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No. 61 May 2006 news from AspenTech - heat exchanger design excellence through research

In this issue....
New generation Aspen New generation of tubular exchanger
HTFS+
solutions
z Aspen Tasc+
Release of aspenONE 2004.2 is a major milestone for users of the Aspen HTFS+
z Aspen Acol+ products.

Worldwide Workshops It brings the next generation of design rating and simulation software for shell and
HEN Lifecycle tube exchangers with our new Aspen Tasc+TM2004.2. For air-cooled heat
Management exchangers (and economisers etc) our new Aspen Acol+TM2004.2 program
provides customers with a huge leap in capability and user friendliness. Acol+ and
Bronswerk host Tasc+ also deliver unparalleled integration with our process simulation tools:
Tubular RP Aspen HYSYS® and Aspen Plus®.

Training
These new aspenONE 2004.2 applications bring greatly enhanced collaborative
Current Products engineering to reduce design project cycle times and reduce engineering cost
through: less re-work, more effective individual unit design optimization, and more
To Contact Us comprehensive overall process optimization. Using common Tasc+ and Acol+
exchanger models through process design, unit detailed design through to
operational monitoring not only delivers capital savings to process operators, but
also brings more effective optimization of operations.

Aspen Tasc+TM our new thermal design program for shell and tube heat
exchangers.
Tasc+ is the result of the merging of the best of Hetran and TASC into our
program of the future. This is the culmination of two years intensive development
effort. In designing the Tasc+ input and output we were greatly assisted by the
Tubular Exchangers Review Panel and over 30 companies who agreed to join our
beta test programme. Tasc+ provides the user with major improvements in ease of
use, functionality and technical methods.

New User Interface (UI)


On starting the program the user will notice a new UI. This will serve as the
launching pad for the new Aspen HTFS+TM heat exchanger design and rating
programs. The user will be able to compare a shell & tube design to an air-cooler,
and then create a mechanical design all from a common environment. The new UI
uses a single file for input and output which is shared by new applications. This
streamlines the maintenance and storage of both input and results.

The UI contains a navigator tree for accessing and displaying the various input
and results forms. The tree highlights essential data items and indicates when all

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required data has been entered. Checks are made at the time of data entry for
incorrect or inconsistent items. The three major systems of measure are
supported. The user can toggle between the three systems of measure, with the
program converting data values if required. There is a highly-flexible facility to alter
the unit of measure for individual data fields.

Input Data Checking

The new UI is capable of translating both TASC or Hetran input files to allow easy
comparison of the results with either of our heritage thermal programs.

The UI is an Active Automation Server. The ActiveX technology enables an


external Windows application to interact with the HTFS+ UI through a
programming interface using a language such as Microsoft's Visual Basic. The
server exposes objects through the Common Object Model (COM).

Output from the program can be exported to Microsoft Word or Excel. It is also
possible to drag and drop output items from Tasc+ to Excel to create dynamic
links.

Physical Property Packages


Tasc+ gives users unrivaled physical property options. Accepted industry
standards for Chemicals, Aspen Properties® and Energy, Aspen COMThermo®,
are included as standard. In addition a range of industrial fluids and combinations
are available through the heritage B-JAC database. The user can control the
properties accessed for both temperature and pressure ranges. Properties can be
retrieved for viewing and validation prior to any design, rating or simulation
calculation.

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Physical Property Preview

The databases include properties of over 2500 components and more than 30
VLE and mixing rule methods.

Optimized Design Search


New Design logic has been developed for Tasc+. This features a much more
exhaustive search for the most economical design than was provided by TASC or
Hetran. The design logic been built upon the full rigour of the TASC checking
mode (rating) calculations and on precise calculation of the tube layout. Users will
find complete consistency between design results and checking calculations.

Design Optimization Output

Background Mechanical Design


Tasc+ performs an ASME mechanical design in the background for the main
exchanger components. In addition it uses the materials of construction and
fabrication databases used by the Aspen B-JAC products including Aspen
Teams®. Users will find that Tasc+ produces a very accurate setting plan and
weight estimate.

An interface is provided for linking to Koch Heat Transfer's DLL for Twisted-Tube
Heat Exchangers. Users wishing to take advantage of this feature should
approach Koch Heat Transfer directly to obtain the KHT Twisted-Tube DLL.

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Additional technical enhancements include:

z User input of fouling thicknesses


z Fouling mode to calculate fouling resistance corresponding to a specified
duty
z Improved calculation method for single phase heat transfer & pressure drop
for low-finned tubes
z TEMA vibration analysis in addition to the HTFS recommended methods
z Creation of a 3-D model through the interface with AutoDesk's Inventor®
program
z Bi-directional transfer of data between Tasc+ and Aspen Teams

Inventor 3-D views

Simulator Run-time Interfaces


High-level run-time interfaces between Aspen Tasc+ and Aspen Plus®/Aspen
HYSYS® allow process engineers to take full advantage of the expertise of a
thermal designer. Tasc+ exchanger models can be readily embedded in a HYSYS
or Aspen Plus simulation to allow more complete optimization of an entire process.
It is also very easy for the process engineer to provide the thermal engineer with a
Tasc+ design case file containing the certified properties and design conditions
allowing the thermal designers to rapidly produce an optimum design. Similarly,
process simulations with Tasc+ exchanger models can be used to optimize
process operations or to accurately evaluate the performance of the heat
exchangers during operations. Multi-disciplinary collaboration is greatly enhanced
with the new tools.

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Tasc+ integrated in HYSYS simulation

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Aspen Acol+TM our new thermal design program for air-cooled heat exchangers.
For many years our HTFS heritage has provided the pre-eminent technology for
design, rating and simulation of process air-cooled heat exchangers. This was
founded on ground-breaking innovation in ACOL modelling and the most
comprehensive programme of air-cooled heat exchanger research stretching back
over 30 years.

Today our program is the number one choice in chemicals, refining and gas
processing. In recent world-scale LNG projects ACOL was the choice for front-end
engineering, detailed engineering and check rating of manufacturer's bids.

Our leadership position is furthered by the major technical developments and the
practical "usability" of AspenTech's new Acol+ program.

Our research has yielded methods for finned tube heat transfer as pressure drop
prediction that have brought unparralleled confidence to operators, engineering
contractors and fabricators alike. Acol+ adds new methods for in-line
configurations of finned tubes, replacing the uncertainties associated with open
literature methods with new HTFS+ correlations which deal correctly with irregular
in-line pitch arrangements. These geometric configurations are often used in heat
recovery applications including steam generators or co-generation plant and air-
heating applications for malting and drying.

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Design Optimization Output

Amongst other powerful technical advances this release significantly enhances the
value of our unique modelling capabilities for A- and V-frame air-cooled
condensers by allowing up-flow condensing with condensate reflux. Many air-
cooled vacuum steam condensers use this configuration.

Setting plan output, front elevation

Based on the user-friendly features derived from B-JAC Hetran & Aerotran, the
new user interface boasts all the flexibility described for Tasc+, including direct
access to Aspen Properties as well as COMThermo. This gives our users access
to the industry-standard property and VLE capabilities for the Chemicals and
Energy sectors.

Acol+ also features an innovative fan curve input. A boon to both designers and
operators, this allows users to assess the effect on thermal performance of
changing fan speed or switching to a completely new fan configuration.

Acol+ has a high level interface to Aspen Plus, bringing the rigor and authority of
HTFS air cooled exchanger modelling to optimise process designs and operations
with this process simulator. Acol+ now offers the same materials of construction
capabilities of Tasc+, Teams, Hetran and Aerotran with selection from ASTM and
other material databases.

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Input for Materials of Construction

The program has a full optimised design capability structured around the design
search method of Aerotran, with HTFS tubeside and airside modelling science at
its core. The extensive simulation capabilities which were a great strength of
ACOL are all retained.

This combination of practical engineering and world recognised methods and


correlations finds many customers clamoring to up-grade to Aspen Tasc+ and
Aspen Acol+.

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Worldwide Workshops on Tasc+ and Acol+

A program of free workshops promoting customer migration to Tasc+ and Acol+


started immediately prior to the release of the products in November 2005. The
first event coincided with AspenTech's European User Group meetings in
Amsterdam. Since then 9 events have been held with 227 attendees.

The workshops are focused on practical hands-on experience with the products,
allowing thermal designers and process engineers to gain confidence in using the
tools with real design and operational problems. The overwhelming feedback can
be paraphrased: "This is great! When can I get these programs in my
company?"

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Further Tasc+/Acol+ workshops are planned for Russia, China and South America
over the coming months. In addition we will be offering Web-presentations on
Tasc+ and Acol+. Keep an eye on our events calendar at:
www.aspentech.com/corporate/events/index.cfm

More information on Tasc+ and Acol+

We have a simple commercial policy which allows customers with current licences
to migrate to the new products. If you would like to know more about Tasc+ and
Acol+ or would like to obtain the new programs, please contact us at:
htfs@aspentech.com.

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Heat Exchanger Network Lifecycle Management using Aspen


HX-Net®

Aspen HX-Net focuses on the design and optimization of heat exchanger networks
(HENs) and provides critical engineering insights in an integrated and interactive
environment. With Aspen HX-Net's seamless integration with Aspen HYSYS and
Aspen Plus process simulators and its easy-to-use energy analysis functionalities,
process engineers can immediately find the potential for further energy efficiency
improvement of an existing process.

Heat Exchanger Network Lifecycle Management

Aspen HX-Net supports every stage of the HEN lifecycle from initial design to its
operation and during the evaluation of improvement projects.

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Heat Exchanger Network Lifecycle

z HEN Design: Design of new heat exchanger networks is interactively


carried out using Aspen HX-Net. From the benchmarking of the process
using Pinch Technology targets to the manual or automatic generation of
recommended designs, several opportunities for energy integration are
explored. These options are easily compared based on annualized cost.
z HEN Operation: Aspen HX-Net is a unique decision support tool for the
operation improvement of heat exchanger networks that suffer from fouling.
Studies of the different scenarios include the benefit when cleaning heat
exchangers and the penalty incurred when taking them out of operation.
The extrapolation of plant data obtained through monitoring helps in
establishing heat exchanger performance trends and analysing the impact
that changes in the operating conditions have. Its objective is improving the
performance in a time horizon.
z HEN Improvement: Evaluation of capital projects to increase plant capacity
or reduce energy consumption and related emissions is effectively done
using Aspen HX-Net. Retrofit and debottlenecking studies of the existing
heat exchanger network are performed manually or by using Aspen HX-Net
automatic feature based on the Network Pinch method. Several project
alternatives are quickly compared based in key performance indicators like
the payback period.

Software Structure and Features

Aspen HX-Net is comprised of two modules Aspen HX-Net Design and Aspen HX-
Net Operations.

Aspen HX-Net Design module (HEN Design and HEN Improvement): an


environment that assists on the design or improvement of heat exchanger
networks to simultaneously minimize operating costs and capital investment.

z Pinch Analysis Tools: Manual input of heat integration data or the


automatic transfer of data from an Aspen HYSYS or Aspen Plus simulation
to Aspen HX-Net quickly benchmarks the process using Pinch Technology
targets. Through analysis of thermal flows, Aspen HX-Net calculates utility
and temperature target values while minimizing heat exchanger surface
area and number of heat exchanger units. Composite curves and other
Pinch Analysis graphic tools are readily available for the evaluation of
process integration improvements.

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Pinch Analysis Tools

z Heat exchanger Network Analysis: Aspen HX-Net helps engineers rapidly


assess design options, simplify networks to enhance controllability, and
improve the energy efficiency of existing facilities. The use of a specialized
grid diagram to display the key variables of the network facilitates the
understanding of key interactions and opportunities for improvement. The
latest automatic methods for design and retrofit of heat exchanger networks
have been implemented allowing the user to generate alternative projects
and compare them in a single environment. Aspen HX-Net's combination of
intuitive graphics and advanced algorithms slashes the time needed to
design or retrofit heat exchanger networks. Engineers can quickly screen
and scope alternative heat integration projects to simultaneously minimize
energy consumption and capital investment.

Heat Exchanger Network Analysis

Aspen HX-Net Operations Module (HEN Operation): an environment to analyse


and improve the operational performance of heat exchanger networks that suffer
from fouling. The module addresses operating issues such as fouling monitoring
and feedstock changes. Data extraction from an Aspen HYSYS or Aspen Plus
simulation models and the grid diagram representation are used to isolate the key
elements of the heat transfer system. Aspen HX-Net Operations decision support
capabilities and the use of operational economics of the plant assure a proactive
operation. Decisions like the cleaning of heat exchangers in the network and the

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trade-offs that arise from taking units out of service are quickly evaluated to ensure
the optimal operation of the network.

z What If Analysis feature: Establish the current operational point by plant


data reconciliation and evaluate the effect of changes in the operating
conditions. Assess among other operational changes the anticipated benefit
of cleaning heat exchangers and the penalty incurred when taking them out
of operation at a specified point in time. Easily compare different options
based on operating cost and the performance improvement of the heat
exchanger network.
z Trend Analysis feature: Extrapolation of plant data obtained through
monitoring helps on establishing heat exchanger performance trends. Using
this information, the Trend Analysis feature allows users to study the impact
of changes in the operating conditions for a better performance in a time
horizon. Different scenarios that include cleaning schedules and changes in
plant throughput can be easily studied and compared in order to select
options that improve profitability.

WhatIf Analysis feature

Tend Analysis feature

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65th year Celebration and Review Panel at Bronswerk Heat


Transfer B.V.

It is always heart-warming to celebarate with friends. We were delighted when


Johan Van der Kamp, Chief Design Engineer at Bronswerk Heat Transfer BV,
offered to host our Tubular Exchangers Review Panel meeting in their Nijkerk
offices as part of their celebrations for their 65th year in June 2005. The business
sessions, chaired by Jim McNaught, dealt with a range of planning and technical
issues on Tasc+, Acol+ and our Supporting Research. This was a critical meeting
where members helped the Aspen HTFS team to map out a sound technical
strategy on airside pressure drop calculations for the new Acol+ program. As well
as regular members we had some guest contributers to facilitate a full discussion
including Henk Van der Spek of Howden Cooling fans and Adriaan Bembaron of
ABB Lummus. In addition to a very fruitful panel meeting, members were treated to
a guided tour of Bronswerk's excellent manufacturing facilities seeing an
impressive number of air-cooled and shell and tube exchangers in a variety of
stages of construction.

For Research Network Members, meeting minutes can be viewed on-line at:
www.htfs.com/resnet/review_panels/review.asp

Tubular Exchanger Review Panel meeting

Bronswerk manufacturing facilities

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Training

Check out our training web site at:


support.aspentech.com/supportpublictrain/TrainHome.htm

Full course descriptions can be viewed and you can register online.

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Current Products

Aspen Tasc+ 2004.2TM


Design and performance simulation of all your shell and tube heat exchanger
requirements, including thermosyphons

Aspen TASC 2004.0TM / Aspen Hetran 2004.2TM


Design and performance simulation of all your shell and tube heat exchanger
requirements, including thermosyphons

Aspen Teams 2004.2®


Mechanical design of shell and tube heat exchangers

Aspen Acol+ 2004.2TM


Software for design and performance simulation of air cooled heat exchangers and
simulation of heat recovery units, air conditioning and refrigeration exchangers

Aspen ACOL 2004.0TM / Aspen Aerotran 2004.2TM


Software for design and performance simulation of air cooled heat exchangers and
simulation of heat recovery units, air conditioning and refrigeration exchangers

Aspen APLE 2004.0TM


A single package for design, rating and performance simulation of gasketed plate
and frame heat exchangers

Aspen MUSE 2004.0TM


Performance simulation layer by layer, crossflow calculation and 'first-shot' thermal
design of multistream plate-fin heat exchangers

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Aspen FIHR 2004.0TM


Simulation of fired process heaters

Aspen FRAN 2004.0TM


Rating and performance simulation of power plant feedwater heaters

Aspen PIPE 2004.0TM


Single phase and two phase flashing flow calculations in unbranched pipeline
systems

Aspen TICP 2004.2TM


Thermal insulation calculation

Register at support.aspentech.com/supportpublicasp/RegisterBegin.asp to enable


you to download the latest patches, receive relevant monthly e-Bulletins, search
Knowledge Base for solutions and submit & track your own enquiries.

HTFS Research Network TM www.htfs.com/resnet.asp


The HTFS knowledge base developed over the past 35 years. This includes online
access to the Handbook, research reports and a selection of design reports via the
web. Customers can also have a close involvement in directing our research and
the evolution of our products through participation on Review Panels.

Review Panel Chairmen


Tubular Heat Exchangers Jim McNaught
Furnaces & Fired Heaters Laurie Haseler
Compact Heat Exchangers Vishwas Wadekar

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To contact us

E-mail: htfs@aspentech.com
Web: www.htfs.com

Development centre
Reading
UK
Tel:+44 (0)118 9226405
Fax:+44 (0)118 9226401

Details of further office locations can be found at:


www.aspentech.com/corporate/locations.cfm

Technical Support Centres

e-mail: esupport@aspentech.com

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support.aspentech.com/SupportPublic/centers.html

See the website for a complete list of phone & Toll-free numbers in your area

Europe, Middle East and Africa (EMEA)


+ 32 2 701 95 55

North America, Latin America (NALA)


+ 1 888 996 7100 (Toll-free from US, Canada, Mexico)
+ 1 281 584 4357 (from outside US, Canada, Mexico)

Asia and Pacific Region


+ 60 3 216 12880 (Kuala Lumpur, Malaysia)
+ 81 3 3262 1743 (Tokyo, Japan)
+ 61 7 5448 1355 (Australia)
+ 86 10 845 38 613 (China)
+ 91 20 56230614 (India)

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Aspen Technology, Inc., Worldwide Headquarters, Ten Canal Park, Cambridge, MA


02141-2201, USA
Tel:+1 617 949 1000 Fax:+1 617 949 1030

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