Nirma University
Institute of Technology
Chemical Engineering Department
Lab Manual for Advanced Process Equipment Design-I (M Tech – CPPD)
List of Laboratory Practical for APED-I
During laboratory hours calculations for the following problems will be carried out manually as well as
using software like Hysys and HTRI. Each student will be having different problem. Detail problem will
be defined during semester. Each student has to carry out calculations for design for respective equipment
manually and then they have to use this data and design and simulate using software.
Sr.
No.
1
List of experiment
Software to be used
Aspen.Hysys and SuperPro Designer
8
Introduction to Simulators and Building up of
Process Flow Diagram (PFD) with Aspen.Hysys
and SuperPro Designer
Significance of thermodynamic fluid package in
simulation and its selection for given problem.
Some guidelines for selection of fluid package
Simulation of short-cut
distillation column –
Determination of optimum operating temperature
and pressure for distillation column
Design and Simulation of distillation column –
binary
Design and Simulation of distillation column –
Binary system with SuperPro Designer and
Comparing results with Aspen.HYSYS
Design and Simulation of distillation column –
multicomponent
Design and Simulation of packed absorption
column
Design of liquid-liquid extraction column
9
Sizing of Packed/Tray column using K G Tower
2
3
4
5
6
7
10
11
12
Dr R K Mewada
-1-
Aspen.Hysys
Aspen.Hysys
Aspen.Hysys
SuperPRo Designer
Aspen.Hysys
Aspen.Hysys
Calculation and other software like
SuperPro Designer or SciLab can be
used
K G Tower is software for sizing of
column
Nirma University
Institute of Technology
Chemical Engineering Department
Lab Manual for Advanced Process Equipment Design-I (M Tech – CPPD)
Experiment 1:
Introduction to Simulators and Building up of Process Flow Diagram (PFD) with Aspen.Hysys and SuperPro
Designer.
Experiment 2:
Objective: Significance of thermodynamic fluid package in simulation and its selection for given
problem. Some guidelines for selection of fluid package.
Algorithm or flow chart or decision making tree for selection of suitable fluid package for various types
of components.
Thermodynamic models are used to represent the phase equilibrium behavior and energy level of pure
compound and mixture systems. In many cases, simulation results DO NOT reflect what is really happening
in a plant. This is due to
• Improperly selected thermodynamic models
• Inadequate model parameters
• Incorrect hypothetical components generation
• Problems with plant data consistency
Example:
• A mixture of Ethane and Propane at 30 atm
• The PR Equation of State most closely represents the true phase behavior of the system
Aspen HYSYS contains over 30 thermodynamic models
• Equations of State
• Activity Coefficient Models
• Vapor Pressure Models
• Semi-Empirical Models
• Specialty Models
– Steam Tables
– Amines Package
– Clean Fuels Package
– Glycol Package
– OLI
– Neotec Black Oil
– Infochem Multiflash
– etc.
EQUATION OF STATE MODELS
• Peng-Robinson (PR)
– Most enhanced model in Aspen HYSYS
– Largest applicability range in terms of T and P
– Special treatments for some key components
– Largest binary interaction parameter database
• PRSV
– Modified PR model
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Nirma University
Institute of Technology
Chemical Engineering Department
Lab Manual for Advanced Process Equipment Design-I (M Tech – CPPD)
– Better representation of vapor pressure of pure components and mixtures
– Extends applicability of the original PR model to moderately non-ideal systems
• SRK
– Modified RK model
– Can provide comparable results to PR in many cases, but with a lot less enhancement in Aspen HYSYS
• PR-Twu
• SRK-Twu
• Twu-Sim-Tassone (TST)
– Modified equations of state models for hydrocarbon systems-non ideal systems (used for glycol package)
• Generalized Cubic Equation of State (GCEOS)
– Provides a framework which allows users to define and implement their own generalized cubic equation of
state including mixing rules and volume translation.
• MBWR
– Modified BWR model
– Having 32 parameters, this model works extremely well with a number of pure components within specified
T and P ranges
• Lee-Kesler-Plocker
– Also a modified BWR model
– Can be used for non-polar substances and mixtures
• BWRS
– Modified BWR to handle multi components
– Requires experimental data
• Zudkevitch Joffee
– Modified RK model with better prediction of VLE for hydrocarbon systems, and systems containing
hydrogen
• Kabadi-Danner
– Modified SRK model with the enhancement to improve the VLE calculations for H2O-hydrocarbon
systems, particularly in dilute regions
• Sour PR/Sour SRK
– Used for sour water systems containing H2S, CO2, and NH3 at low to moderate pressures.
• Modified Antoine Model
– Applicable for low pressure systems that behave ideally
• Braun K10 Model
– Strictly applicable to heavy hydrocarbon systems at low pressures
• Esso K Model
– Also strictly applicable to heavy hydrocarbon systems at low pressures
-3-
Nirma University
Institute of Technology
Chemical Engineering Department
Lab Manual for Advanced Process Equipment Design-I (M Tech – CPPD)
• Chao-Seader model
– Applicable to hydrocarbon systems in the range of T=0-500C, and P<10,000 kPa
• Grayson-Streed model
– An extension to the Chao-Seader model with special emphasis on H2
– Recommended for heavy hydrocarbon systems with high H2 content, such as hydrotreating units
SPECIALTY MODELS
• Glycol Package
– For accurate representation of TEG circulation rates, purities of lean TEG, dew
points and the water content of the gas stream used in natural gas dehydration process
• Clean Fuels
– For systems containing thiols and hydrocarbons
• OLI
– For electrolyte systems
• Amines Models
– For modeling sour system sweetening processes using amines (DEA, TEA, MEA, MDEA, DGA and DIPA)
• Steam Table Models
– ASME Steam – ASME 1967 Steam Tables
– NBS Steam – NBS 1984 Steam Tables
ASPEN HYSYS RECOMMENDATIONS FOR OIL AND GAS APPLICATIONS
• Hydrocarbon systems – PR, SRK or any other EOS*
• Hydrate inhibition – PR (special fit of BIP)
• Natural gas dehydration with TEG – Glycol package
• Sour gas sweetening with amines
• Utility systems using H2O – Steam Table
RECOMMENDED DESIGN TREE
When faced with choosing a thermodynamic model, it is helpful to at least a logical procedure for deciding
which model to try first. A decision tree is included in below figure. For non- polar fluids, an equation of state
may suffice. For polar fluids , a fitted activity coefficient model is preferred , possibly in combination with
the Hayden-O'Connell method or in combination with some other model. The property packages available in
HYSYS allow you to predict properties of mixtures ranging from well defined light hydrocarbon systems to
complex oil mixtures and highly non-ideal(non-electrolyte) chemical systems. HYSYS provides enhanced
equation of state(PR and PRSV) for rigorous treatment of hydrocarbon systems; steam correlations for
accurate steam property predictions; and activity coefficient models for chemical systems. All of these
equations have their own inherent limitations and you are encouraged to become more familiar with the
application of equation.
-4-
Nirma University
Institute of Technology
Chemical Engineering Department
Lab Manual for Advanced Process Equipment Design-I (M Tech – CPPD)
TYPES OF SYSTEM
RECOMMENDED PROPERTY METHOD
TEG Dehydration
Sour Water
Cryogenic Gas Processing
Air Separation
Atm. Crude Towers
PR
PR, Sour PR
PR,PRSV
PR, PRSV
PR, PR Optionws, GS (<10 mmHg), Braun K10,
Esso K
Lee Kesler Plocker
PR, ZJ or GS
Stream Package, CS or GS
PR
Activity Model, PRSV
PRSV, NRTL
PR
Kabadi Danner
Ethylene Towers
High H2 Systems
Reservoir Systems
Hydrate Inhibition
Chemical Systems
HF Alkylation
TEG Dehydratipon with Aromatics
Hydrocarbon systems where H2O
solubility in HC is important
Systems with select gases and light HC
-5-
MBWR
Nirma University
Institute of Technology
Chemical Engineering Department
Lab Manual for Advanced Process Equipment Design-I (M Tech – CPPD)
The following diagrams show the process for choosing a property method.
* See
-6-
Nirma University
Institute of Technology
Chemical Engineering Department
Lab Manual for Advanced Process Equipment Design-I (M Tech – CPPD)
Guidelines for Choosing a Property Method for Polar Non-Electrolyte Systems
-7-
Nirma University
Institute of Technology
Chemical Engineering Department
Lab Manual for Advanced Process Equipment Design-I (M Tech – CPPD)
Guidelines for Choosing an Activity Coefficient Property Method
-8-
Nirma University
Institute of Technology
Chemical Engineering Department
Lab Manual for Advanced Process Equipment Design-I (M Tech – CPPD)
Experiment 3:
Simulation of short-cut distillation column – Determination of optimum operating temperature and pressure
for distillation column
Problem: Find out best possible operating temperature and pressure for separation of Vinyl chloride
and Ethylene Dichloride.
Experiment 4:
Design and Simulation of distillation column – Binary system
Problem: Design distillation column for separation of Vinyl chloride and Ethylene Dichloride based on
best operating conditions data. Also carry out simulation to optimize operating parameters like reflux
ratio, no. of stages, feed point location, condenser and reboiler duty, product purity etc.
Experiment No. 5:
Design and Simulation of distillation column – Binary system with SuperPro Designer and Comparing results
with Aspen.HYSYS
Problem: Carry out simulation to optimize operating parameters like reflux ratio, no. of stages, feed
point location, condenser and reboiler duty, product purity etc using SuperPro Designer for the above
case.
Experiment No. 6: Design and Simulation of distillation column – multicomponent
Problem: Proposed various sequence to separate mixture of C3-C5 alkanes. Feed composition is given
in following table. Design any one column. Also carry out simulation to optimize operating parameters
like reflux ratio, no. of stages, feed condition, condenser and reboiler duty, product purity etc.
Experiment 7:
Design and Simulation of packed absorption column
Experiment 8:
Design of liquid-liquid extraction column
Experiment 9:
Sizing of Packed/Tray column using K G Tower
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