Aspen HYSYS Training

Module 3: Basic Equipments in HYSYS

Tutor:
M. Ersharry Yunashtanto
Zayyanatun Zulfa
Ikha Muliawati
Mada Harahap

Supported by:
 BASIC EQUIPMENTS IN HYSYS

1. Mixer 8.Cooler

2. Tee (Flow Splitter)

9. Heater

3. Separator
10. Heat Exchanger

4. Pump
11. Reactor CSTR
5. Compressor
12. Reactor PFR
6. Expander

13. Distilation Column

7. Valve
1. Mixer
Important Design
Unit Function
Parameter

• To Mix/Combine • Automatic Pressure

two/multiple feed streams Assignment
as one product stream • Equalize All
• Set Outlet to Lowest
Inlet
OPEN EXERCISE 3.1

Objective of Unit

• To calculate the final properties of

mixed fluid (using flash calculation)
1. Mixer (Cont’d)
A. Set Outlet to Lowest Inlet
1. Mixer (Cont’d)
B. Equalize All
2. Tee (Flow Splitter)

Important Design
Unit Function
Parameter

• To divide one feed • Flow Ratio

stream into • Flow ratio (Fr) for
two/multiple each stream
product streams 0 ≤ Fr ≤ 1

Objective of Unit

• To get multiple product streams

with same operating condition (P&T)
and composition as feed stream
3. Separator
Why do we need
Separation ??? 2-Phase
Separator

Disperse Phase can have

undesirable effects, i.e: 3-Phase
Separator
1. Steam which has a little
moisture entrained in it can
leave undesirable silica
deposits on superheater tube
2. Water carried over into turbine
from a boiler can erode the
blades.
3. Gas carried under into pump
from a vessel can erode the
impeller.
 3. Separator
Separation in HYSYS

1. HYSYS use P-H flash to determine

Products: 2-Phase
P : lowest Feed Pressure – Delta Separator
Pressure
3-Phase
Separator

H: Sum of Feed Enthalphy ± Duty

3. Separator
Important Design
Parameter

• Delta P (Pressure Drop)

• Inlet
• Vapor Outlet

By Default: Delta P = 0
Actual : Delta P > 0
3. Separator
Unit Function BY DEFAULT:

• To separate multiphase feed stream/streams into several “single” Separator Unit

phase product stream (vapor, light liquid, heavy liquid) in HYSYS Æ
PERFECT
SEPARATION

ACTUAL:
NO PERFECT
SEPARATION

IF REQUIRED

Separator Unit
in HYSYS Æ
can model
IMPERFECT
SEPARATION
4. Pump
Basic Theory:
System
1. Objective of pump : curve
™ Transfer/move liquid from source to
destination (higher head) System
™ Circulate liquid around a system head Friction
head

2. Pumping System Characteristic Static head

™ Total Head = Static Head + Friction Head
™ Pump Performance Curve
Flow
™ Pump Operating Point
- Duty Point: rate of flow at certain head Pump performance
- Pump Operating Point : intersection of curve
pump curve and system curve Pump
operating
Head System point
curve

Static
head

Flow
4. Pump
Unit Function

• To increase the head of inlet liquid

stream

Objective of Unit

• To calculate one of these unknown data:

• Pressure
• Temperature
• Pump Horse Power
• Pump Efficiency
4. Pump
Important Design
Parameter

• Delta P
• Adiabatic Efficiency
• Duty (Pump Horse Power)
 4. Pump
Pump Curve Æ Head Vs. Flow
Pump performance
curve

Commonly, this curve is provided by vendor Pump

operating
Head System point
Check this box to use curve

the pump curve Static

head

Flow
5. Compressor
Ideal Work is calculated for mechanically reversible process

Along a particular compression path

Adiabatic Compressor
- Follow Isentropic compression
path from inlet pressure to outlet
pressure

Polytropic Compressor
- Compression path is also
adiabatic or isothermal

Actual Work and ΔH is determined

from Wrev and Efficiency

T &/ or P is determined from ΔH

5. Compressor
Unit Function

• To increase the head of inlet gas

stream by adding Work.

Objective of Unit

• To calculate one of these unknown data:

• Pressure
• Temperature
• Compressor Horse Power
• Compressor Efficiency
5. Compressor
Important Design Parameter

• Compressor Efficiency:
• Adiabatic Efficiency
• Polytropic Efficiency
• Duty
• Operating Mode
• Centrifugal
• Reciprocating
 5. Compressor
Compressor Curve
Commonly, this curve is provided by vendor,
consists of: flow rate, pressure head , &
efficiency To choose Adiabatic/ Polytropic as Efficiency Basis

To enable the curve

Click to add the curve

Click to activate the curve

 5. Compressor
Input flow, head, &
Optional if only 1 curve available efficiency data

For Single Curve, the

combination of input data
will solve:
Choose
- Inlet pressure & flow the Unit
- Inlet pressure & duty
- Inlet and Outlet Pressure
- Inlet and efficiency
6. Expander
Unit Function

• To decrease the pressure of inlet gas with

higher pressure into produced work

Objective of Unit

• To calculate the Work produced

Application

• As model for Turbine & Turbo Expander

6. Expander

Important Design Parameter

• Expander Efficiency:
• Adiabatic Efficiency
• Polytropic Efficiency

Expander : liquid, Turbine : gas

7. Valve

Unit Function

• To drop the pressure of the

inlet which has higher
pressure

Objective of Unit

• To calculate one of these unknown

conditions:
• Outlet T or Outlet P
• Inlet T or Inlet P
7. Valve
Important Design
Parameter

• Delta P
• Specified by user.
8. Cooler
Theory

Heat Duty
8. Cooler
Unit Function

• To cool down the temperature of inlet

stream

Objective of Unit

• To calculate one of these unknown data:

• Outlet Temperature
• Cooler Duty

Cooler is one-sided Heat Exchanger,

Q is removed (-)
8. Cooler
Important Design
Parameter

• Delta P
• By Default=0 or
• Specified by user.
• Duty
8. Cooler
Theory

Heat Duty
9. Heater
Unit Function

• To heat up the temperature of inlet

stream

Objective of Unit
• To calculate one of these unknown data:
• Outlet Temperature
• Heater Duty

Heater is one-sided Heat Exchanger

Q is added (+)
9. Heater
Important Design
Parameter

• Delta P
• By Default=0 or
• Specified by user.
• Duty
10. Heat Exchanger
Theory

1. Type of HE based on flow direction

10. Heat Exchanger
2. Energy Balance

Duty which increase Duty which decrease

the temperature the temperature

3. Heat Exchanger Duty

10. Heat Exchanger
Unit Function

• To transfer the energy from warmer

fluid to colder fluid

Objective of Unit
• To increase the energy efficiency of the
overall facility
10. Heat Exchanger
Heat Exchanger has two sided:
- Hot Side
- Cold Side

Basic Equation:
[Mcold x ΔHcold – Qleak]- (Mhot x ΔHhot – Qloss]

= Balance Error = 0 (Typically)

10. Heat Exchanger
Important Design Parameter

• Heat Transfer model

• End Point
• Weighted Point
• Steady State Rating
• Dynamic Rating
• Delta P
• On Shell & Tube Side
• Overall Heat Transfer Coeff. Area (UA)
• Heat Exchange Geometry
• Tube
• Shell
10. Heat Exchanger

Parameter to be specified:
- Temperature/ Delta Temp.
- Minimum Appro. Temp.
- UA
- LMTD
- Duty
- Duty Ratio
- Flow

Ada contoh kasus error

 10. Heat Exchanger
Heat Exchanger Requires Recycle Operations:

1. Start with unconnected heater & cooler

2. Connect heater and cooler with one single energy stream

3. Replace heater and cooler with Unit Heat Exchaner

4. Use Recycle Block if the calculation seems difficult to be matched.

Distillation

• Distillation process use 40% of energy

in a chemical plant.
• The traditional approach for solving
distillation columns uses the concept
of equilibrium or theoretical stages.
This concept assumes the vapor and
liquid phases leaving any stage are in
thermodynamic equilibrium with each
other.
Principle

Minimum number of tray

Parameter adjustment
 Design of Distillation Column

Obtain: Obtain: Optimization

• Operating pressure • Initial value of number
of tray
• Initial value of feed
stage
 Study Case
• Design a distillation column to get propene in top stream with purity 96%
(mole).

Components Mass Flow Conditions Value

(kg/h) Temperature (C) 38
Ethane 4.1
Vapour Fraction 0
Propane 4000.4
Fluid Package Peng-Robinson
Propene 131.8

n-Butane 10498.2
11. Reactor

• Function : used when there is a reaction occurs in the process

simulation

• There are 6 type of reactors provided by hysys:

1. General reactors consist of : Gibbs Reactor, Equilibrium
Reactor, Conversion reactor, Yield Shift Reactor
2. Continuous Stirred Tank Reactor (CSTR)
3. Plug Flow Reactor (PFR)

• Before begin the simulation it is important to describe the

reaction on the hysys simulation basis manager.
 Type of Reactor

Can be used when we do not know the

reaction sets

Can be used for modelling equlibrium

reactions

Can be used for modelling conversion

reactions
can be used for complex reactors where no
model is available

The CSTR is a vessel in which Kinetic, Heterogeneous Catalytic

and Simple Rate reactions can be performed.
The conversion in the reactor depends on the rate expression of
CSTR Reactor the reactions associated with the reaction type.

The PFR can modelled Kinetic, Heterogeneous Catalytic and

Simple Rate reactions.
PFR Reactor
Example Using Reactor in Simulation
 How to Add Reaction Set

Choose Reaction type

Input stoichiometric
Input component coefficient
involved in reaction
Add Reaction to Fluid Package
How to Add Reactor (1st method)
 How to Add Reactor (2nd method)

click Double
click
Reactor Designs Tab
Reactor Reactions Tab (To Add Rxn set to Reactor)

Click to select Rxn and Rxn

Set
 REACTOR EXERCISE
Problem Description:
One possible way to produce acetone is by dehydrogenation of Isopropyl Alcohol (IPA).
The Reaction mechanism is as follow:
Type of reaction: Heterogeneous Catalytic Reaction

Basis of reaction: Vapor Phase, IPA

With Reaction Rate:

By Using PFR as reactor, with design condition given as below, determine the acetone product
flowrate.
Pressure drop in the PFR is assumed to be zero

OPEN FILE:
IPA- REACTION EXERCISE-STARTER.HSC
REACTOR EXERCISE ANSWER
Thank You
M. Ersharry Yunashtanto
Zayyanatun Zulfa
Ikha Muliawati
Mada Harahap
 Referensi
1. Separation. http://lhd52.files.wordpress.com/2011/09/group-6-separation-
operations.pdf
2. HYSYS Design Tutorial for CHEE470.
http://m.chemeng.queensu.ca/courses/CHEE470/documents/HYSYSTutorial.
pdf
3. HYSYS Tutorial Che 3G4.
http://jpkc.tongji.edu.cn/jpkc/hgyl/second/site/Hysys.pdf
4. http://www.departments.bucknell.edu/chem_eng/cheg200/HYSYS_Manual/a
_BlueHYSYS.pdf
5. Dr. Istadi, ST, MT. Perancangan Process Kimia (Chemical PRocess Design).
http://tekim.undip.ac.id/staf/istadi/files/2009/05/presentasi_perancangan_pr
oses_kimia_1.pdf
6. Tutorial Apps.
http://www.uam.es/personal_pdi/ciencias/vferro/documentacion/doc/Hysys
%203.2/Doc/HYSYS/TutApps.pdf
7. Peter Griffith. www.thermopedia.com/Vapor-Liquid Separation
 REFERENCES
• Aspen Hysys Unit Operation Guide, Aspen Technology, 2011

• Turton, R., Bailie, R. C., Whiting, W. B., Shaeiwitz, J. A., &

Bhattacharyya, D. (2012). Analysis,Synthesis, and Design of
Chemical Processes. Pearson Education, Inc.