Create Project Basis - WS6 - 7

Creating a Project Basis
Lesson Objectives
 Implement project basis and scope specifications via Standard Basis Files and Template Files
 Workshop 6: Create a basis for your project
 Workshop 7: Start a New Project – With Simulator Data
© 2019 Aspen Technology, Inc. All rights reserved. 2
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Aspen Process Economic Analyzer’s Modules
Simulator User Project User
Report
Aspen Process Economic Analyzer

Project Scope Capital Cost and Schedule Investment Analysis
• Project Style • Engineering • Revenues

• Simulator Data • Procurement • Expenses
• User-Added Data • Construction • Cash flows
• Schedule (E-P-C)
Scoping Capabilities
Built-In Knowledge Bases

Simulator Properties of
report formats chemicals and utilities
Operate and maintain Expert systems Map blocks

equipment knowledge bases into equipment
Design and cost

equipment Size equipment
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Scope Consists of . . .
 Stuff… the cost components in the project:
– Process equipment
– Plant bulks
– Site development
– Buildings
 Style… the rules for:

– Loading and mapping simulator models to equipment
– Sizing equipment
– Selecting utilities and developing usages
– Designing, costing, and scheduling
The Stuff of the Project
 Sources
– Simulator (typically major equipment)
– User-added (minor equipment, off-sites, etc.)
– Imports from:
– Prior projects (for example, sewer system, storage area)
– “Additional project components”
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Standard Project Specification Files
 Stored outside project as Libraries
– Basis for Capital Costs
– Units of Measure
– Project Component Map Specifications
– Design Criteria
– Investment Parameters
– Utility Specifications
– Operating Unit Costs
– Raw Material Specifications
– Product Specifications
 You begin a project by assembling copies

 Then modify within the project as required
Basic Steps for Using Aspen Process Economic Analyzer

1. Develop standard project specification files
2. Create a new project and evaluate:

– LOAD DATA
– DEFINE PRODUCTS AND RAW MATERIALS
– MAP AND SIZE SIMULATION BLOCKS
– VERIFY SIMULATION BASED EQUIPMENT AND ADD OTHER
EQUIPMENT
– EVALUATE
3. Recall an existing project to evaluate
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File Types: System, Standard, Scenario
 System Files
– Shipped with Aspen Process Economic Analyzer
– Templates for user’s Standard Files
– Changes do not affect already created projects
 Standard Files
– Copies of System Files
– You “calibrate” for your projects
– Changes do not affect already created projects
 Scenario Files
– Copies of Standard, or System Files
– Contained in scenario’s directory
– Changes do not affect System or Standard files
General Specs and Project Basis (1)
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General Specs and Project Basis (2)
 Process information
These options are affect the style of the
Description Proven.....Unproven project.
Complexity Simple........Highly Complex
Control PLC, Digital, Analog Details are described in Online help (F1)
 Project information
Type Grass Roots........Revamp
Eng. start date Day, Month, Year
 Location
In the world Geographic area
Soil condition Sand, Clay, etc.
 General
Country US, UK, JP, EU, ME
Currency Name, symbol, rate/country unit
Other Project title, creator
 Other
Project Type Influence on Power Distribution
Project Type MAIN Substation UNIT

Grass Roots/Clear Transformers, MCC, SW
Field Switchgears Transformer
Plant addition:
Switchgear MCC
Adjacent to existing
Plant addition: Inside
Switchgear MCC
existing
Plant addition:
Suppressed None Added None Added
Infrastructure
Plant modifications /
Switchgear MCC
Revamp
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Project Type Influence on Process Control
Project Type Operator Center Control Center

Grass Roots/Clear
YES YES
Field
Plant addition:
Suppressed NO NO
Infrastructure
All Others NO YES
Impact of Project Location
Location Domestic Ocean Taxes* Rotating

Freight* Freight* Spares**
North America 4 0 6.25 7
South America 5 8 4.00 10
Central America 5 5 4.00 10
Europe 1 0 0.00 7
Asia 1 0 6.00 10
Africa 4 8 4.00 15
Australia 2 12 7.00 7
* % of material cost ** % of purchased cost
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Simulator Type
Units of Measure (1)
 Units converted from any set, even mixed, to a uniform set
Aspen Process
Economic
Analyzer
Simulator Design and Cost Engine
• SI Units of • Metric
• Metric Measure -or-
• English Converter • I-P
• Mixed
• Custom
 Custom units MUST be manually mapped to load into Aspen Process Economic Analyzer
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Units of Measure (2)
Project Component Map (1)
 Use default and simulator data mapping
Simulator Aspen Process Economic Analyzer
HEATX Float-head heat exchanger

RADFRAC Various “configurations”:
• Single or double diameter tower
• Trayed or Packed tower
• Reflux loop options
• Reboiler options
 Change mapping by:

– Class (in “standard file” and in a project)
– Component (in a project only)
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Project Component Map (2)
Customized Mapping is available
Design Criteria (1)
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Design Criteria (2)
 Translate operating conditions into design conditions
- Specify parameters for design
temperature and pressure for five
different ranges of operating
temperature and pressure
 General sizing parameters

– Vessels: Process, agitated, storage
– Heat exchangers: Shell+tube, A/C, plate+frame
– Towers: Trayed/packed; multiple diameters
Design Criteria (3)
 Vessels
- Liquid Volume = Holdup x Volumetric Flow
- Residence time overrides H:D ratio spec
- VL separators
– Liquid entrainment method (Demister)
– Particle size separation
- Final vessel dimensions combination of residence time, H:D ratio, Vapor/Liquid

disengagement velocity, etc.
- Note: Specs can be overwritten on component level
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Design Criteria (4)
 Heat Exchangers
- 2/3 Rule for Design Pressure
- Default air cooler exit temperature = Inlet air T + 10°F
 Packed Towers
- Derating Factor (Default = 1.0)
– Lowers predicted flood vapor / liquid load
– Used often with foaming systems
- Default Flooding Factor = 0.6
- HETP – Usually estimated by program, can be user supplied
- Packed Section Height  # of packed sections
Design Criteria (5)
 Trayed towers
Actual Vapor Velocity
- Flooding factor Flooding Factor 
Flooding Vapor Velocity
- Foaming tendency
• Residence time for vapor/liquid disengagement
• Downcomer liquid velocity = f(foaming, tray spacing)
- Key component relative volatility
• Used to estimate tray efficiencies if missing
- Tray efficiency
• Used to calculate actual trays when no simulation sizing data
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Investment Parameters (1)
 General
– Number of time periods to analyze
– Tax and interest rates
– Depreciation method
– Economic life and salvage value at end
 Length of start-up period (owner’s)

 Escalation
– Capital cost
– Feedstocks and products
– Labor and utilities
 Other
Investment Parameters (2)
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Utility Specifications – Heat Transfer (1)
 Properties for up to twenty media

– Inlet/outlet temperatures
– Range used to select
– Use one with closest outlet T to process fluid inlet T
– Pressure
– Energy transferred per unit (heat source or sink)
– Cost per unit
 Defaults for steams, refrigerants, water

 Change the defaults
 Add your own media
Utility Specifications – Heat Transfer (2)
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Operating Unit Costs (1)
 Labor (loaded wage rates)

– Operator
– Supervisor
 Utilities (costs per unit)

– Electricity
– Fuel
– Instrument air
– Potable water
Operating Unit Costs (2)
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Raw Material and Product Specifications (1)
 Usage rates determined from:

– Stream data, if identified as stream
– Flowsheet-derived
– User-created
– User entry if no stream data
 Unit costs are:

– Costs for raw materials (negative)
– Prices for products (positive)
Raw Material and Product Specifications (2)
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Utility and Operator Values
 Utility values and rates come from the Simulator when applicable
 Utility and Operator Unit Costs need to be supplied by the user

– Many forms have place holder values, that are not updated.
– The user should supply their own values
 Capital Cost craft rates are supplied by APEA but can be overridden by the user
Starting The Workshop

 Workshop 6: Create a basis for your project
 Edit the project basis to reflect results of a specific location
 Understand how to customize the “style” of the project
 Generate your own project templates
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Basic Steps for Using Aspen Process Economic Analyzer
1. Develop standard project specification files
2. Create a new project and evaluate

– Define “STYLE”
– Assemble copies of project specification files
– Make required adjustments
3. Recall an existing project to evaluate
Starting The Workshop

 Workshop 7: Start a New Project – With Simulator Data
 Load simulation data from the APEA interface
 Explore simulation streams
 Review block flow diagram
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Create a Template for Your Project
Workshop
Objective
(SKILLS: customize standard files (project “style”) for a specific location)
This example is designed to familiarize you with the process of defining templates to be
used with your projects. The template files define the “style” of the project, including
design methodologies, work methods, investment criteria, available utilities, adjustments
to material and manpower calculations, and raw material and product definitions.
1. Open new Aspen Process Economic Analyzer. Exit any open project if Aspen
Process Economic Analyzer is active, or if Aspen Process Economic Analyzer is not
active, double-click the shortcut on the Windows desktop to start the program.
2. With the main Aspen Process Economic Analyzer window visible, choose File | New
Template and specify the Template Name as LA Template. For the Project
Description enter “Ethanol Production Flowsheet”. Select the appropriate units of
measure (I-P or Metric) and click the OK button. Close the Special Units window since
we are not changing the units of measure.
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3. The General Project Data window will appear. In the Project Title field, enter “LA
Projects”. Enter your initials in the Prepared By field, and then enter the estimate date
using the date format indicated in the Properties window. Click OK when complete.
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4. The Design Criteria allows the user to change the definitions contained in this file.
Navigate the tree on the left to access the data input forms. When you double click an
entry in the tree on the left, the data input for that section appears. Change the values
in the Design Criteria file to those listed below while reviewing all parameters and
categories. For values not provided, use default file values. When finished, click the
OK button to save all data entries in a form area before double clicking the next area
for data entry. When all values have been satisfactorily entered, select File | Close
from the main menu to save the file and close the editing process.
Specification Value Units [Metric]
Design Design Temp: Range 3 70; 150; -100; 200 °F [22; 65; -100; 95 °C]
Conditions
Design Temp: Range 4 150; 600; 0.00; 50 °F [65; 325; 0.00; 30 °C]
Heat Area Minimum 1.25
Exchanger Overdesign
Fuel Heating Value 1,000 BTU/LB [2,250 KJ/KG]
Vessels | Number of Holding 7
Storage Days
Height to Diameter 0.75
Ratio
Trayed Foaming Tendency High
Towers
Packed Packing Type Structured
Towers
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5. Now go to Investment Analysis | Investment Parameters and enter the following:
Specification Value Units [Metric]
Interest Rate [%] 8 /PERIOD
Economic Life of 20 /PERIOD
Project
Raw Material 4 %
Escalation
Operating Charges 20 %/PERIOD
Plant Overhead 40 %/PERIOD
G and A Expenses 10 %/PERIOD
Process Fluids Liquids & Gases
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6. Now go to Investment Analysis | Operating Unit Costs and enter the following:
Operating Unit Specification Value Units [Metric]
Costs
Labour Unit Costs Operator 23.75 /HR
Utility Unit Costs Electricity 0.12 /KWH
Potable Water 1.75 /MMGal [0.00046/M3]
Instrument Air 3.25 /KCF [0.115/M3]
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7. Look for Basis for Capital Costs and make the following modifications:
Basis for Capital Specification Value Units [Metric]
Costs
General Specs Process New Process
Description
Project Type Plant add. –
Suppressed
infrastructure
Contingency 18%
Basic Eng. Start January 1st of
next year
Construction
Workforce
– General Rates All Crafts Fixed: $20.40 /HR
Productivity 72.5 %
– Craft Rates Pipefitter & $22.50 /HR
Pipewelder
Productivity 110 %
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8. Now double click Utility Specifications and make the below modifications:
Utility Specification Value Units [Metric]
Specifications
Modify Unit Cost 3.75 /KLB [8.25/MEGAG]
Steam @100PSIG
[690kpa]
High Temp Heating Inlet Temp 700
Oil Exit Temp 650

Low Temp Heating
Oil
Create Name Cooling Tower
Water Water
Design 115 DEG F [46 DEG C]

Temperature
Design Pressure 100 PSIA [690 KPA]
Inlet Temperature 65 DEG F [18 DEG C]
Exit Temperature 90 DEG F [32 DEG C]
Pressure 50 PSIA [345 KPA]
Energy Transfer 25 BTU/LB [14 Cal/g]
per Unit Mass
Unit Cost 62.50 /MMGAL [0.0165/M3]
Utility Type Heat Sink
Disable Disable the existing “Cooling Water” by unchecking the checkbox.
Cooling Water
9. Modify existing Utility.
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10. Create New Utility.
11. Disable existing utility by unchecking the checkbox.
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12. Now let’s learn how to make the Library, export the utility specifications as “LA
Utility”. We can use this utility information in future estimation.
When the new simulator is loaded on Aspen Process Economic Analyzer, simulation
utility information will override the template information. To void this, we will re-
load library utility specifications after the load of simulation.
13. Navigate to Palette View | Library, check if the new “LA Utility” information is
well preserved.
14. Click File | Save, then Close, and answer “Yes” to the prompt “Do you wish to save
any changes to this project?”.
15. End of Workshop
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Notes:
14 - 10
Start a New Project – With Simulator
Data Workshop
Files can be found in folder: WS07_Start_Simulator
Objective
(SKILLS: start a new project; load simulator data; explore the user interface - Process
View)
This example is designed to familiarize you with the process of creating a new project that
involves simulation data. These exercises involve evaluations of flowsheet alternatives for
the production of ethanol from pre-pulverized sugarcane waste.
Background
Management of your company has decided to try and use the waste pulverized sugarcane
that is generated by your sugarcane processing plant in LA. This waste cannot be combined
with the food grade sugarcane since it is contaminated with organic, oils, and other non-
desirable particulate in minute quantities. It is your job to propose a process that
converts this waste into a saleable product, and the flowsheet below is your first
attempt. The process you are proposing takes the waste sugarcane, ferments it, separates
the CO2 from the ethanol/water mixture, then fractionates the ethanol / water mixture
to obtain an ethanol product and a waste stream of H2O.
15 - 1
1. Open ETOH1_Base_design.bkp, reset and re-run the simulation.
2. You now see the simulation in the Aspen Plus flowsheet window. We are about to run
Aspen Plus and Activated Economics, but before you do that, we will load the LA
Template we created in the previous workshop. To do this, click on the Economics
tab in the Ribbon, and the “Cost Options”. There will be three tabs in your open
window; make sure you have the “Cost Options” tab open. The first field you can
adjust will be the field for your Template. Click on “Browse” and locate the LA
Template, choose it, and click OK.
3. Input the Scenario name as “WS07” and description as “ETHANOL PROJECT”.

Set the Operating life of plant as 10 years, Length of plant start-up as 4 weeks and
set the start of basic engineering at the first date of the next year.
4. Next, we will run the Aspen Plus file. Click on the N (Next) Button and click OK to
the “Run the simulation now?” window.
15 - 2
5. When Aspen Plus has finished running, click on the Activated Economics Window
to run the Activated Economics.
6. When you turn this toggle on, APEA will automatically map, size and evaluate the
project. Note down the Total Capital Cost and Total Utility Cost that are indicated in
analysis box.
Total Capital Cost (USD) Total Utility Cost (USD)
7. After Activated Economics has finished running, double click on the Activated
Economics pane to bring up the “Equipment” tab. Click on the Utilities tab and note
that the “Cooling Tower Water” you had defined in the template appears. Note the
rate and cost per hour.
Rate Cost per Hour
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8. We now are going to send the economics file to Aspen Process Economic Analyzer
(APEA), Click on the Economics tab in the Ribbon. Notice on the right side of the
Economics ribbon, there is an option “Send to APEA” and if it is dim (not
available). That is because before a file can be sent to APEA, the Activated
Economics must be turned off in the simulation. To do this, uncheck the box next to
“Economics Active”. Notice that when you do this, the “Send to APEA” becomes
available to use.
9. You are now going to send your Aspen Plus results to APEA. Click on the “Send to
APEA” field. It will open APEA, and give you a screen to “Create New Project”. On
this screen, notice the “Template” button. When the Aspen Plus results are sent to
APEA, the cost options is not sent (like the template). You need to click on the
“Template” and choose “LA Template”, and click OK. Take the “ETOH1” as
Project Name and “Base Case1” as Scenario Name, click OK.
10. On the Project Properties screen, click OK.
11. Click Close on the “Input Units of Measure Specifications” screen.
12. Click OK on the “Genera Project Data” screen.
13. Click OK on the “Load Simulator Data?”, this will enable user to load the simulation
data.
14. Now select the Project Basis View tab in the Project Explorer window at the left. Click
the various menu to see if the information we have provided in LA template is preserved
in the project file.
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15. Now click the Load Data icon in the toolbar , or alternatively select Run | Load
Data from the main menu. Click the Yes button to reiterate your wish. During this step,
you will see various status bars go by at the bottom border of the program. You will
also see messages regarding the progress of many tasks. When there are no more status
bars updating, then this step is complete.
16. Select the Process View tab in the Project Explorer window to see the simulation
blocks.
Notice that the objects in this window of Aspen Process Economic Evaluator are
yellow. This means that the simulation results have been loaded but these objects have
not been converted to physical equipment items.
17. Go to Project View tab and check the Utility specifications, you will find that “LA
Template” Utility information is overwritten. We will use Utility Specifications
Library that you saved in the previous workshop.
18. Right click the Utility Specifications, click Select.
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19. Select Utility Specifications file windows will pop-out. Choose LA Utility and click
OK. Check if the utility information is well defined.
20. Select File | Save As and accept the previously entered project name and scenario and
allow the software to overwrite the existing work in the course folder.
Tip : After making changes to a project it is a good idea to save your work.
21. Now that the simulator file is loaded, explore the block flow diagram. Select View |
Block Flow Diagram from the menu. The block flow diagram will appear in the Main
window. In addition, some previously inactive icons in the main toolbar are now active.
The enabled functions include zoom in and zoom out.
When viewing the block flow diagram, you can double-click a stream or a unit
operation to view the simulation data underlying that object. To close the block flow
diagram, click on the close window “X” underneath the close program “X” near
the upper right of the window.
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22. Now, explore the simulator streams list. Choose View | Streams List from the menu.
The streams list from the simulation will appear in the Main window. The rows and
columns of the streams list can be moved. Click the row or column header. Then click-
hold-and-drag to the new row or column location desired.
In addition to the streams from the simulation file, there are streams named with an
ICP prefix. These streams are determined by Aspen Process Economic Analyzer to
represent internal streams needed for sizing and costing of equipment. For example,
the vapor stream that leaves the top of the tower and enters the condenser must be
known to determine details regarding the condenser. Therefore, stream ICP-OVHD
appears in the stream list, even though it was not part of the simulation file.
End of exercise, but please keep open the project file. we will use this file from the next
workshop.
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Notes:
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Creating a Project Basis

 Workshop 6: Create a basis for your project

 Workshop 7: Start a New Project – With Simulator Data

© 2019 Aspen Technology, Inc. All rights reserved. 2

Simulator User Project User

Aspen Process Economic Analyzer

• Project Style • Engineering • Revenues

© 2019 Aspen Technology, Inc. All rights reserved. 3

Built-In Knowledge Bases

Operate and maintain Expert systems Map blocks

Design and cost

© 2019 Aspen Technology, Inc. All rights reserved. 4

 Style… the rules for:

© 2019 Aspen Technology, Inc. All rights reserved. 5

The Stuff of the Project

© 2019 Aspen Technology, Inc. All rights reserved. 6

 You begin a project by assembling copies

© 2019 Aspen Technology, Inc. All rights reserved. 7

Basic Steps for Using Aspen Process Economic Analyzer

2. Create a new project and evaluate:

3. Recall an existing project to evaluate

© 2019 Aspen Technology, Inc. All rights reserved. 8

© 2019 Aspen Technology, Inc. All rights reserved. 9

General Specs and Project Basis (1)

© 2019 Aspen Technology, Inc. All rights reserved. 10

© 2019 Aspen Technology, Inc. All rights reserved. 11

Project Type Influence on Power Distribution

Project Type MAIN Substation UNIT

© 2019 Aspen Technology, Inc. All rights reserved. 12

Project Type Operator Center Control Center

© 2019 Aspen Technology, Inc. All rights reserved. 13

Impact of Project Location

Location Domestic Ocean Taxes* Rotating

* % of material cost ** % of purchased cost

© 2019 Aspen Technology, Inc. All rights reserved. 14

© 2019 Aspen Technology, Inc. All rights reserved. 15

Units of Measure (1)

 Units converted from any set, even mixed, to a uniform set

© 2019 Aspen Technology, Inc. All rights reserved. 16

© 2019 Aspen Technology, Inc. All rights reserved. 17

Project Component Map (1)

 Use default and simulator data mapping

Simulator Aspen Process Economic Analyzer

HEATX Float-head heat exchanger

 Change mapping by:

© 2019 Aspen Technology, Inc. All rights reserved. 18

© 2019 Aspen Technology, Inc. All rights reserved. 19

Design Criteria (1)

© 2019 Aspen Technology, Inc. All rights reserved. 20

 General sizing parameters

© 2019 Aspen Technology, Inc. All rights reserved. 21

Design Criteria (3)

- Final vessel dimensions combination of residence time, H:D ratio, Vapor/Liquid

© 2019 Aspen Technology, Inc. All rights reserved. 22

© 2019 Aspen Technology, Inc. All rights reserved. 23

Design Criteria (5)

© 2019 Aspen Technology, Inc. All rights reserved. 24

 Length of start-up period (owner’s)

© 2019 Aspen Technology, Inc. All rights reserved. 25

Investment Parameters (2)

© 2019 Aspen Technology, Inc. All rights reserved. 26

 Properties for up to twenty media

 Defaults for steams, refrigerants, water