Aspentech HYSYS

Basic Training

Tutor:
Fadli Yusandi

S
Supported
t d bby:

Rules in Classroom

#1

No mobile
phone, social
media and
media,
any other
applications
li ti
during training
sessions

#2

If urgent, please go outside first

#3
If you have any
questions, please just
raise to your tutors,
not to your friends

#5

Last But Not Least..

Least

Have fun!!

Rundown
Introduction to HYSYS
Getting
g Started
Basic Equipment
Logical Operation
Utilities
Subflowsheet and Column

WHY USE SIMULATION MODELS?

Whats it worth?

How can we control it?

How will it work?

60

H
How
do
d we build
b ild it?

58
56
54
52
50
48
46
44
42
M easure

S etpoint

40
0

20

40

60

Tim e (seconds)

How do we run it?

Whyy isnt it working?

g

How much more can we do?

P ro d u ctio n P ro file
8
6
4
2
0
1

S2
S1
6

80

WHY USE SIMULATION MODELS?

Reduces plant design time
Allows designer to quickly test various plant configurations

Helps improve current process

Answers what if questions
Determines optimal process conditions within given
constraints
Assists in locating
g the constraining
gp
parts of a p
process
(debottlenecking)

Simulation

+
Use of a computer program to quantitatively model the characteristic
equation of a process in term of material and energy stream.

Principle
Known Feeds

Predict
P d t
Products

Given
Process Model
Process Design/Analysis
Optimization
Equipment Sizing, Costing

HYSYS Uniqueness
Interactive Simulation ((Automatic Calculation))
Automatic detection of Degree of Freedom
Automatic stream Flash calculation
Full Microsoft Windows Program (click, cut and paste, object,,,)
Bi-directional calculation (non-sequential)
Easy to learn & use
Fast solver (speed)
Extensibility
No Input text file (think about MS Excel)
Fully integrated Steady and Dynamic simulation

HYSYS Main Characteristics

Steady-State Modeling: Input Output = 0

FV
F

Solution Space

F(x)
xi

xs
F(x)=0

FL

F FV FL

Design
Operation
Optimization

Simulation Taken Time

or Number of Iteration

Dynamic Modeling: Input Output = Accumulation

PC

F
FC

FV

x
Design Verification
Operation Analysis
Control
Control Strategy
Operator Training

LC

FL

dV / dt F ( FV FL )

Time

HYSYS Steady State Simulation

Based on components
Material Balance
Component
p
Balance
Energy Balance
Equilibrium
q
information ((Thermodynamic
y
information is required)
q
)

VLE / VLLE.

Pressure drop is a data

Accumulation
A
l ti = 0
0, we d
do nott need
d any iinfo
f regarding
di th
the sizing
i i off

the equipment

Let start
> Run New Case

Rundown
Introduction to HYSYS
Getting
g Started
Basic Equipment
Logical Operation
Utilities
Subflowsheet and Column

How HYSYS is structured

Basis Environment
En ironment (container for all the thermo
thermo. info
info.))
Select components
p
g ( )
Select a fluid package(s)
Oil Environment (focused on Oil modeling)

Simulation
Si
l ti E
Environment
i
t PFD ((process flflow di
diagram))
Main Flowsheet
Sub-Flowsheet
Column Environment (each column added in the PFD contains
a sub-flowsheet)

Environment Basis

Components

Pure Components
e.g H2O, CO2, N2, Methane, Ethane, etc

HypoComponents
A hypothetical component can be used to model non-library
components, defined mixtures, undefined mixtures, or solids
The minimum information required for defining a hypo is the Normal
Boiling Pt or the Ideal Liq Density and Molecular Weight

Pure Components

HypoComponent

HypoComponent (2)

HypoGroups

HypoGroups (2)

Fluid Packages

Equations of State (EOS)

PR, PRSV, SRK, MBWR, ZJ, KD, LKP

Activity Models
Margules, van Laar, Wilson, NRTL, UNIQUAC

Others
Chao-Seader
Vapor pressure models
ASME Steam
Amines
some empirical models

Fluid Packages Selection

Type of System
TEG Dehydration
Sour Water
Cryogenic Gas Processing
Air Separation
Atmospheric Crude Towers
Vacuum Towers
Ethylene Towers
High H2 Systems
Reservoir Systems
y
Steam Systems
Hydrate Inhibition
Chemical Systems
HF Alkylation
TEG Dehydration with
Aromatics

Recommended Property Package

PR
PR, Sour PR
PR PRSV
PR,
PR, PRSV
PR, PR Options, GS
PR, PR Options, GS<10mmHg,
GS 10mmHg, BK10, Esso K
Lee Kesler Ploker
PR, ZJ or GS
PR,, PR Options
p
Steam Package, CS or GS
PR
Activity Models, PRSV
PRSV, NRTL
PR

Input Fluid Packages

Simulation Environment

Object Pallete
Material and Energy Stream

Unit Operations

Sub-Flow Sheets
And
Columns (= Special types of Sub-Flow Sheets)
Logical Operations

Material Stream

Composition

Properties Result

Rundown
Introduction to HYSYS
Getting
g Started
Basic Equipment
Logical Operation
Utilities
Subflowsheet and Column

Mixer

Function = to mix/combine two or multiple feed streams as one product

stream
Result = Final properties of mixed fluid

Mixer (2)

Mixer (3) Design Parameters

Mixer (4) Design Parameters

Equalize All
Automatically equalize pressure of all stream
Only required pressure condition at one stream

Set Outlet to Lowest Inlet

Automatically set the pressure of combine stream at the lowest
pressure of inlets

Tee

Function = to divide one feed stream into two/multipleproduct streams

Result = Multiple product streams with same operating condition (P&T)
and composition as feed stream

Tee (2)

Tee (3) Design Parameter

Only use to divide flow into several stream

Not use to split composition

Separator

Function = to separate multiphase feed stream/streams into several

single phase product stream (vapor, light liquid, heavy liquid)

2 Phase Separator
2-Phase
Function = to separate multiphase feed stream/streams into two single
phase product stream (vapor and liquid)

3 Phase Separator
3-Phase
Function = to separate multiphase feed stream/streams into three single
phase product stream (vapor,
(vapor light liquid and heavy liquid)

Separator Design Parameter

Pressure Drop or Delta Pressure

Inlet = pressure drop that caused by inlet device separator and
impacted on all product stream.
Vapour outlet = pressure drop that caused by gas outlet device
(such as demister, etc) and impacted only on vapor stream.

Separator Design Parameter (2)

Separator - Energy
Function = to give heat to separator in case of insulation and to maintain
temperature at certain value

Separator - Sizing

Function = to estimate dimension of separator

Separator Imperfect Separation

Function = to simulate imperfect separation by adding carry over

condition

Pump

Function = to increase the head of inlet liquid stream by

adding work

Result = calculation of these unknown data;

Pressure
Temperature
Pump Horse Power
Pump Efficiency

Design Parameter
Delta Pressure = pressure drop between outlet and
inlet pressure
Pressure Ratio = ratio of outlet pressure and inlet
pressure
Duty = estimated or calculated pump horse power
Adiabatic Efficiency = efficiency of pump

Pump Design Parameter

Pump - Curves

Pump - NPSH

Function = to estimated NPSH available with using suction pressure

only (without friction).

Compressor

Function = to increase the heat of inlet gas stream

by adding work

Result = calculation of these unknown data;

Pressure
Temperature
Compressor Horse Power
Compressor Efficiency

Compressor Design Parameter

Efficiency
Adiabatic Efficiency
Polytropic Efficiency

Duty

Type of Compressor
Centrifugal
Reciprocating

Pressure
Delta P or Pressure Drop
Pressure ratio

Compressor - Curve

Commonly, this curve is provided by vendor and consist of flowrate,

Commonly
flowrate
pressure head and efficiency

Expander

Function = to decrease the pressure of inlet gas with higher pressure

into produced work

Result = calculation of work produced as model for turbines or turbo

expander

Expander Design Parameter

Efficiency
Adiabatic Efficiency
Polytropic Efficiency

Valve

Function = to drop the pressure of the inlet which has higher pressure
Result = calculation of these unknown condition;
Outlet T or P
Inlet T or P

Valve Design Parameter

Delta P or pressure drop that specified by user

Cooler

Function = to cool down the temperature of inlet stream

Result = calculation one of these unknown condition;
Outlet T
Cooler Duty

Cooler Design Parameter

Delta Pressure or Pressure drop

Delta Temperature or Temperature Outlet
Cooler Duty

Heater

Function = to heat up the temperature of inlet stream

Result = calculation one of these unknown condition;
Outlet T
Heater Duty

Heater Design Parameter

Delta Pressure or Pressure drop

Delta Temperature or Temperature Outlet
Cooler Duty

Heat Exchanger

Function = to transfer the energy from warmer fluid to colder fluid

Result = increment of energy efficiency of the overall facility

Heat Exchanger Design Parameter

Heat Exchanger Model

Exchanger Design (End Point)
Exchanger Design (Weighted)
Steady State Rating
Dynamic Rating

Delta P or Pressure Drop

On Shell side and Tube side

Overall Heat Transfer Coeff. Area (UA)

( )

Heat Exchanger Geometry (if required)

Tube side and Shell side

Heat Exchanger Result

Pipe

Function = to calculate the condition of fluid inside pipe

Pipe Segment takes into account the topography

(elevation level)

Includes three calculation modes:

Pressure drop
Length
Flow

Depending on what information is specified, the mode

will automatically be assigned.

Pipe Design Parameter

Pipe Design Parameter

Selection of correlation

Pipe - Rating
Input pipe and fitting
fitting, length of pipe
pipe, elevation change
change, pipe size
size, etc

Pipe Rating
Append a Segment
Select the fitting/Pipe cell

Pipe
Swage
Elbow
Bend
180 Degree Close return
Tee Branch Blanked
Tee as elbow

Specify
p
y the length
g and the elevation change
g
Press the View Segment
to select
The Schedule (Nominal and inner diameter)
Pipe Material
Roughness
Pipe Wall Conductivity

Coupling union
Gate valve
Diaphragm Valve
Globe Valve
Angle Valve
Blowoff Valve

Plug Cock
Butterfly Valve
Ball Valve
Check Valve
Foot Valve
Water meter

Pipe Heat Transfer

Input Heat Transfer from outside to inside of system

Pipe Heat Transfer

Heat loss

Overall HTC
Global
By segment

Estimate HTC
Global
By segment
Pipe
p wall
Inner HTC
Insulation
Outer HTC

Pipe - Result
Shows the pressure outlet,
outlet temperature outlet,
outlet flow regime,
regime liquid hold
hold-up,
up etc

Reactor

Reactor - Type

Reactor Conversion (example)

A stream of pure methane at 400 bar and 87 C
C and flowing at 32 kg/hr
enters in a reactor, where it undergoes complete combustion. There is
excess air during in the reactor and the conversion is 95%.

CH 4 O2 CO2 H 2O

Reactor Conversion (example)

Choose Reaction type

Input component
involved in reaction

Input stoichiometric
coefficient
ffi i t

Reactor Conversion (example)

Input the percentage of conversion

Reactor Conversion (example)

Reactor Conversion (example)

Reactor Conversion (example)

Specified the reaction

Specify
S
if the
th propane and
d air
i streams.
t
Th
The propane enters
t
th
the reactor
t att 400
bar, 87 C, and has a flow rate of 37 kg/hr. The air enters in at 1 atm, 25 C,
and is in excess with the propane, so has a flow rate of 75 kg/hr.

Reactor Conversion (Result)

Rundown
Introduction to HYSYS
Getting
g Started
Basic Equipment
Logical Operation
Utilities
Subflowsheet and Column

Logical Operations Used in HYSYS Steady State

The
e Set Operation
Ope at o

The Adjust
j
Operation
p

The Balance Operation

The Recycle Operation

The Spreadsheet

SET OPERATION

Set Operation

Function : used to set the value of specific Process Variable (PV)

in relation to another PV.

The set operation only can be used to define relationship

between the same PV in two like objects,
i.e.: relationship between two temperatures of two different
streams.
t

The dependent, or target variable is defined in terms of

independent, or source variable according to the following linear
relation:
Y = MX + B
where: Y = Dependent (target) variable
X = Independent (source) variable
u t p e (slope)
(s ope)
M = Multiplier
B = Offset (intercept)

How to Add Set Operation (1st method)

How to Add Set Operation (2nd method)

Double
D
bl
click

click

Example Using Set in Simulation

Set temperature of
Stream 13 to have
40 degrees lower
than stream 14

Set Connections Tab

Click to choose Target Object

and variable to set

Click
Cli
k tto choose
h
S
Source
Object where independent
variable placed

Set Parameters Tab

Define Multiplier and offset

for dependent
p
variable
towards independent
variable

ADJUST OPERATION

Adjust Operation

Function : varies the value of one stream variable (the independent

variable) to meet a required value or specification (the dependent
variable) in another stream or operation (automatically conduct the
trial and error iterations
iterations.))

Unlike set operation, Adjust can be used for both different and same
P
Process
Variable
V i bl in
i two
t
different
diff
t objects.
bj t

How to Add Adjust Operation (1st method)

How to Add Adjust Operation (2nd method)

Double
click

click

Example Using Adjust in Simulation

Adjusting mass
flow to get
specific molar
flow rate in gas
outlet
l

Adjust Connections Tab

User can input

specific
p
target
g
value, or choose
the value from
another object
with the same
process variable

Click to choose object

and variable that want to
be adjusted
Click to choose target
object and variable

Type the specified

target value

Adjust ParametersTab
Define convergence criteria on this tab.
Method:
Broyden: used this to quickly converge
to the desired value
S
Secant:
t generally
ll results
lt iin good
d
convergence once the solution has
been bracketed
Tolerance: The maximum difference
between the Target Variable and the
Target Value
Step Size: The initial step size
employed until the solution is
bracketed
Minimum/Maximum: The upper and
lower bounds for the independent
variable (optional) are set in this field
Maximum Iterations: The number of
iterations before HYSYS quits
calculations

EXERCISE

1000 kg/h hydrogen is converted at Methanol plant with reaction :

CO2 + 3 H2 CH3OH+ H2O
Only 75% of hydrogen can be converted in reaction
Operating condition of feed is 40 degC and 4000 kPa

EXERCISE RESULT

BALANCE OPERATION

Balance Operation

Function : provides a general-purpose heat and material balance

facility
facility.

There are six Balance types which are defined in the table below:
Type

Definition

Mole

An overall balance is performed where only the molar flow of each

component is conserved.
conserved

Mass

An overall balance is performed where only the mass flow is conserved.

Heat

performed where onlyy the heat flow is conserved.

An overall balance is p

Mole and
Heat

An overall balance is performed where the heat and molar flow are
conserved.

Mass and
Heat

An overall balance is performed where the overall mass flow and heat flow
are conserved.

General

HYSYS will solve a set of n unknowns in the n equations developed from

th streams
the
t
attached
tt h d to
t the
th operation.
ti
Component ratios may be specified on a mole, mass or liquid volume
basis.

How to Add Balance Operation (1st method)

How to Add Balance Operation (2nd method)

Double
click

click

Example Using Balance in Simulation

create a stream that

has the same molar
composition and
flow rate as another
stream, but
b a
different pressure
and temperature
(e g - at dew point
(e.g.
conditions)

Example Using Balance in Simulation

Determine the
temperature of 7
Copy stream when
there are half of
stream 7 phase
condense to gas
during same pressure

Balance Connections Tab

Click to choose
inlet stream

Click to choose
outlet stream

Balance Parameters Tab

Click to choose
balance type

Balance Worksheet Tab

Temperature of
7 Copy

Molar Flow for each

stream is the same

RECYCLE OPERATION

Recycle Operation

Use this operation every time you need to recycle a stream

stream.

The logical block connects the two streams around the tear stream
(stream with temporary specification)
specification).

Before you can install the RECYCLE the flowsheet must have
completed.
l t d Th
Thatt means there
th
need
d tto be
b values
l
ffor both
b th
the assumed stream and the calculated stream.

Once the Recycle is attached and running, HYSYS compares the

two values, adjusts the assumed stream, and runs the flowsheet
again.
g
HYSYS repeats
p
this p
process until the two streams match
within specified tolerances.

How to Add Recycle Operation (1st method)

How to Add Recycle Operation (2nd method)

Double
click

click

Example Using Recycle in Simulation

Recycle Connections Tab

Click to choose
inlet stream
Inlet stream will always
b a product
be
d t stream
t
from a unit operation.

Click to choose
outlet stream
Outlet stream will
always be a feed
stream to a unit
operation

Recycle Parameters Tab

to set the
convergence criteria
factor for each of
the variables listed

to select the transfer

di ti
direction
off th
the
variable

SPREADSHEET

Spreadsheet

The Spreadsheet applies the functionality of Spreadsheet programs

to flowsheet modeling. With essentially complete access to all
process variables, the Spreadsheet is extremely powerful and has
many applications in HYSYS
HYSYS.

The HYSYS SPREADSHEET has standard row/column

f
functionality.
ti
lit Y
You can iimportt a variable,
i bl or enter
t a number
b or
formula anywhere in the spreadsheet.

Complex mathematical formulas can be created, using syntax which

is similar to conventional Spreadsheets. Arithmetic, logarithmic, and
trigonometric
g
functions are examples
p
of the mathematical
functionality available in the Spreadsheet.

How to Add Spreadsheet (1st method)

How to Add Spreadsheet (2nd method)

Double
click

click

Example Using Spreadsheet in Simulation

Example Using Spreadsheet in Simulation

From Stream 15, calculate reynolds number of the liquid. If pipe ID : 3 in

Re = Reynold number, dimensionless

= liquid density (kg/m3)
D = pipe ID (m)
v = liquid flow velocity (m/s)
= liquid viscosity (kg/m-s)

TARGET
SPREADSHEET

Viscosity
1cP = 0.001
0 001 kg/m
kg/m-ss

Spreadsheet Connections Tab

Used to Add, Delete

and
a
d Edit
d t Imported
po ted and
a d
Exported variable

Spreadsheet Parameters Tab

Used to edit number of
column and rows on
the spreadsheet

Show cells that contain

calculated
l l d results
l fform
formulas define on the
spreadsheet

Spreadsheet Formulas Tab

Show the results of

the calculation
Show Formulas
used
d ffor
calculation

Spreadsheet Tab
C l C
Color
Code:
d
Blue: Show
independent value
i
imported
t d ffrom stream
t
in the simulation or
value/text that we
manually type on the
spreadsheet.
d h t
Black: Show
dependent value
i
imported
t d ffrom stream
t
in the simulation.
Red: Show cell that
contain formulas

How to Import Data to Spreadsheet Tab (1st Method)

1
1.

2
2.
3.

On th
O
the spreadsheet
d h t cell,
ll
right click the mouse
and then choose import
variable
S l t variable
Select
i bl tto b
be
import
Click OK

How to Import Data to Spreadsheet Tab (2nd Method)

Select targeted cell

Rundown
Introduction to HYSYS
Getting
g Started
Basic Equipment
Logical Operation
Utilities
Subflowsheet and Column

Utilities in HYSYS

The utilities are a set of tools, which interact with a process by

providing additional information or analysis of streams or operations.
In HYSYS
HYSYS, utilities become a permanent part of the flowsheet and
are calculated automatically when appropriate.
Utilities can also be used as target objects for Adjust operations.

How to Add Utility? (1st Method)

How to Add Utility? (2nd Method)

Critical Properties

Envelope Utility

Hydrate Utility

Exercise

Propane Refrigeration Loop

100% Propane with 5000kg/h mass flow is used as refrigerant.
Pressure drop at chiller and pressure drop is assumed about
0 5 bar.
0.5
bar
Stream outlet condenser is assumed all liquid at 50 degC and
chiller is used to maintain temperature at -20 degC.

Propane Refrigeration Loop

Calc P

Fix P

Fix Vf, T, %mol., M

Calc T
C l P
Calc

Calc P
Calc Q

Calc Q

Calc P

Fix Vf, T

Fix P

Calc P, T, Vf

Rundown
Introduction to HYSYS
Getting
g Started
Basic Equipment
Logical Operation
Utilities
Subflowsheet and Column

Subflowsheet in HYSYS

The subflowsheet operation uses a multi

multi-level
level flowsheet
architecture and provides a flexible and simplified method for
building a simulation.

It is very useful when simulating a large, complex processing

facility with a number of individual process units.

Example of Using Subflowsheet

How to Add Subflowsheet? ((1st

Method)

How to Add Subflowsheet? ((2nd

Method)

Source for Subflowsheet

1. Read an Existing Template: Using existing
template available in Hysys (.tpl)
2 Start
2.
S
Wi h a Blank
With
Bl k Flowsheet:
Fl
h
U i
Using
our own
template
3. Paste Exported Objects: Hysys imports
pre io sl exported
previously
e ported object (.hfl)
( hfl) into a new
ne
subflowsheet

Transfer Basis
Each subflowsheet can have its
own fluid property package. For
example, in main flowsheet using
Peng-Robinson
g
and subflowsheet
using Amines package.
In this case, transfer basis in
subflowsheet shall be considered.
Transfer basis determines which
parameter that we want to keep
the value equal when we transfer
stream to different fluid package

Exercise

Create subflowsheet that contain propane refrigerant loop and adjust

the mass flow of propane to handle heat Q-104 from E-100

Column

Distillation p
process use 40% of
energy in a chemical plant.
The traditional approach for solving
distillation columns uses the concept
of equilibrium or theoretical stages.
This concept assumes the vapor
and
d liliquid
id phases
h
lleaving
i any stage
t
are in thermodynamic equilibrium
with each other.

Column - Principle

Minimum number of
tray

Parameter adjustment
j

Column
# Columns Specifications
=
# Side Heat Exchanger + # Side draws +
# Side Strippers
pp
+ # Pumparounds
p

Absorber = 0 Spec
Refluxed Absorber = 1 Spec
Reboiled Absorber = 1 Spec
Distillation Column = 3 Specs

Column

Sub-flowsheets
Sub
flowsheets
Contain equipment and streams
Exchange information with the parent flowsheet through the
connected streams

Columns Subflowsheets
From the main environment, the column appears as a single,
multifeed multiproduct operation
You can enter the column subflowsheet by clicking the Column
Environment icon on the Column p
property
p y view
You can return to the parent environment by clicking either:
the Parent Environment button on the Column runner view
the Enter Parent Simulation Environment icon in the tool bar.

Exercise
Target

Exercise

Component consist of Nitrogen, Carbon Dioxide, Methane, Ethane, Propane, iButane & n-Butane

Feed1 consist of 6 MMscfd of molar flow with operating pressure and temperature are
41.37 bar & 60 degF, respectively. With % mole of component:
Nitrogen
0 01
0.01
Carbon Dioxide
0.01
Methane
0.60
Ethane
0.20
p
0.10
Propane
i-Butane
0.04
n-Butane
0.04

Feed2 operate at 60 degF and 600 psia with 4 MMscfd. With % mass of component:
Nitrogen
6.00
Carbon Dioxide
0.00
Methane
120.00
Ethane
60.00
P
Propane
60 00
60.00
i-Butane
30.00
n-Butane
30.00

Exercise

No pressure drop on inlet separator and LTS separator

Pressure drop on gas/gas exchanger and chiller are 10 psi (on shell
and tube side for G/G)
G/G).

Gas/gas exchanger only consist of 1 shell and 1 tube.

Delta Temp between Tube Inlet and Shell Outlet is 10 degC.

Dew p
point criteria for sales g
gas is 15 degF
g at 800 p
psia ((obtainalbe byy
adjusting)

Exercise

Column is full reflux which mean all liquid from condenser is flow to
column.
The reboiler has once through configuration
Operating pressure at condenser are 200 psia and 205 psia for reboiler
Temperature at condenser and reboiler is estimated at 40 degF and
200 degF, respectively.
Vapor rate of overhead is 2 MMscfd.
Specify the bottom only consist of 2% of propane

S
Supported
t d bby: