Experiment No.

1
Title:
Simulation of a Pump on Aspen HYSYS.

Problem Statement:
Pumps are used to move liquids. The Pump increases the pressure of liquid. Water at 120 oC
and 3 bars is fed to the pump that has only 10% efficiency. The flowrate of water is 100
kgmole/hr and its outlet pressure from the pump is 84 bars. Use Peng-Robinson equation of
state as a fluid Package, Determine the outlet temperature of water.

Learning Outcomes:
Following are the learning outcome of the respective simulation

 Operate a Pump operation in HYSYS to model the Pumping process

 Connect streams to unit operations
 Determine the Pump efficiency and outlet temperature

Pre-Requisites:
The pre-requisites of the respective simulation are listed below
 Starting the HYSYS program
 Selection of components
 Defining and selecting a fluid package
 Add and specify material streams

Simulation Setup:
 Open Aspen HYSYS
 Create a new simulation on HYSYS by selecting New on the start page.
 Create a component list. This list is made by adding the given components in the
problem statement. For this particular problem its water. In the component list folder
and select the given component and then click add button.
 Now, select a fluid package. For this particular problem select the Peng-Robinson
equation of state fluid package. This can be done by going to the fluid package tab and
then selecting the respective package.
 Now enter the simulation environment and from the “Palette”, select the pump symbol
and drag it to the main flowsheet.
 Then do the same for two material streams “1 & 2”. Define the material streams by
adding the composition, temperature, pressure and flowrate.
 Connect the material streams to the Pump by opening the pump’s property window and
create the Inlet and outlet streams named 1 & 2 respectively.
 Also, create an energy stream by naming the energy stream as “Work”.
  If the pump has the enough information, then its property window will show a “Green
lit OK” sign in the bottom.
 Moreover, go to the pump parameters in the design tab and enter the pump efficiency as
10%.
 After completing the whole procedure open the worksheet and take look at conditions
and properties such as outlet stream temperature.

Flowsheet:
Simulation Results:
The Results are as follows.
 The temperature of outlet stream is higher and its value is 138.1oC.
 The simulation shows that this Increase is due to the fact that when a pump has less
efficiency the conversion of the pump’s work is to the pressure head is lower and a
considerable amount of energy is converted into the internal energy of the fluid.
Hence, Increasing the fluids temperature.

Case Study:
Simulate a pump in Aspen HYSYS with an increased efficiency say 75% on the same
problem as given previously and observe the change in outlet temperature value.

Conclusion:
After conducting this case study and simulating according to the given conditions it is
concluded that the increased efficiency of the pump results in the less increase of the outlet
temperature of the fluid or water.
Hence proving that the less efficient pump increases the outlet temperature of the fluid more
considerably as compared to the more efficient pump. The worksheet of the said simulation is
given below.
Experiment No.2
Title:
Simulation of a Compressor on Aspen HYSYS.

Problem Statement:
Compressors are used to move gases. The compressor increases the pressure of Gases. A
mixture of Natural Gas (containing C1, C2, C3, i-C4, n-C4, i-C5, n-C5, n-C6, C7+) at 100oC and 1 bar
is fed to a compressor that only has 30% efficiency. The flow rate of natural gas is 100
kgmole/hr and its outlet pressure from the compressor is 5 bars. Use the Peng Robin-Son
equation of state as a fluid package, Determine the outlet temperature of the gas.

Learning Outcomes:
Following are the learning outcomes of the respective simulation
 Define a new component using hypotheticals
 Operate a compressor operation in HYSYS to model the compressing process
 Determine the compressor efficiency and outlet temperature

Pre-requisites:
The pre-requisites of the respective simulation are as follows
 Start HYSYS
 Select Components
 Define and select fluid package
 Add and specify material streams

Simulation Setups:
 Open Aspen HYSYS
 Create a new simulation on HYSYS by selecting “New” on the start page.
 Create a component list. This list is made by adding the given components in the
problem statement. For this particular problem its Methane, Ethane, Propane, i-
Butane, n-Butane, i-Pentane, n-Pentane, Hexane and C 7+. In the component list folder
and select the given component and then click add button. One component that is C7+
is not available in the component list or data of HYSYS. Hence we will add it as a
hypothetical component by clicking on create a hypo and it will create a hypo
component. We would then rename it to C7+ and put its given boiling point (from
experimental data) and the HYSYS will automatically estimate its other properties
once we click the estimate other properties button.
  Now, select a fluid package. For this particular problem select the Peng-Robinson
equation of states fluid package. This can be done by going to the fluid package tab
and then selecting the respective package.
 Now enter the simulation environment and from the Palette, select the compressor
symbol and drag it to the main flowsheet.
 Then do the same for two material streams “1 & 2”. Define the material streams by
adding the composition, temperature. pressure and flowrate.
 Connect the material streams to the compressor by opening the compressor’s property
window and create the Inlet and outlet streams named 1 & 2 respectively.
 Also, create an energy stream by naming the energy stream as “Work”.
 If the compressor has the enough information, then its property window will show a
“Green lit OK” sign in the bottom.
 Moreover, go to the compressor parameters in the design tab and enter the compressor
efficiency as 30%.
 After completing the whole procedure open the worksheet and take look at conditions
and properties such as outlet stream temperature.

Flowsheet:
Simulation Results:
The results are as follows.
 From the whole simulation run, it is concluded that when a gas is compressed, the
temperature of the of gas rises and reaches a value of 165.3oC.
 Moreover, the efficiency of a compressor determines the rise during the compression.
Moreover, efficient compressors are prone to smaller temperature rise and vice versa.
Case Study:
If the outlet temperature is 400oC, what is the efficiency of the compressor?

Conclusion:
When the outlet temperature is 400oC, the efficiency of the compressor is lowered i.e. 14.544.
Experiment No. 3
Title:
Simulation of an Expander on Aspen HYSYS.

Problem Statement:
The expander operation is used to decrease pressure of a high pressure inlet gas stream to
produce an outlet stream with low pressure and high velocity. A mixture of natural gas
(containing methane, ethane and propane) at 25oC and 20 bars is fed into an expander that
only has 30% efficiency. The flowrate of natural gas is 100kgmole/hr and its outlet pressure
from the expander is 5 bar. Using Peng-Robinson equation of states as a fluid package,
determine the outlet temperature of the natural gas.

Learning Outcomes:
Following are the learning outcomes of the respective simulation
 Operate and expander operation in Aspen HYSYS to model the expansion process
 Determine the expansion efficiency and outlet temperature

Pre-Requisites:
Following are the pre-requisites of the respective simulation
 Start HYSYS
 Select Components
 Define and select a fluid package
 Add and specify material streams

Simulation Setup:
 Open Aspen HYSYS
 Create a new simulation on HYSYS by selecting New on the start page.
 Create a component list. This list is made by adding the given components in the
problem statement. For this particular problem its methane, ethane and propane. In the
component list folder and select the given component and then click add button.
 Now, select a fluid package. For this particular problem select the Peng-Robinson
equation of state fluid package. This can be done by going to the fluid package tab
and then selecting the respective package.
 Now enter the simulation environment and from the palette, select the “expander”
symbol and drag it to the main flowsheet.
 Then do the same for two material streams “1 & 2”. Define the material streams by
adding the composition, temperature, pressure and flowrate.
 Connect the material streams to the expander by opening the expander’s property
window and create the Inlet and outlet streams named 1 & 2 respectively.
 Also, create an energy stream by naming the energy stream as “Work”.
 If the expander has the enough information, then its property window will show a
“Green lit OK” sign in the bottom.
  Moreover, go to the expander parameters in the design tab and enter the expander
efficiency as 30%.
 After completing the whole procedure open the worksheet and take look at conditions
and properties such as outlet stream temperature.

Flowsheet:
Simulation Results:
The results are as follows
 From the whole simulation run, it is concluded that when a gas is expanded, the
temperature of the of gas falls and reaches a value of -6.190oC.
 Moreover, the efficiency of an expander determines the temperature fall during the
expansion. More efficient expanders decrease more temperature.

Case Study:
If the outlet temperature is -30oC, what is the efficiency of the expander?

Conclusion:
When the outlet temperature is -30oC, the efficiency of the expander is increased i.e. 70.730.
Experiment No. 4
Title:
Simulation of a heat exchanger in Aspen HYSYS.

Problem Statement:
Hot water at 250oC and 1000psig is used to heat a cold stream of water in a shell and tube
heat exchanger. The inlet temperature and pressure of the cold stream is 25 oC and 130psig,
respectively. The outlet temperatures of cold and hot streams are 150oC and 190oC,
respectively. If the flowrate of hot stream is 100kg/h, determine the flowrate of the cold
stream passing through the exchanger.

Learning Outcomes:
Following are the learning outcomes of the respective simulation
 Operate a heat exchanger operation in HYSYS to model the heat transfer process

Pre-Requisites:
Following are the pre-requisites of the respective simulation
 Start HYSYS
 Select Components
 Define and select a fluid package
  Add and specify material streams

Simulation Setup:
 Open Aspen HYSYS
 Create a new simulation on HYSYS by selecting New on the start page.
 Create a component list. This list is made by adding the given components in the
problem statement. For this particular problem its water. In the component list folder
and select the given component and then click add button.
 Now, select a fluid package. For this particular problem select the Peng-Robinson
equation of state fluid package. This can be done by going to the fluid package tab
and then selecting the respective package.
 Now enter the simulation environment and from the palette, select the “Heat
exchanger” symbol and drag it to the main flowsheet.
 Add four material streams from the palette and name them “tube in (Hot stream), shell
in (cold stream), tube out and shell out” and then specify them by giving them
flowrates, temperature, composition and pressure.
 Open the property window of the heat exchanger and connect these material streams
to the heat exchanger. The hot water stream will be attached to the tube side and the
cold water stream to the shell side.
 The default configuration of heat exchanger is; 2 tube passes, 1 shell pass. And we are
going to work with that
 Now specify the pressure difference as “zero”.
 Hence the property window will show a green lit “OK” sign.
 After completing the whole procedure open the worksheet and take look at conditions
and properties such as cold stream flowrate.

Flowsheet:
Simulation Results:
The results are as follows
 The flowrate of the cold is 55.21 kg/h
 Moreover, the heat transfer rate increases as the flow rate of the cold stream is
increased.
Case Study:
If the flowrate of cold stream is 100kg/h, determine the flowrate of the hot stream passing
through the exchanger. What is the amount of heat transferred from hot stream to cold
stream?

Conclusion:
As the flowrate of the cold stream is increased, the amount of heat transfer also increases for
the same inlet and outlet temperatures of the streams.
Experiment No. 5
Title:
Simulation of a flash separator on Aspen HYSYS.

Problem Statement:
We have stream containing 15% ethane, 20% propane, 60% butane and 5% n-butane at 50 oF
and atmospheric pressure and a flowrate of 100lbmole/hr. This stream is to be compressed to
50 psia and then cooled to 32oF. The resulting vapor and liquid are to be separated as two
product streams. What are the compositions and flowrates of these two streams?

Learning Outcomes:
Following are the learning outcomes of the respective simulation
 Operate the flash separator in HYSYS to model flash separation process

Pre-Requisites:
Following are the pre-requisites of the respective simulation
 Start HYSYS
 Select Components
 Define and select a fluid package
 Add and specify material streams

Simulation Setup:
 Open Aspen HYSYS
 Create a new simulation on HYSYS by selecting New on the start page.
 Create a component list. This list is made by adding the given components in the
problem statement. For this particular problem its water. In the component list folder
and select the given component and then click add button.
 Now, select a fluid package. For this particular problem select the Peng-Robinson
equation of state fluid package. This can be done by going to the fluid package tab
and then selecting the respective package.
 Now enter the simulation environment and from the palette, select the “Compressor”
symbol and drag it to the main flowsheet.
 Add material streams to this compressor and specify their properties and name them
as “Gas” at inlet and “comp gas” at outlet of compressor. Do the same steps for the
compressor as done in the previous simulation.
 Now, select the “cooler” symbol and drag it to the main flowsheet. Also, add material
streams to it just like the compressor but its inlet will be the compressors outlet hence
only add one additional material stream to its outlet named “Cool gas”. The energy
must also be specified for the cooler and name it “cool q” Then by specifying the
 pressure drop as “zero” in parameters, it will be specified and now move on to the
separator.
 Keep checking their worksheets at the end of each of simulation to get an idea of their
parameters like outlet stream temperature and pressure.
 Hence, select the “separator” symbol and drag it to the main flowsheet. Now add two
streams to the flash separator from the property window and also name the product
streams as “top” and “bottom”. The property window will show green “OK” sign
indicating that the equipment is specified.
 Lastly, Check the worksheets of the equipment.

Flowsheet:

Simulation Results:
The results are as follows
 The flowrates and compositions of the top and bottom streams are

Components Top Bottom

Flowrates(Kgmole/hr) 10.59 34.77
Compositions
Ethane 0.4026 0.0731
Propane 0.2479 0.1854
i-butane 0.3299 0.6823
n-butane 0.0196 0.0593
Case Study:
If the cool gas temperature is 10oF, what are the new flowrates and compositions of these two
streams.

Conclusion:
Components Top Bottom
Flowrates(Kgmole/hr) 0.8024 44.56
Compositions
Ethane 0.6100 0.1417
Propane 0.1877 0.2002
i-butane 0.1917 0.6074
n-butane 0.0106 0.0507
Experiment No. 6
Title:
Simulation of a Conversion reactor on Aspen HYSYS.

Problem Statement:
The interest in production of hydrogen form hydrocarbons has grown significantly in the last
decade. Efficient production of hydrogen is enabling technology, directly related to the fuel
cell energy conversion device. The conversion of fuels to hydrogen can be carried out by the
partial oxidation. The partial oxidation method relies on the reaction of the fuel for example
methane with air in order to produce carbon oxides and hydrogen.

Develop a model that represents partial oxidation of methane to produce hydrogen.

Learning Outcomes:
Following are the learning outcomes of the respective simulation.
 Simulate conversion reactor and reaction in HYSYS
 Add the reactions and reaction sets
 Attach reaction sets to fluid package

Pre-requisites:
Following are the pre-requisites of the respective simulation

 Navigate the PFD

 Add streams in the PFD or the Workbook
 Add and connect unit operations
Simulation Setup:
 Open Aspen HYSYS
  Create a new simulation on HYSYS by selecting New on the start page.
 Create a component list. This list is made by adding the given components in the
problem statement. For this particular problem its methane, oxygen, carbon-
monoxide, carbon-dioxide, hydrogen. In the component list folder and select the given
component and then click add button.
 Now, select a fluid package. For this particular problem select the Peng-Robinson
equation of state fluid package. This can be done by going to the fluid package tab
and then selecting the respective package.
 Now, go to the reactions tab below the fluid packages tab and a set will be created.
Add two reactions in this set by clicking on add reactions and select the conversion
reactions. Add your components to the reactions according to the given reactions in
the problem and by assigning these components stoichiometric coefficients by using
given chemical equations we will specify which is of the components is reactant and
which is the product.
 Then we will give some conversion value to the reactions such as 60% for the second
reaction and 40% for the first reaction. Hence we will finish this step by ranking the
reactions by giving both reactions a value as 0 and 1 respectively. It will specify
which reaction will take place first. Add these reactions to already specified fluid
package by clicking “Add to FP”. Panels which will be green lit will show that our
system is specified and we can move forward to the simulation of the reactor
 Go to the simulation environment and select conversion reactor from the columns
given in the palette.
 Add two material streams named “Methane” and “Air”. Set their compositions,
flowrates, temperature and pressure.
 Now, Open the conversion reactor property window by clicking on the reactor and
attach the streams to the reactor. Also, name the vapor and liquid outlets respectively.
 Go to the reactions tab in the property window and select the reaction set as “Set-1”.
The panel under the property window will be green and it will be showing a sign of
“OK” meaning that you’ve run the simulation correctly.
 After completing the whole procedure open the worksheet and take look at conditions
and properties such as outlet stream composition and flowrate.

Flowsheet:
Simulation Results:
The results are as follows
 The product stream is entirely vapors as expected from the reactions and they have a
flowrate of 454.6 kgmole/h showing that there is generation due to chemical
reaction.z