Aspen HYSYS Advanced Process Modeling EHY202

EHY202
Aspen HYSYS®:
Advanced Process
Modeling Topics
AspenTech Customer Education
Training Manual
Course Number EHY202_V9.0_rev1

Copyright © 2016 by Aspen Technology, Inc. 20 Crosby Drive, Bedford, Massachusetts
01730, USA. All rights reserved. This document may not be reproduced or distributed in
whole or part in any form or by any means without the prior written permission of Aspen
Technology, Inc.
The information contained herein is subject to change without notice, and Aspen
Technology assumes no responsibility for any typographical or other errors that may
appear.
Aspen Technology may provide information regarding possible future product

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design, architecture, etc. that may be represented as “product roadmaps.” Any such
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Contents
Sections
Introduction 1-1
Getting Started 2-1

Workshop # 1: Get Started 3-1
Advanced Columns 4-1
Workshop # 2: Advanced Columns Workshop 5-1
Model an Acid Gas Cleaning Process 6-1
Workshop # 3: Model an Acid Gas Cleaning Process Workshop 7-1
Sulsim 8-1
Workshop # 4: Sulsim Workshop 9-1
Modeling Real Separators 10 - 1
Workshop # 5: Model Real Separators Workshop 11 - 1
Dynamic Depressuring 12 - 1
Workshop # 6: Dynamic Depressuring Workshop 13 - 1
Blowdown 14 - 1
Workshop # 7: Blowdown Workshop 15 - 1
Safety Analysis Environment 16 - 1
Workshop # 8: Safety Analysis Workshop 17 - 1
Reactors 18 - 1
Workshop # 9: Reactors Workshop 19 - 1
Optimization 20 - 1
Workshop # 10: Optimization Workshop 21 - 1

1-1

1-2

1-3

1-4

1-5

1-6

2-1

2-2

2-3

2-4

2-5

2-6
Getting Started Workshop
Files can be found in folder: 01_GetStarted
Objective
In this workshop, you will build a turbo expander and NGL fractionation plant model.
You will also use the LNG Exchanger unit operation to simulate a multi-pass heat
exchanger. The liquids produced from the inlet hydrocarbons will feed into a
fractionation section consisting of a pair of distillation columns for liquefied gas
recovery. You will also review reporting in Aspen HYSYS by applying desired physical
properties via the Correlation Manager.
In this workshop, you will build the flowsheet that will be used throughout most of the
modules of this course. The process is a Turbo Expander plant where LPG Product is
obtained from a feed natural gas stream by cooling, expanding, separating, and distilling
the condensed liquids. The remaining gas is then re-compressed for export.
The workshop is an introduction to the multi-pass exchanger unit operation and to the
different options available to display properties both on the streams and on tables by
using the stream tools and the HYSYS Workbook.
This workshop includes the following tasks:
Task 1 – Set Up the Turbo Expander

Task 2 – Adding the Fractionation Columns
Task 3 – Sales Gas Compression
Task 4 – Customizing Stream Properties
Task 1 – Set Up the Turbo Expander

You’ll begin this Turbo Expander/Fractionation process model from scratch. Therefore
the first step in HYSYS is to set up the Properties Environment. We’ll begin by defining
a suitable property package and component list for use in the simulation.
1. Start a new case by opening Aspen HYSYS and selecting the New option.
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2. Select the Component Lists folder on the Navigation Pane and click on the
Add button at the bottom of the page to create a new component list.
3. Select Nitrogen, CO2, Methane, Ethane, Propane, i-Butane, n-Butane, i-

Pentane, n-Pentane, n-Hexane, n-Heptane, n-Octane, and H2O.
Note: To sort the components, you can click on the name on the component that you want
to move and drag it to the desired position on the component list.
4. Click the Fluid Packages folder in the Navigation Pane, and Add a new Fluid
Package.
5. Scroll down through the Property Package Selection list and select Peng-
Robinson.
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6. Select the Simulation button below the Navigation Pane to enter the
Simulation Environment.
7. Add a Material Stream representing a mixture of natural gas, condensate, and

produced water with the following conditions and composition:
Name Feed Gas
Name Feed Mix

Temperature 22 ºC (72 ºF)
Pressure 3500 kPa (508 psia)
Flow rate 4145 kgmole/h (9138 lbmole/hr)
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Component Mole Fraction
Nitrogen 0.0108
CO2 0.0017
Methane 0.4127
Ethane 0.1643
Propane 0.1149
i-Butane 0.0441
n-Butane 0.0313
i-Pentane 0.0302
n-Pentane 0.0296
n-Hexane 0.0274
n-Heptane 0.0193
n-Octane 0.0165
H2O 0.0972
Before sending the feed mixture on to the Turbo Expander and Fractionation sections, it
would be wise to attempt an inlet separation to knock out any produced water and as
much liquid condensate as possible. To perform this separation, you will apply the
standard Aspen HYSYS 3-Phase Separator.
8. Add a 3-Phase Separator to your flowsheet. Define the separator using the
connections listed below:
In This Cell... Enter...
Connections
Name Inlet Sep
Inlet Feed Mix
Vapour Product Inlet Sep Vap
Light Liquid Product Inlet Sep Liq
Heavy Liquid Product Inlet Sep Water
Multi-pass exchangers are known as Liquefied Natural Gas (LNG) Exchangers in Aspen
HYSYS. The LNG Exchanger allows for multiple hot and cold streams, while the Heat
Exchanger model allows only one hot side stream and one cold side stream.
The LNG Exchanger model solves heat and material balances for multi-stream heat
exchangers and heat exchanger networks. The solution method can handle a wide variety
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of specified and unknown variables. This allows the user to specify various parameters,
including heat leak/heat loss, UA, and temperature approach.
For this unit operation, two solution methods are employed. In the case of a single
unknown, the solution is calculated directly from an energy balance. When there are
multiple unknowns, an iterative approach is used to attempt to determine the solution that
satisfies not only the energy balance, but also any constraints, such as temperature
approach or UA.
9. Double click on the LNG Exchanger button on the Object Palette.
LNG Exchangers require an inlet stream and outlet stream, a pressure drop, and a
Hot/Cold side designation. These will be used as an estimate for calculations and will
also be used for drawing the flowsheet. If a designated hot pass is actually cold (or vice
versa), the operation will still solve properly as it will pick up the required designation.
The actual Hot/Cold designation (as determined by the LNG) can be found on the
Performance tab in the Results page.
10. View the LNG Exchanger menu and select the Design | Connections page.
Specify the following stream connections:
Inlet Stream Outlet Stream Pressure Drop Hot/Cold

Inlet Sep Vap 1A 20 kPa (2.9 psia) Hot
7 7A 20 kPa (2.9 psia) Cold
9 9A 20 kPa (2.9 psia) Cold
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Hint: To fill in the third side stream connections, click the Add Side button at the bottom
of the Design | Connections page. This will add a side to the LNG Exchanger.
11. Select the Design | Parameters (SS) page. No changes will be made here, but
feel free to read up on the following options available on this form:
The Exchanger Design (Weighted) method is used to split the heating curves into
intervals, rather than simply considering the end points. The number of intervals is set in
the Exchanger Details table. The Step Type parameter sets whether Aspen HYSYS splits
the curves by temperature, enthalpy, or automatically to minimize the errors.
By selecting the Dew/Bub pt. checkboxes, Aspen HYSYS will include points on the
heating curves for any phase changes that occur. The Pressure Profile options set how
Aspen HYSYS decides the pressure profile during the iteration.
Heat Losses will not be considered. All streams on the same side with the Equilibrate
checkbox selected are considered to be in equilibrium before entering the exchanger
calculations. Thus, the driving force will be reduced.
These options are discussed in more detail in the Aspen HYSYS Operations Guide.
12. Go to the Design | Specs (SS) page.
The Degrees of Freedom Analysis display should show 6 as there are 7 unknown
variables and 1 constraint so far. We will add two extra specifications in addition to the
default Heat Balance spec (i.e., conservation of energy).
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LNG Exchangers, like normal Aspen HYSYS Heat Exchangers and Column models,
allow the user to enter as many specifications as required. Only the active specifications
are used to solve the operation.
If the Est. checkbox is selected, Aspen HYSYS will use the spec value as an initial
estimate in its iterative solution. Hence, specifications can be used for more than just
being an active spec. They can provide an initial estimate only (Uncheck Active, Check
Est.) or be used to monitor how important variables change as the operation iterates
(Uncheck Active and Est.)
13. Click on the Add button twice to add two new specifications.
Create the first spec to ensure the two cold side streams have the same outlet
temperatures, and the second spec to set the overall minimum approach temperature in
the exchanger is 10 ºC (18 ºF). Use the images below as a guide:
14. Make sure the Active checkbox is selected for both of these two new
specifications.
By adding two new specs, the number of degrees of freedom is reduced to 4. Later, when
more of the flowsheet is built, these 4 degrees of freedom will be used up and the
exchanger will have enough information to solve. For now, we will leave it this way and
will continue to build our simulation.
15. Return to the Flowsheet and double click on the Cooler icon on the Object
Palette, thus adding it to the flowsheet. Specify the following parameters:
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In This Cell… Enter…
Connections
Name E-100
Inlet 1A
Outlet 2
Energy Q-100
Parameters
Pressure Drop 20 kPa (2.9 psia)
Worksheet
Stream 2, Temperature -62 °C (-79.6 °F)
The necessary cooling duty in the E-100 Cooler is provided through an ethane/propane
refrigeration skid. This refrigeration skid can be modeled rather easily in HYSYS. In
fact, a HYSYS Template file already exists that you can quickly incorporate into your
model. This refrigeration loop model is included with your provided training course
HYSYS files.
HYSYS Templates are convenient in that they can be added readily to any other HYSYS
simulation. As long as the template file does not introduce any kind of numerical
inconsistency or thermodynamic incompatibility, they are very useful features. Their use
in merging multiple HYSYS files, specifically, is extremely helpful.
16. Add a Blank Sub-Flowsheet to your simulation:
Introducing a Template file to an existing HYSYS case is best done through a blank Sub
Flowsheet.
17. Select the option to Read an Existing Template.
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18. Browse to the folder location containing your provided HYSYS course files and
select the MixedRefrig.tpl file.
Note: The insertion of a template file into your simulation will introduce a second Fluid
Package – the Fluid Package associated with the template case. In certain cases HYSYS
may note that the Fluid Package of your template file is similar to the one used by the
existing simulation. If so, you’ll see the following pop-up:
19. Click Yes to apply the existing Fluid Package to the template file.
20. Re-name the sub-flowsheet as Mixed Refrig Unit, on the Sub-Flowsheet

Operation window Connections tab.
21. Define the Inlet Connection to the Sub-Flowsheet as Q-100 on the Connections
tab. This should be selected in the Inlet Connections to Sub-Flowsheet
section next to the Q-Chill energy stream. See below:
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Even though the E-100 Cooler is not fully calculated, note that the material stream 2 is.
You can continue building the Turbo Expander portion of the model using this stream.
22. Add another 3-Phase Separator to your flowsheet. Define it with the following
connections:

Connections
Name V-100
Inlet 2
Vapour Product 3
Light Liquid Product 4
Heavy Liquid Product Waste Water
23. Select the Expander operation from the Object Palette and add it to your
flowsheet; define it as follows:

Connections
Name K-100
Inlet 3
Outlet 5
Energy QK-100
Worksheet
Stream 5, Pressure 2800 kPa (406.1 psia)
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QUESTION: What is the power produced by the K-100 Expander? [Write your
answer below]
24. Add a two-phase Separator to the flowsheet and define it as shown:

Connections
Name V-101
Inlet 5
Vapour Outlet 7
Liquid Outlet 6
The liquid from the first Separator (V-100) is flashed down to the same pressure as the
Expander (K-100) outlet. When the simulation is manipulated later, the Turbo Expander
outlet pressure is one of the process parameters that will be changed; hence, it makes
sense to link these parameters within Aspen HYSYS rather than manually changing both.
We are going to use a Set logical operation to achieve this.
25. Add a Valve to the flowsheet using the following connections:

Connections
Name VLV-100
Inlet 4
Outlet 8
26. Double click on the Set icon on the Object Palette and install a Set with the
following parameters:

Connections
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Target Variable Object Stream 8
Target Variable Pressure
Source Stream 5
Parameters
Multiplier 1
Offset 0 kPa (0 psi)
27. Save your case as 01-GettingStarted.hsc.
Task 2 – Adding the Fractionation Columns

The vapor phase hydrocarbons that are processed in the Turbo Expander model have now
been isolated. You’ll turn your attention back to that side of the process later on.
But now we wish to combine the hydrocarbon liquids (liquefied natural gas and
condensate) and further process those material streams. As of now you flowsheet should
consist of three primarily liquid phase hydrocarbon streams (6, 8, and Inlet Condensate).
Stream 6 only contains a small amount of material flow. Assume that this stream will be
collected, stored, and used on a batch-wise basis.
Streams 8 and Inlet Condensate will be passed on to a pair of fractionation columns. The
first, a demethanizer, will attempt to draw a methane rich product off its overhead. The
bottoms liquids will continue on to a deethanizer column, where an ethane-rich product is
taken form the overheads, and a bottoms draw of propane and heavier hydrocarbons are
drawn off the bottoms.
The Inlet Condensate stream still exists at its feed conditions, while stream 8 has been
refrigerated and brought to a lower pressure. The Inlet Condensate also needs to be
brought to the proper thermodynamic conditions. The means for doing this in practice
are not of concern in this model, so you will use a simple HYSYS Cooler to set the
conditions of the Inlet Condensate to required values.
28. Add a Cooler to the flowsheet, using the following data:
In this cell... Enter...

Connections
Name E-200
Inlet Inlet Sep Liq
Outlet 10
Energy Q-200
Worksheet
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Stream 10 Temperature -85 °C (-121 °F)
Stream 10 Pressure 2790 kPa (404.7 psia)
29. Add a Material Stream, titled 11, to the flowsheet. This will be used to
represent the Demethanizer column bottoms liquid product stream.
30. Add a Set operation to define the pressure of stream 11 so that it is the same as
stream 5.
31. Add another Set to your flowsheet; set up this one in such a way that the stream
9 pressure is 35 kPa (5 psi) less than that of stream 5.
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The Column is a special type of sub-flowsheet in Aspen HYSYS. Sub-flowsheets
exchange information with the parent flowsheet through the connected streams while they
contain equipment and streams. From the main environment, the Column appears as a
single, multi-feed, multi-product operation. In many cases, you can treat the Column in
exactly that manner.
Using the Column Sub-flowsheet provides a number of advantages such as isolation of

the column solver, optional use of different fluid packages, construction of custom
templates and the ability to solve multiple towers simultaneously.
By isolating the column solver, the Column Build Environment allows you to make
changes and focus on the Column without the re-calculation of the entire flowsheet.
The Column Sub-flowsheet uses a simultaneous solver whereby all operations within the
sub-flowsheet are solved simultaneously. The simultaneous solver permits the user to
install multiple interconnected columns within the sub-flowsheet without the need for
Recycle blocks.
Aspen HYSYS allows you to specify a unique (different from the Main Environment)
fluid package for the Column Sub-flowsheet. This may be useful in instances such as
when a different fluid package is better suited to the Column (for example, a Gas Plant
using PR may contain an Amine Contactor that needs to use the Amines Property
Package). This feature is also useful to speed up column convergence when the column
property package does not need to use all the components used in the Main Flowsheet.
After the column is created, you can enter the Column Sub-flowsheet by clicking the
Column Environment button on the Column Property View. This gives you the
possibility to review the results and configuration of the column, and also to customize
the sub-flowsheet using various combinations of equipment. When you are inside the
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Column Environment, you can return to the Parent Environment by clicking either the
Parent Environment button on the Column Runner view or the View Parent button on the
ribbon.
32. Add the first column model (the Demethanizer) by selecting the Columns
section of the Object Palette and adding a Reboiled Absorber operation.
Note: By default Aspen HYSYS includes an Input Expert to guide the user through setting
up the column. The Input Expert has five pages; you must enter all the required
information on each page before the Next > button will become active.
33. Double-click the Reboiled Absorber icon that now appears on your main
flowsheet. The Column Input Expert should appear. Enter the following
information on the Connections page. When finished click the Next> button.
Connections
Column Name Demethanizer
No. of Stages 10
Top Stage Inlet 10

Optional Inlet Stream / Stage 8 / Stage 2_Main Tower
Overhead Vapour Product Stream 9
Bottom Product Stream 11

Reboiler Energy Stream Q-102
34. Click the Next button to proceed to the Reboiler Configuration page. Select
the desired Reboiler Configuration using the available radio buttons. Accept
the default Once-through / Regular Hysys reboiler.
35. Since the product stream pressures have already been defined (via the Set
operations), the Pressure Profile page automatically picks these up. Click
Next> to continue.
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36. Go to the Optional Estimates page by clicking the Next > button. Temperature
estimates are used to aid in convergence, helping a column solve more rapidly –
or solve period! If you already have an idea of the conditions in the column (for
example, if you are modeling an existing plant), then you can enter the
information. In this exercise, the temperatures are not known, so these estimates
will be left blank.
37. Click the Next > button to move to the final page. The final page of the
Column Input Expert always has some typical specifications for the particular
type of column. If different specifications are used, these must be added after
the Input Expert has been completed. Keep this form blank and click the Done
button.
Before the column is ready to run, some more information must be entered. We will be
adding an additional Inlet Stream and new specifications.
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38. Return to the main flowsheet and create an Energy Stream. Title this energy
stream Side Duty and specify a Heat Flow value of 3.3 E+06 kJ/h (3.128 E+06
Btu/hr).
39. Connect the Side Duty stream to stage 4_Main Tower in the Optional Inlet
Streams box on the Design | Connections page.
40. Go to the Design | Monitor page and review the existing column specs.
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Since no values were entered for the Specs in the Input Expert, no values are present
here. Since the column has fully defined feeds, the pressures are known, and one spec is
activated, the Degrees of Freedom display is showing 0. Of course, that active spec has
no numeric value, rendering it useless!
41. Specify a value of 800 kgmole/h (1764 lbmole/hr) for the Ovhd Prod Rate.
Click the Run button to run the column if it does not solve automatically.
QUESTION: Go to the Performance | Summary page. What is the mole fraction of

methane in stream 9? [Write your answer below]
It is preferred to solve this Demethanizer column with a different specification from the
default overhead molar flow rate. You will instead use a specification for the Reid Vapor
Pressure (RVP) of the bottoms product (stream 11).
42. Return to the Design | Monitor form and click the Add Spec…button to add the
spec described below:
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Spec Data
Type Column Vapour Pressure Spec
Name Btms RVP
Stage Reboiler
Type Reid Vap Pressure
Phase Liquid
Spec Value 1380 kPa (200 psia)
43. Modify the existing Ovhd Vap Rate spec to be set up as an Estimate. Make
the Btms RVP spec the Active spec and Run the column.
Note: The other unused specs can be deleted by going to the Specs page on the Design
tab and pressing the Delete button, or by double-clicking the spec on the Monitor page
on the Design tab and clicking Delete button. If desired, you may leave them in place for
reporting/analysis purposes.
You should see some messages in the Trace Window (bottom right message pane of the
HYSYS window) as the column solves. When the column has solved, the LNG
Exchanger should then fully calculate, along with all remaining material streams in the
flowsheet.
QUESTION: What is the new overhead molar flow rate? [Write your answer below]
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QUESTION: What happened to the mole fraction of methane in stream 9? Did it
increase? Decrease? [Write your answer below]
44. Save your case.
Stream 11, the Demethanizer bottoms, will now be further processed. A Deethanizer
column removes ethane and lighter components in the overhead draw, while propane and
heavier hydrocarbons are drawn from the bottoms. Continue by adding this column to
your flowsheet.
45. Add a Distillation Column from the Columns section of the Object Palette.
Define the Connection page of the Input Expert as follows. Click the Next>
button when finished.

Connections (Page 1)
Column Name Deethanizer
Number of Stages 16
Inlet Stream / Inlet Stage 11 / 7_Main Tower
Condenser Type Full Reflux
Overhead Vapour Product 12
Bottoms Liquid Outlet 13
Condenser Energy Stream Q-103
Reboiler Energy Stream Q-104
46. For the Reboiler Configuration page, keep the default settings. Click Next>.
47. Define the Pressure Profile page with the following. Click Next > to move on.

Pressures (Page 3)
Condenser Pressure 2730 kPa (396 psia)
Condenser Pressure Drop 20 kPa (2.9 psi)
Reboiler Pressure Drop 0 kPa (0 psi)
Reboiler Pressure 2785 kPa (404 psia)
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Continue through the Temperature Estimates and Specifications forms of the Input
Expert without entering any inputs. Click Done once you reach the last page of the Input
Expert.
48. Move to the Design | Monitor page On the Column Property View window.
QUESTION: How many degrees of freedom currently are present on the Deethanizer?
[Write your answer below]
49. On the Monitor page, the specification for Reflux Ratio should be present.
Specify a value of 3.0 for it.
50. One more specification is needed. Specify a fractional recovery specification

for propane using the data below:
Spec Data
Type Column Component Recovery
Name C3 Recovery
Draw 13 @COL2
Spec Value 0.95
Components Propane
51. Check the Active boxes for the Reflux Ratio and C3 Recovery specs. Run the
column.
QUESTION: What is the molar recovery of ethane in the overhead stream 12? [Write
your answer below]
52. Save your case.
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Task 3 – Sales Gas Compression
The simulation is almost complete. The two product gas streams from the LNG
Exchanger will now be mixed and re-compressed for export.
53. Add a Mixer operation to the flowsheet and define it using the following table:

Connections
Name MIX-100
Inlets 9A, 7A
Outlet 14
54. Add a Compressor to the flowsheet. Connect QK-100 (the energy stream
connected to the K-100 Expander) as the energy input. See the following
screenshot for the inlet and outlet connections:
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55. Add one last Compressor, defined with the parameters listed below:

Connections
Name Export Gas Comp
Inlet 15
Outlet Sales Gas
Energy QK-102
Worksheet
Outlet Pressure 6000 kPa (870.2 psia)
56. Save your case.
In this Aspen HYSYS exercise, there are two compressors specified differently. K-101
has a fully specified inlet stream and a specified duty calculated via expander K-100,
while the Export Gas Compressor has a fully specified inlet stream and a specified outlet
pressure.
Aspen HYSYS can also solve for a flow rate given an otherwise fully specified feed
stream, a duty, and an outlet pressure. Additionally, Aspen HYSYS compressors can be
supplied with head and efficiency curves. These curves can be obtained from vendors,
online databases, and through aspenONE Exchange.
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Task 4 – Customizing Stream Properties
In this part of the workshop we will modify the properties being displayed on each
stream. We can add or remove properties (also referred to as Property Correlations),
change the order of the properties, and save sets of property correlations to apply them on
other streams in the simulation.
There are two places in Aspen HYSYS where these correlations are controlled. The
Property Correlation Controls section on the stream Properties page allows the
correlations for an individual stream to be customized. To make changes to the property
correlations for the whole case, use the Correlation Manager on the Home tab on the
ribbon.
57. To modify the properties at stream level, we use the buttons at the bottom of the
stream window on the Properties page on any stream.
These buttons have the following functions:
Button Flyby Text Notes
View Correlation Set List Allows the user to pick from a list of previously
defined correlation sets.
Append New Correlation Brings up a window where all correlations are

displayed in a tree and can be selected and added.
Correlations are added to the bottom of the list.
Move Selected Correlation
Down
Move Selected Correlation Up
Sort Ascending
Remove Selected Correlation
Remove All Correlations
Save Correlation Set to File The Correlation Set can then be loaded with the
View Correlation Set List function.
View Selected Correlation See settings specific to the selected correlation.
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View All Correlation Plots See all correlation plots for the stream. Currently
greyed out as none of the correlations have plots.
58. Double click on the Inlet Sep Vap stream. Go the Properties menu and click
the Remove All Correlations button ( ) to clear all the correlations on the
stream.
59. Click on the Append New Correlation button ( ) and add Gas – HC Dew
Point. Click on Apply.
60. Repeat the same steps for Gas | HHV Molar Basis, Gas | LHV Molar Basis,
Gas | Wobbe Index and Standard | Std Gas Flow. Close the Correlation
Picker window when finished.
61. On the Inlet Sep Vap stream Properties page, select the HHV Molar Basis
[Gas] entry in the table.
62. Click the View Selected Correlation button ( ).
A window appears giving details of the property. Note that the Reference temperature
option cannot be changed here as it appears in black.
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63. Back on the Inlet Vapor stream Properties page, click the Save Correlation Set
to File button ( ) to save the properties in this stream as a correlation set
called Inlet Sep Vap-CorrSet.
64. Open the Properties page for the Sales Gas stream. Remove all the existing
correlations and add the Inlet Sep Vap-CorrSet correlation set to the stream
using the View Correlation Set List button ( ).
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Note: All user defined correlation sets are stored by default on the file.
StreamCorrSets.xml under the \Support subdirectory of the Aspen HYSYS installation.
The name and location of this file can be configured on the Preferences menu located
under File | Options from the HYSYS ribbon. This file is not created until a correlation
set is added.
To customize the properties for all the streams in the simulation, Aspen HYSYS includes
a Correlation Manager where global changes for the whole case can be made. This
Correlation Manager is accessed through the Simulation section on the Home menu on
the ribbon.
65. Navigate to the Home ribbon tab and select the Correlation Manager. See the
screenshot below for guidance:
The Correlation Manager contains a listing of available properties/correlations – much

like the one used in the Correlation Picker menu that can be accessed for a single material
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stream. It also contains a section describing a selected correlation and displaying where
in the simulation it is applied.
At the bottom of the Correlation Manager is collection of controls – again, similar to

those seen on the Properties form of a single material stream. The functions of the
buttons are shown on the next page:
Button Flyby Text Notes

Scan System Correlations Click this icon to manually scan the system
registry and build a list of available property
correlations.
Clone Selected Correlation Only enabled when a property with variable
parameters is selected (details are given in
the following sections).
Delete Cloned Correlation From Only enabled when a previously cloned
List property is selected in the Clone part of the
tree and when no streams are showing the
property.
Activate Selected Global Adds the selected property correlation to all
Correlation the streams in the case.
Remove Selected Global Removes the selected property correlation

Correlation from all the streams in the case.
Remove All Global Correlations Removes all the property correlations from
all the streams in the case.
Some properties, like Higher Heating Value for instance, have user adjustable parameters
that can only be modified from the Correlation Manager. You will now learn how to
customize these parameters.
66. Select the Gas | HHV Molar Basis property from the property tree in the
Correlation Manager.
67. Change the Ref. Temp. Option to 0.0 °C using the drop-down menu.
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68. Go back to the main flowsheet and note that the HHV-Molar Basis values
calculated in the Inlet Sep Vap and Sales Gas streams have changed due to the
altered reference state.
When you change a correlation’s parameters, all the streams displaying the correlation
will use the new parameters. Hence Aspen HYSYS has a clone feature that allows
multiple copies of the same correlation to be used. Cloned correlations can have different
parameter values to the original correlation.
69. Return to the Correlation Manager and make sure the HHV Molar Basis
correlation is selected. Click the Clone Selected Correlation button ( ) to
clone the Higher Heating Value property.
70. Find the cloned property in the User section of the property tree.
71. Add this correlation to all the streams in the case using the Activate Selected
Global Correlation button ( ).
3 - 29
Verify that the reference temperature for the cloned correlation is different from the
original correlation (i.e. original is set at 0 °C and the clone’s is at 15 °C).
72. Compare the values of the two correlations for the Inlet Sep Vap and Sales Gas
streams.
When viewing a single correlation/property in the Correlation Manager, you will

notice that there are six bars at the right hand side of the window on the Status
group. They are described on the following table. This Status section indicates the
statues of the selected correlation in your simulation.
3 - 30
Status Bar Description
Stream Indicates that the correlation can only be applied to
material streams.
Point/Potable Indicates whether the property correlation is a point
or potable property.
Black Oil/Electrolyte/ Indicates which correlation type the property
Gas/RVP/Solid/ correlation resides within the Available Correlations
Standard/User/Clone list.
Active/Inactive Indicates whether the property correlation has
been activated by the correlation manager.
If the status bar is green, any new stream added to
the flowsheet with the same fluid type as the
correlation will automatically have the property
correlation added.
In Use/Not in Use Indicates whether the property correlation is being
used by a stream in the case.
Available/Unavailable Indicates whether the property correlation exists in
the window registry of the system.
The View Global Correlation Set List button in the Stream Correlation Set Controls
(Global) group allows a previously saved Correlation Set to be displayed for all the
streams in the case
With this option, you can load a defined set of correlations to all streams in a given
simulation. This can be very beneficial in cases where you wish to standardize physical
property reporting, simplify the display of stream properties, or otherwise customize your
property reporting techniques.
73. Click the button to Remove All Global Correlations.
74. Click the View Global Correlation Set List by clicking the appropriate icon.
75. Select the Inlet Sep Vap-CorrSet and click the Apply button to load the
correlation set to all streams in the flowsheet.
3 - 31
QUESTION: What is the standard gas flow rate of stream 12? [Write your answer
below]
76. Save your case as 01-GettingStartedCorr.hsc.
Recommended Reading
Knowledge Base Solution 114348
How do I customize stream properties for all my streams in the HYSYS case?
3 - 32
Notes:
3 - 33
Getting Started Solutions
Solutions
Files can be found in folder: 01_ GettingStarted/Solutions
Questions
Task 1
QUESTION: What is the power produced by the K-100 Expander?
60.79 kW (81.53 hp)
Task 2
QUESTION: Go to the Performance | Summary page. What is the mole fraction of
methane in stream 9?
0.9242
QUESTION: What is the new overhead molar flow rate?
768.7 kgmole/h (1695 lbmole/hr)
QUESTION: What happened to the mole fraction of methane in stream 9? Did it

increase? Decrease?
0.9547; Yes, it increased from the original case
QUESTION: How many degrees of freedom currently are present on the Deethanizer?
Two (don’t be deceived by any Active specs that don’t have a value!)
QUESTION: What is the molar recovery of ethane in the overhead stream 11?
98.56%
3 - 34
Task 4
QUESTION: What is the standard gas flow rate of stream 12?
14470 STD_m3/h (12.26 MMSCFD)
Results Summary
Feed Mix Inlet Sep Inlet Sep Inlet Sep

Vap Water Liq
Vapour Fraction 0.5374 1 0 0
Temperature C 22 22 22 22
Pressure kPa 3500 3500 3500 3500
Molar Flow kgmole/h 4145 2227.57 400.36 1517.07
Mass Flow kg/h 139412.09 51027.53 7212.89 81171.67
Liquid Volume Flow m3/h 297.79 141.74 7.23 148.82
Heat Flow kJ/h 512256461 183170676 114661141 214424644
7 9 1A 7A
Vapour Fraction 1 0.9998 0.9039 1
Temperature C 70.481 63.712 8.831 12
Pressure kPa 2800 2765 3480 2780
Molar Flow kgmole/h 1074.133 768.735 2227.571 1074.133
Mass Flow kg/h 18799.338 12888.333 51027.530 18799.338
Heat Flow kJ/h 83929144 60796333 189277976 80211713
9A 2 3 4
Vapour Fraction 1 0.4895 1 0
Temperature C 12.000151 62 62 62
Pressure kPa 2745 3460 3460 3460
Mass Flow kg/h 12888.33 51027.53 19231.46 31761.26
Heat Flow kJ/h 58406463 202942268 85349436 117027649
Waste 5 6 8
Water
Vapour Fraction 0 0.9851 0 0.0842
Temperature C 62 70.481 70.481 67.317
3 - 35
Pressure kPa 3460 2800 2800 2800
Mass Flow kg/h 34.81 19231.46 432.12 31761.26
Heat Flow kJ/h 565183 85568295 1639151 117027649
10 11 12 13

Vapour Fraction 0 0 0.9997 0.0000
Temperature C 85 66.200 9.124 127.558
Pressure kPa 2790 2800 2730 2785
Mass Flow kg/h 81171.67 100044.60 18709.79 81334.80
Heat Flow kJ/h 232792150 251652845 55712341 179301039
14 15 Sales Gas

Vapour Fraction 1 1 1
Temperature C 11.887 15.460 84.986
Pressure kPa 2745 2858 6000
Molar Flow kgmole/h 1842.87 1842.87 1842.87
Mass Flow kg/h 31687.67 31687.67 31687.67
Liquid Volume Flow m3/h 100.97 100.97 100.97
Heat Flow kJ/h 138618176 138399317 133970603
3 - 36

4-1

4-2

4-3

4-4

4-5

4-6

4-7

4-8

4-9

4 - 10

4 - 11
Advanced Columns Workshop
Files can be found in folder: 02_AdvancedColumns
Objective
In this workshop you will learn about customizing column configurations for enhanced
condenser and reboiler modelling. This can be done either inside or outside of the
Column Sub-Flowsheet. Another aspect of the exercise is to learn about column stage
efficiencies and how they can influence the separation performance of your column
models. You will also learn how to perform tray sizing and rating calculations with the
Aspen HYSYS Column Analysis tool.
In this module, the prebuilt LPG Recovery column from the last workshop will be
modified. You will learn about column stage efficiencies and how to use the Column
Analysis tool to size and rate column tray sections in the column. Also, the Spreadsheet
will be used to calculate a simplified profit for the Turbo Expander/Fractionation plant.
Task 1 – Simulate a Condenser Externally

Task 2 – Modify the Column Sub-flowsheet Reboiler
Task 3 – Tune Stage Efficiency
Task 4 – Perform Column Internals Sizing and Rating Analysis
Task 5 – Build the Spreadsheet
Task 1 – Simulate a Condenser Externally

The default Condenser and Reboiler operations that Aspen HYSYS utilizes inside the
Column Environment are idealized operations. For instance, the standard Condenser is
essentially the condenser heat exchanger, accumulator, and reflux/distillate split all in
one. This setup, while convenient for steady state process simulation, presents some
difficulty if you’re interested in equipment sizing or in detailed dynamic calculations.
One potential method of simulating a condenser or reboiler with a Heat Exchanger is to

use the Internal Streams feature of the HYSYS column models and then to make a copy
of the condenser/reboiler on the main flowsheet. This approach is very convenient as it
does not affect the internal column solver, or the solving of any other flowsheet objects.
Think of it as a side calculation entirely dedicated to the study of your condenser or
reboiler.
5-1
In this portion of the workshop, you’ll further study the condenser on your Deethanizer
column. This way of modeling the condenser is just as accurate as adding the heat
exchanger to the column sub-flowsheet, although it may look a bit odd as there are in
essence two condensers: one integrated with the column sub-flowsheet, and another “for
calculation purposes.”
Again, to make this approach work you’ll be using an Internal Stream. This is a special
Aspen HYSYS stream that represents a fluid inside the column (for example, the vapor
leaving the top tray, or the liquid leaving the bottom tray).
1. Continue with your HYSYS simulation from the last workshop (01-
GettingStartedCorr.hsc).
2. From the main flowsheet, double-click the Deethanizer column icon.
3. Go to the Flowsheet | Internal Streams page and click on the Add button.
4. Type in To Cond as a stream name and select Stage 1_Main Tower as the Stage.
5. Select Vapour and then click the Export check box.
6. Run the column and you should see the To Cond stream out on the main
flowsheet.
Note: The Net/Total column is relevant only in the case of streams with external draws.
When Total is selected, the draws are included, i.e. the total flow leaving the stage is
considered. When Net is chosen, only the flows in the column are considered and the
effect of external draws is excluded.
7. Add a Heat Exchanger to the flowsheet and define it with the following
specifications:
5-2
Connections
Name Condenser
Tube Side Inlet To Cond
Tube Side Outlet To Acc
Shell Side Inlet Cool In
Shell Side Outlet Cool Out
Parameters
Heat Exchanger Model Simple Weighted
Shell Side Pressure Drop 7 kPa (1 psi)
Tube Side Pressure Drop 20 kPa (2.9 psi)
8. View the Cool In material stream and select the Composition form. Assume the
Cool In stream is a mixed refrigerant with composition of 95% mole propane
and 5% mole ethane. Specify the corresponding mole fractions for Cool In.
9. Assume a Vapor Fraction of 0.0, a Pressure of 260 kPa (37.71 psia), and a Molar
Flow of 880 kgmole/h (1940 lbmole/hr) for the Cool In process conditions.
QUESTION: What is the temperature of Cool In? [Write your answer below]
10. Use a Set operation to specify the To Acc stream temperature to be the same as
stream 12@COL2 (thus giving the main flowsheet Condenser the same heat load
as the Deethanizer column Condenser).
5-3
11. Add a Separator to the main flowsheet and define it as follows:

Connections
Name Accumulator
Inlet To Acc
Vapour Outlet Ovhd Prod
Liquid Outlet Reflux
12. Save your case as 02-AdvColumnsCond.hsc
QUESTION: What is the calculated UA of the Condenser? The LMTD? [Write your
answer below]
Task 2 – Modify the Column Sub-flowsheet Reboiler

Whenever a column is added into an Aspen HYSYS simulation, a Column Sub-flowsheet
is created. The sub-flowsheet is essentially another layer in the Aspen HYSYS
simulation. The nature of the layering scheme can be seen by selecting the hot-key
<CTRL+P>, where the Column is listed under the Main PFD. Selecting the desired
flowsheet and clicking the View button will open that particular layer for viewing.
5-4
Alternatively, the flowsheet of a particular column can be seen by right-clicking the
column flowsheet icon and choosing Open Flowsheet as New Tab.
In order to edit the column (for example, to add and modify operations), it is best to enter
the Column Environment. The Column Environment is accessed through the Column
Property View. To bring up the Column Property View, double-click the column icon on
the parent flowsheet. With the Column Property View as the active view, click the
Column Environment button. This will make Aspen HYSYS display the Column
Environment and Column Runner menu. The operations within the column sub-
flowsheet can be deleted, modified, replaced, and controlled just like ordinary unit
operations in the Main Environment.
When in the Column Environment, you can return to the Main Environment by clicking
the Go to Parent button located on the Flowsheet/Modify Toolbar.
This task will involve the Demethanizer column you built in the Getting Started module.
The column was constructed as a generic reboiled absorber with a generic type reboiler.
An energy stream applied to the reboiler partially vaporizes the liquid from the bottom
stage. The vapor returns to the bottom stage of the column and the liquid leaves the
reboiler as a product draw. The generic reboiler will be replaced with a HYSYS Heat
Exchanger unit operation.
13. From the main flowsheet, double click on the Demethanizer column.
14. Go to the Parameters | Solver form and change the Solving Method to Modified
HYSIM Inside-Out.
Note: The Modified HYSIM Inside-Out is a General purpose method which allows adding
unit operations such as Mixers, Pumps, Tees, Valves and Heat Exchangers inside the
column sub-flowsheet.
5-5
15. After changing the solving method, the column will become un-solved. Click the
Run button to re-calculate.
Now that the proper solver strategy is in place, you are ready to begin modifying the
column sub-flowsheet.
16. Click the Column Environment button on the Demethanizer column window.
5-6
Note: As an alternative option, you may return to the main flowsheet and right-click on
the column icon. From there, select Open Flowsheet as New Tab. By right-clicking the
column icon and opening the flowsheet in a new tab, you can view both the main and
column flowsheets in distinct windows. Clicking the Column Environment button
changes the flowsheet window in HYSYS from the main flowsheet to the column sub-
flowsheet (i.e. only one flowsheet can be displayed in your workspace).
17. Delete the existing Reboiler and associated energy stream (Q-102) from the
column sub-flowsheet view.
The generic HYSYS reboiler has no pressure drop. You’ll be replacing it with a Heat
Exchanger that has some assumed pressure drop. Therefore you must add a Pump to the
sub-flowsheet to “push” the fluid through the exchanger.
18. Display the column sub-flowsheet Object Palette and add a Pump to the sub-
flowsheet. Configure the Pump with the following specifications:

Connections
Name Reboiler Pump
Inlet Stream To Reboiler
Outlet Stream Pump Out
Energy Stream Pump-HP
Parameters
Delta P 75 kPa (10.9 psia)
19. Continue by adding a Heat Exchanger to the column sub-flowsheet and define it
with the following connections and input:
In This Cell... Enter

Connections
Name Reboiler
Tube Side Inlet Stream Steam In
Tube Side Outlet Stream Steam Out
Shell Side Inlet Stream Pump Out
Shell Side Outlet Stream Reboiler Out
Parameters
Shell Side Pressure Drop 75 kPa (10.9 psi)
Tube Side Pressure Drop 50 kPa (7.25 psi)
5-7
20. Define the Steam In stream as superheated steam at 200 °C (392 °F) and 1500
kPa (217.6 psia). The mass flow rate is 17125 kg/h (37750 lb/hr). Don’t forget
to define its composition as well!
21. Finish the column sub-flowsheet by adding a Separator with the following
connections:

Connections
Name V-100
Inlet Stream Reboiler Out
Vapour Outlet Stream Boilup
Liquid Outlet Stream 11
22. Return to the main flowsheet by clicking the Go to Parent button on the
Flowsheet/Modify tab of the Ribbon.
Note: If you are viewing the column sub-flowsheet as a unique tabbed window, simply
click the tab for the main flowsheet.
Normally when the reboiler is deleted from the column sub-flowsheet, the pressure that
was specified at the bottom of the column is lost and must be added back on the
Parameters | Profiles page. However, in this case the pressure at the bottom of the
column is set by the pressure in the bottoms liquid product stream 11, which is linked to
the Turbo Expander outlet pressure by a Set operation. So your pressure profile should
be intact.
However, since the Reboiler was deleted, Aspen HYSYS removed the reboiler liquid
Reid Vapor Pressure spec. Therefore we need to add this spec back to the column.
5-8
23. Double click on the Demethanizer column, view the Design | Monitor page, and
select Add Spec - Column Vapour Pressure Spec:
RVP Spec...
Type Column Vapour Pressure Spec
Name Btms RVP
Stage V-100
Type Reid Vapour Pressure
Phase Liquid
Spec Value 1380 kPa (200 psia)
Since the Heat Exchanger was installed in the Column Environment, its specifications
appear on the Design | Monitor page along with the specifications of the column. Heat
Exchanger specifications can be activated and deactivated just like column specifications.
They can also be added in exactly the same manner as Column specifications.
24. Ensure that the two active specifications for the column are the Btms RVP and E-
100 Heat Balance.
Column sub-flowsheets containing more complex unit operations, such as Heat

Exchangers, tend to have more tricky convergence requirements than standard columns.
To address these convergence issues, you’ll need to make a few adjustments to the
Demethanizer solving parameters to enable it to solve.
5-9
25. Move to the Parameters | Solver form. Reduce the Equilibrium Error
Tolerance to 1.0 E-06 and the Heat/Spec Error Tolerance to 5.0 E-05.
26. Run the column.
5 - 10
Hint: You will likely receive a Consistency Error message when you try to solve the
Demethanizer. Don’t’ worry – the problem is not overspecified. You should note that the
Consistency Error points out a very slight difference in calculated enthalpy values for a
stream inside the Column Environment. These slight discrepancies are usually caused by
small numerical inconsistencies and often are not a problem. Follow the procedure
below to fix this issue.
27. Close any Consistency Error message windows you might have received.
Viewing the Home ribbon tab, click the Active button to make the HYSYS
Solver active once again. The main flowsheet should now be fully calculated.
QUESTION: What is the minimum approach temperature of the Reboiler heat

exchanger? [Write your answer below]
QUESTION: What is the vapor fraction of the Reboiler Out material stream in the
column sub-flowsheet? [Write your answer below]
28. Save your case as 02-AdvColumnsReb.hsc.
Task 3 – Tune Stage Efficiency

Aspen HYSYS column models employ a theoretical stage model. Meaning that the
specified stages are all assumed to be theoretical equilibrium stages, rather than actual
trays or packing. While you will investigate the influence of actual column internals in
the next section of the workshop, it’s important to note that these calculations will not
affect the separation results of a given column – meaning they only calculate hydraulic
considerations.
Since real columns in the field do not experience perfect theoretical equilibrium it is
important to know how to adjust the theoretical column stages for a more realistic
performance. The approach to do is by working with efficiencies. Aspen HYSYS allows
you to modify efficiencies on both a stage basis, and on a component basis. In this task,
you’ll work with and manipulate stage efficiencies for the Deethanizer column to
approach a more realistic performance.
29. Double-click the Deethanizer column.
5 - 11
30. Start by recording the molar recovery of ethane in the overhead product. This
value can be found on the Performance | Summary form.
QUESTION: What is the current molar recovery of ethane in the overhead product?
31. Navigate to the Parameters | Efficiencies form.
The current solution for the Deethanizer assumes 16 theoretical equilibrium stages in
addition to a full reflux condenser and a reboiler. The design targets for the column were
a molar reflux ratio of 3.0 and a fractional recovery of propane in the bottoms product of
0.95.
As the Deethanizer column goes to detailed engineering design, your designers inform
you that they are likely going to use trays for the column stages. These trays have,
according to the vendor, a percentage efficiency of about 70% with the current process
fluids in the Deethanizer.
32. Click and highlight all non-condenser/reboiler stages in the Stage Efficiency list.
33. Enter 0.7 in the Eff. Multi-Spec field on the Parameters | Efficiencies form.
34. Select all the non-condenser/reboiler stages and click the Specify ---> button to
write this efficiency in for all non-condenser/reboiler stages.
5 - 12
35. Allow the column to re-calculate.
QUESTION: What is the new calculated molar recovery of ethane in the overhead
product? [Write your answer below]
QUESTION: What happened to your calculated recovery of ethane? Did it decrease or

increase? Why would you expect it to do so? [Write your answer below]
Feel free to explore other column performance parameters as you experiment with
varying the stage efficiency.
36. Save your case as 02-AdvColumnsEfficiency.hsc.
5 - 13
Task 4 –Column Analysis
Aspen HYSYS contains a Column Analysis tool that greatly simplifies the hydraulic
design of a distillation column. Users can size full towers or just sections of towers by
specifying information related to various tray or packing types.
While Aspen HYSYS is able to size and rate tray sections, the values that it provides are
only estimates and should be treated as such. It is also important to note that these
internals calculations only return hydraulic-related results. They do not influence or
modify the separation calculations within the tower itself. Those are still based upon the
equilibrium-related assumptions and efficiencies defined in the column model.
For this step of the module, you’ll perform some hydraulic calculations on the
Deethanizer column using the HYSYS Column Analysis.
37. You can use the Internals tab for the Column to explore multiple column
configurations or use the flowsheet icon to perform the analysis.
Note: The Internals tab includes pages for each tower within your column
subflowsheet; Main Tower, Side Strippers and Side Rectifiers.
When you open a HYSYS case in V9.0 that includes a column, icons on the flowsheet
indicate
For columns without internals, a gray icon appears to the left of the column.
For columns with internals specified and without errors, a blue icon appears to the
left of the column
For columns with internals specified and with errors, a red icon appears to the left
of the column.
You could click on that icon as well to lead to the same internals page of the column.
The Aspen HYSYS Column Analysis is very versatile in that you can add any section of
stages you wish. This “Section” could be an entire tower, a portion of stages in a singles
tower, or a side stripper column. The Analysis also allows users to add multiple sections
which all calculate at the same time. This is particularly useful for comparing the
performance of different tray/packing types, modeling different sections of a column with
different internals simultaneously, or for any other reason.
38. Click the Add New button to create a new internals section. A row appears,
named CS-1 by default. Add Column Description as Sizing Case.
5 - 14
Note: If you click the Auto Section button, HYSYS automatically creates column
sections based on feed and draw locations or internal flow rates.We will use option
later in this task.
39. Keep the default Sieve tray internals. Note that the default calculation type of
Interactive Sizing.
40. Click the View to open the Geometry Form to specify more details for the
column internals.
You will notice that the default column internals sizing has resulted in some errors.
5 - 15
41. Move to the Messages Tab to view the error warnings or select View Hydraulic
Plots and click the Stages with Errors/Warnings tab to view only the stages
with errors or warnings.
Note: The Hydraulic Plots form is divided into these main sections: The column
diagram appears on the upper left. Below it, when a tray is selected, the downcomer
loading and weir loading diagrams appear. The large plot on the right is the
stability diagram. Below it is the carousel, which shows a small version of the
stability diagram for each of several stages.
42. According to one of the warnings, it is recommended to increase the tray spacing
or downcomer clearance. We will increase the downcomer clearance in this case.
We will use the Geometry form to change the Downcomer Clearance to 58.80
mm (2 in) for the column.
5 - 16
43. We still have the weeping issue, in order to avoid this decrease the ‘Hole Area To
Active Area’ ratio to 0.06.
By reducing the "Hole Area To Active Area", the velocity of the vapor going through
each hole will be higher and has more momentum to push the liquid away from the
hole. Therefore, weeping will be less likely.
5 - 17
44. Accept all of the remaining default values that are presented.
45. Move to the Results Tab | Summary page to check the Design calculation
results.
46. You could also select View Internals Summary option to review the results.
This will take you to the Performance tab | Internals Results page for your column, here
you can view Internals results data for the entire Tower when you use Column Analysis.
Aspen HYSYS will calculate the dimensions of the column using preset and user-defined
values for the column internals and for other various parameters. The results are
presented on the Results tab. HYSYS estimates the total pressure drop over the section
and the maximum pressure drop per tray.
The Number of Flow Paths corresponds to the number of times liquid crosses the tray.
Most trays are single-pass, or have an NFP of 1. The Maximum downcomer Backup
represents the maximum amount of liquid hold-up in the downcomer that can be tolerated
by the column before flooding occurs. The Maximum Weir Loading measures the
amount of liquid flowing over the weir.
QUESTION: What is the required section diameter? [Write your answer below]
5 - 18
QUESTION: What is the section height? [Write your answer below]
QUESTION: What is the section pressure drop? [Write your answer below]
47. Save your case as 02-AdvColumns-Sizing.hsc.
You will now notice that for the Deethanizer column, a blue icon appears to the left of the
column indicating that this column with internals specified has no errors.
You are now going to perform a simple exercise to evaluate some different tray options in
the Deethanizer column.
Follow the steps on the next page to perform these tray rating calculations.
48. You can use the Internals Manager to create and analyze multiple Internals
configurations within the same HYSYS simulation.
49. To access the Internals Manager: From the Column Design ribbon tab, click
the Internals Manager button.
5 - 19
50. Click the Add button to Internals-2 configuration.
51. Then select the Auto Section button to add a new configuration option and
column description as Auto Section- Based on Feed/Draw Locations.
By using this option, HYSYS automatically creates column sections based on feed and
draw locations or internal flow rates.
52. Click the Based on Feed/Draw Locations option.
HYSYS uses the following logic to auto section the column:

HYSYS starts Section 1 from the top tray.
The Stage Number is increased by 1 until a Feed, Product, Pump Around
Draw, or Pump Around Return is encountered.
o If a Feed or Pump Around Return is encountered at Stage M, HYSYS
ends Section 1 at Stage M-1 and starts Section 2 at Stage M.
o If a Product or Pump Around Draw is encountered at Stage M, HYSYS
ends Section 1 at Stage M and starts Section 2 at Stage M+1.
HYSYS repeats the same logic until the bottom tray is reached. If there is no
reboiler, this is the Nth stage. Otherwise, it is the (N - 1)th stage.
5 - 20
QUESTION: How many column sections are created? [Write your answer below]
53. Change the Downcomer Clearance to 58.80 mm (2 in) for both column sections
and decrease the Hole Area To Active Area ratio to 0.06 for CS-2.
54. Move to the Results Tab | Summary page to check the Design calculation results
QUESTION: What are the section pressure drops? And what are the required section
diameters? [Write your answer below]
The other type of calculation you can perform using the Column Analysis is a Rating
calculation. In the Rating mode, Aspen HYSYS allows you to perform column hydraulic
calculations based on a specified tower diameter and fixed tray configuration.
Assume you have the following options available for following two internals
configuration:
Diameter, Internals Type No. of Flow Downcomer

m (ft) Paths Clearance
2.541(8.34) Sieve Tray 1 58.8 mm (2 in)
2.541(8.34) Sieve Tray 3 58.8 mm (2 in)
Note: Make sure the Hole Area To Active Area ratio is set to 0.06.
55. Click the Add button to create another internals (Internals-3) configuration and
column description as Rating-Number of Passes-1.
56. Select the Add New option and cchange the Mode to Rating and Number of
Passes to 1.
5 - 21
57. Click the Add button to create another internals configuration in the Internals
Manager and column description as Rating-Number of Passes-3. Then, select
the Add New option.
58. Change the Mode to Rating and Number of Passes to 3.
59. Make sure below highlighted inputs are given.
5 - 22
Note: Make sure you edit the Side Downcomer Width to 300mm, if not you will have a
warning showing Input Incomplete.
60. Once the inputs are in place, view the Results Tab | Summary tab and click the
View Warnings… button.
QUESTION: Compare the results of both the ratings configurations. If low delta P is
preferred and you wish to avoid other hydraulic concerns, which option (internals
configuration) looks to be better? [Write your answer below]
61. Save your case as 02-AdvColumns-Rating.hsc
Task 5 – Build the Spreadsheet

With complete access to all process variables, the Spreadsheet is a very powerful tool in
Aspen HYSYS. The power of the Spreadsheet can be fully realized by the addition of
formulae, functions, logical operators, and basic programming statements.
The Spreadsheet’s ability to import and export variables means that seamless transfer of
data between the Simulation Environment and the Spreadsheet is a simple matter. Any
changes in the Simulation Environment are immediately reflected in the Spreadsheet, and
vice-versa.
The Spreadsheet has several common applications. For example, the Spreadsheet can
collect key inputs and results between flowsheet objects, include known relationships in
the model (for example, relate the pressure drop in a Heat Exchanger to the flow rate) and
perform mathematical operations using variables from the simulation.
Any variable in the simulation can be imported into the Spreadsheet. There are three
ways of doing this: Drag and drop, Variable browsing and using the Connections page on
the Spreadsheet.
To Drag and Drop, position the cursor over the desired item and then click and
hold the left mouse button. Move the cursor over to the Spreadsheet. When the
cursor is over the Spreadsheet, the cursor’s appearance will change to a target.
Release the left mouse button when the target cursor is over the desired cell. The
specific information about the imported variable will appear in the Current Cell
group.
A variable may also be imported into the Spreadsheet by placing the cursor on an
empty cell in the Spreadsheet and clicking (and releasing) the right mouse button.
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Choose Import Variable from the list, and select the variable using the Variable
Navigator.
Another option is through the Connections Page. On the Connections page, click
the Add Import button and select the desired variable using the Variable
Navigator. After selecting the variable, choose the desired cell from the drop-
down list.
Exporting variables from the Spreadsheet into the Simulation environment is also a
simple procedure. The methods for doing this are very similar to the ones for importing
variables. Notice that the contents of any Spreadsheet cell can only be exported to any
specifiable (blue) variable on the simulation.
In this module, a Spreadsheet to calculate a simple profit margin will be added to the
Turbo Expander/Fractionation plant.
62. Add a Spreadsheet to the main flowsheet from the Object Palette.
63. Double-click the Spreadsheet icon on your flowsheet and view the Connections
tab. Rename the spreadsheet Profit Analysis.
64. Select the Parameters tab and enter 15 for the Number of Rows. Your
Spreadsheet will be a bit larger in size than the default.
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65. Move to the Spreadsheet tab and add the following text labels:
66. Import the following variables into the cells listed.
Cell Flowsheet Object Variable Description

B1 Main 2 Temperature
B2 Main 5 Pressure
B4 Mixed Refrig Unit Comp-HP Power
B5 Main QK-102 Power
B6 Demethanizer Pump-HP Power
B9 Main Inlet Sep Water Mass Flow
D1 Main 12 Std Gas Flow
D2 Main 13 Std Ideal Liq Vol Flow
D13 Main QK-100 Power
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Note: You can import these variables using any method you prefer. You can right-click
on the listed cell and choose Import Variable, drag-and-drop the numeric value in from
its source window to the Spreadsheet cell, or search for the variable from the
Connections tab of the Spreadsheet.
67. Define the Power Cost (cell B11) as 0.1 and the Water Disposal Cost (cell B12)
as 0.14. These two values are considered unit less.
68. Enter the following formulas into your Spreadsheet:
In this Cell... Enter...

B7 =B4+B5+B6
B14 =(B7*B11)+(B9*B12)
D4 =6.5*@SQRT(D1)
D5 =1.1*(D2^1.5)
D7 =D4+D5
D9 =D7-B14
The Spreadsheet should now look like this:
The only cells remaining to be completed are D11 and D14. These will be used to
calculate the temperature of the refrigerant in the Mixed Refrig Unit sub-flowsheet and
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apply a power loss in the transfer of power from the Turbo Expander to the compressor
K-101
69. Add a formula in cell D11 calculating a result temperature which is 5 °C less than
the Chiller exit temperature (cell B1).
70. Return to the flowsheet and enter the Mixed Refrig Unit sub-flowsheet. In the
Mixed Refrig Unit sub-flowsheet, delete the temperature in stream 3.
71. Click the Go to Parent button in the Flowsheet/Modify ribbon tab to return to the
main flowsheet and go back to your Spreadsheet. Export the temperature from
D11 to stream 3 in the Mixed Refrig Unit flowsheet.
72. Return back to the main flowsheet and break the connection between the energy
stream QK-100 and the compressor operation K-101. (Be careful, don’t delete
the energy stream!)
73. Connect a new energy stream QK-101 to the compressor K-101.
74. Return back to the Spreadsheet and enter a formula in cell D14 to calculate the
power transferred to the compressor K-101 as 95% of the power generated by the
Turbo Expander (D13).
75. Export the power value calculated in cell D14 to the new energy stream QK-101.
We have now made the Spreadsheet an integral part of solving the flowsheet. While in
this example we used simple calculations that could also have been done by Set
operations, in general the Spreadsheet provides a powerful tool for introducing custom
calculations into flowsheet models. A single Spreadsheet can also do the job of multiple
Set operations and as a result can be a tidier and easier to approach when multiple
variables must be set.
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Cells can also be named in order to make it easier to access and use them in another unit
op (e.g. an Adjust, Case Study, etc.). This is done either by selecting the cell on the
Spreadsheet tab and typing a name in the Variable field above the Spreadsheet, or on the
Parameters tab of the Spreadsheet operation.
76. Go to the Parameters tab of the Spreadsheet and rename cells B14, D7 and D9 to
Total Costs, Total Revenues, and Profit, respectively.
77. Save your case as 02-Spreadsheet.hsc
With a Chiller outlet temperature of -62 °C (-79.6 °F) and an Expander exit pressure of
2800 kPa (406.1 psia), there should be a profit of about $752.60 per hour.
QUESTION: Change the chiller exit temperature to -60 °C and the expander exit
pressure to 2500 kPa. What is the new profit? [Write your answer below]
The Spreadsheet can be a very useful tool in Aspen HYSYS to pull together important
parameters in the simulation into a single unit operation. Use it to try “what if?” studies
by changing process variables and seeing if your target variables change, and if they
5 - 28
change in the right direction. Additionally, it allows you to perform calculations that are
not possible in Aspen HYSYS directly, such as the profit calculation you have just done.
You can also use it to combine data from process streams, energy streams, or utility
streams and use multiple Spreadsheets to calculate, for example, your total cooling water
requirements or power requirements.
Careful use of Spreadsheets can save you from having to open several windows in Aspen
HYSYS in order to input information or examine results.
You can see that a Spreadsheet can be used to set various parameters in the flowsheet as a
result of a calculation on another variable. So in our flowsheet, the three Set operations
controlling the pressures of streams 8, 9, and 10 could be replaced with a single
Spreadsheet doing the same thing.
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Challenge Exercise
Use the rigorous modeling option available in HYSYS Heat Exchanger operations to
generate a feasible design for the Deethanizer condenser (i.e. the Heat Exchanger you
built during Task 1).
From the Design | Connections (or Design | Parameters) page of the Condenser heat
exchanger, invoke the Rigorous Shell&Tube option to design an exchanger via the EDR
Sizing Console.
Hint: Choose the Interactive Size Rigorous Shell&Tube option to see the EDR Sizing
Console. From there, you can adjust geometry preferences, allowable pressure drops,
and fouling factors to design a new heat exchanger.
Discuss your results when finished.
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Notes:
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Advanced Columns Solutions
Files can be found in folder: 02_AdvancedColumns/Solutions
Questions
Task 1
QUESTION: What is the temperature of Cool In?
-23.83 °C (-10.89 °F)
QUESTION: What is the calculated UA of the Condenser? The LMTD?
UA: 5.327 E+05 kJ/°C-h (2.805 E+05 Btu/°F-hr)

LMTD: 31.36 °C (56.45°F)
Task 2
QUESTION: What is the minimum approach temperature of the Reboiler heat
exchanger?
133.80 °C (240.9 °F)
QUESTION: What is the vapor fraction of the Reboiler Out material stream in the
column sub-flowsheet?
0.5409
Task 3
QUESTION: What is the current molar recovery of ethane in the overhead product?
Ethane in Ovhd: 98.56%
QUESTION: Allow the column to re-calculate. What is the new calculated molar
recovery of ethane in the overhead product?
Ethane in Ovhd: 93.7%
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QUESTION: What happened to your calculated recovery of ethane? Did it decrease or
increase? Why would you expect it to do so?
The calculated recovery decreased. It decreased (thus giving a less pure overhead
product) due to the decrease in stage efficiency. The less efficient stages provide poorer
separation quality; hence the lower calculated recovery of ethane.
Task 4
QUESTION: What is the required section diameter?
2.541m (8.34 ft)
QUESTION: What is the total section height?
9.754m (32 ft)
QUESTION: What is the section pressure drop?
132.4 mbar (53.20 inH2O 60̊F)
QUESTION: How many column sections are created?
2 Sections (1-6 stages and 7-16 stages) were created.
QUESTION: What are the required section diameters? And what are the section pressure
drops?
CS-1: 1.879m (6.165 ft)

CS-2: 2.541m (8.34 ft)
CS-1: 41.0 mbar (16.48 inH2O 60̊F)
CS-2: 89.35 mbar (35.91 inH2O 60̊F)
QUESTION: If low delta P is preferred and you wish to avoid other hydraulic concerns,
which option looks to be best?
Internals-3: 135.1 mbar (54.31 inH2O 60̊F) and Internals-4: 128.9mbar (51.78 inH2O
60̊F)
Internals-4 has the lowest overall pressure drop and is free of any flooding or loading
errors – so it appears to be the best choice.
5 - 33
Task 5
QUESTION: Change the chiller exit temperature to -60 °C and the expander exit
pressure to 2500 kPa. What is the new profit?
802.6 $/hr
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Model an Acid Gas Cleaning Process
Workshop
Files can be found in folder: 03_AcidGas
Objective
In this workshop, you will simulate the effect of adding monoethanolamine (MEA) to
Methyl diethanolamine (MDEA) based gas treatment process to effectively remove H2S
to a concentration of 3:1 ppm and CO2 to a concentration of 0.6% (by mole) in the sales
gas. Also, you will configure a Liquid-Liquid Extractor to determine how much MDEA is
required to achieve a desired H2S content in an LPG stream.
Task 1 – Review the gas-liquid acid gas treating process using MDEA and add
MEAmine component.
Task 2 – Run a Case Study to determine the effect of adding MEA
Task 3 – Configure a Liquid-Liquid Extractor
Task 1 – Review the gas-liquid acid gas treating process

using MDEA and add MEA.
1. Open the 03-AcidGasStarter.hsc from the workshop folder.
In this example, a traditional gas-liquid acid gas treating process using MDEA as a
chemical solvent at high pressure to remove H2S and CO2 from sour gas is being
modeled. 10 MMSCFD of acid gas feed (2.5 mol% H2S and 5 mol% CO2) is fed to a high
pressure absorber (800 psig), where the acid gases are removed to a sales gas
specification of < 4 ppm H2S. Acid gases are stripped from amine by a regenerator
column at low pressure (7.3 psig) and high temperature (245F) from the MDEA solvent,
which is recycled with makeup back to the absorber column.
QUESTION: What are the CO2 (mol %) and H2S (ppm) compositions in the Sweet Gas
Stream? [Write your answer below]
7-1
2. Navigate to the Properties Environment. Check which Acid Gas property
method is being used and the list of components added.
In this case, the Acid Gas – Chemical Solvents is being it used. The Acid Gas -
Chemical Solvents property package for these models was developed with the Peng-
Robinson equation-of-state for vapor phase and the electrolyte non-random two-liquid
(eNRTL) activity coefficient model for electrolyte thermodynamics (Song and Chen,
2009). The property package contains the eNRTL model parameters and other transport
property model parameters identified from regression of extensive thermodynamic and
physical property data for aqueous amine solutions (Zhang and Chen, 2011; Zhang et al.,
2011). The package also rigorously accounts for chemistries of the aqueous amine
solutions.
The models support thermodynamic and rate-based process modeling of acid gases (CO2
and H2S) removed by major amine solvents such as MDEA, activated MDEA, DEA,
7-2
MEA, DGA, etc. The related contaminants such as heat stable salts, light mercaptans,
carbonyl sulfide, and carbon disulfide are also accounted for. Furthermore, the models
support modeling of inert gases, light hydrocarbon components, and petroleum pseudo
components. Validated with lab, pilot, or plant data, reaction rate expressions are also
incorporated to properly model non-instantaneous reactions.
Reference papers citations are available in the help menu (F1).
3. Move to the Component Lists folder to review the component list.
4. Add MEAmine to the existing component list.
5. Select the Reactions folder in the HYSYS Navigation Pane. You should be able
to review three reaction sets.
6. All required input for the Properties Environment has now been provided, so click
the Simulation button to enter the Simulation Environment.
7-3
Select No for the above message.
7. Save your case as 03-AcidGasFluidPackage.hsc.
Once you move to the simulation environment in Active mode, the flowsheet will not
converge. The reason is because the MEAmine concentration is not yet defined.
Task 2 – Run a Case Study to determine the effect of

adding MEA
In this portion of the workshop, you will be studying the effect of adding MEA.
7-4
8. Add a Concentration of 0% for MEAmine in the Makeup Block and allow the
flowsheet to converge.
Stream? [Write your answer below]
We will now create the Case Study for determining the effect of adding MEAmine. The
Case Study tool lets you monitor the steady state response of key variables to changes in
your process. From a list of all variables in the flowsheet, you pick the independent and
dependent variables for each case study. The Case Study utility can easily manage
hundreds of independent and dependent variables and allows you to add and re-order
numerous variables simultaneously.
9. To add a case study, either select Case Studies from the Simulation Environment
navigation pane or on the Home ribbon tab, in the Analysis group, click Case
Studies.
7-5
10. On the Case Studies form, click the Add button.
11. To perform variable selection for your case study, on the Case Study form, select
the Variables Selection tab.
7-6
12. In the Independent Variables section, click the Find Variables button.
The Variable Navigator view appears, allowing you to select from the
following Input variables.
Independent Variables
Surge Tank – Outlet Concentrations (MDEAmine)
Surge Tank – Outlet Concentrations (MEAmine)
Surge Tank – Total Outlet Volume Flow
13. Select the desired Input variables, and then click Done.
14. In the Dependent Variables section, click the Find Variables button.
The Variable Navigator view appears, allowing you to select from the
following Output variables.
Dependent Variables
Absorber – Sweet Results (SWEETGAS-H2S Composition (ppm))
Absorber – Sweet Results (SWEETGAS-CO2 Composition (Mole %))
Absorber – Lean Amine Results (LEANIN-H2S Composition (ppm))
Absorber – Lean Amine Results (LEANIN-CO2 Composition (Mole %))
Absorber – Rich Amine Results (RICHOUT-H2S Composition (ppm))
Absorber – Rich Amine Results (RICHOUT-CO2 Composition (Mole %))
Regen Bottoms – H2S Loading
Regen Bottoms – CO2 Composition (Mole %)
7-7
15. After selecting the desired Output variables, and click Done.
16. You could also go to the Performance|Acid Gas page of the Absorber and right
click LEANIN-H2S Composition (ppm), select Send To-Case Study-Case
Study1. This procedure can be followed for other absorber results (Rich Amine).
Alternately, you can Drag and drop variables from the flowsheet. If the variable is
an Input variable, it will appear in the Independent Variables table. If the variable is
an Output variable, it will appear in the Dependent Variables table.
7-8
17. Once you have added the independent and dependent variables your Case Study
Form should look like below.
Click to move the selected variable up or to move the selected variable down
to rearrange your variables.
18. On the Case Study Setup tab of the Case Study form, from the Case Study Type
drop-down list, you can select one of the following types:
Sensitivity: An isolated variable study which examines one variable at a time.

Nested: Examines every possible combination of variable changes.
Discrete: Allows you to specify the values of each variable for each case that you
want to run.
Base & Shift: Lets you set a number of base cases and shifts off of the base cases.
7-9
19. For this case, you will select “Discrete” Case Study Type with 5 States with the
following specifications:
– Vary the MDEAmine Concentration from 45% to 35% in equal

increments
– Vary the MEAmine Concentration from 0% to 10% in equal increments
– Ensure each case maintains total amine summing to 45%
– Keep amine stream flow rate at 100 USGPM
20. Run the Case Study. Visualize and analyze the results.
21. You can use the Results tab of the Case Study form to view the case study
results.
Select the Transpose results check box to view the cases as rows and the variables as
columns. Click the Send to Excel button to save your results in a .csv format for
further analysis in Excel.
22. On the Plots tab of the Case Study form, you can view case study plots. The plots
that appear vary depending on your selection from the Case Study drop-down list
on the Case Study Setup tab.
23. Save your case as 03-AcidGasCaseStudy.hsc.
QUESTION: What happened to the sweet gas H2S and CO2 concentrations in the sweet
gas? [Write your answer below]
7 - 10
QUESTION: What do you observe about the rich amine coming off the absorber and the
lean amine loading off the regenerator? [Write your answer below]
QUESTION: What have you learned about amine selection, mixed amines, and their
effect on the process? [Write your answer below]
Task 3 – Configure a Liquid-Liquid Extractor

In this part of the workshop, you will determine how much MDEA is required to achieve
a desired H2S content in an LPG stream.
24. Open a new Aspen HYSYS case and navigate to the Properties Environment.
25. Add an “Acid Gas – Liquid Treating” property package.
26. Add all the required components with MDEAmine and the following components.
7 - 11
27. Return to the Simulation Environment in “Active” mode.
28. Add a new material stream to the flowsheet titled “Rich LPG”. Your LPG feed
typically comes into the plant at 249 kgmole/hr (549 lbmole/hr), 37.78 ̊C
(100 ̊F), 3447 KPa (500 psia) with the following average composition (mole
fraction). (Normalize composition if required)
Methane 0.00932
Ethane 0.02797
Propane 0.83000
i-Butane 0.00933
n-Butane 0.00933
n-Pentane 0.00102
n-hHexane 0.00093
CO2 0.01865
H2S 0.09345
7 - 12
29. Add a “Liquid-Liquid Extractor” unit op from the object palette to the
flowsheet
30. Attach a “Lean Amine” stream and “Rich LPG” stream as inlets
31. Add a “Lean LPG” stream and “Rich Amine” stream as outlets and specify 20
stages.
32. Specify 3427 KPa (497 psia) as Top Stage Pressure, 3447 KPa (500 psia) as
Bottom Stage Pressure.
7 - 13
33. For an initial design, assume you have capacity to bring a “Lean Amine” stream
in at 54.44 ̊C (130 ̊F), 3427 KPa (497 psia), 1992 kgmole/hr (40 MMSCFD),
with a set 0.0015 mole fraction of H2S
34. Start with a 0.2 mole fraction MDEAmine and 0.7985 mole fraction H2O
35. Return to the Extractor column and click Run to solve the column.
QUESTION: What is the concentration of H2S (ppm) in the Lean LPG Product? [Write
your answer below]
36. Put the column on hold and reset the column for testing at which concentration of
MDEAmine is H2S around 10 ppm in the Lean LPG Product.
7 - 14
If you get the above Fatal Error message. Go to the Column, Reset and Run.
QUESTION: What is the mole fraction of MDEAmine for this H2S (ppm)? [Write your
answer below]
37. Save your case as 03-AcidGasLLE.hsc.
Recommended Reading
CBT: Getting Started With Acid Gas Cleaning in Aspen HYSYS V8.3

Enhancements to Acid Gas Cleaning in Aspen HYSYS

Acid Gas Cleaning using a Physical Solvent (DEPG)
7 - 15
Notes:
7 - 16
Model an Acid Gas Cleaning Process
Solutions
Files can be found in folder: 03_AcidGas/Solutions
Questions
Task 1
Stream?
0.5840 mol%
3.121 ppm
Task 2
Stream?
0.5840 mol%
3.121 ppm
QUESTION: What happened to the sweet gas H2S and CO2 concentrations in the sweet
gas?
H2S concentration decreased and CO2 concentration increased.
QUESTION: What do you observe about the rich amine coming off the absorber and the
lean amine loading off the regenerator?
H2S concentration decreased and CO2 concentration increased in the rich amine coming
off the adsorber.
H2S Loading decreased.
QUESTION: What have you learned about amine selection, mixed amines, and their
effect on the process?
Try different concentrations of MDEA and MEA in the outlet stream of the Makeup
Block and re run the simulation.
7 - 17
Task 3
QUESTION: What is the concentration of H2S (ppm) in the Lean LPG Product?
5.268 ppm
QUESTION: What is the mole fraction of MDEAmine for this H2S (ppm) in the Lean
LPG Product?
For 9.5 ppm H2S in Lean LNG achievable. Lean Amine concentrations (at 40 MMSCFD
total):
0.11 mole fraction MDEAmine (~ 45 % by mass)
0.8885 mole fraction H2O
0.0015 mole fraction H2S
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Build a Sulfur Recovery Unit
Files can be found in folder: 04_Sulfur Recovery Unit
Objective
In both the refining and midstream industries, recovery of sulfur from oil & gas streams
is an essential and growing process. The Sulfur Recovery process produces elemental
sulfur from gaseous hydrogen sulfide removed from sour natural gas and from the
byproduct gases containing H2S derived from refining crude oil and other industrial
processes. H2S can originate in gas treatment units in refineries and natural gas plants,
sour water stripping facilities, and coal gasification and syngas plants. Since H2S is
harmful to the environment, extremely flammable, and can dissolve in petroleum
products and degrade quality, sulfur removal is a highly important process.
In this workshop, you will build a Sulfur Recovery Unit (3 Stage Claus Process). The 3
Stage Claus Process consists of one thermal stage (Furnace, Waste Heat Exchanger, and
Sulfur Condenser), and three catalytic stages (Reheater, Catalytic Converter, and Sulfur
Condenser) to remove elemental sulfur from an acid gas. You will learn to set up the
Sulsim property package, configure the thermal and catalytic stages in the Sulfur
recovery process and optimize the recovery process.
Task 1 – Set up Sulfur Recovery Property Package

Task 2 – Configure the Thermal Stage
Task 3 – Configure the Catalytic Stages
Task 4 – Configure the 2nd and 3rd Catalytic Stages
Task 5 – Review the Performance and Optimize the Furnace Air Flow
Task 1 – Set up Sulsim Fluid Package

Modified Claus Process is the most common method of processing H2S containing
streams and producing sulfur. In V9, Sulsim technology (created by Sulphur Experts) is
integrated within HYSYS and this simulates the Modified Claus Process from beginning
to end by incorporating industry knowledge and data to recover elemental sulfur from
gaseous H2S, COS, CS2, and SO2.
Sulsim integration includes a new Sulsim (Sulfur Recovery) property package. When
you add a Sulsim (Sulfur Recovery) property package to your simulation, the
component list will automatically include the required components and supported
9-1
components, allowing you to easily integrate your sulfur recovery simulation with other
gas processes.
In this portion of the workshop, you will add the Sulsim property package and create feed
streams for the Sulfur Recovery process.
1. Create a new HYSYS case.
2. Select Add to add a new a fluid package.
3. From the property packages selection, select Sulsim (Sulfur Recovery) method.
9-2
4. HYSYS creates a compatible component list with full set of required and
supported components. It also features new sulfur components: S1 through S8 and
Liquid Sulfur.
9-3
5. Enter the Simulation Environment and add a Sulfur Recovery Unit from the
object palette to the flowsheet.
6. Select ‘Start With a Blank Flowsheet’.
7. Open the SRU-1 form and explore the options. Then enter the ‘Sub-Flowsheet
Environment’.
9-4
Note the options on the Sulfur Recovery Unit ribbon tab and become familiar with
the various unit ops and combinations available.
8. Add an “Acid Gas” material stream inside the Sulsim sub-flowsheet with the
following specifications.
– Temperature: 95 ̊F
– Pressure: 10 psig
– Molar Flow: 2.008 MMSCFD
– Composition by mole: 24.2% CO2, 75% H2S, 0.5% Methane, 0.2%
Ethane, 0.1% Propane
9. Add an “Air to Furnace” material stream with the following specifications.
9-5
– Temperature: 122 ̊F
– Pressure: 10 psig
– Molar Flow: 3.75 MMSCFD
– Composition by mole: 78.09% N2, 20.95% O2, 0.93% Ar, 0.03% CO2
10. Save your case as 04-SulsimFluidPackage.hsc
Task 2 – Configure the Thermal Stage

The first step in the sulfur recovery process is the thermal stage where 60-70% of sulfur
is produced in this stage of an SRU. In this stage, H2S is partially oxidized with air in the
reaction furnace at a high temperature. Two-thirds of the H2S reacts to sulfur; some H2S
remains unreacted, and some SO2 is produced.
The thermal stage includes all front-end process units, excluding the initial train source
gas and inlet feed stream junctions. A standard SRU has a single thermal stage composed
of the following three units:
Reaction Furnace
Waste Heat Exchanger
Sulfur Condenser (optional)
Additionally, the front-end of the process can include:
A Tee (for split-flow or recycle configuration)

Heaters, Coolers, or additional Inlet Streams
11. Add a “Single Chamber Reaction Furnace” unit op to the flowsheet using the
palette.
9-6
12. Configure the “FUR-100” unit by double-clicking and navigating through the
various tabs on the form.
13. Connect the “Acid Gas” and “Air to Furnace” streams and add a “Furnace
Effluent” outlet gas stream. The unit op should converge.
The Empirical furnace model uses proprietary empirical relationships developed by

Sulphur Experts based on hundreds of sulfur plant test results to predict the unit
conversion efficiency, as well as quantities of COS, CS2, H2, CO, and H2S at the outlet.
The H2S and CO2 content of the furnace feeds have a significant effect on the net
reactions in the furnace. However, many of the minor components (hydrocarbon, NH3)
will also influence the extent of various side reactions and the resulting concentration of
the key minor species, including H2, CO, COS and CS2.
The main sulfur products from the furnace are SO2 and Sx vapor; COS and CS2 are
typically produced in smaller quantities. The Empirical Reaction Furnace carries out
combustion reactions according the model selected and performs Free Energy
Minimization to calculate the product composition.
Although many factors influence the design and configuration of the Claus plant, the
concentration of H2S in the acid gas feed to the furnace is the largest contributor.
Typical configuration for various concentrations of H2S in feed is shown in the following
table. For more detailed information check in F1 help menu.
9-7
Case H2S in Acid Gas Configuration
(mol %)
Rich Feed 50-100 Straight-Through
Lean Feed 20-50 Split-Flow
Lean Feed 10-20 Split-Flow with Preheat of Feed

Streams
Very Lean < 10 Sulfur Recycle
Feed
Very Lean <5 Direct Oxidation
Feed
NH3 50-100 Straight-Through w/ NH3
Destruction burning configuration
14. The Acid Gas inlet has a high concentration of H2S. So, select a “Straight
Through Amine Acid Gas” empirical model from the model drop-down list oin
the Design| Parameters page (if not already selected) and specify a pressure drop
of ~ 3 kPa (0.4 psig).
QUESTION: What is the Air Demand %? [Write your answer below]
Next, the Waste Heat Exchanger (WHE) is placed after the Reaction Furnace. It is
sometimes referred to as the "Waste Heat Boiler." The Waste Heat Exchanger cools hot
gas from the furnace outlet, generating steam. Some liquid sulfur may be recovered,
depending on operating conditions. The Single-Pass Waste Heat Exchanger includes an
inlet stream, an outlet stream for cooled vapor, and a second outlet stream for when liquid
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sulfur is produced. You can also opt to use a Double-Pass Waste Heat Exchanger which
is used when a Hot Gas Bypass stream is present for your Waste Heat Exchanger.
Here, we will add a single pass waste heat exchanger.
15. Press F12, and then select Waste Heat Exchanger (Single Pass) or from the
model palette, select the icon.
16. Configure the “WHE-100” unit by connecting the “Furnace Effluent” stream as
Inlet Gas stream.
17. Add “WHE Outlet Gas”, “WHE Liquid Sulfur Outlet”, and “WHE Energy”
outlet streams.
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18. Specify an outlet temperature (WHE Outlet Gas stream) as 300°C (570°F) on the
Design | Parameters page.
By default, the Allow simulation of back-reactions in the WHE check box is selected;
you can clear it if desired. Various reactions occur in a typical Waste Heat Exchanger.
These reactions include H2+S re-association reactions and CO + S reactions. Select
this check box to use empirical models (originally created by Sulphur Experts) which
predict the extent of these reactions for your simulation.
Next, the Sulfur Condenser will be added to complete configuring the thermal stage. It
removes elemental sulfur vapor produced in reactors by condensing it to liquid phase.
The Sulfur Condenser performs a flash calculation and a sulfur equilibration on all of
the sulfur species. The inlet stream is re-equilibrated at a temperature and pressure
desired, and the resulting sulfur liquid is removed to the extent required.
In the Sulfur Condenser, sulfur is recovered for each reactor set and these condensers
typically operate between 130 - 150 °C.
19. To add a Sulfur Condenser, press F12, and then select Sulfur Condenser or from
the model palette, select the icon.
20. Configure the “COND-100” unit by connecting the “WHE Outlet Gas” as Inlet
Gas stream.
21. Add “COND100 Gas Outlet”, “COND100 Liquid Sulfur Outlet”, and
“COND100 Energy” outlet streams.
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22. Specify an outlet temperature (COND100 Gas Outlet) as 135°C (275°F) on the
Design | Parameters page.
QUESTION: How much percent of liquid sulfur is recovered from the thermal stage
condenser? [Write your answer below]
Hint: Click the “Performance” tab on the COND-100 to check the recovery.
23. Save your case as 04-SulsimThermalStage.hsc
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Task 3 – Configure the Catalytic Stage
Catalytic stages normally appear in the process after an initial thermal stage. The catalytic
recovery of sulfur consists of three steps; Heating, Catalytic reaction, with decreasing
temperature over each reactor and Cooling plus condensation.
The following catalytic reaction occurs:
2 H2S + SO2 → 3 S + 2 H2O
These three steps are normally repeated a maximum of three times. When an incineration
or tail-gas treatment unit (TGTU) is added downstream of the Claus plant, typically only
two catalytic stages are usually installed.
A typical sulfur recovery sub-flowsheet may contain between one and four catalytic
stages composed of the following units:
Heater or Direct Fired Heater (or Mixer, in some cases)

A series of catalytic converters (between two and four, depending on desired
recovery)
Catalytic Converter, Sub-Dew point Catalytic Converter, and/or Selective
Oxidation Converter
Sulfur Condenser
Let’s begin by adding the first simple unit of the catalytic stage, the Heater.
24. Add a “Heater” unit operation to the flowsheet from the object palette.
25. Connect the “COND100 Gas Outlet” as Inlet and add “E100 Energy” stream
and an “E100 Gas Outlet” stream.
26. Specify an outlet temperature (E100 Gas Outlet stream) of 270 ̊C and Delta P of
0.4 psi on the Design | Parameters page.
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Next, we will add the Catalytic Converter which is the central component of a catalytic
stage and provides sulfur conversion downstream of the reaction furnace.
HYSYS performs an isenthalpic, Free Energy Minimization calculation based on the

inlet materials and inlet temperature at the outlet pressure.
The stream CO, H2, NH3 HCN, mercaptans, and hydrocarbons are constrained from
reacting. The extent of the H2S/SO2 reaction (deactivation) is controlled through input
of a desired percent approach to equilibrium. CS2 and COS hydrolysis are predicted
using empirical data, with consideration of the inlet materials and the temperature of the
reaction. You can edit calculated values to simulate any desired extent of hydrolysis.
27. Add a “Catalytic Converter” unit to the flowsheet. Press F12, and then select
Catalytic Converter or from the model palette, select the icon.
28. Connect the “E100 Gas Outlet” as Inlet and then add “CONV100 Effluent” as
Outlet Gas.
29. Ensure Alumina Catalyst is selected and that 100% H2S/SO2 equilibrium is
reached on the Design | Parameters page.
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Only the H2S/SO2 reaction value must be specified in order for the Catalytic Converter
to solve. You can adjust the values in the Approach to equilibrium (%) of section.
Type the percentage approach to equilibrium to specify the extent of the H2S/SO2
(modified-Claus) reaction in the converter. This value controls the simulation of
catalyst deactivation in the unit. When the Catalytic Converter is not solved, the default
value is 100%, which simulates completely active catalyst with a 100% approach to
equilibrium. If you specify a value lower than 100%, HYSYS simulates deactivated
catalyst with a less than 100% approach to equilibrium.
Next, the Sulfur Condenser will be added to complete configuring the catalytic stage.
The Sulfur Condenser is generally considered mandatory in the catalytic stage and is an
optional part of the thermal stage.
30. Add a “Condenser” unit op to the flowsheet and then connect the “CONV100
Effluent” as the inlet stream.
31. Then add “COND101 Gas Outlet”, “COND101 Liquid Sulfur Outlet”, and
“COND101 Energy” outlet streams.
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32. Specify a temperature of 135°C (275°F) for the “COND100 Gas Outlet” and a
Delta P of 0.4 psi on the Design | Parameters page.
QUESTION: How much percent of liquid sulfur is recovered from this 1st stage
33. Save your case as 04-SulsimCatalyticStage1.hsc
Task 4 – Configure the 2nd and 3rd Catalytic Stage

In this task, we will add 2nd and 3rd catalytic sections to the flowsheet. We will add the 2nd
stage by using the “Combinations” group option. “Combinations” are available for rapid
flowsheet building and can be added using either the palette or the Sulfur Recovery Unit
ribbon.
34. Add a catalytic section to the flowsheet by navigating to the “Combinations” tab
on the palette or on the ribbon.
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35. Delete “Stream 1” to the “E-101” heater and replace with the “COND101 Gas
Outlet” stream.
36. Configure the “E-101” unit by specifying a pressure drop of 3 kPa (0.4 psi) and
an outlet temperature of 220°C (430°F).
37. Next, configure the “CONV-101” unit by choosing Titania as the catalyst on the
Design | Parameters page. Then specify space velocity of 1000 hr-1 on the
Rating Tab.
38. Configure the “COND-102” unit by specifying a gas outlet temperature (stream
“4”) of 135°C (275°F).
QUESTION: How much percent of liquid sulfur is recovered from this 2nd stage
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Next, we will add the 3rd catalytic stage.
40. Start by adding a “Direct Fired Heater” to the flowsheet by selecting icon
from the model palette or press F12, and then select Direct Fired Heater.
41. Then connect stream “4” (the outlet gas from “COND-102”) as the inlet gas.
The Direct Fired Heater burns a fuel gas stream and an air stream to heat a feed
stream.
42. Using the material stream option on the palette, add a “Fuel Gas” stream to the
flowsheet and specify the stream with 100% methane at 275 kPag (40 psig) and
15°C (60°F) and an estimated initial flow rate of 2 kgmole/hr (4.40 lbmole/hr).
43. Connect this “Fuel Gas” stream to “DFH-100” as the fuel gas stream.
44. Add a new material stream to the flowsheet and name it “DFH Air”.
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45. Use the “Define From Other Stream” option to clone the stream conditions from
“Air to Furnace”. Do not specify the flow rate at this time.
46. Connect the “DFH Air” stream to “DFH-100” as the Air Stream.
47. Add a DFH outlet gas stream titled “DFH Effluent”.
You will notice that DFH Air stream flow is calculated.
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QUESTION: What is the DFH Effluent temperature? [Write your answer below]
48. Let us target the DFH Effluent temperature at 150°C (302 °F) as it is a bit high at
~ 305°C (581.76 °F).
49. In order to target that temperature spec. Add an “Adjust” block to the flowsheet,
and specify the following:
50. Specify a minimum of 0.1 kgmole/hr (0.22046 lbmole/hr) and a maximum of 5

kgmole/hr (11.023 lbmole/hr) on the Parameters tab. The unit op should iterate
and solve
QUESTION: What is Fuel Gas flow rate now? [Write your answer below]
In this final catalytic stage, the Selective Oxidation Converter will be added. It uses a
selective oxidation catalyst and, if present, usually appears in the final catalytic stage.
The Selective Oxidation Converter is used in the Jacobs SUPERCLAUS selective
oxidation process. It is a simple conversion reactor in which the following reactions
occur:
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2 H2S + O2 2 S + 2 H2O
2 H2S + 3 O2 2 SO2 + 2 H2O
One can specify conversion and selectivity. The Selective Oxidation Converter
requires an additional air feed. Normally, only one Selective Oxidation Converter
appears in a SRU train.
The reaction is implemented based upon the conversion specification

(the Conversion (H2S reacted) field on the Parameters tab), the Selectivity
(reacted H2S to S) field on the Parameters tab (percentage of H2S converted to
elemental sulfur), and a measure of air flow into the unit.
51. Add a “Selective Oxidation Converter” to the flowsheet, by selecting icon

from the model palette.
52. Attach “DFH Effluent” as the inlet gas stream.
53. Create a new air stream named “CONV102 Air” and define stream conditions
from “Air to Furnace”.
54. Do not specify a flow rate and attach this stream as the Air stream.
55. Add an outlet stream titled “CONV102 Effluent”.
56. In the “CONV-102” unit op form, specify an “Approximate O2 at outlet”

concentration of 0.5 mol% on the Design | Parameters page.
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One can specify the percentage of the total available H2S that is reacted in the bed in
the Conversion (H2S reacted) field. (The default value is 98%) and specify the
percentage of the total H2S that is converted to elemental sulfur in the Selectivity
(reacted H2S to S) field. (The default value is 90%). The remainder is converted to
SO2.
One can either specify the Approximate O2 at outlet on this page or specify an air
rate on the Air Stream inlet property view. Due to Free Energy Minimization (FEM),
this can only be an approximation without additional looping. To achieve a precise
O2 outlet concentration, you can use an Adjust operation.
57. To complete this stage, add a “Condenser” to the flowsheet.
58. Connect the “CONV102 Effluent” stream as the inlet.
59. Add “COND103 Gas Outlet”, “COND103 Liquid Sulfur Outlet”

and “COND103 Energy” streams to “COND-103”.
60. Specify a gas outlet temperature of 135°C (275°F) on the Design | Parameters
page.
QUESTION: How much percent of liquid sulfur is recovered from this 3rd stage
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Task 5 – Review the Performance and Optimize the
Furnace Air Flow
In this task, you will review the overall performance of the Sulfur Recovery Unit
configured and optimize the Furnace Air Flow using the Air Demand Analyzer.
62. Click the “Performance Summary” button on the Sulfur Recovery Unit ribbon
to check overall performance.
63. Save your case as 04-SulsimPerformance.hsc
QUESTION: Which units are performing well? [Write your answer below]
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QUESTION: Which units may require some optimization? [Write your answer below]
Say, you are the Claus Plant process engineer and are tasked with improving the sulfur
recovery of your plant. You recognize that the air flow rate to the furnace is not
optimized and may be a major factor as to why your sulfur recovery is lower than it
should be. You want to use HYSYS to determine a more ideal air demand.
To determine a more ideal air demand we will use the “Air Demand Analyzer
(ADA)”. The Air Demand Analyzer controls the air flow to a single upstream
Reaction Furnace. It adjusts the air flow into a Reaction Furnace and performs
Iterative calculations to meet your specifications.
64. Open the “FUR-100” form and note the current air demand (-11.3%)
65. Add an “ADA” to the flowsheet from the palette and open the ADA form.
The Air Demand Analyzer should be connected to a stream and a reaction furnace.
66. Select the outlet from the 3rd condenser as your sample stream (stream “4”) and
target an Air Demand of 0% (ideal stoichiometric ratio of 1:2 SO2:H2S). Select
reaction furnace (FUR-100)
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67. Complete the required inputs on the “Parameters” tab:
• Increase maximum iterations to 100
• Set minimum value of 2 MMSCFD
• Set maximum value of 5 MMSCFD
68. The solver should start automatically and should converge.
69. Click the “Performance Summary” button on the Sulfur Recovery Unit ribbon
to check overall performance improvement.
QUESTION: How did the overall performance improve? [Write your answer below]
70. Save your case as 04-SulsimADA.hsc
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Challenge Exercise
You are the Claus Plant process engineer and are tasked with improving the
conversion efficiency of your plant. You recognize that the dew point temperature
margin on one of your catalytic converters is quite high. Having a positive dew point
margin is beneficial to ensure liquid sulfur is not laid down on the catalyst, but is not
ideal to achieve maximum conversion. You want to use HYSYS to determine how
much your conversion efficiency would increase at a dew point margin of 10C.
1. Check the dew point margin on CONV-101 (32C) in the Sulsim-ADA.hsc
2. Add an Adjust block to the flowsheet from the palette and open the Adjust form
Select an adjusted variable by filtering by “Stream”, selecting an Object of “2”
and selecting a Variable of “Temperature.”
Select a target variable by filtering by “UnitOps”, selecting an Object of “CONV-
101” and selecting a Variable of “Outlet Sulfur Dew point Margin”
Specify a target dew point margin of 10C
3. Complete the required inputs in the “Parameters” tab:

Increase the maximum number of iterations to 100, and increase the step size to
20C
Set a maximum value of 100C, and set a minimum value of 250C
Specify a tolerance of 0.1C
4. The solver should start automatically and should converge.

Navigate to the “Monitor” tab to track progress.
Notice the solver is adjusting the converter inlet temperature to meet the targeted
dew point margin.
The conversion efficiency has increased from 56.67% to 60.49% by decreasing
2nd converter temperature.
QUESTION: Did the overall performance improve? [Write your answer below]
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Notes:
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Sulsim Solutions
Files can be found in folder: 04_Sulsim/Solutions
Questions
Task 2
QUESTION: What is the Air Demand %?
-11.31%
QUESTION: How much percent of liquid sulfur is recovered from the thermal stage
condenser?
S Recovery Efficiency [%] = 99.75%
Task 3
QUESTION: How much percent of liquid sulfur is recovered from this stage condenser?
Task 4
QUESTION: How much percent of liquid sulfur is recovered from this stage condenser?
QUESTION: What is the DFH Effluent temperature?
305.4 ̊C (581.7 ̊C)
QUESTION: What is Fuel Gas flow rate now?
0.1606 kgmole/hr (0.3541 lbmole/hr)
QUESTION: How much percent of liquid sulfur is recovered from this 3rd stage
condenser?
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Task 5
QUESTION: Which units are performing well?
Thermal, CONV-100 and CONV-101
QUESTION: Which units may require some optimization? [Write your answer below]
CONV-102
QUESTION: How did the overall performance improve? [Write your answer below]
The S Recovery Efficiency % increased from 78.67% to 89.23% for CONV-102.
Challenge Exercise
Check overall performance improvement
Increased recovery efficiency from 95.78% to 98.71% with two simple optimizations.
9 - 28

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Model Real Separators Workshop
Files can be found in folder: 05_RealSeparators
Objective
In this workshop, you will review the options for including non-ideal separation
calculations in a given process design problem. The two options studied are a direct
specification of multi-phase carryover from a separator, and the calculation of the
carryover based on vessel geometry and inlet conditions using provided correlations.
The workshop will also explore how to model an exit device to mitigate carryover of
liquids in the vapor phase product from a separator.
The Aspen HYSYS Separator unit operation assumes perfect phase separation by default.
But it can also be configured to model imperfect separation by using the ability to specify
or calculate phase carryover.
The real separator calculation ability includes carryover options so that your model better
matches your process mass balance or separator design specifications. When correlation
based approaches are invoked, it also predicts the effect residence time, vessel volume,
nozzle characteristics, and exit devices on phase separation.
In this workshop, you will review the concepts needed to use these real separator
features. We will focus on using the Aspen HYSYS Real Separator capabilities to model
imperfect separation in a 3-phase oil-water-gas separator. This workshop also includes
an exercise where a demister pad is added to the model as a secondary separation device
to reduce liquid carryover into a vapor product.
Task 1 – Specifying Carryover Effects

Task 2 – Using Carryover Correlations
Task 3 – Adding a Secondary Separation Device
Task 1 – Specifying Carryover Effects

In real world separators, separation is not perfect: liquid can become entrained in the gas
phase and each liquid phase may include entrained gas or entrained droplets of the other
11 - 1
liquid phase. In many cases, the vessel internals (i.e. mesh pads, vane packs, weirs, etc.)
are applied to reduce the carryover of entrained liquids or gases.
The Aspen HYSYS separator unit operations allow the user to directly specify what
fraction of each feed phase is entrained in other phases. Product-based specifications are
also allowed. These options provide simple methods that can be used to match your
HYSYS simulation results to your design assumptions, a known material balance, or to
field data from a real separator.
You will begin by looking at phase separation and carryover in the Inlet Sep separator in
your workshop simulation. The Inlet Sep separator is a HYSYS 3-Phase Separator
operation, thus producing distinct vapor, oil/organic, and water/aqueous product streams.
This workshop will study the separation taking place in this vessel and explore the
downstream effects of the separation. You’ll begin by assuming a specified phase
carryover.
1. To begin the workshop, open the case 05-RealSeparatorsStarter.hsc. It should

be available in your course files folder provided by your instructor.
2. View the main flowsheet and double-click the Inlet Sep separator.
3. Navigate to the Worksheet tab and check the default separation results.
QUESTION: What is the vapor fraction of the Inlet Sep Vap stream? Is there any
liquid phase (organic or aqueous) flow in the vapor? [Write your answer below]
Recall again that separator operations in HYSYS operate under an assumption of perfect
equilibrium separation by default. This means that no assumption of volume or residence
time is made. The separator will always produce pure vapor, light liquid and heavy liquid
products.
Let us say that we know (from a plant mass balance or from a design assumption) that
approximately 1800 kg/h of light liquid (condensate/oil) and 300 kg/h of heavy liquid
(water) is entrained in the vapor product stream. We will specify this in our model and
ensure an accurate mass balance.
4. Select the Rating tab, C.Over Setup form for Inlet Sep separator.
Note: You’ll see that the Carry Over Model selected by default is the ‘None’ option. This
indicates no carryover is assumed and perfect separation will result.
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5. Select Product Basis as the active model and select the Flow radio button to
define the carryover by flow rate.
There will be warning related to Column feed stream, just click ok.
6. Change the basis to Mass and enter the following flow rates:
Light liquid in gas 1800 kg/h (3968 lb/hr)
Heavy liquid in gas 300 kg/h (661 lb/hr)
7. Select the Rating | C.Over Results form. This form will show fraction and
flow based carryover results around the separator.
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QUESTION: What is the vapor fraction of the Inlet Sep Vap material stream now?
8. Save your case as 05-RealSeparatorsSpec.hsc.
Task 2 – Using the Carryover Correlations

As an alternative to defining imperfect separation amounts, Aspen HYSYS allows gas
and liquid carryover to be calculated by using three different correlations. These
correlations are the Generic, the Horizontal Vessel, and the Profes ProSeparator models.
All the three correlations follow the same basic calculation sequence; first, the program
calculates the initial phase dispersion based on the feed flow through an inlet nozzle. All
three methods assume the inlet dispersion follows a Rossin Rammler distribution.
After this inlet dispersion is calculated, the correlations calculate the carryover after the
primary separation (gravity settling) of each phase in every other phase, i.e. the light
liquid entrained in the vapor, the heavy liquid entrained in the vapor, the vapor entrained
in the light liquid, the vapor entrained in the heavy liquid, the light liquid entrained in the
heavy liquid, and the heavy liquid entrained in the light liquid.
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Finally, based on the separation extent from the previous step, the program calculates the
effect of any installed secondary separation device (e.g., demister pads or vanes) on the
liquid carryover into the vapor product. This is only available in to the Horizontal and
Profes ProSeparator correlations.
The Generic Correlation should be used when your only criterion for separation is
specifying a critical droplet size. Inlet phase dispersion is calculated using a generic
method that ignores the vessel geometry. The user specifies inlet splits and Rossin
Rammler parameters, which are used to calculate the inlet dispersion. Carryover is
calculated by assuming that all liquid droplets smaller than a user-specified critical
droplet size are carried over into the vapor product.
The Horizontal Vessel Correlations are designed with the horizontal 3-phase separator
in mind. Inlet phase dispersion is calculated using inlet device efficiency (rather than
specified splits) and user-supplied Rossin Rammler parameters. Primary separation has
two contributions: Gas-Liquid and Liquid-Liquid. Gas-Liquid separation is calculated
based on settling velocities of each liquid from the gas and from a residence time of gas
in the liquid. Basically a droplet will be carried over if it does not travel far enough (back
to its parent bulk phase) in the time allowed. The Liquid-Liquid separation is calculated
in a similar way.
The Profes ProSeparator correlations are rigorous but are limited to calculating liquid
carryover into gas. Both light and heavy liquid entrainment is calculated, but no
carryover calculations are done for gas in the liquid phases. Inlet phase dispersion is
calculated based on the inlet flow conditions and the inlet nozzle size. ProSeparator
calculates its own Rossin Rammler parameters using this information, while the primary
separation is based on critical droplet size. The critical droplet size is not user-specified,
but calculated using gas velocity through the vessel.
Rossin Rammler distributions are defined by:

F = exp(–d/dm)z)
Where:
F = fraction of droplets larger than d
dm is related to d95
x = RR index
d95 = 95% of droplets are smaller than this diameter for the specified dispersion
RR Index = exponent used in the RR equation (also known as the “spread parameter”)
Real Separators in Aspen HYSYS
If desired, the user can select a different correlation for each of the calculation steps. If
that was the case, a correlation is specified for each sub-calculation, rather than
specifying an overall correlation. Only those parts of the correlation that apply to the
particular sub-calculation will be used. In this exercise, sub-calculations will not be used.
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You’ll explore the Profes ProSeparator correlation via the Inlet Sep separator in your
flowsheet.
9. Return to the main flowsheet of your simulation and double-click the Inlet Sep
separator.
10. Navigate to the Rating | C.Over Setup form and choose the Correlation Based
option.
11. Select the Profes ProSeparator correlation as the Overall Correlation.
12. Click the View Correlation button for further customize the correlation-based
approach.
In this case, the Setup | Inlet page can be left as is. The ProSeparator correlations will
calculate the inlet dispersion without the need for further information.
We will not initially have an Exit Device on this separator. That being the case, go to the
Setup | Vap. Exit Device page. Select Mesh Pad and enter a Pad Thickness of 0.0.
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13. Close the Correlation window and return to the Rating | C.Over Setup form.
Now that a correlation has been identified and its preferences/options defined, you can
move on to provide the dimensions and other details of your vessel.
14. Select the Dimensions Setup radio button.
You’ll be entering the dimensions of an available separator vessel that your vendor has
can provide. The goal of the study will be to see if this vessel is compatible with your
overall process.
15. Make sure the Vessel Orientation is set as Horizontal, and enter the vessel
dimensions as follows: Length = 5.486 m (18 ft), Diameter = 1.524 m (5.0 ft),
and Light liquid level = 0.762 m (2.5 ft).
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You can keep the default Boot sizing information and leave all other inputs empty. Move
on by clicking on the DP / Nozzle Setup radio button.
16. Enter the following values for the Nozzle Location (i.e. the horizontal distance
from the feed location):
Feed Mix 0 m (0 ft)
Inlet Sep Vap 5.029 m (16.5 ft)
Inlet Sep Liq 5.486 m (18 ft)
Inlet Sep Water 4.267 m (14 ft)
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17. Keep the default values for Nozzle Diameter and Height.
18. Review the results on the Worksheet tab.
QUESTION: What is the vapor fraction of the Inlet Sep Vap stream? [Write your
answer below]
19. Select the Rating tab and click the C.Over Results page. This form presents
total flows or fractions of phase carryover with little detail.
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20. Click the View Dispersion Results button to view the carryover details
21. Save your case as 05-RealSeparatorsCorr.hsc.

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Task 3 – Adding a Secondary Separation Device
While the separator studied in the previous task seems to work well enough, your heat
exchanger designer is a bit concerned. The LNG-100 LNG Exchanger brings in the Inlet
Sep Vap stream as its hot side inlet. Based on your correlation-based real separator
calculations a significant flow of liquid droplets will feed into the exchanger. It’s these
droplets and their effects at high velocity that your exchanger designer is concerned
about.
You need to look into using some king of secondary separation device (i.e. mesh pad,
vane pack, etc.) to try and knock out these liquid droplets. Your target is to remove 99%
of all liquid droplets 50-55 microns (0.05-0.055 mm) in diameter.
22. Open the Rating tab on the Inlet Sep separator and select the C.Over Setup
page.
23. Select the Correlation Setup radio button and click the View Correlation
button.
24. Go to the Setup | Vap. Exit Device page and make sure Mesh Pad is selected.
Enter a Pad thickness of 100.0 mm (4 in).
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25. Review the effect of the mesh pad on the droplet sizes by clicking the View
Dispersion Results button on the Rating | C.Over Results page.
QUESTION: What is the mass flow of the 50-55 micron droplets? Are any larger
droplets present? [Write your answer below]
26. Go back to the Rating | C.Over Setup form. To check the efficiency of the
mesh pad separation device, you can get more direct results by viewing the
correlation.
27. Click the View Correlation button.
28. Select the Results | Exit Dev. Eff’cy form.
QUESTION: Does the 100 mm (4 inch) mesh pad remove at least 99% of the 50-55
micron droplets? [Write your answer below]
29. Save your case as 05-RealSeparatorsMesh.hsc.
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Recommended Reading
Real Separator User Guide: How to model carry over in separators?

Three-phase separator horizontal correlation enhanced in Aspen HYSYS V7.3.1 with
variable feed nozzle location.
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Notes:
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Modeling Real Separators
Solutions
Files can be found in folder: 05_RealSeparators/Solutions
Questions
Task 1
QUESTION: What is the vapor fraction of the Inlet Sep Vap stream? Is there any liquid
phase (organic or aqueous) flow in the vapor?
Vapor fraction = 1.0; No, there are no liquids in the Inlet Sep Vap stream
QUESTION: View the Inlet Sep Vap material stream. What is the vapor fraction of this
stream now?
0.9779
Task 2
QUESTION: What is the vapor fraction in the Inlet Sep Vap stream?
0.9711
Task 3
QUESTION: What is the mass flow of the 50-55 micron droplets? Are any larger
droplets present?
0.946 kg/h (2.086 lb/hr); Yes, ~64 micron droplets are also present at 0.237 kg/h (0.524
lb/hr)
QUESTION: Does the 100 mm (4 inch) mesh pad remove at least 99% of the 50-55
micron droplets?
Yes, the separation efficiency is 0.9992

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Dynamic Depressuring Workshop
Files can be found in folder: 06_DynDepressuring
Objective
In this workshop, you will review the Depressuring Analysis tool in Aspen HYSYS. The
Depressuring Analysis can be applied to both relief and blowdown type calculations.
Valve sizing and rating may both be considered as well.
Aspen HYSYS includes a feature to model the pressure let-down of a vessel. It uses the
rigorous dynamic solver from Aspen HYSYS Dynamics within a steady-state HYSYS
simulation. This feature can be configured with various valve models and heat transfer
scenarios. It also has the flexibility to consider valve sizing and rating calculations for
either emergency/fire scenarios or vessel blowdowns. This feature has proven extremely
useful and approachable as no additional knowledge of HYSYS Dynamics is required to
use it.
In this workshop, you will review how to use the Depressuring Analysis tool in Aspen
HYSYS for both valve rating and valve sizing.
Task 1 – Size a Blowdown Valve

Task 2 – Rate a PSV for a Fire Case
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Task 1 – Size a Blowdown Valve
The Inlet Sep 3-phase separator in your main flowsheet has been targeted for some
additional study. First off, you need to size an appropriate blowdown valve for the
vessel. In the case of plant shutdown or routine maintenance it will be imperative to de-
pressurize the vessel to atmospheric conditions within 20 minutes. You’ve been tasked
with calculating a valve flow coefficient (Cv) appropriate for this situation. You’ll then
pass this Cv on to your valve vendor for selection.
1. Continue with the HYSYS case file from the previous workshop (it should be
05-RealSeparatorsMesh.hsc).
2. Click on the Blowdown and Depressuring button on the Home view of the
ribbon to open the Depressuring Manager.
3. Click the pull-down arrow next to the Add button and select Depressuring
Utility to create a Depressuring Analysis.
4. Name it Inlet Sep BD.
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5. Click the Open button to display the Inlet Sep BD Depressuring Analysis
window.
The Depressuring Analysis window serves as the interface for all your required input data
into the Depressuring calculation. Recall that HYSYS creates a sub-flowsheet upon
initiation of the Depressuring calculation. This sub-flowsheet is where the actual
dynamic Depressuring calculations occur. As a convenience, the Depressuring Analysis
window accepts all required inputs, displays key results, and allows for more thorough
studies via Strip Charts. Thanks to this Depressuring Analysis window, you don’t need
to be a HYSYS Dynamics expert to use the Dynamic Depressuring Analysis! Begin by
populating the required input for the blowdown valve sizing calculation.
6. Select Feed Mix as the Inlet stream on the Design | Connections page.
Note: If you receive a message related to the usage of Fluid Packages in your
Depressuring Analysis template that is created, simply click OK. This message just tells
you that your template /sub-flowsheet being added for the Analysis will use the same
Fluid Package that’s being applied to the parent flowsheet.
7. Select the Horizontal radio button as this is a horizontally configured separator.
8. Delete the Flat End Vessel Volume value. This will allow you to directly
define the vessel linear dimensions.
9. Enter the Inlet Sep vessel dimensions (Height & Diameter) used in the Real
Separators workshop.
Hint: The Height is 18 ft and the Diameter is 5 ft!
10. Keep the default Initial Liquid Volume as this should ensure approximately a
50% initial liquid volume within the vessel.
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The next step is to configure the heat flux into and out of the Depressuring system. Since
this first task involves a vessel blowdown, no additional heat input (for example, from a
fire) will be considered. Heat loss/gain with the environment can also be considered in
the Depressuring Analysis, but you won’t study this until after you perform your initial
valve sizing calculation.
11. Move to the Design | Heat Transfer page and make sure the Operating Mode is
set to Adiabatic.
12. Select None as the Heat Loss Model.
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13. Click on the Design | Valve Parameters page and accept the default of
Universal Gas Sizing for the Vapour Flow Equation. For more information on
which equation to use please click on Valve Equation Help button.
14. Enter 35 USGPM as an initial Cv estimate.
15. Enter 50.0 for the valve % Opening.
16. Keep all other items at their defaults:
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17. Select the Design | Options page and enter a PV Work Term Contribution of
90%.
18. Go to the Design | Operating Conditions page and choose the Calculate Cv
Option.
19. Enter a Depressuring Time of 20 minutes.
20. Enter a Final Pressure of 102 kPa (14.8 psia).
Note: Recall the objective of the calculation is to blowdown the vessel to atmospheric
pressure. HYSYS will not allow us to enter 101.3 kPa (14.696 psia) as the Final Pressure
as this is the backpressure on the system; the final pressure must be greater than the
backpressure. To get around this you’re defining a final pressure slightly higher than
atmospheric.
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21. Leave all other values at their defaults:
22. The Depressuring Analysis should now be ready to calculate. Click the Run
button.
Once the calculation finishes (allow a few moments for all the iterations to complete),
view the Performance | Summary page to check your results.
Note: The graph window that appears when you calculate is known as a Strip Chart. It
displays various model variables as time passes in the Depressuring calculation. You
can just close this default Strip Chart as it has too many variables to monitor. You’ll
create your own in the next task.
QUESTION: What is the calculated Vapour Cv? [Write your answer below]
QUESTION: What is the final temperature of liquid in the vessel? [Write your answer
below]
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QUESTION: What is the peak vapor phase flow rate through the valve? [Write your
answer below]
23. Save your case as 06-Blowdown.hsc.
As was previously mentioned, the effects of heat loss/gain with the environment need to
be studied. The HYSYS Depressuring Analysis has two heat loss models that can be
invoked to predict the effects of the environment on a depressuring case: a simplified
model and a more detailed model. We’ll explore the influence of these two models on
the vessel blowdown considering a very cold ambient condition for the vessel.
Record the following results from the blowdown valve sizing calculation you just
performed. You’ll compare them with your results with the Heat Loss Models activated.
Final Liquid Phase Final Vapor Phase Peak Flow Through

Settings
Vessel Fluid Temp. Valve Outlet Temp. Valve
Heat Loss = None
24. Return to the Design | Operating Conditions page and click the Calculate
Pressure radio button. Keep your calculated Cv value.
25. Select the Design | Heat Transfer page and change the Heat Loss Model to
Simple.
26. Change the Ambient Temperature to -40 °C (-40 °F).
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27. Click the Run button to re-calculate.
Record your results with the Simple Heat Loss Model in the table below:
Final Liquid Phase Final Vapor Phase Valve Peak Flow Through
Settings
Vessel Fluid Temp. Outlet Temp. Valve
Heat Loss =
Simple
28. Return back to the Design | Heat Transfer page and change the Heat Loss
Model to Detailed.
29. Leave all other values at their defaults:
30. Enter a Metal Thickness of 9.525 mm (0.375 in) and leave all other Metal and
Insulation inputs at their defaults.
Note: These default heat transfer items are not modified in this workshop for simplicity.
However they are all available for modification to better fit your actual equipment in
your own calculations.
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31. Click the Run button to re-calculate.
Record your results with the Detailed Heat Loss Model in the table below:
Settings
Heat Loss =
Detailed
32. Save your case as 06-BDHeatLoss.hsc.
Task 2 – Rate a PSV for a Fire Case

The Inlet Sep will require some overpressure protection in the case of some kind of plant
fire or other emergency. The HYSYS Depressuring Analysis can support Heat Flux
calculations based on a variety of Fire Case scenarios. You’ll utilize API 521 RP
calculations to test different relief valve orifice sizes to see which are able to relieve the
Inlet Sep should they be needed.
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33. Return to the Home tab in the HYSYS ribbon and double click on the
Blowdown and Depressuring icon; this should re-open the Depressuring
Manager.
34. Click the pull-down arrow next to the Add button and select Depressuring to
create a new Depressuring Analysis.
35. Name the new analysis Inlet Sep Fire.
36. Click on the Open button to open the Inlet Sep Fire Depressuring Analysis
window.
37. Set up the Design | Connection page with the following inputs:
Design | Connections
Inlets Feed Mix
Orientation Horizontal
Height 5.486 m (18 ft)
Diameter 1.524 m (5 ft)
All others… Leave at their defaults
38. Move to the Design | Heat Transfer page and set the Operating Mode to Fire
API521, selecting Transient Liquid Level for the Wetted Area
39. Set the C3 parameter equal to 1.0 which is used in:
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To take into account the Wetted Area inside the Depressuring Analysis while modeling a
Fire API521there are three options:
Calculated: HYSYS calculates the wetted area as per API521 at the start of
the simulation.
User Specified: You calculate the wetted area for use in the Fire API521
equation and type this value in the Wetted Area field.
Transient Liquid Level: HYSYS calculates the wetted area as per API521 at
each time step. The wetted area changes with time based on the current Liquid
Level
40. Ensure the Heat Loss Model is set to None.
41. Select the Design | Valve Parameters page and select Relief for the Vapour
Flow Equation.
42. Enter an Orifice Diameter of 6 mm (0.2362 in) and a Discharge Coefficient of

1.
43. Define a Set Pressure of 3801 kPa (551.3 psia) and a Full Open Pressure of
4001 kPa (580.3 psia).
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44. Click the Design | Options form and set the PV Work Term Contribution to
90%.
45. Go to the Design | Operating Conditions page make sure the Calculate
Pressure option is selected. Enter a Depressuring Time of 2 hours.
The Depressuring Analysis uses a general HYSYS Valve operation as default for the
pressure relief. Therefore, after we select the Relief flow equation, we need to initialize
the analysis so it can create a relief valve within the sub-flowsheet it uses for the
depressuring calculations. To do so, you need to run the Depressuring Analysis and after
a couple seconds, stop the calculation. At that point, you can enter the Depressuring
Analysis sub-flowsheet and enter additional parameters into the relief valve unit
operation, thus more closely modeling an actual relief valve.
46. Click the Run button at the bottom of the Depressuring Analysis window to
start the calculations. Then after one or two seconds, click Stop.
47. Return to the main flowsheet view and locate the sub-flowsheet icon titled Inlet
Sep Fire (Flowsheet). Double-click this sub-flowsheet icon.
48. Click the Sub-Flowsheet Environment button to view the sub-flowsheet itself.
49. Double-click on the VapourReliefValve.
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50. Go to the Dynamics | Specs page and check the box labeled Enable Valve
Hysteresis.
51. Set the relief valve Closing Pressure as 3601 kPa (522.3 psia) and the
Reseating Pressure as 3551 kPa (515.1 psia).
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52. Click the Go to Parent button in the Flowsheet/Modify tab of the ribbon to
return to the main flowsheet.
To help see what is happening with the Inlet Sep system as it undergoes the Fire Case
calculations, it is useful to create a view that monitors key variables as a function of time.
The Performance | Summary page you used for results reporting in the blowdown
calculation was useful for some results, but it didn’t really give any indication of what
happened during the depressuring calculation.
To monitor conditions over time, Aspen HYSYS uses a feature known as a Strip Chart.
Strip Charts can be built with any selection of model variables that you would like to
view. Before running the Fire Case calculation, create a Strip Chart to track the key data.
53. View the Inlet Sep Fire Depressuring Analysis.
54. Click the Create Strip Chart button on the Design | Config. Strip Charts
page.
55. Type in Inlet Sep Fire as the Logger Name.
56. Click the Add Variable button at the bottom of the window.
57. Select the Mass Flow rate through the relief valve as shown below:
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When finished, you may click either the Select buttons.
58. Repeat this process to add the following variables listed below:
Object Variable
Vessel @TPL3 Vessel Temperature
Vessel @TPL3 Vessel Pressure
Vessel @TPL3 Liquid Mass
VapourReliefValve @TPL3 Percentage open
VapourReliefValve @TPL3 Full Open Pressure
VapourReliefValve @TPL3 Set Pressure
VapourReliefValve @TPL3 Closing Pressure
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59. Click the View Strip Chart button to show the strip chart window.
60. Right-click the graph background and select Graph Control. Here you can set
the colors and style of the curves to make the plot easier to follow and read.
Note: Change the background color from the General tab (just click the pull-down button
on the color tile and choose a new color). Change the colors and styles of the plot lines
on the Curves tab.
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61. Select General tab of the Graph Control window, click the Set-up Logger
button. Set the Logger Size to 8000 and the Sample Interval to 1.0 sec to
ensure the plot captures all the relevant data.
62. Return to the Inlet Sep Fire Depressuring Analysis window and click the Run
button. Follow the run through your Strip Chart you created.
63. Save your case as 06-Fire.hsc.
Your objective now is to find a relief valve size so that under the Fire Case scenario the
pressure in the vessel never exceeds the fully open pressure of the valve, which is 4001
kPa (580.3 psia). At present, Aspen HYSYS cannot do this automatically, so the valve
orifice diameter has to be manually changed until the pressure objective is met. To
monitor this, position the windows so you can see the Strip Chart you just created and
also the Design | Valve Parameters page of the Depressuring Analysis. This will allow
you to change the valve orifice diameter and monitor the pressure profile in the vessel.
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QUESTION: Evaluate a valve with an Orifice Diameter of 8 mm (0.315 in). Does this
satisfy the pressure requirement? [Write your answer below]
If it does not, try successively larger orifice diameters (i.e. 10 mm, 12 mm, etc.). If you
can’t find a valve that keeps the vessel pressure below the valve full open pressure, check
with your instructor!
When an appropriate valve size is found, complete the table below:
Result Value
Orifice diameter (mm)
Max flow through valve
Max opening of PSV
Final vapor temperature at valve outlet
Max pressure reached
Time for valve to start opening
Time to reach max opening
Time till valve begins closing
64. Save your case.
Recommended Reading
On the Modeling of Vessel Depr670essuring

What are the differences among heat transfer models available in the dynamic
depressuring utility?

Vessel Depressuring in HYSYS Dynamics.
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Notes:
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Dynamic Depressuring
Solutions
Files can be found in folder: 06_DynDepressuring/Solutions
Questions
Task 1
QUESTION: What is the calculated Vapour Cv?
76.4 USGPM (60F, 1psi)
QUESTION: What is the final temperature of liquid in the vessel?
-18.24 °C (-0.8296 °F)
QUESTION: What is the peak vapor phase flow rate through the valve?
1.604 E+04 kg/h (3.357 E+04 lb/hr)
Record the following results from the blowdown valve sizing calculation you just
performed. You’ll compare them with your results with the Heat Loss Models activated.
Final Liquid Phase Final Vapor Phase Peak Flow Through

Settings
Vessel Fluid Temp. Valve Outlet Temp. Valve
1.604 E+04 kg/h

Heat Loss = None -18.24 °C (-0.8374 °F) -18.30 °C (-0.9466 °F)
(3.357 E+04 lb/hr)
Record your results with the Simple Heat Loss Model in the table below:
Settings
Heat Loss = 1.604 E+04 kg/h

-19.63 °C (-3.336 °F) -19.71 °C (-3.486 °F)
Simple (3.357 E+04 lb/hr)
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Record your results with the Detailed Heat Loss Model in the table below:
Settings
Heat Loss = 1.604 E+04 kg/h

-16.33 °C (2.601 °F) -16.40 °C (2.472 °F)
Detailed (3.357 E+04 lb/hr)
Task 2
QUESTION: Evaluate a valve with an Orifice Diameter of 8 mm (0.315 in). Does this
satisfy the pressure requirement?
Yes – the maximum Vessel Pressure is about 3930 kPa while the Vapour Relief Valve
Set Pressure is 4001 kPa
When an appropriate valve size is found, complete the table below:
Result Value
Orifice diameter (mm) 8 mm
Max flow through valve 1704 kg/hr (3782 lb/hr)
Max opening of PSV 80.27 %
Final vapor temperature at valve outlet 169.9 °C (337.6 °F)
Max pressure reached in vessel 3930 kPa (570 psia)
Time for valve to start opening About 3 min
Time to reach max opening About 63.46 min
Time till valve begins closing About 64.63 min
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Blowdown Workshop
Files can be found in folder: 07_Blowdown
Significant challenges arise in the process industry to reduce the capital cost of pressure
relief systems while still ensuring the required safety standards. Simulation is widely used
during the design and revamp of pressure relief systems; therefore, accurate models are
required. Although conservative approaches are often desirable for safety considerations,
uncertainties and inaccuracies can lead to gross overdesign.
The BLOWDOWN software program developed by Professor Stephen Richardson of

Imperial College London and Dr. Graham Saville formerly of Imperial College London
was acquired by AspenTech on March 12, 2015. BLOWDOWN has been used in
hundreds of studies in oil and gas and chemical companies to identify locations in a
system where temperatures can decline dramatically during depressurization.
BLOWDOWN has been incorporated into Aspen HYSYS V9.0 in order to provide an
accurate determination of these low temperatures, which is a critical activity in the design
and operation of every process plant as it can reduce capital cost but more importantly
improve the safety of the plant.
Objective
In this workshop, you will be introduced to the BLOWDOWN depressuring utility
workflow and learn how to use this tool for a designing an orifice for pool fire
depressurization scenario and for cold case depressurization.
Task 1 – Design an orifice for pool fire depressurization scenario

Task 2 – Design for cold case depressurization scenario
Task 1 – Design an orifice for pool fire depressurization

scenario
The Inlet Sep 3-phase separator in your main flowsheet has been targeted for some
additional study. First off, you need to size an appropriate blowdown valve for pool fire
depressurization scenario.
The BLOWDOWN Analysis flowsheet functions similarly to a HYSYS subflowsheet.

However, unlike a traditional HYSYS subflowsheet, you cannot add stream connections
between the BLOWDOWN subflowsheet PFD and the main PFD. Also, the
BLOWDOWN subflowsheet environment does not use traditional HYSYS solvers.
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1. Open 07-BlowdownStarter.hsc file.
The property package and calculations used to simulate the depressurization system in the
BLOWDOWN Analysis tool is proprietary and distinct from the main PFD simulation; it
is not available in the Properties environment.
2. To add a BLOWDOWN unit, from the Home ribbon tab, under the Safety
Analysis group, click the BLOWDOWN and Depressuring button and from on
the Depressuring form, click Add | BLOWDOWN Utility. The BLOWDOWN
Analysis form appears.
Alternatively, from the Home ribbon tab, from the Safety Analysis group, click the arrow
next to the BLOWDOWN and Depressuring button, and then click BLOWDOWN. The
BLOWDOWN Analysis form appears.
3. On the BLOWDOWN Analysis form, edit the Name of the BLOWDOWN unit to
Fire Case. Then, from the Template drop-down list, select the SingleVessel.blo -
Single Vessel BLOWDOWN Template.
This template is a pre-configured template which sets up the geometry and connections
on the BLOWDOWN flowsheet for a single vessel with piping. For details about this
prebuilt template F1 Help menu has the information.
Note:
The button lets you import BLOWDOWN templates from the Support site
and aspenONE Exchange.
4. Click the Start Analysis button.
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5. On the Design tab of the BLOWDOWN Analysis form, you can set up the layout
of the unit operations in the simulation to fit the actual process equipment layout.
6. On this form you will select an appropriate Inlet Line, Blowdown Line and
Vapor Outlet Line configuration.
7. For the Inlet Line, select “Without pocket” option. Which implies that all liquid
within the inlet line segments will drains towards the main vessel.
8. For the Blowdown Line, select “Attached to Vessel” option, implying that the
Blowdown Line is attached directly at the top of the vessel.
9. For the Vapor Outlet Line, select “Leaves Vessel vertically”, indicating that the
initial orientation of the vapor outlet line is vertical.
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Next, the Number of Segments in Each Line will be specified. The rows in the
Number of Segments in Lines table change depending on the Inlet Line, Blowdown
Line, and Vapor Outlet Line configurations selected.
10. In this case, we are modeling a single vessel without piping so set all of the line
segments to 0.
You can define a maximum of five pipe segments on each line; these inputs are used to
capture pipe diameter or metallurgy changes that can occur along the line. We
recommend that you add the fewest possible additional piping segments. The goal is to
try to capture accurately the volume, surface area, and holdup in the equipment upstream
of the orifice. Therefore, only add additional piping segments if there is a significant
change in piping diameter or metallurgy along the line. Otherwise, one piping segment
per required line is sufficient for the analysis. There is no pressure drop modeled
upstream of the orifice.
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Next, on the System tab, you will specify equipment, fluid, and ambient information for
all BLOWDOWN unit operations at the same time.
11. Start by specifying Template Parameters which will apply to the entire template.
12. In the Ambient Air Properties section, specify the Air Temperature
(Temperature of ambient conditions) as 21 ̊C (70 ̊F) and Air Speed (Speed of air)
as 2.438 m/s (8 ft/s).
Note: These values apply to all unit operations on your BLOWDOWN subflowsheet.
13. For now you won’t specify Equipment Conditions Upstream of Orifice. These
will be updated from a HYSYS stream that will be linked in the Initial
Inventory section.
Next, you must define the initial inventory in the system at time zero. In the Single
Vessel template, you can specify the inventory of the Main Vessel.
14. Expand Initial Inventory | Main Vessel, on the left-hand side of the System tab.
The composition used in the BLOWDOWN Analysis can be defined either manually, by
linking to a stream on the flowsheet, or by copying and pasting from a stream on the
flowsheet. In this we will choose the Manual option.
15. Select the Manual radio button, then click the Copy from Stream button.
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16. Select the Feed_Mix_Fire_RP stream, on the Select Process Stream dialog box
and then click OK. HYSYS copies the composition of the selected stream.
Feed_Mix_Fire_RP stream has been created with the same composition as Feed Mix
stream but at relieving conditions. (Considering a Design Pressure = 500psig so the
Relieving Pressure will be 1.21*500psig= 605psig)
17. Click the Copy to Initial Conditions button. This button overwrites the Initial
Temperature and Initial Pressure values in the Equipment Conditions
Upstream of Orifice table in the Template Parameters section.
Now the Template Parameters section will have the icon indicating that you have
specified all of the inputs necessary for the BLOWDOWN run to begin.
Next, you must specify the Vessel Information.
18. Select Vessels in the left-hand pane to specify vessel information on the
Geometry, Heat Transfer and Initial Conditions tabs.
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19. On the Geometry tab provide the following geometry specifications.
Orientation Vertical
Tan-tan 5.486 m (18.0 ft)
Cylinder Inner Diameter 1.524 m (5.0 ft)
Wall Material Carbon Steel
Cylinder Wall Thickness 25.40mm (1.0 in)
Head Wall Thickness 25.40mm (1.0 in)
Min Design Metal -20.0 ̊C (-4 ̊F)

Temperature
Max Design Metal 648.9 ̊C (1200 ̊F)
Temperature
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20. Check the “In Fire Zone?” box and make sure Apply to liquid is selected as the
Fire Heat Flux Method,on the Heat Transfer tab. (In this method, the heat is
applied directly to the liquid inside the equipment).
F1 Help menu has details about the equation used by this method
21. On the Initial Conditions tab, specify the Initial Liq. Volume Percent (%) as
50% which is the percentage of total volume that is filled by the liquid at the
beginning of the blowdown event.
Next, you must specify the Restriction Orifice Information.
22. For the Restriction Orifice geometry information, provide an orifice Diameter of
12.70 mm (0.50 in) and Discharge Coefficient of 1.0.
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Once all of the icons appear as , you can move on to the Mapping tab. Make sure
component mapping is successful.
Next, you must specify the Halt Conditions. BLOWDOWN can solve and show results
over any time range with second-by-second reporting of events.
You can control the solver’s behavior. On the Run Controls tab, you can define the
simulation time intervals and conditions.
23. Select the Run Controls tab of the BLOWDOWN Analysis form.
24. In the Halt Conditions group, type a halt time of 900 Seconds and halt pressure
of 14.70 psia. When you run your simulation, once the simulation reaches one of
these conditions, it will stop.
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Now the Blowdown case has all the necessary inputs for it to be run.
25. To run the BLOWDOWN simulation, either click the Run button from
the BLOWDOWN ribbon tab | Run group.
26. Or on the BLOWDOWN Analysis form, click the Run BLOWDOWN button
on the bottom of the form.
27. When the BLOWDOWN simulation is finished, a message appears in the status
bar, indicating that the simulation run is complete.
28. On the Results Summary tab of the BLOWDOWN Analysis form, you can
review overall system plots and key results or warnings from the simulation.
29. On the Results Summary tab | Major Findings page of the BLOWDOWN
Analysis form, you can view major findings from your BLOWDOWN
simulation.
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30. On the Results Summary tab | Plots page of the BLOWDOWN Analysis form,
you can view BLOWDOWN results in a graphical format.
QUESTION: What is the Vessel Pressure at the final Halt Time? [Write your answer
below]
QUESTION: What is the Orifice Mass flow rate at the final Halt Time? [Write your
answer below]
31. Save your case as 07-FireCase.hsc
Next, the restriction orifice can be designed in BLOWDOWN using the Adjust unit
operation on the main flowsheet.
32. After fully defining the BLOWDOWN Analysis and running the case.
33. Ensure that the simulation always ends at Halt Time rather than at the Halt
Pressure conditions.
34. Select the Run BLOWDOWN on input changes check box at the bottom of the
BLOWDOWN form.
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35. Return to the main flowsheet using either the BLOWDOWN tab
Note: The BLOWDOWN tab will be active only when the blowdown flowsheet is
selected.
36. Or the Flowsheet/Modify tab in which the BLOWDOWN block is located.
In case BLOWDOWN Analysis window is selected/active, you could use the Go to

Parent Flowsheet Environment.
37. Add an Adjust block to the flowsheet from the Object Palette.
38. On the Connections tab | Connections page, for the Adjusted Variable, specify
the Orifice Diameter.
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39. For the Target Variable group, specify the Final Pressure.
40. For the Target Value group, select the User Specified option and specify 50% of
the Design Pressure which is 250psig (1825.015 KPa).
In the Specified Target Value field, type as the required depressuring pressure, or
around 50% of the vessel design pressure.
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41. On the Parameters tab | Parameters page, in the Tolerance field, specify a
tolerance of around 1-10% of your desired final pressure. So specify 4 psi (27.6
KPa) as the tolerance and 0.1 in (2.54 mm) as the Step Size.
42. Start the Adjust block convergence.
QUESTION: What is the size of the Orifice? [Write your answer below]
43. Save your case as 07-FireCaseOrificeDesign.hsc
Task 2 – Design for Cold Case depressurization scenario

In this portion of the workshop, a cold case run for the same system will be run. In this
case, add tail pipes to the system because the goal is to identify if carbon steel is
sufficient for the tail pipe – and if not where to put the spec break between stainless steel
and carbon steel.
Cold ambient conditions (32 ̊F), and maximum expected operating conditions (535 psia,
from plant data (for example)) are considered.
44. On the main flowsheet, copy and paste the Fire Case.
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Right click on the BLOWDOWN Fire Case and select Copy. Paste on the main flowsheet.
This will resolve the entire flowsheet, please wait until it is solved.
45. On the BLOWDOWN Analysis form, edit the Name of the BLOWDOWN unit to
Cold Case and add 3 Tail Pipe Segments while on the Design tab.
46. Move to the System tab, review Template Parameters copied.
47. Make the Air Temperature is 0.0 ̊C (32 ̊F) and change the Air Speed (Speed of
air) as 0 m/s (0 ft/s). (For the cold blowdown scenario, we recommend an air
speed of 0.)
48. For the Equipment Conditions Upstream of Orifice specify Initial Temperature
as 0.0 ̊C (32 ̊F) and Pressure as 3688.70 KPa (535 psia).
49. Next, on Initial Inventory | Main Vessel page, select the Manual radio button,
then click the Copy from Stream button.
50. On the Select Process Stream dialog box, select the Feed Mix stream, and then
click OK.
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51. Select Vessels in the left-hand pane to verify the vessel information on the
Geometry, Heat Transfer and Initial Conditions tabs.
52. Uncheck the “In Fire Zone?” box on the Heat Transfer tab.
53. Select Pipes in the left-hand pane to specify the 3 tail pipe information. Input the
values as shown in the screenshot below.
54. Move to the Initial Conditions tab to specify the initial conditions. Input the
values as shown in the screenshot below.
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After specifying the pipes specifications, all of the icons on the left should appear as ,
then move on to the Mapping tab to make sure component mapping is successful.
Now the Blowdown case has all the necessary inputs for it to be run.
55. To run the BLOWDOWN simulation, either from the BLOWDOWN ribbon tab
| Run group, click the Run button or on the BLOWDOWN Analysis form, click
the Run BLOWDOWN button.
When the BLOWDOWN simulation is finished, a message appears in the status bar,
indicating that the simulation run is complete.
56. On the Results Summary tab of the BLOWDOWN Analysis form, you can
review overall system plots and key results or warnings from the simulation.
57. On the Results Summary tab | Major Findings page of the BLOWDOWN
Analysis form, you can view major findings from your blowdown simulation.
The warnings related to the Tail Pipe indicate that the wall temperatures are equal to or
less than MDMT between a certain length ranges. As our aim for this task was to identify
if carbon steel is sufficient for the tail pipe – and if not where to put the spec break
between stainless steel and carbon steel.
58. Save your case as 07-ColdCaseCS.hsc
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59. We will now change the material for Tail Pipe-1 and Tail Pipe-2 to Stainless
Steel and the MDMT to -88.89 ̊C (148 ̊F).
60. Now Run the Blowdown Case and review the results summary.
61. Save your case as 07-ColdCaseSS.hsc
Recommended Reading
White Paper: BLOWDOWN Technology in Aspen HYSYS Validation
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Notes:
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Blowdown Solutions
Files can be found in folder: 07_Blowdown/Solutions
Questions
Task 1
QUESTION: What is the Vessel Pressure at the final Halt Time?
1427 KPa (207.50 psia)
QUESTION: What is the Orifice Mass flow rate at the final Halt Time?
1533 kg/hr (3380 lb/hr)
QUESTION: What is the size of the Orifice?
11.05 mm (0.435 in)
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Safety Analysis Workshop
Files can be found in folder: 08_SafetyAnalysis
Objective
In this workshop, you will use the Safety Analysis Environment to analyze overpressure
scenarios, determine which contingencies will require pressure relieving devices, size
these devices according to appropriate standards, and generate required documentation.
The Safety Analysis Environment streamlines the workflow in designing overpressure
protection by saving numerous man-hours per project.
With the HYSYS Safety Analysis Environment, you have the ability to seamlessly
transfer process data from the Simulation Environment and make use of it for pressure
relief and other process safety calculations. This workflow greatly speeds up the
computation of multiple relief devices with a variety of scenarios. Industry standard PSV
design capabilities have been introduced into the Safety Analysis Environment for
consistent and reliable relief valve calculations. This workshop will explore those
capabilities.
Your turbo expander/fractionation plant model requires some additional attention to some
pressure relief items. In the last workshop, you used the HYSYS Dynamic Depressuring
Analysis to study an adiabatic blowdown and fire case scenario around the Inlet Sep
separator. Recall that the Depressuring Analysis only permitted you to study one valve
undergoing one pressure relief scenario per calculation.
In this workshop, you will apply the capabilities of the HYSYS Safety Analysis
Environment to perform some more versatile and wider range studies. Namely you will
explore a dual-scenario relief situation around the Inlet Sep separator – something the
Depressuring Analysis is incapable of. You’ll also study an overpressure situation on the
Deethanizer column.
Task 1 – Perform a Dual-Scenario Relief Study

Task 2 – Configure Multiple Valves
Task 3 – Size a PSV for a Distillation Column
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Task 1 – Perform a Dual-Scenario Relief Study
The Inlet Sep 3-Phase Separator needs to be outfitted with an appropriate pressure safety
valve (PSV) to handle a few types of potential overpressure situations. Using the Safety
Analysis Environment, you can define these overpressure scenarios all in one convenient
form. Your objective is to find a PSV that can handle the following scenarios: a blocked
outlet control valve, a fire case, and a local power failure.
1. To begin the workshop, open the case 08-SafetyStarter.hsc. It should be

available in your course files folder provided by your instructor.
The Safety Analysis Environment in Aspen HYSYS makes it easy to use process
conditions from an existing steady state model for use in relief valve sizing calculations.
Since there are full results available around the Inlet Sep separator, you can move on and
pursue the necessary PSV sizing calculations.
2. Enter the Safety Analysis Environment by selecting the Safety Analysis

button in the bottom-left corner of your HYSYS window. (You can also click
the Pressure Relief button in the Home ribbon tab.)
The Safety Analysis Environment contains a unique Home tab menu. This menu
contains selections and options for units of measure, PSV design codes, output
documentation management, and the ability to add a PSV to your model.
3. Click the Home ribbon tab and review the options.
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Notice also that the Navigation Pane at the left-hand side of the HYSYS window is
different. The Navigation Pane contains three items, Unit Operations, Unattached
Streams, and Storage Tank Protection. You can use the Unit Operations menu to view all
unit operations in your flowsheet. From these unit operations, you can add a PSV to that
operation.
So when it comes to adding a PSV to your flowsheet, you have two options. Either select
the Add PSV icon on the Home tab of the ribbon and connect it to an appropriate
flowsheet object, or right-click on a unit operation in the Navigation Pane and select and
appropriate connection. We’ll use the second approach.
4. Expand the Unit Operations menu item In the Navigation Pane.
5. Locate the Inlet Sep menu item and right-click on it.
6. Expand the Create PSV menu item and select the Inlet Sep Vap option. This
will add a PSV to the vapor outlet side of the Inlet Sep separator.
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The PSV will now be visibly attached to the Inlet Sep Vap stream out on the main
flowsheet of the Safety Analysis environment.
7. Double-click the PSV icon on your flowsheet. Otherwise switch over and
view the 100 PSV 001 menu.
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8. Right-click on the 100 PSV 001 object and select Rename in the Navigation
Pane. Title the PSV as IS PSV 100.
9. Back on the Equipment tab of the IS PSV 100 menu you can provide design
conditions for the protection unit operation. Begin by entering 40 °C (104 °F)
as the Design Temperature.
10. In the Design Pressure field, assume a value of 37 barG (536.6 psiG).
At this point, all minimum required inputs for the protected vessel should be specified.
Now to size the proposed valve under some relief condition, you must add at least one
Scenario. Scenarios represent some of overpressure situation, such as a power failure,
shut in control valve, plant fire, etc. You can add as many Scenarios as you wish to a
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given PSV and check the valve sizing requirements for each. From those results, you can
select a PSV size that will handle all required scenarios.
11. Select the Scenarios tab of the IS PSV 100 menu, to add scenarios to be
considered by the PSV,
12. Click the Create Scenario button to define a relief valve sizing scenario.
13. Note that a line item has now been added to the PSV window, labeled as
Scenario100. Click Create Scenario once more to add another scenario to
this PSV.
14. Select the first scenario, Scenario100, and click the Open Scenario button.
15. Rename this scenario as Inlet Sep Blocked CV.
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Relief Scenarios cover a wide variety of phenomena. As was previously mentioned, this
exercise will cover two scenarios; a blocked outlet control valve and a fire case. Of
course many other types of overpressure scenarios are possible for a variety of equipment
types.
The HYSYS Safety Analysis Environment contains a listing of many common relief
scenario types. These can be selected on demand and used to fill in much of the required
input for your Scenario. Please note, you also have the ability to manually define a
Scenario if greater user control is needed. But you’ll make use of the readily-available
Scenario options in order to size the Inlet Sep PSV.
16. Click the pull-down menu on the Scenario Type field and select the Blocked
Outlet option.
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This scenario will assess the pressure relief requirements in the case of a failure of an
outlet control valve on the Inlet Sep Vap stream. We will propose that this valve fails
closed and the vapor phase flow from the Inlet Sep needs to be relieved.
To set the flow rate of relieving fluid (equivalent to the Inlet Sep Vap flow rate),
click the Reference radio button at the bottom of the form. This will call in the
flow rate via the Reference Stream of the PSV (in this case Inlet Vapor).
17. Click the Edit button next to the Relieving Pressure field. Keep the
Allowable Overpressure as 10% of Set Pressure and click OK.
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Note: Set Pressure default value will be equal to the Design Pressure, if you want to
specify it differently please exit the current scenario and go to the valve
specification > PRD Data tab > PRD Specifics > Set Pressure and uncheck the
box Design Pressure value. Press F1 to open HYSYS enhanced help for more
information.
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18. Click the Edit button next to the Total Backpressure field. Specify a
pressure of 2.2 bar (31.91 psi) for the Variable Superimposed BP. This
assumes some backpressure on the PSV due to other relieving PSVs in the
system. Click OK when finished.
Note: Constant Superimp. BP default value will be equal to the Atmospheric Pressure,
and Built-up Backpressure is the pressure drop in the tail pipe during relieving, user can
manually modify this value. Change the built-up backpressure value to 0.5bar to avoid
the warning Exceeded 10% limit on Backpressure. Press F1 to open HYSYS enhanced
help for more information.
19. Back on the Scenario Setup form, HYSYS should inform you that the
calculation is complete. The Valve Results table in the top-right corner of the
window should show the Calculated Orifice area.
QUESTION: What is the calculated Orifice area for the Blocked CV Scenario? [Write
your answer below]
You can take the PSV sizing one step further by selecting an industry-standard orifice
size for this valve.
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20. Choose the orifice size that corresponds to the next size larger than your
calculated orifice area, From the Selected Orifice input.
21. Return to the IS PSV 100 menu and highlight the Scenario101. Click Open
Scenario to view it.
This next scenario will account for a potential fire case around the Inlet Sep. Define this
scenario using the following data:
In this cell… Enter
Scenario Name Inlet Sep Fire
Scenario Type General | Fire
For the Inlet Sep Fire scenario, the HYSYS Safety Analysis feature can make use of API
521 RP methodologies which apply to vessels with wither vapor, liquid, or multi-phase
inventories. It is important to make sure the Scenario references the proper material
stream that best represents the feed into the protected unit operation.
In this case, the feed to the Inlet Sep (Feed Mix) should be accessed as the reference
stream. Since this is a multi-phase mixture, the API 521 calculation will propose either
the API Wetted calculation model or the Semi-Dynamic Flash model. The Semi-
Dynamic model is more applicable to liquid-only systems, so you will use the API
Wetted calculation. After V8.8 the workflow for fire scenarios has been improved. For
more information please refer to the enhanced HYSYS help by browsing Safety Analysis
Environment or by pressing F1 directly.
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22. Click the Override checkbox next to the Reference Stream field, select the
Feed Mix stream and click OK.
Note that the Required Relieving Flow is calculated using the Wetted (API)
method.
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23. Make sure the Drainage & Firefighting parameter is set as Absent and the
Estimate Latent Heat? Parameter is set as Yes.
24. Define the vessel size in the Vessel Parameters section, using the same
dimensions as in the earlier Dynamic Depressuring workshop. The Diameter
should be 1.524 m (5 ft), Vessel Tan/Tan should be set at 5.486 m (18 ft),
and assume a Liquid Level of 0.6096 m (2 ft), please note that after V8.8 user
can add the Vessel Head Type.
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The scenario should be solved. You can keep the defaults for all other settings.
QUESTION: What is the Calculated Orifice area for the Inlet Sep Fire? [Write your
answer below]
25. Select an Orifice to satisfy this calculated size. Is it larger or smaller than the
orifice needed for the Blocked CV scenario?
26. Save your case as a compound file, remember that when you work on the
Safety Analysis Environment an *.mbd and *.hsc are created and user needs
to maintain them together all time, to avoid problems you can use the HYSYS
compound file *.hscz which will zip them. Please go to File> Save as> Save
as type: HYSYS Compound file> 08-DualScenario.hscz
Task 2 – Configure Multiple Valves

After performing the PSV sizing calculations for the Blocked Outlet and Fire scenarios of
the Inlet Sep, it should be clear that the Blocked Outlet scenario requires a much larger
PSV orifice than the Fire scenario. Since the vessel must be protected against both
scenarios, a PSV must be selected to handle the worst-case pressure relief. This could
cause a problem with the Fire scenario however, as the PSV would be grossly oversized.
This could lead to valve chatter and other undesirable behaviors.
The HYSYS Safety Analysis Environment offers a capability to set up multiple relief
valves for a given sizing case. This approach allows for split flow from an overpressure
situation into multiple PSVs. As a result, the combined area of the two valves could
support the larger relief scenario (Blocked Outlet in this case), while the smaller of the
two valves could support the lower flow scenario (Fire Case). Follow the steps below to
define the multi-valve arrangement.
27. Click the checkbox for Sizing Case on the Blocked Outlet scenario on the
Scenarios tab. This sets the Blocked Outlet scenario as the relief situation used
for final valve sizing.
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28. Move to the PRD Data tab and click the Add PRD button.
The relief system should now be configured with two relief valves in parallel to
accommodate the Inlet Sep relief flow.
29. Select the Rating tab, to configure the size and characteristics of the multiple
valves.
Using the table blow, configure the following options for IS PSV 100 A and IS PSV 100
B:
IS PSV 100 A
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Required Flow Split % 65
Select Orifice 18.406 (L)
IS PSV 100 B
Set Pressure Increase % 0.00
Required Flow Split % 35
Select Orifice 8.303 (J)
The PSV calculation should now be complete.
QUESTION: If the Fire Case is the active scenario, which PSV should be active for the
overpressure protection? Is this PSV properly sized for the Fire Case? [Write your
answer below]
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Explore any of the other Results on the Rating tab. You can view various rating
estimates using the Displayed Rating Estimates field.
as type: HYSYS Compound file> 08-SplitPSV.hscz
Task 3 – Size a PSV for a Distillation Column

The Deethanizer column contains a full reflux condenser that requires some overpressure
protection. Namely, we wish to study the effects of a reflux failure on the overhead
accumulator of the column setup. You can use the Safety Analysis Environment, and the
techniques you just learned, to apply a PSV to the Deethanizer column overhead.
Once you select an appropriate PSV orifice size, you’ll apply the Line Sizing option in
the Safety Analysis Environment to size inlet and outlet piping from your selected PSV.
HYSYS can check for any excessive pressure losses in this piping. You’ll conclude by
documenting your results with the Documentation Builder option in the Safety Analysis
environment.
31. Return to the main flowsheet in the Safety Analysis environment. Select the
Home tab in the ribbon and click the Add PSV icon.
32. Point and click on the stream 12 arrow to add a PSV to that stream. There
should be a small blue box you can click to make the connection.
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33. Double-click the PSV icon that now appears on your main flowsheet.
34. Viewing the PSV Equipment tab enter a Design Temperature of 30 °C (86
°F) and a Design Pressure of 28 barG (406.1 psiG).
35. Move to the Scenarios tab and click the Create Scenario button. Select the
scenario and click the Open Scenario button to view its input form.
Specify the following settings on the Scenario Setup form:

Scenario Name Reflux Fail
Scenario Type Distillation Column/Tower | Reflux Failure
Relieving Flow Method Reference
Relieving Temperature Manual – 12 °C (53.6 °F)
For the Reflux Failure pressure relief option select the Direct Integration (HEM) method.
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QUESTION: What is the Calculated Orifice diameter? Which Selected Orifice would
be the best choice for this PSV? [Write your answer below]
36. Return to the PSV menu and select this Reflux Failure scenario as the Sizing
Case.
37. Move to the PRD Data tab and change the Valve Type to a Pilot Operated
valve.
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Once you have a fully specified and calculated PSV, the Safety Analysis Environment
offers line sizing capabilities. You can use this feature to define PSV inlet and outlet
piping specifications and then see how those influence pressure drop considerations.
Follow the next few steps to add some piping for the Deethanizer overhead PSV.
38. Click the Line Sizing tab in the PSV window.
39. Keep the same sizes as the PSV inlet and outlet flanges for the connecting
piping. Do so by entering the following pipe specifications:

In Line Nominal Diameter 3 in
In Line Pipe Schedule Sch. 40
Out Line Nominal Diameter 4 in
Out Line Pipe Schedule Sch. 40
Flow Rate Method Rated (area)
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The constraints for the line sizing calculations can be accessed by clicking the Constraint
Setting button. From here you can modify limits for inlet piping pressure drop, outlet
pipe average velocity, and outlet pipe exit velocity.
The Line Sizing feature also allows you to consider the length of inlet and outlet piping,
along with any fittings on those lines. Simply click the Calculate Equivalent Length
checkbox to access options for calculating equivalent lengths of the inlet and outlet
piping.
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40. Click the Calculate Equivalent Length checkbox and view the options that
appear at the bottom of the form:
41. Enter the following piping details for the inlet and outlet lines from the PSV:

PSV Inlet Line
Pipe Length 0.3 m
Nozzle Exit 1
PSV Outlet Line
Pipe Length 6m
Ball Valve 1
Elbow – 90 Degree Standard 2
Tee – Three Way Straight Through 1
QUESTION Are there any concerns with the inlet piping configuration? Outlet piping
configuration? [Write your answer below]
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as type: HYSYS Compound file> 08-ColumnPSV.hscz
To properly document and present results of PSV sizing calculations, many standard
forms are required to meet various regulatory and compliance requirements. The HYSYS
Safety Analysis environment includes a Documentation Builder reporting environment to
help you generate these reports with minimal effort. The Document Builder is based on
Microsoft Access functionality, which must be installed on your computer in order to
utilize.
43. Make sure you are viewing either the Home tab or the Reports tab in the
ribbon.
44. Click the Documentation Builder icon.
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Allow a moment for the Documentation Builder to load. Once it’s available, you should
see the following menu:
45. Click the View icon, under the Process Data Sheets section. Use the arrow
keys at the bottom of the form to scroll through the pages of the report. After
browsing the process conditions, close the form.
46. Click and select the View ISA Form S20.53 button, under the Mechanical
Data Sheets section
Arrow over to page 3 of the report and view the ISA data sheet for the Deethanizer
overhead PSV.
47. Click on PRD Booklet Switchboard and click on Summary Data this will
show you the different reports you can have through Documentation Builder.
Browse through any other forms and reports in the Documentation Builder that you might
want to check out.
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The Reports tab in the HYSYS Safety Analysis environment ribbon contains links to
some additional reporting capabilities. The Built-in HYSYS Reports are set up as
follows:
Calculation Sheet – Opens a calculation report of the scenario in the context of the
valve, or of the valve in the context of the scenario.
Relief Load Calculation – A report pertaining to the Relief Load section within
the relief scenario.
Line Sizing – Reports the key line sizing data pertaining to the line sizing
calculation (note that for single-phase flow situations, like Line Sizing report is
included with the Calculation Sheet report).
Equivalent Length – Reports any data from the piping equivalent length
calculation, provided it was initiated during the Line Sizing calculation.
Browse through any of these built-in reports that you like. Use the arrows in the
Reporting window to move from one page to the next. You can zoom in on any of
the reports by right-clicking and choosing the Zoom option. These reports can easily
be printed as well.
Recommended Reading
Jump Start Guide: Relief Sizing in Aspen HYSYS and Aspen Plus V8.6

Jump Start Guide: Multiple Relief Valve Analysis in Aspen HYSYS and Aspen Plus

Jump Start Guide: Storage Tank Protection in Aspen HYSYS and Aspen Plus

Fire Overpressure Analysis in Aspen HYSYS and Aspen Plus
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Notes:
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Safety Analysis Solutions
Files can be found in folder: 08_SafetyAnalysis/solution
Questions
Task 1
QUESTION: What is the calculated Orifice area for the Blocked CV Scenario?
18.97cm2
QUESTION: What is the Calculated Orifice area for the Inlet Sep Fire?
3.279 cm2
QUESTION: Select an Orifice to satisfy this calculated size. Is it larger or smaller than
the orifice needed for the Blocked CV scenario?
The selected orifice has an area of 5.064 cm2 (H). This is smaller than the orifice for the
Block CV scenario, which required a 23.22 cm2 (M) orifice.
Task 2
QUESTION: If the Fire Case is the active scenario, which PSV should be active for the
overpressure protection? Is this PSV properly sized for the Fire Case?
IS PSV 100 B should be the valve used for the Fire Case scenario
Task 3
QUESTION: What is the Calculated Orifice diameter? Which Selected Orifice would
be the best choice for this PSV?
Calculated Orifice area = 5.907 cm2; Selected Orifice = 8.303 (J)
QUESTION: Are there any concerns with the inlet piping configuration? Outlet piping
configuration?
The inlet piping checks out OK; the outlet piping shows OK
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Reactors Workshop
Files can be found in folder: 09_Reactors
Objective
In this workshop, you will define chemical reactions and reactor unit operation models in
Aspen HYSYS. You will also work with various logical operations (Set, Spreadsheet,
and Adjust models) to automate certain specifications and meet targets in your model.
In this workshop, you will simulate a Synthesis Gas Production facility. This will
introduce you to the reaction modelling capabilities of Aspen HYSYS.
The production of synthesis gas is an important step in the production of many different
chemical products. The main role of the synthesis gas plant is to convert natural gas,
primarily methane, into hydrogen. Synthesis gas is comprised of hydrogen, nitrogen,
carbon dioxide, and carbon monoxide. Typically the synthesis gas product is further
refined by removing carbon dioxide and carbon monoxide through amine contact,
pressure swing adsorption, or some other means. This workshop will focus on the
reaction portion of the process.
In most synthesis gas plants, four reactors are used. However in our simulation five
reactor unit operations will be used. This is because the combustion reaction, typically a
single vessel, will be modelled as two reactors in series with two different reaction types.
The first stage of the combustion will involve conversion-type reactions while the second
will involve equilibrium reactions.
Task 1 – Isolate the Natural Gas Feed

Task 2 – Set up Reactions and Reaction Sets
Task 3 – Build the Synthesis Gas Process
Task 1 – Isolate the Natural Gas Feed

One of the products from your turbo expander/NGL fractionation plant is a high pressure
gas product, mainly consisting of methane. It has been decided to split off a fraction of
this gas product for sale to a neighboring plant with a synthesis gas production facility.
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In your HYSYS simulation, you need to isolate the desired amount of natural gas flow for
transmission to the Syn Gas Plant. The natural gas also needs to be brought to the proper
conditions for the Syn Gas process. Set up these items in the first part of the workshop.
1. Start the exercise with your HYSYS simulation utilized in the last workshop
(08-ColumnPSV.hsc).
If the HYSYS file is still in the Safety Analysis Environment, click on the Simulation
button to return to the Simulation Environment.
Viewing the main flowsheet, locate the portion with the K-101 compressor, material
stream 15, the Export Gas compressor, and the Sales Gas stream.
2. Break the connection between stream 15 and Export Gas Comp.
3. Add a Tee to the flowsheet and define it as follows:
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Connections
Name Gas Split
Inlet 15
Outlets Export Gas

To Syn Gas
Worksheet
To Syn Gas, Molar Flow 90 kgmole/h (198.4 lbmole/hr)
4. Connect the Export Gas stream to the inlet of the Export Gas Comp.
The Synthesis Gas Process will be modeled within your current workshop flowsheet. But
to avoid having a main flowsheet window with excessive amounts of operations and
streams, you’ll make use of the sub-flowsheet modeling capability of Aspen HYSYS and
place the Syn Gas Process inside its own sub-flowsheet. This should help to better
organize your growing process model!
5. Add a Blank Sub-Flowsheet from the Object Palette and select the option to
Start with a Blank Flowsheet.
6. Double-click the sub-flowsheet icon that now appears on your main flowsheet.
On the Connections tab rename the sub-flowsheet as Syn Gas Plant.
7. List To Syn Gas as an External Stream in the Inlet Connections list.
8. Click the Sub-Flowsheet Environment… button to view the Syn Gas Plant
sub-flowsheet.
The To Syn Gas material stream you see in the sub-flowsheet is a mixture of light and
medium hydrocarbons, CO2, nitrogen, and a small amount of water. This stream needs
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to be compressed and heated to certain conditions before it can enter the synthesis gas
reactor train.
It’s also important to consider the components present in the stream and how/if they’ll
react in the synthesis gas process. To Syn Gas is primarily composed of methane, but
there are also small amounts of ethane, propane, butanes, etc. As part of the synthesis
gas process, combustion of methane is a reaction of interest. But of course if methane
is present and combusted, it can be reasoned that any other hydrocarbons would be
combusted as well. To simplify the reaction definitions, you’ll remove any
hydrocarbons heavier than propane prior to feeding the gas into the first reactor, thus
ignoring the combustion of any heavier hydrocarbons.
9. Add a Compressor to the Syn Gas Plant sub-flowsheet. Set it up with the
following connections and conditions:

Connections
Name Natural Gas Comp
Inlet To Syn Gas
Outlet HP Gas
Energy QK-NGC
Worksheet
HP Gas, Pressure 3500 kPa (507.6 psia)
The HP Gas stream needs to feed into the reaction section at 370 °C.
10. Add a Heater to Heater model to do this.
Connections
Name Natural Gas Heater
Inlet HP Gas
Outlet Hot HP Gas
Energy Q-NGH
Parameters
Delta P 0 kPa (0 psi)
Worksheet
Hot HP Gas, Temperature 370 (698 °F)
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The last step before setting up the reactions and reactors is to remove all hydrocarbons
heavier than propane from the reactor train feed.
11. Use the HYSYS Component Splitter unit operation to do this. It can be added
from the Columns section of the Object Palette and define it as follows:

Connections
Name Remove Heavy HC
Inlet Hot HP Gas
Overhead Outlet Natural Gas
Bottoms Outlet Heavy HC
Energy Q-Split
Parameters
Stream Specifications Use Stream Flash Specifications
Equalize All Stream Pressures
Natural Gas Temperature 370 °C (698 °F)
Heavy HC Temperature 370 (698 °F)
12. Move to the Design | Splits form. For Natural Gas, enter a split of 1.0 for
Nitrogen, CO2, Methane, Ethane, Propane, and H2O.
13. Enter a split of 0.0 for all other species.
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14. Save your case as 09-Reactors.hsc.
Task 2 – Set up Reactions and Reaction Sets

The definition of any chemical reactions to be considered within a HYSYS flowsheet
must be made in the Properties Environment. All tools and features needed for
specifying various classes of reactions are available there. Once the reactions have been
define, specified, and properly assigned to the active Fluid Package they can be used in
the Simulation Environment. One more thing to consider – make sure any components
needed for the reactions are specified in your component list!
15. Return to the Properties Environment. Note that there are two Component
Lists and two Fluid Packages present.
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The Basis-1 Fluid Package and Component List-1 are the active items for the Syn Gas
Plant sub-flowsheet.
16. Select Component List-1 from the Navigation Pane.
17. Add the following components to the list: CO, Hydrogen, and Oxygen.
18. Stay in the Properties Environment, select the Reactions folder on the
Navigation Pane and click the Add button to create a new Reaction Set or you
can click on the Reactions icon on the Home tab of the ribbon.
19. Click back on the Reactions folder in the Navigation Pane. Under the Name
field, re-name the created Reaction Set (Set-1) as Combustor Rxn Set.
20. Select the Combustor Rxn Set folder in the Navigation Pane; then click the
Add Reaction button at the bottom of the Reaction Set window.
21. Make sure the Reactant Source is set as HYSYS and choose Conversion as
the reaction type. Then click Add Reaction.
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22. Click Add Reaction four more times. You should have five reactions total
(Rxn-1, Rxn-2, Rxn-3, Rxn-4, and Rxn-5) when finished. Then you may close
the Add Reactions window.
23. Expand the Combustor Rxn Set folder in the Navigation Pane; you should see
the five reactions listed. Click on Rxn-1 to view it.
In the Stoichiometry Info section, list out Methane, H2O, CO, and Hydrogen. List their
stoichiometric coefficients as -1.0, -1.0, 1.0, and 3.0 respectively.
24. Make sure Methane is shown as the Base Component in the Basis section and
enter a percentage conversion of 35% in the Co field.
25. Check your inputs for Rxn-1 against the figure below:
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26. Continue by defining the other four Conversion reactions in the Combustor
Rxn Set. Use the following characteristics:
Name Reaction Base Component Co
Rxn-2 CH4 + 2H2O CO2 + 4H2 Methane 65
Rxn-3 CH4 + 2O2 CO2 + 2H2O Methane 100
Rxn-4 2C2H6 + 7O2 4CO2 + 6H2O Ethane 100
Rxn-5 C3H8 + 5O2 3CO2 + 4H2O Propane 100
27. Return to the Combustor Reaction Set folder and click on the Add to FP
button.
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28. Select the Basis-1 Fluid Package, and then click Add Set to Fluid Package.
29. Click back on the Reactions folder in the Navigation Pane and click Add to add
a new Reaction Set.
30. Rename this Reaction Set as Shift Rxn Set.
31. Click the Add Reaction button in the Shift Rxn Set and choose Equilibrium as
the reaction type.
32. View the created reaction (Rxn-6) and click the Library tab.
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33. Highlight the reaction with the form: CO + H2O CO2 + H2. Click Add
Library Rxn to set this as the reaction for Rxn-6.
34. Go back to the Shift Rxn Set folder and click on the Add to FP button. Add
this reaction set to the Basis-1 Fluid Package.
35. Return to the Reactions folder in the Navigation Pane and add one more
Reaction Set; title it Reformer Rxn Set.
36. View the Reformer Rxn Set menu and click the pull-down arrow on the Add
Reaction button. Select the Existing Reaction option.
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37. Add Rxn-1 and Rxn-2 to the Reformer Rxn Set.
38. Click on the Add to FP button to attach this set to the Basis-1 Fluid Package.
39. Save your case.
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Task 3 – Build the Synthesis Gas Process
There are six different reactor unit operation types in Aspen HYSYS. By using
combinations of these six operations, virtually any real reactor can be modeled given
sufficient information. The six reactor types available are Conversion, Yield Shift,
Equilibrium, Gibbs, Continuously Stirred Tank Reactor (CSTR), and a Plug Flow
Reactor (PFR).
The Conversion Reactor calculates the composition of the outlet stream given the
stoichiometry of all the reactions occurring and the conversion of the base component.
The Yield reactor does the same given an implied yield for each component.
In the case of the Equilibrium Reactor, it determines the composition of the outlet stream
given the stoichiometry of all reactions occurring and the value of the equilibrium
constant (or the temperature dependent parameters that govern the equilibrium constant)
for each reaction. The Gibbs Reactor valuates the equilibrium composition of the outlet
stream by minimizing the total Gibbs free energy of the effluent mixture.
In the case of the CSTR, it assumes that the reactor contents are completely mixed in
computing the outlet stream conditions, given the stoichiometry for all the reactions that
are occurring and the kinetic rate constant (or the temperature dependence parameters for
determining the kinetic constant) for each reaction. The PFR assumes that the reaction
stream passes through the reactor in plug flow in computing the outlet stream
composition, given the stoichiometry of all the reactions occurring and a kinetic rate
constant for each reaction.
For the synthesis gas reactions, you’ll be making use of the Conversion and Equilibrium
reactor models. Follow the steps below to build these reactors and their associated
operations.
40. Click on the Simulation Environment button.
If your flowsheet appears to be un-solved, return to the Parent Flowsheet (click Go to

Parent) in the Flowsheet/Modify ribbon tab) and allow the main flowsheet to solve.
Hint: You may see a message about a “Fatal Error.” Check your Demethanizer column
to ensure that it solved. If it did not, open the column property view and click the Reset
button, and then Run it. If you receive a Consistency Error message, just click to make
the Solver Active. The main flowsheet should solve at this point. If you have any further
problems check with your instructor.
41. Locate the Syn Gas Plant sub-flowsheet icon. Double-click on it and re-enter
the sub-flowsheet.
42. Create three new Material Streams with the following inputs:
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Name Reformer Air Combustor
Steam Steam
Temp., °C (°F) 250 (482) 16 (60.8) 250 (482)
Pressure, kPa (psia) <empty> <empty> <empty>
Molar Flow, kgmole/hr 240 (529.1) 90 (198.4) 140 (308.6)

(lbmole/hr)
Molar Composition 100% - H2O 79% - N2 100% - H2O

21% - O2
The first reactor in the synthesis gas plant is the Reformer. This reactor will be modelled
as a Conversion Reactor and it will utilize the Reformer Reaction Set.
43. Add the Conversion Reactor into the flowsheet from the Columns section of
the Object Palette
44. Name this reactor Reformer and attach Natural Gas and Reformer Steam as
inlets.
45. Name the Vapour Outlet Combustor Feed and the Energy stream as
Reformer-Q.
Even though there will be no liquid flow from this reactor, we still must create a liquid
phase product stream for flowsheet connectivity purposes.
46. Name the liquid product stream as Reformer LP
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47. Move to the Reactions | Details page and select Reformer Rxn Set as the
Reaction Set. This will automatically connect the proper reactions to this
reactor.
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48. Select the Conversion% radio button.
49. Select Rxn-1 from the Reaction drop down menu and change the Co value to be
40%.
50. Do the same for Rxn-2 and choose Co to be 30%.
Note: You have the ability to alter reaction specifications from their original settings
after you install them in a reactor block. This capability provides helpful flexibility to
adjust reaction data without having to go back into the Properties Environment.
51. Enter a temperature of 930 ºC (1706 ºF) for the outlet stream Combustor Feed,
on the Worksheet tab.
At this stage, the first reactor will not solve yet. The pressure is unknown in the
Reformer Steam stream. As you build the flowsheet, you’ll use a logical operation (Set)
to define this pressure. But you’ll add the next reactor in the sequence first.
The second reactor in a synthesis gas plant is the Combustor. The Combustor will be
modelled as a Conversion reactor and an Equilibrium reactor in series. This is because
Conversion reactions and Equilibrium reactions cannot occur in reactors of the opposite
type. That is, conversion reactions cannot be associated with equilibrium reactors, and
vice versa.
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52. Add another Conversion Reactor with the following data:

Connections
Name Combustor
Inlets Air, Combustor Steam,
Combustor Feed
Vapour Outlet Mid Combust
Liquid Outlet Combustor LP
Reactions | Details
Reaction Set Combustor Rxn Set
Rxn-1 Conversion 35% (Default)
Recall that we did not enter any pressure data for the Air or Steam streams. To provide
the necessary pressures, we will use a pair of logical operations to call in known pressure
data on another material stream. First we’ll use the Set operation to link stream
pressures, and then we’ll apply the Spreadsheet operation as an alternate approach.
53. Select the Set Operation from the Common section of the Object Palette.
54. Select Reformer Steam | Pressure as the Target Variable. Define Natural
Gas as the Source Object.
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On the Parameters tab and ensure the Multiplier is set at 1 and the Offset at 0. For this
pressure association, we want equality between the two stream pressures, so a multiplier
of 1 and an offset of 0 will result in this type of relationship.
You also need to set the pressures of Air and Combustor Steam. Rather than take the Set
operation approach and require two additional unit operations, you can use a Spreadsheet.
You’ll find that a single Spreadsheet can do the same calculations as two Set operations.
55. Add a Spreadsheet from the Object Palette. Rename it as Pressure

Assignment.
56. Move to the Spreadsheet tab and provide the following labels:

A1 Natural Gas Pressure
A3 Air Pressure
A4 Combustor Steam Pressure
57. Right-click in cell B1 and select the Import Variable option. Select Natural
Gas | Pressure from the variable browser menu.
58. Enter the following formulas into the cells indicated:

B3 =B1*1
B4 =B1*1
59. Right-click on cell B3 and select the Export Formula Result option. Select
Air | Pressure from the variable browser menu.
60. Do the same for cell B4, exporting this result to the Combustor Steam material
stream.
QUESTION: What is the calculated heat flow/duty of the Reformer? [Write your
answer below]
As mentioned before, the Combustor is to be modelled as a Conversion reactor followed

by an Equilibrium reactor, so you must still add the Equilibrium side of the combustion.
The Shift Reactors will also be modelled as Equilibrium Reactors. Therefore, a total of
three equilibrium reactors must be added to complete the flowsheet.
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61. Add an Equilibrium Reactor from the Columns section of the Object Palette
with the following information:

Connections
Name Combustor Shift
Inlet Mid Combust
Vapour Outlet Shift1 Feed
Liquid Outlet Combustor Shift LP
Reactions | Details
Reaction Set Shift Rxn Set
QUESTION: What is the calculated outlet temperature from the combustion section of
the reaction train? [Write your answer below]
62. Add another Equilibrium Reactor with the following information:

Connections
Name Shift1
Inlet Shift1 Feed
Vapour Outlet Shift2 Feed
Liquid Outlet Shift1 LP
Energy Stream Shift1-Q
Reactions | Details
Worksheet
Shift2 Feed, Temperature 450 °C (842 °F)
QUESTION: How much energy must be removed from Shift1 to meet the desired outlet
temperature? [Write your answer below]
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63. Add the third and final Equilibrium Reactor with the following information:

Connections
Name Shift2
Inlet Shift2 Feed
Vapour Outlet Synthesis Gas
Liquid Outlet Shift2 LP
Energy Stream Shift2-Q
Reactions | Details
Worksheet
Synthesis Gas, Temperature 400°C (752°F)
QUESTION: What is the molar flow rate of hydrogen in the Synthesis Gas stream?
QUESTION: What is the molar flow rate of nitrogen in the Synthesis Gas stream?
QUESTION: What is the ratio of hydrogen to nitrogen in the Synthesis Gas stream?
What is the easiest way to calculate this value in HYSYS? (E.g. not using a calculator,
MS Excel, etc.) [Write your answer below]
64. Save your case.
To control the temperature of the product stream leaving the combustion section (the
Shift1 Feed stream), the flow rate of steam to the Combustor Conversion reactor
operation is manipulated. It is desired to have an outlet temperature from the combustion
section of 930 C (1706 F). The steam flow can be adjusted manually until the desired
temperature is achieved. However, this might take a lot of time and will not be
automatically updated if something else in the process were to change. You can utilize
the Aspen HYSYS Adjust operation to adjust/manipulate one variable until the desired
condition is met for a define target variable
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65. Select the Adjust unit operation from the Object Palette and add it to the
flowsheet.
66. Attach the Adjusted Variable, Target Variable, and Target Value as shown:
67. Enter the Step Size as 20 kgmole/h (44 lbmole/hr) and define a Minimum of 0
kgmole/h on the Parameters tab.
A second Adjust operation will be used to manipulate the Air stream flow rate. This is
important as the Air flow rate determines the ratio of hydrogen to nitrogen in the
synthesis gas product. We want this value to be set at 3.5.
Since a component ratio is not a normally available HYSYS variable, it needs to be
calculated within the program and made available to other features. This is a great
opportunity to apply the HYSYS Spreadsheet. So if you did not already create a
Spreadsheet to compute the hydrogen-to-nitrogen ratio in the Synthesis Gas stream, you
might want to do so now!
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68. Add another Adjust operation to your flowsheet. Select Air | Molar Flow as
the Adjusted Variable.
69. Select the Spreadsheet operation containing your calculated hydrogen-nitrogen

ratio as a Target Variable, and the cell containing that value as the Variable.
70. Set a Specified Target Value of 3.5.
71. Enter the Step Size of 20 kgmole/hr (44 lbmole/hr and ensure a Tolerance of
0.001 is specified on the Parameters tab
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In certain HYSYS simulations, solving two Adjust operations might result in the two
interfering with one another while they solve. This is because changing either one of the
adjusted variable may affect both target variables simultaneously. To prevent this
interference, the Adjusts can be set to solve simultaneously by using a different solution
algorithm.
72. Select the Simultaneous Solution checkbox on the Parameters tab of the
ADJ-1 operation.
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73. Repeat this procedure for the second Adjust operation, ADJ-1.
74. Start the simultaneous Adjusts solving by clicking the Start button on either
Adjust block.
You can also open the Adjust Manager menu from the Home tab in the ribbon. The
Adjust Manager allows you to manage and solve any and all simultaneously solved
Adjust blocks through a common interface.
75. Start the Adjust calculations and allow them to solve. You may need to initiate
the calculations from one Adjust rather than the Adjust Manager to get things
started.
QUESTION: What is the new Air stream molar flow rate? [Write your answer below]
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QUESTION: What is the molar flow rate of the Synthesis Gas product? [Write your
answer below]
76. Save your case.
Challenge Exercise
The Gibbs Reactor can be used to represent both equilibrium and constrained equilibrium
systems. Replace the Shift2 Equilibrium Reactor with a Gibbs Reactor, and specify the
same outlet temperature
1. Make the appropriate changes to the Gibbs Reactor to ensure the results are
consistent with the original simulation.
2. Save your case as 09-ReactorsChallenge.hsc.
Recommended Reading
How does HYSYS calculate the energy balance around a reactor?

Can I prioritize the reactions in a Conversion Reactor?

Equilibrium reactor predicts carbon formation while the Gibbs Reactor does not. Why?
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Notes:
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Reactors Solutions
Files can be found in folder: 09_Reactors
Questions
Task 3
QUESTION: What is the calculated heat flow/duty of the Reformer?
2.197 E+07 kJ/h (2.082 E+07 Btu/hr)
QUESTION: What is the calculated outlet temperature from the combustion section of
the reaction train?
719.9°C (1328 °F)
QUESTION: How much energy must be removed from Shift1 to meet the desired outlet
temperature?
8.234 E+06 kJ/h (7.804 E+06 Btu/hr)
QUESTION: What is the molar flow rate of hydrogen in the Synthesis Gas stream?
338.9157ole/h (747.1735 lbmole/hr)
QUESTION: What is the molar flow rate of nitrogen in the Synthesis Gas stream?
73.1597ole/h (161.2878 lbmole/hr)
QUESTION: What is the ratio of hydrogen to nitrogen in the Synthesis Gas stream?
What is the easiest way to calculate this value in HYSYS? (E.g. not using a calculator,
MS Excel, etc.)
4.633
Use a Spreadsheet; import in hydrogen and nitrogen molar flow rates in Synthesis Gas,
divide them by one another
QUESTION: What is the new Air stream molar flow rate?
117.2kgmole/h (258.4 lbmole/hr)
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QUESTION: What is the molar flow rate of the Synthesis Gas product?
875.5 kgmole/h (1930 lbmole/hr)
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Optimization Workshop
Files can be found in folder: 10_Optimization
Objective
In this workshop, you will make use of your Turbo Expander/Fractionation plant
simulation to introduce a pair of optimization techniques built into Aspen HYSYS and to
describe their corresponding applicability.
First, you will further apply the Spreadsheet operation in Aspen HYSYS to define an
objective function for the Original Optimizer, and using the available algorithms within
the Original Optimizer, find the maximize profit for the process. Then, you will apply
the Hyprotech SQP Optimizer to the same problem, albeit with various constraints. By
trying both optimization techniques, you can test out their relative functionalities.
In this workshop, you will examine certain operating parameters in the existing turbo
expander/fractionation flowsheet developed in earlier modules. Based on the Case Study
analysis in the previous workshop, there is a good indication that there may be an
optimum operating point from a profit perspective.
Aspen HYSYS contains a multi-variable steady state Optimizer tool. Once a flowsheet
has been built and a converged, the Optimizer can be used to find the operating
conditions that will minimize or maximize an Objective Function. The HYSYS Original
Optimizer has its own Spreadsheet to define the objective function and any constraint
expressions to be used. This gives the flexibility of constructing objective functions to
minimize utility usage, maximize profit, minimize exchanger UA, etc.
The Hyprotech SQP Optimizer will be presented as an alternative to the Spreadsheet-

based Original Optimizer. The Hyprotech SQP uses a sequential quadratic algorithm.
This algorithm can be used to solve complex problems containing many variables and
constraints and objective function elements (cost and profit items).
Task 1 – The Original Optimizer

Task 2 – Hyprotech SQP Optimizer
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Task 1 – The Original Optimizer
Optimization in steady-state Aspen HYSYS requires an iterative calculation that can be,
at times, tricky to converge. To help improve the convergence of the Optimization, it is
useful to tighten the convergence of any iterative objects within the overall flowsheet.
Before configuring the Original Optimizer, we will tighten the tolerance parameters for
the two column models and the LNG Exchanger. This should improve the accuracy of the
solution obtained via the optimization tools.
1. To begin the workshop, open the case 10-OptimizerStarter.hsc. It should be

available in your course files folder provided by your instructor.
2. Re-set the stream 2 temperature at -62 °C (-79.6 °F) and the stream 5 pressure
at 2800 kPa (406.1 psia).
3. Open the property view for the LNG Exchanger LNG-100 and change the
Tolerance value to 1.0 E-06 on the Design | Specs page.
4. View the Demethanizer column and change the Heat/Spec Error Tolerance to
1.0 E-06 on the Parameters | Solver page.
5. View the Deethanizer, set both the Equilibrium Error Tolerance and
Heat/Spec Error Tolerance to 1.0 E-06 on the Parameters | Solver page.
There are several optimization terms which will be used frequently in this portion of the
workshop.
Primary Variables correspond to flowsheet variables whose values are

manipulated in order to minimize or maximize the objective function. You set the
upper and lower bounds for the primary variables and these are used to set the
search range. Only user-specified process variables (i.e. blue numbers) can be
used as Primary Variables.
The Objective Function is the function which is to be minimized or maximized.

The function has to be defined within or referenced by the Optimizer Spreadsheet.
This allows the user a great deal of flexibility in defining the function.
The Constraint Functions are inequality and equality functions that are defined
in the Spreadsheet. In solving the Objective Function, the Optimizer must also
meet any constraints that are defined by the user.
In our case, we want to maximize the total profit while achieving a Reid Vapor Pressure
(RVP) of 1380 kPa (200 psia) from the liquid outlet of the Demethanizer column. We
also need to limit the power drawn from the K-100 Expander to 50 kW. The revenues
from the plant are based on the Deethanizer products and the associated costs are for
21 - 2
power and waste water disposal. The profits are defined as the difference between
revenues and costs.
6. To invoke the Optimizer, select Optimizer under the Analysis section on the
Home tab of the Ribbon, or press F5 on the keyboard.
Note: The Optimizer is not a unit operation block and it will not show up on the
flowsheet. It is only available for steady state calculations and cannot be used inside a
sub-flowsheet.
The Optimizer window should now appear.
7. Select Original for the Data Model.
8. Go to the Variables tab, and click on the Add button to add the Process
(Adjusted) Variables used in the optimization.
The optimization calculation will utilize the same independent variables used in the Case
Study from the previous workshop.
9. Add the first of these variables: Stream 2 | Temperature.
10. Continue by adding the second independent variable, Stream 5 | Pressure.
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11. Back on the Optimizer Variables form, set the Low Bound for the temperature
at -70 ºC and the High Bound at -40 ºC.
12. Define the pressure Low Bound at 2500 kPa and the High Bound at 3475 kPa.
13. Check your Adjusted (Primary) Variables against the image below:
Note: Reasonable upper and lower bounds are important. Use values which can be
achieved in your actual design. In other words, don’t set boundaries for a variable that
are less/more than what is available at your plant.
The Optimizer has its own Spreadsheet for defining the Objective Function and any
constraints. Primary Variables may be imported and functions defined within the
Optimizer Spreadsheet. This spreadsheet has the same capabilities as the standard
Spreadsheet operation.
14. Click the Spreadsheet button at the bottom of the Optimizer view to open the
Optimizer Spreadsheet.
15. Select the Optimizer Spreadsheet Parameters tab and make sure the Units Set
is SI.
16. Move to the Spreadsheet tab.
Had we not previously configured the Profit Analysis spreadsheet, then we would have to
add all the process economic calculations to the new Optimizer Spreadsheet. But since
all needed economic variables are readily available, we’ll just reference them within the
Optimizer Spreadsheet.
Since it is not possible to copy variables from one Spreadsheet and paste them into
another (i.e. all the variables will be pasted as numbers only, with no links to the
associated variables), we will import only the Temperature of stream 2, the Pressure of
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stream 5, and the calculated Profit Value to the Optimizer Spreadsheet. The remaining
variables will be left in the existing Profit Analysis spreadsheet.
17. Enter the following labels into the Optimizer Spreadsheet:
Cell... Label…
A1 Stream 2 Temp
A2 Stream 5 Pres
A4 Profit - $/hr
18. Import the variables in the table below into the Optimizer Spreadsheet.
Recall you can import variables into a Spreadsheet in a variety of ways – use the
approach you prefer.
Cell... Object... Variable...

B1 Stream 2 Temperature
B2 Stream 5 Pressure
B4 Profit Analysis D9: Profit
After all of the necessary variables have been imported the Spreadsheet should resemble
the following figure:
19. Close the Optimizer Spreadsheet and go to the Functions tab on the
Optimizer window.
The Functions tab in the Optimizer property view contains two groups: The Objective
Function and The Constraint Functions. This is where you will reference the item to be
optimized and any constraints that must be honoured.
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20. Click the drop-down menu in the field adjacent to the Cell entry in the
Objective Function group and select cell B4. Notice that the Current Value of
the Objective Function will be provided automatically.
21. Select the Maximize radio button.
Recall that we wish to maintain a Reid Vapor Pressure in the Demethanizer column
bottoms at 1380 kPa (200 psia) and that the K-100 Expander power must be capped at 50
kW. The RVP constraint is already achieved by the column algorithm as a specification
and therefore does not need to be defined in the Optimizer. The K-100 Expander power
limitation, on the other hand, must be defined.
22. Click the Add button to add a constraint on the Functions tab of the Optimizer.
23. Open the Optimizer Spreadsheet once again. In cell A6, type in the label: K-
100 Power. In cell A7, type in K-100 Power Limit.
24. Import the cell B6 variable to QK-100 | Power. In cell B7, simply type in 50 –
this value will represent the 50 kW power limitation on the K-100 Expander.
25. heck your constraint inputs to the Optimizer Spreadsheet using the image
below:
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26. Close the Optimizer Spreadsheet and return to the Optimizer Functions tab. In
the space for your added constraint, click in the LHS Cell field and select cell
B6. For the RHS Cell field, select cell B7.
27. Ensure the condition of the constraint shows B6 to be less than B7,as the
calculated value of the K-100 power must be less than the 50 kW limit
Note: When a constraint is defined, the Constraint Function is multiplied by the Penalty
Value. The higher the Penalty Value, the more weight is given to that constraint.
28. Go to the Parameters tab and select the Mixed method as the scheme for the
optimizer.
29. Reduce the Tolerance to 1.0 E-06.
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30. Keep the defaults for other parameters:
31. Move to the Monitor tab and click the Start button to begin the optimization.
Allow a few moments for all iterations to complete and the optimization
algorithm to converge.
QUESTION: What is the maximum profit? What is the stream 2 temperature and stream
5 pressure at this maximum? [Write your answer below]
QUESTION: Are there any concerns with the simulation at this optimum state? [Write
your answer below]
32. Save your case as 10-OriginalOpt.hsc
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Task 2 – Hyprotech SQP Optimizer
The Hyprotech SQP Optimizer uses a sequential quadratic programming (SQP)
algorithm. This algorithm can be used to solve complex problems containing many
independent variables and constraints as well as complex objective function elements
(cost and profit items).
The Hyprotech SQP requires the use of the Aspen HYSYS Derivative Model Analysis
feature to hold all the data used to define the Optimizer variables, constraints, and the
objective function. The first step in setting up an SQP optimization problem is by
creating a Derivative Analysis.
33. Continue with the HYSYS file you were utilizing at the conclusion of the last
task of this workshop.
34. Reset the original conditions in the material streams 2 and 5. Set the temperature
of stream 2 as -62 °C (-79.6 °F) and the pressure of stream 5 as 2800 kPa
(406.1 psia).
35. Click on the Model Analysis folder in the Navigation Pane, then click Add and
select a Derivative Analysis. Alternatively, select the Model Analysis icon in
the Home tab of the Ribbon and select Derivative.
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The Derivative Analysis property view appears.
The first step in setting up the Derivative Analysis is to define its scope. The Derivative
could govern a handful of unit operations, entire flowsheet, or just a single unit operation.
This provides some flexibility in that you can choose to optimize only a portion of your
overall model. This flexibility is just one of the enhancements the SQP Optimizer offers
over the Original Optimizer.
36. Click the Operation button found near the top of the Derivative Analysis form.
37. Choose the Flowsheet Wide option in the Object Filter group box near the
bottom-left corner.
38. Click the right-pointing arrows button in the middle of the form.
FlowSheetWide should then appear under the Scope Objects list.
39. Click Accept List when finished.
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The next step is to define the independent variables that the Optimizer will adjust/vary in
order to optimize the objective function. In the SQP Optimizer, these independent
variables are referred to as Optimization Variables, or OptVars. For this task of the
workshop, the optimization variables will be the same as for the previous task (Stream 2
Temperature and Stream 5 Pressure).
All Derivative Analysis variables (i.e. Optimization Variables, Constraint Variables, and
Objective Function variables) can be added directly from the Variables tab of the
Derivative Analysis window. There is a drop-down list in the top-right of the window
that allows you identify each one of these variable types. Clicking the Add button when
one of these options are visible adds one of those variable types to the Derivative
Analysis. There are four options: Process Constraints (ProcCons), Optimization
Variables (OptVars), Objective Function (ObjFunc), and State Variables (StateVars).
40. Select OptVars from the variable selection pull-down menu and click the Add
button. A variable selection menu should then appear.
41. Browse for Stream 2 as the Object, and Temperature as the Variable. Click
Done when finished.
An Optimization Variable is now created (Stream 2 Temperature) and has been added
into the Derivative Analysis. You can see your variable when viewing the Variables |
Config. view from the left-side menu. The new variable is given a default name,
OptV100. However, you can edit the variable name to a more descriptive term directly
from this form.
42. Make sure you are viewing the Variables | Config page of the Derivative
Analysis and rename the variable Chiller Exit Temp.
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In this Variables | Config. window, note that it is the Object Name column that lets you
modify the name of the created variables. In addition, the Attached Object and Property
columns are also displayed in the view, as well as the current value of the variable. These
indicate the flowsheet location of the variable.
The left-side menu on the Derivative Analysis window contains various views for each
selected variable type:
Option Description
All All Properties
Input Properties requiring user input
Output Calculated and outputted values
Results Solution results
The items on the Input form for optimization variables are: Optimize Flag, Minimum,
Maximum, Range (optional), Global Minimum and Global Maximum. The Global items
are appropriate only for real-time applications and can be left at the same values as the
Minimum and Maximum.
The Optimize Flag works in conjunction with the Optimizer to expose desired variables.
When the optimization problem is being set up, this flag is evaluated for each variable. If
the flag is false (un-checked), then the variable is not exposed to the Optimizer and the
value remains at its starting value for the duration of the solution. This allows you to
easily switch between optimization problems by turning variables and constraints on and
off.
The value for the variable Range is used in the calculation of a perturbation (i.e. the range
multiplied by the perturbation factor). If none is provided, the span (maximum -
minimum) is used for the calculations. Typically this is left blank.
For this workshop exercise, we need to add all the remaining optimization variables.
Remember that only user defined variables can be selected as they must be available for
adjustment during the optimization.
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43. Click the Add button with the OptVars option selected in the variable type
drop-down list.
44. Select stream 5 | Pressure and rename the new variable as Exp Exit Pres on the
Variables | Config. Form.
Your completed list of optimization variables should be as shown below:
Note: In case you added the wrong variable, or added one too many variables, you can
go back and delete anything that is unneeded. Simply double-click on the unneeded
variable and a separate window should appear. Click Delete on that new window.
45. Select the Variables | Input from the left-side menu.
46. Complete the Minimum and Maximum values for each of the variables.
Minimum Variable Maximum

-70 ºC Chiller Exit Temp -40 ºC
2500 kPa Exp Exit Pres 3460 kPa
Check your bounds against the image below:
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The SQP Optimizer is able to solve constrained optimization problems. In the workshop
case, it will be necessary to maintain some power requirements within certain limits.
These limits will be added to the Derivative Analysis as constraint-type variables.
The SQP Optimizer treats all constraints as ranged constraints. This means that the value
of the constraint should lie between the minimum and maximum at solution. The Scale
value can be considered as an approach, or as the boundary around the minimum and
maximum values that defines whether the constraint is active, or violated. This
information is reported during and after the solution as the status of the constraint.
It is a requirement that at least one constraint be defined when using the SQP Optimizer.
In your case, you’ll provide two constraints: the first will limit power produced by the K-
100 Expander at 50 kW; the second will limit the total power consumption of the process
at 6500 kW.
47. Select ProcCons (process constraint) as the variable type from the variable-type
selection menu in the top-right corner. Then click Add.
48. Choose QK-100 | Power and click Done, in the variable selection window.
You should see the added variable under the Constraints/Objective Function tab of the
Derivative window. Look in the Process Constraint | Config. form and it should be
available.
49. Rename the newly added constraint to Expander Power.
50. Select the Process Constraint | Input view and define the minimum expander
power as 0 kW and the maximum value as 50 kW.
21 - 14
51. Set the Scale value to 1.0.
52. Click the Add button once again to add another constraint (ProcCons) variable.
This constraint will represent the total power of the process. This was calculated in
your Profit Analysis Spreadsheet. Select the proper variable most likely cell B7) and
click Done.
53. Rename the variable as Total Power, on the Process Constraint | Config form.
54. Move to the Process Constraint | Input form and set the Minimum to 0 kW
and the Maximum as 6500 kW. Make sure the Scale is set as 1.0.
21 - 15
Objective Function variables are installed individually, which facilitates the calculation of
the gradient during the course of Jacobian evaluations. Alternatively, an Objective
Function can be built in a Spreadsheet operation, with a single cell representing the
results and having a single Objective Function object attached to this result cell. This
approach aligns with our case as we have already computed the Profit of our process in
the Profit Analysis Spreadsheet.
All the variables with an associated cost or revenue may be entered on the Constraints/
Objective Function tab. The Hyprotech SQP Optimizer can either minimize or maximize
the Objective Function. Objective Function variables also include a Price input.
Typically this Price value is set as positive for a credit, and negative for a debit. Most
frequently the Price term is used when defining the Objective Function inside the
Derivative Analysis. In your case, you’ll just make sure the Price is a positive value and
you’ll choose to maximize the function. But in theory, you could set the Objective
Function as a negative, and set the Optimizer to minimize – but this is a bit backwards!
Every single objective function variable will have its current value multiplied by the
associated cost/revenue. The Jacobian will modify the individual values that will result
in a global optimum based on the sum of all the values from the list.
55. Click the Add button with the ObjFunc option selected to add an objective
function variable.
56. Browse for the Profit Analysis Spreadsheet as the Object, with D9: Profit as
the Variable. Click Done when finished.
The SQP Optimizer will be configured to maximize the objective function, so we must
ensure that the profit value that it sees is positive. This is achieved by giving it a price of
1.0.
57. Move to the Objective Function item in the left-side menu. Rename the
Objective Function variable as Profit.
58. Make sure the Price value reads as 1.0.
21 - 16
Now that the optimization variables, constraints, and objective function have been
identified and defined, you are done with the Derivative Analysis. Recall that the
purpose of the Derivative Analysis is to hold and organize all the SQP Optimizer
variables. The actual settings for Optimization and numerical/convergence related items,
are still coordinated through the Optimizer menu.
59. Go back to the Optimizer window by selecting it from the Home tab of the
Ribbon, or pressing F5 on your keyboard.
60. Select Hyprotech SQP as the optimizer configuration, On the Configuration

tab.
61. Click the Hyprotech SQP tab and select Maximize from the Objective
Function drop-down menu in the Setup group box. This option indicates that
the objective function defined in the SQP Derivative Analysis will be
maximized.
62. Click on the Select Utilities to Run button in the bottom-left corner. In the pop-
up window select the check box next to the Derivative-FlowSheetWide utility
21 - 17
to activate it. Then close the pop up window. Check your settings against the
following image:
63. Move to the Monitor tab so you can follow the optimization calculations as
they run. Then click the Start button to run the Optimizer.
64. Save your case as 10-SQPOpt.hsc.
QUESTION: What is the Profit value as derived from the SQP Optimizer? [Write your
answer below]
QUESTION: Are both constraints honoured? What is the calculated K-100 Expander
power? Total power? [Write your answer below]
21 - 18
Recommended Reading
In the optimization problem, what is the difference in treatment of a constraint vs. a hard
constraint?

User Unit Operation to specify (and optimize) column feed location
21 - 19
Notes:
21 - 20
Optimization Solutions
Files can be found in folder: 10_Optimization/Solutions
Questions
Task 1
QUESTION: What is the maximum profit? What is the stream 2 temperature and stream
5 pressure at this maximum?
Profit = 1110.3 $/hr; Temperature = -40.0 °C; Pressure = 3475 kPa
QUESTION: Are there any concerns with the simulation at this optimum state?
Yes – two problems stand out on the flowsheet

1) There is a pressure rise across VLV-100; the optimum pressure might be too high
2) The K-100 Expander power calculates as a small negative number, this affects the
K-101 Compressor – whose power is linked to the Expander
Task 2
QUESTION: What is the Profit value as derived from the SQP Optimizer?
1109.5$/hr
QUESTION: Are both constraints honoured? What is the calculated K-100 Expander
power? Total power?
Yes; K-100 power = 0.145 kW; Total power = 3662.9 kW
21 - 21

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EHY202

Course Number EHY202_V9.0_rev1

Aspen Technology may provide information regarding possible future product

Getting Started 2-1

Workshop # 2: Advanced Columns Workshop 5-1

Model an Acid Gas Cleaning Process 6-1

Workshop # 3: Model an Acid Gas Cleaning Process Workshop 7-1

Workshop # 4: Sulsim Workshop 9-1

Modeling Real Separators 10 - 1

Workshop # 5: Model Real Separators Workshop 11 - 1

Workshop # 6: Dynamic Depressuring Workshop 13 - 1

Workshop # 7: Blowdown Workshop 15 - 1

Safety Analysis Environment 16 - 1

Workshop # 8: Safety Analysis Workshop 17 - 1

Workshop # 9: Reactors Workshop 19 - 1

Workshop # 10: Optimization Workshop 21 - 1

This workshop includes the following tasks:

Task 1 – Set Up the Turbo Expander

Task 1 – Set Up the Turbo Expander

3. Select Nitrogen, CO2, Methane, Ethane, Propane, i-Butane, n-Butane, i-

7. Add a Material Stream representing a mixture of natural gas, condensate, and

Name Feed Gas

Name Feed Mix

In This Cell... Enter...

Name Inlet Sep

Inlet Feed Mix

Vapour Product Inlet Sep Vap

Light Liquid Product Inlet Sep Liq

Heavy Liquid Product Inlet Sep Water

9. Double click on the LNG Exchanger button on the Object Palette.

Inlet Stream Outlet Stream Pressure Drop Hot/Cold

12. Go to the Design | Specs (SS) page.

16. Add a Blank Sub-Flowsheet to your simulation:

17. Select the option to Read an Existing Template.

20. Re-name the sub-flowsheet as Mixed Refrig Unit, on the Sub-Flowsheet

In This Cell... Enter...

In This Cell... Enter...

24. Add a two-phase Separator to the flowsheet and define it as shown:

In This Cell... Enter...

25. Add a Valve to the flowsheet using the following connections:

In This Cell... Enter...

In This Cell… Enter…

27. Save your case as 01-GettingStarted.hsc.

Task 2 – Adding the Fractionation Columns

28. Add a Cooler to the flowsheet, using the following data:

In this cell... Enter...

Using the Column Sub-flowsheet provides a number of advantages such as isolation of

Top Stage Inlet 10

Bottom Product Stream 11

QUESTION: Go to the Performance | Summary page. What is the mole fraction of

44. Save your case.

In this cell... Enter...

In this cell... Enter...

50. One more specification is needed. Specify a fractional recovery specification

52. Save your case.

In This Cell... Enter...

In this cell... Enter...

56. Save your case.