HYSYS simulation software

Footprint of such an important process in Carbon equivalent quantities is of high interest these days as immediate mitigation measures should take place in order to optimize current technologies used aiming to assure environmental sustainability of the process. Direct emissions of Carbon Dioxide from the process and its major utility sections (furnace, turbines, steam heaters and boilers) are targeted in this case study. In order to provide a good estimate of Carbon Footprint of Ammonia process HYSYS simulation software and MS Excel can be integrated to calculate process Carbon emissions. 

HYSYS simulation software was used as a tool to complete the simulation of the process (sample is shown in Fig.l). Fluid packages used in the simulation were Amines package which was used for Acid Gas Sweetening and CO2 Removal units, and Peng Robinson which was used for the rest of the units. When simulation was finalized, the following were collected ... 

Abstract In this paper, we discuss the results of a preliminary systematic process simulation study the effect of operating parameters on the product distribution and conversion efficiency of hydrocarbon fuels in a reforming reactor. The ASPEN One HYSYS-2004 simulation software has been utilized for the simulations and calculations of the fuel-processing reactions. It is desired to produce hydrogen rich reformed gas with as low as possible carbon monoxide (CO) formation, which requires different combinations of reformer, steam to carbon and oxygen to carbon ratios. Fuel properties only slightly affect the general trends. 

The fouling factor has to be determined from actual heat exchanger performance based on online measurements taken from a process unit test run. Heat exchanger clean performance is obtained from process flowsheet simulation software (e.g., Hysys by Aspen Tech or Unisim by Honeywell), while dirty performance from exchanger rating software (e.g., HTRI by Heat Transfer Research Institute). 

Nowadays dynamic simulation is commonly used during process design, e.g. for compressor surge analysis. Simulation software tools like UniSim (Honeywell), DynSim (SimSci), Hysys, Aspen Dynamics (both AspenTech) and GPROMS (PSE Ltd) have become very powerful and are relatively easy to use. In this way the plant controllability and operability can be tested and its robustness against process upsets verified. 

In this paper, we focused on the relevance of the commercial software HYSYS for the simulation of catalytic distillation columns. As in the current version of HYSYS the built-in RD module is not directly suitable for the simulation of the heterogeneous catalytic distillation process, this study is concentrated to develop a model for heterogeneous RD and to implement it in the HYSYS simulation environment. The objectives of this work are to develop a suitable simulation module for heterogeneous reactive distillation compatible with HYSYS and to apply it to an intermediary scale pilot plant unit. 

Regarding the potential commercial use of millistructured reactors, one of the main aspects to be considered is its possible integration in industrial processes. In this context, not only the design of the reactor but also the way in which it interacts with the different equipment linked to it in terms of mass and heat balances should be taken into account. For the latter purpose, process simulation software such as Aspen HYSYS, Aspen Plus, PROMAX, UNISIM, and/or... 

Perform hand calculations and verify their results with Hysys, Provision, and Aspen simulation software. 

Hand-calculated pressure drop value is 17.59 kPa, and according to Hysys, PRO/II, and Aspen it was found to be 17 kPa, 1714 kPa, and 17.16 kPa, respectively. Simulation software results were very close to each other on the contrary, hand calculation is greater than all the other results, and this is attributed to the incompressibility assumption made during hand calculation. It is clear from the solution of this example that the density of gases is a function of both temperature and pressure. 

The results of hand calculations and the four simulation software are shown in Table 8.4. Results reveal that hand calculations and those obtained from the software packages were in good agreement. The result obtained by PRO/II is close to hand calculations in contrast, the Hysys results were far from hand calculations. 

The best pairing among these three alternatives, i.e. 4,10, and 18, will be found through RGA analysis of a water-ethanol distillation column. A common approach is to use a process simulation software package to determine the necessary gains for the RGA analysis and NI. For this example we have used HYSYS. Process [7]. The condenser and reboiler levels will be assumed to be under perfect control. For the water-ethanol system the NRTL activity model with the ideal gas vapour model was selected. The column feed stream is shown in Table 9.2. 

For any process simulation that involves only vapor-liquid phases, certain key physical and thermodynamic properties must be available for each phase. Table 1.3 lists these properties for all phases. We can typically obtain these properties for pure components (i.e. n-hexane, n-heptane, etc.) from widely available databases such as DIPPR [2]. Commercial process simulation software (including Aspen HYSYS) also provides a large set of physical and thermodynamic properties for a large number of pure components. However, using these databases requires us to identify a component by name and molecular structure first, and use experimentally measured or estimated values from the same databases. Given the complexity of crude feed, it is not possible to completely analyze the crude feed in terms of pure components. Therefore, we must be able to estimate these properties for each pseudocomponent based on certain measured descriptors. 

The last step is to place the blend into the flowsheet (Figure 2.23). We have to create a new blend each time the composition of the assays changes. For the purposes of a basic simulation, a blend of assays or a blend of back-mixed products is sufficient. However, if we want to evaluate a variety of crudes, the component list can quickly become unmanageable. Recent updates to the Aspen HYSYS introduce a unified component list across all assays. Other simulation software vendors may offer similar features. A unified component list is mostly a convenience feature for the purposes of crude distillation and is not required for most simulation-based studies. 

Throughout this book, we have seen that when more than one species is involved in a process or when energy balances are required, several balance equations must be derived and solved simultaneously. For steady-state systems the equations are algebraic, but when the systems are transient, simultaneous differential equations must be solved. For the simplest systems, analytical solutions may be obtained by hand, but more commonly numerical solutions are required. Software packages that solve general systems of ordinary differential equations— such as Mathematica , Maple , Matlab , TK-Solver , Polymath , and EZ-Solve —are readily obtained for most computers. Other software packages have been designed specifically to simulate transient chemical processes. Some of these dynamic process simulators run in conjunction with the steady-state flowsheet simulators mentioned in Chapter 10 (e.g.. SPEEDUP, which runs with Aspen Plus, and a dynamic component of HYSYS ) and so have access to physical property databases and thermodynamic correlations. 

The two basic flowsheet software architectures are sequential modular and equation-based. In sequential modular, we write each unit model so that it calculates output(s), given feed(s), and unit parameters. This is the most commonly used flowsheeting architecture at present, and examples include Aspen+ plus Hysys (AspenTech), ChemCAD, and PROll (SimSci). In equation-based (or open-system) architectures, all equations are written describing material and energy balances as algebraic equations in the form/(x) = 0. This is the preferred architecture for new simulators and optimization, and examples include Speedup (AspenTech) and gPROMS (PSE pic). Each is discussed in turn. 

In this chapter, the methods for shortcut C R analysis, using the results of steady-state simulations, have been described. The methods require the use of software for the solution of material and energy balances in process flowsheets (e.g., ASPEN PLUS, HYSYS.Plant) and for controllability and resiliency analysis (i.e., MATLAB). The reader is now prepared to tackle small- to medium-scale problems, and in particular should... 

Aspen IPE usually begins with the results of a simulation from one of the major process simulators (e g., ASPEN PLUS, HYSYS, CHEMCAD, and PRO/II), it being noted that users can, alternatively, provide equipment specifications and request investment analysis without using the process simulators. In these notes, only results from ASPEN PLUS are used to initiate Aspen IPE evaluations and only capital cost estimation is emphasized. Readers should refer to the Aspen IPE User s Guide (press the Help button in Aspen IPE) for detailed instructions, explanations, and for improvements in new versions of the software system. 

Smejkal Q. and Soos M. (2002). Comparison of computer simulation of reactive distillation usign ASPEN PLUS and HYSYS software. Chemical Engineering and Technology 41, 413-418. 4.3... 

In order to simulate the RD column this was represented as an ensemble of three components corresponding to the software chemical operation modules available in HYSYS. The calculated iso-amylenes conversion was compared with measured values on a pilot plant RD unit. 

HYSYS An abbreviation for Hyprotech Systems, it is process-modelling software developed by AspenTech. It is used for steady-state and dynamic simulation of processes, process design, process performance monitoring, and process optimization across a wide range of industries and processes. 

The comparison between pressure drop values calculated by hand calculation (50.4 kPa), Hysys (51.69 kPa), PRO/II (52.1 kPa), and Aspen (51.51 kPa) reveals that there is a slight deviation between hand calculations and software simulations. The discrepancy in the hand-calculated value is due to the assumption made by taking the inlet conditions in calculating Reynolds number, while the average of inlet and exit streams should be considered to have better results. 

Simulate an entire process using Hysys, PRO/II, Aspen Plus, and SuperPro software packages. 

The reaction of ethylene (C2H4) and hydrogen chloride (HCI) over a copper chloride catalyst supported on silica to produce of ethylene chloride (CjHjCI) is a highly exothermic reaction. In this example, the reaction is assumed to take place in an isothermal conversion reactor. The heat evolved from the reaction is removed from the reactor to keep the reaction at constant temperature. The reactor effluent stream is compressed, cooled, and then separated in a flash unit followed by a distillation column. The flash and distillation top products are collected and then recycled to the reactor after a portion of the stream is purged to avoid accumulation of an inert component (Nj). The recycled stream is depressurized and heated to the fresh feed stream conditions. The liquid from the bottom of the flash enters a distillation column where ethyl chloride is separated from unreacted HCI and ethylene. The entire process is simulated using Hysys/Unisim, PRO/II, Aspen, and SuperPro Designer software packages. 

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