Document Text Contents
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ChE 3G4
HYSYS TUTORIALS
Tutorial 1: Introduction to HYSYS – Not Graded ........................................................ 1
A. Learning Objectives:............................................................................................... 2
B. Defining the Simulation Basis ................................................................................ 2
C. Selecting a Unit Set................................................................................................. 3
D. Adding a Stream ..................................................................................................... 3
E. Flash Calculations................................................................................................... 4
F. Adding Utilities....................................................................................................... 5
G. The Stream Property Value..................................................................................... 5
H. Customizing the Workbook .................................................................................... 5
I. Flash Calculations of a Ethanol-Water Mixture ..................................................... 6
J. Additional Exercises (For Extra Practice using the GasPlant Example) ................ 7
Tutorial 2: Propane Refrigeration Loop – 15 Marks .................................................... 8
A. Learning Objectives ................................................................................................ 8
B. Base Case (5 marks)................................................................................................ 8
C. Manipulating the PFD........................................................................................... 10
D. Manipulating Process Variables (10 marks) ......................................................... 10
E. Printing.................................................................................................................. 11
Tutorial 3: Refrigerated Gas Plant - 10 marks ............................................................ 12
A. Learning Objectives .............................................................................................. 12
B. Building the Simulation ........................................................................................ 12
C. Adding the Balance Operation.............................................................................. 14
D. Adding the Adjust Operation ................................................................................ 15
E. Using the Case Study............................................................................................ 15
F. Bonus (5 Marks) ................................................................................................... 16
G. Saving the Simulation as a Template.................................................................... 16
Tutorial 4: Recycle Operations - 10 marks.................................................................. 17
A. Learning Objectives .............................................................................................. 17
B. Building the Simulation ........................................................................................ 17
C. Installing the Recycles .......................................................................................... 19
Tutorial 5: Separation Columns – 10 marks ................................................................ 21
A. Learning Objectives .............................................................................................. 21
B. Building the Simulation ........................................................................................ 21
C. Column Sub-Flowsheets (Read Only) .................................................................. 26
Tutorial 6: Optimization in HYSYS – 15 marks.......................................................... 27
A. Learning Objectives .............................................................................................. 27
B. Building the Simulation ........................................................................................ 27
C. The Optimizer ....................................................................................................... 29
D. Bonus ( 3 Marks) .................................................................................................. 33
ChE 3G04 Winter 2004 McMaster University
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Tutorial 1: Introduction to HYSYS – Not Graded
A. Learning Objectives:
• Define a Fluid Package
• Add streams and a separator
• Perform simple flash calculations
B. Defining the Simulation Basis
1. To start HYSYS go to Course Folders, Chemical Engineering, ceng3g03 and click
on HYSYS.Plant. Start a new case by Selecting File, New, Case.
2. Select the Components tab. This tab allows you to add components to your case.
Select these components: N2, H2S, CO2, C1, C2, C3, i-C4, n-C4, i-C5, n-C5, C6 and
H2O. You can also add components by typing their names (ie. methane rather
then C1) with Match. The components should be listed under Component List-1.
Minimize the window.
3. Select the Hypothetical button under Add Component to add a hypothetical
component to the fluid package. These components can be used to model non-
library components, defined mixtures, undefined mixtures or solids. In this case it
will be used to model the components in the gas mixture heavier then hexane. To
create this component, select the Quick Create a Hypo Comp button.
4. On the ID tab type the name, C7+. Move to the Critical tab. Enter 110oC for its
Normal Boiling Pt. Press Estimate Unknown Props to estimate all the other
properties of the hypothetical component. You should get the following base
property values:
Molecular Wt: 111.00
Ideal Liq Density: 745.38
5. Add the hypothetical component to the current component list by
highlighting/selecting it in the Hypo Components group and then pressing Add
Hypo button.
6. HYSYS contains various Fluid Packages that contain necessary information for
performing flash and physical property calculations. Select the Fluid Pkgs Tab.
Create a fluid package by selecting the Add button and choose Peng-Robinson
Equation of State Model (PR)
7. Change the Name from Basis-1 to GasPlant.
8. The fluid package is now defined and you can now start a simulation. Press Enter
Simulation Environment or the Interactive Simulation Environment in the top
toolbar.
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19. Add a second variable. Select the HC Dewpoint Temperature and press the Add
button. Press the close button to return to the Databook.
20. In the Databook, switch to the Case Studies tab. Press the Add button to add a
new case study. Select the Gas to LTS Temperature as the independent variable
(Ind) and HC Dewpoint Temperature as the dependent variable (Dep.)
21. Press the View button to setup the case study. Enter the values for Low Bound,
High Bound and Step Size of –25oC, 5oC and 5oC respectively. Press the Start
button to begin the calculations.
R
S
F
W
m
i
S
M
t
t
G
H
f
p
r
t
n
t
C
What Gas to LTS temperature range will satisfy the HC Dewpoint specification
(-15oC)?
eactivate the Adjust operation by unchecking the ignore box.
AVE THIS CASE ON A DISK
. Bonus (5 Marks)
hat is the log mean temperature difference (LMTD) for the exchanger with an
inimum approach temperature of 5oC? Double Click on the heat exchanger to find this
nformation.
uppose now the available UA for the Gas-Gas exchanger is only 1.5 x 105 kJ/oC h.
ake the necessary modifications to your exchanger design to achieve this UA. What is
he affect on your LMTD and minimum approach temperature? Describe the steps you
ook to solve this problem in HYSYS.
. Saving the Simulation as a Template
YSYS allows the user to save a simulation as a template. A template is a complete
lowsheet that has been stored to disk with some additional information included that
ertains to attaching the flowsheet as a sub-flowsheet operation. Typically, a template is
epresentative of a plant process module or portion of a process module. The stored
emplate can be read from disk and installed as a complete sub-flowsheet operation any
umber of times into any number of different simulations. The main advantage of a
emplate is it can link two or more cases together.
22. Choose Main Properties from the Simulation menu.
23. Press Convert to Template button. Press Yes to convert the simulation case to a
template. Answer No to the question “Do you want to save the simulation case.”
Name your template file.
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The following constants should be added to the spreadsheet. Do not include their units.
Cell Comment Value
B2 RVP Specification 96.5 kPa
B6 Oil Price 94.35 $/m3
B10 Compression Cost 0.1 $/kw-h
B15 Steam Cost 0.682 $/kw-h
D6 Gas Price 0.106 $/m3_gas
Conversion factor which you will need: 1 kw-h = 3600 kJ
13. In cells D7, D8 and D9, calculate the Gas Revenue, Oil Revenue and Total
Revenue. Watch your units. To write a formula in a cell you do not have to type
the = sign first. Here are the functions you need to know for this case with an
example of what to type in a cell.
Addition (+): +A1+A2
Subtraction (-): +A1-A2
Multiplication (*): +A1*A2
14. Other functions are available by selecting the Functions Help button. The wrong
units will be displayed when each value is calculated. To make these values
unitless go to Variable Type and scroll down to SG.
15. In cells D12, D13, calculate the Compression and steam costs. In cell D14
calculate your Net Revenue (Profit).
16. The Function tab contains two groups, the objective function and the constraint
functions. Close the spreadsheet window and return to the optimizer window.
Select the Functions tab. Select the objective function cell (D14) and select
maximize. For the constraint function select the Add button. For the LHS cell
select cell B1 (current RVP). Select < for the condition. Select cell B2 (RVP
Specification) for the RHS cell. Leave the penalty function as is.
17. Select the Parameters tab. This is used to select the optimization scheme. Select
SQP (Sequential Quadratic Programming). Use the defaults for tolerance and
number of iterations.
18. Move to the Monitor tab and press Start to begin the optimization.
ChE 3G04 Winter 2004 McMaster University
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ChE 3G4
HYSYS TUTORIALS
Tutorial 1: Introduction to HYSYS – Not Graded ........................................................ 1
A. Learning Objectives:............................................................................................... 2
B. Defining the Simulation Basis ................................................................................ 2
C. Selecting a Unit Set................................................................................................. 3
D. Adding a Stream ..................................................................................................... 3
E. Flash Calculations................................................................................................... 4
F. Adding Utilities....................................................................................................... 5
G. The Stream Property Value..................................................................................... 5
H. Customizing the Workbook .................................................................................... 5
I. Flash Calculations of a Ethanol-Water Mixture ..................................................... 6
J. Additional Exercises (For Extra Practice using the GasPlant Example) ................ 7
Tutorial 2: Propane Refrigeration Loop – 15 Marks .................................................... 8
A. Learning Objectives ................................................................................................ 8
B. Base Case (5 marks)................................................................................................ 8
C. Manipulating the PFD........................................................................................... 10
D. Manipulating Process Variables (10 marks) ......................................................... 10
E. Printing.................................................................................................................. 11
Tutorial 3: Refrigerated Gas Plant - 10 marks ............................................................ 12
A. Learning Objectives .............................................................................................. 12
B. Building the Simulation ........................................................................................ 12
C. Adding the Balance Operation.............................................................................. 14
D. Adding the Adjust Operation ................................................................................ 15
E. Using the Case Study............................................................................................ 15
F. Bonus (5 Marks) ................................................................................................... 16
G. Saving the Simulation as a Template.................................................................... 16
Tutorial 4: Recycle Operations - 10 marks.................................................................. 17
A. Learning Objectives .............................................................................................. 17
B. Building the Simulation ........................................................................................ 17
C. Installing the Recycles .......................................................................................... 19
Tutorial 5: Separation Columns – 10 marks ................................................................ 21
A. Learning Objectives .............................................................................................. 21
B. Building the Simulation ........................................................................................ 21
C. Column Sub-Flowsheets (Read Only) .................................................................. 26
Tutorial 6: Optimization in HYSYS – 15 marks.......................................................... 27
A. Learning Objectives .............................................................................................. 27
B. Building the Simulation ........................................................................................ 27
C. The Optimizer ....................................................................................................... 29
D. Bonus ( 3 Marks) .................................................................................................. 33
ChE 3G04 Winter 2004 McMaster University
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Page 2
Tutorial 1: Introduction to HYSYS – Not Graded
A. Learning Objectives:
• Define a Fluid Package
• Add streams and a separator
• Perform simple flash calculations
B. Defining the Simulation Basis
1. To start HYSYS go to Course Folders, Chemical Engineering, ceng3g03 and click
on HYSYS.Plant. Start a new case by Selecting File, New, Case.
2. Select the Components tab. This tab allows you to add components to your case.
Select these components: N2, H2S, CO2, C1, C2, C3, i-C4, n-C4, i-C5, n-C5, C6 and
H2O. You can also add components by typing their names (ie. methane rather
then C1) with Match. The components should be listed under Component List-1.
Minimize the window.
3. Select the Hypothetical button under Add Component to add a hypothetical
component to the fluid package. These components can be used to model non-
library components, defined mixtures, undefined mixtures or solids. In this case it
will be used to model the components in the gas mixture heavier then hexane. To
create this component, select the Quick Create a Hypo Comp button.
4. On the ID tab type the name, C7+. Move to the Critical tab. Enter 110oC for its
Normal Boiling Pt. Press Estimate Unknown Props to estimate all the other
properties of the hypothetical component. You should get the following base
property values:
Molecular Wt: 111.00
Ideal Liq Density: 745.38
5. Add the hypothetical component to the current component list by
highlighting/selecting it in the Hypo Components group and then pressing Add
Hypo button.
6. HYSYS contains various Fluid Packages that contain necessary information for
performing flash and physical property calculations. Select the Fluid Pkgs Tab.
Create a fluid package by selecting the Add button and choose Peng-Robinson
Equation of State Model (PR)
7. Change the Name from Basis-1 to GasPlant.
8. The fluid package is now defined and you can now start a simulation. Press Enter
Simulation Environment or the Interactive Simulation Environment in the top
toolbar.
ChE 3G04 Winter 2004 McMaster University
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19. Add a second variable. Select the HC Dewpoint Temperature and press the Add
button. Press the close button to return to the Databook.
20. In the Databook, switch to the Case Studies tab. Press the Add button to add a
new case study. Select the Gas to LTS Temperature as the independent variable
(Ind) and HC Dewpoint Temperature as the dependent variable (Dep.)
21. Press the View button to setup the case study. Enter the values for Low Bound,
High Bound and Step Size of –25oC, 5oC and 5oC respectively. Press the Start
button to begin the calculations.
R
S
F
W
m
i
S
M
t
t
G
H
f
p
r
t
n
t
C
What Gas to LTS temperature range will satisfy the HC Dewpoint specification
(-15oC)?
eactivate the Adjust operation by unchecking the ignore box.
AVE THIS CASE ON A DISK
. Bonus (5 Marks)
hat is the log mean temperature difference (LMTD) for the exchanger with an
inimum approach temperature of 5oC? Double Click on the heat exchanger to find this
nformation.
uppose now the available UA for the Gas-Gas exchanger is only 1.5 x 105 kJ/oC h.
ake the necessary modifications to your exchanger design to achieve this UA. What is
he affect on your LMTD and minimum approach temperature? Describe the steps you
ook to solve this problem in HYSYS.
. Saving the Simulation as a Template
YSYS allows the user to save a simulation as a template. A template is a complete
lowsheet that has been stored to disk with some additional information included that
ertains to attaching the flowsheet as a sub-flowsheet operation. Typically, a template is
epresentative of a plant process module or portion of a process module. The stored
emplate can be read from disk and installed as a complete sub-flowsheet operation any
umber of times into any number of different simulations. The main advantage of a
emplate is it can link two or more cases together.
22. Choose Main Properties from the Simulation menu.
23. Press Convert to Template button. Press Yes to convert the simulation case to a
template. Answer No to the question “Do you want to save the simulation case.”
Name your template file.
hE 3G04 Winter 2004 McMaster University
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The following constants should be added to the spreadsheet. Do not include their units.
Cell Comment Value
B2 RVP Specification 96.5 kPa
B6 Oil Price 94.35 $/m3
B10 Compression Cost 0.1 $/kw-h
B15 Steam Cost 0.682 $/kw-h
D6 Gas Price 0.106 $/m3_gas
Conversion factor which you will need: 1 kw-h = 3600 kJ
13. In cells D7, D8 and D9, calculate the Gas Revenue, Oil Revenue and Total
Revenue. Watch your units. To write a formula in a cell you do not have to type
the = sign first. Here are the functions you need to know for this case with an
example of what to type in a cell.
Addition (+): +A1+A2
Subtraction (-): +A1-A2
Multiplication (*): +A1*A2
14. Other functions are available by selecting the Functions Help button. The wrong
units will be displayed when each value is calculated. To make these values
unitless go to Variable Type and scroll down to SG.
15. In cells D12, D13, calculate the Compression and steam costs. In cell D14
calculate your Net Revenue (Profit).
16. The Function tab contains two groups, the objective function and the constraint
functions. Close the spreadsheet window and return to the optimizer window.
Select the Functions tab. Select the objective function cell (D14) and select
maximize. For the constraint function select the Add button. For the LHS cell
select cell B1 (current RVP). Select < for the condition. Select cell B2 (RVP
Specification) for the RHS cell. Leave the penalty function as is.
17. Select the Parameters tab. This is used to select the optimization scheme. Select
SQP (Sequential Quadratic Programming). Use the defaults for tolerance and
number of iterations.
18. Move to the Monitor tab and press Start to begin the optimization.
ChE 3G04 Winter 2004 McMaster University
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