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- Herausgeber: John Wiley & Sons
- Kategorie: Fachliteratur
- Sprache: Englisch
* Facilitates the process of learning and later mastering Aspen Plus® with step by step examples and succinct explanations * Step-by-step textbook for identifying solutions to various process engineering problems via screenshots of the Aspen Plus® platforms in parallel with the related text * Includes end-of-chapter problems and term project problems * Includes online exam and quiz problems for instructors that are parametrized (i.e., adjustable) so that each student will have a standalone version * Includes extra online material for students such as Aspen Plus®-related files that are used in the working tutorials throughout the entire textbook
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Seitenzahl: 876
Veröffentlichungsjahr: 2016
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Table of Contents
COVER
TITLE PAGE
COPYRIGHT
DEDICATION
PREFACE
THE BOOK THEME
ABOUT THE AUTHOR
WHAT DO YOU GET OUT OF THIS BOOK?
WHO SHOULD READ THIS BOOK?
NOTES FOR INSTRUCTORS
ACKNOWLEDGMENT
ABOUT THE COMPANION WEBSITE
CHAPTER 1: INTRODUCING ASPEN PLUS
1.1 WHAT DOES ASPEN STAND FOR?
1.2 WHAT IS ASPEN PLUS PROCESS SIMULATION MODEL?
1.3 LAUNCHING ASPEN PLUS V8.8
1.4 BEGINNING A SIMULATION
1.5 ENTERING COMPONENTS
1.6 SPECIFYING THE PROPERTY METHOD
1.7 IMPROVEMENT OF THE PROPERTY METHOD ACCURACY
1.8 FILE SAVING
EXERCISE 1.1
1.9 A GOOD FLOWSHEETING PRACTICE
1.10 ASPEN PLUS BUILT-IN HELP
1.11 FOR MORE INFORMATION
HOMEWORK/CLASSWORK 1.1 (
PXY
)
HOMEWORK/CLASSWORK 1.2 (Δ
G
MIX
)
HOMEWORK/CLASSWORK 1.3 (LIKES DISSOLVE LIKES) AS ENVISAGED BY NRTL PROPERTY METHOD
HOMEWORK/CLASSWORK 1.4 (THE MIXING RULE)
CHAPTER 2: MORE ON ASPEN PLUS FLOWSHEET FEATURES (1)
2.1 PROBLEM DESCRIPTION
2.2 ENTERING AND NAMING COMPOUNDS
2.3 BINARY INTERACTIONS
2.4 THE “SIMULATION” ENVIRONMENT: ACTIVATION DASHBOARD
2.5 PLACING A BLOCK AND MATERIAL STREAM FROM MODEL PALETTE
2.6 BLOCK AND STREAM MANIPULATION
2.7 DATA INPUT, PROJECT TITLE, AND REPORT OPTIONS
2.8 RUNNING THE SIMULATION
2.9 THE DIFFERENCE AMONG RECOMMENDED PROPERTY METHODS
2.10 NIST/TDE EXPERIMENTAL DATA
HOMEWORK/CLASSWORK 2.1 (WATER–ALCOHOL SYSTEM)
HOMEWORK/CLASSWORK 2.2 (WATER–ACETONE–EIPK SYSTEM WITH NIST/DTE DATA)
HOMEWORK/CLASSWORK 2.3 (WATER–ACETONE–EIPK SYSTEM WITHOUT NIST/DTE DATA)
CHAPTER 3: MORE ON ASPEN PLUS FLOWSHEET FEATURES (2)
3.1 PROBLEM DESCRIPTION: CONTINUATION TO THE PROBLEM IN CHAPTER 2
3.2 THE CLEAN PARAMETERS STEP
3.3 SIMULATION RESULTS CONVERGENCE
3.4 ADDING STREAM TABLE
3.5 PROPERTY SETS
3.6 ADDING STREAM CONDITIONS
3.7 PRINTING FROM ASPEN PLUS
3.8 VIEWING THE INPUT SUMMARY
3.9 REPORT GENERATION
3.10 STREAM PROPERTIES
3.11 ADDING A FLASH SEPARATION UNIT
3.12 THE REQUIRED INPUT FOR “FLASH3”-TYPE SEPARATOR
3.13 RUNNING THE SIMULATION AND CHECKING THE RESULTS
HOMEWORK/CLASSWORK 3.1 (OUTPUT OF INPUT DATA AND RESULTS)
HOMEWORK/CLASSWORK 3.2 (OUTPUT OF INPUT DATA AND RESULTS)
HOMEWORK/CLASSWORK 3.3 (OUTPUT OF INPUT DATA AND RESULTS)
HOMEWORK/CLASSWORK 3.4 (THE PARTITION COEFFICIENT OF A SOLUTE)
CHAPTER 4: FLASH SEPARATION AND DISTILLATION COLUMNS
4.1 PROBLEM DESCRIPTION
4.2 ADDING A SECOND MIXER AND FLASH
4.3 DESIGN SPECIFICATIONS STUDY
EXERCISE 4.1 (DESIGN SPEC)
4.4 ASPEN PLUS DISTILLATION COLUMN OPTIONS
4.5 “DSTWU” DISTILLATION COLUMN
4.6 “DISTL” DISTILLATION COLUMN
4.7 “RadFrac” DISTILLATION COLUMN
HOMEWORK/CLASSWORK 4.1 (WATER–ALCOHOL SYSTEM)
HOMEWORK/CLASSWORK 4.2 (WATER–ACETONE–EIPK SYSTEM WITH NIST/DTE DATA)
HOMEWORK/CLASSWORK 4.3 (WATER–ACETONE–EIPK SYSTEM WITHOUT NIST/DTE DATA)
HOMEWORK/CLASSWORK 4.4 (SCRUBBER)
CHAPTER 5: LIQUID–LIQUID EXTRACTION PROCESS
5.1 PROBLEM DESCRIPTION
5.2 THE PROPER SELECTION FOR PROPERTY METHOD FOR EXTRACTION PROCESSES
5.3 DEFINING NEW PROPERTY SETS
5.4 THE PROPERTY METHOD VALIDATION VERSUS EXPERIMENTAL DATA USING SENSITIVITY ANALYSIS
5.5 A MULTISTAGE EXTRACTION COLUMN
5.6 THE TRIANGLE DIAGRAM
REFERENCES
HOMEWORK/CLASSWORK 5.1 (SEPARATION OF MEK FROM OCTANOL)
HOMEWORK/CLASSWORK 5.2 (SEPARATION OF MEK FROM WATER USING OCTANE)
HOMEWORK/CLASSWORK 5.3 (SEPARATION OF ACETIC ACID FROM WATER USING ISOPROPYL BUTYL ETHER)
HOMEWORK/CLASSWORK 5.4 (SEPARATION OF ACETONE FROM WATER USING TRICHLOROETHANE)
HOMEWORK/CLASSWORK 5.5 (SEPARATION OF PROPIONIC ACID FROM WATER USING MEK)
CHAPTER 6: REACTORS WITH SIMPLE REACTION KINETIC FORMS
6.1 PROBLEM DESCRIPTION
6.2 DEFINING REACTION RATE CONSTANT TO Aspen Plus
®
ENVIRONMENT
6.3 ENTERING COMPONENTS AND METHOD OF PROPERTY
6.4 THE RIGOROUS PLUG-FLOW REACTOR (RPLUG)
6.5 REACTOR AND REACTION SPECIFICATIONS FOR RPLUG (PFR)
6.6 RUNNING THE SIMULATION (PFR ONLY)
EXERCISE 6.1
6.7 COMPRESSOR (CMPRSSR) AND RadFrac RECTIFYING COLUMN (RECTIF)
6.8 RUNNING THE SIMULATION (PFR + CMPRSSR + RECTIF)
EXERCISE 6.2
6.9 RadFrac DISTILLATION COLUMN (DSTL)
6.10 RUNNING THE SIMULATION (PFR + CMPRSSR + RECTIF + DSTL)
6.11 REACTOR AND REACTION SPECIFICATIONS FOR RCSTR
6.12 RUNNING THE SIMULATION (PFR + CMPRSSR + RECTIF + DSTL + RCSTR)
EXERCISE 6.3
6.13 SENSITIVITY ANALYSIS: THE REACTOR'S OPTIMUM OPERATING CONDITIONS
REFERENCES
HOMEWORK/CLASSWORK 6.1 (HYDROGEN PEROXIDE SHELF-LIFE)
HOMEWORK/CLASSWORK 6.2 (ESTERIFICATION PROCESS)
HOMEWORK/CLASSWORK 6.3 (LIQUID-PHASE ISOMERIZATION OF
n
-BUTANE)
CHAPTER 7: REACTORS WITH COMPLEX (NON-CONVENTIONAL) REACTION KINETIC FORMS
7.1 PROBLEM DESCRIPTION
7.2 NON-CONVENTIONAL KINETICS: LHHW TYPE REACTION
7.3 GENERAL EXPRESSIONS FOR SPECIFYING LHHW TYPE REACTION IN ASPEN PLUS
7.4 THE PROPERTY METHOD: “SRK”
7.5 RPLUG FLOWSHEET FOR METHANOL PRODUCTION
7.6 ENTERING INPUT PARAMETERS
7.7 DEFINING METHANOL PRODUCTION REACTIONS AS LHHW TYPE
7.8 SENSITIVITY ANALYSIS: EFFECT OF TEMPERATURE AND PRESSURE ON SELECTIVITY
REFERENCES
HOMEWORK/CLASSWORK 7.1 (GAS-PHASE OXIDATION OF CHLOROFORM)
HOMEWORK/CLASSWORK 7.2 (FORMATION OF STYRENE FROM ETHYLBENZENE)
HOMEWORK/CLASSWORK 7.3 (COMBUSTION OF METHANE OVER STEAM-AGED Pt–Pd CATALYST)
CHAPTER 8: PRESSURE DROP, FRICTION FACTOR, ANPSH, AND CAVITATION
8.1 PROBLEM DESCRIPTION
8.2 THE PROPERTY METHOD: “STEAMNBS”
8.3 A WATER PUMPING FLOWSHEET
8.4 ENTERING PIPE, PUMP, AND FITTINGS SPECIFICATIONS
8.5 RESULTS: FRICTIONAL PRESSURE DROP, THE PUMP WORK, VALVE CHOKING, AND ANPSH VERSUS RNPSH
EXERCISE 8.1
8.6 MODEL ANALYSIS TOOLS: SENSITIVITY FOR THE ONSET OF CAVITATION OR VALVE CHOKING CONDITION
REFERENCES
HOMEWORK/CLASSWORK 8.1 (PENTANE TRANSPORT)
HOMEWORK/CLASSWORK (8.2) (GLYCEROL TRANSPORT)
HOMEWORK/CLASSWORK 8.3 (AIR COMPRESSION)
CHAPTER 9: THE OPTIMIZATION TOOL
9.1 PROBLEM DESCRIPTION: DEFINING THE OBJECTIVE FUNCTION
9.2 THE PROPERTY METHOD: “STEAMNBS”
9.3 A FLOWSHEET FOR WATER TRANSPORT
9.4 ENTERING STREAM, PUMP, AND PIPE SPECIFICATIONS
9.5 MODEL ANALYSIS TOOLS: THE OPTIMIZATION TOOL
9.6 MODEL ANALYSIS TOOLS: THE SENSITIVITY TOOL
9.7 LAST COMMENTS
REFERENCES
HOMEWORK/CLASSWORK 9.1 (SWAMEE–JAIN EQUATION)
HOMEWORK/CLASSWORK 9.2 (A SIMPLIFIED PIPE DIAMETER OPTIMIZATION)
HOMEWORK/CLASSWORK 9.3 (THE OPTIMUM DIAMETER FOR A VISCOUS FLOW)
HOMEWORK/CLASSWORK 9.4 (THE SELECTIVITY OF PARALLEL REACTIONS)
CHAPTER 10: HEAT EXCHANGER (H.E.) DESIGN
10.1 PROBLEM DESCRIPTION
10.2 TYPES OF HEAT EXCHANGER MODELS IN ASPEN PLUS
10.3 THE SIMPLE HEAT EXCHANGER MODEL (“Heater”)
10.4 THE RIGOROUS HEAT EXCHANGER MODEL (“HeatX”)
10.5 THE RIGOROUS EXCHANGER DESIGN AND RATING (EDR) PROCEDURE
10.6 GENERAL FOOTNOTES ON EDR EXCHANGER
REFERENCES
HOMEWORK/CLASSWORK 10.1 (HEAT EXCHANGER WITH PHASE CHANGE)
HOMEWORK/CLASSWORK 10.2 (HIGH HEAT DUTY HEAT EXCHANGER)
HOMEWORK/CLASSWORK 10.3 (DESIGN SPEC HEAT EXCHANGER)
CHAPTER 11: ELECTROLYTES
11.1 PROBLEM DESCRIPTION: WATER DE-SOURING
11.2 WHAT IS AN ELECTROLYTE?
11.3 THE PROPERTY METHOD FOR ELECTROLYTES
11.4 THE ELECTROLYTE WIZARD
11.5 WATER DE-SOURING PROCESS FLOWSHEET
11.6 ENTERING THE SPECIFICATIONS OF FEED STREAMS AND THE STRIPPER
REFERENCES
HOMEWORK/CLASSWORK 11.1 (AN ACIDIC SLUDGE NEUTRALIZATION)
HOMEWORK/CLASSWORK 11.2 (CO
2
REMOVAL FROM NATURAL GAS)
HOMEWORK/CLASSWORK 11.3 (PH OF AQUEOUS SOLUTIONS OF SALTS)
APPENDIX 11.A DEVELOPMENT OF “ELECNRTL” MODEL
CHAPTER 12: POLYMERIZATION PROCESSES
12.1 THE THEORETICAL BACKGROUND
12.2 HIGH-DENSITY POLYETHYLENE (HDPE) HIGH-TEMPERATURE SOLUTION PROCESS
12.3 CREATING ASPEN PLUS FLOWSHEET FOR HDPE
12.4 IMPROVING CONVERGENCE
12.5 PRESENTING THE PROPERTY DISTRIBUTION OF POLYMER
REFERENCES
HOMEWORK/CLASSWORK 12.1 (MAXIMIZING THE DEGREE OF HDPE POLYMERIZATION)
HOMEWORK/CLASSWORK 12.2 (STYRENE ACRYLONITRILE (SAN) POLYMERIZATION)
APPENDIX 12.A THE MAIN FEATURES AND ASSUMPTIONS OF ASPEN PLUS CHAIN POLYMERIZATION MODEL
APPENDIX 12.B THE NUMBER AVERAGE MOLECULAR WEIGHT (MWN) AND WEIGHT AVERAGE MOLECULAR WEIGHT (MWW)
CHAPTER 13: CHARACTERIZATION OF DRUG-LIKE MOLECULES USING ASPEN PROPERTIES
13.1 INTRODUCTION
13.2 PROBLEM DESCRIPTION
13.3 CREATING ASPEN PLUS PHARMACEUTICAL TEMPLATE
13.4 DEFINING MOLECULAR STRUCTURE OF BNZMD-UD
13.5 ENTERING PROPERTY DATA
13.6 CONTRASTING Aspen Plus DATABANK (BNZMD-DB) VERSUS BNZMD-UD
REFERENCES
HOMEWORK/CLASSWORK 13.1 (VANILLIN)
HOMEWORK/CLASSWORK 13.2 (IBUPROFEN)
CHAPTER 14: SOLIDS HANDLING
14.1 INTRODUCTION
14.2 PROBLEM DESCRIPTION #1: THE CRUSHER
14.3 CREATING ASPEN PLUS FLOWSHEET
EXERCISE 14.1 (DETERMINE CRUSHER OUTLET PSD FROM COMMINUTION POWER)
EXERCISE 14.2 (SPECIFYING CRUSHER OUTLET PSD)
14.4 PROBLEM DESCRIPTION #2: THE FLUIDIZED BED FOR ALUMINA DEHYDRATION
14.5 CREATING ASPEN PLUS FLOWSHEET
EXERCISE 14.3 (RECONVERGING THE SOLUTION FOR AN INPUT CHANGE)
REFERENCES
HOMEWORK/CLASSWORK 14.1 (KCl DRYING)
HOMEWORK/CLASSWORK 14.2 (KCl CRYSTALLIZATION)
APPENDIX 14.A SOLIDS UNIT OPERATIONS
APPENDIX 14.B SOLIDS CLASSIFICATION
APPENDIX 14.C PREDEFINED STREAM CLASSIFICATION
APPENDIX 14.D SUBSTREAM CLASSES
APPENDIX 14.E PARTICLE SIZE DISTRIBUTION (PSD)
APPENDIX 14.F FLUIDIZED BEDS
CHAPTER 15: ASPEN PLUS® DYNAMICS
15.1 INTRODUCTION
15.2 PROBLEM DESCRIPTION
15.3 PREPARING ASPEN PLUS SIMULATION FOR Aspen Plus DYNAMICS (APD)
15.4 CONVERSION OF ASPEN PLUS STEADY-STATE INTO DYNAMIC SIMULATION
15.5 OPENING A DYNAMIC FILE USING APD
15.6 THE “SIMULATION MESSAGES” WINDOW
15.7 THE RUNNING MODE: INITIALIZATION
15.8 ADDING TEMPERATURE CONTROL (TC) UNIT
15.9 SNAPSHOTS MANAGEMENT FOR CAPTURED SUCCESSFUL OLD RUNS
15.10 THE CONTROLLER FACEPLATE
15.11 COMMUNICATION TIME FOR UPDATING/PRESENTING RESULTS
15.12 THE CLOSED-LOOP AUTO-TUNE VARIATION (ATV) TEST VERSUS OPEN-LOOP TUNE-UP TEST
15.13 THE OPEN-LOOP (MANUAL MODE) TUNE-UP FOR LIQUID LEVEL CONTROLLER
15.14 THE CLOSED-LOOP DYNAMIC RESPONSE FOR LIQUID LEVEL LOAD DISTURBANCE
15.15 THE CLOSED-LOOP DYNAMIC RESPONSE FOR LIQUID LEVEL SET-POINT DISTURBANCE
15.16 ACCOUNTING FOR DEAD/LAG TIME IN PROCESS DYNAMICS
15.17 THE CLOSED-LOOP (AUTO MODE) ATV TEST FOR TEMPERATURE CONTROLLER (TC)
15.18 THE CLOSED-LOOP DYNAMIC RESPONSE: “TC” RESPONSE TO TEMPERATURE LOAD DISTURBANCE
15.19 INTERACTIONS BETWEEN “LC” AND “TC” CONTROL UNIT
15.20 THE STABILITY OF A PROCESS WITHOUT CONTROL
15.21 THE CASCADE CONTROL
15.22 MONITORING OF VARIABLES AS FUNCTIONS OF TIME
15.23 FINAL NOTES ON THE VIRTUAL (DRY) PROCESS CONTROL IN APD
REFERENCES
HOMEWORK/CLASSWORK 15.1 (A CASCADE CONTROL OF A SIMPLE WATER HEATER)
HOMEWORK/CLASSWORK 15.2 (A CSTR CONTROL WITH “LMTD” HEAT TRANSFER OPTION)
HOMEWORK/CLASSWORK 15.3 (A PFR CONTROL FOR ETHYLBENZENE PRODUCTION)
CHAPTER 16: SAFETY AND ENERGY ASPECTS OF CHEMICAL PROCESSES
16.1 INTRODUCTION
16.2 PROBLEM DESCRIPTION
16.3 THE “SAFETY ANALYSIS” ENVIRONMENT
16.4 ADDING A PRESSURE SAFETY VALVE (PSV)
16.5 ADDING A RUPTURE DISK (RD)
16.6 PRESENTATION OF SAFETY-RELATED DOCUMENTS
16.7 PREPARATION OF FLOWSHEET FOR “ENERGY ANALYSIS” ENVIRONMENT
16.8 THE “ENERGY ANALYSIS” ACTIVATION
16.9 THE “ENERGY ANALYSIS” ENVIRONMENT
16.10 THE ASPEN ENERGY ANALYZER
HOMEWORK/CLASSWORK 16.1 (ADDING A STORAGE TANK PROTECTION)
HOMEWORK/CLASSWORK 16.2 (SEPARATION OF C2/C3/C4 HYDROCARBON MIXTURE)
CHAPTER 17: ASPEN PROCESS ECONOMIC ANALYZER (APEA)
17.1 OPTIMIZED PROCESS FLOWSHEET FOR ACETIC ANHYDRIDE PRODUCTION
17.2 COSTING OPTIONS IN ASPEN PLUS
17.3 THE FIRST ROUTE FOR CHEMICAL PROCESS COSTING
17.4 THE SECOND ROUND FOR CHEMICAL PROCESS COSTING
HOMEWORK/CLASSWORK 17.1 (FEED/PRODUCT UNIT PRICE EFFECT ON PROCESS PROFITABILITY)
HOMEWORK/CLASSWORK 17.2 (USING EUROPEAN ECONOMIC TEMPLATE)
HOMEWORK/CLASSWORK 17.3 (PROCESS PROFITABILITY OF ACETONE RECOVERY FROM SPENT SOLVENT)
APPENDIX 17.A
EXAMPLE 17.1 (UNIFORM CASH FLOW)
EXAMPLE 17.2 (NON-UNIFORM CASH FLOW)
EXAMPLE 17.3
EXAMPLE 17.4
CHAPTER 18: TERM PROJECTS (TP)
18.1 TP #1: PRODUCTION OF ACETONE VIA THE DEHYDRATION OF ISOPROPANOL
18.2 TP #2: PRODUCTION OF FORMALDEHYDE FROM METHANOL (SENSITIVITY ANALYSIS)
18.3 TP #3: PRODUCTION OF DIMETHYL ETHER (PROCESS ECONOMICS AND CONTROL)
18.4 TP #4: PRODUCTION OF ACETIC ACID VIA PARTIAL OXIDATION OF ETHYLENE GAS
18.5 TP #5: PYROLYSIS OF BENZENE
18.6 TP #6: REUSE OF SPENT SOLVENTS
18.7 TP #7: SOLIDS HANDLING: PRODUCTION OF POTASSIUM SULFATE FROM SODIUM SULFATE
18.8 TP #8: SOLIDS HANDLING: PRODUCTION OF CCO
3
-BASED AGGLOMERATE AS A GENERAL ADDITIVE
18.9 TP #9: SOLIDS HANDLING: FORMULATION OF DI-AMMONIUM PHOSPHATE AND POTASSIUM NITRATE BLEND FERTILIZER
18.10 TP #10: “FLOWSHEETING OPTIONS” | “CALCULATOR”: GAS DE-SOURING AND SWEETENING PROCESS
18.11 TP #11: USING MORE THAN ONE PROPERTY METHOD AND STREAM CLASS: SOLID CATALYZED DIRECT HYDRATION OF PROPYLENE TO ISOPROPYL ALCOHOL (IPA)
18.12 TP #12: POLYMERIZATION: PRODUCTION OF POLYVINYL ACETATE (PVAC)
18.13 TP #13: POLYMERIZATION: EMULSION COPOLYMERIZATION OF STYRENE AND BUTADIENE TO PRODUCE SBR
18.14 TP #14: POLYMERIZATION: FREE RADICAL POLYMERIZATION OF METHYL METHACRYLATE TO PRODUCE POLY(METHYL METHACRYLATE)
18.15 TP #15: LHHW KINETICS: PRODUCTION OF CYCLOHEXANONE-OXIME (CYCHXOXM) VIA CYCLOHEXANONE AMMOXIMATION USING CLAY-BASED TITANIUM SILICALITE (TS) CATALYST
INDEX
END USER LICENSE AGREEMENT
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Guide
Cover
Table of Contents
Preface
Begin Reading
List of Illustrations
Chapter 1: INTRODUCING ASPEN PLUS
Figure 1.1 Go to Windows 8.1 Startup menu, click on the down arrow key icon (
left
), and look for “Aspen Plus V8.8” icon (
right
).
Figure 1.2 On the first tiled interface for tablets, key in the keyword “aspen” in Windows Search text box and Windows 8.x will furnish the menu with applications that are related to “aspen”. Click on “
Aspen Plus V8.8
” to open.
Figure 1.3 Aspen Plus first window where the user is furnished with “
Resources
” ribbon and the choice to open either an existing or new file (i.e., simulation project).
Figure 1.4 Clicking on “
Training
” icon will populate the user's screen with different online training media that are available to the registered user.
Figure 1.5 Aspen Plus provides offline examples where the user can benefit from.
Figure 1.6 The difference between “
Chemicals with Metric Units
” (
top
) and “
Specialty Chemicals with Metric Units
” template (
bottom
) lies in what metric units some physical properties are expressed.
Figure 1.7 The main window of Aspen Plus flowsheet simulator.
Figure 1.8 The top portion of Aspen Plus V8.8 main window contains the “
Quick Access
” toolbar (top bar), the “
Top
” toolbar, the help-related textbox and button (middle bar), and ribbon tabs associated with each “
Top
” toolbar menu (bottom bar).
Figure 1.9 The offline built-in help database can be brought via clicking on the “
Show Help
” icon shown at the right top corner of the Aspen Plus v8.8 main window.
Figure 1.10 The “
Navigation
” pane that acts as folder/file explorer.
Figure 1.11 The input form for entering components involved in the process.
Figure 1.12 The “
Environments
” pane where the user has the flexibility to switch from one to another environment.
Figure 1.13 The “
Status
” bar where the user is updated about the
status quo
of Aspen Plus simulator (or solver).
Figure 1.14 The “
Zoom
” bar where the user may zoom in or out the input form under question.
Figure 1.15 Different color-coded symbols used by Aspen Plus to help the user better understand the status of the solver.
Figure 1.16 The field color coding adopted by Aspen Plus for the text of an input form, which is either editable or noneditable by the user.
Figure 1.17 The selected databanks are shown on the right side under “
Enterprise Database
” or “
Databanks
” tab.
Figure 1.18 Inclusion of “
NISTV88 NIST-TRC
” databank that is comprehensive in resources.
Figure 1.19 Entering “
Component ID
” by either name or chemical formula allows Aspen Plus to recognize the component. If it is not automatically recognized, then the component name and alias will be left blank.
Figure 1.20 The “
Find Compounds
” window enables the user to search using either the name or chemical formula of a compound, including the flexibility to refine search results.
Figure 1.21 Aspen Plus provides a wizard for helping the user select the proper property method(s) for a given chemical process or component type.
Figure 1.22 The property method selection wizard that helps the user refine the number of suitable property methods for a given process/component.
Figure 1.23 The user has to further select the type of component system in order to refine the property method selection by Aspen Plus.
Figure 1.24 Further zooming is carried out by choosing between a low- and a high-pressure operating condition.
Figure 1.25 The recommendation by Aspen Plus is to use any of the activity coefficient-based method such as NRTL, Wilson, UNIQUAC, and UNIFAC.
Figure 1.26 The user may select one process type that best describes the process in hand.
Figure 1.27 The property method wizard recommends the activity coefficient-based method for a general chemical process for pressure less than or equal to 10 bar and the equation of state method with advanced mixing rules for pressure greater than 10 bar. Some specialty chemical processes are also pinpointed.
Figure 1.28 The “
Property Method
” selection tree based on different categories: The nature of medium (i.e., polar vs. nonpolar, electrolyte vs. nonelectrolyte, or ideal vs. real), the operating conditions (i.e., high vs. low pressure), the presence/absence of interaction parameters, and the presence/absence of LLE.
Figure 1.29 Three components are chosen to demonstrate the improvement of the accuracy of the default property method for a chemical process, that is, “
NRTL
”.
Figure 1.30 Initially, the binary interaction parameters for MEK–1-hexene are missing. They can be calculated using “
UNIFAC
” method.
Figure 1.31 Select “
Run Property Analysis/Setup
” option to calculate the missing binary interactions parameters for MEK–1-hexene.
Figure 1.32 The binary interaction parameters are shown for MEK–1-hexene using “
UNIFAC
” method.
Figure 1.33 The “
Binary Analysis
” button is shown in “
Home
” ribbon.
Figure 1.34 Carrying out analysis via plotting the isothermal dew- and bubble-point pressure as a function of mole fraction of 1-hexene to see the deviation from ideality.
Figure 1.35 The dew- and bubble-point pressure as a function of 1-hexene mole fraction. Formation of an azeotrope can be seen at 1-hexene mole fraction greater than 0.80, in the form of an azeotrope.
Figure 1.36 Retrieving experiment-based data for the binary mixture of MEK–1-hexene with the help of “
NIST/TDE
” database.
Figure 1.37 A set of 11 data points are obtained from “
NIST/TDE
” databank for the given binary mixture.
Figure 1.38 The NIST/TDE consistency test with an overall data quality of 0.79.
Figure 1.39 The “
Binary experimental data to be saved
” window for saving NIST/TDE data set.
Figure 1.40 The experimental data are saved within Aspen Plus environment under “
Data
” folder.
Figure 1.41 Creation of regression data set called “
DR-1
”, which will be used under “
Regression
” mode.
Figure 1.42 The regression data set “
DR-1
” is ready to be examined using either regression or evaluation step.
Figure 1.43 The data set “
BVLE001
” contains the 11 data points for VLE of MEK–1-hexene binary mixture.
Figure 1.44 The “
Data Regression Run Selection
” window where the user selects the right data set to be examined.
Figure 1.45 The evaluation step results in terms of the statistical parameters that tell us about the model goodness.
Figure 1.46 The plot of estimated versus experimental data for 1-hexene vapor mole fraction.
Figure 1.47 Defining the property model parameters and components for binary parameters calculation under “
Setup
” tab (
left
) and “
Parameters
” tab (
right
).
Figure 1.48 RRMSE is reduced to 9 which is less than 10 for VLE data.
Figure 1.49 The plot of estimated versus experimental data for 1-hexene vapor mole fraction.
Figure 1.50 Further improvement of model goodness using “
NRTL-RK
” model.
Figure 1.51 The regressed binary interaction parameters will replace the existing binary parameters for MEK–1-hexene.
Figure 1.52 Reduction of discrepancy between estimated and experimental data points for VLE of MEK–1-hexene mixture.
Figure 1.53 The plot of estimated versus experimental data for 1-hexene vapor mole fraction.
Figure 1.54 The pairwise (binary) interaction parameters for the three components while the last column indicates that the source is taken from “
DR-1
” data set under “
Regression
” folder.
Figure 1.55 Creation of a binary isothermal
Pxy
analysis sheet for water–octanol mixture.
Figure 1.56 VLLE for water–octanol mixtures where two liquid mixtures exist in equilibrium with the vapor mixture. Water droplets are dispersed in liquid octanol (
top
) and octanol droplets are dispersed in water phase for a mole fraction of water greater than 0.39 (
bottom
).
Figure 1.57 Creation of a pure property analysis to evaluate the mass density of the three pure substances.
Figure 1.58 Estimation of mass density for each pure component.
Figure 1.59 Entering the input data for the mixture property analysis form. “
TXPORT
” property is selected.
Figure 1.60 Estimation of the mass density of a liquid mixture with known temperature, pressure, and composition.
Chapter 2: MORE ON ASPEN PLUS FLOWSHEET FEATURES (1)
Figure 2.1 The “
Find Compounds
” window for locating MIBK from Aspen Plus databanks and adding it to the list of compounds.
Figure 2.2 Renaming the default assigned name “
METHY-01
” to “
MIBK
”.
Figure 2.3 All pairwise (binary) interaction parameters are already given by Aspen Plus.
Figure 2.4 Changing the source of data from “
APV88 VLE-IG
” to any other source will give a new estimate of binary interaction parameters.
Figure 2.5 The addition of a stream mixer to the process flowsheet. The name “
B1
”, which is given by Aspen Plus, can be changed later by the user.
Figure 2.6 Upon selecting the stream type and moving the mouse to the workspace of the process flowsheet, the required and optional stream will show up in the red and blue color, respectively.
Figure 2.7 Connecting two input streams and one output stream to the mixer. Moreover, the name of the mixer was changed as well as the name of each input and output stream. Notice that the “
Simulation Status
” changed from “
Flowsheet not Complete
” to “
Required Input Incomplete
”.
Figure 2.8 Entering the first feed stream properties in terms of
P
,
T
, and compositional flow rate.
Figure 2.9 Entering the second feed stream properties in terms of
P
,
T
, and compositional flow rate.
Figure 2.10 The title and global unit set of the project are entered using “
Setup
” | “
Specifications
” | “
Global
” tab window.
Figure 2.11 The “
General
” tab window shows what items to be included in the final generated report (
left
) and the “
Stream
” tab window how Aspen Plus shall report the process and stream conditions on a molar basis; mass basis; or both (
right
).
Figure 2.12 The pop-up window tells the user that, after all, Aspen Plus is satisfied with input data and it will be ready for the giant step: solution of simultaneous steady-state material, component, and energy balances, augmented by other algebraic/differential equations describing stream and block properties.
Figure 2.13 The “
Economic Analysis
” window used to pop-up, if the solution converged, ending up with results having no simulation error.
Figure 2.14 The Aspen Plus “
Control Panel
” flags, where it tells the user about the progress and performance of the solver (i.e., simulator).
Figure 2.15 The stream results can be seen if a converging solution is reached by Aspen Plus solver.
Figure 2.16 The material and energy balance around the mixer as estimated by the three recommended property methods for a chemical process type.
Figure 2.17 The overall data quality for acetone–MIBK binary interaction parameters.
Figure 2.18 The overall data quality for MIBK–water binary interaction parameters.
Figure 2.19 NIST/TDE binary interaction parameters for acetone–water mixture.
Figure 2.20 The pairwise interaction parameters for three components using “
UNIQUAC
” as the property method. The source of the first column is from regression data set “
DR-3
” with the least RRMSE.
Figure 2.21 The mixer material and energy balance using “
UNIQUAC
” as the property method with NIST/TDE experimental data.
Figure 2.22 A simple process flowsheet for mixing water–hexanol mixture with 1-octanol.
Figure 2.23 A simple process flowsheet for mixing water–acetone mixture with EIPK.
Figure 2.24 Saving the binary VLE data set as BVLE105.
Figure 2.25 Regressing water–acetone VLE data using a two-parameter “
NRTL
” model.
Figure 2.26 The binary interaction parameters for acetone–water system based on the regression step (R-DR-1).
Chapter 3: MORE ON ASPEN PLUS FLOWSHEET FEATURES (2)
Figure 3.1 The “
Clean Property Parameters
” window for cleaning any previously estimated or regressed property parameter.
Figure 3.2 The binary interaction parameters after cleaning followed by “
UNIFAC
” estimation step (
left
). Changing the source of binary data from “
R-PCES
” to “
APV88 VLE-IG
” (
right
).
Figure 3.3 The reinitialization step is carried out to purge out any calculated block, convergence, stream properties, or all of the above.
Figure 3.4 The pop-up warning window for the reset step (
top
) and the confirmation of reinitialization step via the “
Control Panel
” message (
bottom
).
Figure 3.5 “
Display
” and “
Format
” options for adding the stream table to the main flowsheet window.
Figure 3.6 The main process flowsheet with added stream table. The property method is “
NRTL
”.
Figure 3.7 The built-in property sets for “
Specialty Chemicals with Metric Units
” template.
Figure 3.8 An information summary can be obtained via hovering the mouse over a particular set, such as “
FAPP
”.
Figure 3.9 The property set “
TXPORT
” includes three properties of a mixture to be evaluated by Aspen Plus.
Figure 3.10 The “
DMX
” property will be added to streams. “
DMX
” is the diffusivity with units of cm
2
/s.
Figure 3.11 The “
Qualifiers
” tab window, where it allows the user to input the phase he/she would like the property set to be reported for.
Figure 3.12 The “
Property Sets
” window that is invoked by hitting the “
Property Sets
” button under the “
Stream
” tab in the “
Report Options
” sheet of “
Setup
” folder in “
Navigation
” pane.
Figure 3.13 The stream table where the stream transport properties (“
TXPORT
”) are listed.
Figure 3.14 The “
Flowsheet Display Options
” window under “
File
”
|
“
Options
” submenu. Select “
Temperature
” and “
Pressure
” options and hit “
Apply
” and/or “
OK
” button.
Figure 3.15 Showing
P
and
T
in each stream of the process flowsheet.
Figure 3.16 A gray box is drawn around the entire process diagram in the flowsheet window via right-clicking the mouse and selecting “
Page Break Preview
” submenu from the shortcut context menu. Go to “
Top
” toolbar | “
File
” | “
” submenu to print the selected page break preview, if you want to print to a file (i.e.,
) or to a printer.
Figure 3.17 A portion of Notepad file that is created upon invoking the “
Input File
” button.
Figure 3.18 Aspen Plus will give the user the choice for the items to include in the generated report.
Figure 3.19 Report generation by Aspen Plus for a selected block (“
MIXER-1
”). Mass, mole, and energy balances around the mixer are shown.
Figure 3.20 Stream “
TRI-MIX
” was selected first and its transport properties will be shown using the stream property analysis tool provided by Aspen Plus.
Figure 3.21 The calculated transport (“
TXPORT
”) properties of “
TRI-MIX
” stream, using “
NRTL
” as the property method.
Figure 3.22 Addition of “
Flash3
”-type separator and three product streams to the flowsheet.
Figure 3.23 Connecting the “
MIXER-1
” to “
FLSH3-1
” via “
TRI-MIX
” stream.
Figure 3.24 Two out of four variables can be specified for a flash separator:
T
,
P
, vapor fraction, and heat duty.
Figure 3.25 The “
Control Panel
” shows messages related to convergence and warnings.
Figure 3.26 The composition of the first flash separator outlet steams. Notice that “
FL1-H2O
” stream did not hit the target value of 0.95 mass fraction of water.
Figure 3.27 A simple process flowsheet for predicting the partition coefficient of a solute between octanol and water phase.
Figure 3.28 The property set: “
ALCOHOL
” is defined as “
MOLECONC
” (molar concentration) of “
C1OH
” (methanol) component in liquid phase.
Figure 3.29 The molar concentration of methanol in the two immiscible liquid phases: octanol and water.
Chapter 4: FLASH SEPARATION AND DISTILLATION COLUMNS
Figure 4.1 The addition of a second mixer and “
Flash3
” type separator.
Figure 4.2 The addition of mixer and flash separator results in a more purification for water and MIBK streams. The water mass fraction increased from 0.787 for “
FL1-H2O
” to 0.90 for “
FL2-H2O
”.
Figure 4.3 The first “
Define
” tab form of the “
Design Specs
” subfolder, under “
Flowsheeting Options
” folder, where one can define the dependent and independent variable.
Figure 4.4 Defining the “
Design Spec
” variable name as “
H2OMF
”, which accounts for mass fraction of water in “
FL2-H2O
” stream.
Figure 4.5 Entering parameter values appearing in “
Spec
” tab window of the design spec:
DS-1
for
H2OMF
variable. The “
Spec
” value is allowed to fluctuate around 0.95 by a magnitude of 0.001.
Figure 4.6 Defining parameters of the manipulated variable appearing in “
Vary
” tab window of the design spec: “
DS-1
”.
Figure 4.7 The convergence “
Spec History
” tab sheet where it shows the number of iterations needed to converge to the final solution within the prescribed accuracy given by the “
Tolerance
” and “
Target
” value. The “
Error / Tolerance
” column indicates the division of “
Error
” by “
Tolerance
” value.
Figure 4.8 At the initial value of “
MIBK2
” flow rate, “
H2OMF
” is 0.899788 and it jumped to 0.949937 at the final value of “
MIBK2
” flow rate, fulfilling the design specifications (i.e., the target and tolerance value) imposed by the user.
Figure 4.9 Different distillation column models can be found under “
Columns
” tab in “
Model Palette
”.
Figure 4.10 The addition of a third mixer where it combines the two MIBK-based product streams from the two flash separators “
FLSH3-1
” and “
FLSH3-2
”.
Figure 4.11 The addition of “
DSTWU
” distillation column.
Figure 4.12 Inputting the number of stages, the key component recoveries, and the tower pressures.
Figure 4.13 The newly modified input parameters for “
DSTWU
” unit such that we end up with a mass fraction of acetone in top stream equals 0.96 and that of MIBK in bottom stream is 0.998.
Figure 4.14 The “
Reflux Ratio Profile
” for “
DSTWU
” column.
Figure 4.15 Entering input parameters for “
Distl
” column, which were entered in light of “
DSTWU
” column results.
Figure 4.16 The product stream results for “
Distl
” column.
Figure 4.17 The required input “
Configuration
” parameters for “
RadFrac
” type of distillation columns.
Figure 4.18 Selection of the feed basis and component to be used for distillate to feed ratio.
Figure 4.19 Entering the location of feed tray under “
Streams
” tab and phase type of each product stream.
Figure 4.20 Inputting the pressure value at Stage 1 (i.e., condenser pressure) and pressure drop per stage.
Figure 4.21 The composition of inlet and outlet stream for “
RadFrac
” distillation column. The desired degree of product stream purity is not yet fulfilled.
Figure 4.22 The composition of inlet and outlet streams for “
RadFrac
” distillation column, based on “
NRTL
” property method (
left
) and “
UNIQUAC
”-fitted “
NIST/TDE
” binary data for water–acetone system (
right
).
Figure 4.23 The results summary for the “
Condenser / Top stage performance
” table of the “
RadFrac
” distillation tower under “
Results
”
|
“
Summary
” tab.
Figure 4.24 The results summary for the “
Reboiler / Bottom stage performance
” table of the “
RadFrac
” distillation tower.
Figure 4.25
T
emperature,
P
ressure,
F
low, and Heat duty,
Q
, (
TPFQ
) is shown at each stage in “
Profiles
”
|
“
TPFQ
” tab sheet of the distillation tower.
Figure 4.26 The process flowsheet for separating hexanol from water using octanol.
Figure 4.27 “
RDFR-1
” specifications, under “
Configuration
” tab.
Figure 4.28 “
RDFR-2
” specifications, under “
Configuration
” tab.
Figure 4.29 “
FLSH2-1
” specifications, under “
Specifications
” tab.
Figure 4.30 Operating conditions and compositions for each of the outlet streams.
Figure 4.31 The process flowsheet for water–acetone separation utilizing EIPK.
Figure 4.32 The annotated and reduced version of “
Input File
” pertinent to the process flowsheet shown in Figure 4.31.
Figure 4.33 The recycling of EIPK-based product stream to the inlet of the first and second mixers.
Figure 4.34 A schematic for scrubbing acetic acid off CO
2
gas using fresh water as liquid scrubber.
Figure 4.35 Selection of CO
2
and N
2
as Henry's components.
Figure 4.36 Selecting Henry's components via “
HC-1
” group found in “
Methods
” | “
Specification
” | “
Global
” tab window.
Chapter 5: LIQUID–LIQUID EXTRACTION PROCESS
Figure 5.1 The missing MEK–octanol binary interaction parameters are estimated by “
UNIFAC
” method.
Figure 5.2 “
NIST/TDE
” binary VLE data for MEK–octanol mixture is of a bad quality having low data quality indices in consistency test.
Figure 5.3 Selection of the mixing tank from “
Model Palette
” to represent a single-stage extraction unit.
Figure 5.4 A mixer that mimics a single-stage extraction unit for the sake of separating MEK from water using
n
-octanol as the solvent.
Figure 5.5 Selection of “
Free water
” mode as “
Dirty water
” for having some dispersed organics in water phase.
Figure 5.6 “
MCMEK
” is defined as the molar concentration of MEK in a liquid mixture.
Figure 5.7 Defining the qualifier (the phase to which the property is associated) of the selected property.
Figure 5.8 The mass flow rate of MEK in “
H2O+MEK
” stream is to be varied from 0.00001 to 21 kg/h.
Figure 5.9 Defining two flowsheet variables “
MCMEKR
” and “
MCMEKE
” that stand for the molar concentration of MEK in raffinate and extract streams, respectively.
Figure 5.10 In “
Fortran
” tab window, we define
P
(or,
K
OW
) and log
10
P
(or, log
10
K
OW
) as “
DKOW
” and “
DLOGKOW
”, respectively. Both terms are prefixed by “D” to make them double not integer values.
Figure 5.11 The “
Tabulate
” tab window for column-wise data presentation.
Figure 5.12 “
NRTL
” property method simulation results where the lowest log
10
P
value is 0.725 for 0.00001 kg/h MEK flow rate and this value lies above the equilibrium value of 0.29.
Figure 5.13 “
UNIFAC
” property method simulation results where the lowest log
10
P
value is 0.479 for 0.00001 kg/h MEK flow rate and this value is still above the equilibrium value of 0.29.
Figure 5.14 “
UNIQUAC
” property model simulation results where the lowest log
10
P
value of 0.5899 is accomplished at 0.00001 kg/h of MEK flow rate.
Figure 5.15 “
UNIFAC
” property method simulation results using the “
Flash3
” type separator model are the same as those of the mixing tank model (Figure 5.13).
Figure 5.16 The composition of streams using a single-stage extraction (flash drum) unit as described by “
UNIFAC
” property method.
Figure 5.17 Replacement of the single-stage mixer by the multistage extraction column.
Figure 5.18 The “
Specs
” tab window where the number of theoretical stages and the selection of thermal option are defined.
Figure 5.19 Selection of two key components one for the “
1st liquid phase
” and another for the “
2nd liquid phase
”.
Figure 5.20 The
Streams
tab window deciphers what the “
1st liquid phase
” and the “
2nd liquid phase
” are all about.
Figure 5.21 Defining the pressure profile within the extraction column for, at least, one stage.
Figure 5.22 Defining the temperature profile within the extraction column, at least, at one stage.
Figure 5.23 The estimated properties of the multistage extraction column outlet streams.
Figure 5.24 The triangle diagram showing the location of the operable region for extraction processes. The blue standalone square on the right side represents an azeotropic condition for the binary mixture of MEK and water.
Figure 5.25 The “
Ternary Map
” tab form where the user decides on the three components,
T
, and
P
.
Figure 5.26 The composition of the spot within the large red circle is also shown in “
Analysis
” | “
TERDI-1
” | “
Results
” sheet.
Figure 5.27 The addition of “
RadFrac
” distillation column to the existing flowsheet to split “
EXTRCT
” stream into MEK and
n
-octanol streams.
Figure 5.28 Separation of “
EXTRCT
” mixture stream into three pure streams.
Figure 5.29 The process flowsheet for separating MEK from water using 1-octane.
Figure 5.30 Stream results for MEK–water separation using 1-octane. The property method used is “
UNIQUAC
”.
Figure 5.31 The process flowsheet for the extraction of acetic acid from water using isopropyl butyl ether (IPBE).
Figure 5.32 The process flowsheet for extraction of acetone from water using pure 1,1,2-trichloroethane (TCE).
Figure 5.33 The process flowsheet for extraction of propionic acid from water using pure methyl ethyl ketone (MEK).
Chapter 6: REACTORS WITH SIMPLE REACTION KINETIC FORMS
Figure 6.1 Entering reactants and products of the reactions involved in the synthesis of acetic anhydride.
Figure 6.2 Clicking on the “
Methods Assistant…
” button, will invoke the “
Property Method Selection Assistant
” wizard.
Figure 6.3 The property method selection assistant will recommend either “
NRTL-HOC
” or “
WILS-NTH
” for the subcategory: “
Chemical
” | “
Carboxylic acids
”.
Figure 6.4 Following the recommendation by the “
Property Method Selection Assistant
” wizard, the property method is set to “
WILS-NTH
”.
Figure 6.5 The addition of “
PFR
” block to the flowsheet using the “
RPlug
” reactor under “
Reactors
” tab in “
Model Palette
”.
Figure 6.6 Entering feed stream properties in terms of flow,
P
,
T
, and composition.
Figure 6.7 Under “
Specifications
” tab, choose the type of plug-flow reactor (PFR).
Figure 6.8 “
PFR
” is chosen as a single-tube reactor (
i.e.
a cylinder with length 3.0 and diameter 1 m). The “
Process stream
” is “
Vapor-Only
” based on the given pressure and temperature.
Figure 6.9 The reaction type is “
POWERLAW
” with an ID: “
R-1
”.
Figure 6.10 The reaction set “
R-1
” is still undefined for Aspen Plus.
Figure 6.11 The “
Edit Reaction
” window where the user defines the reaction equation and whether or not it is of “
Kinetic
” type. Here, it means that the reaction is first order with respect to acetone (CH
3
COCH
3
).
Figure 6.12 The reaction stoichiometry (
i.e.
, equation) is already defined but the kinetic parameters are not.
Figure 6.13 The reaction phase and the kinetic parameters are defined in “
Kinetic
” tab window, based on Equation 6.9 and in light of Equation 6.10.
Figure 6.14 The reaction phase and the kinetic parameters are defined in “
Kinetic
” tab window, based on Equation 6.4 and in light of Equation 6.11.
Figure 6.15 The user needs to highlight “
R-1
” set on the left side and then to move it to the right side
via
the first top arrow.
Figure 6.16 The stream results of PFR. The conversion, X, can be calculated as (27.89)/ 135.16 = 0.206.
Figure 6.17 For the sake of purification, a compressor and absorption tower (rectifier) will be installed prior to introducing the product stream to the second reactor that will be installed at a later stage.
Figure 6.18 Specifications for the compressor; “
Polytropic using ASME method
” type is chosen and a discharge pressure of 3 bar is assigned (
left
) and a restriction for the presence of vapor phase only (
right
).
Figure 6.19 The “
Configuration
” tab window for the “
Setup
” sheet for the absorption column named “
RECTIF
”. The number of stages; condenser type; reboiler type (if any); and one of “
Operating specifications
”, such as “
Bottoms rate
”, are to be entered here.
Figure 6.20 The location of feed tray from the first top tray (#1) is made
via
“
Streams
” tab window. The vapor feed will be introduced at the bottom; hence, there is no need for reboiler in a rectifying column.
Figure 6.21 The “
Pressure
” tab window is used to define the pressure profile throughout the column.
Figure 6.22 The “
Condenser
” tab window is used to define the condenser temperature.
Figure 6.23 The simulation results indicate that “
RECTIF
” tower managed to isolate acetone from the other two components methane and ketene.
Figure 6.24 The addition of “
RadFrac
” type distillation tower to separate methane from ketene.
Figure 6.25 In “
Configuration
” tab window, condenser and reboiler type, # of stages, and two operating specifications are defined.
Figure 6.26 Location of the feed tray (#6 from the top) for “
DSTL
” column.
Figure 6.27 Pressure profile of “
DSTL
” column.
Figure 6.28 The “
RadFrac
” type distillation column (“
DSTL
”) successfully separated the methane/ketene mixture (“
RECT-TOP
”) into two extra pure streams: “
DSTL-TOP
” (
Y
CH4
= 1.0) and “
DSTL-BTM
” (
Y
CH2CO
= 0.994).
Figure 6.29 Addition of a Rigorous CSTR (“
RCSTR
”) for the sake of carrying out the second reaction, that is, reaction of ketene with acetic acid to form acetic anhydride.
Figure 6.30 Entering stream properties
via
“
Mixed
” tab window under “
Input
” sheet of “
ACETACID
” stream.
Figure 6.31 The reactor conditions in terms of pressure, temperature, reaction phase, and reactor volume.
Figure 6.32 The new reaction is given the ID of “
R-2
” and it is of type “
POWERLAW
”.
Figure 6.33 Enter
−1
for reactant coefficient and
+1
for product coefficient and choose “
Reaction type
” as “
Equilibrium
”.
Figure 6.34 In “
Equilibrium
” tab window, choose the reaction phase to be “
Vapor
” and select the first choice (i.e., Compute Keq from Gibbs energies).
Figure 6.35 Association of “
RCSTR
” with “
R-2
” reaction set.
Figure 6.36 The heat duty, the reactor volume, and the residence time for “
RCSTR
” block. A reactor volume of 20 m
3
is needed with a residence time of 9.7 s and the heat of reaction is exothermic.
Figure 6.37 The inlet and outlet streams of “
RCSTR
” block plus their properties in terms of flow rate,
P
,
T
, and composition.
Figure 6.38 Testing methanol synthesis via the rigorous-CSTR (
RCSTR
) model.
Figure 6.40 Defining the three equilibrium reactions involved in methanol synthesis.
Figure 6.41
T
&
P
of the reactor will be varied to see how they affect the reaction performance.
Figure 6.42 A portion of sensitivity analysis results where both
T
and
P
are varied to see their effects on
MFMETH
.
Figure 6.43 The “
Results Curve
” window where the user decides on X, Y, and the parametric variable.
Figure 6.44 The effect of
RCSTR
operating conditions
P
and
T
on
MFMETH
(
i.e.
, conversion).
Figure 6.45 The feed molar flow rate of H
2
and CO will be varied to see how they affect the reaction performance.
Figure 6.46 The “
Define
” tab window, which includes the composition of feed and product stream. The variables are prefixed by “
D
”, in compliance with
FORTRAN
code, to treat all variables as double not integer (prefix “
M
”).
Figure 6.39 The sensitivity analysis results showing the best feed molar ratios where both the yield and selectivity are maximum.
Figure 6.47 Visualization of H
2
O
2
bottle as “
RBATCH
” type reactor.
Figure 6.48 “
RBATCH
” reactor specifications (constant
P
&
T
).
Figure 6.49 The stop criteria to stop the reaction and report the batch time whenever H
2
O
2
conversion of 0.9 is reached.
Figure 6.50 The batch feed time for H
2
O
2
bottle will be very short and no need for down time, unlike the real batch reactors where they require loading/unloading time.
Figure 6.51 A schematic symbolizes the reaction between acetic acid and ethanol to produce ethyl acetate (an ester) and water (the esterification process).
Figure 6.52 The flowsheet for ethyl acetate production using “
RCSTR
” type reactor.
Figure 6.53 “
R-1
” reaction set is resolved into two kinetic reactions the forward and backward direction.
Figure 6.54 Entering catalyst attributes as the reaction rate is expressed per unit mass of a catalyst not volume of a reactor as is the case with homogeneous reactions.
Figure 6.55 The flowsheet for
n
-butane isomerization using “
RPlug
” type reactor.
Chapter 7: REACTORS WITH COMPLEX (NON-CONVENTIONAL) REACTION KINETIC FORMS
Figure 7.1 A simple flowsheet for methanol production using rigorous-PLUG (
RPLUG
).
Figure 7.2 The feed stream properties in terms of
T
,
P
, flow rate, and composition.
Figure 7.3 “
RPLUG
” specifications in terms of heat transfer and temperature profile.
Figure 7.4 Reactor dimensions in “
Configuration
” tab window.
Figure 7.5 Defining the catalyst properties in terms of its particle density and bed voidage, in “
Catalyst
” tab window.
Figure 7.6 Defining the coefficients for reacting species of
“LHHW”
type reaction in “
R-1
” set (Eq. 7.1). The exponents will be defined later in “
Driving Force Expression
” window.
Figure 7.7 The reacting phase is vapor, rate basis is catalyst weight,
k = 1
, and
E = 0
, as given by Equation 7.3b.
Figure 7.8 The driving force term in Equation 7.3b represents a reversible case (Eq. 7.14). “
Term 1
” is defined here for the forward direction, with given
A
and
B
coefficient for the driving force constant.
Figure 7.9 The driving force term in Equation 7.3b represents a reversible case (Eq. 7.14). “
Term 2
” is defined here for the backward direction, with given
A
and
B
coefficient for the driving force constant.
Figure 7.10 The “
Adsorption Expression
” window where the concentration exponents are concluded by matching, term by term, the adsorption term (i.e., denominator of Eq. 7.3b) with Equation 7.20 The adsorption coefficients A, B, C, and D for “
Term no. 1
” up to “
Term no. 4
” are evaluated by taking the logarithmic value of each term found in the denominator of Equation 7.3b.
Figure 7.11 Defining the coefficients only for reacting species of “
LHHW
” type reaction in “
R-2
” set (Eq. 7.4). The exponents will be later defined in “
Driving Force Expression
” window.
Figure 7.12 The reacting phase is vapor, rate basis is catalyst weight,
k = 1
, and
E = 0
, as given by Equation 7.6b
Figure 7.13 The driving force term in Equation 7.6b represents a reversible case (Eq. 7.14). “
Term 1
” is defined here for the forward direction, with given
A
and
B
coefficient for the driving force.
Figure 7.14 The driving force term in Equation 7.6b represents a reversible case (Eq. 7.14). “
Term 2
” is defined here for the backward direction, with given
A
and
B
coefficient for the driving force constant.
Figure 7.15 The “
Adsorption Expression
” window for the second reaction, where the entries are the same as those used in Figure 7.10; except for the adsorption expression exponent where it is set to
1
here, instead of
3
.
Figure 7.16 Reactor summary results for “
RPLUG
” block with a highly exothermic heat duty.
Figure 7.17 Stream results summary for the inlet and outlet stream of the plug-flow reactor. Methanol is present in the product stream.
Figure 7.18 Reacting medium properties, such as pressure, temperature, molar vapor fraction (for a potential phase change), and heat duty, as function of either reactor length (or residence time), are available via the reactor profile sheet.
Figure 7.19 The molar composition profile for reactants and products as a function reactor length (i.e., the axial direction).
Figure 7.20 Another configuration for “
PFR
” where “
Reactor with constant thermal fluid temperature
” option is selected with a specified overall heat transfer coefficient between the tube and shell sides of the reactor (also as a heat exchanger).
Figure 7.21 The temperature of the gas-phase reactor is to be manipulated, as the first variable, to see the maximum selectivity of methanol production as given by Equation 7.7 for the two parallel reactions.
Figure 7.22 The pressure of the gas-phase reactor is to be manipulated, as the second variable, to see the maximum selectivity of methanol production as given by Equation 7.7 for the two parallel reactions.
Figure 7.23 Defining two “
Sensitivity
” variables: “
YCH3OHP
” the mole fraction of methanol and “
YCOP
” the mole fraction of CO in the product stream.
Figure 7.24 Defining the selectivity by “
SCH3OH
” as the mole fraction (or molar ratio) of the desired over the undesired product for the two parallel reactions.
Figure 7.25 Tabulating “
SCH3OH
” as column number 1 in sensitivity analysis results.
Figure 7.26 For the given feed molar flow rate and composition, it is found that the maximum methanol selectivity occurs at
T = 250°C
and
P = 150 bar
.
Figure 7.27 A schematic for conversion of chloroform into hydrogen chloride, using “
RPLUG
” type reactor.
Figure 7.28 Defining three variables that represent the molar flow rate of C
8
H
10
in “
FEED
” stream; the molar flow rate of C
8
H
10
in “
PRDCT
” stream; and the molar flow rate of C
8
H
8
in “
PRDCT
” stream.
Figure 7.29 Defining two variables that represent the molar flow rate of CH
4
both in “
FEED
” and “
PRDCT
” stream.
Chapter 8: PRESSURE DROP, FRICTION FACTOR, ANPSH, AND CAVITATION
Figure 8.1 Selection of “
STEAMNBS
” as the property method for a water pumping system.
Figure 8.2 The flowsheet for water transport between two tanks that are 2 km apart.
Figure 8.3 Input parameters for the inlet “
0
” stream.
Figure 8.4 Specifications for “
VALVE-1
” block. The outlet pressure will be calculated for the specified valve (under “
Valve Parameters
” tab) and with a valve % opening of 50%.
Figure 8.5 In “
Valve Parameters
” tab window, the valve type is “
Butterfly
” and Aspen Plus provides specifications for “
Neles-Jamesbury
” manufacturer's valve types, which facilitate the calculation of the outlet pressure valve.
Figure 8.6 Checking for the occurrence of choked flow, which is a function of percent opening of the valve.
Figure 8.7 A pipe length of 1 km and nominal diameter of 2.5″, with 40S schedule #, is used for “
PIPE-1
” block.
Figure 8.8 Fittings number and types for “
PIPE-1
” block.
Figure 8.9 For “
VALVE-2
” block, the ball type is used instead of the butterfly type.
Figure 8.10 The minimum input specifications needed for the “
PUMP
” block. A discharge pressure of 3 bar is assumed to overcome downstream friction plus fluid discharging at the end-tank.
Figure 8.11 For “
VALVE-3
” block, the “
Globe
” type is used with “
V810_Equal_Percent_Flow
” series/style.
Figure 8.12 For “
VALVE-4
” block, the “
Globe
” type is used with “
V810_Linear_Flow
” series/style.
Figure 8.13 “
PIPE-1
” block result summary showing the friction pressure drop and the equivalent length.
Figure 8.14 The fluid and flow properties of liquid water flowing in the pipe itself under “
Streams
” tab.
Figure 8.15 The pressure throughout the pipe decreases (i.e., pressure drop) with the axial distance as a result of energy dissipation due to friction.
Figure 8.16 The pump characteristics and performance.
Figure 8.17 The valve status in terms of choking condition as a result of flow area restriction.
Figure 8.18 “
Valve-3
” is most vulnerable, among the four installed valves, to the choking condition.
Figure 8.19 DENSL accounts for
RHO
, which is the density of a pure substance for a given stream.
Figure 8.20 “
PH2O
” accounts for “
PL
”, which is the vapor pressure of water at the given temperature, for a given stream.
Figure 8.21 In “
Vary
” tab window, the user is required to define the manipulated variable, its range, and increment.
Figure 8.22 Defining a list of “
Sensitivity
” variables as block or stream property variable.
Figure 8.23 “
Fortran
” tab window where one-line Fortran code is written to define “
RNPSH
” as a function of vapor pressure, the gravity constant, and the liquid water density.
Figure 8.24 In “
Tabulate
” tab window, the user decides what to present in the final “
Results
” table.
Figure 8.25 Values of “
S-1
” defined variables as a function of water flow rate (i.e., Reynolds number).
N
Re
= 72,830
is the minimum Reynolds number at which onset of cavitation occurs at the entrance of the pump.
Figure 8.26 Imposing a more restriction on fluid flow by “
VALVE-2
”
via
reducing the percent opening to 40 instead of 50%.
Figure 8.27 The choking status of both “
VALVE-2
” and “
VALVE-3
” has changed at the last run of sensitivity case study, indicating the occurrence of choking condition, whereas the first and fourth valve do not suffer from choking (i.e., cavitation).
Figure 8.28 Aspen Plus “
Control Panel
” warns the user that the flow is choked in “
VALVE-2
” and “
VALVE-3
” and the pump also suffers from cavitation.
Figure 8.29 Compression and storage of air.
Figure 8.30 The manipulated variable is defined in “
Vary
” tab window for “
S-1
” case study.
Figure 8.31 The defined variables that account for the choking status of the three valves.
Chapter 9: THE OPTIMIZATION TOOL
Figure 9.1 The flowsheet for water transport between two tanks that are 2000 m apart.
Figure 9.2 Input parameters for the inlet stream.
Figure 9.3 The discharge pressure is assigned a value of 16 atm to avoid any flow-related simulation errors, such as a negative absolute pressure, cavitation, or valve choking condition.
Figure 9.4 In pump “
Calculation Options
” tab window, the “
Suction area
” and “
Checking options
” are specified.
Figure 9.5 Material of construction, length, and diameter for “
PIPE
” block.
Figure 9.6 “
Thermal Specification
” tab window for “
PIPE
” block. A constant temperature profile is selected.
Figure 9.7 Different pipe fittings are installed along the pipeline.
Figure 9.8 For flash options, a single liquid phase is assumed prevailing within the pipe.
Figure 9.9 Defining a list of variables to be exploited later in “
Optimization
” tool under “
Fortran
” tab, where the objective function will be formulated.
Figure 9.10 Defining a property set called “
DENSITY
” that accounts for the density of a pure liquid phase for a given stream. Here, we have only pure water.
Figure 9.11 The manipulated (independent) variable is entered in “
Vary
” tab window where the user is required to define the independent variable and its range.
Figure 9.12 The set of FORTRAN commands written to evaluate the objective function (named “
TOTCOST
”), which is the summation of installed and operating cost (Eq. 9.5).
Figure 9.13 In “
Objective & Constraints
” tab window, the user names the objective function to be either minimized or maximized.
Figure 9.14 Replacement of the default (“
SQP
”) convergence method by the “
Complex
” method.
Figure 9.15 The minimum total annual cost of $92,729/year, evaluated at the optimum diameter.
Figure 9.16 The optimum inside pipe diameter, reported by Aspen Plus, is 283.4 mm or 11.16 inches.
Figure 9.17 The manipulated variable of “
S-1
” set is essentially the same as that of “
O-1
”, except for the modification of both lower and upper limit.
Figure 9.18 Tabulation of “
RNLD
”, “
FCOST
”, “
OPCOST
”, and “
TOTCOST
” as a function of pipe diameter “
DIAM
”. “
RNLD
” is used to tell the flow regime.
Figure 9.19 A portion of the results for the sensitivity analysis “
S-1
”. Notice that “
O-1
” optimization case study is deactivated.
Figure 9.20 The plot of three annual cost indices as a function of the inside pipe diameter (m). The minimum lies at
D
= 283.4 mm (11.16″) with a total annual cost of $92,729/year, as was found in optimization “
O-1
” case study.
Figure 9.21 The inside pipe diameter is defined as “
DIAM
” variable in “
Define
” tab window (
top
) and as the manipulated variable in “
Vary
” tab window (
bottom
) for a typical optimization case study.
Figure 9.22 The “
RGibbs
”-type reactor where two simultaneous gas-phase equilibrium reactions occur.
Figure 9.23 The feed compositional flow rate, pressure, and temperature.
Chapter 10: HEAT EXCHANGER (H.E.) DESIGN
Figure 10.1 A schematic for shell and tube heat exchanger to cool ethylene glycol (
EG
) using Freon-12 (
R-12
).
Figure 10.2 Adding
EG
(C
2
H
6
O
2
) and
R-12
(CCl
2
F
2
) to “
Components
” list.
Figure 10.3 Different options (i.e., models) for a heat exchanger type.
Figure 10.19 Different configurations of TEMA shell type.
Figure 10.4 Addition of “
Heater
” type heat exchanger for the sake of calculating the heat duty,
Q
.
Figure 10.5 Entering the specifications of “
FR12-IN
” stream.
Figure 10.6 Entering the pressure drop (a negative value) and temperature change for the “
Heater
”.
Figure 10.7 Calculation of the heat duty,
Q
, based on the given inlet and outlet Freon flow rate and the temperature change.
Figure 10.8 Insertion of a “
HeatX
” type heat exchanger to the process flowsheet. FR-12 is connected as both the inlet and outlet cold stream, whereas EG as the inlet and outlet hot stream.
Figure 10.9 The inlet flow rate is tentatively assumed to be 5000 kg/h of EG.
Figure 10.10 Selection of “
Model fidelity
” option as “
Shortcut
”, of “
Calculation mode
” option as “
Design
”, and of “
Exchanger specification
” option as “
Exchanger duty
” will allow the calculation of “
EG-OUT
” temperature, for a given EG flow rate.
Figure 10.11 Specifications of “
Shortcut LMTD
” method of calculation.
Figure 10.12 A portion of the block results (here “
Thermal Results
” | “
Summary
” sheet) where “
EG-OUT
” temperature is about 317.52 K, which is slightly higher than the correct value of 315 K.
Figure 10.13 A mass flow rate 4780 kg/h of EG will result in the correct value of
EG-OUT
temperature.
Figure 10.14 The “
Exchanger Details
” tab window after selecting the right flow rate of EG while still selecting the shortcut method.
Figure 10.15 Activation of “
EDR Exchanger Feasibility
” dashboard.
Figure 10.16 The “
Exchanger Summary Table
” window that allows conversion of a simple to rigorous exchanger.
Figure 10.17 The “
Convert to Rigorous Exchanger
” window for selecting the exchanger type and conversion method using either built-in templates or user-specified parameter values.
Figure 10.18 The “
EDR Sizing Console – Size Shell&Tube HEATX
” window where the user has the choice to either retain or modify Aspen Plus initially assigned parameters related to exchanger geometry and process conditions.
Figure 10.20 Different tube bank layout patterns.
Figure 10.21 Segmental baffle (
left
) and rod baffle (
right
).
Figure 10.22 The final recommended geometrical parameters in “
Geometry
” tab window.
Figure 10.23 The final recommended process parameters in “
Process
” tab window.
Figure 10.24 In “
Errors & Warnings
” tab window, the user has to look for critical issues raised by Aspen Plus EDR simulator.
