07 WKS RefrigeratedGasPlant

Aspen HYSYS: Process Modeling
Refrigerated Gas Plant Workshop
Table of Contents
Refrigerated Gas Plant Workshop ............................................................................... 5 - 14
Refrigerated Gas Plant Solutions ................................................................................. 5 - 34
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5 13
Aspen Technology, Inc.

Files can be found in folder: 04_RefrigeratedGasPlant
Objective
After completing this workshop, you will be able to define and calculate the Heat
Exchanger unit operation as well as implement two logical operations; the Balance and
the Adjust. You will also learn how to install a template file into an existing HYSYS
simulation.
Description
In this workshop, a simplified refrigerated gas plant will be modelled to determine the
operating conditions required to meet the product dew point target. In this scenario, the
hydrocarbon dew point temperature of the product gas stream should be equal to -15 C
(5 F) at 6000 kPa (870 psia).
This workshop includes the following tasks:
Task 1 Building the Base Case

Task 2 Adding a Balance Operation
Task 3 Configuring an Adjust Operation
Task 4 Installing a Template
Task 1 Building the Base Case

The GasPlant.fpk fluid package which was created in the Getting Started workshop will
be used as the starting point for this simulation. By utilizing this Fluid Package file, you
avoid the re-work of defining components and physical property options that are already
available elsewhere. This approach helps to standardize physical property assumptions
across a spectrum of simulations by a variety of HYSYS users.
5 - 14
Open Aspen HYSYS and create a New case.

Select the Fluid Packages folder from the Navigation Pane and click the Import
button at the bottom of the form.
Navigate to the GasPlant.fpk Fluid Package file you exported during the Getting
Started workshop. Once you locate and select the file, click Open.
Review the data included in the GasPlant.fpk file. You should note that both the
Peng-Robinson property package and component list from the Getting Started
workshop are in place.
Click the Simulation Environment button to continue.
5 - 15
Add a new Material Stream to the flowsheet with the following values:
In this cell...
Enter...
Name
To Refrig
Temperature
15C (59F)
Pressure
6200 kPa (900 psia)
Flow Rate
1440 kgmole/h (3175 lbmole/hr)
Component Mole Fraction
Nitrogen
0.0066
H 2S
0.0003
CO2
0.0003
Methane
0.7575
Ethane
0.1709
Propane
0.0413
i-Butane
0.0068
n-Butane
0.0101
i-Pentane
0.0028
n-Pentane
0.0027
n-Hexane
0.0006
H 2O
0.0000
C7+
0.0001
Add a Separator to your flowsheet.

Enter the following information on the Design | Connections page of the
Separator to fully define the operation:
In this cell...
Enter...
Name
Inlet Gas Sep
Feed
To Refrig
Vapour Outlet
Inlet Sep Vap
Liquid Outlet
Inlet Sep Liq
5 - 16
Next, you will add a HYSYS Heat Exchanger unit operation. The Heat Exchanger
performs energy and material balance calculations based on a shell and tube-type
exchanger. Depending upon the input parameters, the heat exchanger is capable of
solving for stream temperatures, pressures, mass flows, heat flows (including heat loss
and heat leak) and UA.
Double-click the Heat Exchanger icon on the Object Palette.
On the Design | Connections page, enter the following information:
In this cell...
Enter...
Name
Gas-Gas
Tube Side Inlet
Inlet Sep Vap
Tube Side Outlet
Gas to Chiller
Shell Side Inlet
LTS Vap
Shell Side Outlet
Sales Gas
Select the Design | Parameters page and select Simple Weighted as the Heat
Exchanger Model.
Enter a pressure drop of 7 kPa (1 psi) for the shell side 35 kPa (5 psi) for the tube
side.
5 - 17
To solve the heat exchanger, unknown parameters such as stream flows and temperatures
are manipulated by the solver in order to meet user defined design specifications. Each
design constraint that is entered will reduce the degrees of freedom for the heat exchanger
by one. In order to arrive at a unique solution, the number of constraints must equal the
number of unknown variables.
To solve for the unknown product temperatures in the Gas-Gas exchanger, two design
constraints are needed. You will use the heat balance between hot and cold sides (this is
a default) and a minimum approach temperature specification.
Select the Specs page from the Design tab. Note the first listed specification
mentions a heat balance. This specification is used to ensure that the heat transfer
equations balance for both sides of the exchanger. As a default specification, it is
always enabled by Aspen HYSYS.
Remove the default UA specification by deactivating the Active check box for the
E-100 UA specification.
To add the minimum approach specification, click the Add button on the right
side of the form.
Provide the following information for the Gas-Gas exchanger specification:
In this cell...
Enter...
Name
Temp Approach
Type
Min Approach
Pass
Overall
Spec Value
5C (9F)
The Minimum Approach Temperature defined above is the minimum temperature

difference between the hot and cold stream at any point inside the exchanger.
5 - 18
The Gas-Gas exchanger is not yet ready to solve as the shell side flow rate is not
known. But make sure your Design | Specs form looks like the one below and
move on. The exchanger will solve once the remainder of the flowsheet is
specified.
Note: You can have multiple Estimate specifications. These are just used as initial
conditions to help the exchanger solve. The Heat Exchanger will only use the Active
specifications for the final solution.
Return to the flowsheet and add a Cooler operation, providing the following
information:
In this cell...
Enter...
Connections
Name
Chiller
Inlet Stream
Gas to Chiller
Outlet Stream
Gas to LTS
Energy Stream
Chiller-Q
Parameters
Delta P
35 kPa (5 psia)
5 - 19
Add a Separator and provide the following information on the Connections form:
In this cell...
Enter...
Name
LTS
Inlet Stream
Gas to LTS
Vapour Outlet
LTS Vap
Liquid Outlet
LTS Liq
The flowsheet still has not calculated from the Gas-Gas heat exchanger on
downstream. The LTS Separator is actually the critical item in this flowsheet.
What piece of information is required for the LTS separator to solve that is not
available?
In the next workshop task, the LTS feed temperature will be varied using an Adjust
operation to find a temperature at which the dew point constraint is met. For now, you
will simply estimate a constant value for this temperature.
Specify the temperature of stream Gas to LTS at -20 C (-4 F).

The entire flowsheet should now calculate. What is the temperature of the Sales
Gas stream?
Save your case as 04-RefrigGasPlant.hsc.
5 - 20
Task 2 Adding a Balance Operation

The Balance operation provides a general purpose heat and material balance facility.
There are several different Balance calculation options available in Aspen HYSYS, as
described in the table below:
Balance Type
Description
Component Mole Flow
An overall balance is performed in which only the molar flow of

each component is conserved. Combined outlet streams will
have the same component flow rates as the combined inlet
streams, but will contain no vapour fraction, temperature, or
pressure values.
Mass Flow
An overall balance is performed in which only the mass flow is

conserved. The outlet stream will contain no composition, vapour
fraction, temperature, or pressure.
Heat Flow
An overall balance is performed in which only the heat flow is

conserved.
Component Mole and

Heat Flow
An overall balance is performed in which the heat and

component molar flows are conserved.
Mass and Heat Flow
An overall balance is performed in which the heat and

component mass flows are conserved.
If you open the property view of the Sales Gas stream, you will notice that the stream
parameters are all calculated, so there is no direct way to calculate a dew point
temperature at 6000 kPa (870 psia). Adding a Component Mole Flow Balance allows
you to create a second stream with the same flow rate and composition as the Sales Gas,
without fixing the vapor fraction, temperature, or pressure.
Add a Balance operation by double-clicking the Balance icon on the Object

Palette.
Add the following information on the Connections tab:

In this cell...
Enter...
Inlet Stream
Sales Gas
Outlet Stream
HC Dewpoint
Type (on Parameters tab)
Component Mole Flow
5 - 21
Return to the flowsheet and double-click the HC Dewpoint stream.

Specify a Pressure of 6000 kPa (870.2 psia) and a vapor fraction of 1.0. This
will allow the HC Dewpoint stream to calculate its dew point temperature based
on composition.
5 - 22
What is the calculated dew point temperature in HC Dewpoint?
The required dew point temperature is -15 C (5 F); is the current dew point
temperature higher or lower?
Assuming that pressure is fixed, what other parameter affects the dew point
temperature?
Save your case as 04-RefrigGasPlantBal.hsc.
Task 3 Configuring an Adjust Operation

The Adjust is another logical operation; meaning, like the Balance operation, it is a
mathematical calculation rather than a physical unit operation. The purpose of an Adjust
is to vary the value of one process variable (the independent variable) to meet a target
value or specification (the dependant variable) elsewhere in the simulation.
Double-click the Adjust icon on the Object Palette; the Adjust property view
displays.
5 - 23
Click the Select Var... button in the Adjusted Variable group.
The Variable Navigator view displays. From the Object list, select Gas to LTS.
From the Variable list, select Temperature.
Note: The Adjusted Variable must always be a user-specified value!
5 - 24
Click OK to accept the variable and return to the Adjust property view.
Click the Select Var... button in the Target Variable group.
Select the object HC Dewpoint, and then select Temperature as the variable.
Note: Always work left to right in the Variable Navigator window. Dont forget you can
use the Object Filter on the right side of the form when the Object list is large to help
narrow-down your options to only streams, only unit ops, etc.
Click OK to accept the variable and return to the Adjust property view.
Enter a value of -15 C (5 F) in the Specified Target Value box.
Select the Parameters tab. Here you can specify a different Tolerance or Step
Size value from the defaults, or provide minimum/maximum allowable values for
the Independent variable. In this case the default settings are sufficient.
Note: When adjusting certain variables, it is often a good idea to provide a minimum or
maximum which corresponds to a physical boundary, such as zero for pressure or flow.
5 - 25
Take note of the Step Size used. When entering a step size, select a sufficiently large
value such that an approximate solution can be achieved in two or three iterations. Since
the Secant convergence method works best once the solution has been bracketed, a larger
step size ensures that you are more likely to bracket the solution quickly. It is also
recommended to try a manual change on the adjusted variable prior to running the Adjust
so as to verify the relationship between the adjusted and target variables.
Click Start to begin calculations. To view the progress of the Adjust calculation,
select and view the Monitor tab.
What Chiller outlet temperature is required to achieve the dew point specification?
Save your case as 04-RefrigGasPlantAdj.hsc.
5 - 26
Task 4 Installing a Template

The current setup of your Refrigerated Gas Plant uses a simple Cooler model for the Gas
Chiller. The next step will be to link the Propane Refrigeration Loop you built in the last
workshop to that Chiller. Once linked, the refrigerated propane in the refrigeration loop
will be providing the cooling duty to chill the gas.
View the Object Palette and double-click the Blank Sub-flowsheet icon:
In the Sub-Flowsheet Option dialog box that appears, select Read an Existing
Template.
Navigate to the 03-PropaneLoop.tpl file you saved in the previous workshop,

select it, and click Open.
Note: Once a template is installed as a new sub-flowsheet, any subsequent changes only
affect the template objects as they exist in the current simulation. These changes would
not affect the template file from which the sub-flowsheet was derived.
On the Connections tab of the Sub-Flowsheet Operation property view, you can define all
the inlet and outlet connections between the sub-flowsheet and the main flowsheet. Inlet
connections are material or energy streams entering the sub-flowsheet; Outlet
connections are streams leaving the sub-flowsheet.
5 - 27
In the Inlet Connections to Sub-Flowsheet group box, click the External

Stream box next to Chill-Q and select Chiller-Q from the drop down menu.
You will notice the Chill-Q stream on the sub-flowsheet side is automatically
renamed Chiller Q to match the main flowsheet stream name.
Note: Internal streams refer to streams in the sub-flowsheet. External streams are located
in the main/parent flowsheet.
5 - 28
Rename the sub-flowsheet C3 Refrig Loop.
Aspen HYSYS allows for the option to model a sub-flowsheet using a different fluid
package than the main flowsheet. As a result, a flash calculation must be done for any
material streams passing between flowsheets, as each fluid package could calculate
different vapour-liquid equilibrium or transport properties. The type of flash calculation
performed at a flowsheet boundary is fixed by the user via the Transfer Basis tab on the
Sub-Flowsheet Operation property view. A brief description of each option is given in
the table below:
Flash Type
Description
P-H Flash
The Pressure and Enthalpy of the material stream are passed

between flowsheets. A new temperature and vapour fraction
will be calculated. Since the Enthalpy basis may be different for
each property package this option is only recommended when
the same fluid package is in use for both material streams in the
two flowsheets.
T-P Flash
The Pressure and Temperature of the Material stream are

passed between flowsheets. A new Vapour Fraction will be
calculated.
VF-T Flash
The Vapour Fraction and Temperature of the Material stream

are passed between flowsheets. A new Pressure will be
calculated.
VF-P Flash
The Vapour Fraction and Pressure of the material stream are

passed between flowsheets. A new temperature will be
calculated.
None Required
No calculation is required for an Energy stream. The heat flow

will simply be passed between flowsheets.
In this case, the appropriate choice for a transfer basis would be None Reqd, since
only energy streams pass across the flowsheet boundary. Next, youll explore linking the
parent flowsheet and sub-flowsheet with material streams. This can be a bit of a
challenge when the two flowsheets utilize different Fluid Packages.
Click the Properties Environment button and view the Fluid Packages folder.
Note that there are two Fluid Packages, one associated with the Refrigerated Gas
Plant (GasPlant), and another associated with the Propane Loop (Basis-1). Both
Fluid Packages use the same property package (Peng-Robinson) and the Propane
Loop component (propane) also exists in the GasPlant Fluid Package.
5 - 29
Based on these observations in the Properties Environment, the GasPlant Fluid

Package can be applied to the Propane Refrigeration Loop in the sub-flowsheet.
Return to the Simulation Environment.
Click the Fluid Package Associations button in the Home tab of the HYSYS
ribbon.
Change the Fluid Pkg To Use for the C3 Refrig Loop to GasPlant.
By specifying both the parent flowsheet and sub-flowsheet to use the same Fluid
Package, you are avoiding potential issues that can arise when linking those flowsheets
together. Recall earlier you reviewed available Transfer Basis options for linking
together parent flowsheet and sub-flowsheet material streams. By listing just one Fluid
Package for the entire simulation, you can avoid dealing with Transfer Basis calculation
problems in most cases.
When two different Fluid Packages are required (one in each flowsheet), then the
treatment of Transfer Basis options becomes more complex. To determine an appropriate
Transfer Basis, it is usually a requirement to analyze the connecting material streams,
noting which process variables are specified and which are calculated. These variables
must agree with the Transfer Basis, which indicates the variables to be held constant
across the parent flowsheet/sub-flowsheet transition.
5 - 30
Return to the flowsheet and double-click on the sub-flowsheet icon. Select the
Sub-Flowsheet Environment button. The Propane Refrigeration Loop
flowsheet will then display.
What is the calculated molar flow rate of propane in the refrigeration loop?
Return to the Parent (main) flowsheet by clicking the Go to Parent icon in the
Flowsheet/Modify tab of the ribbon.
Save your case as 04-RefrigGasPlantTempQ.hsc.
The gas chiller is currently represented by linking a Cooler and Heater together via a
common energy steam. This assumes each unit operation as one side of a theoretical
heat exchanger. Although this can be a simple and effective way to simulate a heat
exchanger, it is an impractical way to assess certain performance-related parameters such
as exchanger UA and LMTD. It also makes it difficult to detect operational concerns like
temperature crosses. In the next section, the heater and cooler operations representing the
gas chiller will be replaced with a single heat exchanger unit operation.
Taking this approach will require material stream connections between the parent and
sub-flowsheet levels. Since you defined both levels to use the same Fluid Package, you
should find that these connections should compute without problem!
In the Main flowsheet, delete the Chiller operation and Chiller-Q energy stream.
Add a Heat Exchanger and enter the following information:
In this cell...
Enter...
Connections
Name
Chiller HX
Tube Side Inlet
Gas to Chiller
Tube Side Outlet
Gas to LTS
Shell Side Inlet
C3 In
Shell Side Outlet
C3 Out
Parameters
Heat Exchanger Model
Simple Weighted
Shell Side Pressure Drop
7 kPa (1 psi)
Tube Side Pressure Drop
35 kPa (5 psi)
5 - 31
Return to the flowsheet and double-click the C3 Refrig Loop icon and click the
Sub-Flowsheet Environment button.
Delete the Chiller operation and Chiller-Q energy stream from the sub-flowsheet.
Return to the Main flowsheet by clicking the Go to Parent button on the
Flowsheet/Modify ribbon tab.
Select the Connections tab of the Sub-flowsheet view and click on the External
Stream box beside 3 and select C3 Out from the drop down menu.
In the Outlet Connections to Sub-Flowsheet group box, click the External

Stream box next to 2 and select C3 In from the drop down menu. The Chiller
HX heat exchanger should be able to solve.
What is the UA of Chiller HX? What is the minimum approach temperature?
Save your case as 04-RefrigGasPlantTempHX.hsc.
5 - 32
Challenge Exercises
The available UA for the Gas-Gas Heat Exchanger is only 2.0 E+05 kJ/C-h (1.053 E+05
Btu/F-h). Make the necessary modifications to your exchanger specifications to achieve
this UA.
How does this affect your exchanger LMTD and minimum approach temperature?
In the previous section, the heater and cooler operations representing the chiller were
replaced with a single heat exchanger in the main flowsheet. To facilitate this, two new
streams were created in the main flowsheet and linked with the chiller feed and product
streams in the refrigeration sub-flowsheet.
Reload the 04-RefrigGasPlantTempQ.hsc file you saved in Task 4.

Remove the Chiller unit operations and associated energy streams from both the
parent and sub-flowsheets.
Add a Heat Exchanger with the same settings as Chiller HX used in Task 4 with
one exception! Utilize the propane refrigerant streams already available in the
sub-flowsheet instead of creating new streams.
Hint: Change the Shell Side Flowsheet on the Heat Exchanger Connections page to
access the sub-flowsheet streams.
Is your model able to solve? Would you prefer this approach of linking the parent
flowsheet to the sub-flowsheet, or the option utilized in Task 4 of the workshop?
Recommended Reading
Knowledge Base Solution 123378
Difference between 'Define from other stream' and 'Balance' unit operation
How can I convert a flowsheet into a template? Can I convert a subflowsheet into a
template?
What does "Transfer Basis" mean?
5 - 33
Refrigerated Gas Plant Solutions

Files can be found in folder: 04_RefrigeratedGasPlant/Solutions
Questions
Task 1
The flowsheet still has not calculated from the Gas-Gas heat exchanger on
downstream. The LTS Separator is actually the critical item in this flowsheet.
What piece of information is required for the LTS separator to solve that is not
available?
The inlet stream (Gas to LTS) temperature is unknown and therefore needs to be
specified.
What is the temperature of the Sales Gas stream?
10 C (50 F)
Task 2
What is the calculated dew point temperature in HC Dewpoint?
-19.8 C (-3.64 F)
The required dew point temperature is -15 C (5 F); is the current dew point
temperature higher or lower?
The current dew point is lower than the required dew point.
Assuming that pressure is fixed, what other parameter affects the dew point
temperature?
Composition will also affect the dew point temperature of Sales Gas.
5 - 34

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Aspen HYSYS: Process Modeling

Refrigerated Gas Plant Workshop

Aspen HYSYS: Process Modeling

Refrigerated Gas Plant Workshop

2015 AspenTech. All Rights Reserved.

Aspen Technology, Inc.

Aspen HYSYS: Process Modeling

Refrigerated Gas Plant Workshop

Refrigerated Gas Plant Workshop

Task 1 Building the Base Case

Task 1 Building the Base Case

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Aspen HYSYS: Process Modeling

Refrigerated Gas Plant Workshop

Open Aspen HYSYS and create a New case.

Click the Simulation Environment button to continue.

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Aspen HYSYS: Process Modeling

Refrigerated Gas Plant Workshop

6200 kPa (900 psia)

1440 kgmole/h (3175 lbmole/hr)

Component Mole Fraction

Add a Separator to your flowsheet.

Inlet Gas Sep

Inlet Sep Vap

Inlet Sep Liq

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Aspen HYSYS: Process Modeling

Refrigerated Gas Plant Workshop

Double-click the Heat Exchanger icon on the Object Palette.

On the Design | Connections page, enter the following information:

Tube Side Inlet

Inlet Sep Vap

Tube Side Outlet

Shell Side Inlet

Shell Side Outlet

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Aspen HYSYS: Process Modeling

Refrigerated Gas Plant Workshop

The Minimum Approach Temperature defined above is the minimum temperature

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Aspen HYSYS: Process Modeling

Refrigerated Gas Plant Workshop

2015 AspenTech. All Rights Reserved.

Aspen Technology, Inc.

Aspen HYSYS: Process Modeling

Refrigerated Gas Plant Workshop

Specify the temperature of stream Gas to LTS at -20 C (-4 F).

Save your case as 04-RefrigGasPlant.hsc.

2015 AspenTech. All Rights Reserved.

Aspen Technology, Inc.

Aspen HYSYS: Process Modeling

Refrigerated Gas Plant Workshop

Task 2 Adding a Balance Operation

Component Mole Flow

An overall balance is performed in which only the molar flow of

An overall balance is performed in which only the mass flow is

An overall balance is performed in which only the heat flow is