Consulting Editor
HEINZ HEINEMANN
WiUiam Le Lu n
Lehigh University
Bethlehem, Pennsylvania
MARCEL
DEKKER
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v
vi Preface
design course in most lUüversities only expIored the steady-state aspects ofproc-
ess designo This Iinüted treatment is rapidly giving way to a more comprehensive
study ofboth dynamic controllability and steady-state economics.
The steady-state simulation aspects of using commercial software are fairIy
well covered in textbooks and vendor tutorials. However, the dynanüc aspects
have received only sketchy coverage. There is no structured way for students and
young engineers to learn how to use these commercial dynanüc sirnulation pack-
ages to develop and test dynamic pIantwide contTOl structures.
Learning how to use the dynanlic simuIators is a somewhat painful and slow
process. The number of exampIes provided in vendor tutorials is small, and the
processes are limited in scope. The documentation and help screens can often be
unclear and offer littIe guidance. On-line technical assistance is usually not avail-
able to students, so lUlless a very knowledgeable faculty member 01' graduate stu-
dent is avaiIable, students can struggle with dynanüc simulations. Of course, time
is one commodity that senior students have in very short supply. They have linl-
ited time to invest in leaming the ins and outs of sirnuIators since the typical de-
sign project must be completed in onlya few months.
The purpose of this book is to help students and inexperienced engineers
learn how to rapidly and effectively use dyl1anüc simuIators. Usil1g dynanüc SinlU-
lators requires more than just lmowing the software. It requires the application of
some good solid engineering principIes. Remember the old saying "garbage in,
garbage out!"
The engineering steps that are necessary in moving from a steady-state
simulation to a dynanlic simulation are presented in this book. TIlese include siz-
ing equipment, getting the "plumbing" correct, sizing c¿ntrol val ves, developing a
basic regulatory control structme and tuning controlle[s. The development of a
plantwide basic regulatory control scheme requires 100Ji;:ing at the big pictme and
recognizing that all the units must "dance together." W,e must make sure that the
structme balances the stoichiometry of the reactions by adjusting the flowrates of
1
the fresh feed streams. Of course inert components mu~t have a way to leave the
system so that they do not acclUnulate and degrade the pp..fonnance ofthe process.
Once the overall scheme is in place, it is often mpre efficient to look at the
individual units to do the controller tuning since simuUttions of a single lmit l'lUl
much more quickly than the simulation ofthe whole pl~nt. The secret to success-
fi.Il simulations is "divide and conquer." I
Dynamic simulators can handle many of the impprtant unit operations, but
not all. However, the list of process wüts whose dynamifs can be accurately simu-
lated grows each year. The fieId is a rapidly changing O~le, so new capabilities are
offered with each new version ofthe software. :
A nlU11ber of case-study examples are provided !in this book. They range
from a sinlple single lmit with two or three controllers t9 complex, intercollilecting
lmits in a plantwide system with dozens of controlleI[S and a complex control
structme. These case studies cover a broad range of systems. The accompanying
CD contains the HYSYS and AspenDynamics files oflall the cases. It also COl1-
Preface vii
tains MS® Word files that give aH the figures in the book. These can be useful in
your reading because they are in color and because you can enlarge the figures in
order to see more detail.
It is hoped that this book will serve as an effective learning t001 for students
and inexperienced engineers and serve as an introduction to dynamic simulators.
The intent is not to develop experts who 1mow all the nitty-gritty details of the
simu1ators and use aH the beHs and whistles. For examp1e, there are typically three
different ways to do a task. We on1y cover what 1 have found to be the simplest
and most intuitive.
There are also many advanced capabilities offered by the sinmlators, includ-
ing writing your oW11models. We do not attel11pt to cover any of these advanced
ftillctionalities. The goal ofthis book is to provide a solid starting point for inexpe-
rienced engineers and to give students a good working knowledge ofthe basics.
1 would like to thank Cris Muhrer, Bryon Manor, and Oliver Sl11ith of Air
Products for their tutoring in AspenDynamics and AspenP1us. James Goom of
AspenTech provided technical help with several aspects ofusing AspenDynamics.
1 thank Joe Sieben of Hyprotech for his he1p in app1ying HYSYS. Brad Price and
Paul Bader ofLehigh University provided inva1uable assistance with software and
hardware issues. Thanks are also due to the l11any senior students at Lehigh Uni-
versity who have suffered through the pain of 1earning dynamic simulators. Their
struggles are what have prompted the writing of this book.
Willial11 L. Luyben
ontents
Preface
Part 1 - Fundamentals 1
Index 427
ix
PLfltlTWIDE DyttflMIC
SIMULA IH CHEMICAL
PItOCESSlttG and COtlTItOL
artl
Fundamentals
hapter 1
Introduction
1.1 Status
Dynamic simulation has become increasingly important as processes be-
come more complex and are designed and operated closer to constraints. The use
of intemlediate buffer tanks has been greatly reduced because of envirmmlental
and safety concems. Increasing yields and suppressing the fomlation of undesir-
able and environmentally unfhendly by-products are often achieved by using
complex flowsheets with many recycle streams. Increasing energy costs keep
pushing design engineers toward more heat integration. All of these trends make
dynamic control more difficult and dynamic simulation more inlportant. It is vital
that all the unit operations of a complex flowsheet be able to "dance" together in
the face ofthe inevitable disturbances. These include production rate changes, feed
composition variability, transitions to different product specifications and rapid
ambient temperature changes during storms.
Ideally the dynamics of the process should be considered at the very early
stages ofthe development of a process. Certainly at the pilot-plant stage, trade-offs
between design and control should be explored, and basic regulatory control struc-
tures should be developed and tested. The engineeting time expended at the early
stages can reap enormous economic benefits later in the project in terms of rapid,
trouble-free startups, reduced product-quality variability, less-frequent emergency
shutdowns, reduced enviromnental contamination and safer operation.
Forttmately our ability to perform plantwide dynamic simulations has also
increased. 111ere are several commercial software packages that have dynamic
capability. The two most widely used are "HYSYS" from Hyprotech Inc. and
"AspenPlus/AspenDynamics" from Aspen Tec1mology. These two simulators will
be used in this book. Although these simulators are far from perfect (we will high-
light some of the weaknesses and "bugs" as we go through this book), they do
provide a reasonably effective tool for studying process dynamics. Unfortunately,
there are a variety of bugs in each new version of the software, but these are
gradually being elinlinated.
We will only illustrate the development of convetltional single-input-single-
output control Strllctures that use linear proportional-integral (PI) controllers.
However, dynamic simulators are needed to test any control structure, whether it is
3
4 Chapter 1
1.2 Need
Learning how to use steady-state simulators is reasonably well covered in
several textbooks and vendor tutorials. The recent CD-ROM by Lewin et al.
(ISBN: 0-471-44254-2) provides a good introduction to use ofsteady-state simula-
torso However, learning how to use dynamic sinmlators is not covered thoroughly
in the existing textbooks. The purpose ofthis book is to fill this gap in the educa-
tional phase ofthe tec1mology.
There are some significant steps that must be taken and vital infonnation
that must be available to go fi"om a steady-state sirnulation to a dynamic simula-
tion. The details ofthese steps are covered in this book, and they are illustrated by
a number of case-study examples.
A second need that this book filIs is making available a number of case stud-
ies. These range from very simple systems to complex flowsheets. The simple
systems are useful for learning how to get started in using dynamic simulators.
The complex systems are useful in illustrating how to apply the concepts of plant-
wide control to a realistic process. Control researchers should fmd these complex
case studies useful in providing a challenging process on which to apply their
newly developed advanced control methods.
1.3 Scope
One effective pedagogical approach to learning how to use dynamic simula-
tors is to start with a very sin1ple dynamic system (for example, a single tank).
This simple process has two or three control valves and the same number of con-
trollers. It requires that we learn the basic operations of moving from a steady-
state simulation to a dynamic simulation.
1.3.2 Plumbing
l. Initial values ofthe signal from the process sensor (the PV signaJ) and
the signal to the control valve (the OP signal) must be made available.
Thís requires establishing the ranges of the sensor/transmitter that is
generating the PV signal and establishing the range of the controller
output signa!. If the controller output signal is going to a valve, this
range is Oto 100%. Some ofthe manípulated variables are set directly
from the controller (for example, reboiler heat input or coolant tem-
perature). In that case, the maximum and mininlUm values of the en-
ergy flow or the maximul11 and minimum coolant temperatures must
be specified.
2. The conect "action" of the controller must be specified: direct or re-
verse.
3. The controller ttming constants must be set. Tlming oflevel and flow
controllers is a "plug-in-the-numbers" operation, which requires no
dynanlÍc testing. On the other hand, most temperature and composi-
tion loops require dynamic testing (for exanlple, the simple relay-
feedback test) to develop controller tuning constants. It is important to
use realistic lags andlor deadtimes in the tel11perature/composition
loops so that the predicted performance is not overly optimistic. Using
reasonable and conservative measurement lags in the temperature and
cOl11position loops helps to guarantee that effective control is possible
in a real plant environment, not just on the sil11ulator.
4. Strip-chari recorders are useful in following the dynamic changes oc-
cuning in the many variables. The variables to be observed need to be
selected, and all the chart properties (axis scales, labels, etc.) must be
specified.
These issues are covered in Chapter 3.
The rest of the book presents a series case studies. The approach is to start
with very simple process units that require 0111y two or three controllers. Then
units with several controllers are considered. The complexity of the processes is
Introduction 7
1.5 Conclusion
In tbis chapter we have set the stage for the remaining chapters. The status
of dynamic simulation, the aclclitional information neecled ancl the scope of the
book have been cliscussecl. We are reacly to dig into the details of clynamic sinmla-
tions.
It shoulcl be emphasized that the goal of this book is provide an introduction
to the use of commercial dynamic simulators. We clo not attempt to provicle all the
voluminous material to transfom1 the reacler into a simulation expert. This requires
many months of time ancl effort. Only the simple basic operations that are needed
to get startecl in dynamic simulation are discussed. The commercial simulators
offer many aclvancecl feahrres that can be usefül after the engineer leams the ba-
sics. We hope this book is helpful in getting you off the ground in the important
and fascinating activity of dynamic simulation.
hapter 2
Not a11 of the tmit operations that are useable in the steady-state sUllulators
are supported in dynamics. The flowsheet sometimes must be modified to handle
these lUllitations.
9
10 Chapter2
A. Length: A typical tray spacing is about two feet. So ifthe collUlm has N T
trays, the height of the tray section is 2NT (feet). However, the collUlln requires
some additional height to accoillmodate reflux and feed entry locations and to
provide smge vollUne in the base, particularly if thennosiphon reboilers are used.
Therefore we nonnally increase the length ofthe collmm by about 20%:
This approxinlation assumes that we are using actual trays. Ifthe simulation
uses theoretical trays, which is typically the case, an adjustment in the length
should be made so that the actual volume of the vessel with real trays is used.
This use of theoretical trays also requires an adjustment in the weir height of the
trays so that a realistic estinlate of the total liqlúd holdup on the actual trays is
used. Weir heights are nonnally oue to two inches on actual trays. So the weir
height specified in the simulation should be adjusted upwards by dividing by the
efficiency.
Tray efficiency depends on several factors, but the most in1portant is relative
volatility 01' ease of separation. Components with large differences in boiling
points (high relative volatilities) exhibit large changes in compositions fi'om tray to
tray in the column. This results in low tray efficiencies (vapor and liquid are not in
phase equilibritU11). Components with small differences in boiling points produce
small changes in compositions fi'om tray to tray, so efficiencies are high. In the
absence ofbetter data, some hemistics can be used to estimate efficiency. Relative
volatilities around a=l.l give almost 100% efficiency. Relative volatilities around
a=2 give efficiencies in the 80% range. Relative volatilities arOlmd a=4 give effi-
12 Chapter 2
ciencies in the 50% range. These estimates can be used to adjust column heights
and tray weir heights.
The other aspect of tray height calculation is the type of intemals. Instead of
using trays, the column may use packing. Structured packing is widely used, par-
ticularly in vacuum cohm1l1s, because of its lower pressure drop per theoretical
tray. Corre1ations are given in many references (for example, Kister, H. Z. "Distil-
lation Design" McGraw-Hi11 Co.,1992) for packing height per theoretical tray, and
these should be used if appropriate. The tray model can be used with the number
oftrays selected to match the lllunber oftrays provided by the specified height of
packing.
The liquid holdup (weir height) must also be adjusted if packing is used.
One of the biggest differences between packing and trays is the sma11er liquid
holdup in packed towers. This makes the dynamic response of a packed column
faster than a trayed colun1l1, which means that disturbance rejection is worse in
packed colun1l1s than in columns with trays.
F-Factor == ~nax -J Pv
In English Engineering lmits, the velocity V max has units of fi/sec and the
vapor density Pv has units oflb/fi3 . In SI lmits, velocity is in m/sec and density is
in kg/m3 . An F-Factor of 1 in English Engineering units or l.22 in SI units can be
used to determine the diameter ofthe column.
From the steady-state columll profiles, se1ect the tray with maximmn vapor
velocity from the given vapor flowrate and density.
fOlmance page tab. The Summary view gives the flowrates on aH trays in either
mas s units or actual volumeüic lmits (select the appropriate Flow Basis).
AspenPlus: In order to get vapor densities on all ü·ays, before running the
steady-state case, expand the block used for the colunm and under "RepOlt" check
the "include hydraulic parameters" box. Then run the case. Look in the colunm
block lmder "Profiles" at the Hydraulics page tab. The volumeÍlic flowrates and
den sities are given in whatever lmits you select.
To illusü·ate this calculation, let's take a numerical example. Suppose we
have a colunm in which the maximul11 vapor rate is 5572 1b/hr (2527 kg/hr) and
the vapor density is 1.8241b/ft3 (29.26 kg/m3). Using the recoml11ended F-Factors,
the maximul11 vapor velocity is
F-Factor 1
~nax = ¡;:-- r;-;;:::;-; = 0.74 ft/ sec
-V Pv ,\,,1.824
v = F-Factor 1.22
~ =
_1
0.226 l1J/sec
max ¡;:--
"I/Pv ,\,,29.26
Separators are tanks that have both liquid and vapor streams leaving the unit.
Their fi.mction is to disengage the two phases and provide liquid surge capacity.
Therefore the vapor velocity must be kept low enough so that liquid entraimnent is
small. The F-Factor can be used to ca1culate the minimum diameter ofthe vessel.
We use a more conservative F-Factor (0.5 in English Engineering units) so that
effective separation ofthe two phases is achieved.
We also must check to see if the liquid holdup is adequate. The normal heu-
ristic is to provide at least five minutes ofholdup. This means the volume ofliquid
in the tank (normally with the interface at 50% ofthe tank height, assuming a ver-
tical cylindrical vessel) should be five times the vohunetric flowrate of the liquid
leaving the tank.
To illustrate the ca1culations, we consider a flash tank operating at 48.9°C
(120°F) and 3l.7 bar (460 psia). The vapor leaving the tank is 613 kg/br (1251
lb/hr) with a vapor density of 46.3 kg/m3 (2.89lb/ft3). The liquid leaving the tank
is 1635 kg/br (3604 lb/hr) with a liquid density of 460 kg/m3 (28.7 lb/ft3). The tank
is a vertical cylindrical vessel with an aspect ratio (length-to-diameter ratio) of
two.
First we will calculate the required diameter based on the vapor velocity. The
maximum vapor velocity, using a 0.5 F-Factor, is
Vmax = F-Factor
r::- 0.5
~.
= O 294 ft/ sec
-V Pv -'1/2.89
The volumetric flowrate is (1251 Ib/hr)(ft3/2.89 lb)(hr/3600 sec) = 0.130 ft3/sec.
Therefore the cross-sectional area of the tank is
Area = 0.294 ft3/ sec = 0.442 ft2
0.13 ft/sec
Thus the tank diameter must be at least [(4)(0.442)/n:]0.5 = 0.75 feet.
Now we need to check the liquid holdup requrrements. The volumetric
flowrate ofliquid is (3604lb/hr)(ft3/28.7lb) (lrr/60 min)= 2.09 ft3/¡nin. To have 5
minutes holdup of liquid with the tank half full, the volume of the tank should be
(2)(5 min)(2.09 ft3/min) = 20.9 ft3. With an aspect ratio of two, the relationship
between volume and diameter is
Volume = !!-. D 2 L = !!-. D 2 (2D) = !!-. D 3
442
Therefore the diameter is 2.37 ft. Since this is larger than that ca1culated from the
vapor F-Factor, we specifY a tank with a diameter of 2.5 ft and a length of 5 ft.
Note that we have used vertical tanks in all the examples aboye. IfhOlizontal tanks
are used, the ca1culations must be modified to accommodate this change.
The dyuamics ofheaters and coolers (and column reboilers and condensers) are
usually assumed to be fast compared to the composition and flow dyuamics. In
Steady State to Dynamic 15
Tanks and surge volumes are required whenever liquid is to be pumped. The
reflux drum and the base (or reboiler) of a distillation column are examples. From
a steady-state economic design point of view, capital investment is minimized by
making these vessels as small as possible. However, from a dynamic point of
view, we want to have lots of surge capacity so that disturbances in flowrates can
be attenuated and we don't lose liquid levels.
The commonly used heuristic for surge vessel sizing is to provide about 5 min-
utes of liquid holdup with the vessel half full. This is based on the total flowrate of
liquid into the vessel. Ifthe liquid level is at 50% for the steady-state conditions, it
will take 5 minutes to completely drain or fill the vessel ifthe inflow or outflow go
to zero.
For example, suppose the total flow fi'om a distillation colm1111 reflux dlUm
(distillate plus reflux) is 5577 lb/hr with a liquid density of 29 lb/fi3. The size of
the reflux dnun should be
(5577lb/hr)(ff /29Ib)(hr/60 min)(lO min) = 32 ft3
In HYSYS, the volmne can be directly entered by going to the column sub-
flowsheet, double clicking the Condenser, clicking the Dynamic page tab and en-
tering the volunle. In AspenPlus, before going into AspenDynamics, the size of
the reflux dnun must be entered using the Dynamics button of the column block
and going to the Condenser page tab. The details of this operation are illustrated in
the distillation column example given in Chapter 8.
To calculate drum diameter and length from the knOW11 volume, an aspect ratio
(LID) must be knOW11. Aspect ratios of various vessels vary from 1 to 4, but for
surge vessel a value of2 is typical.
Volume = D 2 L = Jr D 2 (2D) = Jr D 3
Jr
442
Surge volume is also used in decanters, which are vessels used to separate two
liquid phases. The settling velocity of the droplets of the discontinuous heavy liq-
uid phase in the continuous light phase depends on the density difference between
the two phases. Large holdup times (20 to 30 minutes) are typically used in de-
canters to make sure there is good phase separation.
The volumes of both sides of the heat exchanger must be calculated if these
contribute significant dynamics. For a tube-in-shell heat exchanger, these volumes
16 Chapter2
can be quickly estimated fi-om the known heat-transfer area that has been calcu-
lated in the steady-state simulation from the specified heat duty, overall heat-
transfer coefficient and temperature differential driving force.
Let the known total heat-transfer area be AOlol (in eithe1' m 2 01' ft2). Let the tube
length be L and tube diameter D (m or ft). The circwnferential heat-transfer area
of each tube is
A tubc == reDL
The number oftubes required is
N - Atota! _ Atota!
tubes - A - DL
tube re.
_
Vtubes - Ntubes [ -4-,
2
reD
JL -_ (reDL J[' reD JL -_ (4
Atota!
-4-,
2 'J
D
Atota!
Thus the calculation ofthe volume inside the tubes requires that we know the heat-
transfer area and that we select a tube diameter.
Vtubes == ( ~ JAtota!
Typical tube diameters are 25 to 50 nml (1 to 2 inches).
For a numerical example, suppose the required heat-transfer area is 625 ft2
and a tube diameter of 1 inch is selected. Then the tube volwne is
D I
Vtubes == ( 4)Atotal == ~-4-l25 ==
(11121
13ft
3
Now we need to ca1culate the volume of process material in the shell side.
This is the total volume ofthe shell minus the volwne ofthe tubes. The shell vol-
wne depends 011 the layout and spacing of the tubes, but at the conceptual design
stage we do not need to go into all the nitty-gritty details. A simplifying approxi-
mation can be made that works pretty well for most tube-in-shell designs. We as-
swne that the shell volume is equal to the tube volwne.
2.3.5 Furnaces
The volmue ofthe process material inside the tubes of a fired fumace must be
estimated so that the dynamics of the unit can be inc1uded in the simulations. The
result of the steady-state simulator is usually just a required heat-transfer duty in
the fhmace. How can this duty be converted into a furnace size?
Robert Moore (private communication, March 2001) has provide some typi-
cal furnace size information from a natural-gas/steam refonuing reactor/fumace.
The fumace duty is 688x106 Btu/hr. The total volume inside the tubes in the radi-
ant section (363 tubes, 6 inch diameter, 49 feet long) is 3500 fi3 and in the convec-
tive section (724 tubes, 4.5 inch diameter, 64 feet long) is 5200 fi3. The total vol-
ume ofthe furnace box is 45,000 fi3, which means the volul11e on the firing side is
45,000 - (3500 + 5200) = 36,300 fi3.
Therefore, the following rough estinlates of the volumes of theprocess and
cOl11bustion si des of a fired fumace can be used:
Process inside tube volmue = 14 fi 3/l 06 Btu/hr
Total furnace vohmle = 66 fi3/l06 Btu/hr
2.4 Plumbing
One of the most striking featmes of almost all chemical and petroleum plants is
the tremendous amount of piping. Pipe racks are full of pipes of aH diameters,
rmming between pieces of equipl11ent and between different processes in the plant.
In dynamic simulations, we normally do 110t need to be concemed with the details
of the piping layout. Unless a pipe is quite long, piping dynamics are usually fast
compared to equipment dynamics. However, ifthe deadtime caused by a long pipe
is significant, the pipe should be included as a dynamic unit in the simulation.
However, it is important to get the phunbing cOilllections between lll1Íts cor-
rectly positioned and conectly designed. Water does not flow uphill, so there must
be pressure differences for material to flow f1-om one location to another. Pmups,
compressors and val ves must be positioned and sized to provide the required
variations in process flowrates. Tanks or liquid surge vohmles must be instaHed to
provide NPSH (net positive suction head) requirements for all pmups and to at-
tenuate flowrate disturbances.
Figure 2.1 shows a typicalliquid flow system with the required tank, plll11p and
val ve. Liquid from the tank is pmllped up to a higher pressure by a centTifugal
pmnp. The material flows through a heat exchanger and a reactor. There is pres-
sure drop through these müts, and these pressure drops must be specified (or cal-
culated). There is also pressure drop through the control val ve, which is located at
the point directly before the process material enters the downstream tanlc
18 Chapter2
P = 5 bar
LW=lbar LW = 1 bar
Note that the control valve is located afier the pump, not before the pump. Putting
a valve in the plilllp suction doesn't work because the pump NPSH requirements
would not be met. So the First Law ofPlul11bing is
Note that ifthe flow is split into multiple streal11S (a tee in the line or a "splitter" in
the sil11ulation), there can only be one valve in each lineo Figure 2.2 illustrates
S0l11e good pltill1bing and S0l11e forbidden plul11bing arrangel11ents.
The plumbing systel11s considered aboye used centrifilgal pmnps. If positive
displacel11ent plill1pS are used, val ves should not be installed to regulate flow. The
speed ofthe plill1p or its length of stroke are used to set the flowrate ofliquid.
COl11pressors are used in gas systel11s to provide the required pressures for flow
through equipl11ent and val ves. Because COl11pressors are volumetric devices, they
pump a constant volmne per time at suction conditions if operated at constant
speed. Therefore, putting a valve in the discharge piping of a cOl11pressor does not
change the al110unt of material flowing through the COl11pressor. It just increases
the cOl11pression ratio and the work. The Third Law ofPlul11bing is
B. F orbidden Plumbing
However, throttling the suction of a compressor does affect the amount of material
going through the compressor. The pressure drop over the valve reduces the pres-
sure at the compressor suction, which reduces the gas density. Thus less mass is
compressed for the same volul11e.
111ere are three basic ways to control flow through a compressor, as shown in
Figure 2.3. Suction throttling, bypassing (spill-back) or varying speed can be used.
The last is the most energy-efficient, but requires a variable-speed drive. Steal11
turbines are ofien used in these applications. The control valve on the high-
pressure steam supplied to the hu'bine sets the cOl11pressor speed. Of course, the
issue of cOl11pressor surge preventionmust be addressed in real applications. With
reciprocating compressors, the flowrate is adjusted by varying speed, stroke dis-
tance or minimunl compression volunle in the cylinders.
In dynamic simulations, the compressor variable-speed operation can be ap-
proximated by having the output signal from a controller (flow, pressure, tempera-
ture, etc.) adjust the work to the cOl11pressor.
20 Chapter 2
A Good Plumbing
Gas....-~_)~·
Process Gas Compressor
Precess
1)
o(
Turbine
High Pressure
Steam ---C::i::l-~r1--~t=11
Compressor
B. F orbidden Plumbing
~~ Compressor
changer, a tubular reactor and a control valve into a vessel operating at a pressure
of 5 bar. The volmnetric flowrate is (10,000 kg/hr)(m3/800 kg)(hr/60 min) = 0.208
m3/min.
The pressure drop through the heat exchanger is 1 bar at the nonnal design
flowrate. The design pressure drop through the reactor is also 1 bar. The pressure
drop througll'the control valve and the pmnp discharge pressure are design vari-
ables. The higher the valve f1P, the higher the pmnp head.
Let us take two cases. In the frrst, we use the common (but poor) heuristic that
the pressure drop over the valve at design should be 50% of the system pressure
drop. Putting it another way, the heuristic is to set the control valve f1P equal to the
sum of the pres,ure drops through aH other parts ofthe piping system. In our ex-
anlple, the heuristic would set the valve f1P at design to be 1 + 1 = 2 bar.
Case 1 - Design f1Pv = 2 bar: The pump discharge pressure is the static pres-
sure of the vesse1 into which the liquid is flowing (5 bar) plus the pressure drops
over the heat exchanger and the reactor (1 + 1 = 2 bar) plus the pressure drop over
the control val ve. So in this case the pump discharge pressure is 5 + 2 + 2 = 9 bar.
For simplicity we assmne that the pump curve is flat, so this discharge pressure is
constant for all flowrates through the pmnp.
A simple equation describing the flow through a control valve is
F = ¡(x) C v ~ ¡j,Pv
where F = flowrate through the valve, fcs) = fraction of the valve opening, Cv =
valve size coefficient and f1Pv = valve pressure drop. We assmne that the valve is
50% open at designo The control valve (Cv) is sized at design conditions.
Cv = F = 0.208 m 3/mín = 0.294
fix)~f:,Pv 0.5~2 bar
Now let us fmd out how much the flow through this system can be increased.
We call the maximum flowrate F max . The pressure drop through the heat ex-
changer and the reactor vary with the flowrate through the units. We assmne tur-
bulent flow, so pressure drop is proportional to the square ofthe flowrate.
M@F=M@FdeSign(-F_J2
l Fdesign
So at the maximmn flowrate the pressure drop through the heat exchanger and
reactor will be
f:,R
@Fm ",
= f:,R
@Fdeslgn
. l F;Tlax
Fdesign
2
J= (
1+ 1 F;Tlax
{ 0.208 )
2
The pressure drop over the control val ve (which is wide open so f(x) = 1) wiH be
22 Chapter2
(2)( F;nax
0.208
)2 + ( 0.294
Fmax )2 + 5 = 9
Solving for the maximum flowrate gives 0.263 m 3 /min. ll1is means that the
flowrate can be increased 26% aboye the steady-state flowrate of 0.208 m 3/¡mn.
This rangeability may be fine for some applications. However for others, much
larger increases in flowrates may be required. One important example is the cool-
ant flowrate through the jacket of an exothenmc chelmcal reactor. In this applica-
tion, dynamic transients in the heat generation rate may require that the flowrate of
coolant be doubled or tripled.
Case 2 - Design ~Pv = 5 bar: To illustrate that more upward rangeability can
be achieved if more pressure drop over the control valve is used at the design
stage, let us consider another case. The design valve pressure drop is increased
from 2 bar to 5 bar. The design conditions are now:
Pump discharge pressure = 5 + 2 + 5 = 12 bar
Control valve size:
ev = F = 0.208 nhmin = 0.186
j(x)~;l..Pv 0.5~5 bar
The pressure drops and pressure conditions at the maximum flowrate with the
valve wide open are:
(2)( Fmax
0.208
)2 + (F;nax
0.186
)2 + 5 = 12
Solving for the maximum flowrate gives 0.305 m 3 /lmn. This means that the
flowrate can be increased 47% aboye the steady-state flowrate of 0.208 m 3/min.
This increased rangeability permits the system to handle larger disturban ces with-
out running into valve constraints. This improvement in control has a cost in a
higher pump head, which means higher energy costs.
It is worth noting that the down-side rangeability is also improved by using
higher valve pressure drops. Control val ves do not provide effective control be10w
about 10% opening. Let us compare the minimum flowrate Fmin obtainable with fcs)
= 0.1 for each of the cases considered aboye.
Steady State io Dynamic 23
F., 2 ( )2 + 5 = 12 =?
Case 2: (2)(~
0.208
F."
) + (0.1)(0.186) 111111
3
F ' = 0.0488 m /min
mm
Thus the flow can be reduced to 28% of design in Case 1, but to 23 % in Case 2.
hl a typical plantwide simulation there are dozens of control val ves. At the con-
ceptual design stage we do not want to spend a lot oftime doing detailed control-
valve sizing calculations. We need to be able to quicldy pick some reasonable
pressme drops so that a basic regulatory control stmctme can be developed and
evaluated.
The larger the valve pressme drop selected, the better the control. This is par-
ticularly true when we are trying to get the dynamic simulation offthe launch pad.
My experience has been that pressme drops in the range of20 to 50 psi (2 to 4 bar)
provide effective control. This is probably too high for gas systems because ofthe
higher cost of compressing gas compared to pwnping liquids. Afier the control
structme has been developed, you can go back and explore in more detail the inl-
pact ofreducing valve pressme drops on control perfol1nance.
There is one important aspect of control valve design that should be mentioned.
fu reallife, we use both air-to-open and air-to-close val ves, depending on how the
valve should fail. The action of the valve dictates the actio11 of the controller (re-
verse or direct). However, neither ofthe dynamic simulators, in their present ver-
sions, allow air-to-close val ves. All val ves are air-to-open. Hence the engineer
must remember this lirnitatio11 when translating control structure and, controller
action from a dynamic simulation to a real plant control system.
2.5.2 Changing Control Valve Size or Pump Head in the Dynamic Mode
When you are running the dynamic simulation, you ofien fínd out that the con-
trol valve is hitting a constraint, i.e., going wide open 01' opel'ating almost shut.
This requires that a change be made in the size of the valve or the pressme drop
available over the val ve. So you need to make a change in the equipment designo
You could go back to the steady-state mode and make this change. However,
switching back and forth between steady state and dynamics is 110t as "seamless"
as it should be and can take a fair amOlmt of time. Therefore you may want to
change control valve sizes and/or pwnp head while in the dynamic mode. fu HY-
SYS, this requires simply double clicking the valve or pwnp icon and changillg
the nlUllerical value of the val ve Cy or the pwnp power (on the Dynamics page tab
ofthe valve or the plilllp).
24 Chapter2
The procedure in AspenDynamics for resizing a valve is similar. Right click the
valve icon and select "Fonns" and "AH Vmiables". The valve size coefficient
"COmax" can be changed.
Changing pwnp head is a little less intuitive. AspenDynamics uses a typical
pump curve as the default. To specify a value for power, the procedure is:
1. Right click the pump icon, se1ect Fomls and then Configure.
2. Change the "use performance curves" to "false".
3. Change "specified electrical power" to "fixed'.
4. Enter a numerical value for power.
2.6 Conclusion
This chapter has discussed some basic concepts and tools needed to convert
from a steady-state simulation to a dynamic simulation. Equipment sizing is an
impOltant part ofthis effort. Getting the fluid mechanics (plumbing) correctly de-
signed is vital for cOlTectly modeling what actuaHy occurs in the real plant in
terms of flows and pressure drops. Some common elTors in plwnbing are given.
Control valve design (specifying control valve pressure drop) is also impOltant for
effective and robust control.
Chapter 3
Tuning Controllers
The tuning offlow contTollers is usuaIly a no-brainer. The majority offlow control
loops feature an orifice-plate sensor, a differential-pressure transmitter, a PI con-
troller and a control val ve. The dynamics of flow measurement are fast. The time
constants for moving control val ves are smaIl (several seconds unless very large
val ves are involved). Therefore, the controller can be hmed with a sma11 integral or
reset time constant 'tI. A value of 'tI = 0.3 minutes works in 1110St flow contro11ers.
The value of controller gain should be kept modest because flow-
measurement signals are sometime noisy due to the turbulent flow through the
orifice plateo A value of contro11er gain ofK" = 0.5 is ofien used. Derivative action
should not be used.
In a real plant application, filtering of the flow signal is also recommended
because of the noise. In a simulation, noise is not a problem. However, the equa-
tion-based integrator in AspenDynamics appears sometimes to have stability prob-
lems in flow contTol loops unless a sma11 amOlmt of filtering is used. Fortunately
this is easy to do in AspenDynan1ics. Ifyou go to the Configure view ofthe con-
troller and click the Filtering page tab, a filter time constant 1:F can be specified. A
good number to use for a flow loop is 1:F = 0.1 minute. We will go through a11 the
details of setting controller ttming constants in the next chapter for a specific sim-
ple example.
So the plug-and-chug controIler ttming constants for a typical PI flow COll-
troIler are:
Kc = 0.5
TI = 0.3 minutes
TF = 0.1 minutes
Tuning 27
There are a few flow controlloops in which the process configuration is dif-
ferent than that discussed above and for which the recornmended tlming does not
work. The most important example is a flooded condenser. The flowrate of vapor
into the heat exchanger is sometimes controlled by manipulating a control valve in
the liquid condensate line at the heat exchanger exit. This may seem like an odd
arrangement. Why not just flow control the liquid condensate? At steady state, the
vapor flow into the condenser is equal to the liquid flow out. But dynamically this
is not true. The vapor flowrate depends on the rate of condensation, which de-
pends on the heat-transfer area available for condensing. The area is changed by
covering or exposing more ofthe tube length (ifthe condenser is vertical) or more
ofthe tllbes (ifthe condenser is horizontal).
Filling and draining ofliquid take time, so the dynamics ofthis flow loop are
slow. The tuning of this type of flow controller requires experimental identifica-
tion. Derivative action is ofien beneficial.
K e =2
Most pressure controllers can be fairly easily tuned. The process time con-
stant is estimated by dividing the gas volume of the system by the volunletric
flowrate of gas flowing through the system. Setting the integral tinle equal to
about 2 to 4 times the process time constant and using a reasonable controller gaill
usually gives satisfactory pressure control. Of course the gaill used depends on the
span of the pressure transmitter. Some simple step tests can be used to find the
value of controller gain that yields satisfactory pressure control. Typical pressure
con1ro11er ttming constants for colUll1l1s and tanks are Kc = 2 and 1:1 = 10 minutes.
Pressure contro11er settings in very fast loops such as compressor controls have
much smaller integral times.
K
u
= 4h
al[
The period of the output N cmve is the ultimate period PI<' From these two pa-
rameters, controller tUlling constants can be ca1culated for PI or PID controllers,
using a variety of tlming methods proposed in the literature that require only the
ultimate gain and ultimate frequency, e.g., Ziegler-Nichols, Tyreus-Luyben, etc.
30 Chapier3
K = 4h =~=75
u aTe O.l7Te .
0.2,----:----.,-:--+-:---\---,---\------,
0.1 .
~PV o
0.5
~OP o·
·0.5 .
·1 t:.======:t==~===:t=====::::i
5 Time (minutes) 10 15
The test has many positive features that have led to its widespread use in real
plants as well as in simulation studies:
The autotw1e test sometimes does not work properly in the cWTent version of
HYSYS. Instead of switching when the error signal changes sign, the switch is
delayed. This produces a sequence of curves with increasing amplitude. Ifthis bug
occurs, you can perform the test by setting lin1its on the controller output and us-
ing a large value of gain. Output limits are specified on the Advanced window of
the controller face plateo
It is important to note that you should record the PV signal to the controller and
OP signals from the controller. The PV signal is the signal afier any lags and dead-
times. A common mistake is to record the original process signal (temperature,
composition, etc.) before the lags and read the amplitude ofthis signal. This wiIl
not give the correct ultimate gain. The correct amplitude is that from the signal
that the controller sees, i.e., the PV signal.
Using the relay-feedback test in AspenDynamics requires more effort and is
less reliable than in HYSYS. The steps are:
1t sometimes takes a little trial and error to fmd a value of gail1 that works effec-
tively. Ifthe value is too sma11, the loop does not oscillate. Ifthe value is too large,
the mm1erical integrator gets into difficulty. The result is either an error message
or the integrator takes such tiny steps that the simulation essentially comes to a
stop.
Knowing the ultin1ate gain Ku and ultimate period Pu permits us to calculate
controller settings. There are several methods that require only these two parame-
terso The Ziegler-Nichols tuning equations for a PI controller are:
K c ==K u /2.2
TI == Fu /1.2
These tlming constants are frequently too aggressive for many chemical engineer-
ing applications. The Tyreus-Luyben tuning method provides more conservative
settings with increased robustness. The TL equations for a PI controller are:
K e == KlI /3.2
TI == 2.2Pu
There are many other ÍUl1Íng methods, but many of these require more infonnation
about the process. The IMC tunii1g mIes usually provide good control, but thl'ee
process parameters must be known. The process is assumed to be approximated by
a fll'st-order lag and deadtime transfer firnction.
32 Chapter 3
K p e -Ds
G = -'----
rs+1
If the gain K¡" deadtime D and openloop time constant 1: are known, the IMC tun-
ing equations for a PI controller are:
A = max(1.7 D, 0.2T)
KK =2T+D
e p 2A
TI = T+ D/2
0.1
Time constant = 2
Ob-~--~--~~~----~----~--~~
o 6 10
Time (minutes)
At the ultimate frequency, the magnitude of the process transfer function (1 GI )is
equal to the reciprocal of the ultimate gain Ku, which is known. So the process
gain can be ca1culated.
~'-1+-(m-,-,r-)2-
K =--'-----------
P Ku
The cascade control structure is illustrated in Figure 3.3. Two controllers are
used: a primary controller and a secondary controller. The setpoint of the secon-
dary controller comes from the primary contToller (it is the output signal of the
primary controller).
This is a standard feature in both simulators. In HYSYS, double c1icking the
controller icon (or c1icking the Tlming button on the face plate) brings up the con-
troller view. Select the Connections page tab. On the left side ofthis view there is
a box called "Remote Setpoint Source." The drop-down alTOW can be used to se-
34 Chapter3
lect the controller from which the secondary controller is receiving its setpoint
signal. This controller then has three altemative modes that can be selected on the
faceplate (or in the controller view window): manual, automatic (local setpoint)
and cascade (remote setpoint). We illustrate the details ofthis procedme in subse-
quent chapters.
Primary
Conu-oller
/ Secondary
TT .......~
OPT ~ SPF Controller
TC .......>; /
N r :
OPF
..:.......... 1
¡
ic I<;........·~j FVF
FT
Steam
*. . . . . .~
PfF2
Ratio l· ...>: /
SPF
:
~
(Remote Set)
Controller
=•••••••••• ~ ...••••••••»:
~ PlFJ.
~ ~
OPF
•
Manipulated
Stream
réJ eL
3.5.3 Overrride Control
Ovenide control uses high and low selectors to change the structure of the
control system. As illustrated in Figure 3.5, several signals are fed into a selector.
These signals are usually the OP signals from two or more controllers. The selec-
tor output signal is either the highest or the lowest of all the input signals. The
signal from the selector goes to a valve or the setpoint of a cascade controller.
Thus the selector is picking which controller should be setting the val ve. This
variable-structure control is a very powerful but simple way to achieve constraint
control.
TT ....... ~/
: OPT
t"~7-¡1~--t~¡~-- '"~ 1
:<.......... ¡ p(L ,--..:..---,
1$
.
E
.
l ......................................»:
'-' Bottoms
t......................................................................................~
36 Chapter3
HYSYS has a Selector block, which can be added to the process flow diagram
(PFD). On the Connections page tab, all the input signals are specified. On the
Parameter page tab, the mode of the selector is seto It can find the minimum, the
maximum, the average, the median or the sum of all the inputs.
AspenDynamics provides the same capability. Under Dynamics, select Con-
trol Models and drag the HiLOSe1ect on to the PFD. Connect the two input signals
and the output signal. Highlight the icon by left c1icking, Right c1ick and select
Forms and then All Variables. On this view you can specifY the type of selector
(high or low) and see the values ofthe input and output variables.
AO
lifl'
=<:-.......................)'
c. h-j¡~nQ)!mlIDÜ;;S Simulation
:<.............................................. ~ Rev.
Heat Exchanger ; •
--..---~I--nll
! )1.
~ [IT} .... ·..>[~l.... Sphtge
'~;J--) R7
AO
- - : Dlrect
~= = :.(: ............................................'!t:
3.7 Conclusion
In this chapter we have discussed sorne of the tools and techniques that are
required to get a control systern configured and ttmed. Level and flow loops usu-
ally require no ttming. Ternperattrre and cornposition loops need dynanüc identifi-
cation, and the relay-feedback test is useful for this jobo The inc1usion ofrealistic
lags and deadtirnes in these loops is needed to guarantee conservative designs.
Several advanced control strucUrres can be easily incorporated in the dynamic
sirnulati ons.
The detailed procedures for installing and using these elernents are illustrated
in the examples in subsequent chapters.
a 11
ingle nit ynamic
i ulations
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
hapter
Tank Process
The remaining chapters in this book present detailed case studies of dynamic
simulations of a wide variety of processes. hl this chapter we begin with the sim-
plest possible dynamic process, a tank with inlet and outlet streams. There are two
or three controllers required to operate even this simple unit: a level controller and
a flow controller (and in sorne cases a pressure controller). fu a detailed, step-by-
step procedure, we cover moving fi.-om a steady-state simulation into a dynamic
simulation and installing controllers and strip-chart recorders. The steps are pre-
sented using both HYSYS and AspenDynamics.
The primary process considered is a separator vessel with both vapor and
liquid exit streams. Later in this chapter we alsodiscuss a tank with only a liquid
exit stream. Although the second system seems more simple than the first, there
are sorne subtle modeling differences between the two simulators that make tlle
liquid product tank somewhat more complexo
Figure 4.1 gives the PFD from HYSYS, and Figure 4.2 gives the workbook
with aH stream conditions shown. A liquid feed stream is fed into a 2.13 m 3 verti-
cal cylindrical tank (1.1 m diameter, 2.2 m length). Feed flowrate is 100 kg-
molelhr of a mixture of 10 mol% ethane, 20 mol% propane, 30 mol% isobutane
and 40 mol% n-butane at 70°C and 20 bar. The feed stream flashes as it drops
pressure through control valve VI. The separator tank operates at 5 bar and is
adiabatic. The steady-state temperature is 27.5°C. The liquid stream leaving the
tank goes through a pump and control valve V2. The vapor stream leaves through
control valve V3.
41
42 Chapter4
v V3
v30ut
Separator
v10ut
V1
v20ut
V2
wk
The plumbing has been inserted in the system. This would not be necessary
ifwe only wanted to look at the steady state. Ifwe do not add the control valves,
when we try to switch into the dynarnic mode, the HYSYS "dynamic assistant"
will advise us to insert valves to achieve a pressure-driven simulation. It is good
practice (and good training) to do the plumbing before switching into dynarnics.
The feed control valve VI has been designed for a 15 bar pressure drop. The
liquid control valve V2 and the vapor control valve V3 have been designed for 2
bar pressure drops. Make sure you have sized each ofthe control valves and speci-
Tank 43
fied their percent open. Double c1ick the valve icon and go to the Dynamics page
tab. Figures 4.3A, B and C show this for the three val ves. Specify the percent open
(usually 50% unless higher flowrates are required), check the Check Valve button
and c1ick the Size Valve button. This will calculate the C v size coefficient for the
valve.
Figure 4.3A - Vi
Figure 4.3B - V2
44 Chapter4
Figure 4.3C - V3
The dynamic specification for the plUnp must also be specified. Double
c1ick the pwnp icon and click the Dynal11ics page tab (see Figure 4.3D). Click the
Pressure Rise and the Efficiency buttons. This willl11aintain the same plUnp pres-
sure head as flowrates change during the dynamic simulation.
The volume ofthe tank has been specified to be 2.13 m 3 . To converge the
steady state, this value would not have to be knOW11. However, to run the dynamic
simulation, it is vital.
The tank is sized by looking at two criteria. First, the superficial vapor veloc-
ity must be low enough for good vapor/liquid disengaging. This means the cross-
sectional area ofthe vessel must be large enough. Second, the holdup ofliquid in
the tank must be sufficient to provide the required surge capacity. We provide 10
minutes ofliquid holdup with the tank 50% full ofliquid.
To check the vapor load, we look at the vapor flowrate (1752 kglhr) and its
density (10.6 kglm3 ). The vollU11etric flowrate is
For 10 minute of liquid holdup, the liquid volume should be 1.065 m 3 , and the
total tank vollU11e is 2.13 m 3 . Assurning a LID aspect ratio of 2, the diameter can
be ca1culated from
This gives a diameter of 1.11 m. Since this is larger than that required for the va-
por load, we select the larger ofthe two.
46 Chapter4
The size ofthe tank is specified on the Dynamics page tab, as shown in Fig-
ure 4.4. The percent liquid level is 50%.
When the steady state is converged and the plumbing has been specified,
c1ick the Dynamics button on the top tool bar. The dynamic assistant will suggest
that some changes be made in some specifications so that the flow-driven simula-
tion is correctly set up, as shown in Figure 4.5.
This might be a good place to mention the procedure for switching back to
the steady-state mode from the dynamics mode. You may want to do this if you
want to change the structure of the flowsheet or use different equipment sizes or
conditions. Ideally one would like to be able to move back and forth seamIessly.
However, when HYSYS switch es ii"om dynanucs to steady state, it does not return
you to the initial steady-state conditions that you had when you originally moved
from steady-state to dynanlics. The values of some of the variables are different,
and some ofthe variables that are specified (the variables fixed to satisfy the avail-
able degrees of freedom) have changed from the original steady-state case. For
example, suppose you have specified in the steady-state mode the purities in a
distillation column ofthe distillate and bottoms streams. These two specifications
will give zero degrees of freedom in the steady-state mode. If you switch to dy-
namic mode and then switch back to steady-state mode, the degrees of freedom of
the column will be given as -2 (too many variables specified). The condenser and
reboiler duties have been specified in the switch from dynanlics to steady state.
48 Chapter4
You must go to the column flowsheet and de1ete these two energy streams before
the column can be reconverged in the steady state to the COrrect specifications.
One way to overcome these re-initialization problems is to save the original
steady state case as a different file to which you can always retum.
1. Click the Controller icon on the pallet and, with the right mouse but-
ton held down, drag it on to the PFD.
2. Double c1icking on the controller icon brings up the controller win-
dow. The first page tab is Connections, shown in Figure 4.6.
3. Click the Select PV button to specify the unit or stl'eam and the vari-
able to be controlled. For example, to select the PV fol' the flow con-
troller for the feed, we select the stream "F" and the variable "molar
flow" as shown in Figure 4.7. If a controller is to get an extemal set-
point signal, there is a box (Remote Setpoint Source) in which the
Tank 49
4. Select the target of the OP signal (the place where fue controller
output signal is sent). Figure 4.8 shows the OP signal goes to VI.
Figure 4.9 shows the cOllilections page view with both fue PV and
OP cOlmections specified.
8. SpecifY the controller tuning constants: gain Kc, integral time 'tI
and derivative tinle 'tD. To achieve a propOliional-only controller,
delete whatever number is in the integral box ("empty" should ap-
pear). For the flow controller we specifY a gain ofO.5 and an inte-
gral time of 0.3 minutes. See Figure 4.11.
9. Put the controller into manual or automatic. If the controller re-
ceives its setpoint from another controller, c1ick the "Remote" SP
Mode button on the Connections page tab.
10. The final step is to c1ick the Faceplate button at the bottom of the
window. This places a faceplate on the workspace, as ShOW11 in
Figure 4.12. 1 usually line up all the controller faceplates at the top
of the screen for easy viewing. The values of the process variable
PV and the controller output OP are displayed as horizontal bar
charts. The red arrow at the top of the PV display is the setpoint
value. To change the setpoint, when the controller is on automatic,
double c1icking on the PV display opens a window where you can
enter the desired value. When the controller is on manual, double
c1icking on the OP display opens a window where you can enter
the desired value ofthe signal to the valve.
52 Chapter4
The autotuner can be also be started :fi:om this window. However, since the
level and flow controllers require no tuning, the autoumer is not needed in this
example. Its use will be illustrated in the composition controller used in the blend-
ing process considered in the next chapter. For the same reason, we wait until the
next chapter to illustrate the installation oftransfer functions.
The other two controllers are installed in a similar malmer. Figure 4.13
shows that the source ofthe PV signal for the pressure controller is selected as the
Vessel Pressure in the Separator. As shown in Figure 4.14, the OP target ofthe
pressure controller is valve V3. The Parameters page tab is shown in Figure 4.15.,
The action of the pressure controller is direct. A pressure trallsmitter range of4 to ..
7 bar is specified. The tuning of the pressure controller is selected empirically to
be a gain of2 and all integral time of2 minutes. The latter tuning constant is based
on a estirnate of the vapor time constant. The vapor volumehic flowrate is 2.76
m 3/min. The total tank volume is 2.13 m 3 . So the vapor time constant is about 1
minute. An integral time of2 minutes is reasonable for this process.
The PV of the level conh·oller is the Liquid Percent Level of the Separator
(see Figure 4.16). Figure 4.17 shows that the action of the level controller is direct,
and propOliional-only action is selected (the Ti value is "empty") by deleting the
number in the integral time. A gain of2 is specified.
The final PFD with the flow, pressure and level conh·ollers is given in Fig-
ure 4.18. The three conh·oller face plates are positioned at the top of the screen.
54 Chapter4
We need to be able to see how vatiables are changing with time. Strip-chart
recorders or data-loggers are useful for this purpose. In addition we can output a
file of the time history of a simulation for plotting using software packages such as
Matlab or Excel.
56 Chapter4
Fe
F v10ut
V1
v20ut
wk
The steps for installing and defining the properties of a reeorder are:
1. Cliek Tools on the top menu bar and elick DataBook (see Figure
4.19).
2. On the Variables page tab, elick msert. Select the variable to be
recorded. For example, to record the flowrate of liquid from the
tank, we select under Object the "L" stream, as shown in Figure
4.20. Under Variable, we select Molar Flow. Then elick the OK
button. To add the level in the separator, we elide msert again and
select the Liquid Percent Level in the Separator (see Figure 4.21).
You insert all the variables you want to record.
Tank 57
3. Click the Strip Chart page tab. This ope11s the view shown in Fig-
ure4.22.
4. Click Add butt011. This installs a data logger. You may have sev-
eral stripcharts.
5. Specify which vruiables in the list 011 the right you want to record
011 this strip chart. The example shown in Figure 4.23 has 011e strip
chart, DataLoggerl, for which four of the Active boxes are
checked in the right cohunn, so these four variables will be plotted
011 this strip chart.
In addition to seeing the data fiom a dynamic run on a strip chart, these data
can be saved in a file and exported to sorne other program for plotting or analysis.
Go to Tools and Databook, and the11 open the Stlip Charts page tab. Highlight the
data logger of interest a11d c1ick the Historical button. Atable of all the time data
011 the strip chart appears. The data can be saved as a file or you can use Edit on
the top tool bar to copy the data and paste them into another programo We will
illustrate this operation in the 11ext chapter.
The stlip charts in HYSYS have a very useful featlU"e. Ifyou move the ClU"-
sor to a point 011 a ClU"ve, the values of the variable and the value of time at that
point are displayed. This is particularly useful when running a relay-feedback test.
It makes it easy to pick off the ultimate period (the time between peaks) and the
amplitude ofthe PV signal (halfthe difference between the maximum and míni-
mum values).
Now that all the elements are ready to go, the integrator can be started.
Clicki11g the green button on the top tool bar starts the integrator. Before doing this
you may want to change the display interval since the default value is one minute.
Go to Simulation at the top ofthe screen and select Integrator. A window opens up
(see FiglU"e 4.28A) on which you can set the Display Interval (5 to 10 seconds).
You can also set the current value of time and specifY the time you want the inte-
grator to stop (End Tinle). Figme 4.28B illustrates a case in which the integrator is
stopped at 15 minutes.
The nonnal procedure is to start the integrator and closely observe what the
controller outputs are doing on the faceplates. If everything is at steady state and
correctly connected, the values of all vmiables should just stay constant. But there
may be sorne momentary transients. When the process has lined out at the desired
steady state, save the file. If you need to start again from these conditions, go to
File, select the file name, click Open and specifY Reload.
HYSYS and AspenDynarnics have different ways of dealing with initial
conditions and "rewinding" to sorne previously saved conditions. In HYSYS you
must save the file mld reload. As discussed later in this chapter, in AspenDynam-
ics you can take Snapshots (store all the state vmiables at sorne point in time) and
rewind to any initial conditions you have saved.
To illustrate the use ofthe strip chart, we make a step change in the setpoint
of the feed flow controller at time equal 15 minutes from 100 to 120 kg-mollhr.
Then at time equal 60 minutes, the flow controller setpoint is dropped to 80 kg-
mol/hr. Figure 4.29 shows how the vapor flow V, the liquid flow L, the liquid
level and the pressure P vary with time. The proportional-only level contr·oller lets
the level float up and down as rate changes occur and provides good flow smooth-
ing. The PI pressure controller retums the pressure to the setpoint within about 10
minutes (the pressure scale is Oto 7 bar). This loop could be retuned iftight pres-
sure control were important.
The HYSYS strip charts are not very suitable for making good figures. The
time scale is not given in integers, and only one ordinate scale is displayed. To see
a different axis, light click the strip chart and click Select Curve.To get good plots
fi'om the data, the file can be saved to a file and then plotted using other software.
This is illustrated in the next chapter.
The separator tank considered aboye had both liquid and vapor streams leav-
ing the vessel. In many processes we have tanks with only a liquid streanl. Unfor-
tunately HYSYS requires that a tank must have both vapor and liquid exit streams.
So we must install a vapor line and place a control valve in this lineo Of course, the
flowrate ofthe gas is zero, so the valve cmUlot be sized in the nonnal way. Other
problems arise when the dynmnic simulation is mn because HYSYS as sumes that
the liquid is at its bubblepoint. This results in chmlges in the pressure in the tank as
temperature andJor composition change.
To illustrate this situation, Figure 4.30 gives the PFD of a process with only
a liquid stream leaving the tank. A liquid feed stream is fed into a 196 ft3 vertical
cylindlical tank (5 ft dimneter, 10 ft length). Feed flowrate is 100 lb-mole!hr of a
50/50 molm' mixture ofpropane and isobutane at 150°F and 269 psia. The liquid
stream leaving the tank goes through a pump and a control valve.
Since HYSYS requires that a tank have both liquid and vapor exit stremns,
we must install a vent line and a control valve in the simulation. We will speci:fy
that this valve is shut.
The feed and product control valves (VI and V2) have been designed for a
40 psi pressure drop in this example. To size the valve in the vent line (V3), dou-
ble click the valve icon and go the Rating page (see Figure 4.30). Speci:fy the valve
opening to be 0%, enter a nominal pressure dl'op (5 psi) mld enter an arbitrary Cv
value (500).
When the Start Integrator button is clicked in this tank example, a message
appears requesting you to do something about the fact that the temperature and
pressure specified for the contents of the tank do not cOlTespond to bubblepoint
liquid conditions. Three altemative initial conditions are suggested, but the rec-
ommended action is to increase the temperature of the liquid in the tank. The
sirnulator makes the temperature cOlTespond to the bubblepoint temperature of the
liquid mixture in the tank at the specified pressure.
As the integrator runs, the temperature in the tank will chmlge to the level
that satisfies the energy balance, so the pressure will change. In this tank exmnple,
the initial pressure specified was 229 psia in the tm1k with a temperature of 150°F.
The sirnulator increased this temperature at the beginning of the runo When the
final steady-state conditions are obtained, the tank temperature retums to 150°F,
but the pressure drops to 207 psia. Of course, this changes the pressure drops over
the control val ves. So the feed flow controller OP signal moves from 50% to 40%
64 Chapter4
because the pressme drop over the feed valve increases as the tank pressme drops.
The level controller OP signal moves from 50% to 74% because the pressme drop
over this valve decreases. This is the final steady-state condition with bubblepoint
liquid in the tank. As discussed in the next section, AspenDynamics treats the is-
sue oftanks \vith bubblepoint liqlúds in a completely different way.
Tbis startup transient can be annoying. In the next chapter we overcome tbis
problem by feeding a small inert gas stream to the tank and using a pressme con-
troUer. However, in some processes tbis artificial "fix" is l1l.1l.1atmal and lmdesir-
able. Another altemative is to make sme at the steady-state sirnulation stage that
the liquid in the tank is at a temperatme that is precise1y the bubblepoint tempera-
ture at the pressme specified.
vent ~t
P1 4
V2
Tank 65
Separator Tank
When the steady-state flowsheet has been converged with the correct
plumbing, the Dynanúcs button on the top tool bar is c1icked. See Figure 4.33. If
the Dynanlics button is not showing, go to the View button, select Toolbar and
c1ick the Dynamics box. The blocks in the flowsheet that contain capacitance have
buttons in the Setup view that are labeled Dynanlic. The button will show red if
additional inf0l111ation is needed to go into dynamics.
66 Chapter4
Make Dynamic
Dynamic
Stream:;
IB'íAl 2
é-íAl 4
lB íAl6
IB'íAl 7
IB-tz¡] F
IB[2¡]L
S"lA} v
El ¡ID Block~
@~P1
Btz¡] SEP
! !..·_eJ Input
o Hculve:
(!J Oynamic
--f!J B!ockOptiom
, ~Re~ulb
, '©JSlIeam Ae:;ul$
1ti·tz¡]V1
IBtz¡]V2
, IB·[2¡]V3
!1l D Aeactions
!B r;J :onvelgence
Tank 67
When all of the dynamic data have been entered, nm AspenPlus to converge
the steady-state flowsheet. Then click the Pressme-Check button on the top tool
bar. Ifthe plumbing is properly designed and sized, a message wiH appear that the
flowsheet is ready to go into a pressme-driven dynamic simulation (see Figme
4.34).
One of the confusing factors in working with Aspen is the several files that
are generated. Three files are produced in steady-state AspenPlus. Suppose we caH
om simulation "sep." AspenPlus wiH generate a "sep.apw" file, a "sep.bkp" file
and a "sep.appdf' file. The "bkp" file is the one to save because it can be used as
new versions of the software are released. Two other files are produced when we
go into AspenDynamics. These are "sep.dynf' and "sepdyn.appdf." The latter has
aH the physical properties for the dynamic simulation.
AH these files can cause some confusion, but just remember to save the bkp,
the dynfand the " ... dyn.appdf' files. The HYSYS file management is simpler.
Go to File and elick Export. SpecifY that you want to save the file as a pres-
sme-driven simulation (see Figme 4.35). Of comse, save the steady-state apw and
bkp files. Now close AspenPlus and open AspenDynamics. Open the "dynf' file.
If everything is in order, it should load with no enors. Sornetirnes an enor
message appears that sorne parameter values are missing. This occms when some
ofthe blocks are not in the "available" list. Go back to AspenPlus, go to Setup and
elick the Reports Options button. Then click the Block page tab. Clicking the In-
elude Blocks button shows aH the blocks that are available. Ifthey are not alllisted
in the right column caBed Selected Blocks, use the double "»" button to move
them aH over to the right. Then export the file to AspenDynamics as a pressme-
driven simulation.
68 Chapter4
Dblend Deg-rd1
Destr Deg-rd2
Destr1 D final steady state
DDehyd Dgood2
Ddist3 Dhintdis
Ddpe" Dh"d Pressure
driven
Three windows appear when you open a file in AspenDynamics: the flow-
sheet, the Explore-Sim window and a message window as shown in Figure 4.36.
The flowsheet comes up with some basic default controllers already in-
stalled. For this tank example, a tank level controller (LC!) and a pressure control-
ler (PC2) appear. The pressure controller is fully configured with its PV signal
coming from the tank (vessel pressure) and its OP signal going to control valve
V3. The leve! controller output is not connected because there is a block (the
pump) between the tank and the valve. We must make the output connection on
the level controller to valve V2 and install a flow controller on the feed stream.
Before doing anything, it is good idea to make an Initialization nm to make
sure that everything is set up correctly and the equation-based integrator is work-
ing. As shown in Figure 4.37A, se!ect "Initialization" from the drop-down menu
on the top tool bar and click the Rlm button, which is located just to the righí. If all
is set up correctly, the message shown in Figure 4.37B appears. Then use tlle drop-
down menu to retum to Dynamics.
¡___ H ___________________ : V3
1------1
Separator Tank.
Dynamics
Separator Tank
Stream
Types
Separator Tank
72 Chapter4
1- - -- -- - - - -- - --- - - - --- - -,
I
Separator Tank
Fe
--D
~ ~ ~1./1V2 ,,1, •
~~
Tank 73
,-----------------------, V3
,, ,I
Separator TanJ::
Fe
:---->-0
I
ing the controller. Clicking the left-most button puts the controller
on automatic. Clicking the second button from the left puts the
controller in manual. Clicking the third puts the controller in cas-
cade (remote setpoint).
10. The fourth button (Configure) opens a window with several page
tabs. Figure 4.45 shows the views given for the flow controller
when the Tuning page tab, the Ranges page tab and the Filtering
page tab are elicked.
11. The first thing you should do is eliele the Initialize bar at the bot-
tom of the window. This inserts values for the PV and OP signals,
default values for transmitter ranges and some default controller
settings.
Pause
: __________ w ____________ V3
~
I------i
Separator Tank
Procedure= Fe
El Reactor:
'Seripl: :---->-0------,
6l {iJ Sepalato!~ : :
S@llStreamTypes
~Connection
.~ ;t~rii~l$igti~
i--~ Hea]5l1eam
, ~MatelialSt¡aam
~ Polymer5tleam
-.-~WorkS1Jeam
f,i
ffi .. Sy~temLlblary
Lf5:I Component Li~l~
12. On the Tuning page tab, select direct or reverse action. The flow
controller is reverse-acting. The selection of direct or reverse con-
trol action is probably the most important item in setting up a con-
Tank 75
troller. If you have the wrong action, the loop will drive the con-
trol valve to a limit. The conventional flow-controller tuning con-
stants are specified on this page tab.
13. Click the Ranges page tab and change the transmitter ranges ifyou
do not like the default values chosen. Reasonable spans for tem-
perature transmitters are 100 to 200°F. Flow spans are usually
twice the steady-state flowrate. Pressure spans are usually about
50% ofthe absolute pressure.
14. The output ranges can also be specified. For signals going to con-
trol valves, the range is O to 100%. For signals goil1g to energy
flows, the range is from the mil1imwn energy flow (OPmin) to the
maximwn energy flow (OPmax). The sign convention must also
be taken into account. Remember that energy added to a unit is
positive in AspenDynarnics. Energy removed is negative. So for
heat removal, the OPmin is a negative nwnber and the OPmax is
zero. For heat addition, the OPmin is zero and the OPmax is a
positive nwnber.
15. The Filteling page tab can be used to filter the PV signal if de-
sired. The nwnerical integrator seems to have fewer problems if a
small (0.1 minute) filter is used in flow loops, probably because
the flow transmitter and valve are treated as instantaneous in the
model.
The pressure controller tuning and ranges are ShOWf1 in Figure 4.46. The
controller is direct-acting. A pressure transmitter range of 3 to 7 atm has been
specified, and tuning constant entered (Kc =2 and 'el = 2 minutes).
The level controller tuning and ranges are ShOWf1 in Figure 4.47. The con-
troller is directing and proportional-only with Kc = 2. The proportional-only action
is achieved by speci:fYing a very large value for integral time.
When the all the controllers are installed, clicking the Run button (se e Fig-
ure 4.44) will start the integrator. When the process lines out at steady state, you
can reset time back to zero by pausing the n.m, making an initialization run and
rewinding (see Figure 4.48). This becomes the initial conditions for the simulation.
We give more details ofrunl1ing the simulation and storing initial conditions 1ater
in this chapter.
76 Chapter4
Manual
Tuning Filtering
1. Go to Tools on the top tool bar. Click New Plot on the list that
opens up. A plot window appears.
2. Left c1ick the stream or unit containing a variable you want to
plot. Then light c1ick, select Forms and c1ick AH Valiables. Figure
4.49 shows the plot window and the All Vmiables window for the
feed stremn F.
78 Chapter4
3. Left elide the variable you want to plot. Then left elick again and
hold the mouse burton down. The molar flowrate is se1ected in
Figure 4.50.
4. Drag the variable to the strip-chart and drop it (release the mouse
button). Figure 4.51 shows that a vertical axis has been installed
with the feed flow. Several variables can be plotted on the same
plot with different scales.
5. Right elide the plot and select Properties. Figure 4.52 shows the
various page tabs that appear. Labels, axis scales, colors of lines
and other properties can be customized to your liking.
Tan" 79
o 1 3.:1 5 6
Time Hours
80 Chapter4
Each variable can have its OWl1 scale by specifYing this option in the Axis-
Map page tab. Figure 4.53 shows the Axis page tab view on which the scales for
all the vatiables are specified. If you want a fixed scale, remove the check in the
box to the lefi of"Reset axis ratlge to data." Figme 4.54 shows the Runtime page
tab view on which the ratlge oftime can be specified.
Text can be added to the plot by right c1icking the plot and selecting Modify.
Then c1ick Add Text. This opens the window ShOWl1 in Figure 4.55 in which text
material can be placed on the plot. Afier you have typed in what you want and
clicked the "OK" button, the cursor is positioned where you want the text placed
on the plot and c1icked. This featme is convenient for labe1ing curves.
The plots generated in AspenDynanucs are much better than those generated
in HYSYS. The main reasons are the reasonable time scales and the multiple
scales. AspenDynanlics gives integer values of time (1, 2, 3, .. , hours). HYSYS
gives time scales that at'e fractions ofminutes or hours, which makes it difficult to
read time.
Tank 81
There are several buttons on the top toolbar that make rUlming the simula-
tian, pausing and rewinding easy. Figme 4.44 shows five buttons to the right of
the window showing "Dynamic." The first is the Run button. The third is Pause,
and the fifth is Rewind.
With faceplates for a11 the contro11ers displayed, select Initialization and
click the Rlll1 button. If everything is okay, a message will appear telling you the
TIll1 is completed. Now select Dynamics and click the Rlll1 button. The integrator
should start, and if everything is insta11ed cOlTectIy, a11 the controller outputs
should remain constant. One common elTor is to have the wrong action on the
controllers, so check this carefü11y before starting the integrator. If the system is
not stable and diverges, click the Pause button and then the Rewind button. Select
the initial conditions file and click Rewind. This wi11 retUll1 you to the original
conditions.
Once the simulation has come to a steady state that you like, pause it and se-
lect Initialization from the dropdown list given in the window to the left ofthe Run
button. Then c1ick the Run button. This sets time equal to zero and stores the val-
ues of a11 vatiables. This can be saved and then used as the initial conditions for
later TIll1S.
Switch back to Dynamics. Rewind to the hutialization Run just generated
and save the file. A number of useflll things can be done by taking "snapshots"
(storing the values of a11 variables) at a given point in time.
y ou may want to stop the integrator at some point in time. This is done by
going to Rlll1 at the top ofthe screen, clicking Integrator, clicking "Pause At.oo Fig-
ure 4.56 shows the window that opens. You can specifY a value of time at which
to stop the integratar.
82 Chapter4
Figure 4.58 illustrates the use of plots. Two plots are ShOW11. One shows the
flowrates ofthe feed, liquid and vapor streams. The same vertical scale is used in
this plot. The second plot shows the tank level and pressure, each having its oW11
scale.
Tal1k 83
The disturbances are positive and negative step changes in feed flowrate at
time equal 0.25 hours and 1 hour, respectively. Notice that fue PI pressure control-
ler retums the pressure to the setpoint value (5 atm), but fue P level controller lets
fue tank level float up and down. The P action gives gradual changes in the liquid
flowrate.
~
: ...... , .... i······,····"- •••• •••••• '•••••• i• • • i
: ······:·····T····r···~~'·····T"····:······:······1
§
s
iil
.......!....... :.......¡- ...... :
: , ,
,:rr~~l::' ,,,
~._--_._-
,,
----. -- ---
,,
-~--
,,
--_.-',
sin r~
. . . LI~E;L¡L
JI j:LJ 1~ 1~ ;..: : ': : : ,
' , , , , , ,
T, \:rJl,:,r~·
rIfIfIIli Time Hours
~ ~ ······r·····'······r·····'······,······1·····r·····:
0.25 0.5 0.75 1
Time Hours
1.25 15 175
The separator tank considered aboye had both liqrnd and vapor streams leav-
ing fue vessel. In many processes we have tanks with only a liquid stream. Aspen-
Plus and AspenDynamics permit the use of a tank with only a liquid outlet. This
block is fOlmd in the Mixer page tab in AspenPlus.
To iHustrate fuis situation, Figure 4.59 gives the AspenPlus flowsheet of fue
same process considered in Section 4.1. 7 in which only a liquid stream leaves the
tanlc To set up the tank, we c1ick the Dynamic view, open the Vessel page tab and
specify vertical tank (not instantaneous). Clicking the Initial Condition page tab
opens the window shown in Figure 4.60 in which the Liqtúd volume fraction is
84 Chapter4
specified to be 0.5. We also need to open the Input view of the tank (see Figure
4.61) and specifY the Va1id phases to be "LiqlÚd Only."
4.3 Conclusion
In this chapter we have covered all the basic steps and methods in moving
from a steady-state simulation flowsheet into a dynamic simulation. Providing
equipment size data, adding controllers and installing strip charts are essential
steps required. Starting and stopping the simulation and saving initial conditions
have been covered. The details of the procedures have been illustrated using a
simple single tank example for both dynamic sinmlation software packages.
Controller tuning and the use oflags and deadtimes were not covered in this
chapter because they are not required in level and flow control loops. In the next
chapter we consider another simple process in which more controllers are in-
volved. A composition controller is used, which requires the use ofmeasurement
lags and relay-feedback testing.
hapter 5
Blending Process
The previous chapter covered most of the details of developing, starting up
arrd running a dynamic simulation. A very simple tank level and pressure control
example was used. In this chapter we extend our coverage slightly to include a
compositioll controller that requires a rigorous tuning procedure. The process corr-
sidered is a blellding tank with two feed streams. There are several controllers
requirecl to operate even this simple unit: a composition controller, a level control-
ler, a pressure contToller alld two (or three) flow controllers. We move from a
steady-state simulation into a dynamic sil11ulation, insta11 controllers and strip-
chart recorders, install a deadtime in the composition loop, tune this controller and
evaluate performance. These procedures are presented using both HYSYS and
AspenDynal11ics.
Figure 5.1 gives the flowsheet PFD from HYSYS. Two liquid feed streams
are fed into a 1000 ga110n tank. One stream is 100 lb-mole/hr of ethanol at 90°F
and 150 psia. The second streal11 is 600 lb-mole!hr of n-pentane at 90°F and 150
psia. The tank operates at 110 psia and with a liquid level of 50%. The composi-
tion of the liquid leaving the tank is 14.17 mol% ethanol and is controlled by ma-
nipulating the fi"esh feed of ethanol.
There is also a small flow of nitrogen into the tank. In the second tank con-
sidered in the previous chapter, we kept the vapor flow fi"om the tank at zero, so
the liquid in the tank had to be at its bubblepoint pressure for the temperature set
by the energy balance. This resulted in a tank pressure that changed with tank
temperature, which affected control valve pressure drops. To avoid these prob-
lems, the sma11 stream of inert gas is fed to the tanlc, and the pressure is controlled
in the tank by manipulating the valve (V4) in the vent stream fi"om the tanlc We
are essentially simulating the coml110nly used vent/bleed pressure control system.
The flowrate of the nitrogen is set at 7 lb-mole/hr.
87
88 Chapter 5
......
vent
'l><I~-....
-+
v40ut
FFE V4
V1 v10ut
inert v30ut
v20ut wk
---""¡;;;><I---'
FFP
V2
The phmlbing has been inselied in the system. Valves VI, V2, and V3 are
designed to be 50% open with 40 psi pressure drops. The val ve on the vent line V4
is designed to be 20% open and discharge into a vent header operating at 20 psia.
The Dynamics page tabs are opened to size the control val ves and specifY there
can be no back flow (check val ve). The dynamic specification of constant head for
the pmnp must also be set on the pump Dynamics page tab.
The flowsheet is ready to switch to the dynamic mode.
Figure 5.2 shows the PFD with all the controllers installed and a deadtime
element in the composition loop. The procedure for adding controllers was pre-
sented in detail in Chapter 4. The control structure has the following loops:
The tmlÍng constants ofthe level and flow conlrollers are the standards dis-
cussed in Chapter 3. The pressure controller in this example is not critical, so we
pick some reasonable tmling constants (Ke = 2 with a pressure transmitter range of
Oto 200 psia, and integral time '[1 = 5 minutes).
The new feature in this example is the deadtime element. Many composition
measurements are achieved by the use of chromatographic analyzers. These de-
vices have inherent deadtimes, which significantly affect controller performance.
Blending 89
v20ut wk
Blending
Process
The procedure for installing a transfer function is the same as that for install-
ing controllers, which was presented in detail in Chapter 4.
l. Drag a transfer function from the pallet and drop it on the PFD.
2. Double clicking the transfer function icon opens the left window
shown in Figure 5.3.
3. The Connectian page tab is used to select the input signal (PV) and
the output signal (called the transformed PV target, PV'). The input
connectian is selected as the campasition of ethanol ("Comp Mole
Frac (Ethanol)") in the stream leaving the tank ("Tkout"), as shown
in Figure 5.4. The output connection is specified as the PV signal
going into the composition controller. Note that the connection
between the output of the transfer function and the input to the
composition controller input must be made from the controller
connection window. Trying to make the connection from the
transfer-function window doesn't work because the controller PV
is not listed as ane ofthe available signals.
90 Chapter5
4. Clicking the Parameter page tab opens the window shown in Fig-
ure 5.5. The PV Min and PV Max are specified to be the same as
the range used in the controller. In this example, the steady-state
composition is 0.1417 mole fraction ethanol. We select a composi-
tion transmitter range of Oto 0.25 mole fi·action.
5. The left column on the Parameter page has several types oftransfer
functions. To install a deadtime, click DeJay. First-order 01' second-
order Jags can be illstalled by clicking Lag 01' 2nd Order.
6. Clicking DeJay opens the window shown in Figure 5.6. Click the
DeJay box undel' Active Transfer Ftillctions, and specifY the gain
(1) and the delaypel'iod (3 minutes).
Blending 91
7. Click the Face Plate button to bring up a faceplate that shows the
PV and PV' signals.
The initial conditions of these transfer function blocks are 110t nrunediately
displayed on the faceplate. The integrator has to be started. It is a good idea to
leave the composition controller on manual when you first start the integrator.
HYSYS has a bug in the deadtiIne element. Ifyou reset the tinle to zero, the
deadtime element is disabled (its output signal does 110t change). Therefore do not
change the tiIne. This makes it inconvenient for making plots. You have to copy
92 Chapter 5
the history file into sorne other plotting software, and subtract the initial time to
get a plot that starts at zero time.
Another problem with HYSYS shows up when you try to put transfer func-
tions in series. Sometimes it works and sometimes it does not. For example, iftwo
lags are installed in series, the first lag seems to work okay, getting the correct
input and output signals. However, the signal that the second lag sees is not the
same as the output of the first lag. This problem makes it difficult to put multiple
elements in series in a control loop. For example, you cannot put a selector or
surnmer block in series with a lag. Later versions of HYSYS should eliminate this
problem.
Now the composition controller must be tuned. First we install a strip chart
that records the PV and OP signals from the composition controller. A cornmon
error is to record the original variable before the transfer function. If lags are used
in the loop, using the amplitude ofthis incorrect signal gives an error in the ca1cu-
lated ultimate gain because the lags attenuate the signal.
One of the most convenient features in HYSYS for controller performance
evaluation is the Autotuner. It automatically implements the relay-feedback test.
Sinlply click the Tuning button on the controller faceplate. Going to the Parame-
ters page tab and clicking the Autotuner button opens the window shown in Figure
5.7.
h
Blending 93
y OH can select the type of controller (PI or prD) and the amplitude of the
change in the controller output (default value is 5%). Clicking the Start AutoÍlmer
button launches the relay-feedback test. Figure 5.8 shows the PV and OP values of
the composition controller. The loop starts to oscillate. Afier several cyc1es the
testing stops, alld some suggested PID settillgs are displayed. For the composition
cOlltroller in this example, the recommended settings fOl' a PID controller are Kc =
0.295, 'tI = 11.3 and 'tD = 2.5l. We compare the perfomlance ofthese settings with
other alternatives in Section 5.3.
a = (0.006)100 = 2.4%
0.25
Knowing Pu and Ku , we can use one of the tuning methods proposed in the
literature. The most well knoW11 are the Ziegler-Nichols tuning rules. These ofien
give c1osedloop damping coefficients that are too sma11 for many chemical engi-
neering processes (too oscillatory). The Tyreus-Luyben tuning rules are more con-
servative and better suited for most (but not a11) chemical processes. These rules
are
Ku
3.2
The TL settings for the blending process are Kc = 0.8 and 1:¡ = 19. A comparison
ofthe perf0l111anCe of severa! tuning methods is given in Section 5.3.
Figure 5.9 gives the steady-state flowsheet tor the blencling process in As-
penPlus. It is identical to the HYSYS flowsheet except for the addition of a control
valve in the inert feed lineo AspenDynamics requires the insertion of a valve on
this line to achieve the pressure-driven dynamics.
When the steady-state flowsheet has been converged with the correct
plumbing, click the Dynamics button on the top tool bar. The tank is the only
dynamic element in the process.
Blending 95
Go to the Tank block and click the Dynamic button. The tank can be speci-
fied to be instantaneous or to have dynamics. To choose a dynarnic tank, select the
Vertical (or Horizontal) option anci specifY a vessel diameter. Note that the volurne
of the tank has already been specified in the tank setup.
When aH of the dynarnic data has been entered, click the Pressure-Check
burton on the top tool bar. If the plumbing is properly designed and sized, a mes-
sage will appear that the flowsheet is ready to go into a pressure-driven dynanric
simulation.
Go to File and then Export. Specify that you want to save the file as a pres-
sure-driven simulation. Close AspenPlus and open AspenDynamics. Open the
"dynf' file.
Blending Process
The flowsheet opens up with some basic default controHers already in-
stalled. For this blending tank example, tank level and pressure controllers appear
(see Figure 5.10). The pressure controller output is cOIU1ected to the valve in the
vapor line (V4). The level controller output is not cOlU1ected because there is a
block (the pump) between the tank and the val ve. The additional controllers are
installed in the nonnal way, as discussed in detail in Chapter 4. The fmal flow-
sheet with all controlloops installed is shown in Figure 5.11.
96 Chapter 5
deadtime
¡-------O~---~-«-----1
~ , ¡~----- ¡-------------------¡ BIending Process
:t? ¡ ¡V4
:i~~ I
TANK: Le
---.¡--------------->O---------------------~
P1 : V3
It should be noted that the values ofthe input and output signals ofthe dead-
time are not initialized to the correct values until the Run button is c1icked. In Fig-
ure 5.12 the input and output match the steady-state ethanol composition (0.1417
mole fraction ethanol). Multiple lags and deadtimes can be installed in series in
AspenDynamics.
If you make the gain too large, the integrator may fail and give an error message
(see Figure 5.13B). The equation-base integrator used in AspenDynamics does not
handle step changes well, and making the gain very large means abrupt changes.
l. At time equal 0.5 hours, the setpoint ofthe pentane fi'esh feed flow COll-
troller (FC) is changed fi'om 600 lb-mole/lu' to 400 lb-mole/hr.
2. At time equal 4 holU's, the setpoint ofthe compositioll controller (CC) is
changed fi'om 0.1417 mole fi'action ethanol to 0.16 mole fi'action.
Blending 101
3. At time equal 8 hours, two step changes are made: pentane flow to 600
lb-mole/hr and ethanol composition to 0.1417 mole Ji'action.
Figures 5.l5A, B and C compare these three tuning methods using As-
penDynamics strip-charts. Both the PV and the OP signals ofthe composition are
plotted. Figure 5.16 illustrates the use of exporting the data to Matlab and using
this software to generate the plots. The TL and the HYSYS settings are compared.
Fina1ly, in Figure 5.17 the Matlab figures are copied and pasted into Power Point.
Now we can easily modifY any of the labels, add text, change line thickness and
type, etc.
The procedure for exporting files is straightforward.
HYSYS:
AspenDynamics:
I: ~~:¡-.......VT¡ • • • j~:::::
0.11 0
: : j:
:------+----+--..-;.., : :
+,_ _ _+ ___:!:-_ _-l.
Time (hours)
l 4j
... '"
o.
~~,---~---~--~,---~---~--~
;fif11e (hours)
5.3 Conclusion
In this chapter we have covered sorne additional basic steps and rnethods in
rnoving frorn a steady-state simulation flowsheet into a dynamic simulation. Add-
ing dynamic elernents (lags and deadtimes), using the re1ay-feedback test and tun-
ing critical controllers have been illustrated. The procedures have been illustrated
on a simple single-tank blending example for both dynamic simulation software
packages. In the next chapter we consider another single-unit process in which
chemical reactions are considered.
Chapter 6
CSTR Reactor Process
The previous chapter considered a single tank that nllxed together two
streams. No reaction occurred and no thermal effects (heating or cooling) were
considered. In this· chapter and the next, we expand our treatrnent to consider re-
acting systems. Reactors are the heart of many chenllcal processes, and dynamic
simulation of these critical units is absolutely essential for the safe and profitable
operation ofthe entire plant.
There are a tremendous number of different types of reactors that are used
cornmercially. Sorne have fairly benign dynarnics, but many offer very challeng-
ing control problems. Reactors in which exothermic, irreversible reactions take
place are the most challenging because of the potential for temperature runaways.
Reactors with low per-pass conversions are particular1y sensitive because there is
plenty ofreactant around to fuel a runaway. Many ofthese reactor s are open1oop
unstable, so a feedback controller is required to achieve stable operation.
Environmental pollution resulting from safety valve or rupture disk venting
should be minirnized. The potential safety hazards from explosions, decomposi-
tions and fires must be high-priority items for consideration in the design and op-
eration of a chenllcal plant. The chenllcal and petroleum industries have experi-
enced a number of devastating fires, explosions and enllssions of toxic material
during the last century caused by chemical reactors. Many of these could have
been prevented by betier design and operation. Therefore reactor dynarnics and
control are probably the most vital parts of dynamic simulations.
We cover continuous stirred-tank reactors (CSTR) in this chapter and plug-
flow tubular reactors (PFR) in the next. Both HYSYS and AspenDynamics simu-
lators are used. The two simulators handle reactors in significantly different ways,
and it is vital to understand the capabilities and lirnitations of each and to be aware
ofthe fundamental dynamic models that are "under the hood."
105
106 Chapter 6
Although the chemistry is real, the kinetics are assumed and are not based on real
kinetic data. Probably the most difficult and error-prone aspect of simulation, both
steady state and dynamics, is getting reaction kinetics correct. The data in the lit-
eratme uses different units, different bases, different composition dependency, etc.
The highly nonlinear relationships used in kinetic expression, particularly tem-
perature dependence, make the results extremely sensitive to any mistakes in con-
verting units ofthe reaction rates. The situation is not helped by the fact that each
sin1Ulator has its own conventions and requirements.
The assumed reactor conditions are 595 psia and 250°F. The liquid-phase
reaction occurs in a 1200 ft3 vertical cylindrical vessel in which the liquid level is
80%. See Figure 6.1.
The reaction kinetics are picked in each simulator such that the aniline con-
version is 76%. The activation energy is set at 20,000 Btu/lb-mole (11,111 cal/g-
mole). In HYSYS the reaction rate basis is lb-mol/hr/ft3 and the reaction is flrst
order in the molar concentrations (lb-mol/ft3) of each ofthe reactants.
where VI? = reactor liquid volume (ft3). The temperatme dependence ofthe specific
reaction rate k is assumed to be given by
-20.000
le = 10 8 e ----:RT
where T is temperature (R). In AspenDynamics the reaction rate basis is kg-
mol/sec/m3 , the molar concentrations are in kg-mol/m3 and specific reaction rate
giving the 76% conversíon is
-11,111
le = 2 xl O4 e ----¡¡;¡:--
The pure reactants are fed into the reactor in two fresh feed streams. The
aniline fi-esh feed is 100 lb-mol/hr at 650 psia and 100°F. The hydrogen fresh feed
is 400 lb-mo1/hr at 650 psia and 100°F. The per-pass conversion of aniline is 76%.
The reaction is highly exothermic (82,000 Btu/lb-mole ofCHA), so the sys-
tem must be designed for adequate heat-removal capacity. This translates into a
large heat-transfer area. The steady-state heat-transfer rate is 5.l3xl06 Btu/hr.
Unforhmately both ofthe simulators handle heat transfer in a somewhat su-
perficial way, which does not make obtaining realistic dynamic results easy. There
is no explicit consideration ofwhether 01' not the reactor geometry will provide the
assumed heat-transfer area. You must exercise some caution in using these mod-
els.
CSTR 107
HYSYS Models: Xhe CSTR model in HYSYS has two options: use a dírect
heat-transfer rate Q or use a cooling (or heating) fluid with a given heaHransfer
area and overall heaHransfer coefficient. The second option assmnes the cooling
medium is in a cooling jacket and the jacket is perfectIy mixed. This is an impor-
tant assumption. It applies in reactors with circulating-coolant systems. This COl1-
figuration features a large flow of coolant that círculates through the jacket or
coils, and this circulating stream is coolecl in an external heat exchanger or by the
aclditíon of a colcl make-up stream.
Thus the clifferentíal temperature driving force fOI heat transfer ís the reac-
108 Chapter6
tor temperature minus the temperature of the cooling fluid in the jacket, which is
the temperature of the coo1ing fluid leaving the reactor jacket. The coo1ant
flowrate is the manipulated variable.
(T - T ) - (T - T )
I'1TUvI = reaclor e(oo/~tIn/et _ T reaclor :coo/antOlIl/el
In ~actor. coo/anan/el
T;'cactor - TeDolanlOutle!
Thus the AspenDynal11ics model of the jacket or coil cooJing assumes plug flow
of the coolant. The HYSYS model, 011 the other hanel, assumes the jacket is well
l11ixed at a ulliform temperature.
There are oiher basic differences in the CSTR moelels between the simula-
torso One is the number of streams leaving the reactor. HYSYS requires both va-
por and liquid out1et cOlmections. The version of AspenP1us used in this book
(10.2) 0111y permits one exit stream. This restriction is removed in Version 1I.
Sign conventions for heat flows are hanelled different1y also. In HYSYS,
heat duty can be defined as either cooling or heating. In AspenDynamics, heat
removed fiom a block is a1ways negative and heat adeled is always positive. These
conventions affect the selection of the action of the controller (reverse or direct)
and the output ranges ofthe controllers that set heat duties.
The pressure controller is direct acting anci is tuned by estimating the gas
time constant. The flowrate ofvapor leaving the CSTR is 577 lb/hr and the density
is 0.262 lb/fi3, giving a volumetric flowrate of 36.7 fi3/min. The total vohmle of
the tank is 1200 fi3 but it is 80% full ofliquid. To be conservative we use the total
vessel volU111e to calculate the time constant.
1200ft 3 .
~---- = 32 111m
36.7 ft 3 Itnin
So an integral time of 30 minutes is used in the PI pressure controller, which is
direct acting. A pressure range of 500 to 700 psia is specified, and the controller
gain is set equal to 2. We could go through a detailed hming procedure for the
pressure controller, but precise pressure control is not vital in this application.
C. Performance: Simulation results are given in Figures 6.6A and B. The distur-
bance is a step change in the setpoint of the temperature controUer from 250°F to
252°F at either time equal 5 or 10 minutes. Figme 6.6A is for the 1-minute lags
case. The HYSYS and TL hming results are quite similar. Figme 6.6B is for the 2-
minute lag case. The HYSYS settings produce a closedloop unstable system. The
TL settings are stable, but fairly oscillatory.
112 Chapter6
These results illustrate the importance of keeping aH the lags in the control
loop as small as possible. These lags can be in temperature measurement or in the
heat-removal equipment. An irreversible exothermic reactor with modest conver-
sion can be openloop unstable. The numerical example in this case study is unsta-
ble if the temperature controller is put on manual. Try it. Any delays in detecting
temperature changes or in manipulating heat transfer make the control perform-
ance significantIy worse. In fact, ifthe lags are too large, the reactor is uncontrol-
lable.
15l5·
~lSl -
1500!--L-.-----f.-------~,_---~
Time (min)
::::A::::::::~ . '-'-'-'~-'-'
~:::~I:---~-ªi~:: ;:4Il'[SXS;
H
....L------f.------,-------~,_---~.
Time (min)
CSTR 113
Tirn«min)
Tiwe(min)
The third cmves shown in Figure 6.6B are fo1' the case when a proportional-
only controller is used. The gain is set at half the ultimate gain (Kc = 2.4). The
dynamic response using P control is much beiter than using PI. Of course, the P-
only controller does not dtive the temperature exactly to the setpoint (252.2°F in-
stead of252°F).
It is inte1'esting to note that the "offset" for this openloop lIDstable system is
negative, i.e., the ftnal value ofthe change in the controlled variable is larger than
the change made in the setpoint. The steady-state elTor ("offset" 01' "droop") fOl'
openloop stable systems with proportional-only control is positive (the controlled
variable does not reach the setpoint).
~<l
11T''"t
Openloop unstable systems give a servo response where the controlled variable
goes beyond the setpoint. The steady-state ratio of I1T/I1T sct is greater than one.
This highly exothennic process is provides an example 01' a "conditionally
stable" process. If the value 01' the controIler gain is made too small, the system is
closedloop unstable. If the value 01' the gain is made too large, the system is again
closedloop lIDstable. These conditionally stable systems present challenging con-
trol problems.
can be specified. The controller manipulates the flowrate of the cooling (or heat-
ing) fluid. Reat is transferred fi"om the reactor into the cooling fluid. Only sensible
heat changes in the cooling fluid are permitted, so a phase change (for example,
generating or condensing steam) cannot be modeled.
The heat-transfer model in HYSYS assumes that the cooling fluid is per-
fectly mixed in the jacket. This means that the ~T for heat transfer is the differ-
ence between the reactor temperature and the cooling mediwn exit temperature.
As we have already mentioned, the model in AspenDynamics uses plug flow cool-
ing fluid and a log-mean temperatlli"e difference. This is an important difference
between the two simulators.
D= ·(2V)1I3
- = (2X1200)1I3 =9.14ft
re re
and the length is 18.28 ft. The tank liquid level is 80%, so the circumferential heat-
transfer area is
(0.8)reDL = (0.8)re(9.14)(18.28) = 420 ft2
This means that the temperahlre of the cooling water in the jacket is 250 -
81.4 = 168.6°F. Finally, if the inlet cooling water temperature is specified (90°F),
the flowrate ofthe cooling water can be calculated.
F cw = Q 5.13x10 6 =3626lb-mol/hr
e p (TcWout - TcrVin ) (18)(168.6 - 90) ,
Assuming the thickness of the jacket slli"rounding the walls of the reactor is 6
CSTR 115
inches, the jacket holdup is (420 W)(1I0.8)(0.5 ftX62.3 Ib/W)(lb-mol/18 lb) = 909
lb-moles.
We select the maximum cooling water flowrate to be 10,000 Ib-mo1/hr, al-
most three times the steady-state value. Entering these parameters in the window
shown in Figure 6.7 completely specifies the heat removal system.
% maximum tlow
C. Performance: Using PowerPoint plots, Figures 6.8A and B give results for a
+2°F step change in the tell1perature controller setpoint for two values of ll1eas-
urell1ent lag. The ll1al1ipulated variable is the coolal1t flowrate. The cOl1trolled
variable plotted is the controller PV signal after the two lags, 110t the reactor tem-
perature.
The TL settings are significantly better than those recomll1ended by HY-
SYS. Remember also that a sill1pler algorithm is used (PI versus PID). The larger
the ll1easurement lag, the longer the transient settling time of the systel11.
A comparison ofthese results with Figme 6.6 shows the difference between
manipulating Q directly and manipulating coolant flowrate. Oue would expect the
additionallag associated with the cooling jacket to make the dynamics of the sys·-
tem usiug the heat-transfer model worse than the dynamics using the direct Q
model. The closedloop time constant is indeed larger for the heat-transfer model.
The peak overshoot temperature is significantly larger for the heat-transfer model
(255°F for the TL settings with 1 minute lags) cOll1pared to the direct-Q model
(253.7°F). Therefore the use of this more realistic model is a more conservative
approach.
Time (min)
Tirn~ (min)
Tirnc(rnin)
Time (min)
This model assumes that the temperatme of the cooling or heating fluid can
be set by the tel11peratme controll er. Thus the capacitance of the jacket or coil is
assumed negligible. In reality the cooling fluid tel11peratme cannot be changed
instantaneously, so it is important to include lags in the temperatmeloop that ac-
count for these neglected dynamics.
This model is well suited for systel11s with condensing or vaporizing pure
fluids where jacket pressure control is equivalent to setting jacket temperature.
Steal11 generation and heating are the most common examples. Jacket dynamics in
these situations are usually fast.
For the numerical case studied, the reactor temperai1Jre is 250°F, and a cool-
ant temperature of 150°F is specified. AspenDynamics calculates the required UA
from the known Q (- 4.98x10 6 Btu/hr) and the known L'l.T (250 - 150 = 100°F).
This UA is 49,800 Btu/hr-°F. There is no consideration ofwhether or not this UA
is possible with the given reactor geometry.
The output signal ofthe temperature controller is a coolant tel11perature. The
controller is reverse acting. The range of coolant tel11peratures is specified 100 to
250°F.
120 Chapter 6
This model assumes that the cooling fluid travels in plug flow through a
eoil. A lag-mean temperature differential is used. The ~T at the eold end is the
difference between the reactor temperature and the inlet cooling fluid. The ~T at
the hot end is the difference between the reactor temperature and the outlet cooling
fluid.
During the steady-state design phase in AspenPlus, you specify the coolant
inlet temperature (called Medium temperature in Figure 6.12) and the temperature
approach (the ~T at the hot end, reactor temperature minus cooling fluid exit tem-
perature). AspenPlus then calculates the required UA and the flowrate of coolant.
After expOlting the file ¡nto AspenDynan1Ícs, the value of UA can be
changed by opening up the AH Variables window for the reactor block. Of course,
the flowrate of the coolant and its exit temperature must also be changed to
achieve the same heat-transfer rateo
For the numerical case studied, the jacket heat-transfer area was calculated
earlier in this chapter to be 420 ft2 and a U of 150 Btu/hr-oF-ft2 was assmned.
Therefore a UA of 63,000 Btu/hr-oF is used in the LMTD model. With a coolant
inlet temperat1ITe of 90°F, the reqlúred coolant exit temperature is 218°F and the
flowrate is 38,900 lb/hr. The temperature controHer output signal is a cooland
flowrate. The range is specified to be from O to 150,000 lb/hr. The temperature
controller is direct acting.
Note that the exit coolant temperature is aboye the boiling point of water at
atmospheric pressure. The coolant used in this fairly high-temperature reactor
would be high-pressure tempered water or a high-boiling oil.
CSTR 121
The file is exported from AspenPlus into AspenDynal11ic, and the PFD
opens as shown in Figure 6.13. Only the direct-Q model has a default temperature
controller installed. The nom1al procedures of installing the flow controllers, tel11-
perature controllers and 1ags on each of the tln'ee reactor systems give the fmal
PFD shown in Figure 6.14.
The normal flow-controller tuIling is used on the six flow controllers. The
three level controllers are proportional-only with gains of 10. Two frrst-order lags
with l-minute tinle constant are installed in each tel11perature contTOlloop. Each of
the three tel11perature controllers are tuned by using relay feedback tests. The
height of the relay is set at 5% of the output range. Different gains are used for
each reactor to achieve oscillations. If the gain is made too large, the integrator
stops and gives the l11essage shown at the top of Figure 6.15. Table 6.2 gives re-
sults.
RUlliling a relay-feedback test takes quite a bit oftrial and error in this reac-
tor systel11 since the system is quite nonlinear. However, reasonable estimates of
tuning constants are obtained. The test for the LMTD model (cstr3) is shown in
the lower part of Figure 6.15. The COllllmmication Time is shortened to 0.001
homs for this faidy fast process.
122 Chapter6
Simulation results are shown in Figure 6.16. As expected, the Direct Q and
the coolant temperature models give about the same results because the dynamics
ofheat transfer are assumed to be instantaneous. The LMTD model results show a
poorer, but probably more realistic performance.
CSTR Proce••
FAl
I FCA1 !V1
:---X)-------,
.....,
,,,
,~._--------.-------------------------
,,
,.. _ _ _ _ _ _ _ _ _ _ _ _ • • • • 4 _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ..,
,, ,,
·l------>Óo:~--------j : :---~--,-~--.>-ó"--j
::------>o""----~:r ----I~,'
I fCH3
l~~,DR' c::,_:j_~
§_~:_~~-F--l
I
__~L
~~ '_·______·u _:' ,... "
,'_' : __ __"'_'____ E_"'
___
:-------->0---------,
CSTR 123
cstr3
t(J
o
'.~~
."
t ..... --------,-- - -, --- - ,- . ----------
:;2¡(¡ ,/-
N
i~
~ N _____________ ~-------------~- ____________ , __
o
~
@ I : f\. I
01 ___ __________ : ____________ _ : - _____________ : __________ __ _
,, ,,
, ,
0.5 1 1.5
Time Hours
K" 54 170 46
*AdJusted to 20
124 Chapter6
It is interesting to compare the testing and simulation results found with As-
penDynamics with those found with HYSYS. The only direct comparison that can
be made is with the Direct Q model. The ultimate gain and ultimate and ultimate
frequency results are significant1y different, probably due to the difficulties associ-
ated with running the re1ay-feedback test in AspenDynamics. However, a com-
parison ofFigure 6.6A (HYSYS) with Figure 6.16 (AspenDynamics) shows that
the responses are similar.
6.4 Conclusion
The CSTR process is an important unit in many chernical plants, and re1i-
able dynamic simulations are vital for safe and profitable operation. In this chapter
we have studied the simulation of the CSTR process. The different models and the
significant differences between HYSYS and AspenDynamics have been dis-
cussed.
In the next chapter we studyan equally important and wide1y used reactor:
the plug-flow tubular reactor. This type of reactor is more difficult to model, has
more complex dynamics and provides challenging design and control problems.
R2 -k
-
P P -(117
2 e3 en - . e
-6860/(RT)ln P
Fe3 el2
The reaction takes place in a pipe, which is 2 inches in diameter and 15 feet
long. The inlet gas fed to the reactor is 0.85 lb-molJhr at 392°P and 29.4 psia with
a composition 80 mol% propylene and 20 mol% chlorine. Pressure drop through
the reactor is 3.7 psi at design conditions. The physical property package used is
PRSV.
Ifthe reactor is operated adiabatically, the temperature of the gas leaving the
reactor is predicted by HYSYS to be 716°P and the chlorine concentration is 9.89
mol% (50% conversion). Several cases are considered in the following section
with varying types and amounts ofheat transfer. In these cases the outlet tempera-
tures are different, as are the conversions of chlorine. A control valve on the gas
feeding the reactor is designed for a 20 psi drop when 50% open at design
flowrate. A flow controller manipulates this valve to control feed flow. A valve on
the exit line from the reactor is used to hold pressure in the reactor. This valve is
designed for a 10 psi pressure drop when 50% open at design flowrate.
To illustrate the use of tubular reactors with and without catalyst, we con-
sider both cases. The kinetics given aboye are used in both cases. The steady states
are identical (for the same net volume, accounting for the volume occupied by the
catalyst), but the dynamics are different because ofthe thermal capacitan ce ofthe
solid packing.
process. This is the only flow pattem option in HYSYS. If the reactor contains
catalyst, this can be included in the model. The temperature of the process fluid
and the solid packing are assumed to be the same at aH axial positions.
HYSYS uses a "lumped" model ofthe distributed tubular reactor even in the
steady state. The default value for the munber of lumps is 20. You should explore
the effect of this parameter on the model predictions. Reactors with large axial
changes in tel11peratures and/or compositions require more lumps for accurate
modeling. This effect is seen in Table 7.1 for the steady-state adiabatic case ofthe
example being studied.
As more lumps are used, the distributed nature of the process is more accu-
rately modeled. The lumped model exhibits "nwnerical diffusion," which malees
the predicted temperature increase as fewer lumps produce more backmixing. It is
clear that using about 60 lwnps gives fairly good results, at least at steady state.
However, the more lwnps used, the slower the simulation runs. In the simple ex-
amples in the previous chapters, computer time has not been an issue. As the com-
plexity of the process increases, the time it takes to generate results can become
important. In fact this factor ofien lirnits the size ofthe process that can be practi-
caHy handled. A 20-lwnp model is used in aH the simulations discussed below.
The munber oflumps used is specified by double clicking the PFR icon and
opening the Reactions page tab (see Figure 7.1). The Number of Sections is set at
20 in PRFl.
As we wiH see in Section 7.3, the adiabatic steady-state output temperature
predicted by AspenPlus is considerably different than that predicted by HYSYS.
So the conservative engineer should always have a healthy skepticism conceming
the accuracy ofthe results of any dynamic simulation.
128 Chapter7
A. Direct Q: Figure 7.2 shows the three cases considered with the homogeneous
reactions, i.e., no catalyst in the reactor. Figure 7.3 gives the workbook with
stream conditions. The first two cases (PFRl and PFR2) use the direct Q model. It
is not clear how the heat-transfer duty is distributed among the lumps. The first
reactor (PFRl) is run adiabatically, so there is no ternperature control. In the sec-
ond reactor (PFR2) heat-removal is manipulated directIy. Two 0.5 minute first-
order lags are installed in the temperature controller loop. The flow controller uses
the standard tuning. The pressure controller has Kc = 1 and 'tI = 2 minutes with a
pressure transmitter range of lOto 60 psia.
The direct-Q model is specified in HYSYS as shown in Figure 7.4. Double
c1ick the reactor icon on the PFD, c1ick the Design page tab and c1ick Parameters.
The two options are Direct Q and Formula. The case shown is for PFR2 in which a
steady-state heat removal (cooling has been specified) of 500 Btu/hr. Clicking the
Heat Transfer view on the Design page tab opens the window shown in Figure 7.5.
Then clicking Duty on the Dynarnics page tab opens the window shown in Figure
7.6 in which the minirnum and maximum heat-transfer rates are specified.
Tubular Reactors 129
1'5~~
PFRwl!hCoolllnlMilnlplllallon
V6
The tbree cases have the steady-state conditions given in Table 7.2. A relay-
feedback test is run for the temperature controller in each case. These results and
the TL tuning constants are also given in Table 7.2.
There are three places where heat-transfer information can be specified, and
this can cause sorne confhsion in setting up this rnodel. The Heat Transfer window
on the Design page tab shown in Figure 7.7 has a number ofpararneters that can
be entered. The three that seern to work well are:
The second place where parameters can be entered is on the Dynamics page
tab using the Duty view, as shown in Figure 7.8. The parameters in this window
that should be specified are:
l. A vailable DA
2. Dtility Holdup.
Tubular Reactors 133
Note that there are several "mole flow" entries in the window. They do not have
the same units as the flowl'ate specified in the window shown in Figure 7.7.
The third location fol' entering pal'ametel's is in the window that appears
when the Control Valve burton is clicked on the temperature controller Parameters
view. This can be accessed by clicking the Tuning burton in the lowel' right comer
of the contl'oller faceplate and going the Parametel' page tab. The window that
opens is shown in Figure 7.9. This is the best spot to specify parameters.
The remaining parameters are calculated from those specified. Note that the
temperature level of the cooling fluid is too high to use cooling water. A high-
temperature fluid, such as DowThenn, would be used to cool this reactor.
Figure 7.lOC gives results for the PFR3 with coolant flow manipulation.
The response is again very slow, and as noted aboye, the computing time is much
longer than for the other cases.
lli
14 •
~12-
10 - ••• __ ._-_ ••• __ ....
A porous solid catalyst is placed inside the tllbe. The reactÍons must be
specified as heterogeneous catalyst when the choice ofreaction type is selected on
the "Rxns" page tab of the Fluid Package window (see Figure 7.11). The kinetics
for one of the reactions are specified in Figure 7.12. Then the catalyst properties
are specified in the Reactions page tab ofthe PFR4 unít as shoWJ.1 in Figure 7.13.
The void volume is specified on the Rating page tab. Figure 7.14 shows this win-
dow. Note that the length ofthe reactor has been increased by a factor of(1I0.7) to
21.4 ft so that the same net reactor volume is available.
Tubular Reacíors 137
Dynamic Mode
140 Ghapter7
Figure 7.16 shows the window in which some ofthese choices are made. If
reactor temperature is chosen, the window changes to that shown in Figure 7.17
where the selection is made among the first three options in the list aboye. None of
these three specified temperature options in steady-state AspenPlus can be used in
dynarnic simulations in AspenDynamics.
B!ock$
EH l2Il ADIABAT
EtlI2Il FC·WCI\T
EBi2lJ TC·WCI\T
á~ TCOOL
á~V1
E¡J~V2
~I2IlV3
~i2lJV4
EBi!CiJ V5
EB-tZiil V6
EBI2Il V7
EB~V8
EtI~V9
Reactions
Tubular Reactors 143
A. Catalyst: The presence ofthe catalyst adds thermal inertia to the system. Addi-
tional data about the catalyst must be provided. Clicking the Dynamics button
under the reactor block opens the window shown in Figure 7.20. The voidage vol-
ume, heat capacity and density ofthe catalyst must be given.
There are three options about heat-transfer between the process fluid and the
packing: (a) no heat transfer, (b) process and catalyst at the same temperature or
(c) process and catalyst at different temperatures. The second selection is made in
Figure 7.20.
Reactor 1ength is increased from 15 feet to 22.8 feet in Cases 2 and 4 when
catalyst is present to provide the same net reactor gas volrnne.
peak temperature is about 447°F, which occurs at about 10 feet down the reactor.
Figure 7.21C is for the 22.8-foot reactor packed with catalyst and using the same
coolant temperature. The longer tube gives a lower outlet temperature (731°F) and
a lower peak temperature (445°F at about 9 feet).
•
i
• i ¡ •
9 95 lO 105 11 115 12 125 1~ 135 1.1 H! 1!:l
Tubular Reactors 145
. . . ,
Figure 7.21D shows the process and coolant temperature profiles for Case 2
(FC-WCAT). Remember the flows are counter-current. The cooling stream leav-
ing the front end ofthe reactor is actual1y heating the process stream for the first 3
feet in the reactor. Reactor outlet temperature is 421°F with the specified coolant
flow and outlet temperature.
Tprocess
Tcoolant
Lengthft
146 Chapter7
7.7.3 Dynamics
Control valves are installed and sized and the file is exported into AspenDy-
namics. The initial flowsheet has default reactor pressure controllers manipulating
the control val ves on the reactor oudet stream. Three 0.5 minute first-order lags
are used in the temperature loops. Flow controller tuning is standard. Using a pres-
sure transmitter range of O to 50 psia, pressure controller gain is 10 and reset time
is 1 minute since the time constant is quite small. For the same reason, the Com-
munication Time is reduced :fi:om the default value ofO.01 hours to 0.001 hours.
A. Adiabatic Reactor: Figure 7.22 shows the dynamic response of the adiabatic
reactor with no catalyst. Temperature transients are fast, with the new steady states
being achieved in about 5 minutes. The setpoint to the feed flow controller is
changed from 0.85 to 1.2 1b-mol/hr at time equal 0.1 hours. It is changed again at
0.3 hours from 1.2 down to 0.6Ib-mol!hr. There is no temperature control.
,o
,._ ...>(]._._.,
; .... -->0""........... -------....... -----:::
~1>~11:;<11~~Q
bgl) lo¡¡J:! b¡¡:l1 ;
_.~--.r-ª'---[;i]<-;
~---------~j
148 Chapter7
- i'l
-
- F
- i'J
-
~ ~
.-'
-
~ ~
:g
~
;:;
~
~
~
~ ¡l;l c:;l o 0025 0.05 0.075 0,1 0.125 0.15 0.175 0.2 0.225 0.25 0.275 0.3 0.325 0.35 0.375 DA 0.425 0.45 0.475 05
Time HOUI$
Tubular Reactors 149
(2) With catalyst: The steady-state reactor outlet temperature is 431°F and the
reactor is longer with more heat-transfer area. The thennal inertia of the catalyst
slows down the dynarnic response significantly, as shown in Figure 7.25. The feed
increase at 0.1 hours causes the temperature to rise. The controller responds by
reducing the coolant temperature. It takes more than 0.3 hours for the system to
get back to the new steady state. Then the decrease in feed flowrate at 0.4 hours
causes reactor outlet temperature to drop, and the temperature controller responds
by increasing the coolant temperature. It takes over an hour to bring the reactor
exit temperature back to its setpoint. .
~ !!)
~
~ ¡¡
~ 1)
~ ~
\{¡ ~
!:l ~
~
iíl fil
¡¡¡ fil
150 Chapter 7
~------I~---------~~Q
The observant reader will note that a second control valve has been installed
in the coolant flow circuit. This violates the First Law of Plumbing. This change
was not required to export the file from AspenPlus into AspenDynamics. Nor were
any errors reported when the file was open in AspenDynamics. However, the case
would not runo Error messages were given that integration interval had been re-
duced to its limit without satisfying error tolerances. When a second valve was
installed, the simulator ran without any problems. This is a good exanlple of the
difference between a simulation and a real system. Only one valve would be used
in a real system, with the coolant being supplied from a pump or a piping header.
The next problem was to figure out how to set the second val ve. Holding a
back pressure with the valve on the exit and manipulating the valve on the inlet to
control temperature did not work, as any good plumber would expect since the
system is liquid filled. The scheme that worked is shown in Figure 7.26. The tem-
perature controller TC4 output signal is sent to both val ves. This split-ranged type
system opens both valves when temperature increases.
A second interesting feature of this process is the problems encOlffitered
with the relay feedback test. Attempts to attain a lin1it cycle were tffisuccessful, so
an altemative step-test approach to calculating the ultimate gain and period was
used. The controller is put in manual, and a small step change is made in the con-
troller output signal. As shown in Figure 7.27, the OP signal is stepped from 36.6
Tubular Reactors 151
to 41.6% of scale at time equal 0.5 hours. There is a corresponding change in the
flowrate of the coo1ant. The reactor outlet temperature decreases, dropping by
about 4°F. Since the temperahu'e transmitter span is 200°F, this corresponds to a
2% change in the PV signal.
G
(s)
=(~I( 1 Y
12s + 1) 0.5s + 1)
A Matlab prograrn that calculates the ultimate gain (48) and the ultimate pe-
riod (5.1 minutes) is given in Figure 7.28, and a Bode p10t is shown in Figure 7.29.
The TL settings are Kc = 15 and 1:1 = 11.
These controller settings give the results shown in Figure 7.30 for changes
in feed flowrate. At time equal 0.1 hours, feed is increased from 0.85 to 1.2 lb-
mol/hr, and at time equa1 0.7 hours, it is decreased to 0.6 1b-mol!hr. MaximlUn
152 Chapter7
deviations in temperature are about 7°F. The flowrate of the coolant is manipulated
to maintain the desired reactor exit temperature.
~; Prcu:Jram fft.u})4.:m rr
nUltl=O.5;
den=conv( [0.5 1], [0.5 1]1;
den=conv(den, [0.5 1]1;
den=conv(den, [1~ 1]1;
~=logspace(-1/1T300);
[mag,deg,w]=bode(num,den,w);
db=20'-log10(magl;
subplot (2".1,1)
seroilogx(w,dbJ
grid
title('Bode Plots Ior G=O.5/(12s+1)/(O.5s+1)A3 1
)
,
,
,
,
,,,
,,
,,
,,
,,
,,
,
,
,,
,,
,,,
,,,
"
"
"
,,
,,,
,,
,,,
,,
,,,
,,, ,,
, ,
!S
e,
'" ~
N i'l ~ F
~
- i'l
"
Ri
"
~ "
~
Fcool
o
Ri 1.2 1.3 14 1.5 1.6
7.4 Conclusion
In this chapter we have illustrated fue dynamic simulation of plug-flow tu-
bular reactors. There are more altemative configurations, and fuese reactors are
more complex fuan CSTRs. Setting up fue simulation is more difficult. The two
simulators have different models available and give somewhat different predic-
tions. The AspenDynamics simulator can handle more configurations and appears
to be more robust and to contain fewer bugs.
j
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ha ter 8
DistiUation Columns
8.1 Introduction
Distillation is the most frequently used separation technique in the
chemical and petroleum industries. The design and control of this important
unit operation is vital for the safe and profitable operation of many plants.
Distillation columns are fairly complex units. They have several inputs
and outputs, so they can present challenging multivariable control problems.
Their dynarnics are a mixture ofvery fast vapor flowrate changes, moderately
fast liquid flowrate changes, slow temperature changes and very slow composi-
tion changes. The manipulated variables ofien have constraints because of col-
umn flooding limitations or heat exchanger limitations. Developing an effec-
tive control system for an individual column is not a trivial jobo There are at
least six loops involved on even the most simple column.
Both dynarnic simulators do a good job in modeling distillation columns.
Simple as well as complex columns (sidestreams, multiple feeds, intermediate
reboilers, etc.) can be fairly easily simulated. In this chapter we look at a sim-
ple single-feed, two-product column. In later chapters we study more complex
columns and groups of multiple columns.
155
156 Chapter8
qc
d
qr
A. Column Diameter: Double left c1icking the cohunn icon opens the window
shown in Figure 8.2. The Design page tab with the Connections and Monitor
views are shO\vn in Figures 8.2A and 8.2B, respectively. Note that the active
specifications are 0.98 mole fraction propane in the distillate and 0.01 mole
fraction propane in the bottoms.
Clicking the Column Environnlent button at the lower left opens a win-
dow with the column sub-flowsheet. See Figure 8.3.
158 Chapter 8
Double clicking the main tower section and selecting the Performance
page tab opens the window shown in Figure 8.4. We can see that the vapor rate
at Tray 30 is 126 lb-mol/hr (5597 lb/hr). The vapor rates decrease as we move
down the column through the rectifying section. However, the vapor rates are
higher in the stripping section because the feed temperature (90°F) is lower
than the temperatures in the stripping section and because there are differences
Distillation 159
in molar heats ofvaporization ofthe components. The highest vapor rate (160
lb-mollhr, 9232 lb!hr) is at Tray l.
To
Condenser qc
Reflux Condenser d
Main TS
Boilup
To
Reboiler
F-Factor 1
At Tray 30: = ¡,-;;;:; = 0.739 ft/sec
.¡¡;;; -v 1. 83
Then the cross-sectiona1 areas ofthe COhU1Jl1S at these two 10cations are calcu-
1ated.
At Tray 30:
AtTray 1:
3
Area= VolumetricFlow = (9232 Ib/hr)(ft /2.27Ib)(hr/3600sec) =1.74ft2
Velocity 0.679ft1sec
B. Sizing Reflux Drum and Column Base: Using the heuristic of 10 minutes
of total holdup, we can calculate the volumes in the reflux drurn and in the
colurnn base. The cohmm sub-flowsheet given in Figure 8.3 gives the streams
to the condenser and the stream to the reboiler. Double c1icking these streams
opens windows on which the total flowrates and liquid densities can be seen.
The total flowrate of liquid leaving the reflux drurn is 5577 lbllu· and its
density is 29 Ib/:ft3. Therefore a vessel with 10 minutes ofholdup must have a
volume of
The liquid entering the reboiler (colurnn base) is 13,130 lb/hr and its density is
29.2 Ib/:ft3. Therefore a vessel with 10 minutes ofholdup must have a volume
of
3
(13, 130lb/hr )(:ft 3129.2Ib)(hr/60min)(lOmin) = 75:ft
Distillation 163
Figures 8.8, 8.9 and 8.10 show altemative ways to enter these ca1culated
holdup volmnes. In the column sub-flowsheet, double c1icking the condenser
and reboiler icons opens windows (Figures 8.8 and 8.9) with Dynamics page
tabs where the size of the reflux drum (condenser) and the colul1m base (re-
boiler) can be specified. Altematively, in the main flowsheet, going to the Dy-
namics page tab on the column window and c1ick:ing Vessels opens the view
shown in Figure 8.10 where both sizes can be entered.
C. Control Valve Sizing: All valves are designed to be 50% open except for
the "valves" on the condenser (discussed below). Nominal pressure drops are
used, and pumps on the bottoms and distillate streams are installed to provide
the val ve pressure drop.
Distillatiol1 165
The feed flow controller has conventional tuning (Kc = 0.5, 1:] = 0.3 min-
utes), as do the two level controllers (Kc = 2). The pressure controller is tuned
using nominal slow settings. With a pressure transmitter range of 150 to 250
psia, the gain is Kc = 1 and the integral time is 1:] = 20 minutes. This setup is
shown in the left picture in Figure 8.11. Clicking the Control Valve button at
the lower right comer of this window opens the window shown in the light
picture in Figure 8.11. The "FRC for qc" specifies the minimtun and maximum
condenser heat-removal rates. The steady-state value is 0.731x106 Btu/hr. The
maximwTI is set at 2x106 Btu/hr. Note that the OP value is 36.6%, not 50%.
The controller is direct acting.
The temperature controller is the only one that requires nming. Two first-
order 1 minute lags are installed in the loop. Of course, the first item to decide
is what tray location should be chosen on which to control temperature. There
are a nunlber of methods for answelIDg this question. They range from the
elegant (singular value decomposition) to the simple (looking at tray tempera-
ture profiles). To illustrate the simple approach, the steady-state temperature
profile is ShOWl1 in Figure 8.12. To see the temperature profile, double c1ick
the colw11ll icon, open the PerfoDllance page tab, c1ick Results, select Tem-
perature and click View Graph. Note that despite the fact that we specified the
trays to be nWllbered from the bottom, the temperature graph numbers from the
top down.
166 Chapter 8
Instead of the re1ay firing when the error crosses zero, it is delayed for
some strange reason. This bug gives results in which the amplitude ofthe out-
put grows with time. When this problem occms we must resort to running the
test by setting up a relay in the same way that we do in AspenDynamics. The
controller gain is set at a high value, and the controller output is limited. Limits
can be placed on the setpoint signal or on the output signa! of a controller.
Clicking the Advanced view on the Parameters page tab ofthe controller win-
dow opens the window shown in Figme 8.14 where these limits can be speci-
fied. To nm the relay-feedback test, these OP lil11its are set at +5% and -5%
aboye and below the nOlmal value.
A relay-feedback test gives the ultimate gain (Ku = 32) and the ultimate
peliod (Pu = 7.3 minutes). Then the TL settings are calculated (Kc =10, 'tI = 16
minutes) and inserted in the TC window on the Parameters page tab in the
Configmation view (see Figme 8.15). Note that the controller is reverse act-
ing.
Distillation 169
8.3.3 Results
Figure 8.16 gives the main flowsheet with all controllers installed and
the six controller faceplates located at the topo All controllers except the pres-
sure controller aTe installed on the main flowsheet. Figure 8.17 gives the sub-
flowsheet window where the pressure controller is shown. Column controllers
can be installed in either the main flowsheet or the sub-flowsheet. In a large
simulation the main flowsheet can get pretty c1uttered, so moving at least the
temperatme and pressure controllers to the sub-flowsheet helps to clean up the
main flowsheet. It is a good idea to keep all the level controllers on the main
flowsheet so that the mateIial-balance flow structure for the whole plant is
easily seen.
170 Chapter8
LC2
wk2
Te PC
Condenser qc
Ref!ux
LC2@Main
.,
TRF-1
@Main
Boilup
'JI
Te
Reboiler
Distillation 171
Figures 8.18A and B give results for two disturbances in feed flowrate.
At 15 minutes the feed is increased from 100 to 120 lb-mol/hr. At 120 minutes
a very large change in the feed flowrate is made (dropped to 80 lb-mol/hr). The
reflux flowrate is constant. The temperature controller does an effective job of
holding Tray 25 temperature. The higher the feed flow, the more reboiler heat
input is required (controller OP increases).
Of course holding a constant tray temperature does not result in constant
product purities. As Figure 8.l8B shows, the lower feed flow with the same
reflux flow and Tray 25 he1d constant results in a higher propane pmity in the
distillate and lower propane impurity in the bottoms. Note how much slower
the changes in product compositions are than the changes in temperature. This
is a charactelistic of distillation colurnn control.
1t should be pointed out at this point that the dynanúc results fOlmd in
HYSYS, as discussed aboye, are quite different than those found in AspenDy-
namics (to be discussed below). We will comment on the importance ofthese
conflicting predictions later in this chapter. Suffice it to say that this is a good
example of the need to not rely too heavily 011 the predictio11s of models. They
provide important and useful informatio11, but their absolute accuracy should
always be viewed with a good deal ofhealthy skepticism.
AspeuPlus requires that trays are mmlbered from the top down, with Stage 1
being the condenser. So the 30-tray depropanizer is fed on Stage 17 and the
reboiler is Stage 32. The active tray section is from Stages 2 down to Stage 31.
It is important to keep this numbering convention in mind. In Aspen we refer
to "stages" when defining locations il1 the COIWlll1.
Distillation 173
D/PColumn
o Tcmpm,lUrc(F)
O Pre~sure (P~1
DF10wRate 0brnr)
:1,r""i"'''"~"'':'·fTnn,±,,:,".:;!
~ ··············1···············1·······················..................... ,..............,..............!............ ;.............. ,
":IJ~:'::: ¡
:
. !
: :
' ! . i ' 1
¡
laG 120 130 140 150 160 170 160 190
TemperOllllfeF
174 Chapter8
AspenPlus uses "Design Specs" and "Vary" to achieve the desired prod-
uct purities. These are specified in the column block. The distillate purity is set
at 98 mol% propane by varying the distillate flowrate. The bottoms impurity is
set a 1 mol% propane by varying the reflux ratio.
Several items need to be done to get ready to move into dynamics. To be
able to see vapor densities tm:oughout the column, click the Report button Wl-
der the column block (labeled "DP" in Figure 8.21). On the Property Options
page tab, click the box in fi:ont of lnclude Hydraulic Parameters. When the
colwnn is converged, the vapor rates and properties can be seen by opening the
Profiles view wlder the column block and looking at the Hydraulics page tab.
Volwnetric flowrates of vapor and 1iquid streams are available to calculate
column diameter and the sizes of the reflux drum and colwnn base (called
"swnp" in AspenPlus).
Then the Dynamic view is opened (shown in Figure 8.23) on which the
sizes of the reflux drum, colwnn base (Sump) and cohunn (Hyelraulics) are
specified. The tray geometry is specified to be sieve trays from Stage 2 down
through Stage 31. Values for the diameter, tray spacing and weir height are
defined on the Hydraulics page tab. We use the reflux drum and colwnn base
sizes ca1culated in Section 8.3.1. Both the condenser and reboiler are defined as
using constant duty in this sirnulation, but there are two other options for heat
transfer (constant coolant and LMTD). The dynamics of the equipment (ther-
mal capacitance of the metal) can be modeled if they are significant by using
the Dynamic Equipment window under the colwnn block.
The file is pressure checked and exported into AspenDynamics. One of
the comrnon messages given by the pressure checker is that the feed is not en-
tering the colwnn at exactly the pressure on the feed stage. This is easily sol ved
by looking at the pressure on the feed stage in the Profiles window, and then
inseliÍng this value for the outlet pressure ofthe feed control valve.
8.4.2 Dynamics
DIP Column
lC
".... _.. _>Q..... _----------------~:
: V2
fI-m->j)~~
----~-----~------G----j
Distillatiorl 177
The pressure controller is reverse acting since its output changes the
negative heat duty in the condenser. The valve range is -1.5x106 to O Btu/hr.
Pressure transmitter range is 150 to 250 psia, and pressure controller tuning is
"1
Kc = 1 and = 20 minutes. These are identical to those used in the HYSYS
simulation.
A strange bug was seen in moving from AspenPlus to AspenDynamics.
The temperature on Stage 7, which is used as the temperature control tray, is
125.7°F in AspenPlus. When the file is exported to AspenDynamics, this tem-
perature is 117 DF. Ifthe temperature setpoint is kept at the 117°F value and the
column is converged to a steady state, the compositions ofthe two products are
not on specification (propane in the bottoms is 1.6 mol% instead of 1 mol%
and propane purity in the distillate is 99.2 mol% instead of 98 mol%). Setting
the temperature controller setpoint at 125.7°F and converging to the COlTe-
sponding steady state give the COlTect product compositions.
Flow, level and pressure controller tuning are the same as used in the
HYSYS simulation. However, the temperature controller tuning is significantly
different. A relay feedback test is run, and the results give an ultimate period Pu
= 8.1 minutes and ultin1ate gain Ku = 8.2. The results in the HYSYS simulation
are Pu = 7.3 minutes and Ku = 32. The peliods are almost identical, but the
gains are different by a factor of 4. This large difference between the two simu-
lators is disconcerting and provides additional evidence that we should always
view the results of simulations (both steady state and dynamic) with a healthy
dose of skepticism and be conservative in our estimates of performance.
-----------'"f' ------------ -~ --. -----------¡- ---- ".-. --_. --i- - --- --- _. .~---- ------ --". ~----- ------ --. ~ .. ---- ----- ---;
~. m
:
•••• m ••••••••••••••• ¡..h •. • .•
:
mm ••••••
o 05 :2 2.5 3
T,meHoUI~
178 Chapter8
c1osedloop perfonnance is essentially the same. See Figure 8.28. This BTX
cohu11ll operates at near atmospheric pressure, while the depropanizer operates
at 200 psia. It is unlmown whether the two simulators model high-pressure
column differently. The higher vapor density would make vapor holdup more
significant.
8.5 Conclusion
ID this chapter we have discussed the dynamic simulation of a single
distillation cohu11ll. Six controlloops are required, even in this simple single-
feed, two-product column. Significant differences in the predicted c1osedloop
dynamic perforrnances ofthe two sinlulators were observed.
ID the next chapter we look at a somewhat sinlllar column, but one
that has an important difference: the occurrence of two liquid phases in the
reflux dnun (which is now a decanter).
~ ~ ~
8 ffi
~
-
~
- a
"
~
\3
~ ~
~ BB~
i~rm J~fa "I~a~I~ 1~;1---i----;--.--'--:
I .;::-=¡....~ .......!;.L+ ...+
\3 15
9.1 Introduction
In this chapter we examine a more complex distillation system. The depro-
panizer colmllil explored in Chapter 8 has ahuost ideal VLE behavior. No
azeotropes are fonued. Very pme propane product can be produced.
We now look at a highly nonideal VLE system in which the components
have such positive deviations from ideality (large repulsion) that two liquid phases
can occm. A decanter is used instead of a reflux drum, and there are two distillate
products :fiom the two liquid phases (organic al1d aqueous). The nonideality re-
quires that we use a VLE relationship in the colmllil and a LLE (liquid-liquid
equilibrimll) relationship in the decanter.
This process also provides om fust example of how to hal1dle a recycle
stream. We will specifY the flowrate and the temperatme of the organic reflux, but
the exact composition of this stream from the decanter to the colmnn is unknoWl1
when we start the steady-state simulation. It is fed to the top tray in the colul11l1,
and these compositions must be lmoWl1 in order to solve the collU11l1 equations.
Therefore, a guess is made ofthese compositions. After the collU11l1 is solved, the
feed streanl to the decanter is knOWl1. Then the decanter equations can be solved,
which yields the compositions ofboth liquid phases. Finally the calculated compo-
sition of the organic reflux is compared with the guessed value, and new guesses
are made. The convergence ofthis "tear stream" is a critical part ofthe getting the
steady-state simulation up and running.
the C01Ulllil overhead, which is about 1.5 m01% in the AspenPlus results, but onIy
0.02 m01% in the HYSYS results. This difference is probab1y due to differences in
the vapor-liquid equilibriUlll parameters and the way the vapor-phase association
of acetic acid is handled.
v50ut R
ReY·1 V5
Rorg
Fin feed
V1
Porg V4 v40ut
Qr
T·100
wk3
L---4~P:;:;1-~P1~ou~t-I~t
V2
The feed is a mixture of viny1 acetate (VAc), water (W) and acetic acid
(RAc). lt is fed to Tray 15 of a 20 theoretica1-tray cohunn at arate of 229.2
kmollhr. The bottoms from the C01Ul11ll is 94.55 m01% RAc, 5.45 m01% water and
<1 ppm ofVAc, and its flowrate is 122.9 kmol!hr.
The vapor from the top ofthe c01Ulnn goes to a condenserldecanter system.
In reality there would be a heat exchanger to condense the vapor and a decanter to
separate the two 1iquid phases. In the simulation flowsheet, these have been com-
bined because this configuration seems to make the ÍUl1ÍTIg of the decanter tem-
peratme controller easier. The decanter heat-removal rate is used to condense and
co01 the c01unm overhead vapor. TIle liquid condensate separates into liquid
phases, a heavy aqueous phase (0.5 mol% VAc, 98.2 m01% water, 1.3 mol% RAc)
and 1ight organic phase (91.0 m01% VAc, 7.6 m01% water and 1.4 m01% RAc).
AH ofthe aqueous phase (54.7 km011hr) is removed as one ofthe products.
Part ofthe organic phase is refluxed back to the top ofthe C01Ul11ll (300 kmol!hr).
The remainder is removed as organic product (51.6 km011hr). The flowrate ofthe
organic reflux is a design degree of freedom, as is the reboiler heat input. The lat-
ter is set (17.l GJ/hr) to achieve the desired water content in the bottoms (5.52
m01%).
Azeotropic Column 183
The column operates at 124 kPa at the top and 152 kPa at the bottom. Base
temperature is 414 K and top temperature is 362 K. The decanter temperature is
313 K. Reboiler heat input is 17.1 GJ!hr. Condenser duty is 16 GJ!hr.
Note that a "reboiled absorber" is used in this simulation, not a complete
column. The column and the decanter use different fluid property packages.
This system was originally developed using HYSYS version 2.2 (Build
3797), and the results reported in this chapter use that version. When the steady-
state case was rerun using the newer version (2.4.1, Build 3870), onIy a single
liquid phase was predicted in the decanter. This is a good example of some of the
frustration of using sin1ulators, both dynamic and steady state. There are subtle
differences among the various versions that can lead to unexpected and unwanted
problems.
Using tl1e HYSYS steady-state results, the maxiInun1 vapor flowrate is at the
bottom ofthe tower (30,045 kg!hr with a vapor density of2.2 kg/m3). Using an F-
Factor of 1.22 (SI units) the maxiInum vapor velocity is 0.822 m/sec. The volu-
metric flowrate is 3.79 m 3/sec, giving a column cross-sectional area of 4.61 m 2 and
a diameter of2.42 m.
The Tray Sizing ca1culation in AspenPlus recommends a column diameter
of2.02 m.
9.3.2 Reboiler
Liquid flowrate to the reboiler is 37,300 kg/hr and the liquid density is 930
kg/m3 . Using the heuristic of 10 minute holdup, the reboiler volume is 6.7 m 3 .
9.3.3 Decaníer
The total flowrate ofliquid from the decanter is 23,290 kg/hr. Most ofthis is
organic (22,340 kg!hr) with a density of909 kg/m3 . Decanters require extra holdup
time to allow the two liquid phase to separate. If 20 minutes of holdup are used, a
decanter volume of 8.5 m 3 is required, giving a vessel that is 1.73 m in diameter
and 3.49 m in 1ength. To be a little more conservative and to make it easy to re-
member vessel diameter (when we start WOITying about the interface levels ofthe
two 1iquid phases), we specifY the diameter to be 2 m and the length 4 m. The
aqueous/organic interface will be controlled at 0.2 m (10%), and the organic level
will be controlled at 1.15 m (65%).
184 Chapter9
Figure 9.1 shows the flowsheet with a11 pumps and val ves insta11ed. Note the
Recyc1e block at the top of the figure. This is where the iIlitial guess of the stream
"Rorg" is made, and the convergence is done. A sma11 flow ofinert gas (nitrogen)
is used in the HYSYS simulation to avoid problems with not having bubblepoint
liquid in the decanter.
Wilson
9.4.2 Dynami.cs
Figure 9.4 shows the control structure with all controllers installed. The con-
trol scheme is:
~-------6- IFC;~--
+<
RCY~l
~~
V5
R
Getting the decanter running in the dynamic mode is tricky. There is a bug
in HYSYS that gives different phase equilibrium results in the dynarnic mode than
in the steady-stated mode. This is illustrated in Figures 9.5 and 9.6. Figure 9.5
gives the compositions ofthe aqueous and organic phases before the integrator is
started. The aqueous phase is about 99% water. The organic is about 95% vinyl
acetate. Figure 9.6 gives the compositions nmnediately after the integrator is
started. Only a single liquid phase is predicted with a composition of about 82%
vinyl acetate.
188 Chapter9
One way to get arolll1d tbis bug is to go back to the Physical Property pack-
age and click the Stab Test page tab. This opens the window shown in Figure 9.7.
Under Dynamic Mode Flash Options, c1ick the Try IO Flash First box and then
c1ick the Decant Water box. This takes all the water phase off as pure water (see
Figure 9.8 for the predicted phase compositions).
Azeotropic Column 189
Two 0.2 minute lags are installed in the temperature loop. A relay-feedback
test gives an ultimate gain of 14 and an ultimate period of 6.5 minutes. The TL
settings are Kc = 4.4 and 'tI = 14.
Figures 9.9 and 9.10 give results for sequential disturbances in feed flowrate
(increased from 231 to 275 kmolJhr at 10 minutes) and organic reflux (increased
from 300 to 350 kmollhr at 90 minutes). Tray 5 temperature is well controlled
with smooth changes in reboiler heat input. More aggressive turIing is possible, but
190 Chapter9
rapid changes in column vapor rates are undesirable due to the possibility of tray
flooding or dumping. So the conservative TL settings are ofien used in distillation
control. The erratic bottoms flowrate signal appears to be due to numerical integra-
tion problems.
Rorg
F
B
Aqueous
Azeotropic Column 191
Figure 9.l3 shows how the Wilson VLE equations are specified for the col-
umn. The Properties view is clicked, and Wilson is selected as the Property
method. Note that Stages 1 through 21 are specified. Sin ce there is no condenser,
the top tray becomes Stage 1 in this column. In the decanter we want to use the
Unifac-LLE method, so this is specified in the Properties view under the Decanter
block as shown in Figure 9.14.
In the Input view under the Decanter block (see Figure 9.15), we can specifY
either a heat duty or a temperature. We fix the temperature at 40°C, so the heat
duty is calculated (Q = 16.15 GJ!hr). h1 this window we also set water as the key
component for the detection of a second liquid phase.
192 Ghapter9
Figure 9.16 gives the flowsheet with aH val ves and pumps instaHed. After aH
dynamic infonnation is supplied and the system is pressure checked, the file is
exported to AspenDynamics.
Azeotropirc Column 193
V2
9.5.2 Dynamics
Figure 9.17 gives the window that opens initially in AspenDynamics. The
default pressure and level controllers are installed, but the level controller outputs
are not connected. Note that there are two level controllers installed on the de-
canter. One is for the aqueous/organic interface level, and the other is for the or-
ganic-phase level. Connecting these two level controllers to the appropriate val ves
and initializing the two liquid levels in the decanter are the key operations of get-
ting the dynamic simulation up and running.
Figure 9.18 gives the window that opens up when AH Variables is selected
in Forrns after right clicking the decanter icon on the flowsheet. Note that there are
two liquid levels that can be specified: "Level" is the organic level (initialized at
l.15 meters in the horizontal decanter with a 2 meter diameter) and the "Leve12" is
the aqueous level (initialized at 0.105 meters). The level controller LC2 manipu-
lates valve V4 to control aqueous level. The level controHer LC3 manipulates
valve V5 to control organic level. Both ofthese controllers are proportional-only
with gains of 2.
Azeotropic Column 195
V2
r-fXk;.--------jREC 1 - - - - - - - ,
LO
DECANTER :>0
r~lIP3 16
I
, LC4
'>-0
~
V4
P2
14
V3
Figure 9.19 shows the final flowsheet with all controllers installed. Colwnn
pressure is controlled by valve V6. This controller is direct acting. With a pressure
transmitter range of 1 to 2 atrnopheres, a gain of 2 and an integral time of 12 min-
utes are used. Colwnn base level controller (LC1) manipulates valve V3 and is
196 Chapter9
: V4
Pl
Aqueous Level
Azeotropic Column 197
Three 0.1 minute lags are inserted in the loop. The relay-feedback test (us-
ing a gain of 2000 and 5% lirnits on the controller output) gave very erratic results
and an unreasonably large ultin1ate gain. Empírical settings of Kc = 10 and '1:1 = 10
minutes provided fue temperature control shown in Figures 9.21 and 9.22. The
disturbances are a step increase in feed flowrate at 1 hour followed by a step in-
crease in organic reflux at time equal 2 hours.
: ~:::::::::::::::::::::¡:::::::::::::::::::::;::::::::::::::::::::I::::::::::::::::::::.::::::::::::::::::::::::::::::::::::::::::::¡
~ ~ ---------------------1---------------------1---------------------T---------------------¡----------------------¡---------------------1
:::::::::::::::::::::]:::::::::::::::::::::]::9~::::::::::::::::¡::::: .................: .................... ~ .....................:
~ :*l------------
~ ?---~========~======~.
m o~------~--------+_------~,-------~--------~------~
198 Chapter9
§? ---------------------;--------------------.;.--------- ---------~~oF--------------------;--------------------¡---------------------~
9.6 Conclusion
In this chapter we have extended distillation column simulation to the case
where the reflux drum is a decanter. The complexities of dealing with two-liquid
phases, a non-standard column and a recyc1e stream make this simulation more
difficult to set up than a "plain-vanilla" distillation column.
In the next chapter we exan1Íne another distillation system that is somewhat
more complex than standard distillation: reactive distillation. The unit operation
combines both reaction and separation occurring simultaneously inside the col-
umn.
hapter 10
Reactive DistiUation
In this chapter we discuss a unit operation that is being used more and more
ofien in chell1Ícal and petroleum plants. The combination of reaction and separa-
tion has significant advantages in many chell1Ícal systems. Ifreactions are reversi-
ble and if the products can be removed by distillation as the reaction proceeds,
high conversions can be achieved even if the reaction equilibrium constant is
sma11. This is the principal advantage ofreactive distillation. Another advantage is
the elimination of complex separation schemes when the use of reactive distilla-
tion avoids azeotropic separations that would be reqtÚfed in conventional reac-
tor/separation flowsheets.
In conventional distillation, tray holdup has no effect on the steady-state de-
signo In reactive distillation, tray holdup (or amount of catalyst) can be a critical
design parameter because of its effect on reaction rates. Tray holdup is not inlpor-
tant if the forward and reverse reaction rates are so fast that chemical equilibrium
occms on each tray. However, ifreactions are kinetically limited, not equilibrium
limited, tray holdup is critically important. Tray holdup depends on both the di-
anleter of the C01Ulllil and weir height. The latter is limited by pressme drop. The
fonuer depends on vapor rates, which vary with tray holdup because ofthe inter-
play between reaction and separation in reactive distillation colmnns. Therefore,
column sizing becomes more complex than is the case in conventional disti11ation.
Pressme is also a key design parameter in reactive distillation because of its
inlpact on both phase and reaction equilibriUlu and on reaction kinetics. Lower
pressmes ofien make separation easier, but lower pressmes mean lower tempera-
tUTes and smaller reaction rates. Ifreactions are exothennic and reversible, equilib-
rium constants decrease as temperatme increases. So there are important trade-offs
between reaction effects and separation effects that must be considered in deter-
mining the optimUlu operating pressme of a reactive distillation colmnn.
In this chapter we will simulate two reactive distillation colUlnns. The first
system reacts water and ethylene oxide to produce ethylene glycol. The second
reacts methanol and acetic acid to produce methyl acetate and water.
199
200 Chapter 10
where xEQ, Xw and XEG are the mole fractions of ethy1ene oxide, water and ethy1-
ene glycol. Temperature T is in Kelvin, Activation energy is in caUg-mole.
The column has 10 trays. Fresh water is fed on the top tray. Fresh ethylene
oxide is fed on Tray 4 (from the bottom). The target for the production rate of eth-
ylene glycol is 25 kmoVhr,
The operating pressure is set at slightly aboye atrnospheric. This gives a re-
flux drurn temperatme (333 K) that perrnits the use of coo1ing water in the con-
denser and gives column temperatures high enough to yield large reaction rates.
The production of di-ethylene glycol impmity should be minimized, Note
that the activation energies ofthe two reactions are identical, so varying tempera-
ture to improved yield is ineffective. The only variable that affects yield is the
concentration of ethy1ene oxide. This must be kept very small so that little di-
ethylene glycol is produced. This means that a large excess ofwater must be pre-
sent The design degree of fi"eedom that has the greatest effect on water concentra-
tion is reboiler heat input Another way to affect yield is to feed small amounts of
the ethylene oxide feed at severallocations. This helps to reduce the ethylene ox-
ide concentrations, The impact ofthese design choices are illustrated in the follow-
ingtext
Reactive Distillatiol1 201
late flow was gradual1y reduced to zero. Equipment sizing is discussed in detail in
Section 10.4.
v40ut
V4
v1in
v2in
v30ut
T-100 V3
AH valves are specified in the nonnal way except V4. A value for Cv = 5 is
specified and the valve opening is set at 0%. Controllers are instaUed as shown in
Figure 10.3. A detailed discussion ofthis scheme is given in the next section.
The dynamic simulation was not successfully runo Sorne strange things oc-
cur as one moves fi·om the steady-state mode to the dynamic mode. Figure 10.4
gives the composition profiles in the steady-state mode. When we switch to dy-
namics, the compositions are aU changed to those in Figure 10.5 (equal concentra-
tions of all components). When the integrator is started, the compositions switch
back to the steady-state values (Figure 10.6). However, as time proceeds, the com-
positions change. Figure 10.7 gives the situation afier 10 minutes. The ethylene
oxide concentrations have increased dramaticaUy.
Figure 10.8 shows a time history ofwhat happens. The ethylene oxide com-
position in the reflux drum builds up. Reflux-drum temperature drops, and its level
increases, which decreases the water makeup coming into the system. EventuaUy
pressure rises.
204 Chapter 10
The system fills up with ethylene oxide. This appears to be caused by the re-
action rates going to zero in the dynamic mode. This problem has not been re-
solved.
Their case given on page 486 was ron on HYSYS and converged to a steady state
that was quite close to the conditions given in the book. However, when the pro-
gram was switched to the dynamic mode, the integrator started but nothing else
happened. Time did not increase.
It appears that HYSYS does not handle dynamic reactive distillation effec-
tiveIy. This system was successfulIy simulated in AspenDynamics, and this study
is presented in Section 10.5.
Figure 10.9 gives the AspenPIus flowsheet with a plUllp and valves attached.
Figure 10.10 shows the window that opens when the Reactions button is c1icked
under the column block and the Holdup page tab is c1icked. The vollUlle of liquid
holdup on each tray is specified. On the Specifications page tab (Figme 10.11) the
reactive trays are specified (2 through 11, nlUllbering from the top) and the reac-
tion set (R-l) is selected. Of comse the two reactions are defined in the Reactions
under Setup for the flowsheet.
Figure 10.12 shows the window that opens when Setup is c1icked under the
co1umn block (RXDIST) and the configuration page tab is selected. The distillate
rate is set at a small value since all the products leave in the bottom stream. The
reboiler heat input is set at 6.9 MW. The resulting bottoms product has a composi-
tion 1.1 mol% water, 93.1 mol% ethylene glycol and 5.8 mol% di-ethy1ene glycol.
208 Chapter 10
Figure 10.13 gives steady-state temperature profiles for two cases. There is a
rapid rise in temperature near the bottom of the cohunn as the ethylene glycol
builds up and the water depletes. Figure 1O.14A gives the ethylene oxide composi-
tions in the column, which are quite small. Figure lO.14B gives the composition
profiles ofthe other components.
I§-'"
!;-------ir----LUJ¿N~ 51a90
In the base case the entire ethylene oxide fresh feed is introduced on Stage
6. To see the effect of distributing the ethylene oxide fresh feed among several
trays, it is split into four equal streams that are fed on Stages 2, 3, 4 and 5. This
results in a higher ethylene oxide concentration in the condenser (Stage 1), as
ShOWl1 in Figure 10.15, which drops the condenser temperature. The impact on
yield of distributing the feed is small. The molar flowrate of di-ethylene glycol in
the single feed case is 1.52 kmol/hr. The distributed feed reduces this to 1.39
kmol/hr.
The other optimization variable that affects yield is reboiler heat input. A
value of 6.9 MW gives 1.52 kmol/hr of di-ethylene glycol for the single feed case.
210 Chapter 10
Increasing heat input to 10 MW (keeping the sarne tray holdup) decreases the di-
ethylene glycol to 1.24 kmollhr.
These results are obtained using an assumed column diarneter of 2.2 meters,
which gives a tray holdup ofO.587 m 3 when a liquid height ofO.152 meters is used
on each tray. To confirm that this diarneter is reasonable, we check the vapor
loading in the colunm. The volumetric flowrate of vapor at the top tray is 17,284
m 31hr and the vapor density is 0.673 kg/m3 • Using an F-Factor of 1.22 (SI units),
the maximum vapor velocity is 1.49 m/sec. This gives a column diarneter of 2.0
meters, which is close to our assumed value of diarneter. This iterative sizing cal-
culation is required for reactive distillation because holdup (or catalyst) affects
both reaction rates and column fractionating performance even in the steady state
if reactions are kinetically limited.
10.4.2 Dynarnics
The holdups in the reflux drum and column base are calculated to give 10
minutes oftotal holdup (5 minutes when 50% full). Reflux drum volume is 2 m 3,
and base vohuue is 4 m 3 . Valves and the pump are specified in the normal way.
The system is pressure checked and expOlied to AspenDynamics.
Figure 10.16 shows the initial window that opens. Defaults level and pres-
sure controllers are automatically inserted. Then the other controllers are installed.
The final control structure is shown in Figure 10.17 with all the controller face-
plates. This control scheme uses the following structure:
l. The fresh feed of ethylene oxide is flow controlled. This is the pro-
duction rate handle. Conversion is almost 100%, except for the
small distillate flow (0.01 kmollhr), which is also flow controlled.
Reactive Distillation 211
V2
AXD!ST
V1
lC2
f--~----------O-------------'c-----;---------
~:>"
m
:------->0---,
~
':V1,
FEO
, -
,----.-----------------------------.--
L-iJ-·-~-,~--~~----------:
212 Chapter 10
The most interesting loop is reflux drurn level adjusting fresh water feed.
Almost all the water fed is consumed in the reaction, except for a small amount
that leaves in the bottoms. The flowrate ofwater into the system must be adjusted
to perfectly balance the consumption. The inventory of water in the system is
mostly in.the reflux drum (96. 7mol% water), so drum level provides a simple way
to detect ifthe water inventory is building up or depleting in the system. We will
see similar types of structures in the plantwide control schemes used in more com-
plex plants considered in subsequent chapters. Feeding a reactant into a process to
maintain concentration or inventory ofthat component in the system is a key fea-
ture of many plantwide control structures. Sorne type of feedback control that uses
infonnation about the amOlmt of reactant in the process is usually required.
You might thinlc that we could simply use a ratio scheme to adjust the two
fresh feeds. These ratio schemes carmot work in a real plant because of flow
measurement inaccuracies and feed composition changes. It is not possible to per-
fectly balance the flows of the two components by measrnmg flows when flow
measurement errors of lOto 20% are typical. The system will gradually fill up
with tlle component that is in excess.
Relay-feedback test results yield a Stage 11 temperature controller gain of2
and a integral time of 10 minutes. Temperature transmitter range is 350 to 450 K,
and the maximum reboiler heat input is 3.3x106 cal/seco
Dynamic performance is shown in Figures 10.18 and 10.19. The distur-
bances are sequential step changes in the ethylene oxide E:esh feed FEO. At t = 0.5
hours, FEO is increased from 27.53 to 35 km01l1u·. At t = 5 hours, it is decreased to
15 km01lhr. These large changes are severe tests ofthe robustness ofthe proposed
control structure.
Stage 11 temperature is well controlled. Notice that the reboiler heat input
ends up at a lower value as more feed is added to the system, which is counter-
intuitive. This occurs because of the increase in the heat of reaction.
Bottoms water composition changes very little, but the amOlmt of di-
ethylene glycol produced increases at higher feed rates and decreases at lower feed
rates. Fresh water feed F w initially changes in the opposite direction to where it
ends up at the new steady state. This is due to the effect of vapor boilup 6n reflux
drum level. Eventually the E:esh water feed adjusts itself to accommodate the
changes in production rateo Notice that although the mass flowrate of reflux is held
constant, the molar reflux flowrate changes slightly due to composition changes.
Reactive Distillation 213
~::::::::::::::::::::::::::::::::::::::::::::::::::::::::::T:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
8 ;; ~
":":':"::::::.::::.:.:.:::J::""':"':'::::::::::::,::,{:,:::::::.':':::::':":":":f:':::: XB.DEG
"
o
:""""""""'~""""1""""""""""""""~T""""""""""""""["""""""""'"""""1
¡¡¡ ¡¡¡
'"
'ii ~ '1 §3 --- ------------ ---- ~ --------------- ------ ------ ----------------r-------- ---------- --------- --1
ill' : :
.. SI SI 18·······,···············
, ,
,
_ _ _ _ M_MM_MM. _ _ _ _ _ _ _ M_M _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ,
~
~. F
el ;il ;il ~·····IL-------+-------il
1: 1: 1: 1 [ ' .......
--------------------------,
A R R : """"""""""""""'j"""""""""""" ••••••••
""""":'::.:::::."::'::::::::'::::::: .. J
lO lO I.rl ~ - _________ - ___ ._. ________ - - - - ~ __ - - - - - - - __ - ______ - - - ___ - __ - . . ¡________________________ "_____ ___________________ "" _______ _
~
2.5 5 7.5
Time H~u¡s
214 Chapter 10
~ ,V1 ¡0---'
~
Pl
216 Chapter 10
10 HOAC MEOR
VI PI V4 P.JO:::OLUMI:l P.JCCOLUMN
To P..xr;OLUMN Rxr::OLUMH V3 PI PJ V2 VI
UQum LIQUID LIQUID LIQUID LIQUID UQUID LIQUlD LIQUID
METHY·Ol 0.0 0.0 .0124212 .Ol:l421:l :J.11.5117 :117.5117 .0124212 :!71.5lli 0.0 0.0
METRA-DI 0.0 280.0000 33609:1::1 33608:1:1 2.139791 2.139791 33608:1:1 :1.139191 0.0 280.0000
WATER 0.0 0.0 :1163153 2763153 l.'JOa848 1209848 :176.3153 l.:!OaS48 0.0 0.0
ACETI·Ol J90.0000 0.0 2336:118 2336218 .1396551 .1396551 2336218 .1396S51 280.0000 0.0
METHY·Ol 0.0 0.0 4.45:l0·1&5 4.45204&5 .9815861 .9875861 4.45:l04E-S .981SSól 0.0 0.0
METRA·OI 0.0 1.000000 1.20460&3 L:10460E-3 1.61492:&3 1.61492&3 1.:10460&3 1.6149JE-3 0.0 1.0GOOOO
WATER 0.0 0.0 .9903113 .9903113 4.30195E-3 4.30195&3 .9903173 4.3019E3 0.0 0.0
ACEnOl 1.000000 0.0 a.3i354E-3 8.37354&3 4.96993&4 4.96993&4 831354&3 4.96993E-4 1.000000 0.0
!oUlFlow J90.0000 280.0000 219.0000 :119.0000 :J81.0000 281.0000 219.0000 28l.0(lOO 280.0000 280.0000
16814.12 B911.805 51J9.8B2 5129.882 20656.64 :10656.64 5129.88::1 :10656.64 16814.12 8971.805
J69.1119 19U34::1 98.69688 107.8661l 383.0546 5:14.4113 98.688:14 3BJ.9SJl 269.1593 194.8160
323.0543 323.0561l 411.39:16 4113210 330.0550 3:19.8916 4173266 329.8!l:l3 323.0000 323.0000
1209302 3.120930 7.000000 ·1.000000 4.000000 1.000000 01.000000 1.000000 2.600000 6.000000
0.0 0.0 0.0 2.38362&4 0.0 1.16403&3 0.0 0.0 0.0 0.0
1.000000 1.000000 1.000000 .9991616 1.00aaao .9988360 1.000000 1.000000 1.000000 1.000000
SolidFnc 0.0 0.0 0.0 0.0 0.0 0.0 0.0 D.O 0.0 0.0
cillmol -1.H61E+5 -56509.61 _6651035 -6651035 ·1.0454E+5 -1.0454E+5 -66512.56 ·1.0455E+5 -1.1461E+5 ·56509.61
c'lllg:n -1908.448 ·1163.60:1 _3611313 -3611.313 ·14:12.088 -H22.088 ·3611.433 -1422.203 ·1909.448 ·1163.60::1
tillsec -89139E+6 -4395:JE+6 _5.l546E+6 -5.1546E+6 ·8.l599E+6 -8.1599E+6 ·5.1.547E+6 -8.1605E+6 ·8.9139E+6 -U95:JE+6
cillmo1·K -13,45698 ·56.00197 -33.15J91 -33.1494:1 -S9.11476 -89.69656 -33.15469 -89.72227 -73.46315 -56.01507
c'lllgtn-K ·1.2J3:111 ·1.147946 -1.803094 -1.802905 -I.:lJ0424 ·1.220116 -1.803191 ·1.220.s:J6 -U233H -1.148169
=lkc .0113367 .0239519 .0411139 .0431081 .0122::162 8.93065&3 .0411180 .0122295 .0113379 .0239542
¡;:Wcc 1.041116 .7614135 .9662688 .79::16::162 .8987682 .65650::15 .8663441 .6990069 1.041187 .1615451
A~M\V 60.05256 32.04216 18.38661 1838661 13.51111 13.51111 1838661 60.05256 32.04:116
LiQVo160F J68.9465 188.::1281 85.61129 85.611:19 311.1331 311.1331 85.611::19 311.1331 266.9465 168Xl61
V
r
JI H20
ri
j MeOH
Slage
10.5.2 Dynamics
¡
:ru
iQ
. ~. _~.......................".....................................;
l...o. . . _
Reactive Distillation 219
Figure 10.25 gives the flowsheet with aH controllers and lags installed. Two
0.5-minute lags are installed in the temperature and composition loops.
Relay-feedback tests were attempted, but the results seemed to be unreason-
able since the ultimate gains were very large and the ultimate periods very small.
The temperature controller tuning constants were empirically set at reasonable
values (Kc = 1 and 1:1 = 20 minutes). Then different tunÍng constants for the com-
position controller were explored.
Figures 10.26 through 10.29 show the response of the coll.l11ÜJ. for a 10%
step increase in the setpoint of the acetic acid flow controHer at time equal 0.25
hours. The acetic acid flow increases from 280 to 308 kg-mol/hr.
Figure 10.26 shows what happens when a proportional-only composition
controller is used with a low gain CKc = 0.2). The methanol fresh feed is gradually
increased as the methanol concentration on Stage 39 decreases. The lower metha-
nol concentration results in a higher acetic acid concentration in the bottoms
(lower conversion). If the composition controller gain is increased "to l(" = 0.5
(Figure 10.27) there is less offset in the methanol composition and more fresh
methanol is brought in. However, the composition loop begins to get somewhat
underdamped. Figure 10.28 shows that a further increase in gain (l(" = 1) keeps
the concentration of acetic acid in the bottoms low, but the response is quite oscil-
latory.
Figure 10.29 gives results when a PI controller is used in the composition
loop. Gain is set a l(" = 0.2 and an integral time of 20 minutes is used. Effective
control ofboth temperature and composition is achieved.
10.6 Conclusion
In this chapter we have simulated a system that combines reaction and sepa-
ration in one unit. Its apparent simplicity hides some interesting and subtle effects.
Tray holdup affects both steady state and dynamics. Fresh feed flows must be ad-
justed to account for reaction stoichiometry.
The AspenDynamic simulations of the two reactive distillation columns
were successful. The HYSYS simulations were not.
The reactive distillation collUnn has some ofthe important features ofmore
complex multi-unit flowsheets. The process acts as apure integrator in terms of
component balances, so some type of feedback of information is required to adjust
at least one ofthe fresh reactant feed streams.
We begin to study these complex processes in the next chapter.
220 Chapter 10
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,
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Reactive Distiliation 221
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Kc=O.2, taui=20
[]S 1 15 25 3 35 4 AS 5 55
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a 111
ulti- nit yna le
i ulations
hapter 11
Pressure-Swing eotropic
DistiUation Columns
11.1 Introduction
In Chapter 9 we studied a system in which a heterogeneous azeotrope was
separated using a single colul1111 and a decanter. The occurrence of two liquid
phases in the decanter pennits the separation ofthis mixture to be l11ade in a single
column.
When the azeotrope is homogeneous, the separation cannot be achieved in a
single colul11u. An azeotrope exists when the composition ofthe liquid phase is the
same as that ofthe vapor phase.
Xj=Yj,j=l,NC
where Xj = mole fraction of component j in the liquid, Yj is the mole fraction of
component j in the vapor and NC is the uumber of components. An azeotrope pre-
sents a distillation boundary or lirnitation to the achievable separation. If there is
no composition difference between the vapor and the liquid, compositions cannot
change from tray to tray, so there is no :further separation. The azeotrope fonns a
pinch condition.
There are a number of techniques for separating azeotropes. One method is
pressure-swing distillation. This can be used in systems where there is a significant
change in the azeotropic composition with pressure.
Consider a column whose feed is a binary mixture of components A and B
with composition z (mole fraction A). The vapor-liquid equilibrium for the system
has a minimum-boiling azeotrope of composition Yaz! at a low pressure PI. The
azeotropic composition shifts downward to Yaz2 at a higher pressure P2.
Two columns, operating at two different pressures, can be used to separate
the feed into two streams of almost pure A and almost pure B. Ifthe feed composi-
tion is less than Yaz!, the feed is introduced into the low-pressure column. The bot-
toms product from this column is almost pure B. The distillate has a composition
that is close to the azeotropic composition Yaz!. It is fed to the high-pressure col-
umn. This feed composition is greater than the azeotropic composition Yaz2 at the
higher pressure, so the bottoms product from the high-pressure column is almost
227
228 Chapter 11
pure A. The clistiIlate from the high-pressure column D2 has a composition that is
close to the azeotropic composition Yaz2. This distiIlate strearn is fed back into the
low-pressure column. Thus the low-pressure column has two feeds: the fresh feed
at composition z and the clistillate D2 from the high-pressure column at a composi-
tion somewhat greater than Yaz2 (but less than Yazl)'
Thus the two columns are intercol111ected by the two distiIlate strearns. They
must be designed and controlled as interacting units, so dynamic simulation ofthe
entire system is required.
The nonnal boiling points ofthe two components are 150.7 °F for THF and
212°F for water, so THF is the light component. However, the liquid phase is
highly nonideal, and a minimum-boiling homogeneous azeotrope is fonned. At
atrnospheric pressure, the composition of tbis azeotrope is 0.828 mole fraction
THF, and the azeotrope boils at 147°F.
If a mixture of THF and water with composition 0.50 mole fraction THF is
fed into a column operating at atrnospheric pressure, the bottoms stream wiIl be
mostly water. But the distiIlate stream can never be any purer than 0.828 mole
fraction THF, even with an infinite number oftrays and an infinite reflux ratio. If
the feed mixture were 0.90 mole fraction THF, the bottoms would be mostly THF
and the clistillate would be slightly greater than 0.828 mole fraction water.
Two columns can be used to separate the mixture into almost pure products
ifthe azeotropic composition changes significantly with pressure. ForturJately this
is true for the THF/water mixture. The azeotropic composition and temperature
predicted by the DISTIL progranl fi.-om Hyprotech are given in Table 11.1. The
Wilson Equation is used for the precliction of activity coefficients, and ideal gases
are assumed.
Figure 11.1 gives xy curves for the THF/water system at two pressures (20
and 115 psia). The shift in the azeotrope with pressure is clearly seen. Figure 11.2
gives Txy cliagrarns at the sarne two pressures.
Pressure Swing 229
11.2.2 COlflfiguration
The process has two cohuTIlls that operate at two pressures. We select a low
pressure of 20 psia and a high pressure of 115 psia. Of course these two pressures
are design optirnization variables, as are the number of trays in each colurnn and
feed-tray locations. There is an optirnum set of pressures that minimizes total an-
nual cost of the separation. The larger the difference in the two pressures, the less
recyc1e is required and the lower the energy consumption. However, the lower the
pressure in the low-pressure colmTIll, the larger the diameter and the cooler the
coolant required in the condenser. The higher the pressure in the high-pressure
colurnn, the higher the pressure ofthe steam that must be used in the reboiler.
230 Chapter 11
Now the distillate from the first cohunn (D]) is known and is fed into the
second (high-pressure) column. We aSSlUl1e a IO-tray column, fed on Tray 6, and a
reflux ratio of 1. The puri1:y specification on the bottoms product is 99 mol% THF.
Then the second column is converged, as shown in the lower left window in Fig-
ure 11.4. The calculated value of the distillate from the high-pressure column is
slightlydifferent than our initia!. guesses, as shown in the upper Jwo windows in
Figure 11.4.
Now the recycle block is activated, and the recycle loop is converged. Fig-
ure 11.5 shows the initial converged values of flowrates, temperature and compo-
sitions of the recycle loop. Note that the two flowrates are somewhat different
(42.05 versus 41.86 lb-mol/hr). TIle default convergence cliteria for the recycle
block can be tightened to drive the two flowrates closer together.
Figure 11.6 gives the HYSYS flowsheet with all the pllUl1bing installed.
PlUl1p PI is vital to provide the pressure to get the distillate D] to flow from the
Pressure Swing 233
low-pressure column into the high-pressure column. AH control val ves are sized
with about 20 psi pressure drops when 50% open lU1der design conditions. Valve
V4 has a much larger pressure drop because it drops pressure fi"om the 115 psia
high-pressure cohunn into the 20 psia low-pressure colmDll.
Figure 11.7 gives the composition profiJes in the two columns. Figure 11.8
gives the temperature profiles. We will use the reboiler temperature in the LP col-
umn as the control temperature location, and Tray 2 in the HP column.
~¡""-I-. -~-;--'11".,
v40ut
v50ut
P2 p20ut
V3
BI~'I'LPCOLUqWd¡,omp","',"PlOr,,¡o~o
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234 Chapter 11
_o;
The diameters of the two columns and fue holdups in fue reflux drums and
column bases must be ca1culated. The usual sizing methods are used to determine
fuese parameters. Table 11.2 gives fue values for the two columns.
LPColumn HPColumn
Diameter (ft) 2.7 1.4
Reflux Drum Holdup (ft3) 28 16
Base Holdup (ft3) 22 41
The control structure selected for this two-column process, as ShOWl1 in Fig-
ure 11.9, has the following 100ps:
This 1ast ratio contro1100p is something that we have not i11ustrated before. We
discuss how to insta11 this ratio scheme in more detail in the next section.
Figure 11.9 shows the main PFD with a11 the contro11er facep1ates shown at
the top and the 1eve1100ps insta11ed on the bottoms and disti11ate flows. The flow-
sheet becomes fair1y cluttered if a11 the 100ps are shown on the main PFD. Figures
l1.10A and l1.lOB show the sub-flowsheets for the two co1umns on which the
temperature and pressure controllers are installed.
Deadtirnes of 1 minute are inserted in the two temperature 100ps, and re1ay-
feedback tests are run on both temperature contro11ers. The resu1ting TL settings
are Kc = 0.88 and 'Ir = 7.3 minutes for the LP co1umn and Kc = 7.4 and 'Ir = 8.1
minutes for the HP co1umn. The temperature transmitter ranges are 150 to 250°F
in the LP column and 250 to 350°F in the HP co1umn.
-~:;2
@Main
L -_________________________ ~R~~n
FRC1
@Main
To
Reboiler q'
Remote SP
Figure 11.12 shows the Advanced view for FRC1 on which the ''Use PV
units" burton has been selected on the Remote SP line in the SetPoint Options
section of the view. The selection of "Use PV units" instead of "Use %" must be
Pressure Swing 239
made with the controller in the remote-set mode to get the correct setpoint value
from the spreadsheet (Ratio 1) if the setpoint is ca1culated in engineering units.
Figure 11.l3A shows the Connections page tab view of the spreadsheet Ra-
tiol. The value ofthe DI distillate flowrate is imported into Cell Al. The value in
Cell A2 is exported to the flow controller FRCI as its remote setpoint. The Pa-
rameters page tab of Ratio2 is also shown in Figure 11.13A. The Unit Set is se-
lected as "SI" in the upper left comer under Spreadsheet Parameters.
Figure 11.13B shows the Fonnulas page tab view of the spreadsheet. Cell
B2 is the desired reflux ratio. The formula ShOWl1 ca1culates the value given in Cell
A2. This cell is then exported to the reflux flow controller as its remote setpoint
input.
11.4.3 Results
Figure 11.14 gives results for a step increase in fresh feed flowrate from 100
to 120 lb-mol/hr at time equal about 1550 minutes. The control temperature in the
LP column decreases about 5°F and bottoms water composition takes a dip when
the feed flowrate is increased. The controller increases the reboiler heat input and
gradually retUl11S the temperature back to the setpoint. The bottoms water compo-
sition also retums close to the initial steady-state value.
The ternperature in the HP column decreases more gradually and only drops
about 0.2°F. The reboiler heat input in the HP column increases to retum the tem-
perature to the setpoint. The bottoms THF composition from the LP column un-
dergoes a small dip but retums to the initial steady-state value.
All the flowrates ofthe distillate and bottoms streams gradually increase as
the proportional-only level controllers attenuate the step change in feed flow into
gradual exponential lises to the new steady state. This demonstrates the flow-
smoothing performance of P-only level controls in a multi-unit plant. This be-
comes more and more important as the number of units in series increases, as we
will see in the complex multi-unit plants studied in subsequent chapters.
Pressure Swing 241
This setup is made on both columns, and the final flowsheet with all control-
lers, ratios and lags installed is shown in Figure 11.18. The blocks labeled RRl
and RR2 are the two multipliers or ratio elements. Two dynarnic elements are in-
stalled in each temperature loop: a 0.5 minute deadtime and a 0.5 minute first-
order lag. The manual re1ay-feedback test seems to ron better with both types of
elements in the loop. Test results give TL settings for the temperature controllers:
Kc = 3.3 and 1:¡ = 5.3 minutes for the LP column and Kc = 1.6 and 1:¡ = 6.0 minutes
for the HP column.
Pressure Swing 245
Fe
~-»-o---,
,
11.5.2 Results
Figures 11.19 and 11.20 give results for a step change in feed flowrate from
100 to 120 lb-mollhr at time equal 0.5 hours. The temperatures controller tuning is
somewhat aggressive, but the tighter temperature control (compared to the HY-
SYS results) produces a smaller change in product quality.
Note that the compositions shown in Figure 11.20 are the impurity in the
stream. The combination of temperature control and reflux ratio control gives re-
sponses to feed rate changes that return product pmities to their desired levels.
This would not necessaIily occur for ChaIlges in feed composition.
246 Chapter 11
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ili
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Time Hours
Pressure Swing 247
11.6 Conclusion
In this chapter we have simulated a two-mút system with material integra-
tion between the m1Íts. The recyc1e of distillate jiom the second cohmm back to
the fust produces an interacting system. The dynamics and control of the entire
system must be studied simultaneously. In the next chapter we look at another
two-colmnn system, but the coupling is through heat transfer, not material streams.
1
1
hapter 12
Heat-Integrated istiUation
Columns
12.1 Introduction
Distillation columns are major energy consumers in many petroleum and
chemical plants. One commonly used method to reduce the energy requirements in
distillation systems is heat-integration. The basic idea is to use the overhead vapor
from one colunm as a heat source in another collillm. Multiple-effect evaporators
use the same technique.
The pressures in the two columns are adjusted so that there is a reasonable
differential temperature driving force for heat transfer in the heat exchanger serv-
ing as the condenser for the high-temperature COIUlllil and the reboiler for the low-
temperature cohmm. A small temperature difference results in lower temperature
heat source in the high-temperature column but a larger heat-transfer area in the
reboiler/condenser. Typical temperature differentials are about 30 to 50°F, depend-
ing on the relative cost of heat-exchanger area and energy. There are interesting
design optimization trade-offs that involve the many design degrees of freedom:
number of trays in each colunm, reflux ratios and pressures. The typical system
has the low-pressure cohillm pressure set by the use of cooling water in the con-
denser. Then the pressure in the high-pressure COIUlllil is set to provide a reason-
able temperature differential in the condenser/reboiler.
Heat integration can be used in systems where two cohmms separating dif-
ferent chemical components have the required temperature levels. The reflux-
drum temperature ofthe high-temperatme column must be sufficiently higher than
the base temperature of the low-temperature cohillm to give reasonable heat-
exchanger area. Of course, the heat duties of the two columns must be similar.
Any differences between tllese duties require the use of auxiliary condenser andlor
reboilers. Even ifthe duties are perfectly balanced, auxiliary heat exchangers may
be required to improve dynarnic controllability.
Heat integration can also be used to separate a single feed stream. Instead of
using one column with a reboiler and a condenser, two columns are used. One
operates at high pressme and the other column operates at low pressure so that the
appropriate temperatures are achieved in the coupled condenserlreboiler heat ex-
changer. This type of system is nonnally limited to
249
250 Chapter 12
Systems that do not have these properties may require excessive pressure differ-
ences between the two columns, so the heat-integration economics become unfa-
vorable.
A typical heat-integrated distillation system may involve somewhat higher
capital investment, but the savings in energy costs can usually justify this invest-
ment.
There are a munber of altemative heat-integration flowsheets. Two of the
more widely used are:
1. Feed split: Fresh feed is split between two columns that operate at
different pressures to provide the specified LiT in the con-
denser/reboiler. Specification products are produced at the ends of
both columns. This is the configuration we use in this chapter.
2. Light split: All the fresh feed is introduced into one column. The
distillate from this column contains about half of the lighter com-
ponent in the feed. The bottoms contains the rest ofthe lighter com-
ponent and aH of the heavy component. This is fed into the second
column where the lighter component goes overhead in the distillate
and all of the heavy component goes out in the bottoms. The heat
integration can be in the direction of flow (the first colmnn run at
high pressure) or opposite the direction offlow (the second column
run at high pressure). One ofthe factors that influences this choice
is the temperature level of the available heating medimn. The direct
scheme has a lower base temperature in the high-pressure column
because the bottoms composition is a mixture of light and heavy
components.
H28t-lnt.egrated
Dlstillatlon
Columns v220ut
V22
f2in f2
V21
p20ut
T2
b2 v240ut
V24
f1in
V11
v130ut
V13
desired botloms purity. The corresponding reflux ratio is 1.62. Figure 12.3B gives
the PFD from the sub-flowsheet and the workbook with stream information. Note
that the reflux ratio in the LP column is much lower than the reflux ratio required
in the HP column because of the increase in relative volatility with decreasing
pressure. This indicates that the optimum design ofthe system would feature a HP
column with more trays than the LP column and probably somewhat more feed
sent to the LP column.
Reflux
To
Condenser
Main '--_---1-_---'''''+
TS
bot2
No.te that in the simulatio.n the liquid fro.m the drum representing the base o.f
the LP co.lumn is pumped thro.ugh the rebo.iler/co.ndenser. This type o.f rebo.iler is
called a forced circulatio.n rebo.iler. In a real plant, the co.ndenser/rebo.iler is usually
a kettle o.r thermo.-sipho.n type. The fo.rmer is preferable because it eliminates the
sensitivity o.f heat-transfer co.efficients to. liquid level, which o.ccurs in so.me
thenno.-sipho.n designs and can limit the use o.f averaging level co.ntro.l to. smo.o.th
o.ut flo.w disturbances.
No.w the flo.wrates and co.mpo.sitio.n in the two. mo.st impo.rtant pieces o.fthe
flo.wsheet have been established. Next we must malee the co.nnectio.ns between the
two. co.lumns thro.ugh the co.ndenserlrebo.iler.
The pieces ofthe flowsheet have now been individually converged. Next the
two recyc1e blocks are activated and the whole flowsheet is converged. Figure
12.5 gives the HYSYS workbook with all the stream infonnation.
256 Cilapter 12
N otice that the HP Column reflux drum and the LP Colurnn base drLUn both
have vapor strearns attached as required by HYSYS. The two val ves in these lines
(V14 and V23) are specified to be shut.
The diarneters of the two columns, the colurnn-base vohunes, the reflux-
drurn volurnes and the volurnes of the heat exchanger must be calculated and
specified. Tab1e 12.1 surnrnarizes results.
Figure 12.6 shows the control structure for the process. The basic control
scheme for each ofthe cohmll1s is the same:
This last loop is different in the two columns. In the HP column, controller TC 1
changes reboiler heat input directly. This is installed in the sub-flowsheet, as
shown in Figure 12.7. Two 0.5 minute lags are inserted in this loop. Temperature
transrnitter range is 250 to 350°F. Relay-feedback testing gives TL settings ofKc =
4.7 and 'e¡ = 7.9 minutes.
The setup in the LP column is somewhat more complexo The output signal
from temperatme controller TC2 uses a split-ranged valve configuration to change
both the flowrate from the base ofthe column through the reboiler/condenser and
the heat input to the auxiliary reboiler. As shown in Figure 12.8, two identical
temperature controllers in parallel are used to simulate the split-range valve con-
figuration. Two 0.5 minute lags are used in each loop. The main TC2 controller
changes the flowrate by using a temperature/flow cascade arrangement. Flow con-
troller FC23 has a remote setpoint coming from TC2. Note the faceplate in Figure
12.9 for FC23 shows a remote setpoint. The flow transrnitter span is 200 lb-
mol/hr. Relay-feedback testing gives TL settings of Kc = 11 and 'e¡ = 14 minutes.
258 Chapter 12
,-----------~.~~.----------~
~3----~i LC22
F21 I
f2in f2 pp30ur v220ut
\/21 V22
b2
~
LC21 ,
v240ut
V24
V13
v150ut
vap1
Beilup
Te b1
Rebeiler
Heat-Integrated Distillation 259
qraulC@Main
lag528
The other controller TC2B changes the heat input in the auxiliary reboiler.
The "valve" is sized for a maximum heat input of lxl0 6 BtuIbr. Relay-feedback
testing gives TL settings of Kc = 22 and 'L¡ = 9.3 minutes. 1t should be emphasized
that the use of these two controllers in parallel is not what would be done in a real
plant, nor what is done in the AspenDynarnics simulation discussed later in this
chapter. It is one way to model split-range valve setups in HYSYS. Figure 12.9
shows the final control scheme with all controller faceplates.
12.4.3 Results
Figures 12.10 through 12.12 give results for feed flowrate disturbances. At
time equal 10 minutes, the feed to the HP column is increased fi:om 100 to 120 lb-
mollhr. At time equal 90 minutes, the feed to the LP cohunn is decreased to 80 lb-
mol/hr. Finally at time equal 150 minutes, the feed to the LP column is increased
to 110 lb-mollhr. The system rides through these disturban ces with good tempera-
ture control and gradual changes in product flows. Figure 12.10 gives product and
feed flowrates.
Figure 12.11 shows that temperature in the HP column is well controlled,
with a drop of only about l°F for the 20% step change in feed. Pressure and tem-
perature are returned to their setpoints in about 60 minutes. The LP column is not
affected at all by the change in feed to the HP column (see Figure 12.12).
260 Chapter 12
T2
OP2B
25
Heat-Integrated Columns
~
.P3~
~
'
V2
~ cmmEB f!J
AAUX
COL
7
e
24
V6
, u
~T:
Vll
~
6 V5
,,<:>
2ü 81
V4
L -_ _----j 10l------1><1<é----- 1 9 1 - - - - -
There are no explicit recycle blocles because AspenPlus does not require
their use. The selection of "tear stream" is supposed to be automatic. In theory,
you simply make aH the connections, specify aH the necessary parameter values
and runo However, if convergence does not occur (which usuaHy happens), you are
lefi in tlle darle as to what the problem is. Therefore, 1 find it much more effective
to break the connections in the recycle streams and manuaHy set them. Afier aIl
the problems with the individual units have been straightened out and the discon-
nected flowsheet has converged, the recycle streams are connected. Remember to
explicitly specify them as Tear Streams.
264 Clhapter 12
After the equipment sizes are provided, the file is exported into AspenDy-
namics. Figure 12.14 shows the initial window that opens with the default control-
lers. Note that there is a pressure controller on the HP cohunn and on the HP re-
flux dnl1Il. The latter is initialized with its OP connected to valve VIO. The col-
urnn pressure controller is removed, and the output signal of the dnnn pressure
controller is connected to the heat duty ofthe auxiliary condenser.
Heat-Integrated Columns
25
~ ¡ - - I - - - - I [ i l l f - - - - - - - - U:C"-'_~""".J.-
~ CQNRE9
v,
'-----110 1-----IXl<ó------I19I------.J
The level controllers are cOilllected, and the temperature controllers are in-
stalled with one 0.5 minute lag and a 0.5 minute deadtime in the loops. ll1e man-
ual relay-feedback test seems to work better with both of these elements, com-
pared to using two lags.
The split-ranged valve setup in AspenDynarnics uses the Split control
model. The AH Variables view of Split is shown in Figure 12.15. This device gets
its input from the temperature controller TC2, which is set up so that the normal
controller output signal is 50%. This OP signal from TC2, which is reverse acting,
is specified as the input to the Split block. This block has two outputs, which are
sent to two places. The first goes to the setpoint of a remote-set flow controller
(FC22). The second goes to change the heat duty of the auxiliary reboiler. The
steady-state values ofthe two outputs are 137.llb-moI/hr and -O.134xI06 BtuJhr
when the TC2 temperature controller output signal is at the steady-state 50% level.
Heat-Integrated Distillation 265
A. Output 1: The range of the first output is specified to be from O to 274.2 lb-
mol/hr as the controller output signal changes fi'om Oto 100%.
Figure 12.16 illustrates the relationships between the input signal to the Split
block (TC2 controller output signal) and the two output signals from the Split
block. Relay-feedback tests are run on TC1 and TC2, giving the results shown in
Table 12.2 for the TL settings.
Figures 12.17 and 12.18 give the flowsheet with all controllers installed and
all faceplates shown.
TC1 TC2
HPCo1umn LPCo1umn
Temperature Transmitter Span (OF) 350-350 150-250
274 0.2
Output2
=HcatDuty
Outputl
= FC22
Em;,:
(l06Btu/hr)
¡¡~il)J 137
(lb-molJhr) -0.134
···········-OA7··· IL.......J~.....J;=--J.="'
o
o 50 100 O 50 101!
TC2 OP Signal
TC2 OP Signa!
,-----------------------------------------------------,
1 i 25
--~~~-, -®--::----
~ :RAUX
é-------1191-----.J
: lagl DT1 TCl :
,>{g--)@]->c--------;
12.5.3 Results
Figures 12.19 through 12.21 give results when step disturbances in the two
feed flowrates are made. At time equal 0.5 hours, feed flow F 1 to the HP colurnn is
increased from 100 to 120 lb-mollhr. At time equal2 hours, feed flow F 2 to the LP
colurnn is decreased from 100 to 80 lb-mollhr. Finally at time equal 4 hours, LP
feed is increased to 110 lb-mollhr.
The temperature control in the two colurnns predicted by AspenDynamics is
not as tight as that predicted by HYSYS. Deviations of about 5°F are seen in Fig-
ures 12.20 and 12.21, while Figures 12.10 and 12.11 show deviations ofless that 1
°F. This is because the controller gains used in HYSYS are larger than those used
in AspenDynamics. The comparison is not exactly a fair one because two 0.5 min-
ute lags are used in HYSYS, while one 0.5 minute lag and one 0.5 minute dead-
time are used in AspenDynamics because the relay-feedback tests seem to work
better with these combinations.
l . .: · · · · · · · · · · · · · · · · · ;· · · · · · . . . .
,,
n~~:··················T·······································1
,,
~
,,,
,,, ,,
,,,
Fl ,,, ,,
--------------.-----------------._------------------.---
§ f - - - - ' - - - - - - - - i ......................... . F2
li1 ......•••••••..........••••••••..........•••••••..........••••••••.........•••••••........••••••••......•.•••••••.........• ;
12 .••••.........; ••.........•••••••....•......•••••••.........•••••••••........•••••••........••••••..........•••••••......•
:~lm~B2:m·~~~~2mni
Time Hours
268 Chapter 12
~ ~
~
~
~
:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: Ql .:::::::::::::::::::::::::::::::::::::::::::::::::::::J
~
~ ~
:2 r;:¡
~
"'._-------- -
~
~ ~ o_L----------------+----------------+---------------~
TimüHout$
-
ª- T2
!
___ o_o_o. ----------------------------------------1------------------------------------------:
;,
¡:
~
!:l
~
!'!
-
I QRaux
- -
lB
~
¡: ¡¡l
TimeHour~
Heat-Integrated Distillaíion 269
Both simulators, however, show the interaction between fue two colurnns
for changes in the feed to the LP colurnn. The pressure in fue HP colurnn is af-
fected when the circulation flow (FR) through the condenser/reboiler responses to
changes in the temperature controller TC2 in the LP colurnn. However, changes in
fue feed flow to fue HP colurnn have very little effect on the LP colurnn because
the auxiliary condenser control s HP colurnn pressure quite well.
12.6 Conclusion
We have shown how two clistillation colurnns that are coupled by energy
flows can be successfully simulated in both commercial simulators. Results are
similar, but not identical. Setting up auxiliary heat exchangers and fue use of split-
ranged valves are important parts ofthe simulation.
In the next chapter we studya multi-unit process consisting of a reaction
section and a separation section with gas recyc1e. In Chapter 14 we willlook at a
similar process except the separation involves a clistillation column and the recyc1e
is a liquid, which means a vaporizer must be used.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
ha ter 13
Tubular Reactor with as
Recycle Process
13.1 Introduction
In the last two chapters, we considered systems with two distillation col-
umns that were interconnected by either material recyc1e streams or energy. The
coupling of the units requires that the dynamics and control of the entire process
must be explored.
We continue our multi-unit examples in this chapter with a process that con-
tains a reactor, two heat exchangers, a compressor and a separator drum. The reac-
tor operates at high temperature and pressure with gas-phase reactions. Energy
recovery is important, so preheating of the feed by the hot reactor effluent is in-
corporated in the designo This feedback of energy malees control more difficult.
Since per-pass conversion is only moderate and an excess of one ofthe reactants is
required, there is a large gas recycle stream.
13.2.1 Flowsheet
Figure 13.1 shows the HYSYS flowsheet ofthe process. The chernistry con-
sists oftwo reactions:
Toluene + 2 Hydrogen ~ Benzene + Methane
2 Benzene <=> Diphenyl
271
272 Chapter 13
The first reaction is exothermic (-18,000 Btu/lb-mole), and the second is slightly
endothermic (3500 Btu/lb-mole).
F~'¡;;V><'t--"V"'lO"'-U'--'
~Dut
toltot Y2
hout
Cond
~
Uquld
V3 v30ut
Two fresh feeds streams are introduced into the process: a gaseous fresh hy-
drogen feed (484 lb-mollhr, 98 mol% Hz and 2 mol% methane) and a liquid tolu-
ene feed (370 lb-mollhr). These are combined with a large gas recycle stream,
which is a mixture ofhydrogen and methane. The mixed stream is heated in feed-
effluent heat exchanger (FEHE), using the hot reactor effluent. A fired furnace
follows the heat exchanger to raise the temperature of the reactor inlet to 1150°F.
The pressure at the reactor inlet is about 521 psia.
The reactor is an adiabatic tubular reactor with no catalyst. The vessel is
9.53 ft in diameter and 57 ft in length. There are 376 lb-mol/hr of toluene and
2132 lb-mollhr of hydrogen in the reactor feed. The large excess of hydrogen is
needed to prevent coking in the reactor at these high temperatures. The reactor
effluent contains 106 lb-mol/hr of toluene, so the per-pass conversion is 72%.
There are 4.8 lb-mollhr of diphenyl produced. The exothermic first reaction causes
an adiabatic temperature rise through the reactor of 72°F (1222°F exit tempera-
ture).
The hot reactor effluent is quenched to 1130°F by adding a cold liquid
stream (135 lb-mollhr) to prevent coking. This hot stream enters a large heat ex-
changer (30,000 W) in which it is cooled to 252°F. The overall heat-transfer coef-
ficient is low (20 Btu/hr-W-OF) because of the gas/gas system. Then a water-
cooled heat exchanger is used to cool the stream to 113°F. Sorne of the stream
condenses to form a mixture of mostly benzene, toluene and diphenyl.
Gas Recyc~e 273
The gas and liquid phases are separated in a separator dnun. A portion ofthe
gas fi'om the dnun is purged (476lb-mol/hr) to remove the methane that is formed
in the reaction. The composition ofthis purge is about 60 mol% methane and 40
mol% hydrogen. The rest ofthe gas (3990 lb-mollhr) is compressed and recycled
back to the front end ofthe process. The liquid product streanl (377lb-mollhr) is a
mixture ofmostly benzene, toluene and diphenyl. In Chapter 15 this stream will be
sent to a separation section consisting ofthree distillation columns.
Kinetic expressions for the two reactions are given in Luyben et al. ("Plant-
wide Process Control", McGraw-Hill, 1999, page 295). However, when these
were used the conversion of toluene predicted by HYSYS was essentially 100%.
An empirical approach was taken. TIle pre-exponential factors in the two reactions
were varied until the molar flowrates oftoluene and diphenylleaving the reactor
were close to those used by Douglas. The equations used in the HYSYS sinmla-
tion are:
Rj = PTP~5 (3.686xl 0 6
) exp( - 9~~00)
Ro = pi (9XI0 4
)exp (-90,800) - PDPH (2.553xl0 5 ) exp (- 90,800)
- RT RT
where reaction rates have units oflb-mol/min-ft3 , pressures are in psia, activation
energy is in Btu/lb-mole and temperature is in Rankin.
Figure 13.1 gives the flowsheet showing that there are three recycle blocks.
The steady state is converged by fixing the fresh feed streams and guessing the
flowrate and composition ofthe gas recycle stream. Then the flow and composi-
tion of the mixed stream after the quench must be guessed (its temperature is
specified at 1150°F). Now the heat exchanger equations can be sol ved, as can the
fumace since its exit temperature is specified to be 1150°F. Then the reactor equa-
tions can be solved.
Now guesses ofthe quench flowrate and composition are made and recycle
block RCY -1 can be activated and converged. Then the rest of the units can be
solved, and RCY-3 can be activated. Finally the purge flowrate is specified to be
274 Ghapter 13
4761b-mollhr, and RCY-2 can be activated. Figure 13.2 gives the workbook with
aH streams in the flowsheet.
The reactor volume (4000 ft3) provides the largest capacitance in the proc-
ess. Other volumes inc1ude:
Control val ves on the fresh feed streams, the purge and the liquid product
are sized at 50% open and 50 psi pressure drops. The compres sor is run with con-
stant work.
Figure 13.3 gives the control structure used in this gas recycle system and
shows aH the controHer faceplates. The following loops are installed:
The first loop described aboye (system pressure control) is one ofthe most
important. The pressure in this gas-filled system is basically affected by three
things: the :fi:esh feeds into the system, purge flow out and the rate of condensation
in the condenser. The flowrate offresh hydrogen is 484lb-mollhr and the flowrate
ofthe purge is 476 lb-mollhr, so either ofthese streams could be used for pressure
control. However, the purge rate has a direct impact on methane impmity in the
gas recycle, so it is chosen to control composition. This leaves fresh hydrogen feed
to control pressure.
This particular process is somewhat atypical for this type of system in which
a purge stream is used. Usuallya small amount of an inert is in one of the feeds or
is generated in the system, so the purge flowrate is typically much smaller than the
fresh feed. In these situations, the use of purge flow to control pressure is com-
pletely ineffective because it is so small.
Notice that there is no control ofthe gas recycle flowrate. The power to the
compres sor is fixed at the steady-state value, so the gas circulation rate through the
gas loop is essentially constant. This mode of operation (constant speed or con-
stant power set at the maximun1 value) is typical of what is used in many plants
with gas recycle. At the design stage, the optimum values for reactor size and re-
cycle flowrate are detemlined by balancing capital costs of the reactor and com-
pressor with energy cost of compression. Once the investment in equipment has
been made, the operating economics typically indicate that the optimum operating
condition is to run the gas recycle at its maximum. This gives the highest yield of
the desired products, which normally justifies the energy cost of compression.
276 Chapter 13
13.3.4 Results
Figures 13.4 and 13.5 show results ofthe dynamic simulation. Two distur-
bances are made. At time equal 10 minutes, a step decrease in the :fi:esh toluene
feed is made from 370 to 300 lb-mollhr. At 60 minutes, the setpoint ofthe reactor
inlet temperature controller is increased :fi:om 1150 to 1155°F.
The decrease in toluene feed causes the reaction rate to slow up since tolu-
ene concentration clrops. This causes the pressure in the system to increase. The
peak in the pressure Ís about 10 psi aboye the setpoint of 485 psia. The pressure
controller cuts back on the :fi:esh hydrogen feed. As expected, the system ends up
making les s liquid product and less purge. Reactor inlet temperature is well con-
trolled with a peak deviation of about 8°F. Quench temperature deviation is only
about 2°F.
The increase in reactor in1et temperature setpoint causes an increase in reac-
tion rate, which clrops pressure and brings in slightly more hydrogen :fi:esh feed.
Gas Recycle 277
The same approach used in the section aboye was used to find the kinetic
parameters that gave the specified molar flowrates of toluene and diphenyl in the
reactor effluent. The resulting equations are:
where reaction rates have units of k-mol/sec-m3, pressures are in Pascals, activa-
tion energy is in cal/mole and temperature is in Kelvin. These parameter values
gave 7.S lb-mollhr of diphenyl and 8S.3 lb-mollhr oftoluene in the reactor effluent
at a temperature of 1132°F.
The AspenPlus flowsheet is shown in Figure 13.6. It is converged in the
same way as used in the HYSYS simulation by manually breaking the "tear"
streams and converging parts of the process until the convergence of the whole
process is achieved. All equipment sizes are entered in the Dynarnic views, and
control valves are sized.
13.4.2 Dynamics
Figure 13.7 shows the window that opens when the file is exported into As-
penDynamics. Controllers are placed on the separator drum for level and pressure,
but no output connections are made. Figure 13.8 shows the flowsheet with all con-
trollers installed. Figure 13.9 shows the window with all the controller faceplates
displayed.
The control structure is the same as described aboye with one exception.
The flowrate ofthe total toluene feed is controlled by valve V3, which adjusts the
fresh toluene feed. The other toluene stream TREC is flow controlled. We will use
this setup in a later chapter in which the three-colurnn separation section is added
to this reaction section. Then the TREC stream wiIl come from a distillation col-
urnn.
The reactor inlet temperature control loop (TCR) has two dynarnic ele-
ments: a O.S minute deadtime and a 0.5 minute first-order lag. Relay-feedback
testing gives an ultimate gain of 0.88 and an ultimate period of 4.2 minutes. The
TL settings are Kc = 0.25 and 'tI = 9 minutes.
Gas Recyde 279
161
HDA Reactor Section 575
r---------~~------~
~
FTOL 7
V3 11
22
TREC1-_~><V:}lO=-_-IZll--_---.J
280 Chapter 13
r-------------------~GREe~------------------~
Teo
~------->o----------------:
r-------~~~------~
PO' I DT la9
~-------, :[~~v-[;¡J<----:
TeR J
,:-0<2
,----------- 7
FCT :
~T1
13.4.3 Results
Figures 13.10 and 13.11 give results for disturbances in toluene feed flowrate and
reactor iPJet temperature. At time equal 0.5 hours, total toluene feed flowrate is
decreased from 370 to 300 lb-mollhr. At time equal 3 hours, the setpoint of the
reactor inlet temperature controller is increased from 1150 to 1160°F.
The drop in toluene feed results in reductions in the fresh hydrogen feed
and the purge flowrate. There is a rapid and large increase in reactor inlet tempera-
ture when the toluene feed flowrate is reduced. It takes about 40 minutes to bring
the process back to steady-state conditions. Pressure excursions of about 10 psi
occur.
The increase in reactor inlet temperature produces higher reaction rates and
more product is produced and more hydrogen is fed.
:~~~~~~~~~_~~[--~--'~;-~;~~~~-:---~~]~~~~~~~~---T----!----T---L~~::~~~~~L~::;::~~~~::
o -
LD , I I : : : :
o , , ,Purge ::::,
:-----,:------,' --- ----- ----T----r----T--T
o _____ . . ______ _ ____ .. _____ ... ______ ... _____ ... ______ ... ____ .. ______ ..... __ ._ .. ______ 1- _ _ _ _ _ .. _ _ _ _ _ _ ,_
,:::::::::::
~ : : : --r ---~------r----T----\-
:------~-----r_----~-----t----: -- r----r-----'------:-
Quench
~ -----~------¡-----~------ -----;-----r---;----- --- --1------:-----1------:-----1------~--- --1------:-
0.25 0.5 0.75 1.25 1.5 1.75 2.25 2.5 2.75 3.25 3.5 3.75
TtmeHours
282 Chapter 13
13.5 Conclusion
In this chapter we have illustrated a typical process with gas recycle, fresh
feed makeup streams, energy recovery and a simple separation system. In the next
chapter, we consider a process where the separation section is more complex, re-
quiring a distillation column.
The dynamics of gas systems are fairly fast since the residence times are
usually seconds to several minutes. In liquid systems, residence times are minutes
to hours, so the dynarnics are ofien much slower.
hapter 14
Reactor/Column with liquid
Recycle
14.1 Introduction
Inthe last chapter we simulated a process with a gas-phase tubular reactor
and a large gas recyc1e stream. The product and unreacted components in the reac-
tor effluent were separated by simply cooling the stream and condensing the heavy
products. These were removed in the liquid stream fi:om a simple flash drurn. The
gas phase from the drurn was compressed and recyc1ed. Thus the separation sec-
tion was a one-stage flash. This was feasible because of the large difference be-
tween the light reactant component (hydrogen) and the heavy product (benzene).
In this chapter we look at a process that features a more complex separation
section. The reactant and the product components have similar volatilities, so a
single-stage flash does not provide sufficient separation. Instead of a simple drurn,
we use a distillation colurnn for the separation.
The recyc1e stream in this process is in the liquid phase. This is desirable be-
cause it is much less expensive to pump liquid than to compress gas. However, the
reaction occurs in the gas phase, so the liquid recyc1e stream must be vaporized
before feeding it into the reactor. This vapOlizer presents sorne interesting simula-
tion challenges as we will see below.
The introduction of the fresh feed into the process is also different in this
process. The feed is not apure reactant but is an impure mixture of sorne reactant,
sorne product and an inert component. Instead of feeding this impure fresh feed
into the reactor, it is fed into the distillation colurnn. This provides a reactor feed
stream that is richer in reactant, which reduces reactor size and recyc1e flowrate.
However, it makes the control ofthe process somewhat more complexo
283
284 Cl'lapter 14
nents are present in the cmde oil processed in a petroleum refinery. They also are
produced in other units that crack heavy oils into lighter material.
The isobutane is an important chemical intelmediate component. 1t is used
as a reactant in many petrochemical processes. For example, in the aIkylation
process (see Chapter 16) isobutane and an olefin (e.g., butene) are reacted to form
an important gasoline blending component. So isobutane is a valuable petrochemi-
cal feed stock.
On the other hand, nonnal butane is not worth as mucho Sorne normal bu-
tane can be blended into gasoline, but its octane munber is low and the amount
that can be blended is limited by vapor-pressure (RVP) constraints, particularly in
the summer high-demand periodo
The typical refinery is ofien short on isobutane and long on normal butane.
Therefore sorne refineries operate an isomelization unit to convert normal to iso.
14.2.1 Chemistry
14.2.2 Flowsheet
The per-pass conversion is about 60%, so the urrreacted nC4 must be sepa-
rated fi:om the product iC 4 . The normal boiling points of these two isomers are
fairly close (lO.9°F versus 31.1 °F). The distiIlation colurnn required to malee this
separation (caIled a deisobutanizer, DIB) has a fairly large number of trays (50)
and requires a fairly high reflux ratio (5.6). The operating pressure ofthe colurnn
Uquid Recycle 285
is set at 100 psia so that cooling water can be used in the condenser (reflux-drurn
temperature is 125°F).
The product stream is the distillate from the top of the colurnn. We specify
that the impurity ofnC4 in this stream is 2 mol%. The bottoms from the colurnn is
the recyc1e stream. It is pumped up to a pressure high enough to get it back into
the reactor, which is operating at 320 psia.
This liquid recycle stream must be vaporized and heated to the desired reac-
tor inlet temperature. In theory, this can be done in a single unit. In practice, it is
ofien split up into two operations because of the complex fluid mechanics of two-
phase heat transfer. So the liquid bottoms stream from the distillation colurnn is
fed into a vaporizer (a kettle reboiler) where steam is used to boil the liquid, pro-
ducing saturated vapor. This vapor stream is then superheated in a second heater
(fumace). Figure 14.1 gives the flowsheet.
cout
RCY-1
v60ut rout
v6
pfr
,
dibfeed
...---+-----
w
'- fumace
,
vaporizer
qf
ff
v1
vi v50ut
v5
The hot reactor effluent is cooled and fed into the distillation colurnn on
Tray 30 (counting from the bottom). There is a second feed stream introduced on
Tray 20. This is the fresh feed to the unit. It is a mixture ofpropane, isobutane and
normal butane that comes from an upstreanl refinery light ends unit. Feeding the
fresh feed into the colurnn keeps the propane impurity out of the reactor, since it
goes out the top ofthe DIB. The purity ofthe bottoms recyc1e stream is an impor-
tant design optimization variable. The higher the concentration ofnC4 , the smaller
the reactor and the recyc1e, but the more energy is required in the colurnn. A fairly
impure bottoms is used in the example (70 mol% nC4).
286 Chapter 14
Control valves are sized using reasonable pressure drops, and the pump is
sized to provide the pressure need to get the recycle stream into the reaction sec-
tion operating at the higher pressure.
The usual design methods are used to size the equipment. Tab1e 14.1 sum-
marizes the major components.
BE
,
0:1226 869.9 859.9 869.9 869.9
'.
',12: 5.0569+004 5.0569+004· 5.056e+004 5.056e+004
'7072 -4. 14,,+007 . ,.4.1140+007 . '4..1 149+007 §57ge+007
CompMols e) . 0.0000 ).0000 .. 0.- '000 0.0000 ).0000
Comp ~1010 Frac O-Sutano) 0.2712 0.7297 0:3005 ·0.7297 1.7297
Como Mele Frac n-Buteno) 0.7288 0.2703 0.6995 '.0.210}. 0.2703 l.
-' -- _. __... _ - - - - -
~".
. ..._ " " - - - - - - - ...."" ,~. __...._-"----'---- . - _ . _ - - - - - - - - -- ----,..- - - - - - . ... ------
All.of these problems make this simulation more challenging than the gas
recyc1e process. A lUlit-by-unit approach was taken to get the system switched to
dynamics. The column was simulated first with fixed feed streams and run in dy-
namics. Then the vaporizer was added. Ifthere were a liquid stream from the ves-
sel, it could control leve!. However, there is no liquid product (the flowsheet
shows a liquid line and a val ve, but this is set to give a very small flow of 0.1 lb-
mollhr). After trying many altematives, the scheme that seemed to work best is to
controllevel with a valve in the vapor line and control pressure with heat input.
When the furnace was added, the control valve was moved to the furnace
outlet, and this three-unit process was run in dynamics. Then the reactor was
added, and the control valve was moved to the reactor outlet. Next the condenser
was added. Finally, the recyc1e stream to the column was connected, and the
whole process was run in dynamics. This modular approach was needed because
ofthe sensitivity ofthe vaporizer pressure and levelloops.
1. The bottoms stream from the column is flow controlled. This pro-
vides a steady flow to the vaporizer/reaction section of the process.
However, this appears to violate the First Law ofDistillation Con-
trol (you can't fix the flow of either product and also control a
composition or temperature). However, a more precise statement of
this law is that you can't fix the product-to-feed ratio. Note that the
feed rate to the DIB is not fixed in this control structure since the
fresh feed flowrate is changed.
2. Fresh feed is manipulated to control bottoms leve!. The base ofthe
column is mostly nC4 , and base level tells us if we are converting
or not converting all the nC4 being fed.
3. Reflux is flow controlled.
4. Distillate flow is manipulated to control distillate purity (mol%
nC4). Note that a tray temperature is not used in this system be-
cause temperatures don't change much from tray to tray since the
components have similar boiling points. Direct composition control
is used.
5. Reflux drum level is controlled by reboiler heat input. This is not a
conventional structure and would not be used for a colUlTh""1 in isola-
tion. However, the column is part of a multi-lUlit plant. Its control
structure must fit into tlle plantwide control scheme. The dynamics
Liquid Recycle 289
of this loop are fine because vapor rate changes are felt quickly
throughout the column.
6. Vaporizer pressure is controlled by heat input.
7. Vaporizer level is controlled by the valve V6located after the reac-
tor.
8. Reactor inlet temperature is controlled by manipulating heat input
to the fumace.
9. Condenser exit temperature is controlled by manipulating heat re-
moval from the condenser.
The last loop is not the setup that would be used in a real planto Controlling
the temperature of a condensing stream usually does not work because the sub-
cooling amounts to only a small fraction ofthe total heat removal. In a real plant,
the condensate from the condenser would go to a drum whose pressure is con-
trolled by the heat removal in the condenser. Then another valve would control the
level in the drum. We simplify the simulation by not including all this detail. A P-
onIy controller is used since tight temperature control is not important.
The main loop that requires controller tuning is the distillate composition
loop. Because of the many trays and the low relative volatility, compositions in
this column change very slowly. Two 2-minute lags are used in this composition
measurement loop. A composition transmitter range of Oto 4 mol% nC4 is used.
Relay-feedback tests give TL setting Kc = 0.34 and 1:1 = 84 minutes. This is a very
slowloop.
The controller tuning constants, action, transrnitter ranges and valve ranges
are given in Table 14.2 for the other loops.
14.3.2 Results
Figure 14.5 gives results for a step change in the setpoint of the bottoms
flow controller (the recycle flowrate) from 870 to 800 lb-mollhr. The nC4 impurity
in the distillate (xD) slowly drops, and distillate flowrate is increased by the com-
position controller. It takes over four hours for distillate composition to return
close to its setpoint.
Fresh feed initially decreases because the decrease in bottoms flow raises
base level. However, eventually the fresh feed increases to match the distillate
flow rateo These two streams must be identical at steady state. The increase in
fresh feed is from 526 to about 557 lb-mollhr.
290 Chapter 14
Tout
Pvap
xD
292 Chapter 14
Tin
Tin
I
p
liquid Recycle 295
PFA
Figure 14.9 shows the initial window that opens. Colurnn pressure and re-
flux-drum levelloops are closed, as are a reactor pressure loop and a vaporizer
levelloop. The colurnn pressure loop is the only one configured as we want, so the
controller connections are changed and additional controllers are added to give the
desired control structure shown in Figure 14.10.
The same controller tuning constants, transmitter spans, valve sizes and
composition lags used in the HYSYS simulation are used in the AspenDynamics
simulation. The Ziegler-Nichols settings are used in the composition controller.
296 Chapter 14
CONDENSE ""
r----------------------------------------------------.",
AGUr
r-----~DlIIBBFFElEE'DDr_------4V~~4
r----------------------------------------------------,
v ADUT :
~ :
lag1 lag2 ce
lC2 ~·>!tJ·-,-·>!tJ·--·?()··1
.-?(). :---------"'-''-'__'-l" o :
V4
,
, FOl
~.;
1°.-..1 ,..........
:.. ..... j
I : : :
RECl'CLE
_ V3 ¡' 2 __
Pl
V5
14.4.2 Results
Figures 14.11 and 14.12 give results for two disturbances: a decrease in re-
cyc1e flowrate and an increase in reactor inlet temperature. In Figure 14.11 the
setpoint of the column bottoms flow controller is decreased from 870 to 800 lb-
mollhr at time equal 0.5 hours. There is an initial decrease in the flowrate of fresh
feed F because base level increases when bottoms flow Bis decreased. However,
the lower flowrate through the reactor results in a higher exit temperature, which
Uquid Recycle 297
produces more iC4 in the reactor effluent. The richer column feed produces a de-
crease in the nC4 impurity in the distillate, so the composition controller increases
the distillate flowrate D. This eventually drops base level, and the level controller
brings in more fresh feed. At steady state, which takes about 3 hours to attain, the
flowrates of F and D must be identical, which they are in Figure 14.11 A. The in-
crease in fresh feed is from 526 to about 560 Ib-m01/lu·. Notice that this increase is
about the same as that predicted by the HYSYS simulation. The increase in reactor
exit temperature is also about the same (T out increases from 429 to 442°F) in the
two simulators. .
In Figure 14.12, the setpoint ofthe reactor inlet temperature controller is in-
creased from 390 to 400°F. Fresh feed increases from 526 to 6151b-mollhr, which
is slightly larger than the 602 lb-mollhr predicted in the HYSYS simulation.
""""""""""'""'""""""""':::::::::::L:::::::::::::::::::::""
:1::'"""""":,:::::::::~~~"""""""""",!"""",~"",)"""""""""",~,L"""""""".i~
:"" """~::¡""::::l'::::::: m""""m'l,m""m"",m"",""""::::::::"", ""m""
_.- ---~- _.- ______ .~ ___ B ---------t-... ---.1..----.) ... ---.. 1--- ------------_ .. ; .. ---
_______ ,_____ ...., ._____ ..... _____ ..... _____ L_______ 1. ....... -l ........ l. ........l ................~ ..............
o ••• ~ •••••••••••••• o •••••••••••••••••••• ~. .. t........ 1,......... ~ ........ j, .0 • • • • • • ~ ••••••••••••••
~
"'--"1 ........ ....•• o.l .•......:......•.• ; ••..... L ....... L....... J. ........L....... i •••• '••••••••• ~ • o'" ••. ' ••••
Tim"Hou",
Uquid Recycle 299
14.5 Conclusion
The liquid recyc1e process considered in this chapter presents more simula-
tion challenges because ofthe vaporizer and distillation column. The control struc-
ture used for the process has sorne unusualloops in the distillation column because
of plantwide considerations.
In the next several chapters of this book, four complex flowsheets will be
studied that contain many plantwide control structures. These processes are com-
prised of many unit operations with recyc1e streams and heat integration. They
provide realistic examples of a typical chemical process.
I
j
j
j
j
j
j
j
j
j
j
j
j
j
j
j
j
j
j
j
j
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a I
plex lantwi e
r cesses
In this last part of the book, we illustrate fue dynamic simulation of two
complex multi-unit processes. These plants feature multiple recyc1e streams, heat
integration, complex separation sections and different types of reaction sections.
AH the tools and mefuods learned in fue previous chapters are used with fuese
processes.
In Chapter 15 we extend the HDA gas-phase adiabatic tubular reactor proc-
ess with a gas recyc1e studied in Chapter 13 to include a three-column distillation
separation system. The separation section is linked to the reaction section by a
liquid recyc1e stream of toluene. The three columns use fue direct separation se-
quence, removing light components from fue top of fue first column, benzene
product from fue top of the second and diphenyl byproduct from the bottom of fue
third. The distillate product from the top of the third column is a toluene liquid
recyc1e stream back to the reaction section.
Chapter 16 discusses fue alkylation process, which is widely used in fue pe-
troleum industry. The reaction section consists of multiple CSTRs wifu fue fresh
feed stream split among the reactors. The separation section contains three distilla-
tion columns. One has multiple feed streanlS. A large excess of one of the reac-
tants requires a large liquid recyc1e streanl.
In Chapter 17 we consider a flowsheet wifu two reactors, two columns and
two liquid recycle streams. The process chemistry is fue reaction of efuylene and
benzene to produce ethyl benzene.
Our final case-study is given in Chapter 18. The methyl al11ines process fea-
tures four recycle streams and three product stream produced in four distillation
colwnns, one of which is an extractive distillation column. An "on-demand" con-
trol structure is developed and tested.
301
302 PartlV
15.1 Introduction
The steady-state design of this process has been extensively explored by
Douglas in a number of papers and in bis textbook "Conceptual Design of Cherni-
cal Processes" (McGraw-Hill, 1988). The chernistry and the reaction section are
presented in Chapter 13. As you recall, the reactor is operated adiabaticaUy at bigh
temperature and pressure. The reaction occurs in the gas phase. A large excess of
hydrogen is used to suppress cracki.ng. The hot reactor effluent is used to preheat
the cold feed. A large gas recyc1e stream from the separator dnul.1 is compressed
and fed back to the reactor inlet.
In this chapter we add the separation section. Figure 15.1 shows the flow-
sheet. The liquid from the separator drum is a mixture ofmostly benzene, toluene
and diphenyl with a small amount of dissolved hydrogen and methane. This
stream must be separated into product, byproduct and toluene recyc1e streams. A
three-column distillation sequence is used since the volatilities ofthe various com-
ponents are quite different.
303
Figure 15.1 - HYSYS Flowsheet
(,.J
o
.¡::.
grecycle
i .r--~_~
RCY-2 purge V~
V4 v40ut
11111 tot
Rgas RCY-I
FFH2
VI
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i'-H>~ ['i~:
-)
[)\L
111
/\I ~ FuI'
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Rout qLlel1cl1
dlschg
~¡,
FFtol v20ut FEHEl ~-' RCY-3
Cornp
wl<cornp
V2
qfur
vllout
hout
MIX-l02 Vl'l
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RCY-4
d3
181"'"
.------1>-'
qc~
(12
.~
V8 v80ut
v50ut
V5
(')
qr3 :l"
Ql
1 ~I ~
.~;tt:x~
qr2 (j)
bi b3-1><1----:; ....
....
el
V7 C2 ~--.JP2
. V9
Vl0 vlOout
CJ1
HDA Process 305
The first column has 6 trays, is fed on Tray 3, operates at 150 psia and fea-
tures a pmiial condenser. The distillate vapor product is 18.9 lb-mollhr at 120°F
with a design specification of 4.2 mol% benzene. The bortoms product specifica-
tion is 1 ppm of methane. Figure 15.2 shows the Monitor view of the Design page
tab with these xd1 and xb1 specifications activated.
The co1umn is 1 ft in dianleter, and the reflux ratio is 1.57. Reflux drum
holdup is 7.5 ft3; base holdup is 250 fi3. Reboiler heat input is 4.4x10 6 Btu/hr. The
bortoms is fed into the second column.
The second COlUlllil has 27 lTays, is fed on Tray 15 and operates at 30 psia.
The distillate is the final benzene product, which has a steady-state flowrate of 271
lb-mollhr at 224°F. Note that with this high reflux-dnun temperature, this con-
denser could be heat integrated with an energy consUlning lmit at a lower tempera-
ture somewhere else in the plant. The two design specifications are 0.06 mol%
benzene in the bortoms and 0.03 mol% toluene in the distillate (99.97 mol% ben-
zene purity). See Figure 15.3.
The COlUlllil is 5.7 ft in dimneter, and the reflux ratio is 3. Reflux dlllm
holdup is 293 ft3; base holdup is 316 W. Reboiler heat input is l1.5x10 6 Btulhr.
The bortoms is fed into the third column.
The third colU11U1 has 7 trays, is fed on Tray 5 and operates at 30 psia. The
distillate product is 80.5 lb-mol/lu· at 283°F. At this temperature, low-pressure
steam could be generated. The two design specifications are 0.026 mol% toluene
in the bottoms and 0.002 mol% diphenyl in the distillate (99.93 mol% toluene
purity). See Figure 15.4.
The colU11U1 is 2.5 ft in diameter, and the reflux ratio is 0.32. Reflux drum
holdup is 36 :ft3; base holdup is 46 ft3. Reboiler heat input is 1.6x106 Btu/br. The
bottoms is the diphenyl byproduct and its flowrate is quite small (6.9 lb-molJhr)
compared to the distillate flowrate of 80.5 lb-molJhr. This has implications for the
base level control structure, as we discuss in the next section.
The distillate stream from this column is the recyc1e toluene. It is fed back
into the reaction section. Note that the flowrate ofthe fresh toluene stream is 292.5
lb-mol/hr. The per-pass conversion of the toluene through the reactor is (292.5 -
80.5)/292.5 = 0.72 (72%). So the toluene recyc1e stream is not a large one, but its
economic impact is significant.
FFlol
LC32
(,,)
(;)
(O
310 Chapter 15
~t=r
.------......- -
l' -lJ"'1
:l-~ .¡.
, '1
qc1
Condenser
Boílu
To
Reboiler b1
HDA Process 311
qc2
L r2~1
1d2
Maln
:z>
LC22
@M n
To
Reboiler b2
Reboil r
To qr3
Reboiler
LC31
A. Small Recycle Flows: The flowrate of the total toluene fed into the reaction
section (stream "tottol") is controlled by manipulating valve V2 on the toluene
fresh feed. This scheme works in this HDA process, which has a relatively small
recycle flowrate compared to the fresh feed. Many processes have much larger
recyc1e flows compared to the fresh feed. In this situation the control structure
312 Chapter 15
given aboye is not effective. The altemative scheme discussed below provides
much betler control.
B. Large Recyde Flows: Ifthe Jiesh makeup feed flow is quite a bit smaller than
the recycle flow, the control structure should be modified to that shown in Figure
15.10. The total to1uene is controlled by valve V3, which is now in the 1ine after
the fresh feed and recycle toluene have been combined. The valve V2 in the fresh
feed line control s the reflux-drum level. There is no valve in the distillate line from
the Recycle Column.
The control of reflux-drum 1evel in the Recycle Column is this key plant-
wide stmcture. We must feed into the system exactly the correct amount of fresh
toluene to perfectly match what is being consumed in the reactor. Essentially no
to1uene is lost in any of the product streams leaving the process. So the toluene
feed must perfectly balance the toluene consumption since the process acts as a
pure integrator (any difference between the input and the consumption results in a
gradual bui1dup or depletion). Some type ofinfonnation about the amount oftolu-
ene in the system must be avai1able so that it can be fed back to make the appro-
priate adjustments.
The place in the process where the toluene accumulates is in the top ofthe
Recycle Co1urnn. Ifthe level in the reflux drum is building, we are feeding in too
much to1uene, and visa versa. Therefore the level control manipulates valve V2 in
the toluene makeup lineo
Do not make the common mistake of thinking that the effect of V2 on the
reflux-mum level in the third colunm will take a long time. This is not true. There
is a flow controller FC1 setting the total toluene flow into the reaction section by
manipulating valve V3. Any change in the fresh feed flowrate makes an immedi-
ate change in the flowrate of the distillate stream fi:om the third column because
the total flowrate is constant. This means there is an immediate effect on reflux-
drumlevel.
Figure 15.11 shows the responses ofthe system to a disturbance in the reac-
tor inlet temperature controller setpoint from 1050 °F to 1055°F at time equa1 10
minutes. Reactor outlet temperature increases from 1222 to 1238°F, which results
in larger reaction rates in the reactor. The fresh feed of hym'ogen and the purge
flowrates respond quite quicldy, but it takes over two hours for the fresh toluene
feed to slowlyincrease from 276 to 3061b-mol!hr (see Figure 15.11A).
Figure 15.10 - Plantwide Control Structure for Large Recycle Flows ::r:
o
cc·····
'---1I :t>
~h,"
purge V4 2
II l. ecR -.' T5
(J)
(J)
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cm, .
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_-,-__
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. 1 .
r
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r Rm I
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"__ .;... Con "> ...._ ..._ liq ;+J Pl l' T3
~ ~
~C3~",---,Rtol .'
A.
RGY-4_._"_','-l ~'.~~~
I
-1
n I
I dt
C~G4S-_ '~,,-;:,
~-.....
rdi'j ~,;;t, r l"~ ~)J-
~.C3
.,~, tE!
Cl
I
,_
qrl
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,{, w>L:~,~~
d2 I . \¡.. B.
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....
CH
CH
V7 C2 wk2
314 Chapter 15
H FreshFeed
Figme 15.12 shows the subflowsheet for the C3 Recyc1e Coltmm with an
average temperature control scheme installed. TIle temperatmes on Trays 1, 2, 3
and 4 are averaged using a Selector block. The Connections page tab for this block
is shown, which we label "Average". Figure 15.l3 shows where the average op-
eration is specified. Other options inc1ude lligh and low selectors and the sum of
the inputs.
The output ofthe averaging block is fed into the temperature controller TR3.
Unfortunately HYSYS does not properly handle two elements in selies. So a direct
compatison carmot be made between single-temperatme control (with lags) and
average-temperature control with lags. Results of a relay-feedback test give TL
settings Kc = 0.6 and 1:1 = 25 minutes. Tllis gain is five times larger than the single-
temperatme control (with two 0.5 nlinute lags). As expected, Figure 15.14 shows
that there is much tighter and faster control oftemperature in C3.
HDA Process 317
19
Tl
T3
12
Cl
~_,,'!,15~
~
w
.....
te)
Figure 15. 16 -Initial Controllers in AspenDynamics VJ
N
o
19
~ V6
~3
-3
--'PCS
);:_, c__ ~C4
,' ___ J P2 V13
ío2l>Q~
LC9
;-?O
()
'={~~~[~Ü :r
DI
~
ro
...,
-'
<.TI
::r:
Figure 15 .17 - Plantwide Control Structure
e
:t>
¡;¡
a
()
, - - - - - - - - - - - - - 1 GREC 11----------- (J)
CII
CII
~',~¡-""
roI"P~~ ~
~
T2 :
T1
V3
: >1 -3
,
CC!\lD
L¡;, V10
I F1 1 V4
D.l<I<--: ---
l__~,
¡--:PC.3 LC32~!
¡---x>--_._~~-"_._--j
~f:'-:"l~0 TREC
~I ~2
~?>{¡J. __ .,-,.¡¡:::-¡._.- TC3
. __ , '1.':=J "··;>0·""
LC31 : (.oJ
, ~~!~~"EJ
N
-"
... J
~. _______ ______________ H _____ H
322 Chapter 15
15.5.1 Results
Initial testing with the control structure ShOWl1 in Figure 15.17 gave erratic
results. The sirnulation would fail quite frequently with a message indicating that
there was a severe Fortran error in the Recyc1e Column. The problem was found
to disappear when the control structure in C3 was changed to control Stage 7 tem-
perature (at 455°F) by manipulating reboiler heat input and controlling base leve1
with bottoms flow (V15). It is unc1ear why the original scheme would not work.
Relay-feedback testing with two 0.5-minute lags in the TC3 temperature
loop gives an ultimate gain of 1.25 and an ultinlate period of 3.4 minutes. The TL
settings are I<C = 0.4 and 1:1 = 7.5 minutes. Sirnulations results showed that the loop
was too underdamped, so the gain was reduced to Kc = 0.2.
Figures 15.19 through 15.22 give results for a 5°F step increase in the set-
point of the reactor inlet temperature controller at time equal 0.25 hours. Figure
15.19 shows what happens to conditions in the reactioll section. The increase in
reactor inlet temperature T in causes an increase in reactor exit temperature Tout '
Fresh hydrogen feed and purge flows increase quickly, but it takes about two
hours for the fresh toluene feed stream to increase to its new steady-state flowrate.
HDA Process 323
Figure 15.20 gives results for the Stabilizer Column. The proportional tem-
perature controller lets the temperature decrease slight1y (les s than 2°F). More
vapor distillate DI is removed. Figure 15.21 shows how variables respond in the
Product Column. Temperature is very well controlled. Bottoms flowrate decreases
because more toluene is consumed in the reactor and there is less to recycle. Distil-
late flowrate increases because more product is being produced (more hydrogen
feed and more toluene fresh-feed makeup) at the higher reactor temperature. Re-
member that the total toluene feed to the reaction section is held constant.
Figure 15.22 gives results for the Recycle Colrnllil. There is les s distillate
but more bottoms (more diphenyl produced). Temperature control is quite slow,
taking about 4 hours to return to setpoint. The maximlU11 deviation in temperature
is only about 5°F, despite the high temperature level (455°F) and the very large
temperature gradient from tray to tray.
!?J
?; ~
~ fi
§ ~
~ ~
~ i':
~ ~ ~
El S - 9. o ~ _____ _
:; § ~ §f ~ ~ ------
Q -r iil ~"-'··=···~·11"·'V"'-'~·~"··-
6 ~ ~ -.-- ..
~ ~ ~ q ~
el ~
q q ~ ------
;; .,
~
~ ~
;;
"
~ ~ R
!?, ~
- ~ ~
324 Chapter 15
~ _~ J---------
l~ 1~ l~ - - - - - - -
le: 1m l~ ~----:==t===i=======t========±====i
H1: l:J:r=~C:J::=~~-;;,:;-i-------t--+----j
- 'ci
~ ~
ro~ [~ .----------
~ @ ~ o~--~~----~----~----~----~----~----~----~
HDA Process 325
Fe
----->O------: 03 @
,____ r)~--~----f->- -~ti~--:
YH
L "m3
;__________ ,~, average lagl lil92
~~
,------------------------------------------------------------------------------------------
The scheme works ifthe simulation uses metric units, Now the temperatures
on Stages 5 through 8 are 148, 179, 260 and 292°C, givillg a total of 879°C. The
average temperature is 879/4 = 220 oc. Figure 15,24 shows the AH Variables view
for each ofthe surnmers and for the ratio block The faceplate for the TC3 control-
ler is also shown with a setpoint of220°C.
An altemative to using mehic units is to insert a "flowsheet equation" to
ca1culate the average temperature, We discuss this method of generating user-
supplied equations in Chapter 19,
045 05 055 06
TlmoHour~
Results for the two simulators are given in Table 15.1. The real-time factor
is the ratio of process time to elock time.
HYSYS AspenDynamics
Gateway 650 mHz 15 30
Dell1.8 GHz 27 50
15.7 Conclusion
In this chapter we have developed dynamic simulations ofthe well-studied
HDA process using both commercial simulators. These cases should be useful as
test-beds for process control researchers who wish to try out their new control
strategies on a realistically complex industrial process.
Some important plantwide control features have been pointed out and alter-
native control structures have been discussed.
In the next chapter we study an equally complex industria! process with
multiple interconnected units and severa! recyele streams.
ha ter 16
Ikylation Process
16.1 Introduction
In this chapter we explore another complex multi-unit process, which fea-
tures several unit operations, two recyele streams and many controlloops. There is
a reaction section consisting of three CSTRs in selies with one of the reactant
feeds split among the reactors. The other reactant is kept in excess by a large recy-
ele stream. The reactors operate at low temperature, so refrigeration is required to
remove the exothenllÍc heat ofreactiol1. Reactor cooling is achieved by autorefrig-
eratiol1 (evaporative cooling) in the HYSYS sirnulation and by direct refrigeration
in the AspenPlus simulation. The two fresh feeds contain inert components, so the
separation section must separate these fi:om the reactants and the products. The
separation section contains three distillation colurnns.
The control stmcture for this plantwide system contains some unusual con-
trol loops that handle the problems of (1) balancing component inventolies and
fresh feed addition rates, (2) maintaining product pulities of the three streams leav-
ing the process and (3) providing a large recyele Stream to maintain the desired
yield.
329
330 Chapter 16
The source of essentially all feed stocks in a refinery is the crude oil, which
arrives at the refinery via pipeline or tankers. Crude oil is a mixture of an enor-
mous number of hydrocarbon components. These components are mostly satu-
rated straight-chain hydrocarbons (paraffins) and saturated cyc1ical hydrocarbons
(naphthenes). Few unsaturated components (olefins) are present in the crude oil.
There are small amounts of isobutane in the crude.
The first separation of the crude occurs in a "pipe still", which is a very
large-diameter distillation colurnn. The feed is partially vaporized by an extensive
heat-exchanger network and filrnace. The colurnn has a rectification section, from
which an overhead product and a number of sidestream products are removed.
These products vary from light gases at the top from a partial condenser to heavy
oil at the bottom.
The light gases from the top are fed into a "saturated light ends" unit, which
is a number of distillation colurnn separating the various components. One ofthe
product streams from this unit contains the isobutane from the crude oil. However,
it also contains sorne propane impurity (5 mol%) and sorne normal butane impu-
rity (35 mol%). This "Sat C4" stream is fed into the alkylation unit as Qne ofthe
fresh feed streams. It provides sorne ofthe iC4 for the alleylation reaction.
The unsaturated butene olefins fed into the alkylation unit are typically pro-
duced in a catalytic cracking unit. Sorne ofthe heavy oil streams from fue pipestill
are fed into this tmit. The high-molecular weight saturated hydrocarbons are
"cracked" to produce coke and a wide variety of light hydrocarbons, inc1uding a
number of unsaturated components. The light components from the catalytic
cracking unit are separated in another light ends unit, and one of the streams from
this series of distillation colurnns is a mixture of C4 hydrocarbons: isobutane, bu-
tenes and normal butane. Sorne propane impurity is also present. The "BB" stream
is the source ofbutene for the alkylation units and also sorne ofthe iC4 . But there
is not enough iC4 in this stream to react with all the C4= that it contains. The differ-
ence must be provided by the Sat. C4 stream. The control scheme must be capable
of perfectly balancing the makeup feed flows to satisfy the reaction stoichiometry.
16.2.2 Chemistry
The main reaction is the combination of isobutane and butene to from iso-
octane.
te4 + e: -7 tes
However, there is an undesirable consecutive reaction ofbutene with iso-octane to
form dodecane.
tes e:
+ -7 I2 e
The actual chemistry is more complex than these two simple reactions, but
for our purposes, they capture the essence of the overall chemistry. The kinetic
Alkylatiorl 331
data is taken from a case study given by Mahajanam et al. (Ind. Eng. Chem. Res.
2001, 40, 3208). These exothernnc reactions are irreversible and occur in the liq-
uidphase.
The kinetic expressions assumed to be valid for the system are
-28,000
R¡ = 9.6xl0 13
e ¡¡¡:- (C iC4 ~ Cc: )
-35,000
R2 = 2.4xl0 17
e¡¡¡:- (Ccs {C c: )
where reaction rates are lb-mol/hr-ft3, activation energies have units of Btu/lb-
mole and concentrations are lb-mol/ff.
Note that the activation energy ofthe second reaction is larger than the first.
Therefore low temperature favors the desired first reaction. This is why the reac-
tion is carried out at low temperature (50°F).
The second undesirable reaction is also suppressed by keeping the concen-
tration ofbutene low. This is achieved in two ways. First, there is a large excess of
isobutane (ten to one) fed to the reaction section. Second, the butene feed is not a11
fed into the first reactor, but the stream is sp1it between the first two reactors.
The reaction uses sulfuric acid as a catalyst and is conducted in a heteroge-
neous two-phase liquid mixture of organic and acid phases. We will ignore the
acid phase in our sirnulations.
The flowsheets used in the HYSYS and AspenDynamics simulations dis-
cussed below are slight1y different. The reactors in the HYSYS flowsheet operate
adiabatically, and temperature is controlled by changing the amount of vapor re-
moved from each reactor. Since the AspenP1us CSTR model only has one exit
stream, this evaporative-cooling configuration is difficu1t to sirnulate. Therefore
we will use cooled CSTRs in the AspenPlus and AspenDynamics flowsheet. The
10cation of one ofthe distillation colurnns is also different.
Figure 16.1 gives the HYSYS simulation flowsheet. There are three CSTRs,
each with a v01ume of 100 ft3 and each is 80% full ofliquid. They operate at 50°F
and pressures of about 30 psia. The 1arge recycle stream (630 1b-mol!hr) is fed to
the first reactor along with 251b-mol!hr ofBB feed. The composition of the BB
w
W
N
Figure 16.1 - HYSYS Flowsheet of Autorefrigerated Alkylation Process
Wk~ _
V3 ~9t\lIl!
vaplot
"e
Compressor
disch /...
Cond
dondoul
Ta~>'l.p
Ltk
-~
wk3 P V5'<l--v5ott
~10UI
881
V1
-+
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l
J·2
R1 R3
~20UI
882
V2
..;-1 g-¡;:¡p~
~ V31
I
-+______W~k~·I____ ,
Racycle
<-~~---' .•- -
vI50uI V15 :r r, ;Y:tJ"J' [ qc1 ~
1
I~
~
v-t,"llln
.... ____--"="--__
.
J110UI
V8
qc3 ~ 1l)(COUI j
t fEHE
;t- ~ V~OUI
-1><l~~
vl40ul
V14 83
t><l"'--+--
V7 81 DIB
~<t--~
V4 SalC4
D8 ()
::r
!ll
-g
RCY-2 ....(l)
....
m
Aikyiation 333
'iessul'e [ P S i a 1 6 7 . 0 0 j
IvIble:IFlow[l~ínole/hr] 439.4.
100.0 1 .,. ". 20:00 1
439Al- - - - -..- - ;- -11.02 .-·~~629:6T
95,OD I . 80.00
~ 427.3
I 65.00
47.11
----- ---_ - .. __ ...............
MassFlow[lb/l)l] .. .
:omp Mole Frac (Ptope,ne)
iComp Mole Frac (rBulane)
3.626et004t..._..:..b!66e+004 I
0.0353
0.9470 '. . .0.9567
0.02811 ¡ '.' 4419
0.0000
0.0050
()
:::T
111
!Comp Mble Flac(l ..BLrteos) O.ooog I o.[)úbillo.nOD?1 0.0009 I 0.0019.1 0.0019 10~00081 O.DOoal' 'S.
¡C()mp Mole Frac (n-Bulane-j-'~ ...ro
I
COl)'lPMOle F:rac (3-Mheptilne)
Comp Mole Flfle (n ..C12)
...lo
O'l
»
Figure 16.28 - Stream Information ~
1[
O'
:::!
~~~--~~-. SatC4 v40LÍt 1
apaur Frilctian ~ .. 0.0000 - .0.0000
emperature[F] . '..... 90,00 -·--'-"''''90'''.1'''O'-I-~~~='-''---i~--''---'-'''''''''+--c-:'---''''='-''---i~,.----'-'''''''-' f---'-c----c---'~""c-i-c-~--"'!"?:""-
IPressure[psia} .'. . ~ '. ..:..125.0 85.00
MalarFlow Obmalelhr] . . . 3=5"".0"'0+1--'---'----c'3"'5'-=.0"'0+--'---'"-="'+~--'-""""'--f-C-,-,---',.,.'-"--'''''''"'+~-'--~'''''-++'-'-'--::'=''-+-·..-----'---'-''''~I
OfJo.u'r Fradioh
'emperatuiá[F]
IPressure[psiaJ 225.0.1 205.0 j 200.01 >203.01 65.áil.1 100.0 1 100.01 150.0
'MalárFlaw Obt\lole/hr] ~1 0 . 3 J 2 1 ó . : l j 4 . 4 [ j a l ¿ o ! i : 9 T ? 4 7 . 1 T I 2()5.9, ¡ 6 3 3 : H 4.402
Ivfass F1aw[lblhr] 1.202e+0041 Ü¡j2e~0¡j4T ~n-i9iTr--:;-;iIB2e'0041' 441'911.f82;;;0041 !i¡¡4ge~004í 197.2
Caníp Mole Frác(Propáne) 0.0688 I 0.O(61) I 0.9500 "·0.0500 f o.ooOOT-~~r-- -
0:05001 . 0.0352.1 0.9500
Comp MbleFratQ-BÍllane) 0.90881 0.94711 0.0500
~,apour.Fra.ction!!
l~emPérature [F] '.
0.1409}
47.95
0.0l31j
47.87 J'
'.1.0000, --:T'
103:4 _ ,. 112.21
I
0.0000,1. ~.....~. 0.0000
368.3
0.16.541
6B.89 i
0.2225 I
333.61 45.78 I
Pressure [psia], . . 31:00 1,. 30.00 1 4 5 . 0 0 . '.' 60.00 Lm 62.00 . . .
MolarFlow[lbmollillhr] 654.6j 527.0 I 0:0000 , lR98, p;- ~
IMEíss Flow [lb/hr]3.76ge+004 3.1 He+004[ 0:0000 1161 I , 3258
Cqmp Mole Frac (Propane) 0.0358 0.028Z l ' 0.1390'· 0.0000 1 -0.0000
ICompMoleFrBc(i,BlrtBne) .. ' u,9184 0:886z1 0.ff453 dm181. ·----0,0000
!Comp Mole Frac (l-Butene) 0.0247. I 0.0333' 0.0032 0.0013 1 0.0000
!CompMoleFrac(n'Butane) 0.02091 0.02891 0.0128 0.9869 I 0.0010
'Corrip Moté Frac (3-MheplBne)
'Comp Mole FracCn-CI2)
0.00011
0.0000
. 0.:0.2.2. 0 . . 1..... ..... .......
Q,Ollt'L .~.~
'.. 0.0000 [
. 0.00001
I
0.0000
0.0000
0.8938
0.1052
w
w
(Jj
336 Chapter 16
The three columns, the tank after the compressor, the knock-out clnun before
the compres sor and the heat exchanger must be sized for dynamic simulation. The
usual sizing methods are used, and results are slunmarized in Table 16.1.
Unit
DIE ColumTI ID (ft) 6
RefluxDnlln (ft3) 360
Base (ft3) 300
DP Colmllil ID (ft) 1.2
RefluxDnun (ft3) 20
Base (ft 3) 100
DB Colmllil ID (ft) 1
RefluxDnun (ft3) 9
Base (ft3) 40
KODnun Vollune (ft3) 100
Dnun Vollune (ft3) 62
FEHE Shell Volmne (ft3) 11
Tube Volmne (ft3) 11
Reactors (3) Total Volmne (80% liquid ihll) (ft3) 100
Figure 16.3 shows the main flowsheet with controller installed. Figure 16.4
shows all the controller faceplates. This plant has 24 loops that must be installed
and tlmed. Figures 16.5 through 16.7 show the sub-flowsheets for the cohunns
with controllers and lags installed.
The control scheme for each ofthe reactors is identical:
the third reactor is kept on manual because ofthe small vapor flow
from this stage and because of the erratic temperature signal pro-
duced by the simulator (as shown in the next section).
The control structures for the two colurnns aboye are standard stand-alone
schemes. The control scheme for the De-isobutanizer is not standard and has sorne
important and interesting features. The structure incorporates plantwide considera-
tions and is not at all what one would come up with in a stand-alone situation. The
fresh saturated C4 feed is introduced into this colurnn, and its manipulation must
balance the stoichiometry of the reaction. Also the distillate flowrate from this
w
Figure 16.3 - Flowsheet with Controllers w
00
~l~ut
vllc V13
'-----;0<.:::::11
1(0
ut. I
:=11
-+13
W( p:io.(>1
V5
~l~
vSout
V12
vpp1
r-'---'-,.~?;-I
/_'\
L_~22-.:'~l.¡'. ~ )'?l..I L. vap l V32
-+~ ~;;tut
& ;:1', LC2.
~' ~
(=J
rF~2
t o t l 1 J 1 - L1
Rl
V11
tol2
R2 L2 V21 v210ut
T4
~2out
B¡j¿'
V2
~~~~:'-I
FC3
V1t'ut~1
V1S
qc3
:lr I
..;--l-4;
~~~~1
Vl~~'V14
4;r~
B3 (")
DB ::r
w
lag s
~
..,
RCY-2
hxtlOul
.....
en
Alkylation 339
340 Chapter 16
column is not free to be manipulated. The total recyc1e flowrate is set by flow con-
troller FC3. The total recyc1e is the sum ofthe DIB distillate and the DP bottoms.
The latter is set by the DP base level controller (LC6). So the DIB distillate
changes inversely with DP bottoms and is not a control degree of freedom for the
DIB column.
rC)-": lags@Main
., IpCdib I
'~«¡--' -~~n--:s-er
~5?' ....___~
-----.".¡~~·----·q4\~~;
......_____~l.- __
LCdib1
Reboiler @Main
To
Reboiler B1
PCdp
v50ut
Boilup
Reboiler
To
Reboiler B2
342 Chapter 16
v70ut
Reboiler
To
Reboiler 83
16.3.4 Results
Two 0.5 minute lags are inserted in the two column temperature loops, and a
3-minute deadtime is inserted in the DIB compositionloop. Relay feedback testing
is used to tune these criticalloops. AlI other loops used heuristic tuning.
The temperature controller in the DP column has a gain Kc = 0.8 and inte-
gral time '"] = 22 minutes. The temperature transmitter span is 100 to 200oP, and
the setpoint is 125 0p for Tray 25. The temperature controller in the DB column
has a gain Kc = 0.5 and integral time '"] = 12 minutes. The temperature transmitter
span is 200 to 400oP, and the setpoint is 3000 P for Tray 3.
The composition controller in the DIB column has a gain Kc = 0.9 and inte-
gral time '"] = 40 minutes. The composition transmitter span is O to 0.2 mole frac-
tion iC4 , and the setpoint is 5 mol% iC4 for Tray 10.
The two reactor temperature controllers use Kc =1 and '"] = 5 minutes with
temperature transmitter ranges of 25 to 75°P. The third reactor temperature con-
troller is on manual with the vapor valve 10% open.
Pigures 16.8A and B give results for step change increases of 20% in the
two BB fresh feeds from 25 to 30 lb-mollhr in the first two reactors. Reactor tem-
peratures go up and more vapor is sent to the compressor. Composition in the DIB
Alkylation 343
and temperature in the DP are well controlled. The temperature in the DB experi-
ences a large drop when the feed is increased. The use of an average temperature
controller would probably improve the control in this column because the tem-
perature changes from tray to tray near the bottom of the colmnn are fairly large
(245 to 360°F over 4 trays).
The Sat. C4 stream increases very slowly to satisfY the increased demand
for isobutane resulting fi:om the increase in butene being fed into the process. It is
still not at steady state after 5 hours.
R2 = 4.158xl0 12
e-----R'T(Ccs { Cc~ )
where reaction rates are kg-moVsec-m 3, activation energies have Ul1its of caVg-
mole and concentrations are kg-moVm3 .
,~
'~ ~ V21
~~
w
8i
346 Chapter 16
In the autorefrigerated flowsheet, the vapor streams from the reactors are
compressed and sent to the depropanizer. This is done because the concentration
of propane in the vapor streams from the reactors is fairly high and because the
flowrate is fairly small. There is also onlya very small amOlmt ofthe heavy com-
ponents (Cs and C 12) in the vapor stream.
In constrast, the AspenPlus flowsheet has the entire reactor effluent being
fed to the depropanizer. Thus the size of the depropanizer is larger in this flow-
sheet, and the energy consumption is larger. The bottoms of the depropanizer also
contains more heavy components, which raise the base temperature compared to
the autorefrigerated flowsheet. A 20-tray column (22 stages) was used, operating
at 200 psia.
The DIB column is also somewhat different because its feed flowrate is lar-
ger. A 50-tray column (52 stages) was used, operating at 80 psia. The DB column
is essentially the same. The iC4 recyc1e streanl is the DIB distillate in this flow-
sheet. In the autorefrigerated case, the recyc1e is the sum of the depropanizer bot-
toms and the deisobutanizer distillate.
Converging the steady-state flowsheet was not easy for several reasons. The
large iC4 recyc1e stream makes convergence difficult. In addition, the Sat. C4
stream must be specified as an input variable in AspenPlus, and its flowrate must
be set so that the reaction stoichiometry is exactly satisfied, i.e., there must be just
enough iC4 in this stream to provide the excess iC 4 needed beyond that present in
the BB feeds. After much effort and trying different specification on the depropan-
izer and deisobutanizer columns, the convergence was achieved by setting the
following parameters:
It should be noted that the resulting purity of the D2 recyc1e stream is about 80
mol% iC4 , which is lower than the 95 mol% iC4 recyc1e used in the autorefriger-
ated flowsheet.
The depropanizer and the deisobutanizer columns are sized for the new con-
ditions. The AspenPlus tray sizing gives diameters of 3.2 and 5.7 ft, respectively.
The lirniting stage locations are both at the bottom of the columns (Stage 31 in the
Alkylation 347
Opening the dynf file in AspenDynarnics gives the default control structure
shown in Figure 16.10. Temperature and level controllers are installed on all three
reactors, which will be used. Pressure controllers are installed on all colurnns. The
1evel controllers in both the DP and DB colul11ns are also already installed. The
level controller in the base of the DIB column must be connected to valve V21.
Reflux flowrates are flow controlled in all three colurnns (default structure). Using
feed-to-reflux ratio controllers may be needed to handle large load changes.
The output signal from the level controller in the reflux drum of the DIB
colurnn is connected to the Sat. C4 fresh feed valve (V4). This level controller pro-
vides the feedback l11echanism to bring in just enough isobutane to satisfY the re-
action stoichiometry (and the sl11all losses in the depropanizer and debutanizer
distillate streams).
Unit
DIB ColumnID (ft) 5.5
RefluxDnun (ft 3) 550
Base (ft3) 400
DP ColumnID (ft) 2.4
RefluxDnun (ft3) 18
Base (ft 3) 220
DB ColumnID (ft) 1.2
RefluxDrum (ft3) 9
Base (ft3) 40
FEHE Shell Volume (ft3) 11
Tube Volume (ft3) 11
Reactors (3) Total Volume (80% liquid full) (ft3) 100
w
~
V2 TC15
cX5:::;----;
~
J;BB2l ,, LCl o
"'-"---,
r LC12 ¡ ¡
~~¡! ¡______>~14
----,rv O -------1
.",,-,~ ,¡~--{i,
I
R2 ¡------KT-: i
LC6
----->0
:l--~---------1 @
'Q~Q , ____ ~12
V21 \/>1
()
:::r
ro
"S.
(j)
....
-"
Cl)
Alkylatiol1 349
~.
,,-m
tt
':/ 1
LCR3
-)()- - --- ---------- ------------
~2
: FC2~:-"
•__ -)() ____ J
. .
i-W-i -'----....../-
!
r
~~-----------i----
TCR2
!uuJ;;io<mummj-o(-'um'~
·-FC3----cx--1 : i TCR3 .
i ~'"
:, .. _-,
"" i u, i
'~mmium0"
: : Á :
-'-iiiJ< 1
LC31
lag11 lag12
-~--->[];]---~2 __ J
.:
'"'"
352 Chapter 16
Alkylation 353
transmitter span is 200 to 400°F, and the setpoint is 267°F for Stage 13. This tun-
ing is quite similar to that used in the HYSYS simulation.
The composition controller in the DIB colunm has a gain Kc = 0.2 and inte-
gral time 'el = 34 minutes. The composition transmitter span is O to 0.3 mole frac-
tion iC4 , and the setpoint is 15 mo1% iC4 for Stage 27. The gain is significantly
10wer than tllat used in the HYSYS simulation. Of comse, the two colmnns are not
identical.
The three reactor temperatme controllers use Kc = 5 and 'el = 5 rninutes witl1
temperatme transmitter ranges of 25 to 75°F. These gains are higher tllan tl10se
used in the HYSYS simu1ation because a direct Q mode1 is used.
16.4.4 Results
Figmes 16.16 tllIough 16.19 give the response ofthe system to 20% step
increase in both BB fresh feed flowrates. Figme 16.16 shows that reactor tempera-
tmes are well controlled, witl1 deviations in temperatme of les s than one degree.
The magnitudes of these temperatme deviations increase as we move down the
reactor chain.
::::;LLI['!:i¡¡:li'!lli
~
~
M
~
~ fZJ;
~ ~
: : : : : : : : : : : : : : :
... _-:------!------;-----:-----;-----:-----;-----:-----¡------;-----:-----;-----:-----;-----:------:------:-----:--
: : i
~ ~ ~ ----.:; ----+ ---- -~-- ---~- .-- -j--- -- ~- -". -~_." --~ -- --+---- +_.- -~--- --1-----\-----~- -- --~-- ---\----- -j- --- -~--
Ñ ~ ~ -- - - -~ - - - - -j- ----·l-----~- ----~ -----~ -----~ -----~ -----¡- -----i- ----~- ----~- ----~ -----f ---- -~ --- --¡------l- ----~--
:: ::: ::::::::
o 0.25 0.5 0.75 1 125 15 1.75 2 225 25 275 3 3.25 35 3.75 -1 4.25 45
Time HOlJfS
354 Chapter 16
~ - ~ -" -" ------_o: ------------¡- -----------:" -----------: -----------?f------------: ------------: ------------: -----------":
~ ------------~ ---- --------;" - ---------- ~- -----------~ ------------ ~ --- -------- -; -- ---------- ~ --------.". -;" -------- ----:
'B : : : : , : , : "
: ;! ~ ------------r-----------T-----------r-----------1------------1------------r------------:------------¡--------- ---vi
<O - - - - - - - - - - - - : - - - - - - - - - - - - - : - - - - - - - - - - - - ; - - - - - - - - - - - - ; - - - - - - - - - - - - ; - - - - - - - - - - - - ; - - - - - - - - - - - - ; - - - - - - - - - - - - : - - - - ____ o_o_o:
- <g
~ ------------r------------;""---------':------------:--- ---------:------------r------------:------------¡-------------:
: : : : : : : : :
: ~ ~ ::::::::::::t::::::::::::t:::::::::::j::::::::::::1:::Tci::::;::::::::::::t::::::::::::t::::::::::::t::::::::::::!
~ ('"\¡ : : : : : : : : :
tt1¡'j!+DIQR1!1!!!
"" :;;:
~
12 -------
""
----~-----
"
--- -- - -:- -----------~-- ------ ----,------------, --- --------- f----- ----- --1- -- ------- ---:----- --- -- ---:
: : : : : : : :
('"\¡ - - - - - - - - - - - -~ - - - - - - - - - - - -:- - - - - - - - - - - - ~- - - - - - - - - - - - ~- - - - - -- - - - - - i ------------~ ------------~ ------------:- ------------;
N ~ ~ ------------[-----------+-----------1------------1------------f------------f------------f------------i-------------¡
~ ------------¡.------------:-------------l------------~------------t------------l"------------r------------:-------------:
: ~ ~ :::::::::::o~::::::::::::I::::::::::::I:::::::::::]:::::::::::,'5:::::::::::[:::::::::::I::::::::::::::::::::::::1
TimeHOlJr!;
~ : ~ ::::,:::::::r,:":::'::::r:::,,:::'::r:::::::':':r,:,,,:,:::'i'::::::::::::::::::::::::t::::::::::::t::::::::::::!
: : ~ ~ :::::::::::r::::::::::[:::::::::::¡:::::::::::::::::::::5:::::::::::r:::::::::r:::::::::C:::::::::
~ ~ : ~ ........... ;............!............ ;........... ;... ··D3···f···········;············!············;·········..;
: : : ~ ::··::::.::::::.:.::·::1·:·.:··:·:·'·::·:::::::1:::........1......:.:::1:::.::::.·:1·.::··:.:.:.::::::...::1
¡¡¡• • • I• •· • I·••••••
1: I• • • • • !• • • • • 1~;1!1 • • • !• • • • •!
: : : ~ :·::·······F:·::··::·: :.:::::::::'::::::::::::::::::::::::;:::::::::::::::::::::::::::::::::::::::::::::::::;
R
~ R
~ : I ...........;........ +::::::::::C::::::::L:::::::+::::::::?~:::::::::::r::::::::::c:::::::::
~ ~
'" '"
~
; ; ::::::::::::::::··::·::1:.::::::::·\···.:::::::1::·:::::·:·1·:··:::·:·:1::::.::::::1:::::::::··[.··.::·::·:1
- '" ~ o 05 1.5 2.5 3.5 J.!
Time Hou¡s
HYSYS AspenDynamics
Gateway 8 28
650 mHz
Dell1.8 GHz 23 48
If several step changes had been made, the real-time factors for HYSYS would be
about the same, but those for AspenDynamics would decrease.
16.6 Conclusion
This chapter has presented simulations of an industrially important and typi-
cally complex process. Developing a plantwide control structure for the 21 loops
involved in this plant and testing control performance are challenging but vital
jobs. In the next chapter we simulate another complex process that features two
liquid recycle streams.
hapter 17
Ethyl Benzene Process
17.1 Introduction
The process considered in this chapter produces ethyl benzene from ethyl-
ene and benzene. Ethyl benzene is used for the production of styrene, an exten-
sively used bu1k chemical. The process features large high-capacity equipment.
The ethylene and benzene feed stocks are produced in petrolemn refineries by the
use of catalytic and them1al cracking and refonning. The process studied is a sim-
plified version of the real process with the process equipment and chemistry
trimmed down to make the simulation easier, but it stiU contains the important
topology of the process and illustrates the essential features of a plantwide dy-
narnic simulation. There are two reactors, two distillation COlUlllilS and two recyc1e
streams.
The basic chemical reaction is:
However, there are further reactions of ethylene with ethyl benzene to produce
higher-order components. The fust is:
Reaction 2: Ethyl Benzene (EB) + Ethylene (E) --7 Diethyl Benzene (DEB)
To suppress this reaction, a large excess of benzene is used so that the ethylene
concentration is small. This results in a large benzene recyc1e stream in the proc-
ess. The benzene to ethylene ratio fed to the reaction section is about 2.5. Despite
the large benzene excess, there is a significant amount of diethyl benzene pro-
duced in the reactor. It must be separated from the ethyl benzene and recyc1ed
bac1e to the reaction section where the followil1g reaction occurs:
Reaction 3: Diethyl Benzene (DEB) + Benzene (B) --72 Ethyl Benzene (EB)
The kinetic equations used for these three reactions are given below. These
parameters are se1ected to give typical reaction conversions and yields.
357
358 Chapter 17
-17,000
RI = CE CB (l,528xl0 6 )e-----¡¡;¡-
-20,000
R2 = C E C EB (2.778x10 4 )e-----¡¡;¡-
-15,000
R3 = C DEB C B (0.4167)e RT
Figure 17.1 gives the flowsheet. A small flow ofinert gas (nitrogen) is used
in both reactor vessels so that the pressure can be maintained while achieving the
desired reactor temperature. The N2 fed to the first reactor is 5 kg-mollhr and to
the second reactor is 3 kg-mollhr. Since there is a small amount ofN2 in the liquid
~
::r
~
OJ
Figure 17.1 - HYSYS Flowsheeí ro
::::¡
~
::::¡
ro
v90ut
v80ut
v120ut
~;:$
v1in
Vi
R1out V3 v30ut i elt2 R2
v~out
~
v'l1m •. I
V1'I v2'lin V21 R20ut
V4
~' ...
v2in FFB
V2
cycle2
/5
/ I 811;~.
~o!
V7
v70ut
4 QC2
D2
T ., oF
v50ut
p20ut
..-+. w
wl<2 (J1
1.0
360 Clhapter 17
fed to the first column, a partial condenser is used with a small vapor flow (10 kg-
mol/hr) to remove any nitrogen. These three vent streams result in a smallloss of
benzene.
Equipment sizing is done in the nonnal way. Both columns have diameters
3
of3.7 m. Reflux-drum and base volumes are 35 m 3 and 66 m in column Cl, and
3 3
27 m and 30 m in column C2. Pumps Pland P2 have heads of 7.5 bar and 7.8
bar, respectively.
!!!
::l"
Figure 17.3 - Flowsheet with Controllers ':$..
ro
ro
:¡
N
ID
;::¡
ro
~ ¡;;k;;¡ ir',
v90ut"
V8
--,
~ -.¡:-:j-- -
I el?
~ I
I>~ LflD1
n1n,,'
v80ut
~
V12 v120ut wld
V22 v220ut I I :r==t-1l -
~1J'n
¡--r:'\
, "-,/
ti V4
LCR1 (~=1<%{
[JI
_···--·---1I
._cycle2
, L¿;2 ~I =ro--, /5
~<J ' ~
j OC21
V2
TCR1
~~.
~
v70ut02 I v50ut
-- el." "'*"
\~,' ~JC.......J
~v60ut
I- LC21 ,~ ?nn~ OR2
I
~
p20ut
RCY,2 V6 ""'* (¡,)
Cfl
..>.
wl<2
362 Chapter 17
The plantwide control scheme selected for this process has the following
loops, as ShO\VIl in Figure 17.3.
The fifth item above is the most important for the plantwide control system.
One of the heuristics of plantwide control is to put a flow controller somewhere in
allliquid recycle loops. There are two such loops in this process: the benzene re-
cycle (DI) and the diethyl benzene recycle (B2). Controlling the flow of the feed
to the first distillation places a flow controller in both of these liquid recycle
loops, which prevents the "snowball" effect. Figure 17.6 shows the PFD with all
faceplates.
Reflux Cnnrl"n~"rl_....
Te
Rebeiler
LC11
@Main
LC22
@Main
v40ut
Boilup
To
Reboiler
LC21
@Main
364 Chapter 17
Notice that the control of levels is "in the clirection of flow" downstream
from the el column, but "in the reverse clirection of flow" upstream of this col-
umn. The column levels are held by changing the flows leaving the columns. The
reactor Ievels are held by changing the flows entering the reactors.
17.2.3 Results
Two disturbance runs are made. In the fust, the fresh feed flowrate of ethyI-
ene is increased 20% at time equal 15 minutes. Figures 17.7 A, B and e show that
it takes over 4 hours for the fresh feed of benzene and the ethyl benzene product
(D2) to increase up to their new steady-state 1evels. The benzene fresh feed ini-
tially moves in the wrong direction.
Ethyl Benzene 365
R20ut
TR2
TRI
R20ut
TRI
FFE
Ethyl Benzene 367
In the second set ofruns, both the fresh ethylene feed flowrate and the C1
colrunn feed flowrate are increased 20%. As Figures 17.8 A, B and C show, this
simultaneous change of the two setpoints speeds up the response of the system
dramaticalIy. Higher production rate is achieved in less than 2 hours.
steam at 2.7 bar. With the reactor at 160°C, a 30°C temperature differential is
availab1e. Then the required heat-transfer area is
2
(12.6x106 kcallhr)/(486 kcallhr-oC-m2)/(30°C) = 864 m
This could be achieved by installing 550 tubes in the reactor, 0.05 m in diameter
and 10 m in length. The total volume occupied by these tube is 10.8 m3 .
R2
V1
~---
The columns are slightly different in the AspenPlus flowsheet than in the
HYSYS process. The AspenPlus tray sizing gives column diameters of 4.1 m for
column Cl and 3.0 m for column C2. Reflux-drum volumes for the two columns
are 36.7 m 3 (2.86 m diameter by 5.72 m length) and 27.5 in3 (2.6 m diameter by
5.2 m length), respectively. Base volumes are 69.8 m 3 (3.54 m diameter by 7.08 m
length) and 29.7 m 3 (2.66 m diameter by 5.33 m length), respectively.
VE
,¡...------iRECll----r1XJ<---¡
The two colurnn temperature controllers are retuned with two O.5-minute
lags in each loop. Relay feedback tests give ultimate gains and ultimate frequen-
cies that are almost the same as those found in the HYSYS simulation.
17.3.4 Results
The disturbances are simultaneous step increases in the setpoint of the fresh
ethy1ene FFE flow controller (630.6 to 757 kg-mollhr) and the setpoint ofthe sec-
ond reactor effluent R20UT flow controller (1595 to 1915 kg-mol!hr). Dynamic
results are given in Figures 13 A, B and C. The step changes are made at time
equal 0.25 hours.
Ethyl Benzene 371
LeRl
.I.fFE1----- /Vi-----;-·---.. ----.. ----·----------O<---------------------;.'
~~ - I ; ,-..--..-.. -.. ----.. ---..-.. --..LCR2
0<----.. -...... --- .. ,
n~ ~¡ j
8TOT ~l~ :~--.J~
lV3 -f1Bl-LciF-n.i -~..
j
R2
16 ;--- -.-..:,
i ' =TI
FC1
.... ;>(l .... , ¡e-O<-
TeR
,"""0--<-"-,,-,,,
. ,
¡ log11 h:~glZ TCl ¡
,-~-----~-----»()_ .. _;
i 109 21 log22 TC2;
'-~---, __>[] ___ "--->O----'
372 Chapter 17
It takes over 2 hours for the fresh benzene flow FFB to be brought up to
equal the fresh ethylene flow. Gradual increases in the production rate of ethy1
benzene (stream D2) occur. Both recyc1e streams (DI and B2) increase. The DI
recyc1e stream increases more quickly because it sees the change in the feed
flowrate to column el immediately.
eolumn tray ternperatures are well controlled. In column el the maximurn
ternperature deviation is about 7° e, while in column e2 it is about 3°C. Notice,
however, that in column e2 there is an initial drop in ternperature because of the
increase in c01umn feed (B1), but then the ternperature increases. This secondary
effect is probably due to the increase in the feed composition, as more DEB enters
the c01umn.
This process is fair1y complex and requires significant computing times. The
real-time factors for both simulators are given in Table 17.1 for two computers.
HYSYS AspenDynamics
Gateway 17 33
650 mHz
Dell1.8 GHz 32 38 with CT = 0.001
160 with CT = 0.01
Ethyl Benzene 373
g ~
~ iil
!i !i ~ =
---
1\
~ ~ 1---------- c...-
~
---- ----
~FB
'.~
L\ -'TRl
"-
1\
1:-1----
;ji .\
R7011!
~
~
~ - § ~r----
~ 1------------- \
g '"
~
- ~ ~f-------- :L QKl
~ - ~
- ª ~ ~
¡¡: ¡¡:
~ J ~
~ o
TImO'H,""
l' ~ - "
-
~ ~ - ~
-
§ - "
ª
~ :g ¡\
-::
o
-;-0
"'Eo;;>
a;
8 Q~ 1:'
~.,.,
E R ¿!!!
C;5S
t~ §~
t~ t: t~ !i
~ ~ - ''""
i2 ~
-
~
"
-
~ § - ::
o
¡¡¡ iil - o 0.2 0.5 0.6 0.7 08 0,9 1 1.1 1.3 1.4 15 1.6 1.8 19
TlmeHours
374 Chapter 17
:;; e:
~
N
m ~
m :2 g ro r............... ,.--.--.t(6 /
j v' QR2
~ ~¡------+-' -- /
~8 ~ LI-----+-'~..
1
HPrl:r....-- ..:....¡··\·v
_10 1 ____ . . . . . . . . --.,-- ... ------: .......... - - - - - - . , . . .... -- ..
.--¡A:.::=: i==i='
U2
==i==Í==_~~==:
~ ~r·········--····:]····--·.¡ 1·····:····--············:,··--·············:·----···········;··------·······+···----·······1··----········1····----·······;·····----······1
~ g ~ O~--~O.2---ooT,---O~.6---70'8---T,--~1.'2--~lA--~16c---,~8--~
Time HOlir5
17.4 Conclusion
This chapter presents another fairly complex chemical process involving
multiple interconnected unit operations. The two liquid recycles can present both
dynamic and steady-state difficulties. The plantwide control structure selected for
this system does an effective job in providing a basic regulatory control scheme.
The "snowballing" of recycle streams is avoided by placing a flow controller in a
location (the effluent of the second reactor) through which both recycle stream
flow.
The next chapter presents an even more complex process, which features
four recycles and an interesting "on-demand" control structure.
hapter 18
18.1 Introduction
The production of rnethyl amines is an important chernical process. The
chemistry consists of three sirnultaneous reversible gas-phase reactions produc-
ing rnonornethyl amine (MMA), dirnethyl amine (DMA) and trirnethyl amine
(TMA) frorn ammonia and rnethanol. Water is a byproduct.
CH 3 0H +NH3 <=> CH 3 NH 2 +H 2 0
CH 3 0H +CH 3 NH 2 <=> (CH 3 )2 NH +H 2 0
CH 3 0H + (CH 3 )2 NH <=> (CH 3 )3 N +H2 0
The specific reaction rates of these reactions are quite large, so chernical
equilibrium is achieved as long as the residence time in the reactor is sufficiently
large. The reactor in the specific numerical case used in this chapter has a volume
of 1500 fe (8 ft in diameter and 30 ft long), which gives residence times of about
375
376 Chapter 18
0.5 rrllnutes. Therefore the use of an "RGibbs" reactor in the simulation is justi-
fied and elirrrinates the need to have all the forward and reverse kinetic parame-
ters for the reactions. The RGibbs reactor ca1culates the reactor effluent concen-
trations that rninimize the free energy ofthe stream.
The primary desired product is DMA, and the equilibrium mixture leaving
the reactor contains more TMA and MMA than can be soldo Therefore the excess
amounts ofthese components are recycled back to the reactor from the separation
section. A large excess of ammonia is used drive the per-pass conversion of
methanol to close to 100%.
The process flowsheet is shown in Figure 18.1. The fresh feed of liquid
methanol (558 lb-mol!hr) and the liquid recycle streams of MMA (63.4 lb-
mol!hr) and TMA (50 lb-mol/hr) are fed into a tank. Liquid from this tank is fed
into a vaporizer along with fresh arnmonia (287 lb-mol!hr) and recycle arnmonia
(3774 lb-mol!hr). You can see that there is a very large arnmonia recycle. The
heat duty in the vaporizer is 45x10 6 Btu/br. The saturated vapor from the vapor-
izer at 203°F is preheated to 442°F in a feed-effluent heat exchanger. The heat-
transfer area is 1000 :ft?, and the overall heat-transfer coefficient is 100 Btu/br-ft2-
°F. The heat duty is 13.4x106 Btu/br.
The reactor operates at 570°F and 280 psia. The reactions are somewhat
exothermic, but the feed is cool enough and the recycle of arnmonia is large
enough so that a small amount of heat must be added to the reactor (1.43x10 6
Btu/br). The reactor effluent flows back through the heat exchanger and is fed to
the separation section.
It should be noted that heat integration between the reactor and the vapor-
izer are neglected in the simulation. A higher reactor inlet temperature would be
used in the real process because a tubular reactor is used. Then steam can be gen-
erated in the high-temperature reactor and used in the vaporizer. Altematively,
there can be direct heat transfer between the reactor and the vaporizer. For pur-
poses of simplification, these complexities are not inc1uded in the simulation.
Figure 18.1 -Amines Flowsheet
~
S·
m
l:::j, ~
,-------------------------~~~------------------------~
,,1
~
P3~
T3
~~
V31
w
....¡
....¡
378 Chapter 18
The ammonia and water are easily separated from the amines because of
their large differences in boiling temperatures. The boiling points of the pure
components in the system at 85 psia are given in Table 18.1. This pressure is
used in three ofthe colurnns so that cooling water can be used in the condenser.
and no oth.er property package could be foul1d in HYSYS that drove the TMA
overhead in the extraction column, the simulations of the process presented in
this chapter are only done in AspenPlus and AspenDynamics.
0.9-:
0.8-:
0.3-:
0.2-:
0.1 -: H-I-I---j-,J-+---j
0.0"::<'. . "
diM-Amine l' " ~11' , " l' ,'~I;' " l' "~I¿' " l' ,'~I;' , , I' ,,~I~' , , I tri-M-Amine
0.0 0.2 0.4 0.6 0,8 1
l'>:a!.s~;';
I
i!!
56
54
\
'\"
.a
11
ru
c.
E
~
52
50
\ '"
ru
:¡; 4B
'"
.a
"
m 46
44
'" "" ' ' '
~
"--'- 1'-.....
42;
40
0.00 0.10 0.20 0.30 DAD 0.50
0.9-:
-
0.5-: ¡-/-T---t--:;¡:::::i=:::::t~
-
0.4-: If--!-\·······:f-+-··········-+:-:o~~L-··"'~
0.3 -= Ij-I--I----b'--¡--¡~,..-;==4--"'-,
0.2 -: Ij-j-l-+l-+---·,'Í---I··---;;--i""- -1---1········-···"
0.1
H20 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 M-Amine
C1 C2 C3 C4
Stages 22 42 22 42
D (lb-mollhr) 3774 90 310 120
B (lb-mollhr) 958 3868 3558 190
Reflux ratio 2 15 15 15
Feedstage 11 3/21 11 21
Pressure (psia) 240 85 85 85
Condenser (OF) 112 139 121 105
Reboiler (OF) 207 286 318 141
QC (l06Btu/lrr) -93.6 -14.4 -48.4 -18.6
QR (10 6Btu/lrr) 40.7 10.7 50.6 18.7
Diameter (ft) 9.0 5.0 7.2 5.0
DxL (ft)
Refluxdrum 9x18 7x14 8x16 5xlO
Base 8x16 6x12 7x14 7x14
A. Ammonia eolumn (el): This column has 22 theoretica1 stages and is fed on
stage 11. The distillate product is the excess arnmonia, which is recyc1ed back to
the vaporizer. The c01umn operates at 240 psia and a reflux ratio of 2. The bot-
toms contains very little arnmonia (0.09 mol%). The distillate contains a consid-
erable amount ofMMA (8 mol%) and TMA (1.2 mol%). In fact, ofthe 131 lb-
mol/hr ofTMA leaving the reactor, about one third is recyc1ed bade in this distil-
late stream. So some of the excess MMA and TMA can be recycled along with
the arnmonia in the distillate from Cl. This reduces the load on the downstream
columns.
Reflux-drum temperature is 112°F. Base temperature is 240°F. Reboiler
heat input is 40.7x106 BtuJhr. Figure 18.5 shows the composition profiles in the
column, and Figure 18.6 gives the temperature profile.
'"
o
NH3
H20
11 16 21
Slage
Amines 383
_. r-.~~ ~ _ _ _: 1: \ \ \ /
¡ H20 i ~------~~~-----~~!~---'--~~~
'" I~Te
o
~ ~ J
~
:J
1 6 11 16 21 ,.6 31 36 41
Stage
384 Chapter 18
lower than desired in the real plant, but achieving higher purities would probably
require more trays, which would slow down the simulation. The distillate stream
is split between 40 lb-mol!hr of product and 50 lb-mol!hr of recycle, wrnch is fed
back to the methanollrecyc1e feed tank.
Reflux-drum temperature is 139°F. Reboiler temperature is 286°F. Reboiler
heat input is 1O.7x106 Btu/br. Figure 18.7 shows the composition profiles in the
column, and Figure 18.8 gives the temperature profile.
11 16 21
Srage
D. Product Column (C4): The distillate from C3 contains mostly MMA and
DMA with about 2.8 mol% TMA. This is fed into a 42-stage column operating at
85 psia and a reflux ratio of 15. The distillate is 99.3 mol% MMA at a flowrate of
120 lb-mol!hr. This stream is split between MMA product (56.6 lb-mol!hr) and
MMA recycle back to the methanol tank (63.4lb-mollhr).
Amines 385
I I
Ilu
/-- .
11 16 21 26 31 36
Stage
Total Flaw cuft/hr 1.53883E+S 1.8 1590E+5 19'52.864 2742.497 3231.565 8737.07-1. 175.7075 93.50796
fT:.:,:;:mp~,:;:rn:;:ru:;:"~_ _lr----t_-4:.:;4:::.1.:::.99:.:7:::.7t_--=5:::.7:::.0.:::00:.:0:::.0I-~1~12=.8~1=28~_~3:..:1.8:::6:::.93:::8~_=52=.9:.:2~09:.:3~_6::.:7:....7:::.1:::.60::.:4+-~9:.:4::.:.1:::.94::.:0:::.3+--,1~24~.:::84:.:8~8
~P:"'''='"=U':''''_ _ _-J:...ps=i_ _ _1---=2=8:::5.:::00~0~01---=2~80:::..0:::0:",004-__ ·~33~0~.0=OO=0+---=2~0~.0=00=0=0~--=2~0~.0=00~0~0~--=2=5.=00~0=004-_:::.7:::0.~00:::0~004-_:::70:::..0~0:...00:::0~
VuporFrnc 1.000000 1.000000 0.0 .1661307 .2410479 .2077650 .0296806 .0107945
LiquidFruc 0.0 0.0 1.000000 .8338693 .7589521 .7922350 .9703194 .9892055
Salid Frac 0.0 0.0
Enthulpy Btu/lbmol -23122.74 -22821.45 -27159.19 -19440.80 -22433.38 -16803.63 -19440.80 -22433.42
The PRMHV2 package is lLlsed for Cohunn C3 in both AspenPlus and As-
penDynanücs beca1tlse in the steady-state design regular Peng-Robinson gives
unrealistic temperatures on sorne trays in the column (-240°F). AspenPlus gave
no error message and claimed that the column had converged. But looking at the
Amines 387
temperature profile was enough to see that something was amiss. Switching to
PRMHV2 gave reasonable temperatures.
To Y2 VI e2 P2 el e2 e3 e4
Phase L1QUlD VAPOR MIXED MIXED UQutO VAPOR MIXED MIXED LIQUID
SubS!f'1!<lm: M¡XED
Mole: Flol'? Ibmollhr
NH3 0.0 287.0000 2.3048E-15 1.2384E-14 .4705500 3424.444 .8470565 8.91928E-7 8.91928E-7
MEOH 558.00QO 0,0 1.268352 6.814871 558.0657 1.388297 1.388297 8.083223 4.6694E-13
DMA 0.0 0.0 1.759088 9..151605 3.725788 19-1.7383 188.0507 190.8247 179.6140
MMA 0.0 0.0 .3127812 1.680552 63.18501 421.5452 122.6053 123.8470 121.8537
WATER 0.0 0.0 555.0057 2982.053 2.055170 558.7050 558.7050 3537,059 4.6387E-13
TMA 0.0 0.0 2.96353E-5 !.59232E-l 43.89109 131.5250 86.74957 8.532484 8.532295
MoIcFrnc
NH3 0.0 I.ooonoo 4.!279E-IS 4.1280E·18 7.00856E-1 .7236251 8,83873E-t 2.3057E-1O 2,87719E·9
MEOH 1.000000 0.0 2,271ó2E-3 2.27162E·3 .8312053 2.93363E-4 l,44S6·!E-3 2.08958E·3 1.5063E-'15
DMA 0.0 0.0 3.15053E·3 3.15054E-3 5.54934E·3 .0411504 .1962242 .0493298 .5794001
MMA 0.0 0.0 5.60192E-I 5.60184E-1 .0941102 .0890774 .1:'79343 .0320155 .393I J763
WATER 0.0 0.0 .9940176 .9940176 3.06105E-3 .1180609 .5~29S89 .9143594 1.4964E_15
TMA 0.0 0.0 5.30770E-8 5.30773E-8 .0653731 .0277927 .0905201 2.20572E-3 .02.75235
Totalr-lolV IbmoVhr 558.0000 287.0000 558.3460 3000.000 671.3933 4732.346 958.3460 3868.346 310.0000
TotalFlow Iblhr 17879.53 -1887.771 10128.25 54419.20 22651.46 98076.27 27537.95 76934.04 12386.59
TotalFlow cuMlr 372.5537 4950.472 1697.695 10511.74 478.3583 1.56031E+5 27062.53 35061.72 317.6357
Tcmpe["Jturc 120.0000 200.0000 312.20¡O 309.-1053 87.80778 339.8453 135.9986 232.9515 115.7801
Pressurc psi 100.0000 360.0000 90.00000 85.2459(J 20.00000 244.7619 87.43902 87.38095 87.-13902
Vapor Fr¡¡c 0.0 1.000000 .0306572 .0340777 0.0 I.(JOOOOO .4261640 .1092803 0.0
LiquidFrac 1.000000 0.0 .9693427 .9659222 1.000000 0.0 .5738360 .8907197 1.0DOOOO
Solid Frac 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
EnUl¡¡lpy B~ll/lbmol ·1.0257E+5 -191·15.58 -!.1810E+5 -U810E+5 ·89325.24 -25650.30 -74868.54 -1.1056E+5 -1814-1.10
Ent]¡a!py Btllflb -3201.077 -1124.190 -6510.708 ·6510.708 -2647.616 -1237.670 -26n5.494 ·5559.1-11 -454.0933i
EnU¡¡¡!py -5.7234E+7 ·5.4948E+6 -6.5942E+7 -3.5431E+8 -5.9972E+7 .1.2139E+8 -7. 1750E+7 -1.2769E4-8 .5.6247H6',
Entropy Blll/lbmol-R -57.53241 -28.611636 ·32.-11808 ·32.41430 -62.04042 -27.77331 -50.11041 -36.31545 -78.13I.Hll
Entropy Btu/lb-R .1.795522 ~1.684405 -1.787131 .].786923 -1.838889 ·1.3-10109. -1.743888 -1.825989 _11.95~85
Density Ibmot'cuft 1.497771 .0579742 .3288847 .2853953 1.403536 .0303295 .0354¡22 .11032% ;Jj.7S9609
Dcnsity Ib/CUfl 47.9918! .9873342 5.965881 5.176994 47.35250 .6285687 ].017568 _ 2.194246 38.99623
AvcrageMW 32.04216 17.03056 18.13973 18.13973 33.73799 20.72466 28.73488 19.88FiIO 39.95675
Liq Vol60F cuft!hr 246.2212 163.-1093 878.0004 474.2838 3802.181 578.9849 1334 .. 5~ 293.1185
18.4 Dynamics
18.4.1 Equipment Sizing
The usual design sizing methods discussed in Chapter 2 were used to size
equipment. The methanoIlrecycle feed tank has a 'diameter of 5 ft and a let<lgth of
10 :fl¡, giving a total vohune of 200 ft3. The stream ("Rtot") leaving fue tank is
22,620 lbllrr with a density of 47.41b/ft3. The total holdup time is 25 minutes in
this. tank.
388 Chapter 18
1. The total flow (RTOT) of fresh methanol, recyc1e MMA and recyc1e
TMA coming from the methanol/recyc1e tank is flow controlled..
2. The level in the tank is controlled by V2, which manipulatles fresh
methanol feed flowrate. This loop makes sure that exactly the correct
amount of fresh methanol is introduced into the system as varying
¡'l.lllounts are consumed to make the varying amounts of the three' prod-
u\cts. Every mole of MMA. takes one mole of methanol. Every mole of
DMA takes two. Every mole of TMA takes three. The methanol com-
position in the tank is 83 mol%, so this 1iquid level is a good indicaÍlOr of
the methanol inventory in the system.
~
Figure 18.12 -Initial Flowsheet with Default Controllers S'
m
TMAREC
Vll
REACTOR
,------11 S 11-----
r----Fi~l1
"'
V33 V43
~
~ r;~·~'"
P31
~-2~ 1
T3
.•
V31
~~e<L~
L::.:....J .• - ~
w
~
w
co
o
Figure 18.13 - Plantwide Control Scheme
FCTMA
TANK
REACTOR
,------11 s 1-1- - - - - '
~c---!
~.~_~ L..:..:..J
MMAREC F311=============l
,~ )5~?----------------: ,----------~~-, I
: 3 !,---,: ~ _.y,32 ¡--'-¡: ~"-----' LC42
~
j
~:
~3 !~~j
:--~-j, !
:
V, j l4
:----- '
¡---»O--,---=-~-------;/43
"--104 P42~ ::~~ ____ ~10A
\/11'>
1
'
r MMA
1-<>
3. The total ammonia fed to the vaporizer (ATOT) is flow controlled. This
total is made up of287lb-mollhr offtesh ammonia and 3,774lb-mollhr
ofrecyc1e arnmonia ftom thetop ofeolumn el.
4. The level in the reflux drum ofel is controlled by valve VI, which ma-
nipulates the ftesh feed of ammonia. This loop makes sure that exactly
the correct amount of ftesh ammonia is introduced into the system as
varying amounts are consumed to make the varying amounts of the
three products. Every mole of MMA, DMA and TMA takes one mole
of arnmonia. The ammonia composition in the el reflux drum is 91
mol%, so this liquid level is a good indicator of the ammonia inventory
in the system. Remember that changing fresh ammonia feed using valve
VI has an immediate effect on el reflux-drum level because ofthe flow
controller on the total ammonia downstream ofthe ftesh ammonia addi-
tion point.
5. Vaporizer level is controlled by heat input.
6. Vaporizer pressure is controlled by valve V4 in the vapor exit lineo
7. Reactor exit temperature is controlled by reactor heat input.
8. Reactor pressure is controlled by valve V5 in the line just upstream of
Column el.
9. Pressures in all four columns are controlled by condenser heat removal.
10. Reflux mas s flowrates are flow controlled (default).
392 Chapter 18
11. Base leve1s in Columns C1, C2 and C4 are controlled by bottoms flow.
Base level in Column C3 is controlled by valve V31, which manipulates
the water leaving· the process to exactIy balance that produced in the
three reactions. A large fraction ofthe bottoms from C3 is the extraction
water (S) fed to Column C2. This stream is flow controlled.
12. Because temperatures in C1 do not give a good indication ofthe amount
of arnmonia leaving in the bottoms, it is assumed that an ammonia com-
position analyzer is available on Stage 15 where the concentration is 4
mol% NH3• Reboiler heat input is manipulated to control this composi-
tion.
13. Temperatures in C2 are also not good indicators ofTMA product purity.
A composition analyzer is used to directIy control the composition of
TMA in the distillate product by manipulating reboiler heat input.
14. Temperatures are used in Columns C3 and C4 with reboiler heat input
manipulated. In C3 the temperature on Stage 19 is controlled at 312°F.
In C4 the temperature on Stage 35 is controlled at 131°F.
15. Reflux-drum level in Column C2 is controlled by manipulating valve
V23 in the TMA recyc1e lineo Reflux-drum 1evel in Column C4 is con-
trolled by manipulating valve V43 in the MMA recyc1e lineo Reflux-
drum level in Column C3 is controlled by manipulating valve V32 in
the distillate lineo
The important plantwide control loops are Items 2 and 4 in this list. They
make sure the reactant component balances are satisfied. The dynamic results
shown in the next section demonstrate that this control scheme provides effective
basic regulatory control ofthe plant, which is our objective at this stage.
Higher level optimizing control may be applied on top of this structure.
Note that in addition to the two flow controllers on two of the product streams
and the four flow controllers on the column reflux streams, there are three other
flow controllers:
18.4.3 Results
Severa1 types of disturban ces are tested. These inc1ude changes in the de-
sired MMA and TMA flowrates, changes in the total ammonia flow and changes
in the total methano1-p1us-recyc1e flow.
Figure 18.15 shows the response of the system to a step change at time
equa1 0.25 hours in the setpoint ofthe flow controller on the TMA product stream
from 40 to 50 lb-m01lhr. The recycle flows ofboth TMA and MMA slowly drop
off. There is a gradual increase in fresh methano1 flow (FFM) because TMA con-
sumes more than MMA or DMA. There is a very small decrease in DMA pro-
duction. Figure 18.16 shows the effect of a decrease in TMA product flow. Now
both recyc1es increase, DMA increases slightly and fresh methanol decreases.
.MivlAR,
, . . ,
~
~ ..... _, ...............,. ·; ..·.... ¡TMARe~
~ .. -- .. '. ..... -............. -'.- -........... - -_._-.:......... ;-
~_ .....). __ .. - . , . ,
Figure 18.17 shows the response of the system to a step change at time
equal 0.25 hours in the setpoint of the flow controller on the MMA product
stream from 56.6 to 70 lb-m01lhr. The recyc1e flow of MMA decreases slowly,
but the recyc1e ofTMA undergoes a smal1 increase. There is a gradual increase in
both of the fresh feeds.
394 Chapter 18
lIows2
~
o Rtot
,.,,.,,,
.H>
;~
.. ~
FFA
DMA
1(
Time Hours
Figure lS.IS gives responses to a step change in the flow ofRTOT (fresh
methanol plus MMA and TMA recycles) from 671 to 750 lb-mollhr. There is a
slow increase in TMA recycle and a slow decrease in MMA recycle. Remember
the production rates of MMA and TMA are constant as seen in Figure lS.ISA.
This disturbance results in significant increases in the fresh feeds (both methanol
and arnmonia) and the production ofDMA as shown in Figure lS.I8A. Therefore
this flow controller provides an effective production-rate handle.
Amines 395
~¡fAiRp.r. -
- -i--
¡-- - -
~:
'- A
1111:V ./"
--- TMARec
'"
~ --
TMA
g _.
o 0.5 1 15 25 3 35 45 5 5.5 65 75 85 95
Time Hours
o lIows2
~
Rtot
~
~
FFM
[~~3g
tH¡~
~
FFA
g
o
N
DMA
iil
Time Hours
396 Chapter 18
MMA
~ f···j···· ...,.........i . L ....... ,..... +........,........ j......., ...... j.... L ....... ,........ , . .L .... + ......,........ ,....... , ... '- .... ,
'TMARec
~~ . .,..... , ... ; .......; ........ ; ... ;..,. + ...... ,........ ; .. +- ..... ;.... , .......;........ ;....... ; .. ; +- ....... ;........
g:~ ...... j .......; ........ ,........ i ........ ;........ +......,....... j........., ........ j........ ; ..... ;......c.......;........;.......;....... ;........ ,........; ... ,
FFA
1C
TIme Hours
Amines 397
:g
TMARec
g
:"----- ! .--;..--
-+---+--t ,
'"
"" ~.~
./' '
-........
~
J
¡'f -------
"" '\.
'\.¡""
TMA
.""
:'l
g
"'" ~
~
:<; T\iIl\A"A];> ,
---------- '--
,-.
o ,_
05 1 15
"_,5 3 3.5 4 4.5 5
nmeHours
5,5 6 55 7 75 8 8.5 9 95 1(
110",2
:.(. . . . . . . . . . . . . . .
:~I
Rtot
L ............................. +-................................. .¡ ......................... ,................................... !
~~ FFM
:~
~r······························,·································7·································¡······h ....................... ' ..... h ..................,
FFA
nl'vfA
Time Hours
398 Cl1apter 18
~ ~
~
~ g ~
compos;';"s
~,-----------------------------i-----------------------------------------------------------i--------------------------------;-----------------------------
_________ , ____________________ c________________________ i _________________________ , ______________ _
~
,
_
Lól.\'~ ~~
j111:'l'---------------------------------------------------:--------------------------------------+--"'''-c~---------------------------~'-------------------------------------;--------------------------------------,
~4::-V~XTMA===::~===t====i=,-~-~-=
--'\::::7 xNH3
10
Time Hours
Amines 399
Figme 18.18B shows that tray temperatmes in Co1lUllils C3 and C4 are well
controlled, but reactor outlet temperatme rises from 570 to about 582°F. The
TMA composition is well controlled. The purity ofMMA changes very little, but
the purity of the DMA drops from 95 to 90 mol%. A reflux ratio scheme may
improve this situation. Of comse more precise tuning should help too. Even with
the strictly empirical tuning, the system was able to ride through this significant
distmbance.
The final distmbance tested is an increase in total ammonia flow (fresh
feed plus recycle). At time equal 0.25 homs, a step change in the flow controller
set point is made. Figme 18.19 shows that MMA recyc1e decreases very signifi-
cantly, but TMA recyc1e changes only slightly. There are increases in both fresh
feeds and in DMA production but not as much as when the RTOT stream is in-
creased. Reactor outlet temperatme drops almost 20°F. There is little effect on
product purities.
These simulation results indicate that this basic regulatory control struc-
tmeworks.
:g
g
~ jl\¡f 1""
::l
"~ I;¡/ /!
:;¡~
../ '-.... ------ ~ MMA'
~
"
:'i
:;:
TMA "" ,,< "'-..
"'-..
:<:l
g
"" ~ ---...
---.... r---...
:o
"
l\JIlvf A R ''''
!--.-.
-- --
~
o 05 1 15 2 25 3 3.5 4 45 5 55
. 6 6.5 7.5 8 8.5 9 9.5 10
Time Hours
400 Chapter 18
lIowo2
Rtot
~r"""""""""""'" j.................................. , ................................... ; .................................. +................................ ,
~r··································;················· .................. , ....................................... , ................................ +................................... !
e ;h;;~;;·~F·~·=·==3.FF~M.~~...~...:. =.J.====.==[,.=.=.=.=J.
¡1 1~'r. . . . . . . . . . . . . . . . . .;. . . . . . . . . . . . . . . . . . . ,. . . . . . . . . . . . . . . . . . . ,. . . . . . . . . . . . . . . . . . . ,. . . . . . . . . . . . . . . . . . .,
g ...F1'A .................,
~. • =~;:==:
o 2
Time Hours
I M
M
~r·····'···,··,·····,·····"········,·,····,·······,','.c,~,.
I M B:=' !l / . J Z [
~¡h: 1: :LL. . y ... j . , C...... +.H ...:......... ).14,.:::::. :: : ';: :H.:~'.: ; '.:'.::: :', . . : H...· :.·.',::."·.H:
Ir r I
~ g ~ ··I ... '...+., ........!........,.........,........ ,........,........!........ ¡........,........ ,.........:.........:.........¡......... ¡........ ¡..... H.!.H ..... ¡........, .........,
~~ M l'l" f···'··,/···;·······.········.····+··· .., ....., ......:........ :....... +-....... + .+ .......,.........,........ ,...... ,. +-......,. ;
~ 1··,T¡...... ,l.,.'v.'..u.. '¡ ..... ¡.... + .......¡.........¡........,........ ,..... ¡. ¡ ........,........+ ....¡........,.... . ¡ . ¡........¡ . ¡ ,
m M ~ r'.'...... ; . . .,... ,......' . H'.' .. ¡ ¡ . ¡........, ....... ' ..... H'.H'.¡.¡........,.........
~
~ M ~ I¡·······¡········!········,········:········,········¡, ........ ,............!........,........,.........,.........!........ ,! ........ !........ !........ !........ ,.........,
:1-----
o ---------------------------xN!lv[A---
.................. j....
o _n ____ . ___ ~--~ nn. ___ .nn. __ uu· ______ ··· ......f·····n. · .... ·...... ··· .... ·.... ···i·...... --00 . . . . . . . . . . . . . . . . . - •••••••: • • • __ n ........ ____ . ____ . ___ ........ !
xNH3
_ • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • -;- •••• 0 •••••••••••••••••••••••••••••• :
¿g -- ..................... j.. _-
Time Hours
This process has rnany columns, rnany cornponents and rnany recyc1es.
Cornputing times are quite significant. The realtime factor was found to depend
strongly on the type of disturbance. For the product flowrate disturbances, real-
time factors are about 30 on a Dell1.7 GHz cornputer. For the RTOT and ATOT
changes, the simulation crept along at only about five times real time. So the 10
hour process-time simulations took over two hours of cornputer time.
18.5 Conclusion
The last four chapters have presented sorne realistically cornplex processes.
They provide examples for which plantwide dynarnic simulations are extremely
useful and powerful.
In the final chapter we cover a few rniscellaneous topics and conc1ude our
introduction to dynarnic simulators.
h ter 19
Concluding Tapies
In this final ehapter we wrap up a few loose ends and diseuss a number of
miseellaneous topies.
l. Suppose you have a case with files that are stored in a folder or di-
rectory called "mycases." The three files in this folder are labe1ed
"case.bkp", "casedyn.appdf' and "case.dynf"
2. Move the "case.dynf' file to a different folder or directory (let's
call this folder "convert").
3. Open AspenPlus and run case.bkp. After pressure checking, export
the file to the "mycases" folder as a pressure-driven sinmlation file
called "case.dynf"
4. Replace the new "case.dynf' file in folder "mycases" with the old
"case.dynf' file that you have stored in the folder "convert."
This preserves all the controllers, cOl1llections and plots developed in the previous
version.
403
404 19
l. Suppose the files fOl" the original case that are called "case.bkp"
and "case.dynf." Use your file manager or window explorer to re-
name the "dynf' file. Let's say we rename it "casexx.dynf"
2. Run AspenPlus and make a11 the process changes. Check the Dy-
namics button and then the Pressure Check button.
3. Export the file as a pressure-driven simulation. This generates a
new "case.dynf' file.
4. RUll AspenDynamics and open the "case.dynf' file. This will open
a-flowsheet with the default controllers installed.
5. Go through the flowsheet and delete a11 these default controllers
and a11 the control signal lines. Figure 19.1 shows an example
flowsheet (the depropanizer colunm studied in Chapter 8) with de-
faulí controllers installed. Click each controller and each control
signal line while holding the Shift key down, alld then press the
Delete key. Figure 19.2 shows the flowsheet with a11 ofthe default
controllers deleted.
6. Go to File on the top menu bar and click "hnport File." Then spec-
ify you want to import the file you renamed (casexx.dynf).
7. A window wiU open that shows a11 the duplicate itenls between the
existing and the inlported flowsheet. See Figure 19.3A.
8. Highlight all the items in the list by clicking the first one, scrolling
down to the bottom of the list and clicking the last one with the
Shift key held clown. See Figme 19.3B. Then click the Delete but-
ton in the window and c1ick the OK button. As shown in Figure
19.3C, a11 the duplicated items wi11 be deleted.
Conclusion 405
V1
,,-"'----"0-----~><l--___fVlV30UT
MatelialShearn
MalenalSlream
Valve
Valve
Valve
Pump
Pump
RadFrac
The flowsheet will appear (see Figure 19.4) with all the controllers installed
as in the original case. The picture is usuallya messy one, with several ofthe con-
troller blocks positioned on top of each other. You must zoom in and sort out and
reposition the controllers to get a nice neat flowsheet. This job is a pain, but it is
less work thall reinstalling and specifYing all the controller parameters ifthe flow-
sheet has more than just a few loops.
:PC
'O~-
: Vl
~"/I=
·T·!~
, Lel
-i>o---------- ::
B' _ .J,~3
.-mc--'l ~.
: JLJ ~o-----~~
_________________________ .... _............. t·~.........i
lag1
Both simulators permit you to do sorne calculations using equations that are
appropriate for your process. HYSYS has a simple spreadsheet in which this can
be achieved. We have already illustrated its use in Chapter 9 to achieve reflux ratio
control. The distillate flowrate was imported into the spreadsheet, the desired re-
flux flowrate was calculated and this was exported to a flow controller on the re-
flux flow as an external setpoint.
Equations can also be used in AspenDynarnics, but their use is somewhat
more complexo One of the complexities is that you must remember that all the
calculations are done in metric units. y ou must also use the rather long and com-
plex names of variables. For example, a temperature on Stage 6 of a distillation
colmnn called DP would be called ''Blocks(''DP'').Stage(6).T''. It is important to
get the correct syntax for variable names. Ibis can be obtained by looking at the
All Variables table of a block.
To illustrate the procedure let us calculate the average temperature of four
trays in the Recovery Colmnn ofthe HDA process considered in Chapter 15. You
remember that we did this by using three surnmers and a ratio block in that chap-
ter. Using equations is a more simple aiternative.
The procedure is:
4. Compile the equations by right clicking the editor window and se-
lecting Build and then Compile. Results are included in the Local
variables table in the Flowsheet area.
5. In this example, we must also open the AH Variables window for
the lag (Lagl) and specify the input to be "Free." Figure 19.7
shows the AH Variables window fOl' Lagl and the controller face-
plate, which displays in Engineering units since this has been used
in the example.
LC32
VlO
,-- -->{)
I
:
CONSTRAINTS
! / Flowsheet vaJ::iables sud equal~ions ...
1: 1ag1. input_ = (Block3 ("C3"). Stage (5). T + Blocks ("C3"). Stage (6) . T
lID
COl1c!uslon 409
There are many other uses for these flowsheet ca1culations or spreadsheets.
One fi..equent1y used example is their use to ca1culate reactor conversion and yield.
The molar flowrates of reactants and products in the inlet and exit streams 1i-om
the reactor are used to do these ca1culations.
DIP Colwnn
"
----->0-----1 tC2
---->0-----------------------:
I V2
~
___ o,
: te>
stepfeed 1/ <T~igge~>
Fo~ event d~iven tasks, <T~igge~> can be eithe~:
Runs When <condition> e.g. Runs When Time==2.5, o~
Runs Once When <condition>
Ramp «variable>, <final value>, <du~ation»;
SRamp «variable>, <final value>, <du~ation»;
Note that all va~iable values must be in base units (usually Metric)
Conclusion 411
dpplol FIowsheet
Slreams
412 19
When the program is ron, fhe setpoint of the flow contTOller is changed at
time equal 0.25 hours and again at time equal 2 hours. Results are given in Figure
19.12.
~ ~
ffi 2lo
~ )fi
~
~
6
~ i'l
!Oí
~
ill
~
[3
~ !'l ~
1~
~~
t~ t:
~
l~
1,
t~ I~
i'l 8
6
~
~ ~ o
~
~ B o
i'l
~ i'i
8;
~
~
8; o
~
HYSYS also has the useful feature of scheduling actions to be taken. These
can occm at specific times or when certain conditions occur. The procedure is:
2. Click Add (Figure 19.14B) and click Add again. A window opens
as shown in Figure 19.14.C. Then click Add a third tinle.
3. Figure 19.15 shows a window in which you specity that the action
shou1d be taken at a specific simu1ation time. We specity that this
event will occur at time equal15 minutes.
4. Clicking the Action List page tab opens the window shown in Fig-
ure 19.16. Se1ect Specific Variable. A window opens (Figure
19.17A) in which you can se1ect the variable to be changed and the
specified value by clicking the Target button. In the example we
want to change the setpoint of the feed flow controller (FC) in the
depropanizer column considered in Chapter 8. So we select the tar-
get to be the SP of controller Fe. The llew feed flowrate is entered
(120 lb-mol/hr). Make sure the wüts (lb-mol/hr) are the same as
those shown in the Cunent Va1ue box.
A second event to decrease the feed flow from 120 to 80 lb-mol/hr at time
equal 120 minutes is added using the same procedure (see Figures 19.19A and B).
Figure 19.20 shows that both events are scheduled. Figure 19.21 gives the results
of the simulation in which the feed flow is increased at 15 minutes and then de-
creased at 120 minutes.
Cone! LIsian 417
When there are many controllers in a sirnulations, you can spend a lot of
time arranging them in a logical layout so that the changes occurring in the
process can be easily observed. After you save the file and close it, you would
like the case to open up looking just like it did when you closed it. In HYSYS
this is what happens.
However, in ApenDynamis this does not occur unless the following proce-
dure is followed:
1. When you have arranged the controller faceplates the way you
want, click the Tools button on the top toolbar.
2. Select Capture Screen Layout.
3. AspenDynamics will ask you for a name (this is the name ofthe
script that is being preparing). Suppose we call the "mylayout" as
shown in Figure 19.22.
Of course, the example shown has only five controllers, so saving the lay-
out is probably not worth doing. However, for complex processes such as those
studied in Chapters 15 through 18, preserving the controller faceplate layout can
save a lot oftime. Note that both faceplates and plots are located. You may want
to set up one layout with only plots and one with only faceplates. Two different
scripts would be generated, and you can switch back and forth between the two
as desired.
420 Chapter 19
Dynamics
Syste mLibr ary
.... ~ Component Lists :
LocalVariables
Flowsheet
'§
¡~ ;~;
.
(Q,
t:
~.
~
~ ~
1~ r~,·····,·
s; ~
. ,. . ,. . . :- . . . . . + ..... ,
Computer speed is the biggest problem with simulations that are typically com-
plexo A processor with anything less than 600 MHz will run painfillly slowly.
Another significant problem is monitor space. Y ou need to be able to see aH
the controller faceplates, all the plots and the flowsheet. This requires a lot of
area. A 21-inch monitor is quite c1uttered if you have a complex flowsheet with
many controllers. One ni ce solution to this problem is to use dualmonitors. Two
422
19-inch monitors are about the same price as one 21-inch monitor and provide
25% more viewing area. Windows 98 and 2000 support multiple monitors. Two
video cards or one dual-video card are required. Figure 19.22 shows the HDA
process flowsheet with two monitor s used. Controller faceplate, the PFD and
plots can be seen simultaneously.
19.6 Conclusion
The goal ofthis book has been to provide an introduction to the use of com-
mercial dynamic simulators. 1 hope it has accomplished this objective.
The fundamental operations and calculations required to move from a
steady-state simulation into a realistic dynamic simulation have been discussed in
the early chapters. The microscopic details of the basic procedures for installing
the building blocks of a dynamic simulation (controllers, dynamic elements and
plots) and running the simulation have been covered.
A series of cases have been developed, starting with a simple process with
three controllers and gradually moving to complex, multi-unit processes with over
twenty controIlers. .
Now that you have been introduced to the subject and have learned the fun-
damentals, you are ready to use these tools to help you develop and test plantwide
control structures for your process. There is much more to be learned about using
the commercial dynamic simulators, and if you work extensively in this area you
wiIl want to learn how to use aIl the beIls and whistles that they provide. 1 have
tried to get you from a crawl to a walk. Now you should be ready to learn how to
run on your OWll. Good luck and enjoy!
424 Chapter 19
Chapter 4 5 6 7
HYSYS
Steady State Sepss.hsc Blendss.hsc Cstrss.hsc Pfrl.hsc
Dynamic Sepdyn.hsc Blenddyn.hsc Cstrdyn.hsc Pfrldyn.hsc
Pfr2dyn.hsc
PíBdyn.hsc
Pfr4dyn.hsc
Aspen
AspenPlus Sep.bkp Blend.bkp Cstr1.bkp Tubl.bkp
Cstr2.bkp Tub2.bkp
Tub3.bkp
Tub4.bkp
Physical Sepdyn.appdf Blenddyn. appdf Cstrldyn.appdf Tub 1dyn.appdf
Properties Cstr2dyn.appdf Tub2dyn.appdf
Tub3dyn.appdf
Tub4dyn.appdf
AspenDynamics Sep.dynf Blend.dynf Cstr1. dynf Tubl.dynf
Csrt2.dynf Tub2.dynf
Tub3 dynf
Tub4. dynf
Conclusion 425
Chapter 8 9 10 11
HYSYS
Steady State Dpss.hsc Azeoss.hsc Rxdistss.hsc Thfss.hsc
Meac.hsc
Dynamic Dpdyn.hsc Azeodyn.hsc Rxdistdyn.hsc Thfdyn.hsc
Meacdyn.hsc
Aspen
AspenPlus Deprop.bkp Azeo.bkp Rxdist.bkp Thf.bkp
Meac.bkp
Physical Depropdyn.appdf Azeodyn.appdf Rxdistdyn.appdf Thfdyn.appdf
Properties Meacdyn.appdf
Chapter 12 13 14 15
HYSYS
Steady State Hintdisss.hsc Gasrecyss.hsc Liqrecss.hsc Hdass.hsc
Dynamic Hintdis- Gasrecydyn.hsc Liqrec- Hdadyn.hsc
dyn.hsc dyn.hsc Hdadyn2.hsc
Hdadynaverage.hsc
Aspen
AspenPlus Hintdis. bkp Gasrec.bkp Liqrec.bkp Aspenhda. bkp
Average.bkp
Physical Hintdis- Gasrec- Liqrec- Aspenhdadyn.appdf
Properties dyn.appdf dyn.appdf dyn.appdf Averagedyn.appdf
Chapter 16 17 18
HYSYS
Steady State Alkysss.hsc Eb2ss.hsc
Dynarnic Alkydyn.hsc Eb2dyn.hsc
Aspen
AspenPlus Aspenalky. bkp Eb.bkp Amines8. bkp
Physical Aspenalkydyn. appdf Eb2dyn.appdf Amines8. appdf
Properties
AspenDynamics Aspenalky. dynf Eb2.dynf Amines8.dynf
In ex
Alkylation process, 329 Control valve (see Valves)
Allyl chloride, 125 CSTR,105
Ammonia colunm, 381 Cyc1ohexylamine, 105
Autorefi:igeration, 333
Autotuner, 92 Data logger (see Recorders)
Auxiliary condenser and reboiler, 255 Deadtime, 8, 88
Average temperature control, 316, 325 Debutanizer, 333
Azeotropes in methyl amines system, Decanter, 181, 191
378 dynamics, 187
Azeotropic distillation, 181,227 Default controllers, 68
Deisobutanizer, 284, 333
Benzene/toluene, 250 Depropanizer, 155, 333, 346
Bode plots, 152 Diethyl benzene, 357
Bugs in software, 8 Distillation columns, 155
colurnn sizing, 157, 174
Cascade control, 33 hydraulic parameters, 174
Case study programs, 422 pressure drop, 156
Cornmunication time, 82 reflux drum and base sizing, 162
Compressors sub-flowsheet, 169
control, 18 temperature control tray se1ec-
variable-speed drives, 19 tion, 167
Computing time, 327, 355, 372, 401 Dual monitors, 422
Condenser/reboiler, 254 Dynamic assistant in HYSYS, 46, 287
Controller
action, 50, 74 End time, 61
faceplate, 51, 419 Ethyl benzene, 357
initialization,74 Ethylene glycol, 200
installation, 48, 68 Event scheduler, 413
output limiting, 168 Exporting file to AspenDynamic, 67
Controller tuning, 25 Extraction colunm, 381
flow controllers, 26 Extractive distillation, 378
leve! controllers, 27
parameters, 51 F-Factor, 161
pressure controllers, 28 Flowsheet equations, 407
Control signals, 71 Fluids package, 184
427
428 Index