ASPEN HYSYS

Design Heat Exchanger Network with Aspen

Energy Analyzer (Industrial Case)

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CASE STUDY

Dimethyl ether (DME) is a clean, colorless gas which has potential for an automotive fuel,
electric power generation, domestic applications such as heating and cooking. DME can be
produced directly from methanol dehydration.

Reaction conversion = 97%

The most used catalyst in this reaction is HZSM-5 due to its high activity and stability.
Please, do the simulation using aspen HYSYS then find pich temperature using heat energy
analyzer.
The detail simulation depicted bellow :

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Process flow diagram Dimethyl Ether Industry

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DESIGNING THE SIMULATION

STARTING ASPEN HYSYS

 To start aspen hysys program there are two ways

1. Double click aspen hysys shortcut
2. Click on the Start menu.
Select Programs | AspenTech | Process Modeling V.x | Aspen HYSYS |
AspenHYSYS.
The aspen hysys dekstop appears :

 To start new case, do one of following :

From the File menu, select New and then Case.
Click the New Case icon in the toolbar.

New case
icon

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 Dekstop appearance after clicking new case icon

Building the simulation

 Creating a fluid package

As a minimum, a fluid package contains the components and property method.
Click the Fluid Pkgs tab.

Fluid Pkgs tab

Click Add button the property view will be appeared.

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Choose a property package on the Set Up tab. The current section is <none>. For this tutorial,
select PR-Twu property Package. You can use scroll bar to move up and down the list until PR-
Twu becomes visible. Then select it.

Creating Component List

 After selecting property package, the next step is to select the component on the
components tab.

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  You will see Component List-1 (HYSYS Databanks) in the Component List Selection drop-
down list. Click the View button next to the drop-down list.
Click view button

The component list will be appeared as bellowed

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Firstly, you must understand the meaning of these items

There are several ways to add the components. The easiest ways are using Matching features.
For this tutorial we will use the following components: Methanol, water (H2O), Dimethyl ether.

To add methanol by using Matching Features, type methanol in match column. With methanol
selected, click add pure button. So, do the same step to add other components.
Here, the appearance after adding components.

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Starting Simulation
Click minimize tab of component list view to see simulation basis manager page. Click minimize
button

To start simulation click enter simulation environment button.

Click enter
simulation
environment

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 To Create Stream
1. Click on this symbol on the object palette
Click on this

O
b
j
e
c
Simulation t
page

p
a
l
e
t
t
e

2. Click on simulation page. So, you will get this symbol (see on the picture above).
3. Double click on stream 1. (look at picture above)
4. Set the material stream 1.

Condition
Vapour/ phase Fraction = 0 (it means that stream 1 is completely liquid)
Temperature = 303. 1
Pressure =1
Molar flow = 699.4

Composition
Methanol = 0.9985
H2O = 0.0015
diM-ether = 0.0000

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 To create “pump” object
1. Click “pump” from objects palette
2. Click on simulation page.

pump

Double click on
“pump” object
which located in
3. Double click on “pump” object in simulation page simulation page
4. Set the specification.
Connection
Set the name of these columns:
Name = P-100 (default setting. so,you can modify the name)
Inlet =1
Outlet =2
Energy = Qpump (you can modify the name not the amount)

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 Parameters
Delta P = 1 bar
Pressure ratio and duty will automatically calculated.
Delta pressure indicates the increasing pressure between inlet toward outlet.

After setting up the pump, stream 2 (outlet of pump) will automatically set.

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 To create “recycle” stream
1. Click on this symbol on object palette
2. Click on simulation page
3. Double click on “recycle stream” object
4. Set the condition and composition.
Condition
Name = recycle
Vapour/phase fraction = 0. (it means that this stream is completely liquid)
Temperature = 384.9
Pressure =5
Molar flow = 4.74

Composition
Methanol = 0.9973
H2O = 0.0027
diM-ether = 0.0000

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 To create “mixer” object
1. Click mixer picture on object palette
2. Click on simulation page
3. Double click on “mixer” object
4. Set the operation
Connections
Name = MX-100 (default setting. So, you can modify the name)
Inlets = 2
Recycle
Outlet = 3

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 Parameters
click on “set outlet to Lowest inlet”

 To create “heater” object

1. Click “heater” on object palette
2. Click on simulation page
3. Double click on “heater” object
4. Set the design
Connection
Name = E-100 (default setting. so,you can modify the name)
Inlet =3
Energy = Qvap
Outlet =4

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Parameters
delta P = 0 (it means that heater operates at constant pressure)
delta T = (automatically calculated)
duty = (automatically calculated)

note : stream 4 will automatically set by heater operation.

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 To create “compressor” object
1. Click compressor picture on object palette
2. Click on simulation page
3. Double click on “compressor”
4. Set the design
Connections
Name = K-100 (default setting. so,you can modify the name)
Inlet =4
Energy = Qcomp (you can modify that name not the amount)
Outlet =5
Parameters
delta P = 3.1 (in order to obtaintemperature targeted)

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 To create “cooler” object
1. Click cooler picture on object palette
2. Click on simulation page
3. Double click on “cooler”
4. Set the design
Connections
name = E-101 (default setting. so,you can modify the name)
inlet =5
energy = Qout (you can modify that name)
outlet =6

Parameters
Delta P = 0 (operated in constant pressure)
Delta T = -45.00 (in order to obtain temperature targeted)

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 To create compressor
1. Click compressor picture on object palette
2. Click on simulation page
3. Double click on “compressor” object
4. Set the design
Connections
name = K-101 (default setting. so,you can modify the name)
inlet =6
Energy = Qcomp2 (you can modify that name)
Outlet =7

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Parameters
Delta P = 11.1 (to obtain stream pressure targeted)

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 To create Heater
1. Click heater picture on object palette
2. Click on simulation page
3. Double click on “heater” object
4. Set the design
Connections
name = E-102 (default setting. so,you can modify the name)
inlet =7
Energy = Qhe (you can modify that name)
Outlet = to reactor

Parameters
Delta P = 0
Delta T = 16.75

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 To create REAKTOR
1. Click “general reactor” in object pallet
2. Click “conversion reactor”
3. Click on simulation page
4. Set the design
Name = CRV-100 (default name thus you can modify)
Inlets = to reactor
Vapour outlet = vap reactor
Liquid outlet = liq reactor

5. Back to home view by clicking

6. Click “reactions” menu bar
7. Click “add reaction”
8. Click “conversion”

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9. Click “add reaction”
10. Insert components

11. click “basis” then determine the reaction conversion

12. Click “fluid pkgs” in menu bar

13. Click “view”
14. On RXns menu bar then Click “add set”

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 15. Return to simulation environtment
16. Double click reactor object
17. Click “reaction” on menu bar
18. On “reaction set” select global Rxn 1 and reaction : Rxn-1

 To create EXPANDER
1. Click expander picture on object palette
2. Click on simulation page
3. Double click on “expander” object
4. Set the design

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Connections
name = K-102 (default setting. so,you can modify the name)
inlet = vap react
Energy = Qexpand (you can modify that name)
Outlet = react outlet

Parameters
Delta P = 11

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 To create cooler
1. Click cooler picture on object palette
2. Click on simulation page
3. Double click on “cooler” object
4. Set the design

Connections
name = E-103 (default setting. so,you can modify the name)
inlet = reactor outlet
Energy = Qcooler (you can modify that name)
Outlet = 10

Parameters
Delta P = 0
Delta T = -92.20

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 To create reflux absorber
1. Click reflux absorber on object palette
2. Click on simulation page
3. Double click on “reflux absorber” object
4. Set the design
Connection
Page 1
Colum name = T-100 (default setting)
Condenser = total
Condenser energy stream = Qcond
Bottom stage inlet = 10
Ovhd liquid outlet = 11
Bottom liquid outlet = 12
then click “NEXT”

Page 2
Condenser pressure = 4 atm
Bottom stage pressure = 4.8 atm
Then click “NEXT”

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Page 3
Optional condenser temperature estimate = 334 K
Optional bottom temperature estimate = 390 K
Then click “NEXT”

Page 4
Liquid rate = 348
Basis = molar
Reflux flow = 0.44
Then click “DONE”

Click Next

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Click Next

Click next

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Click done

Click run

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 To create valve
1. Click valve picture on object palette
2. Click on simulation page
3. Double click on “valve” object
4. Set the design

Connections
name = VLV-100 (default setting. so,you can modify the name)
inlet = 12
Outlet = 13

Parameter
Delta P = 3 bar

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 To create Short Cut Distillation
1. Click short cut distillation picture on object palette
2. Click on simulation page
3. Double click on “short cut distillation” object
4. Set the design

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 Connection
Name = T-101 (default setting)
Inlet = 13
Product phase = vapour
Overhead vapour = Me
Condenser duty = Qcondenser
Reboiler duty = Qreboiler
Bottoms = water

Parameter
Light key in bottoms = methanol with mole fraction 0.01
Heavy key in distillate = H2O with mole fraction 0.0027

 To create cooler
1. Click cooler picture on object palette
2. Click on simulation page
3. Double click on “cooler” object
4. Set the design

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Connections
name = COOLER (you can modify the name)
inlet = me
Energy = Qcooler2 (you can modify that name)
Outlet = me liquid

Parameters
Delta P = -0.8bar
Delta T = -46 C

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 To create pump
1. Click pump picture on object palette
2. Click on simulation page
3. Double click on “pump” object
4. Set the design
Connections
name = Pump-101 (you can modify the name)
inlet = me liquid
Energy = Qpump3 (you can modify that name)
Outlet = me out

Parameters
Delta P = 3 bar

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 To Create Recycling proccess
1. Click “recycle” symbol on object pallete
2. Click on simulation page
3. Double click on “recycle” object
4. Set the design

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 Connections
Name = RCY-1
Inlet = me out
Outlet = to pump

TO REDESIGN MIXER

We need to redesign mixer in order to do recycle. Do this following instruction

1. Double click on “mixer”

2. Redesign the inlet = 2 and “to pump” stream

Note : if the simulation is unconverged, we should check each equipment that might be
error. No need to change the items.

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EXTRACTING DATA INTO ASPEN ENEGRY ANALYZER
To start extracting data from hysys simulation into aspen energy analyzer, do these following
steps :

1. Open aspen energy analyzer

2. Click menu bar “managers”
3. Click “heat integration manager”
4. Click “HI case”
5. Click “add”
6. Click “data transfer from aspen HYSYS” icon

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 After clicking “data transfer from aspen HYSYS” icon, extraction wizard menu will be
appeared :

7. Click “next” on extraction wizard menu

8. Input file that we want to extract

- Click browse at simulation file to import

- Find file location in your computer
- After that, click next

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9. Click “next”

10. Click “next”

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11. Click “next”

12. Click “next”

13. Click “next”

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14. Click “next”

15. Click “finish”

Then, we will get this summary page

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 This is the HI case view from extracting aspen hysys simulation

Open taget
view

To know the pinch temperature, click open target view on HI case page depicted above.
Then, we get the summary result

Delta T min
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To see heat networking of this simulation, click “open HEN Grid Diagram” on HI case
view.

Open HEN grid diagram

Here the result of Heat exchanger networking

To obtain the position of pinch point on that diagram, right click then click “show/hide
pinch line”.

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