Aspen HYSYS Training

Module 3: Basic Equipments in HYSYS

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

Supported by:

BASIC EQUIPMENTS IN HYSYS

1. Mixer
2. Tee (Flow Splitter)
3. Separator

8.Cooler
9. Heater
10. Heat Exchanger

4. Pump
11. Reactor CSTR
5. Compressor
6. Expander
7. Valve

12. Reactor PFR

13. Distilation Column

1. Mixer
Important Design

Unit Function
To Mix/Combine

Parameter
Automatic Pressure

two/multiple feed streams

Assignment

as one product stream

Equalize All
Set Outlet to Lowest
Inlet

OPEN EXERCISE 3.1

Objective of Unit
To calculate the final properties of
mixed fluid (using flash calculation)

1. Mixer (Contd)
A. Set Outlet to Lowest Inlet

1. Mixer (Contd)
B. Equalize All

2. Tee (Flow Splitter)

Unit Function
To divide one feed
stream into
two/multiple
product streams

Important Design
Parameter
Flow Ratio
Flow ratio (Fr) for
each stream
0 Fr 1

Objective of Unit
To get multiple product streams
with same operating condition (P&T)
and composition as feed stream

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

2-Phase
Separator
3-Phase
Separator

3. Separator
Separation in HYSYS
1. HYSYS use P-H flash to determine
Products:
P : lowest Feed Pressure Delta
Pressure

2-Phase
Separator
3-Phase
Separator

H: Sum of Feed Enthalphy Duty

3. Separator
Important Design
Parameter
Delta P (Pressure Drop)
Inlet
Vapor Outlet

By Default: Delta P = 0
Actual : Delta P > 0

3. Separator
Unit Function
To separate multiphase feed stream/streams into several single
phase product stream (vapor, light liquid, heavy liquid)

BY DEFAULT:
Separator Unit
in HYSYS
PERFECT
SEPARATION
ACTUAL:
NO PERFECT
SEPARATION
IF REQUIRED
Separator Unit
in HYSYS
can model
IMPERFECT
SEPARATION

4. Pump
Basic Theory:
1. Objective of pump :
Transfer/move liquid from source to
destination (higher head)
Circulate liquid around a system

System
curve

System
head

2. Pumping System Characteristic

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

Friction
head
Static head

Flow
Pump performance
curve

Head

System
curve

Static
head

Flow

Pump
operating
point

4. Pump
Unit Function
To increase the head of inlet liquid
stream
Objective of Unit
To calculate one of these unknown data:
Pressure
Temperature
Pump Horse Power
Pump Efficiency

4. Pump
Important Design
Parameter
Delta P
Adiabatic Efficiency
Duty (Pump Horse Power)

4. Pump
Pump Curve Head Vs. Flow
Commonly, this curve is provided by vendor
Check this box to use
the pump curve

Pump performance
curve

Head

System
curve

Static
head

Flow

Pump
operating
point

5. Compressor
Ideal Work is calculated for mechanically reversible process
Along a particular compression path

Adiabatic Compressor

- Follow Isentropic compression

path from inlet pressure to outlet
pressure

Polytropic Compressor

- Compression path is also

adiabatic or isothermal
Actual Work and H is determined
from Wrev and Efficiency
T &/ or P is determined from H

5. Compressor
Unit Function
To increase the head of inlet gas
stream by adding Work.
Objective of Unit
To calculate one of these unknown data:
Pressure
Temperature
Compressor Horse Power
Compressor Efficiency

5. Compressor
Important Design Parameter
Compressor Efficiency:
Adiabatic Efficiency
Polytropic Efficiency
Duty
Operating Mode
Centrifugal
Reciprocating

5. Compressor
Compressor Curve
Commonly, this curve is provided by vendor,
consists of: flow rate, pressure head , &
efficiency
To choose Adiabatic/ Polytropic as Efficiency Basis
To enable the curve

Click to add the curve

Click to activate the curve

5. Compressor
Optional if only 1 curve available

Input flow, head, &

efficiency data

For Single Curve, the

combination of input data
will solve:
-

Inlet
Inlet
Inlet
Inlet

pressure & flow

pressure & duty
and Outlet Pressure
and efficiency

Choose
the Unit

6. Expander
Unit Function
To decrease the pressure of inlet gas with
higher pressure into produced work

Objective of Unit
To calculate the Work produced

Application
As model for Turbine & Turbo Expander

6. Expander
Important Design Parameter

Expander Efficiency:
Adiabatic Efficiency
Polytropic Efficiency

Expander : liquid, Turbine : gas

7. Valve
Unit Function
To drop the pressure of the
inlet which has higher
pressure
Objective of Unit
To calculate one of these unknown
conditions:
Outlet T or Outlet P
Inlet T or Inlet P

7. Valve
Important Design
Parameter
Delta P
Specified by user.

8. Cooler
Theory

Heat Duty

8. Cooler
Unit Function
To cool down the temperature of inlet
stream
Objective of Unit
To calculate one of these unknown data:
Outlet Temperature
Cooler Duty

Cooler is one-sided Heat Exchanger,

Q is removed (-)

8. Cooler
Important Design
Parameter
Delta P
By Default=0 or
Specified by user.
Duty

8. Cooler
Theory

Heat Duty

9. Heater
Unit Function
To heat up the temperature of inlet
stream

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

Heater is one-sided Heat Exchanger

Q is added (+)

9. Heater
Important Design
Parameter
Delta P
By Default=0 or
Specified by user.
Duty

10. Heat Exchanger

Theory
1. Type of HE based on flow direction

10. Heat Exchanger

2. Energy Balance

Duty which increase

the temperature

3. Heat Exchanger Duty

Duty which decrease

the temperature

10. Heat Exchanger

Unit Function
To transfer the energy from warmer
fluid to colder fluid

Objective of Unit
To increase the energy efficiency of the
overall facility

10. Heat Exchanger

Heat Exchanger has two sided:
- Hot Side
- Cold Side
Basic Equation:

[Mcold x Hcold Qleak]- (Mhot x Hhot Qloss]

= Balance Error = 0 (Typically)

10. Heat Exchanger

Important Design Parameter
Heat Transfer model
End Point
Weighted Point
Steady State Rating
Dynamic Rating
Delta P
On Shell & Tube Side
Overall Heat Transfer Coeff. Area (UA)
Heat Exchange Geometry
Tube
Shell

10. Heat Exchanger

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

Ada contoh kasus error

10. Heat Exchanger

Heat Exchanger Requires Recycle Operations:
1. Start with unconnected heater & cooler

2. Connect heater and cooler with one single energy stream

3.

Replace heater and cooler with Unit Heat Exchaner

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

Distillation
Distillation process use 40% of energy
in a chemical plant.
The traditional approach for solving
distillation columns uses the concept
of equilibrium or theoretical stages.
This concept assumes the vapor and
liquid phases leaving any stage are in
thermodynamic equilibrium with each
other.

Principle

Minimum number of tray

Parameter adjustment

Design of Distillation Column

Obtain:
Operating pressure

Obtain:
Initial value of number
of tray
Initial value of feed
stage

Optimization

Study Case
Design a distillation column to get propene in top stream with purity 96%
(mole).
Components

Mass Flow
(kg/h)

Ethane

4.1

Propane

4000.4

Propene

131.8

n-Butane

10498.2

Conditions

Value

Temperature (C)

38

Vapour Fraction

Fluid Package

Peng-Robinson

11. Reactor

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

simulation

There are 6 type of reactors provided by hysys:

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

Before begin the simulation it is important to describe the

reaction on the hysys simulation basis manager.

Type of Reactor
Can be used when we do not know the
reaction sets
Can be used for modelling equlibrium
reactions
Can be used for modelling conversion
reactions
can be used for complex reactors where no
model is available

CSTR Reactor

PFR Reactor

The CSTR is a vessel in which Kinetic, Heterogeneous Catalytic

and Simple Rate reactions can be performed.
The conversion in the reactor depends on the rate expression of
the reactions associated with the reaction type.
The PFR can modelled Kinetic, Heterogeneous Catalytic and
Simple Rate reactions.

Example Using Reactor in Simulation

How to Add Reaction Set

Choose Reaction type

Input component
involved in reaction

Input stoichiometric
coefficient

Add Reaction to Fluid Package

How to Add Reactor (1st method)

How to Add Reactor (2nd method)

click

Double
click

Reactor Designs Tab

Reactor Reactions Tab (To Add Rxn set to Reactor)

Click to select Rxn and Rxn

Set

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

Type of reaction: Heterogeneous Catalytic Reaction

Basis of reaction: Vapor Phase, IPA

With Reaction Rate:

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

OPEN FILE:
IPA- REACTION EXERCISE-STARTER.HSC

REACTOR EXERCISE ANSWER

Thank You
M. Ersharry Yunashtanto
Zayyanatun Zulfa
Ikha Muliawati
Mada Harahap

Referensi
1. Separation. http://lhd52.files.wordpress.com/2011/09/group-6-separation-

operations.pdf

2. HYSYS Design Tutorial for CHEE470.

http://m.chemeng.queensu.ca/courses/CHEE470/documents/HYSYSTutorial.
pdf

3. HYSYS Tutorial Che 3G4.

http://jpkc.tongji.edu.cn/jpkc/hgyl/second/site/Hysys.pdf
4. http://www.departments.bucknell.edu/chem_eng/cheg200/HYSYS_Manual/a
_BlueHYSYS.pdf
5. Dr. Istadi, ST, MT. Perancangan Process Kimia (Chemical PRocess Design).

http://tekim.undip.ac.id/staf/istadi/files/2009/05/presentasi_perancangan_pr
oses_kimia_1.pdf

6. Tutorial Apps.

http://www.uam.es/personal_pdi/ciencias/vferro/documentacion/doc/Hysys
%203.2/Doc/HYSYS/TutApps.pdf
7. Peter Griffith. www.thermopedia.com/Vapor-Liquid Separation

REFERENCES

Aspen Hysys Unit Operation Guide, Aspen Technology, 2011

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

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