ProMax

A Brief Review

Bryan Research & Engineering, Inc

Chemical Engineering Consultants
P.O. Box 4747 • Bryan, Texas, USA 77805
Office: +1-979-776-5220 • Fax: +1-979-776-4818
E-mail: support@bre.com or sales@bre.com
 Table of Contents
Introduction ......................................................................................................................................1
Environments ....................................................................................................................................3
Thermodynamic Package ................................................................................................................................3
Liquid Density ..................................................................................................................................................4
Components ....................................................................................................................................................4
Process Streams and Blocks ................................................................................................................4
Process Stream ................................................................................................................................................4
Energy Stream .................................................................................................................................................4
Separator .........................................................................................................................................................4
Distillation Column ..........................................................................................................................................5
Heat Exchanger ...............................................................................................................................................7
Fluid Driver ......................................................................................................................................................7
Valve ................................................................................................................................................................8
Recycle Block ...................................................................................................................................................9
Make-up/Blow-down Block .............................................................................................................................9
Saturator Block ..............................................................................................................................................10
Reactor ..........................................................................................................................................................11
Pipeline ..........................................................................................................................................................11
Divider Block ..................................................................................................................................................12
Mixer/Splitter ................................................................................................................................................13
Cross Flowsheet Connector ...........................................................................................................................13
Callout ...........................................................................................................................................................14
Property Table ...............................................................................................................................................14
Analyses .......................................................................................................................................... 15
Calculators....................................................................................................................................... 15
Simple Specifier .............................................................................................................................................16
Simple Solver .................................................................................................................................................17
Priorities ........................................................................................................................................................18
User Value Sets ................................................................................................................................ 18
Embedded Excel Workbook .............................................................................................................. 19
Scenario Tool ................................................................................................................................... 19
Short Monikers ................................................................................................................................ 19
Column Convergence ....................................................................................................................... 20
Enthalpy model .............................................................................................................................................21
Inner Loop model ..........................................................................................................................................21
Delete Last Solution ......................................................................................................................................21
Additional Help ..............................................................................................................................................21
Recoveries ....................................................................................................................................... 22
Exercise: Modeling an Amine Sweetening Unit ................................................................................. 23
Review of ProMax Basics
This document provides a brief explanation of many of the simulation tools available in ProMax. It
serves as an introduction to the software, but can also provide a refresher for those previously
acquainted with it but who have not used it recently. It is also a quick reference guide for those seeking
help with specific tools.

The explanations given are summaries only. For a more complete description of a given topic, refer to
the appropriate section in the ProMax help files.

Introduction
The tools available in ProMax are best understood by demonstrating how each is used in a sample
simulation. The simulation shown is a basic treating process for a gas containing methane, ethane, H2S,
CO2 and water. Note that these tools are not limited to gas treating process; ProMax can model many
other processes with high accuracy, including gas processing operations. For the present

Figures 1-3 show the layout of this sample simulation.

Figure 1: a basic amine sweetening unit.

Figure 1 shows the amine sweetening unit, which removes most of the H2S and CO2 by way of an amine-
based solvent. This solvent selectively removes H2S and CO2 in an absorber, so that the vapor leaving the
top of the column contains only trace amounts of these components. The remaining process equipment

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then removes the H2S and CO2 from the solvent and returns the solvent back to the absorber in a
regenerated state.

Figure 2: a sweet gas processing unit.

Figure 2 shows a simple dehydrator, which reduces the water content of the sweetened gas to within
allowable limits. The gas is then fed through a pipeline before being compressed back up to the required
pressure and split to sales and storage.

Figure 3: an acid gas incineration unit.

Figure 3 shows a simple incineration unit, which converts the H2S from the acid gas stream leaving the
amine unit into SO2.

The sample simulation is included with this document as a tutorial exercise.

The primary tool in ProMax is the “Project Viewer”, which is the separate window that appears
whenever a stream or block is double-clicked, or whenever the “Show Project Viewer” button is clicked
from within the Visio window in ProMax.

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 Figure 4: the Project Viewer. The is the primary tool for inputting properties in ProMax.

The drawing of process blocks and streams takes place within the Visio window. Thereafter all process
information (e.g. temperatures, pressure, flow rates, compositions) is entered using the Project Viewer.

Environments
The first step in configuring a ProMax project is to specify its environment. This determines, among
other things, which thermodynamic packages and compounds will be used for the calculations in each
phase. Note that while a single environment may be shared across different flowsheets, each flowsheet
is only allowed to use a single environment.

Thermodynamic Package
The thermodynamic package determines which models will be used to predict properties throughout
the simulation. Separate models may be specified for the vapor and liquid phases. As one option, an
equation of state (e.g. Peng-Robinson or SRK) could be used for the vapor phase, with an activity
coefficient model (e.g. NRTL or Electrolytic ELR) used for the liquid phase(s).

The best package combination depends upon the specific application. A list of packages recommended
for a variety of different types of models can be accessed by right-clicking on any of the available
environments and selecting “What’s This?”.

A general rule of thumb is to use an equation of state for all phases unless ionic species or chemical
reactions are involved, in which case a specialty package should be used for the liquid phase(s). Thus,
processes such as dehydration, gas separation and acid gas injection can all be modeled well by an
equation of state, while processes such as amine sweetening and sour water stripping require more
specific packages.

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The amine unit for the sample simulation uses the Electrolytic ELR model for the liquid phase, and the
Peng-Robinson model for the vapor phase. The other units do not involve any ionic species and
therefore use the Peng-Robinson equation of state for both vapor and liquid phases.

Liquid Density
Three methods are available for calculating the liquid density: COSTALD(HBT), Rackett, and equation of
state. The first of these, COSTALD(HBT), is generally the most accurate below the critical point and is
therefore the default. In some cases, however, the other methods may be preferred. For example,
above the critical point—where the distinction between vapor and liquid becomes arbitrary—an
equation of state will usually provide better results.

The sample simulation uses the COSTALD(HBT) model for all parts of the process.

Components
All components in the simulation should be specified prior to proceeding with the simulation.
Compounds may be identified by name, chemical formula or CAS registry number.

Process Streams and Blocks

A number of different process items are available in ProMax. Note that only some of these have a direct
physical analog, so that not all appear directly in a process flow diagram (PFD).

Process Stream
Process streams allow mass to flow between different blocks and thus represent pipelines. All inlet
streams to a process must be fully specified, meaning each must have a known temperature, pressure,
flow rate and composition.

Energy Stream
Energy streams allow energy to flow out of, into and between blocks. They are generally used to
indicate power inputs to pumps and compressors, heat inputs to heaters and reboilers, and heat
outputs from coolers and condensers. Because energy flow is not visible, energy streams do not appear
on a PFD.

Separator
As the name implies, a separator serves to separate the different phases found in a given stream. For
example, if a stream contains both vapor and liquid, the separator will split the one stream into two,
with the vapor exiting the top and the liquid exiting the bottom.

A separator must have a specified pressure drop, which should be relatively small (e.g. 0.0-0.2 bar
[~3 psi]). This can be set either directly within the separator or by setting the pressure of one of the
outlet streams. Separators assume equilibrium separation, so that the exiting streams are all at the
same temperature and pressure.

A separator can also have an energy stream attached to provide simultaneous warming/cooling and
separation. When this is the case, the heat duty must be specified, either directly or by setting the
temperature of one of the exiting streams. In this configuration, the separator also functions as a heat
exchanger.

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In the sample simulation, the condenser is a two-phase separator with an energy stream attached.

Figure 5: a two-phase separator with an energy stream attached, which is used to cool
the inlet and separte the vapor from the liquid.

Distillation Column
A distillation column is essentially a number of separators stacked in series. Its purpose is to separate
various components from one another. The stream exiting the top (the “overhead” stream) is
concentrated with the more volatile components, while that exiting the bottom (the “bottoms” stream)
is concentrated with the less-volatile components.

A column must have a specified column type (e.g. equilibrium or kinetic), flash type (VLE, LLE or VLLE)
and pressure drop. If a condenser is attached, it must be explicitly assigned to the column via the
“Condenser” drop-down menu on the “Process Data” tab. A specification regarding the operation of the
condenser must also be supplied, such as the condenser temperature or the reflux ratio. Likewise if a
reboiler is attached it must be assigned to the column via the “Reboiler” menu, and a specification
regarding the reboiler operation must be provided, such as the reboiler duty or the boilup ratio.

For equilibrium columns, equilibrium separation is assumed on each stage, so that no explicit
information is required about the internal column hardware (tray spacing and geometry). For kinetic
columns, however, this information is required in order to calculate the contact time between the
phases on each stage.

In the sample simulation, the absorber and regenerator are both kinetic distillation columns. The former
is a stand-alone column, while the latter has both a condenser and a reboiler.

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 Figure 6: two distillation columns, one with no attachments, the other with both a
reboiler and a condenser. These are both used to separate the more volatile
components in the feed from the less volatile ones.

In some cases, a distillation column will indicate that a pumparound estimate is required for a given
stream. This occurs whenever a stream is recycled back into the column and the program is unable to
estimate the energy change in the return stream. In these cases a pumparound estimate must be added
as an additional specification within the column.

For this specification, choose the “Pumparound Estimate” type, select the indicated stream, and set a
target value, noting that the value will be positive if the net energy change in the stream is positive, and
negative if the net energy change is negative.

Figure 7: steps for creating a pumparound estimate specification in a distillation column.

Once the specification has been created, check the “Active” box next to the pumparound specification.
The “Estimate” box will be checked by default, since a pumparound estimate is, by definition, only an
estimate, not a fixed value for the column.

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 Figure 8: activating a pumparound estimate specification in a distillation column.

Checking both the “Active” and “Estimate” boxes instructs the column to use this value as an initial
guess for the pumparound duty, and to ultimately solve for the actual duty.

Heat Exchanger
A heat exchanger serves to transfer energy between streams. These can be single- or multi-sided. The
former is typically used when the heat transfer fluid is completely external to the process (e.g. air) and is
of little concern, while the latter is used when integrating heat exchange between multiple streams
within the same process.

In the sample simulation there are four heat exchangers: the lean/rich exchanger, the reboiler, the
steam tubes and the air cooler. Note that the reboiler is both an exchanger and a separator.

Figure 9: four different heat exchangers. The first (far left) is a two-sided exchanger.
The second and third (middle) are single-sided exchangers with a shared energy
stream, so together they function as a two-sided exchanger. The fourth (far right) is a
single-sided exchanger.

All sides of a heat exchanger must have a pressure drop specified. If details regarding the geometry of
the exchanger are known, the drop can be calculated. Otherwise, an estimate must be provided.
Generally, this should be a small number (e.g. 0.3 bar or ~5 psig).

A heat exchanger must also have its heat duty specified. This can be handled by inputting the actual
duty, the temperature of one of the exiting streams, or some other heat exchange parameter (e.g.
minimum effective approach temperature).

Fluid Driver
Fluid drivers serve to increase the pressure of a fluid. A pump is used for liquids, while a compressor is
used for vapors. Every fluid driver must have its duty specified, either directly or by setting the pressure
of the outlet stream. An efficiency must also be provided. Alternatively, a performance curve may
supplied, in which case the efficiency and outlet pressure are determined solely by the inlet flow rate.

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In the sample simulation there are three fluid drivers: a circulation pump, a reflux pump and a
compressor. The circulation pump is used in the amine sweetening unit to increase the pressure of the
regenerated solvent back up to that required by the absorber. The reflux pump—also in the amine
sweetening unit—is used to increase the pressure of the condenser liquid back up to that required by
the regenerator. The compressor is used downstream of the dehydrator to increase the pressure of the
gas back up to that required for delivery.

Figure 10: a circulation pump (left), reflux pump (middle) and a compressor (right).
The circulation and reflux pumps are each used to increase the pressure of a liquid,
while the compressor is used to increase the pressure of a vapor.

In nearly all cases, the outlet temperature from a fluid driver should not be set explicitly. Rather, the
outlet pressure and block efficiency should be used to determine the outlet temperature. If, instead,
both an outlet temperature and pressure are set, the implied efficiency may well exceed physical
bounds (i.e. the efficiency will either be greater than 100% or less than 0%).

Valve
A valve serves to reduce the pressure of a fluid. Each valve must have either its pressure drop or its
outlet pressure specified.

Figure 11: a valve, which is used here decrease the stream pressure prior to entering a
distillation column.

Though certainly required in a real plant, frequently a valve is optional in ProMax. This is because most
blocks already include a pressure drop parameter. For example, a separator can be used to
simultaneously drop the pressure and separate the different phases into separate streams. Likewise if
the pressure profile of a column is specified, the column will operate at that pressure regardless of the
inlet stream pressures, and valves on the inlets are not required. This feature is often used in ProMax to
reduce the number of items on the flowsheet and thus simplify the layout.

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Recycle Block
A recycle block provides ProMax with an estimate of the properties of a stream when they are needed
but cannot yet be calculated (e.g. when a stream forms a loop back into a previous portion of the
process). Such is required because ProMax is a sequential solver; it cannot solve a given block unless the
properties of all the inlets to that block are already known.

In the sample simulation, a recycle block is required somewhere upstream of the lean solvent feed to
the top of the absorber. Without the recycle block, the absorber will not execute, since the properties of
all of its inlet streams would not all be known.

Figure 12: a recycle block, which is a numerical tool required to begin the iteration
procedure.

The stream exiting a recycle block must be fully specified. Generally, this implies that a guess must be
made for its temperature, pressure, flow rate and composition. These values are only initial guesses.
They are overwritten during each iteration through the simulation, and the iteration process continues
until the streams entering and exiting the recycle block are identical (to within numerical tolerance).

Note that a recycle block is only a numerical tool and thus has no physical meaning. Thus, it does not
appear on a PFD.

Make-up/Blow-down Block
A make-up/blow-down block serves to maintain mass balances for a steady-state process. In most cases
it is used to make up solvent losses (i.e. maintain a specified solvent flow rate and, optionally,
composition). This block has two specification options: a target outlet composition or a make-up bulk
composition. Specifying the former causes ProMax to add whatever amount of the specified
component(s) is needed to maintain a given solvent composition. The sum of the target outlet
compositions must be less than 100%. Specifying the make-up bulk composition sets the composition of
the remaining fluid added to satisfy the required flow rate. The sum of these compositions must be
equal to 100%.

In the sample simulation, a make-up/blow-down block is used to maintain a set concentration of amine
and a set standard volumetric flow rate. Once the needed amount of amine is added, pure water is used
to restore the flow rate to its target value. This is necessary, in part, because the amine and water are
lost at different rates during the process, the latter being lost in much greater quantities.

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 Figure 13: a make-up/blow-down block, which makes up lost solvent and maintains
the mass balance in a steady state.

In a real process, losses are usually made up periodically in a “batch” process, rather than continuously.
Thus, while the make-up block is not usually represented on the PFD, its function is, though indirectly.

Note that even though the target outlet and make-up bulk compositions are specified within the make-
up/blow-down block, the make-up stream entering the block must still have its temperature and
pressure specified. If the specified pressure is below that of the process, the simulation still executes
properly, but a warning is issued, since the configuration implies flow into (not out of) the make-up
stream.

The make-up/blow-down block is located under “ProMax Auxiliary Objects”.

Saturator Block
The saturator block provides a convenient means of saturating a given stream with a specified
component (the “saturant”). Most commonly, this is used to saturate a stream with water. Gas-phase
water composition measurements can be unreliable or even unavailable, so this block allows the dry-
basis gas composition to be entered, with the exact water content determined automatically by ProMax.

In the sample simulation, a saturator is used to saturate the dry-basis inlet gas with water.

Figure 14: a saturator, which is used here to add water to the feed until is saturated.

The saturator block must have either the fraction of saturation or the outlet saturant concentration
specified. The value specified must fall between 0 and 100% saturation. The pressure drop and
temperature change are also required, but these will default to zero if not supplied. If desired, the
saturation can be also performed at different conditions than those of the inlet stream by specifying
values for the “saturation pressure” and “saturation temperature”. This can be useful, for example, for

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saturating an air stream at ambient conditions while simultaneously pumping it into the simulation at
process conditions. These values also default to zero if not specified.

Obviously, a PFD does not include a saturator block, since the block only mimics the behavior that occurs
naturally when a given fluid is exposed to excess saturant.

The saturator block is located under “ProMax Auxiliary Objects”.

Reactor
A reactor block is used whenever a reaction takes place inside a block. More formally, a reactor is
required whenever one or more of the components exiting the block are not present in the inlets to the
block.

Reactors can be configured to run in a variety of ways. The simplest involves simply finding the
composition of components in the outlet that minimizes the total Gibbs energy. This is the most
common configuration, since it does not require any knowledge of the specific reactions taking place or
their kinetics. More complex methods are also available, but these require more detailed inputs.

As with most blocks, a reactor must have a specified pressure drop. A Gibbs minimization reactor must
also have a “Gibbs set” specified. This automatically controls which components are considered reactive
during the minimization procedure, and also sets some additional constraints to model known
deviations from the minimum Gibbs energy due to process conditions. The reactive species and active
constraints can also be controlled manually.

In the sample simulation, the incinerator is a Gibbs minimization reactor that allows the CH4, C2H6 and
H2S in the acid gas stream to be converted to CO2, H2O and SO2.

Figure 15: a reactor, which is used here to model combustion in an incinerator.

This reactor uses the “Burner” Gibbs set, which considers all species as reactive and has no specific
constraints. Note that the Gibbs minimization procedure only minimizes the energy using the
components available in the specified environment. Thus, if the proper reaction products are not
included in the environment, the predicted products will be inaccurate, and it is even possible that no
reactions will take place.

Pipeline
A pipeline block is used to model the changes in stream properties as a fluid passes through a pipeline.
This includes not only the pressure drop, but also temperature changes and phase behavior.

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In the sample simulation, a pipeline is used to track the behavior of the dehydrated sales gas as it passes
through the pipeline leading to sales and storage.

Figure 16: a pipeline with an energy stream attached. This is used to model the
pressure drop, temperature profile and phase behavior of the fluid as it passes
through a pipeline.

A pipeline requires a number of different inputs. These relate to its size (length and diameter),
orientation (horizontal or angled), material of construction and surroundings. If an energy stream is
attached, heat effects from the surroundings are taken into account; otherwise, the calculated changes
in temperature are due solely to changes in the fluid pressure.

The pipeline block is located under “ProMax Auxiliary Objects”.

Divider Block
A divider block allows compounds to be separated from a given stream generically, without regard for
the methods required to perform the separation, or even for its real-life feasibility. In most cases, it
serves as a convenient shortcut tool to model the effects of a given process without having to simulate
that process explicitly.

In the sample simulation, a divider block is used to remove the bulk of the water present in the
sweetened gas before it passes to the pipeline.

Figure 17: a divider block, which is used here to remove water from a given stream.

A divider block requires that the fraction of each component removed be specified. It also must have an
energy stream attached so that the change in energy due to the “un-mixing” can be accounted for.

The divider block is located under “ProMax Auxiliary Objects”.

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Mixer/Splitter
The mixer and splitter blocks allow different streams to be mixed and split as needed.

A mixer has no required specifications, but it is important to note that its outlet pressure is taken as the
minimum pressure of all the inlets. This is done because any other assumption would imply flow back
into one of the inlets.

A splitter requires that the percent of the flow split to each outlet stream be specified.

The sample simulation uses a mixer to combine air with the acid gas stream prior to incineration, and a
splitter to split the dry sweet gas between sales and storage.

Figure 18: a mixer and a splitter, which are used to combine and split process streams.

Cross Flowsheet Connector

A cross flowsheet connector is used to pass the contents of a stream from one flowsheet to another.

The sample simulation uses two cross flowsheet connectors, one to pass the sweetened gas on to
dehydration and processing, the other to pass the acid gas on to the incinerator.

Figure 19: two different cross flowsheet connectors, which are used to join process
streams on two different flowsheets.

When moving between flowsheets in this manner, all components moving from the source to the
destination must be included in the environment for the destination. If desired, a mole fraction
threshold may be set so that compounds present in only trace amounts will not pass to the destination
flowsheet. Also, note that if the thermodynamic packages for the two flowsheets are different, there
may be a discontinuity in the physical properties between flowsheets.

A cross flowsheet connector can be attached to either a process stream or an energy stream.

The cross flowsheet connector is located under “ProMax Streams”.

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Callout
A callout is a simple display tool. It is manually connected to a single process stream, and allows the
selected physical properties of that stream to be directly displayed on the flowsheet.

The sample simulation includes a number of different callouts, including one to show the flow rate of
circulating solvent in the amine sweetening unit.

Figure 20: a callout, which is used here to display the stream flow rate on the flowsheet.

The display properties for a callout are customizable, including the font size and type, as well as the level
of detail included. If the “show symbols” box is checked, an asterisk is placed next to all user-specified
values, and a pound symbol (#) is placed next to all values that are tied to a calculator.

The callout shape is located under “ProMax Streams”.

Property Table
A property table allows the physical properties of any number of blocks and streams to be displayed in a
single table.

The sample simulation uses multiple property tables. For example, one is used to display the molar flows
rates of all components entering and exiting the incinerator.

Figure 21: a property table, which is used here to display information from multiple
streams at once.

To display information relating to items that do not belong to a stream or block (e.g. environment
characteristics), use the “Moniker” type for the property table.

The property table shape is located under “ProMax Streams”. It has the same customization options as a
callout.

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Analyses
Some properties are only of interest on—or applicable to—certain streams. For example, the Reid vapor
pressure applies only to liquid oil streams. Therefore it is neither reasonable nor desirable for ProMax to
calculate all possible properties for all streams. Instead, only the most common properties are
calculated for all streams, with the remainder calculated only upon request.

Additional calculations are grouped into “analyses”. To add a calculation to a given stream, the
corresponding analysis must be added to that stream. The current set of available analyses is listed
below, including a partial list of the properties within each.

• Amine: pH, acid gas loading (moles of acid gas per mole of amine), molarity
• Combustion: O2 required for complete combustion, CO2 produced, Wobbe Index
• Distillation Curves: true boiling point, various ASTM properties
• Freeze Out, Hydrate, H2O Dew Point: solids formation temperatures for CO2, H2O and hydrates
• Fuel Properties: parrafinic, naphthenic and aromatic mole fractions; C:H weight ratio
• Ionic Info: ionic strength, concentrations and flows of ionic species
• Line Sizing: pressure drop through a specified length of straight pipe.
• Phase Envelope: critical properties, phase curves
• Relief Valve Sizing: effective discharge area, relief pressure
• Vapor Pressure, Dew, Bubble Point: bubble/dew point temperature and pressure, Reid vapor
pressure, true vapor pressure

To add an analysis to a stream, select the stream in the Project Viewer, and from the “Analyses” tab click
the “Add Analysis…” button. Then choose the desired analysis.

Calculators
In a controlled process, it is common to want some parameters to depend on others, either upstream or
downstream. For example, rather than fix the temperature of the lean solvent entering the absorber, it
may be desirable to set this temperature 5°C (9°F) above that of the feed gas to avoid condensing any
hydrocarbons. Alternatively, the desired solvent flow rate may depend on meeting a sweet gas H2S
specification. Such relationships can be configured in ProMax using the built-in “calculators”.

All calculators for a given project are listed collectively in the Project Viewer, as shown below. A red “x”
over a calculator’s icon indicates that it is currently disabled.

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 Figure 22: the list of calculators in the Project Viewer.

The two simplest of the available calculators are discussed below: simple specifiers and simple solvers. A
detailed discussion of the advanced calculators in ProMax is reserved for the “Level 2: Advanced
Simulation Methods” course.

When setting the value of one property (the “specified value”) relative to that of another (the “observed
value”), there are two possible cases:
1. The observed value is already known at the time the specified value is to be set.
2. The observed value is not yet known at the time the specified value is to be set.

Simple Specifier
A simple specifier is used for the first case (when the observed value is known). Such cases involve feed-
forward control: a given value is measured at one point in the process and then fed forward to some
other part of the process. One example of this type of control would be to make the reboiler duty (e.g.
steam flow rate) depend on the amount of circulating solvent, so that the lean solvent composition
remains relatively constant regardless of flow rate. This can be particularly helpful when trying to find
the optimum solvent flow rate.

The sample simulation uses four different simple specifiers:

1. One automatically sets the temperature of the lean amine relative to the feed gas temperature.
2. One sets the pressure of the lean amine relative to the pressure at the top stage of the
absorber.
3. One sets the flow rate of steam through the reboiler relative to the volume of circulating
solvent.
4. One sets the flow of air to the incinerator such that there is sufficient oxygen to fully combust
the acid gas stream.

To create a simple specifier, right-click on any user-specified value and select “Create Simple
Specifier…”. This changes the background color for the value to blue. It also opens the dialog below.

16
 Figure 23: the simple specifier dialog.

To configure the simple specifier, type the needed mathematical equation directly into the top box. If
the equation includes references to other values in ProMax, these must be added to the list of
independent variables at the bottom of the dialog. In the example above, the specified value is the
temperature of the lean solvent exiting the air cooler. The equation sets this temperature to 5°C (9°F)
above that of the feed gas. Since the feed gas temperature is referenced in this equation, this
temperature is added to the list of independent variables. Note that placing two forward slashes in the
equation box causes all remaining content on that line to be neglected. This allows comments to be
included with the equation(s).

Once created, the specifier can be accessed either by right-clicking on the value and selecting “Show
Calculator…”, or by selecting the specifier directly from the list of calculators in the Project Viewer.

Simple Solver
A simple solver is used for the second case (when the observed value is not known). Such cases involve
feedback control: a given value is specified at one point in the process, after which the downstream
effect is measured and fed back upstream. This is an iterative procedure that continues until the
specified value achieves the desired observed value. One example of this type of control would be to set
the solvent flow rate in an amine sweetening unit such that the sweet gas contains only 4 ppm of H2S.

The sample simulation uses only one simple solver. This solver is located on the sales gas processing
unit. It varies the outlet pressure from the compressor until the downstream pressure at the end of the
pipeline is at the required value.

A simple solver is created in the same way as a simple specifier, only the “Create Simple Solver” option is
chosen in place of “Create Simple Specifier”. The setup method, however, differs from that for a simple
specifier.

17
 Figure 24: the simple solver dialog.

For a simple solver, the expression placed in the top box must evaluate to zero when the solver is
satisfied. For example, if the goal is to set the sweet gas H2S content to 4ppm, then the expression
would be “SweetGasH2S – 4”, where “SweetGasH2S” is the H2S content of the sweet gas in units of ppm.
In order to run, this quantity must be added to the list of measured variables. Also, an initial guess for
the quantity being modified must be placed in the “Calculated Value” box.Priorities
Every calculator has a default priority of 0. When more than one calculator is present in a simulation,
changing these defaults can dramatically impact the number of iterations required to converge the
entire simulation. Priorities should be set such that the minimum number of iterations possible is used.

ProMax will attempt to converge the calculator with the highest (largest) priority before checking
whether any calculators with lower priority are also converged. Thus, it is typically best to give the
highest priority to the calculator with the shortest path between its independent and measured
variables.

Priorities must be non-negative integers, and they are only given relative consideration. That is, they are
only considered on a “greater than/less than” basis; the actual values are irrelevant. For example, if only
two calculators, A and B, are present in a given simulation, setting the priority of A to 1 and B to 0 is
identical to setting A to 100 and B to 0. In both cases, A will be converged first, followed by B.

Note that a recycle block is a calculator with a default priority of 1.

User Value Sets

At times a variable is needed in a simulation that is not a physical property of a single stream or block.
Examples include an ambient temperature or a ratio of properties from two different streams. Such
variables can be created in ProMax by way of user value sets. Each user value has an assigned unit and a

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specified value. The latter is either entered manually are calculated by means of a simple specifier. In
this way, ProMax can be configured to calculate virtually any quantity relating to a given simulation.

Figure 25: the list of user values in the Project Viewer.

To create a new set of user values, right-click on “User Value Sets” and select “Add”. To create a new
user value within this set, click “Add”, then specify a name for the user value and designate the
corresponding units. If desired, associate the value with a simple specifier.

Embedded Excel Workbook

An Excel workbook may be embedded within a ProMax project by clicking the button titled “Add Excel
Workbook” ( ). This allows data to be easily exported from ProMax to Excel or
vice versa. Among other things, this allows ProMax output to be graphed using the native chart tools in
Excel.

Scenario Tool
Frequently in simulation a variety of scenarios need to be carried out in order to gauge the effects of
process variations. Examples include the effect of solvent flow rate on acid gas removal. While it is
possible to perform such calculations in ProMax manually, the process can also be automated and
simplified using the Scenario Tool. This is an add-in to Excel that allows the user to specify a series of
scenarios to run automatically in sequence, with specified outputs stored after each scenario.

Short Monikers
Every value in ProMax is given a moniker. This is an absolute path to the property, including the name of
the project in which it is located, and (where applicable) the corresponding flowsheet and block or

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stream name. Monikers are accessed from the Moniker Builder (shown below), which is essentially an
organized table of all monikers in a project.

Figure 26: the Moniker Builder.

Monikers are used in a number of different places in ProMax. Examples include adding a variable to a
simple specifier or solver, or displaying a stream property from within a property table.

Finding the moniker for a given quantity requires navigating to the appropriate place in the moniker
table. This can become quite tedious when the same quantity is repeatedly used in different places in a
given simulation. To simplify this effort, any quantity in the table can be given a unique name and placed
on the “Short Moniker List”. Thereafter, the quantity can be accessed by going directly to the Short
Moniker List and selecting it, rather than by navigating through the full moniker table.

Note that this also allows additional quantities (e.g. user values) to be displayed in property tables, since
a property table can be configured to display items from the Short Moniker List.

Column Convergence
The default algorithms for columns are chosen to balance power with calculation speed. In some cases,
these defaults are not sufficiently robust to achieve column convergence, and more powerful algorithms
are necessary. Use of these alternate algorithms may allow a difficult column to converge, though often
at the expense of greater calculation time.

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Enthalpy model
The default enthalpy model is “Boston-Britt”. When a column will not converge, try changing its
enthalpy model to “Composition-Dependent”, and then re-execute.

Inner Loop model

The default inner loop model is “Boston-Sullivan”. When a column will not converge, and changing the
enthalpy model does not solve the problem, try changing the inner loop model to “Boston-Sullivan
Nonideal”, and then re-execute.

Delete Last Solution

The “Delete Last Solution” button clears the column of any previous solution. At times a column will fall
into a numerical “pit” that is difficult to climb out of. This button clears all previous data and forces the
column to begin its iteration from scratch. This option can be particularly helpful when the process
parameters (e.g. feed composition) have been changed. It may also prove useful after changing the
enthalpy model and/or inner loop model.

Additional Help
If these methods fail to resolve the convergence issue, refer to the ProMax help topic titled
“Troubleshooting Column Execution/Convergence Problems”, or contact BR&E Support directly
(+1-979-776-5220, support@bre.com). BR&E engineers have extensive experience handling difficult
columns, and will provide prompt service.

Figure 27: convergence settings for a distillation column

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Recoveries
In chemical processes, the term “recovery” is used to indicate the amount of a substance exiting in
certain effluent streams relative to the total amount of that substance entering the process. For
example, in an amine the recovery of H2S would generally refer to the percent of the H2S entering the
process that is captured in the acid gas stream leaving the regenerator.

ProMax automatically generates recoveries for every distillation column, flowsheet and project.
Recoveries for a distillation column can be accessed from within the “Stage Data” tab of that column.
Recoveries for a flowsheet or entire project can be accessed from within the “Recoveries” portion of the
Project Viewer. The automatically-generated tables list the recovery of each component in each outlet
stream, so that the sum is always equal to 100%. To customize the list of inlet and outlet streams, add a
new recovery by right-clicking on “Recoveries” and selecting “Add”.

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Exercise: Modeling an Amine Sweetening Unit
Simulate a basic amine sweetening unit. Start from the pre-drawn project titled “ProMaxReview.pmx”, and use the
settings below.

PROCESS SETTINGS
1. The “Amine” flowsheet should use the “Amine Sweetening—PR”
package. Inlet Conditions (“Wet Sour Feed”)
Temperature 40°C
2. The “Processing” flowsheet should use the “Peng-Robinson”
Pressure 30 bara
package. This will require using the “Active Flowsheet” dialog to
Flow 0.25 MSCMD
assign this flowsheet to a new environment.
Composition (“Dry Sour Feed”, mol%)
3. The conditions and composition of the dry inlet gas are given in
Methane 92.0
the table at right. This gas is 100% saturated with water.
Ethane 5.0
4. The absorber has 7 ideal stages and a pressure drop of 0.2 bar. The Hydrogen Sulfide 1.5
absorber trays are operated at 70% flooding, with 0.6-m spacing Carbon Dioxide 1.5
and a 7.5-cm weir height. The real/ideal stage ratio is 3, and the
system factor is 0.8.
5. The lean/rich exchanger pressure drops are both 0.4 bar. The rich solvent leaves the lean/rich exchanger at
99°C.
6. The rich solvent exits the valve at 1.4 bara.
7. The rich solvent enters the regenerator at the second ideal stage from the top.
8. The regenerator has 10 ideal stages, a top stage pressure of 1.3 bara, and a pressure drop of 0.4 bar. The
condenser operates at 50°C, and the reboiler duty is provided by condensing saturated steam at 3.5 barg
(100% vapor inlet, 0% vapor outlet).
9. The steam flow rate is set such that 0.12 kg of steam is used for each standard liter of lean solvent circulated.
Create a user value for the steam-to-solvent ratio, then use this value in a simple specifier on the steam flow
rate.
10. The lean solvent is circulated at 300 slpm and is maintained at 50 wt% MDEA. The make-up stream is at 25°C.
11. The circulation pump has an efficiency of 65% and sets the outlet pressure to 0.4 bar above the pressure of
the top stage of the absorber. Use a simple specifier to configure this relationship.
12. The cooler has a pressure drop of 0.3 bar and sets the outlet temperature to 5 C higher than the temperature
of the inlet gas. Use a simple specifier to configure this relationship.
13. Connect the “Sweet Gas” stream from the amine flowsheet to the “Sweet Gas” stream of the processing
flowsheet. Do the same for the “Acid Gas” stream on each flowsheet.
14. The dehydrator removes 95% of the water from the sweet gas, and generates a pressure drop of 0.5 bar in the
dry gas stream. The extracted water exits at 1 bar.
15. The compressor operates at 75% polytropic efficiency and increases the pressure high enough such that the
sales gas is at 35 bara. Use a simple solver to determine the actual pressure. Note that the solver will fail if the
initial guess for the pressure is insufficient to push the fluid through the pipeline.
16. The pipeline is 12,000 m long. For the first 8,000 m the layout is horizontal, while over the last 4,000 m the
elevation gradually increases 500 m. The pipeline is constructed of Carbon Steel A106 Grade A material, and is
schedule 80 with a nominal diameter of 100. The pipe is buried 1 m underground in the generic “Default”
ground type, and the ambient temperature is 25°C.
17. The splitter sends 80% of the gas to sales and the other 20% to storage.
18. The air (79% N2, 21% O2) mixed with the acid gas is at 20°C and 1.3 bara. It is fed such that 10% excess oxygen
is used. Use the “Required Combustion Analysis” and a simple specifier to configure this relationship.
19. The incinerator has a pressure drop of 0.05 bar, and generates CO2, H2O, SO2, CO and H2. Model the
incinerator using the “Gibbs Minimization” type and the “Burner” Gibbs set.

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PROBLEMS
1. Display the following on the “Amine” flowsheet:
a. A callout indicating the standard liquid volumetric flow rate of lean solvent.
b. A callout indicating the rich loading (i.e. the total acid gas loading of the rich solvent leaving the absorber).
This property is available via the “Amine Analysis”.
c. A property table indicating the temperature, pressure and standard vapor volumetric flow rate (MSCMD)
of the wet sour gas, the sweet gas and the acid gas. Include the mole fractions of H2S (ppm) and CO2 (%)
as well.
d. A property table indicating the steam ratio used to set the flow of steam in the reboiler. Do this by
creating a short moniker for the steam ratio and using the “Moniker” type for the property table.
e. A property table indicating the diameter and residence time of the top stage in the absorber. Use short
monikers to display these properties.
f. A property table indicating the recovery of methane and ethane in the sweet gas, as well as the recovery
of H2S and CO2 in the acid gas. Use standard monikers to display these properties, not short monikers.
This will require un-checking the “Short Moniker” box within the property table.
2. Display the following on the “Processing” flowsheet:
a. A callout on each stream in the sweet gas portion of the flowsheet indicating the stream pressure.
b. A property table indicating the percent of water removed by the dehydrator. Use a short moniker.
c. A property table indicating the water content (g/scm) of the dry sweet gas as well as the total pressure
drop across the pipeline. Use short monikers.
d. A property table indicating the percent split to sales. Use a short moniker.
e. A property table indicating the molar flow rate of each component entering and exiting the incinerator.
3. Use the Scenario Tool to determine the effect that the solvent flow rate has on the following: the mole
fraction of H2S (ppm) in the sweet gas, the mole percent of CO2 in the sweet gas, the rich loading, the
diameter of the top absorber stage (m), and the residence time of the top absorber stage (sec). Vary the flow
rate from 100 to 1000 slpm, the maximum the process equipment is capable of. Use an increment of
100 slpm.
4. Can varying the flow rate alone satisfy a requirement of 4 ppm H2S in the sweet gas?
5. Does increasing the steam-to-solvent ratio to 0.18 allow a 4 ppm H2S specification in the sweet gas to be met?
Determine this by repeating the scenario above, but with the steam-to-solvent ratio set to 0.18.

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SOLUTIONS
1. The displayed properties on the “Amine” flowsheet are the following:
a. Lean solvent flow rate = 300 lpm
b. Rich loading = 0.13
c. Wet Sour Feed = 40.0°C, 30.0 bara, 0.250 MSCMD, 15000 ppm H2S, 1.50% CO2
Sweet Gas = 45.7°C, 29.8 bara, 0.244 MSCMD, 12.8 ppm H2S, 0.83% CO2
Acid Gas = 50.0°C, 1.30 bara, 0.006 MSCMD, 577000 ppm H2S, 26.5% CO2
d. Steam ratio = 0.12
e. Absorber stage 1 diameter = 0.69 m, residence time = 1.29 sec.
f. Sweet Gas: methane recovery = 99.8%, ethane recovery = 99.7%
Acid Gas: H2S recovery = 99.9%, CO2 recovery = 46%
2. The displayed properties on the “Processing” flowsheet are the following:
a. Sweet gas = 29.8 bara, Dry Sweet Gas = 29.3 bara, H2O = 1 bara, “1” = 58.6 bara, “2” = 35 bara
b. Percent wáter removed = 95%
c. Dry gas wáter content = 0.12 g/scm, pipeline pressure drop = 23.6 bar.
d. Percent split to sales = 80%
e. The incinerator contains 6.57 kmol/hr of H2S, nearly all of which (6.57 kmol/hr) is converted to SO2.
3. ---
4. No.
5. Yes. At a flow rate between 600 and 700 slpm the H2S concentration in the sweet gas drops below 4 ppm.

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