Chemical Process Simulations using Aspen Hysys E-Book

Khalid W. Hameed

• Herausgeber: John Wiley & Sons
• Kategorie: Fachliteratur
• Sprache: Englisch

Seitenzahl: 479

Veröffentlichungsjahr: 2025

Beschreibung

An intuitive guide to using Aspen HYSYS for chemical, petrochemical, and petroleum industry process simulations, including interactive process flow diagrams

In Chemical Process Simulations using Aspen Hysys, distinguished lecturer Dr. Khalid W. Hameed delivers an up-to-date and authoritative discussion of the simulation and design of chemical, petrochemical, and petroleum industry processes using Aspen HYSYS. The book includes coverage of many chemical engineering topics including fluid flow, reactors, unit operation of heat and mass transfer, oil refinery process, and control systems.

Readers will also find highly interactive process flow diagrams for building and navigating through large simulations, as well as:

• A thorough introduction to the use of Aspen HYSYS for the chemical, oil, and petrochemical industries
• Skill development techniques for users of Aspen HYSYS and strategies for improving the accuracy of results
• Practical discussions of Dynamic State Simulation with explanations of how to install control systems for the process using flash separator, gas processing, and advanced process control such as ratio control, cascade control, and split range control
• Illustrative examples of Plant Wide Projects that demonstrate the ability of Aspen HYSYS to perform a full plant

Perfect for research and development engineers in the fields of petrochemical, chemical, and petroleum engineering, Chemical Process Simulations using Aspen HYSYS will also benefit researchers with an interest in the area.

Leseprobe

Table of Contents

Cover

Table of Contents

Title Page

Copyright

Dedication

Preface

Acknowledgments

1 Starting with Aspen HYSYS

1.1 HYSYS Menu Command to Ribbon Map

1.2 Starting Aspen HYSYS

1.3 Properties Environment

1.4 Creation of a New Simulation

1.5 Inserting Components to the Simulation

1.6 Adding the Fluid Package

1.7 Methods for Choosing Thermodynamics Model (Fluid Package)

1.8 Simulation Environment

1.9 Creating Material Streams

1.10 Summary

1.11 Printing

Problems

References

2 Physical and Thermodynamics Properties

2.1 Fluid Package

2.2 Steam Table

2.3 Bubble‐Point and Dew‐Point Calculations

2.4 Humidity Calculations

Problems

References

3 Pressure Change Equipment

3.1 Pump

3.2 Expander

3.3 Compressor

Problems

References

4 Heating and Cooling

4.1 Heat Exchanger

4.2 Air Cooler

4.3 Fired Heater

4.4 Summary

Problems

References

5 Flash Separator

5.1 Simulation of Flash Separator

5.2 Simulation of Evaporator

Problems

References

6 Logical Operations

6.1 Set Operation

6.2 Adjust Operation

6.3 Balance

6.4 Recycle

6.5 Spreadsheet

References

7 Piping Equipment

7.1 Pipe Segment

7.2 PIPESYS

7.3 Sizing of Pressure Relieve Valve

7.4 Summary

References

8 Reactors

8.1 Reactor Types

8.2 Parameters in the Reactors

8.3 Conversion Reactor

8.4 Equilibrium Reactor

8.5 Miscellaneous Examples

8.6 CSTR (Continuous Stirred Tank Reactor)

8.7 Plug Flow Reactor

8.8 Gibbs Reactor

Problems

References

9 Separation Columns

9.1 Absorption Column

9.2 Gas Desorption (Stripping)

9.3 Distillation Column

9.4 Extraction Column

9.5 Miscellaneous Examples

Problems

References

10 Refinery Process

10.1 Refinery of Crude Oil

10.2 Simulation of Refinery Process

10.3 Summary

References

11 Optimizer

11.1 Simple Optimizer

11.2 Original Optimizer

11.3 Summary

References

12 Solid Operation

12.1 Cyclone

12.2 Rotary Vacuum Filter

12.3 Baghouse Filter

References

13 Dynamic‐State Simulation

13.1 Problem Statement 1: Flash Separator

13.2 Problem Statement 2: Gas Processing

13.3 Advanced Control

13.4 Summary

References

14 Economic Evaluation

14.1 Problem Statement

14.2 Simulation

14.3 Summary

References

15 Plant‐Wide Projects

15.1 Cyclohexane Production Plant

15.2 Production of Dimethyl_ether

15.3 Gas Sweetening

15.4 Propylene Production

15.5 Methanol Production

15.6 Production of Vinyl_Chloride_Monomer

References

Index

End User License Agreement

List of Tables

Chapter 1

Table 1.1 Typical systems and their recommendation property package.

Chapter 4

Table 4.1 Translation of each option (Selection) for exchanger design and r...

Chapter 6

Table 6.1 Description of the solving parameter of the Adjust operation.

Table 6.2 Description of the two methods of importing and exporting variabl...

Chapter 7

Table 7.1 compositional analysis of the gas condensate.

Table 7.2 summary of elevation data for each of the branches.

Table 7.3

Composition of Well A.

Table 7.4 Information of the second extension.

Table 7.5 Information of the third extension.

Table 7.6 Information of the Fourth extension.

Table 7.7 information of the fifth extension.

Table 7.8 Conditions of the well's stream.

Table 7.9 specifications of Adjust operation.

Table 7.10 Specification of Inline compressor.

Chapter 8

Table 8.1 Summary of Reactions in HYSYS.

Table 8.2 Types of reactors and their suitable reactions.

Chapter 9

Table 9.1 The relation between the diameter and tray spacing.

Table 9.2 Slope of

q

‐line according to the feed's condition.

Table 9.3 Explanation of solving method in HYSYS.

Chapter 10

Table 10.1 Specification of the column.

Table 10.2 Specification of the column that must be added.

Chapter 12

Table 12.1 Description of the parameters of the cyclone that are present in...

Table 12.2 Description of the parameters of the cyclone that are present in...

Chapter 13

Table 13.1 Suggestion of controller parameters.

Table 13.2 Guide of transition unit operation from steady state to dynamics...

List of Illustrations

Chapter 1

Figure 1.1 Window of HYSYS when opened first.

Figure 1.2 Window of New case in HYSYS, Properties environment.

Figure 1.3 How you can select the components from library in HYSYS.

Figure 1.4 Adding components from library to the list of components.

Figure 1.5 Some properties of the ethane.

Figure 1.6 Adding property package.

Figure 1.7 Selecting the Peng–Robinson (PR) as a property package for simula...

Figure 1.8 Using method assistant to select the proper property package acco...

Figure 1.9 Choose the hydrocarbon system as the component type.

Figure 1.10 Method assistant shows the type of proper property package that ...

Figure 1.11 Specification of Peng–Robinson model.

Figure 1.12 Simulation environment of the Aspen HYSYS.

Figure 1.13 Windows of material streams.

Figure 1.14 Page of Composition and its Edit.

Figure 1.15 How you can enter the temperature in the stream of material and ...

Figure 1.16 Entering the pressure in the stream of material and select kPa....

Figure 1.17 After entering the molar flow rate of the stream (all required i...

Figure 1.18 Arriving at the Envelope of the material stream.

Figure 1.19 Plotting the pressure–enthalpy (PH) of the ethane material strea...

Figure 1.20 Window of datasheet.

Chapter 2

Figure 2.1 Adding two types of fluid package, Basis‐1 and Basis‐2, then rena...

Figure 2.2 Changing the Units of Measure to a special one in the Properties ...

Figure 2.3 On entering the conditions of the stream‐1, the software automati...

Figure 2.4 On entering the conditions of the stream‐2, same as conditions of...

Figure 2.5 Streams 1 and 2 with their results.

Figure 2.6 How to add any property to the Results of table.

Figure 2.7 : Compare the mass densities of stream 1 with property package SR...

Figure 2.8 Analysis of the property using Case Study option.

Figure 2.9 Window of case study when first open.

Figure 2.10 Adding the independent variables to the case study.

Figure 2.11 Final window of case study after adding the dependent and indepe...

Figure 2.12 How you can enter the range and steps of independent variable.

Figure 2.13 Some of the tabulated results of mass density as a function of t...

Figure 2.14 Plotting the mass density versus temperature and pressure using ...

Figure 2.15 Arriving at the property table.

Figure 2.16 View of property table.

Figure 2.17 Appearance of Property Table in the Navigation Pane.

Figure 2.18 Specifying the range of independent variables in the property ta...

Figure 2.19 Adding the Mass density as dependent variable.

Figure 2.20 Plotting the mass density versus pressure and temperature.

Figure 2.21 Entering the range of temperature and state values in the Proper...

Figure 2.22 Adding the required dependent variables of saturated steam.

Figure 2.23 Results of steam table of saturated steam in the range of (40 – ...

Figure 2.24 Result of bubble‐point pressure when the temperature is given.

Figure 2.25 Result of bubble‐point pressure for mixture of 3 components.

Figure 2.26 Composition of the vapor phase for 3 components after calculatin...

Figure 2.27 Window of Saturator operation with its streams.

Figure 2.28 Estimating the humidity at

RH

 = 50%.

Figure 2.29 Adding the Independent and dependent variables in the Case Study...

Figure 2.30 Adding the range of independent variables (Temp: 20 – 50°C, step...

Figure 2.31 Plotting the Humidity versus temperature at different Relative h...

Chapter 3

Figure 3.1 Adding a Pump and feed stream in the HYSYS.

Figure 3.2 Window of Pump with material streams, red color of bottom bar ind...

Figure 3.3 Connecting the Pump with its Streams.

Figure 3.4 The pump is converged after specifying the pressure of product.

Figure 3.5 When the Pump efficiency is reduced, the duty will increase.

Figure 3.6 (a) Results of NPSH and Inertia. (b) Torque versus speed curve (R...

Figure 3.7 Window of the expander, Design tab, connection page.

Figure 3.8 Entering the outlet pressure through worksheet tab.

Figure 3.9 Results page ‐ Performance tab of the expander.

Figure 3.10 How you can add the Hypothetical component.

Figure 3.11 How you can add the Hypothetical component (continue).

Figure 3.12 Entering the data required for hypothetical component.

Figure 3.13 When the physical properties of C

7

+ are estimated, it can be add...

Figure 3.14 Connections page of the compressor.

Figure 3.15 Parameters page of the compressor: Entering efficiency 40%, and ...

Figure 3.16 The results of the compressor after entering the efficiency and ...

Chapter 4

Figure 4.1 Heat‐ exchanger, connections page,‐ design tab.

Figure 4.2 Heat exchanger, parameters page, design tab, entering the pressur...

Figure 4.3 Heat exchanger, conditions page, worksheet tab, specify the shell...

Figure 4.4 How you can arrive at the size exchanger.

Figure 4.5 Design results of heat exchanger.

Figure 4.6 Mechanical design of heat exchanger/Setting Plan.

Figure 4.7 Side view of Air Cooler.

Figure 4.8 Parameters page of the Air Cooler.

Figure 4.9 Performance results of Air Cooler.

Figure 4.10 Estimating the size of Air Cooler, parameters page, design tab....

Figure 4.11 How to arrive at the Design Results of Air Cooler.

Figure 4.12 Entering the fouling resistance.

Figure 4.13 Schematic diagram of the Fired Heater.

Figure 4.14 Fired Heater, connections page, design tab.

Figure 4.15 Fired Heater, parameters page, design tab, entering the efficien...

Figure 4.16 Process flow diagram of Fired Heater after convergence.

Figure 4.17 Case study of the Fired Heater.

Figure 4.18 Specifying the start, end, and step size values of independent v...

Figure 4.19 Results of case study of the Fired Heater, molar flow of fuel as...

Figure 4.20 Convert the Fired Heater from Simple to EDR.

Figure 4.21 To import the templates of the Fired Heater, click Import button...

Figure 4.22 Summary results of EDR Fired Heater.

Figure 4.23 Window of details of EDR Fired Heater, Layout page.

Figure 4.24 Layout page > Heater Geometry> Convective Banks.

Figure 4.25 Tubes pages > Heater Geometry > Convective Banks.

Figure 4.26 (Fins + Studs) pages > Heater Geometry > Convective Banks.

Figure 4.27 Process flow diagram (PFD) of the Problem (P.4.3).

Chapter 5

Figure 5.1 Scheme of a continuous single‐stage liquid–vapor separation.

Figure 5.2 Connecting the material streams with the valve and separator.

Figure 5.3 Window of separator, Design tab, Parameters page, entering the pr...

Figure 5.4 Process flow diagram of valve and separator with table of results...

Figure 5.5 After increasing the pressure drop of separator to 62.6 kPa, the ...

Figure 5.6 Adding energy stream to the separator.

Figure 5.7 Entering the flow of Vap stream required from which the Q‐energy ...

Figure 5.8 Selecting vessel/Separator for executing the design.

Figure 5.9 Window of Vessel Sizing, Design tab Connection page, Select Separ...

Figure 5.10 Specifications of vessel design.

Figure 5.11 Sizing results of the separator in the performance tab.

Figure 5.12 Process flow diagram of Heat Exchanger and flash separator as an...

Figure 5.13 Typing the specified terms in the spreadsheet.

Figure 5.14 How to add import variables to the cells in the spreadsheet.

Figure 5.15 Selecting the required variables.

Figure 5.16 Estimating efficiency after entering the results in the cells of...

Figure 5.17 How the steam's temperature affects the steam required.

Figure 5.18 Effect of sucrose concentration in the product on the amount of ...

Figure 5.19 Steam power plant system.

Figure 5.20 PFD of the steam power plant of P.5.1 after executing the simula...

Figure 5.21 Spreadsheet; typing the energy's streams and how to import the v...

Figure 5.22 Steps to import the required variables to the spreadsheet.

Figure 5.24 Result of efficiency of the steam power plant after calculation ...

Figure 5.23 Spreadsheet after importing the energy's streams.

Figure 5.25 Process flow diagram of the compressor, cooler, and flash separa...

Figure 5.26 Refrigeration cycle.

Figure 5.27 Linde–Hampson liquid‐methane system.

Figure 5.28 Liquefaction Process (Claude system).

Chapter 6

Figure 6.1 Connection of set operation.

Figure 6.2 Connection tab of set operation.

Figure 6.3 Parameters of set operation.

Figure 6.4 Connection of Adjust‐operation.

Figure 6.5 Connection page of adjust‐operation, select the User Supplied rad...

Figure 6.6 Connection page of adjust‐operation, select the Another Object ra...

Figure 6.7 Connection page of adjust‐operation, select the SpreadSheetCell O...

Figure 6.8 Connection page of Balance‐operation.

Figure 6.9 Parameters that can be selected in balance‐operation.

Figure 6.10 Picture of the Recycle operation.

Figure 6.11 The property view of Spreadsheet.

Chapter 7

Figure 7.1 Schematic diagram of a fluid flow system.

Figure 7.2 Activating the “Use sizing methods to calculate delta P” radio in...

Figure 7.3 On entering the

C

v

value, the delta

P

will be estimated.

Figure 7.4 Window of pipe segment when opening first time.

Figure 7.5 How you can append segment in the piping system.

Figure 7.6 Entering the dimensions in the pipe segment for Elbow and pipe.

Figure 7.7 Selecting the diameter of pipe segment and its material from Pipe...

Figure 7.8 Segments of (Pipe‐100).

Figure 7.9 Heat transfer page in the pipe‐ segment.

Figure 7.10 Estimating the overall heat transfer coefficient in the pipe seg...

Figure 7.11 completing all parts of the pipe segment (Pipe‐101).

Figure 7.12 Process flow diagram of the piping system in HYSYS.

Figure 7.13 The results of Pipe Network of Pipe Segment (Pipe‐101).

Figure 7.14 The results of pressure of point

D

as a function of mass flow ra...

Figure 7.15 Another method to estimate the pressure drop or pipe diameter.

Figure 7.16 Simplified diagram about estimations of Pipesys.

Figure 7.17 Small gas‐condensate‐gathering system.

Figure 7.18 PFD generated by HYSYS for the completed small gas‐condensate‐ga...

Figure 7.19 How to copy the composition of Well

B

from Well

A

.

Figure 7.20 Connections tab of the Pipesys.

Figure 7.21 Distance and Elevation in the pipeline origin, Elevation Profile...

Figure 7.22 Distance and elevation in pipeline.

Figure 7.23 Selection of nominal diameter and pipe schedule.

Figure 7.24 Selection of heat transfer environment and entering the value of...

Figure 7.25 Elevation profile data required.

Figure 7.26 Results of the elevation data.

Figure 7.27 Temperature profile page in the Pipesys.

Figure 7.28 Process flow diagram of the small gas condensate in Hysys after ...

Figure 7.29 Adding compressor to the Pipesys, branch 5.

Figure 7.30 Window of the compressor in the pipesys.

Figure 7.31 Inline Compressor view, parameters tab.

Figure 7.32 Schematic diagram of Exercise 7.1.

Figure 7.33 PFD for Fired Heater, Heat Exchanger, and Pressure Safety Valve ...

Figure 7.34 Entering the Safety Analysis by clicking the Safety Analysis but...

Figure 7.35 Adding PSV Option in Safety Analysis Environment.

Figure 7.36 Window of pressure safety valve and Entering the Design Temperat...

Figure 7.37 Window of PRD Data and Entering Set Pressure and Set “Discharge ...

Figure 7.38 Scenarios tab of PSV.

Figure 7.39 Relief Load Scenarios Available in the scenario Type list.

Figure 7.40 Valve Results Table inside “Scenario Setup” tab.

Figure 7.41 Results of PSV.

Figure 7.42 Entering the nominal diameter for In Line and Out Line and Resul...

Figure 7.43 Calculating pressure drop in the PSV.

Chapter 8

Figure 8.1 How to add a reaction set.

Figure 8.2 Adding a reaction to the Reaction Set‐1.

Figure 8.3 Window of conversion reaction type.

Figure 8.4 Stoichiometric and conversion information of reaction (8.4).

Figure 8.5 How to add the Reaction Set to the fluid package.

Figure 8.6 Final view of the Reaction Set‐1 (Conversion type).

Figure 8.7 Conversion reactor in the object palette, Columns group.

Figure 8.8 Connection page of the conversion reactor.

Figure 8.9 Adding the reaction set to the conversion reactor.

Figure 8.10 Worksheet tab of the conversion reactor, through which the heat ...

Figure 8.11 Reaction tab, Results page, Reaction Balance radio, explaining t...

Figure 8.12 PFD of the conversion reactor.

Figure 8.13 How to add the new Reaction Set.

Figure 8.14 Choosing equilibrium reaction type.

Figure 8.15 Stoichiometry of reaction (8.5) in the equilibrium reaction.

Figure 8.16 Specifying the type of equilibrium constant of the reaction.

Figure 8.17 Window of equilibrium reactor, Design tab, Connection page.

Figure 8.18 Adding the reaction set to the equilibrium reactor.

Figure 8.19 Reactions tab, Results page: showing the % conversion, equilibri...

Figure 8.20 List of available reactions in the library, e.g. we can add the ...

Figure 8.21 Case study window, adding the independent variables and dependen...

Figure 8.22 Effect of feed's pressure and product's temperature on the react...

Figure 8.23 PFD of the toluene production.

Figure 8.24 Modified PFD of the toluene production.

Figure 8.25 Obtaining the optimum value of the To‐Heat temperature using a c...

Figure 8.26 PFD of the Steam–Methane Reformer (Hydrogen Production).

Figure 8.27 Optimum value of multiple steam flow rate times natural gas flow...

Figure 8.28 PFD of Synthesis Gas production

.

Figure 8.29 Stoichiometry and conversion percent for the reaction (8.11).

Figure 8.30 Choosing an existing reaction from the previous steps.

Figure 8.31 Adding reaction (8.14) from the list of library.

Figure 8.32 Adjust operation for adjusting the temperature of shift1 feed.

Figure 8.33 Parameters page of the adjust operation (Adj‐1).

Figure 8.34 Monitor page of the adjust operation (Adj‐1).

Figure 8.35 Final Activity Model Interaction Parameters table for the Aij co...

Figure 8.36 Entering the Stoichiometry, order of the reaction, and parameter...

Figure 8.37 CSTR in the object palette.

Figure 8.38 Design tab, Connections page in the CSTR and attached streams.

Figure 8.39 Entering the dimensions of CSTR in the Dynamics tab of the CSTR....

Figure 8.40 Worksheet tab, Conditions page, Entering the temperature in the ...

Figure 8.41 conversion's Result of CSTR.

Figure 8.42 PFD of CSTR and its conditions.

Figure 8.43 PFD of the plug flow reactor (PFR).

Figure 8.44 Window of the simple rate reaction of (8.17).

Figure 8.45 Stoichiometry and rate information of the kinetics reaction of (...

Figure 8.46 PFR in the object palette.

Figure 8.47 Attaching the streams with PFR in the Connection page of the PFR...

Figure 8.48 Rating tab, Sizing page in the PFR.

Figure 8.49 Conversion's result of the reactions in the PFR.

Figure 8.50 PFD of the Ammonia Production Plant.

Figure 8.51 Window of kinetics reaction for ammonia kinetics.

Figure 8.52 Reaction Results of plug flow reactor, PFR‐100.

Figure 8.53 Window of Heterogeneous Catalytic reaction.

Figure 8.54 A picture of the formula of Heterogeneous Catalytic reaction.

Figure 8.55 Reaction Rate of Heterogeneous Catalytic reaction.

Figure 8.56 PFD of the plug flow reactor of the hydrogen production.

Figure 8.57 Heat transfer page in PFR.

Figure 8.58 Data required of the Heterogeneous Catalytic reaction.

Figure 8.59 Component mole fraction along length of Reactor.

Figure 8.60 Effect of tube length on the compositions of the components.

Figure 8.61 Gibbs reactor and its connected streams.

Figure 8.62 Selecting a suitable option of the Gibbs Reactor.

Figure 8.63 Effect of feed temperature on ammonia production in the adiabati...

Figure 8.64 PFD of the Gibbs reactor with Set‐operation.

Figure 8.65 Effect of the feed temperature on the ammonia production in the ...

Figure 8.66 PFD of conversion and equilibrium reactor of problem P.8.5.

Figure 8.67 Answer of P.8.10 branch (a).

Chapter 9

Figure 9.1 Input expert of the absorber column, connecting the inlet and out...

Figure 9.2 Page of pressures information.

Figure 9.3 Connection page of the absorber column is now ready to run.

Figure 9.4 Molar flow rate of SO

2

in the exit gas when increasing the number...

Figure 9.5 Internal tab of the absorber column: How to perform the design of...

Figure 9.6 Geometry tab of the absorber column/Tray type.

Figure 9.7 Internal tab of the absorber column/packed type.

Figure 9.8 Geometry tab of the absorber column/packed type.

Figure 9.9 Values of HETP for various packing.

Figure 9.10 Dimensions results of the packed section design of the absorptio...

Figure 9.11 Hydraulic Plot in details of packed column absorption.

Figure 9.12 Vapor composition versus liquid composition at constant pressure...

Figure 9.13 Equilibrium Unit Operation in the object palette.

Figure 9.14 Procedure of equilibrium plotting data.

Figure 9.15 Equilibrium plotting data of the ethanol–water that shows the az...

Figure 9.16 Equilibrium plotting data of the benzene‐toluene that shows no a...

Figure 9.17 Window of the shortcut column, connection page.

Figure 9.18 Window of the shortcut column/parameters page.

Figure 9.19 Results of the shortcut column in the performance tab.

Figure 9.20 PFD of the gshortcut distillation.

Figure 9.21 Estimating the number of theoretical stages using graphical meth...

Figure 9.22 Icon of rigorous distillation column in the object palette.

Figure 9.23 Window of Distillation column input expert with connected stream...

Figure 9.24 Page 3 of 5 (Pressure profile) of Distillation column input expe...

Figure 9.25 Page 5 of 5 (Specifications) of Distillation column input expert...

Figure 9.26 Design tab, Monitor page of the column, show the specification g...

Figure 9.27 Deactivation of Reflux ratio, degree of freedom became 1, and mu...

Figure 9.28 Converging the distillation column (T‐100), and the reflux ratio...

Figure 9.29 Second distillation column with its inlet and outlet streams.

Figure 9.30 Monitor page, Design tab of the second column, Deactivate the Re...

Figure 9.31 Specifications of column that adding; A: Component fraction, and...

Figure 9.32 Convergence of column after adding the required specifications....

Figure 9.33 PFD of the two‐distillation columns that are used to obtain meth...

Figure 9.34 Window of Reboiled Absorber Column Input Expert and the data req...

Figure 9.35 Window of Monitor page, Design tab of Reboiled Absorber Column....

Figure 9.36 Design tab, Monitor page, Specifying the value of “Ovhd Prod Rat...

Figure 9.37 Deactivate the “Ovhd Prod Rate” and add a new specification “Com...

Figure 9.38 PFD of the Reboiled absorber column and specification of the Vap...

Figure 9.39 Liquid–liquid extractor input expert/connection page.

Figure 9.40 Distillation column input expert/ connection page.

Figure 9.41 Adding the Component fraction specification of the 3‐methylhexan...

Figure 9.42 PFD of Extraction of Acetone–Water with 3‐Methylhexane as solven...

Figure 9.43 PFD of Propylene Glycol production.

Figure 9.44 Window of Kinetic Reaction of Propylene Glycol production.

Figure 9.45 CSTR window, Design tab, Connections Page.

Figure 9.46 Distillation column, input expert.

Figure 9.47 Monitor page before converging.

Figure 9.48 Component fraction window: Adding the purity of water as the spe...

Figure 9.49 Results of reaction conversion of the CSTR.

Figure 9.50 Results of distillation column ‐ Worksheet‐Composition page.

Figure 9.51 Schematic diagram of LNG exchanger.

Figure 9.52 PFD of the LPG Process.

Figure 9.53 Connection page of LNG exchanger.

Figure 9.54 The two specifications that must be added to the LNG, (a) delta ...

Figure 9.55 Adding the reaction to the Distillation Column.

Figure 9.56 window of Reaction in the distillation column.

Figure 9.57 Changing the solving method to Sparse continuation solver.

Figure 9.58 Window of the three‐phase column configuration.

Figure 9.59 Window of two liquid‐phase checking.

Figure 9.60 Three‐phase column input expert/condenser setup.

Figure 9.61 Condenser specifications.

Figure 9.62 Connection page of the three‐phases column.

Figure 9.63 PFD for the separation of toluene and n‐heptane using extractive...

Figure 9.64 Setup of property package.

Figure 9.65 Distillation column input expert/connection page without adding ...

Figure 9.66 Adding two‐component fraction specifications: (a) for n‐heptane,...

Figure 9.67 Distillation column input expert/connection page when adding sol...

Figure 9.68 Component fraction specification of

n

‐heptane.

Figure 9.69 Distillation column (T‐101), input expert/connection page.

Figure 9.70 Component column specifications: (a) for toluene and (b) for phe...

Figure 9.71 PFD of azeotropic distillation process of ethanol–water system....

Figure 9.72 Three‐phase column input expert/two liquid‐phase checking.

Figure 9.73 Three‐phase column input expert/condenser setup.

Figure 9.74 Three‐phase column input expert/connection page.

Figure 9.75 Component fraction specification of ethanol.

Figure 9.76 Spreadsheet.

Figure 9.77 Import variables in the spreadsheet.

Figure 9.78 Adjusting operation/connection page.

Figure 9.79 Adjusting the makeup flow in the spreadsheet.

Figure 9.80 PFD of the three‐phase column for azeotropic distillation.

Figure 9.81 The first page of the distillation column shows the separation o...

Figure 9.82 Component fraction specification of water.

Figure 9.83 First page of the shortcut distillation, Design tab, Connections...

Figure 9.84 Design tab/Parameters page of the shortcut distillation with dat...

Figure 9.85 Results obtained from the performance tab of shortcut distillati...

Figure 9.86 Design tab, Monitor page of the rigorous distillation column.

Figure 9.87 Composition of the feed and product streams from distillation.

Figure 9.88 PFD of Problem 9.12; Counter‐current multi‐stage extraction of f...

Chapter 10

Figure 10.1 Importing the petroleum assay, Properties environment.

Figure 10.2 Assay management ribbon.

Figure 10.3 How you can add a new assay.

Figure 10.4 Choosing Assay Components Fahrenheit to 1500  °F.

Figure 10.5 Import an existing assay from the Assay Library.

Figure 10.6 Stream properties of the Kuwait input assay.

Figure 10.7 Entering assay data manually.

Figure 10.8 Characterizing the whole crude properties.

Figure 10.9 Molecular Characterization of the Kuwait assay.

Figure 10.10 Properties that can be plotted for assays.

Figure 10.11 Distillation curve plotting for the Kuwait 2012 crude.

Figure 10.12 Comparison of distillation curve of the Kuwait and Kirkuk assay...

Figure 10.13 How to export assay data.

Figure 10.14 Attaching an existing assay, Add material stream, double‐click ...

Figure 10.15 View of the assay table while in the simulation environment.

Figure 10.16 PFD of refinery of crude oil_1.

Figure 10.17 How to change the units of measure.

Figure 10.18 Arriving at the oil manager.

Figure 10.19 Adding a new assay.

Figure 10.20 How to select TBP from Assay Data Type.

Figure 10.21 Properties of the assay that required defining.

Figure 10.22 Entering the composition in the Liquid volume percent in the li...

Figure 10.23 Bulk properties of assay.

Figure 10.24 Selection of Lagrange method in the calculation of properties....

Figure 10.25 Table of assay percent with temperature.

Figure 10.26 Table of assay percent with molecular weight.

Figure 10.27 API gravity curve data.

Figure 10.28 Viscosity 1 assay data.

Figure 10.29 Viscosity 2 assay data.

Figure 10.30 Selection of User Ranges from the cut option selection.

Figure 10.31 Number of cutting in the range of temperatures.

Figure 10.32 Type the stream name of the crude after installing oil.

Figure 10.33 Refluxed Absorber input expert/connection page.

Figure 10.34 Final view of the side stripper column for kerosene.

Figure 10.35 Final view of the side stripper column of Diesel.

Figure 10.36 Final view of the side stripper column of AGO.

Figure 10.37 Summary of side strippers.

Figure 10.38 specification of pump around.

Figure 10.39 Specification of the Pump around between 2nd stage and 1st stag...

Figure 10.40 Pump around between 17th stage and 16th stage.

Figure 10.41 Pump around between 22nd stage and 21st stage.

Figure 10.42 Summary of pumps around.

Figure 10.43 Adding the column liquid flow as specification.

Figure 10.44 Adding the column duty as a specification.

Figure 10.45 Complete list of the Column Specifications.

Figure 10.46 PFD of Refinery of Crude oil 2.

Figure 10.47 Arriving at the Oil manager.

Figure 10.48 Selection of TBP to appear in the properties.

Figure 10.49 The required properties to be entered in the assay.

Figure 10.50 Value of Standard Density that must be entered in the Bulk prop...

Figure 10.51 Selection of the Lagrange method in the calculation of properti...

Figure 10.52 Table of assay percent versus temperature.

Figure 10.53 Composition of liquid end as liquid volume percent.

Figure 10.54 Creating Blend‐1 by clicking Output Blend Folder in the Navigat...

Figure 10.55 Selecting the User Points from Cut Option Selection group and e...

Figure 10.56 Selecting the Molar Compositions under the Table Type.

Figure 10.57 Typing the “Raw Crude” under the Stream Name and installing oil...

Figure 10.58 Input expert of the crude oil refinery column.

Figure 10.59 Page's Summary of Side Stripper Summary.

Figure 10.60 Page's Summary of the Liquid Pump Around.

Figure 10.61 Specifications of the refinery column to be converged.

Figure 10.62 Converged column of the refinery crude oil.

Figure 10.63 PFD of Sulfur recovery using Claus Process Treating Unit.

Figure 10.64 Sulfur recovery unit in the simulation environment.

Figure 10.65 Sub‐Flowsheet operation of the sulfur recovery.

Figure 10.66 Saturator in the Object Palette.

Figure 10.67 Window of Saturator SAT‐100, Connection page, and its streams....

Figure 10.68 Window of Saturator SAT‐101, Connection page, and its streams....

Figure 10.69 Single Furnace Reaction Chamber, Single‐Pass Waste Heat Exchang...

Figure 10.70 Window of Single Furnace Reaction Chamber (FUR‐100), Connection...

Figure 10.71 Window of Single‐Pass Waste Heat Exchanger (WHE‐100), Connectio...

Figure 10.72 Window of Condenser (COND‐100), Connection page, and its stream...

Figure 10.73 Catalytic Converter in the Object Palette.

Figure 10.74 Performance tab of the Catalytic Converter (CONV‐100).

Figure 10.75 Performance tab of the Catalytic Converter (CONV‐101).

Figure 10.76 Reducing Gas Generator (RGG) unit in the object palette.

Figure 10.77 Window of Reducing Gas Generator (RGG‐100), Connection page, an...

Figure 10.78 Entering the parameters in the RGG‐100.

Figure 10.79 Hydrogenation Bed, Quench Tower, Simple Amine Absorber, and Inc...

Chapter 11

Figure 11.1 Specifying the component fraction specifications for (a) tolugen...

Figure 11.2 Setting the tolerance of the equilibrium error and heat/spec err...

Figure 11.3 Adding the purity specification of THF in the distillation colum...

Figure 11.4 Range of adjusted variables in the optimizer.

Figure 11.5 Variables of the objective function in the spreadsheet.

Figure 11.6 Specify whether the objective function is minimize or maximize; ...

Figure 11.7 PFD of the multiple Heat Exchangers.

Figure 11.8 Specifying the Low and High Bounds of the adjusted variable (mol...

Figure 11.9 Importing the UA value for the Heat Exchangers in the spreadshee...

Figure 11.10 Estimating of the objective function in the optimizer.

Chapter 12

Figure 12.1 Schematic diagram of the cyclone.

Figure 12.2 Window of cyclone, Connection Page, Design tab.

Figure 12.3 Parameters page/Design tab of the cyclone.

Figure 12.4 Design tab, Solids page of the cyclone, selecting a single‐parti...

Figure 12.5 Results of the cyclone's design and the number of cyclones when ...

Figure 12.6 Results of cyclone's design and the number of cyclones when sele...

Figure 12.7 Air stream, PSD Property, PSD Input View.

Figure 12.8 Design tab, Solid page, selection of particle size distribution ...

Figure 12.9 Rating tab, Sizing page, dimensions of the cyclone when selectin...

Figure 12.10 Rotary vacuum filter.

Figure 12.11 Rotary vacuum filter in the HYSYS /connection page.

Figure 12.12 Parameters page, Design tab of the rotary vacuum filter.

Figure 12.13 Rating tab, Sizing page of the rotary vacuum filter.

Figure 12.14 PFD of the rotary vacuum filter.

Figure 12.15 Baghouse filter.

Figure 12.16 Baghouse filter in the HYSYS /connection page.

Figure 12.17 Specifying the independent and dependent variables in the case ...

Figure 12.18 Results of filtration time versus dirty pressure drop in the ba...

Figure 12.19 Adding the kaolin as a new component.

Figure 12.20 Worksheet of the Feed so as to enter the editing of the kaolin ...

Figure 12.21 Entering the parameters required of the PSD.

Figure 12.22 Estimated particle size distribution of kaolin in the feed stre...

Figure 12.23 Window of cyclone, Design tab, Solids page.

Figure 12.24 Removing the solid outlet with air using baghouse filter.

Figure 12.25 Adding mixer to mix the solids from the cyclone and baghouse fi...

Chapter 13

Figure 13.1 PFD of the flash separator.

Figure 13.2 Estimating the sizing of valve from Rating tab, Sizing page, the...

Figure 13.3 How can one obtain the total volumetric flow rate of the liquid ...

Figure 13.4 Entering the dimensions of the separator.

Figure 13.5 Selecting the process variable and output target of the controll...

Figure 13.6 Entering the parameters required for the flow controller FC.

Figure 13.7 The difference between the direct and reverse action of controll...

Figure 13.8 Adding a level controller to the separator from dynamics tab.

Figure 13.9 PFD of the flash separator after adding the controllers.

Figure 13.10 A list of all controllers that can be found using the control m...

Figure 13.11 Selecting the variables SP, PV, OP for the FC's controller.

Figure 13.12 Screen of the stripchart of FC controller.

Figure 13.13 Reducing the value of acceleration.

Figure 13.14 Make change of the items from dynamics assistance.

Figure 13.15 Screens of the FC and PC controllers.

Figure 13.16 Response of controllers and their process variables when changi...

Figure 13.17 PFD of steady‐state simulation of the gas processing.

Figure 13.18 Gas/gas Heat Exchanger, design tab, specs page; adding specific...

Figure 13.19 How the new specification of (delta temp type) is operating.

Figure 13.20 Window of envelope of the sale gas, table data.

Figure 13.21 Phase diagram of the sale gas.

Figure 13.22 PFD of the dynamic state.

Figure 13.23 De‐propanizer column/column environment, inserting a valve betw...

Figure 13.24 Installing control loops in the de‐propanizer column.

Figure 13.25 Dynamics assistant window/parameters that can be adjusted.

Figure 13.26 How to add the strip chart from the dynamics tab in the ribbon....

Figure 13.27 Adding variables to the strip chart.

Figure 13.28 Display the screen of the data logger.

Figure 13.29 Screen of the strip chart (DataLogger1).

Figure 13.30 Process flow diagram of the mixing of benzene and hydrogen stre...

Figure 13.31 Clicking the size valve to ensure the estimation of Cv.

Figure 13.32 Selecting the process variable (PV) and output of controller (O...

Figure 13.33 Entering the ranges of molar flow rate of H

2

‐stream (1), and Bz...

Figure 13.34 Entering the tuning parameters of controller.

Figure 13.35 PFD of ratio control System.

Figure 13.36 Selecting (SP, PV, OP only) as signals for displaying.

Figure 13.37 Activating the box of (equal pressure option active), then clic...

Figure 13.38 Display of the signals on the screen of the controller.

Figure 13.39 Increasing the process controlled variable to 310 kmol/h after ...

Figure 13.40 Some examples of cascade control: (a) Heat Exchanger with casca...

Figure 13.41 Window of the Kinetic Reaction Rxn‐1.

Figure 13.42 PFD of the CSTR.

Figure 13.43 Specifying the utility type of Q‐energy.

Figure 13.44 Slave controller and its signals.

Figure 13.45 Parameters tab of the slave controller.

Figure 13.46 Specifying the minimum and maximum of Q‐utility. See the commen...

Figure 13.47 Connection page of master controller with its signals.

Figure 13.48 Parameters tab of the master controller.

Figure 13.49 Slave controller, Parameters tab, change the mode to “Casc.”

Figure 13.50 Curves of the slave controller.

Figure 13.51 Mechanism of split range control.

Figure 13.52 Window of kinetics reaction data of ammonia production.

Figure 13.53 Process flow diagram of plug flow reactor of ammonia production...

Figure 13.54 Window of the PIC‐100 controller.

Figure 13.55 Split range controller, SPLT‐100, connection tab, OP # 1.

Figure 13.56 Split range controller, SPLT‐100, connection tab, OP # 2.

Figure 13.57 Split range controller, SPLT‐100, parameters tab, configuration...

Figure 13.58 Split range controller, SPLT‐100, parameters tab, operation pag...

Figure 13.59 Split range controller, SPLT‐100, split range setup tab, ranges...

Figure 13.60 PIC‐100 controller, parameters tab, setting the SP mode to * re...

Figure 13.61 PIC‐101 controller, parameters tab, setting the SP mode to * re...

Figure 13.62 Final PFD of split range control of plug flow reactor of ammoni...

Figure 13.63 Stripchart tab, selecting (SP, PV, OP Only), then clicking on d...

Figure 13.64 Screen of the stripchart of the split range controller after ch...

Chapter 14

Figure 14.1 PFD of the gas processing where the economic evaluation will be ...

Figure 14.2 Entering the price of the Feed1 stream.

Figure 14.3 Presenting the prices of the material streams.

Figure 14.4 Utility summary/cost of each utility and the total costs of util...

Figure 14.5 Setting the operating life of plant and operational year.

Figure 14.6 Activating the economics active radio.

Figure 14.7 Selecting the gas/gas (HEATX) from the map.

Figure 14.8 Procedure of selecting the type of unit operation in the map.

Figure 14.9 Procedure of selecting the type of unit operation in the map, ga...

Figure 14.10 Selecting the sizing icon for executing the sizing of the equip...

Figure 14.11 Viewing the sizing of the equipment by clicking the type of equ...

Figure 14.12 Summary results of economic evaluation.

Figure 14.13 Details of cost of unit operation.

Figure 14.14 Executive summary sheet obtained from investment analysis.

Figure 14.15 Cash flow sheet.

Chapter 15

Figure 15.1 PFD of the cyclohexane production plant.

Figure 15.2 PFD of dimethyl_ether production plant.

Figure 15.3 PFD of the gas sweetening.

Figure 15.4 PFD of the propylene production plant.

Figure 15.5 PFD of the methanol production plant.

Figure 15.6 PFD of the vinyl_chloride_monomer production plant.

Guide

Cover

Table of Contents

Title Page

Copyright

Dedication

Preface

Acknowledgments

Begin Reading

Index

End User License Agreement

Pages

iii

iv

v

xv

xvi

xvii

xix

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

60

61

62

63

65

66

67

68

69

70

71

72

73

74

75

76

77

78

79

80

81

82

83

84

85

86

87

88

89

90

91

93

94

95

96

97

98

99

100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

119

120

121

122

123

124

125

126

127

128

129

130

131

132

133

134

135

136

137

138

139

140

141

142

143

144

145

146

147

148

149

150

151

152

153

154

155

156

157

158

159

160

161

162

163

164

165

166

167

168

169

170

171

172

173

174

175

176

177

178

179

180

181

182

183

184

185

186

187

188

189

190

191

192

193

194

195

196

197

198

199

200

201

202

203

204

205

206

207

208

209

210

211

212

213

214

215

216

217

218

219

220

221

222

223

224

225

226

227

228

229

231

232

233

234

235

236

237

238

239

240

241

242

243

244

245

246

247

248

249

250

251

252

253

254

255

256

257

258

259

260

261

262

263

264

265

266

267

268

269

270

271

272

273

274

275

276

277

278

279

280

281

282

283

284

285

286

287

288

289

290

291

292

293

294

295

296

297

298

299

300

301

302

303

304

305

306

307

308

309

310

311

312

313

314

315

316

317

318

319

321

322

323

324

325

326

327

328

329

330

331

332

333

334

335

336

337

338

339

340

341

342

343

344

345

346

347

348

349

350

351

352

353

354

355

356

357

358

359

360

361

362

363

364

365

366

367

368

369

370

371

372

373

374

375

376

377

378

379

380

381

382

383

384

385

386

387

388

389

390

391

392

393

394

395

396

397

398

399

400

401

402

403

404

405

406

407

408

409

411

412

413

414

415

416

417

418

419

420

421

422

423

424

425

426

427

428

429

430

431

432

433

434

435

436

437

438

439

440

441

442

443

444

445

446

447

448

449

450

451

452

453

454

455

456

457

458

459

460

461

462

463

464

465

466

467

468

469

471

472

473

474

475

476

477

478

479

480

481

483

484

485

486

487

488

489

490

491

492

493

494

495

496

497

499

500

501

502

503

504

Chemical Process Simulations using Aspen Hysys

Khalid W. HameedUniversity of Baghdad, Iraq

Copyright © 2025 by John Wiley & Sons, Inc. All rights reserved, including rights for text and data mining and training of artificial technologies or similar technologies.

Published by John Wiley & Sons, Inc., Hoboken, New Jersey. Published simultaneously in Canada.

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, scanning, or otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without either the prior written permission of the Publisher, or authorization through payment of the appropriate per‐copy fee to the Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923, (978) 750‐8400, fax (978) 750‐4470, or on the web at www.copyright.com. Requests to the Publisher for permission should be addressed to the Permissions Department, John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, (201) 748‐6011, fax (201) 748‐6008, or online at http://www.wiley.com/go/permission.

The manufacturer's authorized representative according to the EU General Product Safety Regulation is Wiley‐VCH GmbH, Boschstr. 12, 69469 Weinheim, Germany, e‐mail: [email protected].

Trademarks: Wiley and the Wiley logo are trademarks or registered trademarks of John Wiley & Sons, Inc. and/or its affiliates in the United States and other countries and may not be used without written permission. All other trademarks are the property of their respective owners.

John Wiley & Sons, Inc. is not associated with any product or vendor mentioned in this book.

Limit of Liability/Disclaimer of Warranty: While the publisher and author have used their best efforts in preparing this book, they make no representations or warranties with respect to the accuracy or completeness of the contents of this book and specifically disclaim any implied warranties of merchantability or fitness for a particular purpose. No warranty may be created or extended by sales representatives or written sales materials. The advice and strategies contained herein may not be suitable for your situation. You should consult with a professional where appropriate. Further, readers should be aware that websites listed in this work may have changed or disappeared between when this work was written and when it is read. Neither the publisher nor authors shall be liable for any loss of profit or any other commercial damages, including but not limited to special, incidental, consequential, or other damages.

For general information on our other products and services or for technical support, please contact our Customer Care Department within the United States at (800) 762‐2974, outside the United States at (317) 572‐3993 or fax (317) 572‐4002.

Wiley also publishes its books in a variety of electronic formats. Some content that appears in print may not be available in electronic formats. For more information about Wiley products, visit our web site at www.wiley.com.

Library of Congress Cataloging‐in‐Publication Data Applied for:

Hardback ISBN: 9781394293278

Cover Design: WileyCover Image: © Rudchenko Liliia/Shutterstock

To my creator who taught humans things they did not know before;

To the last prophet Mohammad and to the preceding prophets, peace be upon all of them;

To my first lovely teachers in this life: mom and dad;

To my biochemical engineering students;

To AspenTech, Inc., who sponsored this work;

To the rest, I say: my sincere and warm greetings to all of you.

Preface

Aspen HYSYS is a software program used for the simulation and plant design of chemical processes. It is a market‐leading process modeling tool for conceptual design, optimization, business planning, asset management, and performance monitoring. It is designed by the Canadian company Hyprotech, founded by researchers from the University of Calgary in 1996. In May 2002, AspenTech acquired and modified Hyprotech, including HYSYS. So, the HYSYS software was renamed by AspenTech to Aspen HYSYS. In this text, for brevity, the software is mostly named HYSYS.

Due to the accuracy of this software, it is widely used in industries such as oil and gas production, gas processing, petroleum refining, chemical processing, and air separation. The study shows the advantages of HYSYS and why it is preferred over other software. This book gives an introduction to the workings of HYSYS in various chemical fields. Aspen HYSYS is a core element of AspenTech's AspenONE Engineering applications. Aspen HYSYS has established itself as a very intuitive and easy‐to‐use process simulator in the oil and gas refining industry. Users with little prior knowledge of Aspen HYSYS can pick up and train themselves in its modeling capabilities. Some of the very intuitive capabilities include a highly interactive process flow diagram for building and navigating through large simulations. The software also provides a very flexible and easy‐to‐use distillation column modeling environment. Additionally, the interactive nature of HYSYS enables users to build and use their models quickly and effectively. Aspen HYSYS offers a comprehensive thermodynamics foundation for accurate calculation of physical properties, transport properties, and phase behavior for the oil and gas and refining industries. This software uses mathematical models to simulate the behavior of chemical and physical systems, allowing engineers to predict how a process will behave under different conditions and to test different process scenarios before implementing them in the real world. A comprehensive library of unit operation models, including distillation columns, reactors, heat transfer operations, rotating equipment, controllers, and logical operations in both steady state and dynamic environments, execute the economic evaluation.

A crucial tool for many design, control, and optimization activities is chemical process simulation. Chemical and process engineers are capable of producing intricate computations quickly, as well as assessing various options and operational scenarios. As a result, chemical process simulators are now a crucial teaching tool for chemical engineering, and an appreciation of them will open up new avenues for development in the conceptual and detailed engineering domains.

Simulation is a situation in which a particular set of conditions is created artificially in order to study or experience something that could really exist in reality. It is the act of pretending that something is real when it is not. A computer simulation is an attempt to model a real‐life or hypothetical situation on a computer so that it can be studied to see how the system works.

In this textbook, the principle of calculation will be presented basically to learn and understand the basic calculations in chemical engineering as a review before using the software and if he/she likes in hand calculation and compares with the results obtained by software.

The advantages of the Aspen HYSYS software can be summarized as follows:

Contains the physical and thermodynamic properties of hundreds of chemicals.

Performs the material and energy balance as well as unit conversion.

Performs the design calculations for the equipment.

Perfect for analytical/numerical minds (how the process would behave under different conditions), e.g. Case steady research.

Executes the dynamics and control process as well as steady state.

Performs the economic evaluation.

Obtains a report of the plant details.

Eliminates routine and save of time, i.e. make easier/faster work as well as accuracy of results.

The software can present a virtual lab

It can be applied to the operating conditions by software first, then in the practical field to avoid errors and obtain the optimum conditions.

Excellent for your curriculum vitae as an engineer.

There are two modes of simulation: steady‐state mode and dynamic mode.

Steady‐state

mode:

Initially, process simulation was used to simulate steady state processes. Steady‐state models perform the mass and energy balance of a stationary process (a process in an equilibrium state), but any changes over time have to be ignored.

Dynamics mode:

Dynamic simulations require increased calculation time and are mathematically more complex than a steady‐state simulation. It can be seen as a repeatedly multiply steady‐state simulation (based on a fixed time step) with constantly changing parameters.

In this text, the Aspen HYSYS software will be explained and understood simply by solving examples dealing with unit operation in the chemical engineering process.

Khalid W. Hameed

2024Iraq

Acknowledgments

The author acknowledges with thanks, appreciation, and gratitude for the assistance provided by Aspen Technology Incorporation for the great efforts this incorporation has made in providing help, guides, tutorial manuals, videos, etc., so that the learner becomes a professional in the field of the company's software. The author thanks Natarajan Priyadarshini, Michael Leventhal, and Sabeen Aziz for their help in organizing and arranging this book and their quick response to emails.

1Starting with Aspen HYSYS

This chapter begins by explaining how to start Aspen HYSYS and how to select the right components and fluid package for simulation purposes. Knowing how to start Aspen HYSYS and get familiar with its desktop is very important in this chapter. The second part is about how to enter and reenter the simulation environment, and get familiar with the simulation flowsheet. In this part, users will be informed of some important features of Aspen HYSYS. The last part deals with how to add and specify material streams for simulation. Variable specification is one of the important steps that users need to understand when dealing with Aspen HYSYS.

Upon completion of this chapter, the reader will be able to:

Start the Aspen HYSYS

Select the Components

Determine and pick an appropriate fluid package

Switch to the Simulation Environment

Insert and define the material streams.

Mostly in this book and for making it concise, Aspen HYSYS will be called HYSYS.

1.1 HYSYS Menu Command to Ribbon Map

1.1.1 HYSYS Basis Environment

Command Type

Arrive to the Command

New Case

File | New | Case

Open

File | Open | Open Case

Example Cases

Properties Environment | Resources | Examples

Save

File | Save

Save as

File | Save as

Close Case

File | Close Case | Close Case

Close All

File | Close Case | Close All Cases

Print

File | Print

Print Windows Snapshot

File | Print | Print Snapshot

Print Setup

File | Print Setup

Exit

File | Exit

1.1.2 Simulation Menu

Command Type

Arrive to the Command

Input Summary

Home | Summaries | Input

Optimizer

Home | Analysis | Optimizer

Event Scheduler

Dynamics | Modeling Options | Event Scheduler

Integrator

Dynamics | Run Integrator

Dynamics

Dynamics | Dynamic Simulation | Dynamics Assistant

Solver Active/Holding

Home | Run | Solver Active |on Hold

Enter Basis Environment

Navigation Pane | Properties

Oil Output Settings

Properties Environment | Oil Manager | Oil Output Settings

Costing Options

Economics | Prepare | Cost Options

1.1.3 Flow Sheet Menu

Command Type

Arrive to the Command

Add Stream

Flowsheet/Modify | Flowsheet | Additional Command | Add Stream

Add Operation

Flowsheet/Modify | Flowsheet | Additional Command | Add Operation

Find Object

Flowsheet/Modify | Tool | Find Object

Flowsheet Summary

Home | Summaries | Flowsheet Summary

Notes Manager

View | Show Notes Manager

Palette

View | Model Palette or Flowsheet/Modify | Palette | Models and Streams

Extensions

A tab on the Palette

Reaction Package

Properties Environment | Home tab | Navigate | Reactions or Navigation Pane | Reactions

Fluid Package/Dynamics Model

Properties Environment | Home tab | Navigate | Fluid Package or Navigation Pane | Fluid Package

Dynamic Initialization

Dynamics | Modeling Options | Dynamic Initialization

1.1.4 PFD Menu

Command Type

Arrive to the Command

Select Objects

Navigation Pane | UnitOps

Show Hidden Objects

Flowsheet/Modify | Display Options Hide Object | Reveal

Break a Connection

Flowsheet/Modify | Flowsheet | Break Connection

Swap Connection

Flowsheet/Modify | Flowsheet | Swap Connection

Auto Position All

Flowsheet/Modify | Flowsheet | Additional Commands | Auto Position All

Auto Position Selected

Flowsheet/Modify | Flowsheet | Additional Commands | Auto Position Selected

Select Mode

Flowsheet tab (windows) shortcut menu | Mode

Drag Zoom

Flowsheet/Modify | Flowsheet | Drag

1.1.5 Tools Menu

Command Type

Arrive to the Command

Workbooks

Home | Summaries | Workbook

PFDs

View | Show Flowsheet

Report Manager

Home | Summaries | Reports

Excel Report

Home | Summaries | Reports

Text Report

Home | Summaries | Reports

Data‐Fit

Navigation Pane | Data Fits or Home | Analysis | Data Fit

Face Plates

Dynamics | Tool | Face Plates

Dynamics Assistant

Dynamics | Dynamic Simulation | Dynamics Assistant

Control Manager

Dynamics Tools | Control Manager

Dynamic Profiling Tool

Dynamics | Tool | Profile

Snapshot Manager

Dynamics | Modeling Options | Snapshot Manager

Script Manager