ABE

nmm i i ibi "Pi »h r 1 hl J J J ill

»i Dial n.i

| - 'MM
ni»pMii|tH f -3 * I-
r c w**, I 1 1 r I

[23 ECVwwim

: : .

snWW m , r nti uai

D ttoA .
OiWMit HUM

1107

FIGURE 6.9(c)
294 PROCESS SIMl'UVnON AND CONTROL USING ASPEN

d (BfacK-VlrVJ.rllnpui 0
* E* C«* Tadb Rrf, Plo i±1Mr wnx*. h*

r CAii» la tMtodoUM Peru-Mr ,

2] Kea*:
H EO-M.,

- ,

STfitWK Mm Ffp* SSt*

PaM essr; " '

£jc* ?Ow»ii
_
.HIM

FIGURE 6.9(d)

When the data entry for the feed pump is complete ,

the window should look like
Figure 6.10.

l r _ _
L _
LLJV 'I -isi

a -'
i

.
-r - y

m r
RiMP

f :

O Sim v _J

I MMMta. I ekk I J«M-M« I

£TRDMt
J
FIGURE 6.10
DYNAMICS AND CONTROL OF PRESSURE-DRIVEN PROCESSES 295

In the list on the left, choose Blocks I RDCOLUMN I Setup to ill up Configuration

f
sheet (see Figure 6.11).

'
Wal _LJ «m *) fJMfcl'.KM -I -il - I M -I 71 -I _J
i T I I I'
-
I - Wl I Ml -

3 3|.. ji :. -5j
1
I

i | IWMMi | ttaMlKf***, | CAM | txtin Pmm Omw

-
D-

FIGURE 6.11

Streams sheet defines both the feed streams (see Figure 6.12), FL and FV, as well
as product streams, PI and P2.

FTS C« vW. Dm r«* fW> fta -! i-

PWO| Uaelgl ral-rlai-l-al l »l
_
I I"! .! 1 'I J
r I M PT \ -m i wi

.«B ftH" Ml

- ia Ese
K J . -»...- >. " I MUM

FIGURE 6.12

The pressure profile of the sample RD column is described in window shown in

Figure 6 13.
.
296 PROCESS SIMULATION AND CONTROL USING ASPEN

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In the left pane of the Data Browser window select Blocks/RDCOLUMN/Reactions. ,

Filling out Specifications and Holdups sheets we have two windows as shown in ,

Figures 6.14(a) and (b).

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DYNAMICS AND CONTROL OK PRESSURE DRIVEN PROCESSES -
297

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Select Pack Rating under RDCOLUMN of Blocks folder. Creating a new ID, T,
and specifying the packing section as well as packing characteristics, we obtain
Figure 6.15.

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298 PROCESS SIMULATION AND CONTROL USING ASPEN

Choose Blocks/RDCOLUMN/Convergence and ix up the maximum iterations to

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In the next, dick Dynamic tab wader Blocks/RDCOLUMN The design specifications .

of the reflux drum and sump are reported in Figures 6 17(a) and (b). .

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DYNAMICS AND CONTROL OF PRESSURE-DRIVEN PROCESSES 299

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300 PROCESS SIMULATION AND CONTROL USINd ASRKN1

Hit Next icon to open the Reactions folder. For the forward reaction (Reaction No 1) .

and the backward reaction (Reaction No. 2), the stoichiometric coefficients and
exponents are defined under Kinetic' Reaction type in the two sheets as shown in
'

Figures 6.19(a) and (b).

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DYNAMICS AND CONTROL OF PRESSURE DRIVEN PROCESSES -
301

The Power law kinetdc data for both the reactions are provided in Figures 6 20(a) and (b). .

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Running steady state simulation and viewing results

Results
As we hit Next knob followed by OK, Control Panel window pops up. Under
Summary/Streams the results are displayed in Figure 6.21.
,
302 PROCESS SIMULATION AND CONTROL USINd ASI'KN

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FIGURE 6.21

The mole fraction of MTBE in BOT stream is computed as 0.951.

(b) Exporting dynamic simulation: In order to conduct the dynamic process
simulations, export the steady-state Aspen Plus simulation into Aspen Dynamics
with saving as a pressure-driven dynamic ile.
f

Opening existing simulation

As we press the Start knob, point to Programs, then AspenTech, then Aspen Engineering
Suite, then Aspen Dynamics Version and then select Aspen Dynamics, a blank dynamic
simulation window appears. In the next, open the pressure-driven dynamic ile saved
f

earlier. The screen looks like Figure 6.22.

It is obvious that the process lowsheet includes the automatically inserted two
f

level controllers (LCI and LC3) and one pressure controller (PC2). Each of these
controllers has an operator set point (SP), a process variable (PV), also known as
controlled variable, and a controller output (OP), also called as manipulated variable,
whose values are obtained from the Aspen Plus simulation. These control structures
also have their own tuning parameters, and so on, suggested by Aspen Dynamics.
However, there is a scope to modify (or remove) the controller and its related items.
The Aspen generated control loops defined below should be used in the closed-loop
study of the prescribed catalytic distillation column.
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FIGURE 6.22

Loop 1
Controller: LCI
Type of controller: proportional (P)-only (since reset time is very large)
Controlled variable, liquid level in the reflux drum
Manipulated variable: distillate (DIS) flow rate (percentage opening of valve CV2)
Controller action: direct
Use all default data, except proportional gain of 2 (suggested by Luyben, 2004)
Loop 2
Controller: PC2
Type of controller: proportional integral (PI)
Controlled variable: top stage pressure
Manipulated variable: condenser heat removal
Controller action: reverse
Use all default data (suggested by Luyben, 2004)

the condenser heat removal and P denotes the pressure to be controlled. Assuming
direct control action the controlle r equation can be rewr itten for Aspen Dynamics
Qr = - 47 48 - Kc {PSP - P), where 47.48 is the bias signal (Vr.s' "s
,

**
e from stea dy state position,
.

-'
gn indicates heat removal (cooling operation). If we mov
'
< is dear that when pressure (P) increases, the error (PS/. P) va lue becomes negahv..
d ultimately
.
,
the neRative vain., ofQc decreases. Originally, the negative value should
304 PROCESS SIMULATION AND CONTROL USING ASPEN

increase because if pressure increases, there is a need to increase the heat removal
rate. Therefore, our assumption is wrong and it should be reverse action in Aspen
Dynamics.)
Loop 3
Controller: LC3

Type of controller: P-only

Controlled variable: liquid level in the column base
Manipulated variable: bottoms (BOT) low rate (percentage opening of valve CV3)

f
Controller action: direct

Use all default data, except proportional gain of 2 (suggested by Luyben 2004) ,

Configuring new control loops

The primary objective of the example process is to produce a bottom MTBE product of
high purity. To achieve the desired product purity in presence of disturbance and
uncertainty, several control algorithms need to be employed with the reactive distillation,
It should be noted that in the control system of a RD process, the liquid level and
column pressure controls constitute inventory control, maintaining the basic operation
of the column. Thus, here emphasis is placed on the response of composition control
methodologies to maintain product quality as well as correct stoichiometric ratio between
the feed streams. In the following, different control schemes have been discussed for
three distillation sections, namely feed section, top section and bottom section.
Feed section

For a chemical reaction with two reactants , the type of lowsheet depends on whether
f

we want to operate the catalytic distillation column with no-excess of either reactant or
excess reactant (Kaymak and Luyben, 2005). For a double-feed RD column if there is ,

any imbalance in the inflow of the two reactants ('excess reactant' case) the product
,

purity drops. This is because one of the reactants becomes excess and exits with the
product stream, and this stream would have to be further processed to purify the product
and recover the reactant for recycle. Obviously the 'excess reactant' lowsheet requires
,
f

at least two separating columns and is therefore more expensive. However it is easier
,

to control. On the other hand, the 'no-excess reactant' lowsheet has better steady state
f

economics but presents challenging control problems because of the need to precisely
balance the stoichiometry of the reaction.
Several control structures used to maintain the correct stoichiometric ratio of the
reactants have been proposed by researchers (e g Al-Arfaj and Luyben, 2000; 2002;
. .,

Wang et al., 2003). To meet this control objective the controller requires some type of
,

feedback of information rom within the process to indicate the accumulation or depletion
f

of at least one of the reactants. This can simply be done by the use of an internal
composition controller by manipulating the low rate of one of the resh feeds. There
f

are also other efficient control techniques (e.g. cascade control, inferential control)
,

reported for stoichiometric balancing (Wang et al. 2003). However, it is not practical
,

to simply ratio the two feed streams as has been proposed in some of the literature
,

papers. Flow measurement inaccuracies and feed composition changes doom to failure
DYNAMICS AND CONTROL OF PRESSURE-DRIVEN PROCESSES 305

any ratio controller that does not somehow incorporate information about compositions
inside the reactive system and feed this information back to adjust fresh feed.
For the concerned distillation column the methanol composition is controlled on
,

10* stage by the adjustment of the methanol fresh feed. The butene feed rate is low

f
controlled. It is worthy to mention that manipulating the methanol feed to control an
internal methanol composition is preferred when the butene feed coming rom the

f
upstream units is not ree to be adjusted. If this is not the case then alternatively the
f ,

f so-butene concentration, instead of methanol concentration may be controlled on a

.
,

reactive stage by adjusting the butene feed rate.

We are now moving on to configure the composition controller for methanol feed.
To do this, click on expand symbol (+) of Dynamics subfolder. Then again hit expand
button of ControlModels icon. Subsequently, select the PID object, drag it to the low

f
diagram, place the control block near to CVl block and rename it as CC4. In the next,
expand Stream Types and use ControlSignal icon to complete the CC4 configuration,
shown in Figure 6.23. Chapter 5 presents a detail of how to configure a control structure
in Aspen Dynamics.

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. - B-

FIGURE 6.23

A little detail of the composition control loop for methanol feed is demonstrated
below .

Loop 4
Controller CC4
.

Type of controller: PI
Controlled variable: liquid phase mole fraction of MeOH on Stage 10
Manipulated variable: resh methanol (FL) low rate (percentage opening of v alve
f

CVl)
Controller action: reverse
306 PROCESS SIMULATION AND CONTROL USING ASPLN

Before executing the simulation run, it is customary to have a look on the data
sheet. For this, double-click on CC4 control block and then press Configure knob in the
faceplate to open the Configure dialog box. As mentioned in Chapter 5 it is wise to ,

click on Initialize Values button. Still one doubt is there: is the value of process variable
(PV) displayed same with the steady state liquid phase concentration of MeOH on
Stage 10 obtained in the Aspen Plus simulation? Be sure about it choose Blocks/ ,

RDCOLUMN/Profiles with opening the Aspen Plus simulation file. Then select 'Liquid'
in the View ield in Compositions sheet and obtain the table shown in Figure 6 24, . with
f

liquid mole fraction of MeOH on 10th stage of 0.04886022. This value is identical with
that of PV in the Configure dialog box.

od* Run PV)

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FIGURE 6.24

The controller CC4 is tuned by trial-and-error approach and the parameter values
have been chosen as:

Proportional gain = 5 %/%

Integral time = 5 min
Use default values for other items including bias signal, ranges, etc.
Notice that by the similar way, we can design the low controller for butene feed of the
f

RD column.

Top section
In addition to the LCI and PC2 control structures, the distillate composition can be
controlled by manipulating the reflux low rate. In an alternative approach, along withf
f

the pressure control (PC2), we can control the reflux drum level by the manipulation o
the reflux rate and the distillate low rate can be adjusted by a ratio control law to give
f

a constant reflux ratio. In the present case, the former control scheme has been
incorporated for performance study.
DYNAMICS AND CONTROL OF PRESSURE-DRIVKN PROCESSES 307

Bottom section
In the bottom section of a distillation column, it is a common practice that either the
bottom product purity or the tray temperature near the bottom of the column, which
has a strong correlation with the product purity, is controlled at its desired value by
the manipulation of the reboiler heat duty. For the sample process, we have implemented
a composition control structure for product quality control.
As the CC4 control block has been connected, similarly we can incorporate the
other control structures discussed above with the distillation flowsheet. The window,
shown in Figure 6.25, includes a closed-loop scheme in which the MTBE purity is
controlled in the bottoms by adjusting the reboiler heat input and the methanol impurity
in the top is controlled by manipulating the reflux flow rate. As stated earlier, the
concentration of methanol on the reactive stage it is being fed to (Stage 10) is measured
and controlled by the manipulation of the fresh methanol feed rate. The butene flow
rate is low-controlled. The liquid levels in the reflux drum and the base of the column
f

are maintained by the distillate flow rate and the bottoms flow rate, respectively. The
condenser heat removal is manipulated to control the column pressure. All of the
structures are single-input/single-output (SISO) structures with PI controllers (P-only
on levels).

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FIGURE 6.25

The details of control Loops 5 6 and 7 are presented below. ,

Loop 5
Controller: FC5
Type of controller: PI
308 PROCESS SIMULATION AND CONTROL USING ASPEN

Controlled variable: molar low rate of butene feed (FV)

f
Manipulated variable: brake power (shaft power or brake power of motor or engine
required to drive a compressor)
Controller action: reverse

Proportional gain = 0.5 %/%

Integral time = 0.3 min
Use default values for other terms

Loop 6
Controller: CC6

Type of controller: PI
Controlled variable: MTBE mole fraction in the bottoms
Manipulated variable: reboiler heat input
Controller action: reverse

Proportional gain = 5 %/%

Integral time = 5 min
Use default values for other terms

Loop 7
Controller: CC7

Type of controller: PI
Controlled variable: MeOH mole fraction in the distillate
Manipulated variable: reflux rate (mass low)
f

Controller action: reverse

Proportional gain = 5 %/%

Integral time = 5 min
Use default values for other terms

Now the flowsheet is ready for closed-loop performance study Start the program
.

as usual. It is important to mention that to restart a dynamic simulation click 'Restart'

(F7) rom the Run menu or press 'Re-start Simulation' button on the Run Control toolbar.
f

Performance of the closed-loop RD process

In the present study, two consecutive step changes in methanol feed temperature (46.85
-
» 40oC at time = 1.7 hours and then 40 -> 460C at time = 3.9 hours) have been
introduced to examine the performance of the closed-loop RD process. A change in feed
temperature affects the internal composition in the reactive zone. This, in turn, may
deteriorate the product quality. The system responses to temperature disturbance are
illustrated in Figure 6.26. It is obvious that the proposed structure is able to maintain
the MTBE purity in the bottoms under the influence of disturbance variable. It can
also prevent excessive losses of both methanol and iso-butene in the products.
Each Aspen Dynamics model includes different plots and tables from which we can
easily access the simulation inputs as well as results. For this, irst highlight a
f

block or stream, then right-click to point Forms and inally select the item that we
f

want to access.
DYNAMICS AND CONTROL OF PRESSURE-DRIVEN PROCESSES 309
EBB

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FIGURE 6.26

Performance of the closed-loop RD process with Measurement lags

Aspen Dynamics screen, shown in Figure 6.27 includes three dead time blocks (DTI,
,

DT2 and DT3) connected with three composition controllers (CC4 CC6 and CC7). ,

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FIGURE 6.27
310 PROCESS SIMULATION AND CONTROL USING ASPEN

The measurement lag of 15 sec (0 25 min) is used in all composition loops. To .

incorporate a dead time for a measured variable say methanol mole fraction on ,

Stage 10, highlight DTI block right-click on the block, point to Forms and then select
,

Configure to open the configure table. In the Value cell enter 0.25 min as a sensor ,

dead time. Follow the same approach for other two dead time blocks .

Here, we have used the proportional gain of 1 %/% and integral time of 20 min or

f
all composition controllers. The effects of disturbance in butene feed temperature have
been depicted in Figure 6.28.

mm
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to 23 84
to 23 85
to 23 86

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FIGURE 6.28

Initially a step decrease (76.85 -> 650C at time = 8 hours) and subsequently a step
increase (65 -> 760C at time = 15 hours) have been considered in the simulation study.
The developed closed-loop process lowsheet responds satisfactorily under load variable
f

change and measurement lag.

SUMMARY AND CONCLUSIONS |

In Chapter 5, we have studied the dynamics and control of the low-driven chemical
f

processes. Here, a case study has been conducted on a MTBE catalytic distillation
column using the pressure-driven dynamics. The complete process low diagram includes
f

a distillation column, a feed compressor, a feed pump and three control valves. In the
MTBE synthesis process, a bottom product containing high-purity MTBE and a top
product enriched with n-butene are obtained. To maintain the MTBE purity in the
bottoms stream, several control structures have been configured with the lowsheet in
f
DYNAMICS AND CONTROL OF PKKSSURK-DRIVKN PROCKSSKS .*J 1 1

Aspen Dynamics. All of the structures are SISO schemes with PI controllers (P-only
on levels). The controllers have been tuned by simply using heuristics. The proposed
closed-loop process provides satisfactory results under disturbance input and
measurement lag.

PROBLEMS

6 . 1 A binary mixture of ethanol and l-propanol enters a flash drum (Flash2) The
feed specifications are shown in Figure 6.29 with the process low diagram .

f
Liquid mixture
(UQ-MIX) CV2

Temperature = 90X
Pressure = 1,4 bar
Flow rate = 120 kmol/hr cCH liq-mix f»B-[fgiE
CV1
Component Mol fract

ethanol 06

1-propanol 04 .
-
(pF]->t'i-|pdt-uq1-o
CV3

FIGURE 6.29 A flowsheet of a flash drum

The lash chamber operates at 90oC and 1.2 bar. The vertically placed separator
f

with a length of 2 m and diameter of 1 m has elliptical head type. All the control
valves have a pressure drop of 0.2 bar. Applying the RK-Soave thermodynamic
model as a base property method,
(a) simulate the lowsheet to obtain the product compositions,
f

(b) design the two control schemes to maintain the pressure and liquid level in
the lash chamber, and
f

(c) examine the performance of the designed controllers.

6 2 Styrene is produced by dehydrogenation of ethylbenzene Here we consider an
.
.

irreversible reaction:

C2H5 -> CgHs - CH = CH2 + H2

ethylbenzene styrene hydrogen
The process low diagram that consists of a reactor (RSTOIC) a feed compressor ,
f

(COMPRESS) and a control valve (CV) is shown in Figure 6 30 .

An isentropic compressor discharges the FEED stream that enters the RStoic
reactor at 2 bar The reactor runs at 260oC and 2 bar The control valve involves
.

a pressure drop of 0 2 bar Use the fractional conversion of ethylbenzene equals

08
.
.

Applying the Peng-Robinson thermodynamic method.

(a) simulate the lowsheet and
f

'
b) observe the closed loop process response employing the flow controllers.
-
312 PROCESS SIMULATION AND CONTROL USING ASPECT

Pure ethylbenzene

Temperature = 260oC
Pressure = 1 bar
Flow rate = 100 kmol/hr

"
M ! [pptI-

o
cv
-

|feed|-1
COMPRESS RSTOIC

FIGURE 6.30 A flowsheet for the production of styrene.

6. 3 The hydrogenation of aniline produces cyclohexylamine in a CSTR according to

the following reaction:
C6H5NH2 + 3H2 -> CeHnNHa
aniline hydrogen cyclohexylamine
The complete process flowsheet is provided in Figure 6.31. It includes a pump
having a discharge pressure of 41.2 bar, an isentropic compressor having a
discharge pressure of 41 bar, an elliptical head-type vertically placed reactor
having a length of 1 m and three control valves with a pressure drop of 0.2 bar
in each.

FEED FL P1 -
u

F1
CV1 CV2

PUMP
> <

>ff J 1 PDT-LIQ \-0

CV3

COMPRESS RCSTR

FIGURE 6.31 A flowsheet for aniline hydrogenation

The reactor operates at 41 bar and 120oC and its volume is 1200 t3 (75% liquid). For
,
f

the liquid-phase reaction the inlet streams Fl and F2, are specified in Table 6.2.
, ,

TABLE 6.2

Reactant Temperature (°C) Pressure (bar) Flow rate (kmol/hr)

Pure aniline (Fl) 40 7 45

Pure hydrogen (F2) -

12 7 160
DYNAMICS AND CONTROL OF PKKSSURE DRIVEN PROCESSES 313

Data for the Arrhemus law:

Pre-exponentiaJ factor = 5 x lO8 m3/kmol s
Activation energ>' = 20 000 .
Btu/lbmol

ICJ basis = Molanty

Use the SYSOP0 base property method in the simulation. The reaction is first-
order in aniline and hydrogen, and the reaction rate constant is defined with
respect to aniline.
(a) Simulate the lowsheet to compute the product compositions ,
f

ibi configure the control schemes for maintaining the liquid level pressure and ,

temperature in the CSTR. and

(c) investigate the closed-loop process response under any disturbance input
6.
4 Repeat the above problem with adding a time lag of 0.2 min in temperature
measurement and carry out the closed-loop process simulation to report the
disturbance rejection performance of the developed scheme
6 .5 In addition to the level, pressure and temperature controllers, include the flow
controllers with the flowsheet, shown in Problem 6.3. and inspect the closed-loop
process response.

REFERENCES |
Al-Arfaj. M A. and W L Luyben (2000) "Comparison of Alternative Control Structures
.

for an Ideal Two-product Reactive Distillation Column Ind. Eng. Chem. Res., 39,
"

pp 3298-3307.
Al-Arfaj. M A and W L. Luyben (2002) "Control Study of Ethyl fert Butyl Ether Reactive
,

Di-tillation." Ind. Eng Chem Res., 41, pp. 3784 -3796. .

Jacobs. R. and R Krishna (1993) "Multiple Solutions in Reactive Distillation for Methyl
.

ot-Butyl Ether Synthesis Ind. Eng. Chem. Res., 32. pp 1706-1709.

.
"
t

Kaymak D B and W L. Luyben (2005) "Comparison of Two Types of Two-temperature

,
,

Control Structures for Reactive Distillation Columns "

, Ind. Eng. Chem. Res , 44,

pp 4625-4640.
Luyben ,
W L. i2004i "Use of Dynamic Simulation to Converge Complex Process
Flowsheets Chemical Engineering Education pp. 142-149
"

.
,

Rehfinger A and U Hoffmann (1990)

.
,
"Kinetics of Methyl Tertiary Butyl Ether Liquid
Phase Synthesis Catalyzed by Ion Exchange Resin-I Intrinsic Rate Expression in .

Liquid Phase Activities Chem Eng. Set.. 45. pp. 1605-1617.

"
.

Seader J D and E J Henley 11998) '

.
.
"Separation Process Principles, John Wiley &
Sons In< . New York .

W Bng, S J I) s H WonK and E K Lee (2003) "Control of a Reactive Distillation Column

,
.

m the Kinetic Regime for the Synthesis of n Butvl Acetate Ind Eng. Chem Re* . "

42. pp B182-5194.
This
Thispage
pageintentionally
intentionallyleft
leftblank
blank

Rs. 295.00

PROCESS SIMULATION AND CONTROL USING ASPEN

Amiya K. Jana

ISBN-978-81-203-3659-9

The export rights of this book are vested solely with the publisher.

Published by Asoke K. Ghosh, PHI Learning Private Limited, M-97, Connaught Circus,
New Delhi-110001 and Printed by Jay Print Pack Private Limited, New Delhi-110015.
Index

ABSBR2. 164 ('hmmnil phtnt, 180

AbNorplittn cnliunn, UM Compoaonl ))>, I Ml
'

AnounlinK mformnhon. I I. 'M. 58 ( omponpnt tijuiii<, I it.

Acetone, 93 ('onfiguro dialog bosp li'io
Activation energy, (>r> Control pnncl, 20
Adsorption, 100 Control vnlvi'M. 22!)
Aniline, M (iontrol modali icon, 2(18
ArrhrniUH Inw, Bf*. 70 '
( outI'ol Mi mil icon, 2(18
ASPEN. :J (!yclohoxylamina, (ir»
Aopen batchCAD, 1
Aapen chroniHloKmphv. I
Aapen Dynamica, 1 I cnniei', 7, 51
Ahpimi Dynaniica 22!) ,
1 )(«(>( lianisuir column, n>7
Aapen HYSYS. 1
DcHi n ipac, I7(i
Aapen Plus, I
Di'w point, 35
Aapen polymers pliiH 1
Direcl acting control, 243
.

Anpcn prnpcrl ich I

Diaplay plot, I7i>
Diatillation, l()7
Hhmc method )H Diatillation train, 180, 100
,

Bati hKrac I0H Diatl, 107

Binary diatillation column I )nvirin tor i r, 100

Mth
'

Binary mixture \2 I )i mn modela, 7

BK10 tr>i Dryer, r>2

Block 7 ,
D8TWII. 107. 108
Block inftirmation 33 ,
I dynamic mode, 253
'' "
' '-Me point ,
28 i kynumicN library, 2(i7
Dvnn I'M IS. r>

'
t'tnlvtir dialillation 28fi ,

OIJIOK 152 Mi hyll'onMtne, 56

flbemCad ,
. 1 rixpOlll'lltN, 2il7
316 INDKX

Flash 2, 3, 7 Peng-Robinson 60 ,

Flow-driven, 229 PetroFrac 108,

Flow-driven simulation, 229 PetroFrac model 1 48 ,

Formula, 116 Plot wizard 48. 90, 147 ,

Fraction basis, 195 POLYSRK 204 ,

FSpht, 204 Power law 54, 87 ,

Pre-exponential factor 65 ,

Pressure-driven simulations 229, 285 ,

Geometrv data, 237 PRO/1ITM 3 ,

Process flowsheet window 9 ,

Process variable 249 ,

HETP, 287
Property method 18, 32. 39 ,

Hvdraulics sheet, 299

Pulse input 253 ,

HYSYSTM, 3
Pumparound circuits 149 ,

Initialization mode, 253

RadFrac, 107
Initialize values button, 273
RadFrac model, 127
Input summary, 23, 64
Ranges tab, 247
RateFrac, 108
RBatch, 54
Ketene, 93
Kinetic, 74
RCSTR, 54

Kinetic factor, 100 RCSTR model, 230

Reconnect destination, 192
Kinetic reaction type, 300
Kinetic sheets, 238 Reconnect source, 193
REFINERY, 154
Regulatory performance, 254, 275
LHHW, 54, 93 Rename block, 11, 193
LMTD, 256 Rename stream, 193
Report ile, 23, 122
f

Report options, 15
MTBE column, 286 Requil, 54
Material STREAMS, 7 Results plot dialog box, 251
Measurement lags, 309, 310 Reverse acting control, 243
MELLAPAK, 287 RGibbs, 54
Methane, 93 RK-Soave, 28. 32
Model library, 5 RPlug. 54, 78
Molarity, 76 RStoic, 54, 55
Multi-input/multi-output, 243 Run status, 62
MultiFrac, 107 RYield, 54

NRTL, 52 SCFrac, 108

Sensitivity analysis 172 ,

Sep 1, 2, 7
Object manager, 179 Separators, 42
Operator set point, 247 Servo performance 275 ,

Optimization, 178 Setup, 15

Side strippers 149 ,

Single-inputysingle-output, 243
Pause at time, 251 Solver settings, 13
PENG-ROB, 140 SRK, 52
INDEX 317

Stepwise, 7 UNIFAC. 287

Stoichiometric coeficients, 237 User Models, 7

f
Stream information. 18. 33
Stream table, 22
Styrene, 55 Vapour raction 210
,

f
SULZER, 287 Variable number 180 .

SYSOPO*. 18 Vinyl chloride monomer 189, 203

Temperature approach, 262 Wilson model 43

Template. 5 Winn-Underwood-Gilliland method 107

,
PROCESS SIMULATION
AND CONTROL USING
ASPEN AMIYA K. JANA

As Ihe complexilv of a plant integrated with several process units increases solving Ihe model structure with a large equation
,

set becomes a challenging task. To overcome this situation, various process flowsheet simulators are used. This book describes
the simulation, optimisation, dynamics and closed-loop control of a wide variety of chemical processes using the most popular
'"
commercial flowsheet simulator Aspen .

The book presents the Aspen simulation of a large variety of chemical units, including flash drum, continuous stirred tank reactor
(CSTR), plug flow reactor (PFR), petroleum refining column, heat exchanger, absorption lower, reactive dislittation, disiillation
train, and monomer production unit. It also discusses the dynamics and control of flow-driven as well as pressure-driven chemical
processes using Ihe Aspen Dynamics package.

KEY FEATURES

Acquaints Ihe students with the simulation of large chemical plants with several single process units.
*
Includes a large number of worked out examples ittustrated in step ay-step format for easy understanding of the concepts.
f

Provides chaptered problems lor extensive practice.

This book is suitable for the undergraduate and postgraduate students of chemical engineering. It will also be helpful to research
scientists and practising engineers.

THE AUTHOR

Amiya K. Jana received his B.E. degree in chemical engineering in 1998 from Jadavpur University, M.Tech. in chemical engineering
in 2000 from IIT Kharagpur, and Ph.D. in chemical engineering in 2004 from IIT Kharagpur.
Presently. Or. Jana is Assistant Professor at IIT Kharagpur. His areas of research include control system process intensification,
,

and modelling and simulation. He is also the author of ChemiesJ Process Mode/ting and Computer Simukuon published by
PHI learning.

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