ProMax® Training

BRE 101
Oil & Gas

Bryan Research & Engineering, Inc.

Chemical Engineering Consultants
P.O. Box 4747 Bryan, Texas 77805
Office: 979-776-5220 Fax: 979-776-4818
[email protected] or [email protected]

© 2016 BRE Group, Ltd.

v1702
 BRE Group, Ltd
Copyright 2016

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TABLE OF CONTENTS
1 ProMax Oil & Gas Foundations .................................................................................................................................... 1
1.1. Course Description .......................................................................................................................................... 1
1.2. Course Agenda & Exercises ............................................................................................................................. 2
2 ProMax User Interface ................................................................................................................................................. 3
2.1. Overview ......................................................................................................................................................... 3
2.2. Visio Menus ..................................................................................................................................................... 3
2.3. ProMax Ribbon Menu ..................................................................................................................................... 4
2.4. ProMax Shapes ............................................................................................................................................... 5
2.5. Project Viewer ................................................................................................................................................. 5
2.6. ProMax Message Log ...................................................................................................................................... 6
3 Creating A Process Model ............................................................................................................................................ 7
3.1. Defining Environments.................................................................................................................................... 7
3.2. Drawing the Flowsheet ................................................................................................................................... 8
3.3. Defining Streams/Blocks ................................................................................................................................. 9
3.4. Unit Conversions in ProMax.......................................................................................................................... 20
3.5. Defining an Oil............................................................................................................................................... 21
3.6. Creating New Flowsheets ............................................................................................................................. 23
3.7. Available Analyses in ProMax ....................................................................................................................... 24
3.8. Ideal Stage and Mass+Heat Transfer Column Types ..................................................................................... 25
3.9. Export / Append Project ............................................................................................................................... 26
3.10. ProMax Reports .......................................................................................................................................... 26
3.11. Gibbs Minimization Reactors in ProMax ..................................................................................................... 27
3.12. Utilizing Short Monikers and the Moniker Clipboard ................................................................................. 28
4 Optimizing A Model ................................................................................................................................................... 29
4.1. Overview ....................................................................................................................................................... 29
4.2. Excel Interactions .......................................................................................................................................... 29
4.3. Using Calculators in ProMax ......................................................................................................................... 31
4.4. User Defined Variables.................................................................................................................................. 33
5 Equipment Sizing & Rating Overview ......................................................................................................................... 34
5.1. Overview ....................................................................................................................................................... 34
5.2. Separator sizing ............................................................................................................................................. 34
5.3. Column Sizing ................................................................................................................................................ 35
5.4. Depressurization and Relief Valve Sizing ...................................................................................................... 36
5.5. Control Valves ............................................................................................................................................... 36
5.6. Heat Exchanger Rating .................................................................................................................................. 37
6 Course Exercises ......................................................................................................................................................... 38
Exercise 1: Simple Gas Plant ................................................................................................................................. 38
Exercise 2: Pipeline Simulation ............................................................................................................................. 41
Exercise 3: Simple MDEA Sweetening Unit .......................................................................................................... 42
Exercise 4: Export/Append Project ....................................................................................................................... 45
Exercise 5: Glycol Dehydration Unit ..................................................................................................................... 47
Exercise 6: Simple Turboexpander Demethanizer ............................................................................................... 50
Exercise 7: Excel Import/Export ........................................................................................................................... 52
Exercise 8: Three Bed Claus Unit .......................................................................................................................... 54
Exercise 9: Scenario Tool ...................................................................................................................................... 57
Exercise 10: Simple Specifiers .............................................................................................................................. 60
Exercise 11: Simple Solvers .................................................................................................................................. 61
Exercise 12: User Value Sets ................................................................................................................................. 63
Exercise 13: Incinerator ........................................................................................................................................ 64
Exercise 14: Separator Sizing ................................................................................................................................ 65
Exercise 15: Depressurization............................................................................................................................... 66
Exercise 16: Shell & Tube Heat Exchanger Rating ................................................................................................ 67
7 ProMax Additional Exercises ...................................................................................................................................... 69
Exercise 17: Refrigeration Loop ............................................................................................................................ 69
Exercise 18: Ethylene Glycol Injection .................................................................................................................. 69
Exercise 19: Mixed Amines ................................................................................................................................... 70
Exercise 20: Activated MDEA for Acid Gas Removal ............................................................................................ 70
Exercise 21: Physical Solvent Acid Gas Removal .................................................................................................. 71
Exercise 22: Mercaptan Removal from LPG using NaOH ..................................................................................... 71
Exercise 23: CO2 Removal using NaOH ................................................................................................................. 72
Exercise 24: MEA Flue Gas CO2 Capture ............................................................................................................... 72
Exercise 25: Fractionation Train ........................................................................................................................... 73
Exercise 26: Environmental BTEX Calculations ..................................................................................................... 74
Exercise 27: Simple Sour Water Stripper .............................................................................................................. 75
Exercise 28: Air Cooler Rating............................................................................................................................... 76
8 Additional Help & Troubleshooting ............................................................................................................................ 78
8.1. Basic Specifications for ProMax Blocks ......................................................................................................... 78
8.2. General Guidelines for Diagnosing Errors ..................................................................................................... 79
8.3. Common Errors & Warnings ......................................................................................................................... 80
8.4. Web Tutorials ................................................................................................................................................ 84
8.5. Visio Hotkeys ................................................................................................................................................. 85

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ProMax Oil & Gas Foundations
1.1. COURSE DESCRIPTION
ProMax is a flexible, stream-based process simulation package used for the design and optimization of gas processing,
refining, and chemical facilities. ProMax provides flexibility to its users through access to over 65 predefined
thermodynamic package combinations and over 3200 components, along with crude oil characterization and
compound species capabilities. For unit operations, the user has access to pipelines, fluid drivers (compressors and
pumps), heat exchangers, vessels, distillation columns, reactors, membranes, and valves.

In addition, ProMax provides OLE automation tie-ins, specifiers, solvers, and Microsoft Excel® spreadsheet embedding,
which give the user full access and control of all the information within any stream or block.

The exercises in this course are designed to show the basic functionality of ProMax. This includes the basics of how
to draw flowsheets, create Environments, specify processes, and then display information from a completed project.
This course also demonstrates many ProMax features for automization and optimization, such as how to set up Simple
Specifiers and Solvers and how to utilize the Scenario Tool™. PSV and separator sizing, along with heat exchanger
rating, are also discussed. These topics are discussed using applicable oil and gas processing focused exercises.

The general purpose of processing natural gas is

to convert a raw gas that leaves the well into
saleable products. This process can be separated
into 3 main areas: collection and pre-processing,
gas treating, and gas processing. ProMax can be
used to model most of the systems used in these
three areas. The figure on the right shows a
general gas processing flow diagram; however,
the processing steps might vary depending on the
raw gas composition and requirements. In
addition, field processing, such as dehydration
and sweetening, may be required before the gas
can be sent to the processing facility. Many of
these systems are discussed and analyzed within
the exercises of this course.

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1.2. COURSE AGENDA & EXERCISES

DAY 1 Exercise 1: Simple Gas Plant

Exercise 2: Pipeline Simulation

Exercise 3: Simple MDEA Sweetening Unit

Exercise 4: Export/Append Project

DAY 2 Exercise 5: Glycol Dehydration Unit

Exercise 6: Simple Turboexpander Demethanizer

Exercise 7: Excel Import/Export

Exercise 8: Sulfur Recovery Unit

Exercise 9: Scenario Tool

Exercise 10: Simple Specifiers

DAY 3 Exercise 11: Simple Solvers

Exercise 12: User Value Sets

Exercise 13: Incinerator

Exercise 14: Separator Sizing

Exercise 15: Depressurization

Exercise 16: Shell & Tube Heat Exchanger Rating

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ProMax User Interface
2.1. OVERVIEW
The ProMax interface is built around the Microsoft Visio® package. Therefore, it inherits many of the benefits of this
package (e.g., shape sizing, transformation, text annotations, etc.). Starting ProMax will automatically start Visio with
all of the ProMax interface included.

ProMax Ribbon Bar provides quick

access to all ProMax functionalities and
options.
ProMax Shapes contains all blocks,
streams, and other shapes used in
building the simulation.

Multiple flowsheets ProMax Message Log displays the status,

can be created within warnings, errors, and other information
the same project. when the simulation is run.

2.2. VISIO MENUS

Visio Ribbon Menu options are fully available within the ProMax project by selecting the “Home”, “Insert”, “Design”,
“Review”, “View” or any additional Ribbon Menu options available. Ribbon Menu options can be adjusted through
the Visio Options dialog from the “File” menu.

Some useful options within the Visio Ribbon Menus include shape alignment, pointer tool options, drawing page size,
background borders or titles, image or text box insertion, and layer assignments.

Visual Basic for Applications can be accessed within the Developer Menu. It may also be accessed by pressing Alt-F11
if the Developer Menu is currently hidden.

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2.3. PROMAX RIBBON MENU

General
 Project Viewer – Opens the ProMax Project Viewer, which contains all project information. More details
on the Project Viewer can be found on page 5.
 Active Environment – Displays and manages the Environment in use on the current flowsheet. A drop-
down menu provides access to all available thermodynamic Environments in the project.
 Active Flowsheet – Displays information about what Environment is assigned to the active flowsheet. A
drop-down menu provides access to manage all available flowsheets within the current project.
 Oil – Displays and manages all defined oils in the project, including Single Oils, Curve Oils, and blends.
 Warnings – Displays all warnings currently found within the project.
 Report – Opens the report window to publish the results for the project into a document or worksheet.
 Add Excel Workbook – Embeds an Excel workbook to the current project. Once a workbook is added, data
can be exchanged between ProMax and Excel. Information on embedding an Excel workbook can be found
on page 29.
 Message Log – Displays information during execution such as block status, current solver error, column
iterations, warnings, and errors.
 Moniker Builder – Provides a method of creating “Short Monikers” for use within the project. Information
on “Short Monikers” can be found on page 28.

Execute
 Execute Project – “Runs” the complete project, including all flowsheets and calculators.
 Execute Flowsheet – “Runs” the current, displayed flowsheet only.
 Execute Block – “Runs” any selected block(s).
 Abort – Stops the execution.
 Clear Calculations – Clears any stored calculated data. User inputs, column solutions, and recycle streams
are not updated, reset, or cleared.
 Pause – Temporarily stops the execution.
 Continue – Resumes a paused execution.

Options
 Unit Conversion Drop-down – Allows on-the-fly unit conversions for the entire project. No user inputs or
calculated data are changed.
 Project Options – The icon displayed next to the word “Options” opens the dialog to customize atmospheric
pressure, reference temperature, displayed properties, and other items

Help
 ProMax Help – Provides parameter definitions, simulation setup help, common operating conditions, etc.
 About ProMax – Displays the current version and build number of ProMax, as well as contact information,
and some licensing and security device information.
 Scripting Help – Reference documentation for JScript and VBScript.
 Contact Support – Opens the BR&E Support website.

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2.4. PROMAX SHAPES
ProMax Shapes are a collection of blocks, streams, and other items used in building the
flowsheet. Shape functions in ProMax can be thought of as including:

1. Unit operations – heat exchangers, pumps, columns, etc…

2. Streams – process and energy
3. Simulation specific blocks – recycles, make-ups, etc…
4. Data presentation blocks – callouts and tables

Only ProMax Shapes are loaded when ProMax starts. Other Visio shapes can be loaded,
but will not interact with ProMax. This means that other Visio shapes can be drawn on
the flowsheet for display purposes, but they will not act as ProMax objects with ProMax
capabilities. Shape groups can be opened and closed as needed. To close a group, right
click on the group title and choose Close. To open a group, go to More Shapes > then
choose the desired group to open.

2.5. PROJECT VIEWER

The Project Viewer is the primary graphical interface to input and retrieve information within ProMax. The Viewer
provides access to the majority of the information in a project, and provides additional shortcuts to running ProMax.

Contents
File / ProMax / Window Dropdown Menus –
Contains options for the ProMax Project specific to
the Project Viewer, including the option to open
additional Project Viewer windows for
simultaneous viewing.

Toolbar – Provides easy access to common

ProMax operations (e.g., Environment, Execute,
Report) and navigational buttons.
Navigation Tree – Includes a detailed list of all
Flowsheets, Process and Energy Streams, Blocks,
Calculators, and other objects contained in the
Project. All of the various objects can be accessed
by double-clicking directly in the navigation tree.
Upstream/Downstream Arrows – Provides a
convenient method to navigate successive
streams and blocks.
Data Display – The information displayed here depends on the selection. If a process stream is selected, the Viewer
will have a “Properties” tab showing the stream properties, a “Composition” tab showing the composition of that
stream, an “Analysis” tab, showing any analyses requested for that stream, and a “Notes” tab for user-added notes.
An energy stream will have only a “Specifications” tab for the energy rate and a “Notes” tab. Similarly, a different
set of information is displayed for the different blocks.
Message Log – Similar to the ProMax Message Log but displays messages related to the selected item only.
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Color Convention
The data displayed in the Project Viewer cells are color-coded for easy identification as follows:

Project Viewer Cell "Convention" Explanation

White Cell Background with No Text Available parameter, can be user-specified

White Cell Background with Blue Text 100 User-specified parameter

White Cell Background with Black Text 100 Calculated or default parameter, can be overwritten

Gray Cell Background 100 Calculated parameter, unavailable for specification

Blue Cell Background 100 Value from a solver, specifier, or import from Excel

Red Cell Background 100 Parameter not applicable, calculation failed

Yellow Cell Background 100 Parameter value extrapolated or approximated

2.6. PROMAX MESSAGE LOG

The ProMax Message Log provides a running source of information about the status of a project and whether the
execution is proceeding as desired. This provides an opportunity to see if any column solutions are approaching a
solution, the ability to see if a recycle or solver is converging, and the chance to follow many additional aspects of a
project during execution.

Additionally, any warnings are presented in blue, and failures are shown in red. The text provides the object in the
project that is failing (e.g. ProMax:ProMax!Project!Flowsheets!Gas Processing!Blocks!VLVE-100 indicates the object
“VLVE-100” on the “Gas Processing” flowsheet) and in many circumstances alerts the user to why the failure occurred.

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Creating A Process Model
ProMax provides freedom and flexibility when building a simulation. A simulation is started by defining the
Environment and adding components or by drawing the flowsheet. During this process, changes can be made on any
item as required.

When a new project is created, ProMax will create a flowsheet (Flowsheet 1) and assign an empty Environment
(Environment 1) to that flowsheet. Flowsheets and Environments can be added, deleted, or modified at any point.

3.1. DEFINING ENVIRONMENTS

In ProMax, the term Environment is used to refer to the
thermodynamic package, components, reaction sets, and oils
specific to the simulation. The Environment dialog provides access
to these properties. Multiple flowsheets can utilize the same
Environment, or each may be unique.

To define an Environment, choose the “Edit Environments…” item

from the drop-down options on the ProMax Ribbon Menu. This will
open a window containing all project Environments. The dialog
allows the user to create a new Environment, duplicate an existing
Environment, or edit an existing Environment.

The Environment dialog has several tabs. The most commonly used
tabs are the “Property Package” and “Components” tabs. The
Property Package tab provides a list of thermodynamic equations
that can be selected directly for use on a flowsheet. Alternatively,
the user can modify options by selecting the “Use Custom Package”
option. In this case, the user has the freedom to assign the desired
thermodynamic model for each physical property.

Once a Property Package is set, components can be added to the

Environment under the Components tab. Components may be
added to the Environment by either manually searching in the
components list or by using any of the filtering options provided.
For example, to add methane to the components list, type
“methane” in the Name filtering box and hit the “Enter” key. Many
components have multiple aliases to choose from (e.g. CH4, C1,
carbane, and r-50 are different aliases available for methane).

Choosing the correct Property Package is critical in obtaining

reliable results. The table on the next page gives general guidelines
on which packages apply to which applications. Refer to the
ProMax Help for more information.

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 Process Property Package Suggestion
Acid Gas Injection Systems SRK or Peng-Robinson
Air Separation SRK or Peng-Robinson
Amine Sweetening Amine Sweetening / Electrolytic ELR
Ammonia Absorption Refrigeration Tillner-Roth and Friend NH3 + H2O
Caustic Treating Caustic Treating
Chemicals (e.g. separation of Acetone/Acetic Any non-Electrolytic Gibbs Excess/Activity Coefficient
Acid/Acetic Anhydride) (e.g. DUNIFAC, TK Wilson, UNIQUAC, etc.)
Crude Oil Distillation/Fractionation SRK or Peng-Robinson
Dehydration/Hydrocarbon Removal Using MeOH SRK Polar or Peng-Robinson Polar
Fractionation SRK or Peng-Robinson
Gas Processing with MeOH SRK Polar or Peng-Robinson Polar
Glycol Dehydration SRK or Peng-Robinson
HC Dew Point Control w/ DEPG SRK or Peng-Robinson
Heavy Hydrocarbon Systems PR, SRK, Braun K10, Chao-Seader, Grayson-Streed
(SRK or PR must be used if aqueous phase present)
Hot Oil System Heat Transfer Fluid
Hydrocarbon - Water Separation SRK-Kabadi-Danner
Lean Oil Absorption SRK or Peng-Robinson
LNG Processes GERG-2008, SRK, Peng-Robinson
Methanol-Water Distillation (Binary System) NRTL
Natural Gas Processing SRK, Peng-Robinson, GERG-2008
Physical Solvent Acid Gas Removal w/ NMP or MeOH SRK Polar or Peng-Robinson Polar
Physical Solvent Acid Gas Removal w/ DEPG or PC SRK or Peng-Robinson
Refrigerant Systems (e.g. R13/R22, Propane, etc.) SRK or Peng-Robinson
Sour Water Stripping Amine Sweetening / Electrolytic ELR
Steam Systems NBS Steam Tables
Sulfur Recovery Sulfur or Sulfur ASRL

3.2. DRAWING THE FLOWSHEET

To draw the flowsheet, click and drag any shape from the Shapes Stencils and drop it on the page at the desired
location. Shapes can be connected with process or energy streams at the Connection Points. Connection Points in
the shape are indicated by a small “x” as shown in the figure. These can either be process connections or energy
connections, which are not interchangeable. The number and type of connections for each shape can be viewed in
the Project Viewer.

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Once a block or stream is present on the flowsheet, it can be manipulated using standard Visio techniques. After a
block or stream is created, its process parameters can be defined within the Project Viewer by double clicking on the
desired block or stream.

In Visio 2010, solid red indicates a connected stream outlet and a red outline
indicates a connected stream inlet. Solid blue indicates an unconnected stream
outlet, and a blue outline indicates an unconnected stream inlet.
Visio 2010: Connected inlet
stream, unconnected outlet
stream.

This convention is changed in Visio 2013 and 2016. A green circle indicates a
connected stream outlet, and a circle with a green dot indicates a connected inlet.
A light gray square indicates an unconnected outlet, and a white square indicates
Visio 2016: Connected inlet an unconnected inlet.
stream, unconnected outlet
stream

The Visio Connector Tool provides a convenient way to draw several streams quickly.
This option can be found from the Visio “Home” Ribbon. The user should switch back
Tip to the Pointer Tool when not drawing streams.

3.3. DEFINING STREAMS/BLOCKS

To run any part of the simulation, all the information needed by ProMax to perform the required calculations must be
provided. The information is entered as parameters for process streams, energy streams, or blocks. Keep in mind
that the properties of the streams and blocks are interrelated, which gives the option to either specify the property of
a stream directly or to specify how the block affects the process stream. For example, the temperature at the outlet
of a heat exchanger may be placed in the outlet stream or calculated from a change in temperature from the inlet
stream.

ProMax uses color coding for streams and blocks to help the user along the way. The following table summarizes the
color conventions used within the flowsheet:

Color Block Status Stream Status Comments

Stream: specification(s) missing
RED Unconnected Not ready
Block: stream connection(s) missing
Block has the minimum number of connections
BLUE Unsolved N/A
required
BROWN N/A Unsolved Stream is fully specified and ready for execution
Properties inside a stream or block may also be
ORANGE Approximate Approximate orange, which generally indicates a calculation
outside the correlation range
GREEN Solved Solved
ProMax allows for specifications to be made both upstream and downstream of most blocks, giving the user flexibility
to specify properties in the most convenient fashion. The guide below lists provides a list of all available ProMax
shapes along with specification recommendations.

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Auxiliary Objects

 Divider – This block can be used to split any percentage of any specific components from the main process
stream. This is often useful in cases where a full simulation is unnecessary, such as a dehydration unit that
does not need a rigorous simulation. There must be one inlet and at least one outlet, although typically two
are used. An energy stream should also be connected to keep the simulation in both heat and material
balance. The desired component splits must be set within the block itself.
 Pipeline – The pipeline block can rigorously solve for many properties of single- or multi-phase flow in a pipe
of any alignment. Ambient losses can be calculated based on pipe and ground material if an energy stream
is connected to the pipeline block. Multiple pipe and fitting segments can be modeled in a single pipeline
block.
 Saturator – This block can saturate a stream with any component to whatever saturation level is desired. The
temperature and pressure of the stream being saturated remain unchanged. Generally, multi-phase streams
should be separated before feeding a single phase to the saturator block. Please see the Help for additional
information.
 Make-up/Blow-down – If there are losses in a process, material must be made up to keep a steady circulation
rate. The make-up/blow-down block allows the user to set a desired flow rate to be maintained (set in the
outlet stream). The block will calculate how much to add to maintain this flow rate on an ongoing basis.
When applicable, this block also allows the user to set a desired outlet concentration (such as what weight
percent the amine should be at leaving the make-up/blow down block).

AutoKinetic Reactors

ProMax can perform simulations for a variety of catalytic processes including Isomerization, Catalytic Reforming,
Hydrodesulfurization, Hydrocracking, Hydrodewaxing, Hydroisomerization, Hydroskimming and Hydrofinishing for a
range of oil fractions spanning from light naphthas to heavy vacuum gas oils.
 Oil Speciation – This block estimates the composition of a mixture of species that represents the bulk
properties of a given oil sample. The user defines the species list to be used and the block estimates a
composition to fit the specified oil assay.
 Kinetics Calibrator – This tool provides an easy-to-use graphical interface to calibrate kinetic parameters from
plant data.
 TBP Splitter – The TBP Splitter provides a quick, perfect separation of an inlet stream into as many as 10 cuts
based on TBP spreads. This represents the maximum quantities of each cut that could be produced.
10
  Cut Point – A block for determining the performance of a fractionation unit. The block estimates the Cut
Point Temperature and the degree of cross contamination between the two streams connected to it.
 Catalytic Fixed Bed – A block for modeling a complete fixed particle bed reactor vessel.
 Top Bed – A block for modeling a fixed particle bed located at the top section of a reactor vessel.
 Bed Section – A block for modeling a fixed particle bed located in a middle section of a reactor vessel.
 Bottom Bed – A block for modeling a fixed particle bed located at the bottom section of a reactor vessel.

Distillation Columns

There are predefined distillation columns available from the stencil set that can be used for most common
applications. More complex arrangements may be setup by manually drawing the desired configuration.

ProMax provides two fundamental methods of calculating the column results: Ideal Stage and Mass + Heat Transfer.
Ideal stage modeling can be used for any application to simulate VLE, LLE, and VLLE columns. Ideal stage models use
tray efficiencies or HETP values to model trayed and packed columns using ideal stages. Column internals are generally
not required for Ideal Stage modelling, although they are required for amine absorbers as described in the following
paragraph.

Most Ideal Stage model applications will use the “General Ideal Stage” Column Type, with exceptions for amine
sweetening. Amine absorbers will use the “TSWEET Kinetics” model, and amine regenerators will use the “TSWEET
Stripper” model. The “TSWEET Kinetics” model requires tray and column information to calculate the residence time
on a tray to fully model the reaction kinetics. Typical initial design input values are 70% flooding, a Real/Ideal Stage
Ratio of 3, a system factor of 0.8, tray spacing of 2 ft [0.6 m] and weir height of 3 in [7.6 cm]. These values are input
in the Hardware grouping on the Stage Data tab of the absorber column. Please see the ProMax Help for additional
information on tower hardware specifications.

Mass + Heat Transfer-based modeling can also be used for all VLE applications. Mass + Heat Transfer models use the
actual number of trays in a column. Additionally, with the Mass + Heat Transfer model there is no need to assume an
HETP for packing as the actual packing height may be entered. However, column internals are required for all Mass +
Heat Transfer modelling. Mass + Heat Transfer models account for departures from equilibrium temperatures
between the phases. Matching operating data may be easier with these models due to mass transfer correlation
options.

For help with Mass + Heat Transfer column specification, please see the ProMax Help.

All columns must have a pressure profile set (i.e., pressure drop, or top and bottom pressure, etc…). In addition, each
condenser, reboiler, draw or pump-around adds a degree of freedom. Each degree of freedom requires a
specification, chosen from the following options.

By default, ProMax will solve to zero degrees of freedom. The “Allow over-specification” permits the selection of more
specifications than can be solved exactly, and ProMax will solve to the closest solution it can find based on a least-
squares methodology.

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Available Column Specifications
 Boiling Curve Gap – The difference between boiling curve temperatures at specified fractions for selected
stage(s) and phase(s). For example, the user can specify that the bottoms liquid from a distillation tower
should have a 200°F (110°C) gap between the 10% and 90% boiling curve temperatures for an ASTM D86 test.
 Boil-up Ratio – The flow of vapor returned to the column from the reboiler divided by the flow of bottom
product (molar basis).
 Component Flow/Composition – The flow rate or fraction of one or more of the available components in one
of the streams exiting the distillation column.
 Component Ratio – The ratio determined by specifying a numerator, the flow of one or more components;
and a denominator, the flow of one or more other components.
 Component Recovery – The ratio of the flow rate or fraction of one or more of the available components in
one of the streams exiting the column to the flow rate of the same selection in the total feed to the column.
o If a flow unit is chosen, this designates the fraction of the selected components from all feeds that will
be sent to the specified stream.
o If a fractional unit is chosen, the value is a dimensionless ratio of the fraction of the components in the
specified stream to the fraction of the components from all feeds. For example, if the feed to a
deethanizer contains 7.28 mol% ethane and the bottoms contains 14.45% ethane, then the ethane
fraction recovery in the bottoms is 14.45/7.28 = 1.985.
 Cut Point – The boiling temperature of the oil at a certain percentage distilled for the specified stage and
phase. All distillation curves are calculated on a dry basis.
 Draw Rate – The flow rate in one of the draw streams from the column.
 Draw Recovery – The ratio of the flow rate of one of the streams exiting the distillation column to the flow
rate of the total feed to the column.
 Duty – The duty associated with an unspecified energy stream attached to the distillation column. The value
should be positive for heat injected into the column (and the energy stream arrow points towards the column)
and negative for heat removed from the column (and the energy stream arrow points away from the column).
 Flow Ratio – The ratio of the flow in a draw stream or on a stage to the flow in another draw stream or on
another stage.
 Fraction Vapor – The percentage of vapor in the total distillate or bottoms product. This specification is
intended to be used for a column with a partial condenser including a liquid draw from the reflux, or a reboiler
with a vapor draw from the vapor return stream. The column automatically calculates the liquid draw rate
for the condenser or vapor draw rate for the reboiler to meet the specified value. Note that this specification
does NOT decrease the degrees of freedom for the column; instead it sets the percent split in the splitter
involved.
 Fuel Property – A fuel property for any phase on any stage. These properties are calculated on a dry basis,
and include the following options:

Cetane Index Naphthenic Mole Percent C:H Weight Ration

ASTM D93 Flash Point Aromatic Mole Percent ASTM D86 10% Cut Point
ASTM D611 Aniline Point Research Octane Number ASTM D86 50% Cut Point
Absolute Viscosity at 100F ASTM D97 Pour Point ASTM D86 90% Cut Point
Absolute Viscosity at 210F Refractive Index ASTM D1322 Smoke Point
API Gravity 60F/60F Watson K ASTM D2500 Cloud Point
Paraffinic Mole Percent Kinematic Viscosity at 40C
 Phase Property – A phase property for any phase on any stage in the column. Select the desired property
from the drop-down list which includes all standard properties available for a stream (e.g. Temperature or
Flow Rate) along with the Reid Vapor Pressure and True Vapor Pressure.
 Reflux Ratio – The flow of liquid from the condenser returned to the column divided by the flow of vapor and
liquid overhead products.

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The following items are available through the specifications tab of the column but will not fulfill a degree of freedom.
These items are used as either an initial estimate for iteration purposes, or to report back values for parameters of
interest.
 Lean Approach – The equilibrium composition of the selected component for the specified stage and phase
divided by the calculated composition of the selected component for the same stage and phase. This
specification is useful for determining "Lean End Pinch" for amine sweetening absorbers, and also for
determining the approach to equilibrium water content in glycol dehydration contactors.
 Pump-around Estimate – An estimate sometimes required for pumparound loops. Options are:
a. Fraction Feed Entering Column – If the pump-around path contains a mixer followed by a splitter,
the fraction of added material that reaches the column should be given as the estimate. For
example, 100 mol/h of material is added to a 900 mol/h pump-around via a mixer, and 50 total mol/h
of material is subsequently removed from the pump-around via a splitter. The "Fraction Feed
Entering Column" would be 95% since 95 mol/h of the 100 mol/h feed reach the column. (5 mol/h
or 10% of the 50 mol/h removed via the splitter is attributable to the feed). If the splitter has a %
split specified instead of an outlet flow rate, this estimate is not required.
b. Fraction Draw Returned – If any stream between the draw and the return contains a splitter, the
fraction returned to the column should be given as an estimate. For example, if the pump-around
draw is 1000 mol/h and 150 mol/h is removed from the pump-around via a splitter, then the
"Fraction Draw Returned" is 85%. If the splitter has a % split specified instead of an outlet flow rate,
this estimate is not required.
c. Pump-around Duty – If duty is added to a pump-around by a heat exchanger (other than a condenser
or reboiler) or pump, an estimate may be required for the total pump-around duty amount (positive
if energy is added to the system). If the duty itself is specified, this estimate is not required.
 Rich Approach – The calculated concentration of a selected component in the liquid exiting a specified stage
divided by the equilibrium concentration based on the specified lean feed. Select either: "Maximum
Loading", which reports the rich approach as a percentage of the highest loading attainable (equilibrium), or
"Excess Solvent", which reports the rich approach as the percentage solvent flow in excess of the flow
required for max load. This specification is useful for determining "Rich End Pinch" for amine sweetening
contactors.
 Side Column Estimate – An estimate sometimes required for side columns. Estimate options are:
a. Fraction Feed Entering Column - If either path between the main and side columns contains a mixer
followed by a splitter, the fraction of added material that reaches the column should be given as the
estimate. For example, if 100 moles of material are added to the path from the main column to the side
column via a mixer, and 40 moles of material are subsequently removed from the same path to the side
column via a splitter, the "Fraction Feed Entering Column" would be 60%.
b. Fraction Draw Entering Column - If any stream between the main and side column contains a splitter,
and there is not a mixer like was mentioned above, the fraction that is returned should be given as the
estimate. For example, if the draw from the main column to the side column is 100 moles and 15 moles
are removed from the path to the side column via a splitter, then the "Fraction Draw Entering Column"
is 85%.
c. Side Column Duty – If duty is added to the path from the main column to the side column, or from the
side column to the main column via a heat exchanger, the amount should be given as an estimate
(positive if energy is added to the system).

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Fluid Drivers

All fluid drivers (blowers, compressors, expanders, and pumps) should have either an efficiency or performance curve
designated. An outlet pressure or change in pressure should also be defined. Recommended practice is to set the
pressure in the outlet stream, as doing so will maintain the set pressure even if the upstream pressure is changed.

Heat Exchangers

Pressure drops or outlet pressures must be supplied for each side of an exchanger. A pressure drop is more commonly
specified and is generally recommended.

Having pressure drops set on each side of a single-sided or two-sided exchanger leaves 1 degree of freedom around
the exchanger. This should be specified based on outlet stream temperatures, exchanger duty, UA, or approach
temperatures. Exchangers with more than two sides will have more than 1 degree of freedom, with the degrees of
freedom being equal to the number of sides minus 1.

Mixers/Splitters

Mixers may have an unlimited number of streams mix together into one outlet stream, while splitters may have as
many outlet streams as needed from a single inlet. In splitters, the user may designate the percent splits within the
block or the flow rates in the outlet streams. Each inlet connection point on a mixer can accept multiple inlet streams.
Mixers and splitters have a default pressure drop of zero, but this may be changed if necessary. The outlet pressure
of a mixer is equal to its lowest inlet stream pressure minus any pressure drop designated in the mixer.

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ProMax Property Stencil

The ProMax Property Stencil is designed to add customizable functionality to ProMax, giving an option to embed and
share VBScript-based calculations. Many examples are available for use and modification. The Property Stencils may
be found in the “More Shapes” menu.

 Single Line Property – Displays any single piece of information from the project on the flowsheet.
 Property Input – Displays any user-defined parameter from the project on the flowsheet. The value may be
modified directly on the flowsheet by typing in the new value and pressing enter.
 Property Connector – Connects to another property stencil, such as the “Property Calculator”, to allow the
user to quickly change a variable within that other stencil. This essentially changes the value of the variable
within the stencil to match whatever stream the other end of the “Property Connector” is attached to.
 Property Calculator – Allows a user to write script calculations based on variables within ProMax. The results
are displayed directly on the flowsheet. Any number of variables can be defined by double-clicking in the
grid area and browsing through the tree diagram. Click on “Edit Script Function” to define what will be
displayed on the flowsheet.
 Stream’s Cn+ GPM – Displays the potential Cn+ from any single stream in standard gallons per MSCF
(thousand standard cubic feet). The “n” may be modified by double-clicking on the shape, selecting “edit
source” and then double-clicking on the “intMinCAtoms” value and replacing the number (5 is the default).
 Sum I/O Property – Displays the sum of a selected property across all input streams, if an input stream is
selected; sums the property across all outlet streams if an outlet stream is selected; or sums the property
across all internal (non-outlet/inlet) streams if an internal stream is selected.
 API Vapor Relief Area – Deprecated (Use stream “Relief Valve Sizing Analysis” instead)
 API Steam Relief Area – Deprecated (Use stream “Relief Valve Sizing Analysis” instead)
 Data Exchange – Allows bi-directional specifications between an embedded Excel workbook and ProMax.
This feature is most useful when writing compositions from Excel into ProMax.
 Solver/Specifier Example – A shell that supplies a value to a script based ProMax Calculator (solver or
specifier) with appropriate VBScript edits. Allows the user to write solvers and specifiers with VBScript.
 Cn+ GPM Solver – This stencil works identically to the [Cn+] solver on the following page except that the units
solved for will be standard gallons per MSCF.
 Cn+ Flow/Frac. – Displays the total flow rate or fraction of any single stream of all components containing
the minimum carbon atoms. By default, it calculates the flow rate of C3+. It can report in molar, mass, normal
vapor, standard liquid or vapor, or volumetric units.

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  Flow Duplicator – Copies a reference stream’s composition and sets target stream flow rate. Pressure and
temperature are not set, and must be designated by the user. The target stream MUST be connected to a
block, even if it is a valve with 0 pressure drop. The flow rate will NOT update otherwise.
 UA Wizard – Creates a solver on a selected variable to solve an exchanger to a user-specified UA, LMTD,
Approach Temperature, or percent over design.
 Elemental Flow Example – Displays the total flow of a given element in a selected process stream.
 Copy Stream – Copies a reference stream by transferring molar enthalpy, pressure, component mol fractions,
and molar flow rate. Target stream MUST be connected to a block, even if it is a valve with 0 pressure drop.
The flow rate will NOT update otherwise.
 [Cn+] Solver – Manipulates a selected variable to achieve a desired Cn+ fraction or flow rate in a selected
target stream. A blank Simple Solver must be created on the manipulated variable prior to placing the stencil
on the flowsheet. The connector on the shape should then be placed on the target stream. The desired
fraction or flow rate should be defined by double-clicking on the shape and changing the value.
 PipeLine Mach Number – Solves for a specified Mach number through the pipe. By default, it will change the
flow rate of the fluid until the Mach number is 1. The user should set an inlet flow rate as an initial guess for
the solver. A desired Mach value can be specified by double-clicking on the shape.
 Flow Multiplier – Copies a reference stream’s molar enthalpy, pressure, and composition, then modifies the
reference stream’s flow rate by a multiplier. Default = 2x. Target stream MUST be connected to a block, even
if it is a valve with 0 pressure drop. The flow rate will NOT update otherwise.
 Membrane – Solves for asynchronous vapor separation in a membrane. Permeability values and available
membrane area is defined in the block.
 Membrane Permeabilities Example – Displays component permeability values directly on the flowsheet.
 Orifice Plate – This can simulate either an orifice plate or a nozzle/venturi. It is capable of solving outlet
pressure, inlet pressure OR mass flow, depending on what is specified in the inlet and outlet streams. Double-
click on the shape to specify parameters.
 Salt Example – Double-click on the shape to specify the stream in which an aqueous salt is desired. Then,
select the desired salt and the mass percent of the salt in the solution. The tool will then add the required
acid and base to the Environment, calculate the required amount of each in the stream, and define the
composition based on this.
 Chart – Allows the user to generate simple plots such as the column temperature profile or the temperature
at each increment through a heat exchanger. These plots can be generated using the Plots tab of these
blocks, but the Chart version can be conveniently placed on the flowsheet.
 Component GPM – Displays the standard gallons per MSCF of any single selected component.
 Date Example – Displays the project name and the created, saved, modified, and solved dates and times.
This can be modified by changing the solver scripts.
 Phase Envelope – Displays the phase envelope of a selected stream on the flowsheet. The current stream
conditions are shown on the diagram with a red “X”.
 Heat Transfer – Displays the heat transfer chart of a selected exchanger on the flowsheet.
 Sum Component Flow/Frac. – Displays the sum of flows or fractions of components selected by the user.
Many pre-defined groups are available, such as BTEX and Greenhouse Gases, but any components in the
selected stream may be summed by choosing User Defined in the drop-down list.
 GWP Calculator – Displays the global warming potential of a selected stream in mass flow of equivalent CO2.
 Emission Factor – Calculates the emissions factor for pollutants in lb/bbl for a user-specified vapor and liquid
PStream. Pollutants include VOCs, Benzene, Toluene, Ethylbenzene, Xylenes, n-Hexane, and 2,2,4-
Trimethylpentane.
 Flammable Limit – Estimates the upper and lower flammability limits for a hydrocarbon mix in ambient air.
 Reversipator – This reverse separator calculates the pressurized liquid and flash gas compositions and flow
rates by supplying the temperature, pressure, flow rate, and composition of a condensate stream, and the
temperature and pressure of the pressurized liquid stream. Assumes that the condensate and pressurized
liquid streams are at their bubble point.
 Oil/Water Emulsion – This will modify the properties of an existing Single Oil to create an emulsion, and save
this new component into the current Environment. The water volume fraction is then specified by double-
clicking on the shape.

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 Depressurization Example – This tool estimates an orifice diameter required to depressurize a vessel to a
given pressure in a given amount of time. The user should set the vessel volume, vent pipe diameter, vessel
initial pressure and temperature, downstream pressure, target pressure, time to reach target pressure, etc.
 Latent Heat Example – This example estimates the latent heat of a stream from one vapor fraction to another
at constant pressure.
 Heat of Vaporization – An alternative method of estimating the heat of vaporization of a stream.
 P/H Diagram – Displays the Pressure/Enthalpy diagram of a selected stream on the flowsheet. The current
stream conditions are shown on the diagram with a red “X”.
 P/S Diagram – Displays the Pressure/Entropy diagram of a selected stream on the flowsheet. The current
stream conditions are shown on the diagram with a red “X”.
 Inline Flow Multiplier – Transfers a process stream’s conditions and composition from one connected stream
to another. The flow specification is set from the source stream and multiplied by the Flow Multiplier
parameter. The user has the ability to select which properties to transfer to the target stream.
 HTRI Data Transfer – This shape is designed to facilitate direct data transfer from a ProMax heat transfer unit
operation to an HTRI ® input file. A licensed copy of the HTRI software must be installed on the computer to
use this tool. The data transferred from ProMax to HTRI includes inlet and outlet conditions for the heat
transfer, along with the thermodynamic property data required by HTRI.
 Calculator Callout – Displays calculator related information directly on the PFD.
 Stream’s Component Ratio – Displays a stream's user-defined component ratio.
 Tank Losses – Follows the AP-42 methodology for calculating the rate and composition of volatile losses from
a liquid storage tank. Working losses, breathing losses, loading losses, and flashing losses are calculated for
liquid storage tanks operating at or near atmospheric pressure, and are suitable to calculate the average
annual or monthly loss rate for environmental reporting applications.
 Eductor – Calculates eductor area ratio based on inlet conditions.
 Shortcut Distillation – Estimate ideal stage requirement, feed location, and minimum reflux ratio given a
process stream.
 Liquid Dielectric Constant – Estimate the liquid dielectric constant for a process stream.
 Block Calculator – Creates a new stencil that is based on an existing block from the flowsheet. The stencil
saves user defined properties (e.g., temperature on an outlet stream) and specifiers or solvers associated
with the block. The values can be changed from the dialog for each user defined property. A “Master Name”
should be selected for the stencil name, and then “Store in Stencil” selected to save the shape. Once stencils
have been saved, the “Save” button in the top right-hand corner of the stencil will save the stencil for future
use. Both this saved stencil group and the ProMax property stencil set must be open to use these created
stencils.
 Shape Converter – Modifies any Visio object into a ProMax shape. Connection points can be added from the
connection point tool (in the same group as the connector tool); block type and connection point assignments
are made in the stencil. Once both the shape and stencil set are saved, the shape may be used in any project.
 Shape Swap – Drag this shape out and drop it on a ProMax shape to switch it with another compatible ProMax
block shape.

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Reactors

There are several options for reactors in ProMax, including Conversion, Equilibrium, Gibbs Minimization, Plug Flow,
Plug Flow with Mass Transfer, Stirred Tank, and Stirred Tank with Mass Transfer. The reactors discussed in this training
are generally designed for sulfur recovery units, so this section will focus on the Gibbs Minimization option. The other
options require reaction sets to be defined and used; for more information on these reactors and reaction sets, please
see the ProMax Help.

Within the Gibbs Minimization choice there are “Gibbs Sets” options which are explained below. Each step of the
sulfur recovery process has a corresponding Gibbs Set, with many constraints and reactive species predefined.

 General – This option can be used for any general reactor type for which the Gibbs Minimization option will
be used. This does not include any constraints and all species are reactive.
 Acid Gas Burner – This set includes constraints on COS and CS2 production during the burning of acid gases,
and should be used when modeling a burner that has either H 2S or CO2 in the feed. The NSERC correlations
are valid for an 8%-98% (mol) H2S composition and 0.1%-5% (mol) CO2 composition.
 Burner – This model has no constraints set by default, and all components are Gibbs Reactive (i.e. all
components are included in the reaction). Can be used to model incinerators, Reducing Gas Generators
(RGGs), or fuel gas burners.
 Claus Bed – For all typical Claus beds, this choice is best. All species involved in the Claus reaction are reactive.
Note: COS and CS2 are not reactive at typical conditions for the Claus reactors.
 Equilibrium Hydrolyzing Claus Bed – As opposed to the “Claus Bed” option, the “Hydrolyzing Claus Bed”
allows the COS and CS2 to react, as this bed is designed to be operated at higher temperatures and with a
specialized catalyst to destroy these species.
 GPSA Hydrolyzing Claus Bed – This option adds constraints to the destruction of COS and CS2 in concordance
with the correlations from Section 22 of the GPSA Data Book.
 Reaction Set Only – A reaction set should be created for this option, otherwise no reactions will occur. Gibbs
Reactive components are selected to match the reaction set, and cannot be overridden.
 Sub-Dewpoint Claus Bed – This choice best models those Claus beds that are operated where sulfur
condenses directly on the catalyst and the bed undergoes a regeneration cycle.
 Sulfur Condenser – The Sulfur Condenser allows further reactions for sulfur redistribution at the cooling
temperatures, but no other reactions.
 Sulfur Direct Oxidation – This selection is for sulfur recovery units that utilize direct oxidation methods
typically used where the H2S concentration is too low for combustion, even with a split flow configuration.
 Sulfur Hydrogenation – The hydrogenation option models the reactions of the tail gas with an oxidizing
stream to recreate H2S as the stream is passed on to an amine tail-gas treating unit.
 Sulfur Partial Oxidation – The "Sulfur Partial Oxidation" or SUPERCLAUS® type Reactor uses a special catalyst
for "selective oxidation" that converts almost all of the H 2S directly to sulfur and is usually the final bed in a
Claus unit. In ProMax, Sulfur Direct Oxidation mainly converts H2S to SO2, whereas Sulfur Partial Oxidation
converts the H2S to elemental sulfur.

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  Sulfur Redistribution – This option is used to represent the second pass of the waste-heat boiler in a typical
Claus burner-WHB setup. The only reactions allowed in this Gibbs set are for the redistribution of the sulfur
species; no other species are allowed to react. This can also be used to model reheaters more accurately.
 Sulfur Thermal Reaction Zone – This is used to model the first pass of the waste-heat boiler. Constraints are
added to a few components that cease reacting once the temperature has cooled below a set temperature.

Recycles

 Process Recycle – This block is used when any downstream material is recycled back into the process
upstream. Analyzing the flowsheet to reduce the number of recycles necessary by combining as many as
possible is typically encouraged, as this will reduce the execution time.
o The stream exiting the recycle block must be fully user-defined, including temperature, pressure,
composition, and flow rate. This guess provides ProMax a place to begin its execution, and is
overwritten each time the recycle iterates. This block is considered “solved” when the stream
entering the recycle block is the same, within tolerances, as the stream exiting.
o Priorities must be set for recycle blocks. All default to a priority of 1, but should be adjusted to match
the necessary solve order. Priorities may be set as any integer number with higher priority numbers
solved first.
 Q-Recycle – This block is used when energy is taken from somewhere downstream and applied to an
upstream location. Often this occurs with a glycol reflux coil, as the amount of cooling that occurs in the coil
is generally dependent upon the specification of the distillation column, and the outlet temperature of the
rich glycol is not directly controlled, even though it is upstream of the column. This case is demonstrated in
Exercise 5:“Glycol Dehydration Unit”.
o The initial guess for a Q-Recycle is provided in the block itself, unlike with the Process Recycle. This
guess is provided as the “Calculated Value” on the Process Data tab. Priority, zero by default, should
be adjusted to match the necessary solve order. Higher priority numbers solve first. Bounds and
step size are optional, and typically not recommended.
 Propagation Terminal – The propagation terminal is a specialized recycle block designed to be used in closed-
loop systems where no material enters or leaves the loop, such as is found in refrigeration loops, hot oil loops
and similar systems.
o The terminal allows chosen properties to propagate through the block, unlike a recycle block that
will break all propagation. Two properties should be selected, typically pressure and temperature,
but this depends on how the loop is specified. Please read the ProMax Help or review the ProMax
example files for more information on how to use a propagation terminal.

Separators

 Two Phase Separator – This block allows the separation of liquid and vapor phases of a process stream. There
may be multiple inlet streams attached to the separator but only two outlets: one vapor and one liquid. A
pressure drop or outlet pressure must be specified. Energy streams may also be attached. If this is done, an
additional degree of freedom is given, and should be specified as an outlet temperature or fraction vapor in
the separator.

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  Three Phase Separator – This block is similar to the two-phase separator, except that the three-phase
separator allows separation of vapor, light-liquid, and heavy-liquid phases. On the Process Data tab, there is
an option for the “Main Liquid Phase”. This allows the user to specify whether the liquid phase should use
the light- or heavy-liquid outlet if there is only one liquid phase predicted by ProMax.
 Entrainment – This property may be set within a separator for any phase into any other phase, on a variety
of bases. The values are user-defined.

Streams

 Process Stream – ProMax is a stream-based simulator; therefore, process streams typically contain most of
the specifications. For a stream to be fully specified, two “flash variables” (these include temperature,
pressure, mole fraction vapor, and enthalpy), a flow rate, and a composition should be known or propagated
from upstream or downstream.
 Energy Stream – These are dotted streams representing the energy input or removed from blocks such as
compressors, pumps, some heat exchangers and separators, etc.
Cross Flowsheet Connector – These allow stream information to cross from one flowsheet to another. If a process
stream is connected, then pressure, enthalpy, and molar fractions are transferred. Since Property Packages
may change between flowsheets, warnings can be set for any variation in these values from one flow sheet
to another. The user also has the ability to choose not to transfer components that are below a specified
mole fraction in the stream. This gives the ability to limit the number of components in the new Environment
to decrease the execution time.

Valves

 JT Valve – The valve has several icons available, but all are identical in their operation. Typically, a pressure
drop across the valve or an outlet pressure is specified. In some rare cases, an outlet temperature or fraction
vapor may be specified. Valves may additionally be utilized to model a control valve or differential flow
meter, allowing ProMax to estimate the pressure drop for the block based upon correlations for these
operations.

3.4. UNIT CONVERSIONS IN PROMAX

A drop-down list of various unit sets is available from the ProMax Ribbon Bar or the ProMax Project Viewer. This
selection will update the default units displayed for all streams and properties in the current project.

If a single property is to be displayed in a different unit, most properties have a drop-down menu available where the
current unit assignment is displayed. Selecting in this cell will provide new unit options as demonstrated below.

20
If a particular unit is not available in the dropdown menu, it can be typed directly into the unit box. The ProMax Help
lists acceptable abbreviations for all units available in ProMax.

ProMax will automatically convert any value if the assigned units are changed. Thus, the user should set the correct
units before manually entering a value for an individual property. Alternatively, the user can type a value followed
directly with its desired units when specifying a property value.

3.5. DEFINING AN OIL

ProMax has two oil classifications: Single Oil and Curve Oil. These can be created from the “Oil” option on the ProMax
Ribbon. A description for creating the oils can be found below. A Single Oil is treated as a single component and can
be used to model a single hypothetical component, such as a C 6+ fraction. A Curve Oil is treated as a collection of
several “cuts” and is used to model a crude oil with a large boiling range, typically defined by a TBP curve or D86 curve.
Unlike a Single Oil, a Curve Oil may be fractionated in a distillation column.

After creating an oil, it must be added to the desired Environment(s) from the Environment dialog, under the
components tab.

Single Oil
To define a Single Oil, one of the following combinations must
be provided at a minimum:

 Volume Average Boiling Point

 Molecular Weight AND Specific Gravity
 Molecular Weight AND API Gravity

All other information can be estimated by ProMax using

common correlations. These correlated values may be
overwritten; every additional piece of information provided
by the user will improve the prediction accuracy as the
correlations are updated.

Once added to the Environment, the Single Oil is found in the

component list as a single component, with the properties
that were previously specified.

21
Curve Oil
To define a Curve Oil, a boiling point curve must be
provided to ProMax. This curve can be on several bases,
with the most common being D86 and TBP curves. If it
is available, the TBP curve is preferable because ProMax
will first convert other curves into an estimated TBP
curve before creating the oil.

Independent curve data for Specific Gravity, Molecular

Weight, and High and Low Temperature Viscosity may
also be provided to better define the oil, if available.

Once the curve data is entered, ProMax will calculate

additional properties of the oil. If any of these bulk
properties, such as the API gravity or molecular weight,
are known the ProMax’s predictions can be overwritten.

The second tab, “Cut Points”, provides a preview and allows modification to how ProMax plans to cut this oil into
individual components. The number of cuts ProMax should take between given temperature ranges may be specified.

The predicted properties of each cut point are given in the table on the Cut Points tab.

The “Light Ends” tab allows the user to designate whether there are any light ends involved with this Curve Oil. These
components, typically hexanes, heptanes, and other known hydrocarbons in the oil, will have better properties and
interactions if ProMax can use the pure components instead of estimates from a Curve Oil. The options are:

 Light Ends Free – This sets no light ends in the oil.

 Light Ends Generated – ProMax will generate an estimate of the amount of each light end that is in the oil.
The user must designate which components are present.
 Light Ends Supplied – The user must provide information on which components are present and how much
of each component is in the oil.

The “Correlations” tab provides information on all of the correlations ProMax is using for each property of the oil.
Many of these correlations have alternatives that can be selected for more accurate predictions if the default
predictions are not close enough.

The “Plots” tab provides several charts of the physical properties of the oil as a visual aid. These should be used to
verify that the expected results are achieved.
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Speciated Oil
The most advanced oil characterization method available in ProMax is through the Oil Speciation tool. This tool
provides a composition of a mixture of species that represents the bulk properties of a given oil sample, and provides
a complex mixture from assay data. Look for more in-depth information in the ProMax Help, or at an advanced training
course.

3.6. CREATING NEW FLOWSHEETS

ProMax allows the user to have as many flowsheets in a project as desired. Each flowsheet may have a separate
Environment to allow multiple processes to be modeled in the same project. Additional flowsheets can be added
using the ProMax “Flowsheets” menu option.

Alternatively, the user may right-click on the flowsheet tabs area below the flowsheet and “Add Flowsheet…”.

Note: The  symbol and “Insert” options will insert a Visio page, not a ProMax flowsheet. These can be useful for
certain types of drawings, but are not capable of executing ProMax calculations. ProMax objects drawn on a Visio
page will display in black and white.

When creating a new flowsheet, the assigned Environment can be an existing Environment, a duplicate (copy) of an
existing Environment that can then be modified, or a new Environment to be fully defined.

Once the flowsheet is created, a cross-flowsheet connector may be used to have a process or energy stream flow from
one flowsheet to another. This block will appear on both of the two connected flowsheets as an arrow shape to
indicate the process or energy flow direction. The process or energy flow directions must agree on both sides of the
connector (e.g. an input on one sheet must be an output on the other).
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3.7. AVAILABLE ANALYSES IN PROMAX
Analyses can be added to any stream in ProMax by clicking on the “Analyses” tab from the Project Viewer, and
selecting “Add Analysis…” towards the bottom of the screen. The options are:

Amine Analysis – Presents information on carbon dioxide, hydrogen sulfide, and total acid gas loading in an amine
stream. It also shows the pH and Molarity of the stream.

Combustion Analysis – Determines the required combustion oxygen for a stream, as well as various heating values,
the Wobbe Index, Motor Octane Number, Methane Number, and Heat Release value.

Composition Subset – Calculates properties and flow rates on selected component “groups” within a stream, e.g. “C3+
Hydrocarbons”, “BTEX”, “Kerosene”, “Sulfur Components”, etc. User-defined grouping is also available.

Control Valve – Estimates many properties of a selected control valve for use in a process stream. Tables and plots of
the valve Cv, choked pressure drops, and choked mass flow may also be produced.

Differential Pressure Flow Meter – Calculates the pressure drop, flow resistance, flow coefficient, and other
properties for orifice, nozzle, and venturi flow meters. Other flow meter types may be modeled by specifying the
permanent pressure drop ratio and discharge coefficient. A resistance coefficient calculated from the analysis may
also be used as an input for a fitting segment in a pipeline.

Distillation Curves – Presents a table and plot of a distillation curve based on TBP, ASTM D86, ASTM D1160, ASTM
D2887/SD, or EFV on either a wet or dry basis of the selected stream.

Freeze Out, Hydrate, H2O Dew Point – Determines the solids formation temperature, water content, and water dew
point for any stream phase, including multiple hydrate points, structures and regions. This last point may be useful if
operating below the highest hydrate point, but not in the hydrate region.

Fuel Properties – Predicts fuel properties of the stream, including the Flash Point, high- and low- temperature
viscosity, API gravity, various ASTM cut points, and the smoke or cloud point.

Ionic Information – Presents information on the ions present in the stream if an electrolytic Environment is being
used, including ionic and salt compositions, and pH values.

Line Sizing – Calculates the required nominal pipe size based on a limited gas velocity, pressure drop, or both. Inputs
can include the inclination angle, pipe schedule, pipe roughness, material of construction, corrosion allowance, and
other variables.

Phase Envelope – Generates a plot and table from a stream on either a wet or dry basis. By default, a bubble/dew
point curve is created, but this can be modified. ProMax automatically matches the bubble-point curve if the dew-
point curve is requested, and similarly will match the 90% curve with the 10% curve, etc… A Hydrate Curve, Dry Ice
Curve, or Ice Curve can also be included.

Relief Valve Sizing – Estimates a relief valve size by following a chosen standard, with the default being the ASME API
RP520. Relief Temperature and Pressure, Set Pressure, Over Pressure, Back Pressure, Flow Rates, Coefficients, and
Corrections are all available for specification. The stream Latent Heat can also be found on this analysis as defined by
the standard.

Vapor Pressure, Dew, Bubble Point – Calculates Bubble and Dew Point pressures and temperatures on a wet or dry
basis. The True Vapor Pressure (TVP) at 100°F and the Reid Vapor Pressure (RVP) can also be calculated.

24
3.8. IDEAL STAGE AND MASS+HEAT TRANSFER COLUMN TYPES
ProMax offers both Ideal Stage (equilibrium-based) and Heat + Mass Transfer (non-equilibrium-based) calculation
models. Both models are powerful tools for examining column performance.

Ideal Stage
Ideal Stage models are often used in the design process when determining column configuration, optimum reflux, and
other operating conditions. Since the calculations are relatively simple, the ideal stage models solve quickly, and
generally give consistent results. These models can be used for all applications, with no need to research correlations
for unusual systems or limitations against two liquid phases.

There are 3 column types available when using ideal stage models:

General Ideal Stage – A general equilibrium-based tower type for most distillation types.

TSWEET Kinetics – Designed for amine absorption of acid gases, this model accounts for the rate-dependent kinetic
effects of the slower reaction rate of CO2 with amines, and is required for accurate predictions. Some column
hardware information must be user-defined.

TSWEET Stripper – Created for amine regeneration, this model assumes a 50% efficient column, operating with a
condenser and reboiler, at reasonable pressures and temperatures. No hardware is required to be user-set, however
the number of stages should be set keeping in mind the 50% efficiency inherent to the model. If using a thermosyphon
reboiler, or operating at unusual conditions, please see the Promax Help or contact Support for assistance.

Mass + Heat Transfer

Mass + Heat Transfer models account for non-equilibrium behavior in a column. This model type allows the user to
specify the actual number of trays or height of packing, without making assumptions on the HETP or column
efficiencies. Correlations for many applications are available within ProMax. Mass + Heat Transfer columns provide
multiple correlation options and adjustable parameters for matching operating data and adjusting predicted
performance. This model requires detailed column hardware information for all trays and packing columns.

There are 2 column types available when using Mass + Heat Transfer models:

General Mass + Heat Transfer – A general Mass + Heat Transfer model for most distillation types.

TSWEET Absorber / Stripper – Created for amine absorption and regeneration kinetics.

25
3.9. EXPORT / APPEND PROJECT
ProMax has the ability to export entire projects to be appended to other
ProMax projects. This is a simple two-step process that will import all
streams, blocks, specifications, calculators, Environments, User Value Sets,
and other information from one project into another project.

1. Within the project to be exported, select the “Export Project”

option in the “File” menu. Save the file as a “.pmxexp” file
type.

2. With the destination project open, select the “Append Project”

option in the “File” menu and browse for the desired
“.pmxexp” file.

This process will import the entire project to the new project.

If this option is used often for specific processes, it is recommended to have single flowsheets for each
Tip process so they can easily be combined into the new project.

3.10. PROMAX REPORTS

ProMax provides several options for generating a report after a project has been completed. The Report Options
window shown below is accessed by clicking the “Report” button in the ProMax Ribbon.

2
1
3

1. Optionally supply a Client Name, Location and Job. This will be added to the first page of the report.

2. Choose the output file type, most commonly Word or Excel format. “Template” allows the use of a customized
report designed in Excel. Information can be found in the Help, or by asking BR&E Support.
26
3. Units configuration should be set here. By default, ProMax will override any unit changes that have been made
in streams and blocks so that the same units will be displayed throughout the report. If the “Override Units”
checkbox is unselected, unit changes made for individual streams or blocks will stay as the selected units for
the report. This section also allows for the report to be displayed based on Fraction or Percentage and
Absolute or Gauge pressures, regardless of how the project was created.

4. The tree control diagram allows the user to select which pieces of information are included in the report. To
report the entire project, check the top-most box. A user may select individual flowsheets, process streams,
Environments, User Value Sets, or almost any other desirable combination to report.

5. Which stream properties to report are selected here. The selected properties may be rearranged into any
order. Selected options are “checked” and found at the top of the list. The composition bases available are
listed to the right.

6. Block options are available below the stream options. The selections here will vary depending on the project,
but can include various plots or analyses that the user may want included in the report based on the blocks in
the project. Heat exchanger specification sheets can be created from the options, and are available if the Word
report format is selected and a rated exchanger is included in the simulation.

7. If the user would like either the drawing of the flowsheets or the warnings summary included with the report,
they can select the corresponding options in the window.
Select “OK” when the selections are complete. ProMax will then open a dialog asking for a file save location, and then
the report will be created.
The “Report Navigator” tool will appear when the Report is opened, and can assist in finding information from a
generated report. This navigator does not use a license, but is only available on computers with ProMax installed.

3.11. GIBBS MINIMIZATION REACTORS IN PROMAX

Defining Reactors
This course will focus exclusively on Gibbs Minimization reactors in ProMax. Stoichiometric equations are not required
for this reactor type; rather, equilibrium is determined by minimizing the product free energy. This is a good
estimation when there is sufficient energy available for the reactions to overcome any activation energy barriers and
go to equilibrium. In ProMax, select “Gibbs Minimization” from the “Type” field to enable these estimations.

In many cases, reactors do not have sufficient energy for all possible reactions to occur that are predicted by Gibbs
Minimization estimations. To account for this, ProMax has a family of Gibbs Set constraints, with each member
designed for specific purposes (see Page 18 for a complete list of Gibbs Sets).

Along with choosing the correct Gibbs Set, all reactors need a pressure drop to be defined.

The “Bypass Fraction” setting reflects the percent of material that passes through the reactor without reacting. This
value can be used to estimate reactor efficiencies as well as the effects of catalyst deactivation over time.

27
3.12. UTILIZING SHORT MONIKERS AND THE MONIKER CLIPBOARD
A moniker in ProMax is essentially the name given to each object or property within the project. As seen throughout
the program, such as when adding variables in solvers and specifiers, finding these monikers in ProMax often leads
the user to expand through a “tree” diagram with (+) signs opening to sub-categories.

Two shortcuts are available to find a moniker.

The first option copies the moniker value to a clipboard within the
project. This is performed by right-clicking on the property (e.g. stream
flow rate or temperature) to be used in a specifier, solver, or property
table within the project. Select the “Copy Moniker to Clipboard” option
from the context menu.

Later, when selecting this variable, choose the “Clipboard” option at

the top-right above the tree diagram. Note that only one moniker may
be on the clipboard at a time.

The second option creates a named local variable that is stored within
the project and can be referenced at a later time. This is performed
by right-clicking on the property to be used, and selecting “Add to
Short Moniker List”. Name the variable in the dialog and “Add/reset”
the moniker.

Once created, this local variable can be accessed from any moniker
location by choosing the “Short Moniker” option located above the
tree diagram. Note that not all variables, such as compositions, can
be added as short monikers or to the clipboard using the right-click
feature.

The Moniker Builder button in the ProMax ribbon (pictured at right) allows the user to create
short monikers and add variables to the clipboard using the tree diagram as opposed to right-
Tip clicking on the desired variable. With this button, short monikers can be made for any
variable, including compositions.

28
Optimizing A Model
4.1. OVERVIEW
There are extensive optimization options available within ProMax. ProMax simulations can interact with Excel to
import & export data between the two programs, and can also be used along with ProMax to run case studies or
sensitivy studies to help understand and predict a unit’s behavior. Microsoft VBA coding provides additional
opportunities for project customization.

Calculators can be used to automate simulations and optimize process conditions. Simple Specifiers are used to set
the value of a property based on the value of other known variables or constants. Simple Solvers automatically adjust
a parameter to maintain a spec or goal elsewhere in the process. User Value Sets can be created to store user-defined
variables for additional calculations.

4.2. EXCEL INTERACTIONS

ProMax has several methods to interact with outside programs, most notably Microsoft Excel. The following pages
outline how to use the two most popular Excel applications: Import/Export and Scenario Tool™.

Import/Export from Excel

The simplest Excel interaction is the import/export functionality that is available between ProMax and an embedded
Excel workbook.

To embed a workbook, select the “Add Excel Workbook” option from the ProMax Ribbon. This workbook is embedded
within ProMax and will open, close, and save with the project. It is not available outside of the ProMax project unless
a copy is created in another Excel workbook that is not connected with ProMax.

Once an Excel workbook is embedded,

right-clicking on most properties in ProMax
will give an option for “Export to/Import
from Excel”. Selecting this allows the user
to choose the preferred unit set to be
transferred with the value, along with the
cell in Excel where the property will be
connected.

Both exporting and importing are allowed if there is no value in the ProMax field; however, if there is a value in the
ProMax field then importing options will be disabled and only exporting will be allowed. To delete an incorrect or
unwanted Export/Import connection, right-click on any property and select “Delete Exporting to/Importing from
Excel” to bring up a list of all existing Export/Import connections.

Compositions are exported as an array from the top of the components list down. Select a range of cells
that corresponds to the number of components to export. For example, if the component list has 15
items and only 5 cells in Excel are selected, the top 5 components will be exported. Individual
Tip component’s composition within the list cannot be exported with this tool, as selecting one cell will
always export the top component in the list. Individual components can be exported using the Scenario
Tool, which is explained on the following page.

29
Using the Scenario Tool™ in ProMax
ProMax includes an Excel Add-in that allows the user to create case studies for any unit created in ProMax. The
Scenario Tool™ may be used in either an embedded or external Excel workbook. This tool provides access to all of the
functionality of Excel, such as creating graphs or using “in-house” worksheet formulas for manipulating and
interpreting data.

1. Open an Excel sheet and look for the tool under the ProMax ribbon.

2. If the Scenario Tool is not already available under the ProMax ribbon in Excel it can be added manually by
double-clicking the ProMax Scenario Tool.xla file at the following default locations:
ProMax 4.0: C:\Users\Public\Documents\Bryan Research & Engineering Inc\ProMax4\AddOns\Excel.
ProMax 3.2: C:\Program Files (x86)\Bryan Research & Engineering Inc\ProMax3\AddOns\Excel.
3. Start the Scenario Tool in Excel by clicking on the “Scenario Tool” option.
4. Select from the drop-down list the appropriate ProMax file to be used. A name can be given to the scenario,
and the “Manage Scenarios” button to the right allows for handling multiple scenarios.

5. Organize in Excel the input parameters to be supplied to ProMax and the output locations to display the
calculated results.

6. Add the Input variables to the Tool by using the “Add Variable” button in the ProMax Inputs section. Use the
“Select ProMax Object” button to select the desired ProMax variable. Name the variable, select the desired
Excel range for this variable, and verify the units are correct.

7. Add the Output variables by using the “Add Variable” button in the ProMax Outputs section.
8. Run the tool, selecting which set of “runs” to execute.

The EZ Setup Tool opens a “wizard” to help set up a scenario step-by-step, and the 2D Grid Setup Tool
Tip is designed for easily setting a grid with two input variables and one output variable, respectively.

30
4.3. USING CALCULATORS IN PROMAX
Using Simple Specifiers in ProMax
A Simple Specifier is used to set the value of a property based on the value of other known variables or constants. To
set a specifier, right-click on the property to be calculated, then select Create Simple Specifier.

1. Name the Simple Specifier.

2. Write the expression that defines the specified variable. This must be a single-line expression, but can have
multiple independent variables. Note that the independent variables must be known and calculated prior
to the specified variable being used.

3. A unit selection is also made. ProMax will maintain this selection even if project units are altered.
4. Select the Add button to add the Independent Variables to
be used in the specifier. The Property Moniker dialog box,
as shown to the right, will appear.

5. From the variable selection dialogue, begin expanding the

tree through the project, flowsheets, stream or block, down
to the desired independent variable. When a valid
selection is picked, the gray box below the tree will fill in
with a moniker string.
6. Upon selecting the variable, type a unique name to briefly
identify the value. This name must not include any special
characters, with the exception of the underscore (_); a
space will be replaced with an underscore. The name must
not start with a number and is case-sensitive.
7. Select Add when finished, and repeat for as many variables
as required for the specifier. When an independent
variable has been selected it will appear in the Independent Variables list with its name, value, and units as
shown below.

Selecting the “Hold” check-box in the Property Moniker dialog box will keep the dialog open after adding
Tip the current variable, simplifying the process of adding multiple independent variables.

31
Using Simple Solvers in ProMax
A Simple Solver is used to adjust one variable in order to hit a goal or spec on another variable in a process. A Simple
Solver must be used if ProMax will need to iterate to find the desired solution.
For example, if the goal is to adjust the flow rate of air fed to a Claus unit to achieve a set tail gas ratio of H 2S to SO2,
a Simple Solver could be placed in the inlet air flow rate field. ProMax will use the solver criteria to iterate on the air
flow rate until it achieves the desired tail gas ratio.
To create a Simple Solver, right click on the property that the solver is to adjust and select Create Simple Solver.
1. Name the Simple Solver.

2. ProMax will iterate the Calculated Variable until the equation written here is equal to zero, so the equation
must be written with this in mind.

3. Select the Add button to open a tree dialog as shown in the Specifier example on page 31. Add the
Measured Variable to be used. This is the value ProMax will measure to see if it meets the goal (in this
case, the tail gas ratio).

4. A guess for the “Calculated Value” must also be supplied to give the solver a starting point. Upper and
lower bounds may be set, though this is usually not necessary and will cause the solver to fail if the solution
is outside of the given bounds.

5. A Priority must be set if multiple solvers are present in the simulation for acceptable execution time. It is
suggested that the solvers be prioritized to solve sequentially, with loops solving from the “inside out”.

Writing the Simple Solver Expression:

1. For this example, the Tail Gas Ratio should equal 2 when solved: TailGasRatio = 2
2. Since ProMax expects to solve at zero, this is rewritten: TailGasRatio – 2 = 0
3. ProMax needs only the function written, so the “0 = ” is omitted: TailGasRatio – 2

While writing the function as “TailGasRatio – 2” is acceptable, it is highly recommended that each Simple
Tip Solver expression be “normalized” to aid in convergence. Normalizing the above expression results in
the following: “TailGasRatio/2 – 1”

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4.4. USER DEFINED VARIABLES
ProMax provides a method to define a variable that it does not calculate otherwise. These variables are stored in User
Value Sets, so they may be grouped together as desired. To add a new user-defined variable:

1. Open the Project Viewer and select (double-click) the User Value
Set from the tree diagram in which to add the new variable. If a
new User Value Set needs to be created, right-click on the “User
Value Sets” option in the tree diagram of the Project Viewer and
select “Add”.

2. It is recommended to change the name of the User Value Set to

something descriptive.
3. Select “Add…” to create the new variable.

4. From the new dialog box that appears, tell ProMax what type of
unit this variable will have associated with it. There are three
choices:

a. User Defined Units – Define units for this variable based

on units ProMax can understand, but in an unusual
sequence that is not available in the “Standard Units”
list (e.g. kW*h/ft2). ProMax can perform unit
conversions from these defined units.
b. Unrecognized Units – Define units for this variable
based on something ProMax cannot understand, such
as monetary units (e.g. $, £). Unit conversions are not
available.
c. Standard Units – Select from the list which set of units
this variable will have. ProMax will provide a dropdown
list of available units as normal.

5. Choose whether to associate this variable with a new Simple

Specifier. Choose to associate with a Simple Specifier if any
information must be taken from within the project to calculate
this variable’s value (e.g. flow rates, compositions, horsepower,
etc…). If the value for this variable will be set directly by the user,
leave this unmarked (e.g. setting an ambient temperature for use
in the project).
6. Name the variable and select “OK”.
7. If the user has selected to associate this with a Simple Specifier, it
will create an undefined specifier. Right-click on the blue box,
select “Show Calculator” and define the requirements. Please see
Using Simple Specifiers in ProMax on page 31 for further details.
8. If there is not a specifier associated with this variable, the user
types the desired value for this variable directly into the
parameter box.
9. Lower and upper bounds are optional, but may be set. If the
“Enforce Bounds” box is selected, a warning message box will be
generated if the variable falls outside either of these bounds.

33
Equipment Sizing & Rating Overview
5.1. OVERVIEW
ProMax provides sizing and rating capabilities for many different types of equipment. A variety of separator types can
be sized for adequate separation. Column internals can be designed or existing column information can be specified.
Relief valve sizing can also be performed within ProMax, along with depressurization calculations for a variety of
scenarios. In addition, control valve types can be selected within a ProMax valve block to calculate the pressure drop
over the valve.

Heat exchanger internals can be input into a simulation to determine if an existing exchanger will provide sufficient
heat exchange. Expected pressure drops through the exchanger are calculated according to the actual exchanger
internals.

The following sections provide basic information on sizing applications available within ProMax. These topics are
discussed in great detail in the BRE 232 “Equipment Rating and Sizing” course as well as in the ProMax Help.

5.2. SEPARATOR SIZING

Separator sizing can be performed within ProMax to calculate the required size of a separator for adequate separation.
Sizing for the following types of separators is available: Horizontal 2 Phase, Vertical 2 Phase, Vertical 3 Phase,
Horizontal 3 Phase, Horizontal 3 Phase with Boot, Horizontal 3 Phase with Weir, Horizontal 3 Phase Boot & Weir, or
Horizontal 3 Phase Bucket & Weir.

To enable separator sizing, double-click on the separator to be sized and select the “Include Separator Sizing” option
on the Process Data tab.

With this enabled, a new Sizing tab is created where sizing information will be calculated. Separators are sized to give
the vapor and liquid(s) adequate time to fully separate into their respective phases. Theoretically, there are many
different separator sizes that could achieve the desired separation. By default, ProMax calculates the diameter and
length combination that will give the smallest overall size required to achieve thorough separation. The diameter can
be user-defined, in which case the necessary length will be calculated according to the set diameter.

34
Refer to the “Separator Sizing” web tutorial online for an example of how to size a 3-phase separator or refer to the
ProMax Help for definitions and explanations of separator sizing parameters.

5.3. COLUMN SIZING

Column sizing can be performed for any ideal stage or mass transfer column. Sizing information is found within the
Hardware grouping under the Process Data tab of the column. Within the General section, the user can select whether
the column uses trays, random packing, or structured packing. For an existing column a diameter can be specified,
from which the fraction flooding will be calculated. Alternatively, for column design cases, a fraction flooding can be
set and ProMax will calculate the necessary diameter for the specified amount of flooding. A system factor is set to
account for the expected foaming within the tower.

For Ideal Stage models, a Real/Ideal Stage Ratio is specified to illustrate the conversion of real trays into theoretical
ideal stages. For example, a ratio of 3 would mean that it takes 3 real trays to match 1 ideal stage. For both ideal
stage and mass transfer models, tray and packing information can be specified. Two types of trays are available: Sieve
and Round Valve. Many types of random and structured packing are available. User-defined packing types can also
be input into the simulation.

For packed columns, the Ideal Stage model utilizes a Height Equivalent to the Theoretical Plate (HETP) value to convert
a height of packing into an equivalent number of ideal stages. Mass Transfer modelling allows the user to directly
input the total packing height into the tower internals. The total height is broken into increments (represented as
stages) whereupon the calculations are performed.

For additional information on column internals, including differences between ideal stage and mass transfer models,
contact Technical Support.

35
5.4. DEPRESSURIZATION AND RELIEF VALVE SIZING
Depressurization events can be modelled with the Depressurization Example stencil inside the ProMax Property
Stencils. This stencil allows the user to calculate the orifice diameter necessary for depressurization along with the
maximum flow rate through the orifice. For a known orifice size this stencil can also calculate the time required for
depressurization or the amount of depressurization that would occur given a specified amount of time. Heat input
can be accounted for, including fire case calculations defined by API 521.

Relief valve sizing for blocked flow cases can be performed within any stream using the Relief Valve Sizing analysis.
The analysis calculates the required effective discharge area based on the stream composition and user-specified
parameters such as valve type, relief temperature, relief pressure, and back pressure.

5.5. CONTROL VALVES

Control valve specifications can be input directly into a valve block. Control valve calculations are performed by
selecting “Control Valve” as the Pressure Drop Method on the Process Data tab and then specifying the valve Type,
Identifier, and Opening. ProMax calculates the resulting Valve Cv and Pressure Drop for the specified control valve.

36
5.6. HEAT EXCHANGER RATING
Heat exchanger internal information can be specified in ProMax for rating existing exchangers in a simulated process.
The following heat exchanger types are available for rating: Shell & Tube, Fin Fan, Compact, Double Pipe, and Plate
Frame exchangers.

To enable a rating for an exchanger, double-click on the desired exchanger, go to the Process Data tab, and then select
the Enable checkbox at the bottom of the Heat Transfer grouping.

A new Rating tab is created where the exchanger internals are input and the results are dispalyed. The type of internal
information required depends on the type of exchanger (number of tubes for shell & tube exchanger, number of layers
for compact exchanger, etc.). A fraction over design (FOD) will be calculated for all types of exchangers to compare
the currently simulated conditions with the actual capacity of the exchanger. A negative FOD means the existing
exchanger is insufficient for achieving the stream conditions set in the simulation. Often a Simple Solver is placed on
an exchanger duty or outlet temperature to achieve an FOD of 0%, resulting in a properly fit heat exchanger.

Exchanger rating also provides essential information specific to each side of the exchanger, such as an expected
pressure drop calculation for each side. The user also has the ability to enter a fouling resistance for each side to help
account for the prolonged use of an exchanger.

The exchanger rating feature can also be used for basic heat exchanger design. Please refer to the “Heat Exchanger
Sizing” web tutorial online for an example of how to design a heat exchanger using ProMax rating capabilities.

37
Course Exercises

Exercise 1: SIMPLE GAS PLANT

Process Background: Collection and Pre-Processing
Natural gas liquids (NGLs) recovered through natural gas processing are often stored until they are trucked or piped
away for processing. To avoid excessive emissions and losses, the liquid products may be “stabilized”. The
stabilization process heats the liquids to allow the most volatile components to vaporize, lowering the vapor pressure
of the remaining NGL product.

Note that for all exercises the alternative specifications in metric units have been rounded for convenient values and
are therefore not exact unit conversions.

Goal and Information

This simple system models a gas feed separated into a liquid product and a sales gas by compressing, cooling, and
flashing the gas. The liquid is sent to a stabilizer to achieve product specifications by removing lighter components in
the stabilizer overheads. The column is operated with a reboiler that is used to control the composition of the bottom
liquids.

 Configure the Environment by selecting an appropriate property Inlet Conditions

package (Peng-Robinson or SRK) and adding the listed components. Temperature 95°F [35°C]
 Use the stream conditions in the table to define the inlet stream. Pressure 200 psia [14 bar]
 The compressor outlet pressure is 725 psig [50 barg]. Use 75% Flow 5 MMSCFD
polytropic efficiency. [5600 Nm3/h]
 The outlet of the air cooler should be 110°F [43°C]. A pressure drop
Composition Mole %
should be set in the cooler.
 Sales gas is sent through a gas/gas exchanger to cool the inlet Nitrogen 1.92
stream. The Minimum End Approach Temperature in this first Carbon Dioxide 2.71
cooler is 30°F [16°C]. Two pressure drop specifications are required Methane 58.66
for a two-sided exchanger. Ethane 16.17
 The second cooler chills the stream feeding the propane cooler to Propane 12.86
36°F [2°C]. Set the pressure drops. i-Butane 1.58
 The propane refrigeration cools the stream entering the low n-Butane 0.70
temperature separator to 20°F [-6.5°C]. Set a pressure drop. i-Pentane 0.84
 Set a pressure drop of 0 psi in the LTS. n-Pentane 3.73
 The pressure at the outlet of the JT valve is 200 psig [14 barg]. n-Hexane 0.81
 The column has 8-stages with a 4 psi [0.28 bar] pressure change.
 Common NGL product specifications include: C1 < 0.5 liquid volume percent (LV%) of the NGL product stream;
and a C1/C2 LV% ratio < 0.015. Inside the stabilizer on the Specifications tab, create both of the specifications
mentioned here (see the FAQ on the next page for assistance). Set the C1/C2 ratio as a Specification and
leave the C1 LV% as a Calculation.

38
  Once the unit has solved, recycle the Stabilizer gas stream to the beginning of the system. Supply a guess for
stream “Recycle Guess”, including temperature, pressure, flow rate and composition. A good guess is to
mimic stream 13 from the previous solution by clicking the “Copy Inlet” button inside the recycle block.

QUESTIONS
1. Insert a Property Table to display the temperatures, pressures, flow rates, and compositions of the Inlet, Sales
Gas, and NGL streams.
2. What is the LMTD in the first cross exchanger and the sales gas temperature?
3. What is the duty required for the C3 refrigeration unit?
4. Generate a phase diagram with only the dew point and bubble point lines for the sales gas stream. See the
FAQ section on the next page for an explanation of how to create a phase envelope diagram.
5. Add the 90% and 10% vapor lines to the phase diagram.
6. What are the critical point and the cricondentherm temperature for the sales gas?
7. What are the Reid Vapor Pressure (RVP) and True Vapor Pressure (TVP) of the liquid product? Display these
on the flowsheet using a Callout.
8. The pressure drop in the inlet stream is to be maintained below 5 psi/100 ft [1 bar/100m] of horizontal length.
Using schedule 40 pipe, what diameter is required? What is the actual pressure drop? What is the velocity?

39
FAQs on Exercise 1
 All heat exchangers normally have a pressure drop specified, since this is a property of the exchanger. Setting
an outlet pressure instead can result in unexpected results if conditions change later.
 Generally, an efficiency is set for all pumps, compressors, and expanders. Setting both the outlet pressure
and temperature is strongly discouraged because a small inaccuracy in the temperature can result in
efficiencies less than 0% or greater than 100%.
 Visio shapes can be resized and rotated by utilizing points that become available when the object is selected.
Process and Energy streams can be redirected from similar points.
a. The small green circle above the exchanger to the right is for rotating the
shape; a few shapes restrict this to maintain correct positioning of vapor
and liquid exits.
b. The other green squares are to resize and stretch the shape
c. The yellow diamond, as show on the “20” in the stream to the right,
designates label location; labels can be moved by dragging this diamond.
d. To redirect streams, find the small bright-green squares located in the
middle of the streams, then click and drag from these points.
 When the definition of a property in ProMax is unknown, often the “What’s This” Help menu can provide
some assistance. This feature is found by right-clicking on most cells in the Project Viewer:

 The Callout box option is found in the “ProMax Streams” set, and contains several set-up options to customize
the display. The “Font…” button gives control over the font size, color, and type. The “Color…” button allows
changes to the gridline colors.

 For the Column Specifications mentioned, use “Component Flow” for C1 in total bottoms liquid stream and
“Component Ratio” for the methane to ethane ratio.
 Recycle blocks always require the outlet PStream to be completely specified (Pressure, Temperature, Flow
Rate and Composition).
 Many additional stream properties (such as the Phase Envelope, Vapor Pressure, Line Sizing, etc.) are
calculated within the different analysis available in a stream under the Analysis tab. For a comprehensive list
of analysis available in ProMax, see page 24.

40
Exercise 2: PIPELINE SIMULATION
Goal and Information
Two different natural gas lines are mixed and sent through 17.3 miles of pipeline to a processing facility. Along the
way, a 3rd gas stream from a different production facility is added to the mixture. Build a simulation to represent this
system based on the information below.

PIPE-1:
Stream Gas 1 Gas 2 Gas 3
Segment 1:  24,000 ft [7315 m] length Temperature 100°F [37°C] 100°F [37°C] 70°F [21°C]
 8 in [200 DN], schedule 80 Pressure 600 psig 600 psig 510 psig
 Ambient T = 50°F [10°C] [41.5 barg] [41.5 barg] [35.2 barg]
Segment 2:  45° standard elbow Flow rate 8.2 MMSCFD 5 MMSCFD 8 MMSCFD
[9153 Nm3/h] [5575 Nm3/h] [8930 Nm3/h]
Segment 3:  25,000 ft [7620 m] length
 8 in [200 DN], schedule 80 Composition Mole %
 500 ft [150 m] elevation rise CO2 0.2 0.3 0.1
 Ambient T = 40°F [5°C] N2 0.5 0.3 0.8
C1 84.3 86.9 85.1
Segment 4:  30,000 ft [9140 m] length
C2 5.5 4.8 6.5
 8 in [200 DN], schedule 80
C3 5.1 4.1 3.8
 Ambient T = 30°F [-1°C]
iC4 1.4 0.9 1.1
PIPE-2: nC4 1.5 1.3 1
Segment 1:  2.3 mile [3700 m] length iC5 0.85 0.7 0.6
 10 ft [3 m] elevation rise nC5 0.3 0.3 0.5
 12in [300 DN], schedule 80 nC6 0.3 0.2 0.37
 Ambient T = 40°F [5°C] nC7 0.05 0.2 0.13

 The heat transfer coefficient should be calculated by ProMax based on Carbon Steel A134 welded pipe with
a centerline buried depth of 24 inches [600 mm] in dry clay ground.

QUESTIONS
1. What is the temperature and pressure of the gas exiting the pipeline to the processing facility?
2. What is the calculated overall heat transfer coefficient for the first pipe segment?
3. For each pipe segment, plot length vs. pressure.
4. Where does drip condensate begin to form? How much liquid (bbl/d) exits Pipe-2?
5. If the upstream dehydration facility shuts down and Gas 1 becomes saturated with water, do hydrates form?

41
Exercise 3: SIMPLE MDEA SWEETENING UNIT
Process Background: Acid Gas Removal
The removal of acid gases, specifically hydrogen sulfide (H2S) and carbon dioxide (CO2), can be achieved through
several methods, including the use of: solid scavengers (e.g. iron sponges, etc.), chemical solvents (e.g. MEA, DGA,
MDEA, caustic, potassium carbonate, etc.), physical solvents (e.g. MeOH, DEPG, NMP, etc.), and membranes. Some
recently developed processes reduce the H2S in the natural gas directly to solid sulfur using liquid catalysts or biological
pathways. The chosen method depends on the temperature, pressure and inlet gas composition.

An example of a chemical solvent process can be found in this exercise, while an example of a physical solvent
process can be found in the Physical Solvent Acid Gas Removal exercise on page 71. Further examples of chemical
and physical solvent processes can be found in the example projects located at FileOpen Example ProMax Project.
The chemical solvent examples are contained in the “Amine Sweetening” directory and the physical solvent
examples can be found in the “Gas Processing” directory. See the ProMax Help topic for information on modeling
membranes.

Chemical solvents
Chemical solvents usually consist of one or more amine compounds mixed with water. The solvent is brought into
intimate contact with the gas in an absorption column that typically has ~20 real trays or equivalent packing. In the
absorber, the acid gases are absorbed into the solvent and react with the amine (a weak base). This process is
kinetically-limited. Primary amines (e.g. monoethanolamine (MEA), diglycolamine (DGA), etc.) have the fastest
kinetics, secondary amines (e.g. diethanolamine (DEA), diisopropanolamine (DIPA), etc.) and tertiary amines (e.g.
methyl-diethanolamine (MDEA)) have respectively slower kinetics. ProMax accounts for kinetic effects with a rigorous
rate-based kinetic model.

While primary and secondary amines can absorb H 2S and CO2 quickly, they are typically used at lower concentrations
and with a reclaimer to reduce the amount of amine loss and degradation. Tertiary amines can be used at higher
concentrations and the reaction kinetics favor selective absorption of H 2S over CO2. Typically, these tertiary amines
have no reclaimer since their degradation and losses are much lower.

If the absorber is operated at high pressure the rich amine is sent through a flash tank to reduce the amount of
hydrocarbons present in the rich amine before it reaches the regenerator. A lean/rich heat exchanger is also
commonly used to reduce reboiler duty.

The regenerator is a distillation tower that typically has ~20 real trays. It is operated at the lowest pressure feasible
for downstream processing of the acid gas, typically near 15 psig [2.05 bara]. The reboiler often uses saturated steam
at 50 psig [4.5 bara] and a flow rate equivalent to 0.7-1.5 lb steam/gal [90-180 kg steam/m3] of circulating solvent. A
condenser is also present to reduce the amount of amine loss and to reduce the amount of water sent down-stream.

Additional information on optimization of sweetening systems can be found in the “BRE 231: Sour Gas Processing”
course or within the ProMax Help.

42
Goal and Information
In this exercise, a sweet gas is required to have less than 2 mol% CO2 and less than 4 ppm H2S (molar). Use the
following information to simulate this amine sweetening unit and determine if the requirements are being met. Use
an Amine Sweetening property package, as there are ionic reactions occurring. Use the “Exercise 3 – Simple MDEA
Sweetening Unit.pmx” file.

Part A: Ideal Stage Model

Inlet Conditions
 Select an appropriate Amine Sweetening Environment. Temperature 100°F [38°C]
 The inlet gas stream is 100% saturated with water Pressure 1000psia
 Supply a guess for the recycle block outlet. [70 bar]
 40 wt% MDEA is circulated at 190 sgpm [44 m3/h]. The makeup Flow 50 MMSCFD
stream is at ambient temperature and 20 psig [1.4 barg]. [56000 Nm3/h]
 The pump increases the lean amine pressure high enough to return
to the absorber column. Composition Mole %
 The air cooler outlet temperature is set to 10°F [5°C] warmer than H2S 1.5
the gas feed temperature. CO2 3.5
 The absorber uses the “TSWEET Kinetics” column type that has a Methane 83.4
4 psi [0.3 bar] pressure drop. Ethane 5.65
 The absorber diameter is 4 ft [1.3 m]. Set a system factor of 0.8. Propane 4.07
 Set the real/ideal stage ratio to 3. This represents the fact that 3 n-Butane 0.9
real amine absorber trays are equivalent to 1 ideal stage (amine
n-Pentane 0.5
absorbers are about 33% efficient).
 Weir height is 3 in [7.6 cm] and tray spacing of 2 ft [0.6 m]. n-Hexane 0.32
 The rich flash tank operates at 100 psia [6.9 bar]. n-Heptane 0.15
 The rich amine enters the regenerator at 210°F [99°C]. Benzene 0.005
 The regenerator top stage pressure is 12 psig [0.82 barg] with a 4 Toluene 0.002
psi [0.3 bar] pressure change through the tower. Remember to use Ethylbenzene 0.001
the “TSWEET Stripper” column type. o-Xylene 0.002
 The condenser operates at 120°F [50°C] and the reboiler duty is 17
MMBtu/h [5000 kW].

43
QUESTIONS
1. What are the sweet gas CO2 and H2S compositions?
2. What are the liquid residence time and percent flood on an absorber tray?
3. What are the H2S, CO2, and total rich loadings (mol/mol)? Lean loadings?
4. What are the lean and rich approach in the absorber for H2S?

Part B: Trayed Tower Using Mass + Heat Transfer Model

One advantage of the Mass + Heat Transfer Model available in ProMax is the ability to directly specify the number of
trays in the column.
 Change the absorber tower to use the “Mass + Heat Transfer” model, and select the “TSWEET
Absorber/Stripper” column type.
 Increase the column stages to 20.
 From the “General” selections, keep a 4 ft column diameter, and a system factor of 0.8.
 From the “Tray” selections, use Sieve trays, and maintain the 2 ft spacing and 3 in weir height.
 Solve the flowsheet again. How do the results compare?

FAQs on Exercise 3
 The Saturator block is used in this exercise to fully saturate the sour feed stream with water. The “Water”
stream requires only that a composition of 100% water is set. Allow ProMax to calculate other properties.
The default setting for the block is to saturate the process stream to 100% saturation.

 The Lean and Rich Approach are column specifications used to determine the best way to improve absorber
performance. They are also used to predict absorber stability during process upsets.
o Lean Approach: Analyzes the driving force at the top of the absorber. If the lean approach is too high
(>80%) then the lean amine acid gas concentration feeding the tower is high and there will be little
driving force to move acid gas into the amine at the top of the column. Increasing the reboiler duty
will lower the acid gas concentration in the lean amine and thus increase the driving force at the top
of the column.
o Rich Approach: Analyzes the driving force at the bottom of the column. If the rich approach is too
high (>80%) then the amine solution will approach equilibrium with the incoming feed and there will
be little driving force to move acid gas into the amine at the bottom of the column. Increasing the
amine flow rate will increase the capacity for pickup and increase the driving force at the bottom of
the column.
 The Make-up / Blow-down block controls the composition and flow rate of any make-up stream required –
more details can be found on Page 10. The Make-up stream requires a user-set temperature and pressure.

44
Exercise 4: EXPORT/APPEND PROJECT
ProMax provides a simple method to combine different projects. The options may be found in the File menu as “Export
Project” and “Append Project”. In this exercise, an export file of the amine unit from Exercise 3: is created and
appended to an existing template project of a dehydration unit.

PROCESS INFORMATION
 From the file menu, select “Export ProMax Project…” Save the project in an easily accessible location, and
close the file.
 Open the file named “Ex5 - TEG Unit.pmx”.
 From the file menu, choose “Append ProMax Project…” Browse and select the “.pmxexp” file from step 1.
 From the TEG flowsheet, select “Active Flowsheet”. Then Duplicate the MDEA Environment and rename the
resulting Environment “TEG Environment”. Assign the property package “SRK” to the Environment, and leave
the components unchanged for now. Select OK, and then assign the “TEG Environment” to the TEG
flowsheet.

Flow Multiplier
On the MDEA flowsheet, to double the flow rate of the sweet gas, use the ProMax Property Stencil named “Inline Flow
Multiplier ”. Doubling the flow rate can be used to represent having two identical amine trains that mix before further
processing. Allow this shape to propagate the pressure and enthalpy and set the outlet flow rate as double the inlet
flow rate. The composition will always be unchanged when using this block. The Property Stencil set is found in the
“More Shapes” menu, if not already available in the project.

Drop a Cross Flowsheet Connector, found in the “ProMax Streams” stencil, onto the MDEA page near the Inline
Multiplier outlet stream. Select the TEG flowsheet as the connected page. Connect the Inline Multiplier outlet stream
to the inlet of the Cross Flowsheet Connector as shown below.

45
On the TEG flowsheet, connect the second side of the Cross Flowsheet Connector (which appears in the lower lefthand
corner of the flowsheet by default) into the dehydration unit “Wet Gas” stream.

QUESTIONS
1. Is there a temperature difference between the “Sweet Gas” stream in the MDEA flowsheet and on the TEG
flowsheet? Why? How can this be corrected? (Incorporate this change into the project.)
2. Since the component list from the MDEA unit earlier was duplicated, the current TEG Environment is lacking
the component TEG. When adding TEG to the Environment, also delete the MDEA from the list. Why will
the cross-flowsheet connector no longer solve?

3. In the Cross Flowsheet Connector, a Mole Fraction Transfer Threshold can be set to prevent the transfer of
trace components across flowsheets. This can be useful in cases where the user wants to remove a trace
component from the components list across different units. In this exercise, set the Threshold value to limit
transfer to only those components above 5 ppm. What components will not be transferred to the Dehy
Flowsheet? What issues does this raise? Change the Threshold value to 1.5 ppm.

The “Copy Stream Conditions”

property stencil is an alternative
that will display both inlet
Tip streams. The shape connects to a reference stream
and a blank target stream with connector lines, as
illustrated. Composition, mass flow rate, molar
enthalpy and pressure are transferred.

46
Exercise 5: GLYCOL DEHYDRATION UNIT
Process Background: Glycol Dehydration
Water content of a gas stream often needs to be adjusted to meet specifications for transmission pipelines, storage,
or further processing. There are two methods currently employed in most dehydration systems: direct injection or a
contactor column. Ethylene glycol (EG) and methanol are typically used in the injection method, and triethylene glycol
(TEG) is typically used with the contactor column.

A contactor column with packing or trays is used to allow intimate contact between the wet gas and glycol. These
towers typically have 2-3 ideal stages. Lean TEG is fed to the top of the tower and contacts the vapor stream coming
up from the bottom. The TEG preferencially absorbs water from the gas stream. This rich TEG is then regenerated by
removing the water in a regenerating column. The regenerating column typically consists of a very large reboiler with
a small packed tower.

In general, about 2-5 gallons of TEG are circulated for every pound of water in the wet inlet gas. The reboiler
temperature should not exceed the glycol degradation temperature, approximately 400°F [204°C] for TEG systems. It
is also common practice to cool the temperature of the lean glycol entering the contactor to about 10°F [5°C] above
the inlet gas temperature since colder temperatures improve absorption.

Though glycols do preferentially absorb water, aromatic hydrocarbons also show limited solubility in glycols. As a
result, if the feed gas contains even small amounts of aromatic compounds, non-negligible amounts of these may be
absorbed. Depending on Environmental regulations, the exhaust gases from a glycol dehydration process may need
to be monitored and/or treated for aromatic compounds.

Additional information on optimization of dehydration systems can be found within the ProMax Help or in the BRE
231: Sour Gas Processing course.

47
Goal and Information:
Simulate a TEG unit that dries the inlet gas to a water content of less than 7 lb H 2O/MMSCF (110 mg/scm).

Part A: Ideal Stage Model

 Use the appended project created in the
*Only use table if previous exercise not worked
previous exercise. If starting here, use the
conditions in the table and add a Saturator Inlet Conditions
block to saturate the inlet with water. Temperature 125°F [50°C]
 The Wet Gas stream is cooled to 100°F [38°C]. Pressure 990 psia [68.5 bara]
 Specify a complete guess for the recycle outlet. Flow 96.6 MMSCFD
 Use 5.6 sgpm [1.3 m3/h] for the glycol [107 800 Nm3/h]
circulation rate. Makeup is 99.9 wt% TEG and Composition Mole %
0.1 wt% H2O. H2S 3.3 ppm
 The absorber has 2 ideal stages, and the CO2 1.31
regenerator has 4 ideal stages.
Methane 86.63
 The rich flash operates at 60 psig [5.2 bar].
Ethane 5.87
 The rich feed to the regenerator is heated to
Propane 4.23
300°F [150°C].
n-Butane 0.94
 The regenerator reboiler operates at 390°F
n-Pentane 0.52
[200°C].
n-Hexane 0.33
 The regenerator operates at atmospheric
n-Heptane 0.16
pressure with a small reflux ratio generated
Benzene 0.005
from the reflux coil.
Toluene 0.002
 Use an estimate of 20,000 BTU/h [6 kW] inside
the Q-Recycle block. Ethylbenzene 0.001
o-Xylene 0.002

48
QUESTIONS
1. What is the water content (lb/MMSCF) of the dry gas? The water mass concentration in the Lean TEG stream?
Display these in Callout Boxes on the flowsheet.
2. At what temperature will hydrates form in the dry gas?
3. What is the mass flow of water in the feed gas?
4. How much BTEX (ton/yr) leaves in the Water Gas stream?
5. Create a customized ProMax report for the project. For additional information on reporting see page 26.

Part B: Packed Tower Using Mass + Heat Transfer Model

One advantage of the Mass + Heat Transfer Model available in ProMax is the ability to directly specify a height and
type of packing in the column. Change the contactor tower to use the “Mass + Heat Transfer” model, and select the
“General Mass + Heat Transfer” column type.

 Increase the column “stages” to 6. This number for a packed column represents the number of calculation
increments. Generally, each increment should represent approximately 18 in. [0.5 m] of packing.
 From the “General” selections, choose “Structured” packing, a 4.25 ft. [1.3m] column diameter, 10 ft. [3m]
column height, and a system factor of 0.6.
 From the “Structured” selections, choose “Sulzer Mellapak® 350.X metal” as the packing type.
 Solve the flowsheet again. How do the results compare?

Optional Extended Exercise – Stripping Gas in Dehydration

Goal: See the improvement the use of stripping gas will give to the Exercise 5: Glycol Dehydration Unit model.
PROCESS INFORMATION
 Modify the process to feed 18 SCFM [34 scm/h] of the dry gas stream as stripping gas into the reboiler
(approximately 3 SCF / gallon glycol circulation). Preheat the stripping gas stream to 350°F [177°C], and then
lower the pressure to 20 psig [1.4 barg]. What is the new water content of the dry gas?

FAQs on Exercise 5
 Why is there no flow from the rich flash tank to the regenerator?
This generally occurs if a 3-phase separator is used, but the current conditions only result in 1 or 2 phases.
The separator block in ProMax defaults to the “Light Liquid” outlet for the Main Liquid Phase regardless of
the composition. To change the behavior of the separator, change the “Main Liquid Phase” option within
the separator block to “Heavy Liquid”.
 Stream water content (lb/MMSCF) and hydrate formation temperature can be found in the “Freeze Out,
Hydrate, H2O Dew Point” analysis.
 Use the “Composition Subset” analysis to quickly calculate the amount of BTEX (or other groupings) in a
stream.

49
Exercise 6: SIMPLE TURBOEXPANDER DEMETHANIZER
Process Background: Gas Processing
Raw natural gas coming from the well will contain varying amounts of ethane, propane, n-butane, isobutane, and
pentanes. These compounds comprise what is called natural gas liquids (NGLs). These NGLs are removed from the
methane, which is sold as “natural gas.”

The NGLs are typically removed before the natural gas is introduced to the transmission pipelines. This helps to
maintain the quality of the natural gas within regulations and minimize liquids formation in the pipeline. The removed
NGLs can be used as raw material for chemical plants, in enhanced oil recovery, and as a fuel source. Thus, NGL
products are often more profitable than natural gas and so improved recovery is desired.

The NGLs are removed in a demethanizer column. The methane, at pipeline purity, is recovered at the top of the
distillation column. Depending on the economic situation, ethane will either be sent out the top along with the
methane (known as “ethane rejection”) or recovered in the bottom liquids (“ethane recovery”). All other heavier
hydrocarbons are recovered in the bottom liquid stream where they go on to be fractionated into different marketable
products. Demethanizers are operated at very low temperature ranges (e.g. -150°F [-100°C] at the top) and at
moderate pressures around 200-300 psig [14-21 barg].

The temperatures and reboiler requirements for the demethanizer usually result in the use of a “cold box” exchanger.
This is often a compact exchanger exchanging energy with multiple streams (often 4-5 different streams). These
compact exchangers can achieve closer approach temperatures than shell & tube exchangers and are designed to
handle much lower temperatures. ProMax has the ability to both model and rate these exchangers.

Additional information on optimization of turboexpander systems can be found in the “BRE 201: Gas Processing”
course or within the ProMax Help.

50
Goal and Information
This exercise continues from Exercise 5: Glycol Dehydration Unit. Alternatively, Exercise 6: may be opened and the
table below may be used to specify inlet conditions.

A simple turboexpander-based demethanizer is used to recover ethane and heavier components from the gas stream
as natural gas liquids (NGLs). The residue gas must be delivered at 900 psig [62 barg] with a gross ideal gas heating
value of no more than 1100 BTU/ft3 [41 MJ/m3].

 Add a cross-flowsheet connector to the “Dry Gas” stream *Only use table if previous exercise not
exiting the TEG unit. Connect it to a new stream on the worked
“Turboexpander” flowsheet.
 The feed is completely dehydrated by a molecular sieve; Inlet Conditions
model this with a Divider (under “Auxiliary Objects”) to Temperature 102°F [39.1°C]
remove 100% of water and TEG. Pressure 965 psig [66.5 barg]
 Use a feed split of 25% to the reboilers. Flow rate 96.3 MMSCFD
 The low temperature separator (LTS) inlet stream should [107 500 Nm3/h]
be set to -53°F [-47°C]. ProMax will calculate the Gas/Gas Composition Mol %
Exchanger outlet temperature required to achieve the H2S 3 ppm
specified LTS temperature. CO2 1.55
 The Side Reboiler duty is 5.4 MMBTU/h [1.6 MW]. Methane 86.44
 Operate the Turboexpander at an outlet pressure of 250 Ethane 5.86
psig [17.2 barg] and an 80% adiabatic efficiency. Propane 4.22
 The JT Valve outlet pressure is 252 psig [17.3 barg]. n-Butane 0.93
 The bottoms liquid requirement is a C1/C2 ratio of 0.015, n-Pentane 0.52
on a standard liquid volume basis. n-Hexane 0.33
 The compressors have a 75% polytropic efficiency. Set the n-Heptane 0.15
residue gas pressure to 900 psig [62 barg]. Benzene 47 ppm

51
QUESTIONS
1. What percentage of ethane and propane are recovered in the NGL stream? This can be found in the
Recoveries grouping inside of the demethanizer block.
2. How does the booster compressor pressure change compare to the expander pressure change?
3. What are the Minimum Effective Approach Temperatures for each exchanger?
4. If a kettle-type reboiler was used instead of a plate-fin exchanger, the Reboiler would use the “Pool Boiling”
heat release curve type. Change the Reboiler to “Pool Boiling” and check the new Effective End Approach
Temperature. Would the current process conditions be feasible if a kettle-type reboiler was used?

Exercise 7: EXCEL IMPORT/EXPORT

Goal and Information
This exercise continues from Exercise 6: Simple Turboexpander Demethanizer. Alternatively, Exercise 7: may be
opened. Use the Excel Import/Export feature to see how changing the LTS inlet temperature and turboexpander
efficiency affects NGL production and required residue compression. For additional information on Excel
Import/Export, see page 29.

PROCESS INFORMATION
 Create an Excel workbook by clicking the “Add Excel Workbook” option in the ProMax Ribbon.
 Label the first two columns “LTS Temperature” and “Turboexpander Efficiency”. Below these headers, type
in -53°F [-47°C] and 80%.
 Import the LTS temperature and turboexpander efficiency values from Excel. This is done by right-clicking
on these properties within ProMax. In order to import values from Excel, first delete the user-defined
specifications input for the LTS temperature and turboexpander efficiency inside ProMax.
 Label three more columns “Compressor Power”, “NGL Flow Rate”, and “Residue Gas Composition”. Export
the residue compressor power and NGL flow rate from ProMax into these columns in Excel. Make sure the
selected units are correct. Export the entire Residue Gas composition (mol%) into the last column.

QUESTIONS
1. What happens to the residue compression power when the turboexpander efficiency drops to 70%?
2. What happens to the NGL flow rate when the LTS temperature increases to -45°F [-43°C]?

52
Optional Extended Exercise – Simple VBA Interaction
There are many things that some simple programming can simplify, and the Microsoft Office products provide easy
access to Visual Basic for Applications.

With just 2 lines of code in the current Turboexpander exercise, ProMax will automatically execute after any change
in Excel.

 In the excel workbook, type <Alt>+<F11> to open the VBA interface. This window can also be opened in the
Developer tab by clicking the Visual Basic button
 In the VBA window, go to the Tools tab and select References.
 Within the available references list, select the “BR&E ProMax Type Library”.
 On the left side of the VBA window, double click on “Sheet1” to write code for this Excel sheet.
 Directly above the blank white page that appears, there are two dropdown menus. Set the left dropdown
menu to “Worksheet” and then the right dropdown menu to “Change”. This creates a private sub where
code is written that will go into effect whenever there is a change on the worksheet.
 Inside the “Private Sub Worksheet_Change”, write the following two lines:

Dim PMX as new ProMax.ProMax

PMX.Project.Solver.Solve (True)

 Return to the Excel worksheet and change the LTS temperature to -55°F [-48°C]. ProMax will now
immediately re-execute after this change has been made.

53
Exercise 8: SULFUR RECOVERY UNIT
Process Background: Sulfur Recovery
If sufficient H2S is present, refineries and gas plants will require sulfur recovery units. These units take the hydrogen
sulfide captured from the process and convert it to elemental sulfur for sale and transport. Claus units are the most
common sulfur recovery process. This process entails burning the acid gases in a burner, then passing the gas over a
specialized catalyst that converts the sulfur species into elemental sulfur. The gas is then cooled in sulfur condensers,
and the liquid sulfur is removed. A typical Claus unit repeats this process several times with several catalytic beds,
taking advantage of the equilibrium shift each time sulfur is removed via a sulfur condenser.

There are several variations on the typical Claus plant, including sub-dewpoint Claus beds, direct oxidation reaction
beds, and partial oxidation reaction beds, any of which can be modeled in ProMax. ProMax models these reactors
using Gibbs minimization with preconfigured Gibbs sets to represent each reactor in a sulfur recovery unit.

In many cases, after the acid gases have been sent through the catalytic reactor beds, the tail gas still contains too
much sulfur to incinerate. The most common method of alleviating this concern is to send the tail gas through a
hydrogenation reactor, where hydrogen is added to convert
most of the remaining sulfur species into hydrogen sulfide.
The tail gas is then fed to an amine system for selective H2S
removal. The recovered H2S is recycled back through the
sulfur recovery unit, and the remaining off gas from this tail
gas clean up unit can then be incinerated. This entire process
can be modeled in ProMax by combining the various parts.

Additional information on optimization of sulfur recovery

systems can be found within the ProMax Help or in the BRE
231: Sour Gas Processing course.

54
Goal and Information
This exercise simulates a three-bed Claus sulfur recovery unit. All reactors in this exercise are Gibbs Minimization
reactors, utilizing specialized Gibbs Sets that are preconfigured to select the reactive species and to add the necessary
constraints.

 Set the Environment to “Sulfur ASRL”

Stream Dry Acid Gas Air
 Additional components to include in the
Environment: H2, SO2, CO, COS, CS2, S1 – S8 Temperature 115°F 77°F
[45°C] [25°C]
 The blower increases the air pressure to 16 psig
[1 barg]. The preheater then heats it to 500°F Pressure 15 psig 1 psig
[1 barg] [0.1 barg]
[260°C] with a ΔP = 0.5 psi [0.03 bar].
Flow rate 165 lbmol/h 200 lbmol/h
 The Burner uses the “Acid Gas Burner” Gibbs Set
to create COS and CS2 reaction constraints. [75 kmol/h] [100 kmol/h]
Assume a 0% bypass fraction and ΔP = 0. Composition Mol % Mol %
 The Thermal Reaction zone (1st pass of the waste Hydrogen Sulfide 55 0
heat boiler) produces an outlet temperature of Carbon Dioxide 43 0
1200°F [650°C]. This uses the “Sulfur Thermal Methane 1 0
Reaction Zone” Gibbs Set and has a pressure drop Ethane 0.6 0
of 0.5 psi [0.03 bar]. In this set, certain Propane 0.4 0
components are “quenched” to keep from Oxygen 0 21
reacting below specified temperatures, better Nitrogen 0 78
reflecting actual performance. COS and CS2 are Water 0 1
excluded from reacting.
 The Sulfur Redistribution block (2nd pass of the waste heat boiler) produces an outlet temperature of 700°F
[370°C]. This block uses the “Sulfur Redistribution” Gibbs Set. The pressure drop is 0.5 psi [0.03 bar].
 It may be easiest to specify the Claus Beds, reheats, and condensers sequentially, using the following
information:

a. All sulfur condensers use the Gibbs Set “Sulfur Condenser” with a 0.5 psi [0.03 bar] pressure drop.
Condensers 1 and 2 have an outlet temperature of 320°F [165°C], while condensers 3 and 4 have
outlet temperatures of 300°F [160°C].
b. All reheats have a pressure drop of 0.5 psi [0.03 bar]. “Reheat 1” increases the temperature to 500°F
[260°C], “Reheat 2” heat the stream to 480°F [250°C] and “Reheat 3” heats it to 430°F [220°C].
c. The Claus beds have a 5% bypass fraction and a 0.2 psi [0.01 bar] pressure drop. Claus Bed 1 uses
the “GPSA Hydrolyzing Claus Bed” Gibbs set to partially destroy COS and CS 2. Beds 2 and 3 use the
“Claus Bed” Gibbs Set as they do not have the catalyst and temperature required for COS and CS2
destruction.

QUESTIONS
1. What is the burner outlet temperature?
2. What is the molar flow for H2S and SO2 in the tail gas?
3. How many lb/h of COS and CS2 are formed in the burner?
4. How many long tons per day (tonb/d) are produced from each condenser?
5. Plot the sulfur dew point and bed temperature vs. increment for Claus Bed 2.
6. For Condenser 1, plot liquid sulfur production vs. temperature.
7. Create a recovery in the project to represent the total sulfur recovery from all 4 sulfur condensers. Display
this recovery on the flowsheet by creating a short moniker for this value.

55
Optional Extended Exercise

PROCESS INFORMATION
 Use a cross-flowsheet connector to send the Tail Gas on to the “Hydrogenation” flowsheet.
 The fuel is methane at 30 psig [2 bar] and 77°F [25°C]. The flow rate is 1.5 lb-mol/h [1 kmol/h].
 Ambient air, with an initial flow rate of 13.5 lb-mol/h [9 kmol/h], is compressed to 12 psig [1 barg] by the
blower.
 The Burner uses Gibbs Minimization with the “Burner” Gibbs set. Specify a pressure drop of zero.
 The Hydrogenation Reactor is a Gibbs Minimization reactor and the Gibbs Set is “Sulfur Hydrogenation”.
Set the pressure drop to 0.

QUESTIONS
1. What is the burner outlet temperature?
2. What is the remaining H2S content in the outlet? Is all the SO2 converted in the reactor?

FAQs on Exercise 8
 The sulfur dew point within a Claus Bed can be calculated by performing an analysis inside of the bed. This is
done on the Analyses tab by adding a “Vapor Pressure, Dew, Bubble Point” analysis and selecting the Dew
Point Temperature. This value can then be graphed on the Plots tab.
 Recoveries can be created from within the Project Viewer by right-clicking the
“Recoveries” section and selecting “Add”. In this exercise, the reference stream is
the Dry Gas while the Recovery streams are all four condenser liquid outlet streams.
The “Atomic Basis” checkbox should be selected.

56
Exercise 9: SCENARIO TOOL
Part A: Methanol Injection
Use the Scenario Tool to study the use of methanol injection to prevent hydrate formation. For additional information
on how to load and use the Scenario Tool, see page 30.

PROCESS INFORMATION Inlet Conditions

 Choose a Polar thermodynamic package. Temperature 100°F [38°C]
 Inlet conditions for the Saturated Gas are given in the table Pressure 950psig [65.5 barg]
to the right. Flow 30 MMSCFD
 15 lb/h [10 kg/h] methanol is added at 80°F [27°C] and 950 [35400 scm/h]
psig [65.5 barg].
 The mixed stream is then cooled to 15°F [-10°C] by XCHG- Composition Mole %
100. CO2 2
Methane 85.9
Ethane 5
Propane 5
n-Butane 1
n-Pentane 0.5
n-Hexane 0.3
n-Heptane 0.2
Water 0.1

QUESTION
1. Use the Scenario Tool to vary the MeOH flowrate from 15 to 195 lb/h [10 to 100 kg/h] and compare the solid
formation temperature. If the downstream pipeline requirement states that the gas must have a solid
formation temperature below 0°F [-18°C], what is the optimal methanol feed rate?

Part B: Examining Amine Flowrate Effects

Finding the optimum amine flow rate for an acid gas absorber unit includes studying several variables. Having a sweet
gas concentration that is within specifications is essential, but it is not the only variable to monitor. Some other
variables to consider include:
 Fraction Flood – If this is an existing tower, the flooding on the trays is important to track.
 Rich Loading – especially with H2S, if this is too high, there may be severe corrosion problems.
 Lean and Rich Approach – help determine operational stability. If either of these is near 100%, any fluctuation
of the inlet feed could cause acid gas slip, resulting in a sweet gas that is no longer within specifications.

PROCESS INFORMATION
Use the Scenario Tool to track the Sweet Gas H2S Content, H2S Lean Approach, H2S Rich Approach, Fraction Flooding
on stage 1, and the Total Rich Loading for a 40 wt% MDEA solution with flow rates from 160 sgpm to 280 sgpm in
steps of 10 sgpm [36 m3/h to 64 m3/h in steps of 4 m3/h]. Leave the regenerator disconnected from the system for
the scenario runs.

57
QUESTIONS
1. At approximately what amine flow rate does the rich approach become less than 85%?
2. At approximately what amine flow rate does the absorber reach the H2S specification of 4 ppm?
3. At approximately what amine flow rate does the rich loading reach 0.45 mol/mol?

Optional Extended Exercise: Optimum Turboexpander Pressure

A variety of factors are considered when setting the demethanizer tower pressure. Lower pressures result in colder
tower temperatures which affects the C2 recovery while also affecting how much power is required to recompress
the residue gas. Turboexpander efficiency will also affect both C2 recovery and residue compression power.

PROCESS INFORMATION
Use the Scenario Tool to track the demethanizer overhead temperature, C2 recovery, and residue compression
power while adjusting the tower pressure (controlled by the turboexpander outlet pressure) and turboexpander
efficiency. Run pressures from 225 to 275 psig [15 to 19 barg] at turboexpander efficiencies of 70% and 80%.

QUESTIONS
1. What effect does tower pressure have on C2 recovery? On recompression power?
2. What effect does turboexpander efficiency have on C2 recovery? On recompression power?

Optional Extended Exercise: Wellsite Heater Treater Conditions

Initial wellsite separation is performed to separate sales gas, hydrocarbon liquid, and produced water. In order to
decrease the amount of flash emissions at the atmospheric storage tank, the hydrocarbon liquid is first sent to a
heater treater. The vapors from the heater treater are compressed and re-combined with the sales gas from
upstream separation. The heater treater pressure and temperature determine how much flash emissions will occur
at the downstream hydrocarbon storage tank.

PROCESS INFORMATION
Use the scenario tool to determine what effect changing the heater treater temperature and pressure has on BTEX
emissions from the atmospheric hydrocarbon tank. Run scenarios at temperatures of 125°F, 150°F, and 175°F [50°C,
65°C, and 80°C] with pressures of 20 psig, 30 psig, and 40 psig [1.5 barg, 3 barg, and 4.5 barg]. Also track the
compressor power and the heater treater energy input.

QUESTIONS
1. Why does lowering the heater treater pressure decrease BTEX emissions? How is the required compression
power affected?
2. How does increasing the heater treater temperature affect BTEX emissions?

FAQs on Exercise 9
 Multiple scenarios can be made within the same Excel workbook. To create a new blank scenario, overwrite the
current Scenario Name with a new name for the new scenario. Click Enter and then select “No” from the
message window that appears.

58
 When selecting Input variables, only variables that can
be user-defined within the ProMax project can be
selected. These properties will be shown in bold
lettering. Properties that are calculated by ProMax
cannot be selected as Input variables and therefore are
not bolded in the variable selection window. All variables
can be Output variables regardless of whether they are
user-defined or calculated values.

 Scenario Tool properties can also be used as variables and are found at the
bottom of the variable selection moniker tree. One Scenario Tool property that is
commonly output is called Solve Status, which reports in an Excel common
whether each scenario run converged or failed.

59
Exercise 10: SIMPLE SPECIFIERS
Open the unsolved Exercise 10: “Simple Specifiers” file. Simple Specifiers are utilized to set one variable based on
another already known variable. This automates a project so that when one variable is changed other variables will
adjust accordingly. For more detailed instructions on Simple Specifiers, please see “Using Simple Specifiers in ProMax”
on page 31.

Part A: Lean Amine Temperature

Add a Simple Specifier to maintain the lean amine contactor feed 10°F [5°C] above the sour gas feed temperature.

QUESTION
1. If the feed gas temperature decreases to 90°F [32°C], what is the new sweet gas H2S compositions?

Part B: Reboiler Duty

Add a Simple Specifier to set the reboiler duty based on 1 pound of steam per gallon of amine solution in circulation
[0.13 kg/L solution]. To do this, attach the reboiler block energy stream to a new single-sided exchanger to represent
the steam tubes side. Use 50 psig [3.5 barg] saturated steam at the inlet and saturated water at the outlet.

QUESTIONS
1. What are the sweet gas CO2 and H2S compositions?
2. What is the mass flow of steam required?
3. What is the reboiler duty?

Optional Extended Exercise: Turboexpander JT Valve Pressure

On the second flowsheet in this exercise there is a turboexpander unit. Add a Simple Specifier to maintain the pressure
out of the JT valve 3 psi [0.2 bar] higher than the turboexpander outlet pressure.

QUESTIONS
1. What happens to the ethane recovery and residue compression requirements if the turboexpander outlet
pressure is dropped to 230 psig [16.5 barg]?
2. What equipment issues has this lower pressure (and thus lower temperature) potentially introduced?

60
Exercise 11: SIMPLE SOLVERS
Simple Solvers adjust one variable in order to achieve a target value for another variable in a project. The user must
set an initial guess so that the Simple Solver can iterate until a final solution is reached. This exercise demonstrates
the use of Simple Solvers in a variety of processes previously discussed in this course. For more information on Simple
Solvers, please see “Using Simple Solvers in ProMax” on page 32.

Part A: Amine Rich Loading Solver

Open the unsolved Exercise 11: “Simple Solvers” file. Add a Simple Solver to calculate the amine circulation rate
needed to attain a rich amine loading equal to 0.40 mole acid gas/mole amine. Remember to assign a priority for this
solver.

QUESTIONS
1. Why would a Simple Specifier not work in this situation? Why is a solver necessary?
2. What is the amine circulation rate to achieve a 0.40 rich loading?
3. What are the sweet gas CO2 and H2S compositions?

Part B: Amine Lean Loading Solver

Delete the Simple Specifier on the steam rate. Create a Simple Solver to determine the required mass flow of steam
to achieve a lean loading of 0.0035 mole/mole total acid gas loading. Please review the priorities required for each
solver for efficient execution of the project.

QUESTIONS
1. What are the sweet gas CO2 and H2S compositions when using both solvers?
2. What is the mass flow of steam required to attain the new lean loading?
3. What is the reboiler duty?

Optional Extended Exercise: SRU Tail Gas Ratio Solver

On the second flowsheet, add a Simple Solver to automatically adjust the air flow rate to attain an H2S/SO2 tail gas
ratio of two. Make note of the original air flow rate and overall sulfur recovery prior to creating this solver.

QUESTIONS
1. What is the required air flow rate? What percentage increase of air flow was required?
2. What is the new overall sulfur recovery?

61
Optional Extended Exercise: Turboexpander Exchanger Approaches
On the Turboexpander flowsheet, add Simple Solvers to maximize heat integration in the turboexpander plant.
Control the LTS inlet temperature such that the minimum effective approach temperature of the gas/gas exchanger
is 5°F [3°C]. Set a similar solver controlling the side reboiler duty to achieve a minimum effective approach
temperature of 5°F [3°C]. A third solver is set on the inlet split percentage to the reboilers to achieve a minimum
effective approach temperature in the bottom reboiler of 5°F [3°C]. Set the priority for each solver to zero.

QUESTIONS
1. Why is the priority set to be the same for each solver?
2. With these solvers in place, increase the turboexpander outlet pressure to 275 psig. Note how this affects
the LTS temperature and the ethane recovery.

Optional Extended Exercise: Pipeline Network Delivery Pressure

On the Pipeline flowsheet, use a speciifier to make the “Gas 3” stream pressure equal to stream 2 and another specifier
to make the “Gas 2” stream pressure equal to the “Gas 1” stream pressure. Put a Simple Solver on the “Gas 1” stream
pressure to get a final delivery pressure of 500 psig [34.5 barg] to the facility.

QUESTIONS
1. Why are the Simple Specifiers necessary in this situation?
2. What is the required “Gas 1” stream pressure to achieve the desired delivery pressure?

Optional Extended Exercise: JT Skid – Methanol Injection

As discussed in Exercise 9: Scenario Tool, methanol can be injected into a process stream to prevent hydrate formation
when necessary. On the JT Skid flowsheet, place a solver on the methanol mass flow rate to determine the required
methanol injection rate so that stream 5 will be 10°F above solid formation. Use a step size of 10 lb/h [5 kg/h].

QUESTIONS
1. How much methanol needs to be injected?
2. OPTIONAL: Put solvers on the Gas/Gas and Gas/Liquid exchanger outlet temperature’s so that both
exchangers have approach temperatures of 10°F [5°C].

62
Exercise 12: USER VALUE SETS
A new user-defined variable can be specified to represent any desired value that is not defined within ProMax by
default. The following exercise shows some examples of how this can be useful. For additional information on creating
these user-defined variables and User Value Sets, please see User Defined Variables on page 33.

Part A: Steam Ratio

Add a user-defined variable to represent a reboiler steam ratio (pounds of steam per gallon amine in circulation). Set
this ratio to 1.2 lb/gal [0.15 kg/liter]. Put a Simple Specifier on the reboiler steam rate on the MDEA flowsheet to
utilize this ratio.

QUESTIONS
1. Use a “property input” stencil to display the steam ratio on the flowsheet. Adjust the ratio to 1.3 lb/gal [0.163
kg/liter] and note the change to the lean loading and Sweet Gas H2S concentration.

Part B: Cost Estimation

Some operations can estimate an operating cost based on the BTUs required. Create a user-defined variable to input
this energy cost; start with a cost of $6.00/MMBtu. Add an additional user-defined variable in the same set to display
the cost of running the amine reboiler based on this information.

QUESTIONS
1. What is the current operating cost of the amine reboiler ($/day), based only on the required energy? What
would the operating cost be if the energy cost was $6.50/MMBtu?

Optional Extended Exercise: Refrigeration Loop Compression Power

Create a user-defined variable to sum the total compressor horsepower requirement for the Refrigeration flowsheet.
Once created, add the value as a short moniker in the project. Then add a property table to display this value on the
flowsheet, based on the short moniker name.

QUESTIONS
1. What happens if an upper bound of 225 hp [168 kW] is set?

Optional Extended Exercise: Glycol Flow Rate Ratio

Glycol flow rates are typically set according to the amount of water in the feed gas. Typical ratios are between 2 and
5 gallons of glycol for each lb of water in the feed gas [15-40 L/kg]. On the dehydration flowsheet, add a user-defined
variable to represent a glycol flow ratio of 2 gal/lb [15 L/kg]. Put a Simple Specifier on the glycol flow rate to utilize
this ratio.

QUESTIONS
1. How are the BTEX emissions affected when this ratio is changed to 3 gal/lb [24 L/kg]?

63
Exercise 13: INCINERATOR
Process Background: Incineration
As discussed previously, sulfur recovery units convert hydrogen sulfide captured from upstream processes and convert
it to elemental sulfur for sale and transport. The tail gas, with small amounts of hydrogen sulfide remaining after
processing, is typically sent to an incinerator. Tail gas generally has a very low heating value due to large
concentrations of incombustibles so fuel is often mixed with the tail gas in order to ensure combustion. Sufficient air
must also be supplied in order for enough oxygen to be present for complete combustion of hydrogen sulfide.

Goal and Information

This exercise shows how to model an incinerator to combust tail gas from a sulfur recovery unit. The effects of fuel
gas and air flow rates will be analyzed and discussed.

PROCESS INFORMATION
 The tail gas stream is pre-configured to represent tail
gas leaving a sulfur recovery unit.
 Temperature, pressure, and composition are pre-
defined in the air and fuel gas streams.
 To begin the exercise, set the fuel gas flow rate to 0
lbmol/h [kmol/h].
 Use a Simple Specifier on the air flow rate to mix 20%
excess oxygen with the combined gas. The amount of
oxygen necessary for combustion can be found by
performing a Combustion analysis in the combined gas
stream.
 The incinerator is modeled as a Gibbs Minimization
reactor, using the Burner reaction set.
 Set a 0 psi pressure drop in the incinerator. Set the
bypass fraction to 2%.

QUESTIONS
1. What is the current incinerator outlet temperature? Why is a higher temperature desireable?
2. Fuel gas is used to achieve a sufficiently high temperature to ensure combustion. Put a Simple Solver on the
fuel gas flow rate to get an incinerator outlet temperature of 1600°F [870°C]. What is the calculated fuel gas
flow rate to achieve an outlet temperature of 1600°F [870°C]?
3. Change the air flow rate to run at 50% excess oxygen and re-converge the simulation. How does the required
fuel gas flow rate change?
4. What does a bypass fraction of 2% represent?
5. What are the SO2 emissions from the incinerator in ton/yr?

64
Exercise 14: SEPARATOR SIZING
Use the following information to size a 3-phase horizontal bucket & weir separator.

PROCESS INFORMATION
 Create a hypothetical component to represent the C6+ with a Inlet Conditions
molecular weight of 180 lb/lbmol and API gravity of 42. Temperature 155°F [68°C]
 The feed conditions and composition are shown in the attached Pressure 415 psia [29 bar]
table. Flow Rate 58,225 lbmol/h
 Check the “Include Separator Sizing” box inside the separator on [26 410 kmol/h]
the Process Data tab.
Composition Mole %
 On the Sizing tab, select “Horizontal 3-phase Bucket & Weir” for the
Methane 4.9
Vessel Type
Ethane 1.9
 Use a K-value of 0.5 ft/s [0.15 m/s] for V-L separation.
Propane 1.5
 Use a liquid droplet diameter of 150 micron for L-L separation.
n-Butane 1.0
 Both the light liquid and heavy liquid holdup times are 0.5 minutes
and surge times are 0.25 minutes. n-Pentane 0.5
 The light liquid low level shutdown depth is 6 inches [15 cm]. Water 84.5
C6+ 5.7
 Demister pad thickness & overhead clearance are 6 inches [15 cm].
 Light and heavy liquid residence times are 3 minutes.
 Design temperature is 200°F [93°C] and MAWP is 435 psig [30 barg].
 Corrosion allowance is 0.0625 inches [0.15 cm].
 Use carbon steel A516-70 for the shell and head material of construction.
 Use ellipsoidal heads.

QUESTIONS
1. What is the calculated L/D ratio?
2. In the range 1.5 < L/D < 6, what is the smallest (by mass) separator that will meet design requirements? What
is the mass when the vessel is filled with water?
3. What are the shell and head thicknesses?
4. What is the settling compartment length?
5. Create an entrainment within the separator to make the heavy liquid outlet stream contain 1 vol% light liquid.
Set this entrainment up on a volume per volume basis with 0.01 gal light liquid/0.99 gal heavy liquid.
6. Does this entrainment affect the sizing results?

65
Exercise 15: DEPRESSURIZATION
In this exercise, the blowdown orifice for depressurizing a vessel will be sized to a target pressure within a certain
timeframe in case of fire using API 521.
PROCESS INFORMATION
 The drawn process stream represents the contents of the vessel.
Vessel Contents
Operating conditions are pre-defined as described in the table.
 Drag the “Depressurization Example” shape from the ProMax Property Temperature 100°F
Stencil onto the flowsheet. Select the “Vessel Contents” stream from [38°C]
the dropdown menu. Pressure 560 psig
 The vent phase should be set to vapor. [38.6 barg]
 Set the vessel volume to 400 ft3 [11.33 m^3]. Composition Mole %
 The initial pressure and temperature are the pressure and temperature
of the vessel when relieving begins. Note that this is not the normal C1 26
operating pressure and temperature. For this case, set the vessel relief C2 30
pressure at 688 psig [48 barg] with a relief temperature of 138°F [59°C].
C3 15
 Pipe inner diameter is 2 inches [6 cm]. Vent Pressure is atmospheric.
 Target Pressure will be half of the relief pressure (344 psig [24 barg]). iC4 10
Set the target time to 15 minutes. nC4 15
 Check the “Use API521 for heat estimation?” box. Tank shape is C5 4
“Horizontal Cylinder”. Fire-fighting is available.
 Tank surroundings is set to bare. Tank elevation is 2 ft [0.6m] above grade. Specify the tank length to
radius ratio as 8. Check the “Use EOS for liquid phase” selection.”
 Click “Solve” at the bottom of the Depressurization window to execute the stencil.

QUESTIONS
1. What is the initial liquid volume fraction in the vessel?
2. What is the calculated orifice diameter?
3. What is the maximum venting mass flow rate?

Optional Extended Exercise – Relief Valve Sizing

PROCESS INFORMATION
 On the Relief Valve Sizing Flowsheet, relief conditions for a C4/C5 C4/C5 Mix
mixture are specified in the stream according to the table. Temperature 170°F
 Add a “Relief Valve Sizing” analysis to the C4/C5 mix stream. [76.7°C]
 Use the API520 standard and a Conventional valve. Pressure 75 psig
 Relief Temperature and Set Pressure are set at stream conditions [5.2 barg]
 Fraction Over Pressure is 10%. Back pressure is atmospheric. Flow Rate 50,000 lb/hr
 The required mass flow rate is 50,000 lb/hr [22,700 kg/h]. [22 700 kg/h]
nC4 70 mol%
QUESTIONS nC5 30 mol%
1. What are the calculated Effective Discharge Area and Mass Flux?
2. What is the Relieving Fluid Type? Why?
3. Set Back Pressure to 20 psig [1.4 barg] and switch to Balanced Bellows. What is the new Effective Discharge
Area? What is the Back Pressure Correction Factor?
66
Exercise 16: SHELL & TUBE HEAT EXCHANGER RATING
Use the shell & tube exchanger specification sheet provided to rate the Lean/Rich Exchanger in an amine unit.

QUESTIONS
1. What is the area available in the exchanger for heat transfer?
2. Display the percent over-design on the flowsheet.

Optional Extended Exercise: Fraction Over Design Solver

Add a Simple Solver to the shell & tube outlet temperature going into the regenerator. Set this solver to achieve a
fraction over design of 10%. Remember to assign the best priority to the solver for the most efficient execution.

QUESTIONS
1. What is the new temperature going into the regenerator?

FAQs on Exercise 16
 Tube service is set to Demand for this exchanger since the rich amine stream (2) that is being heated runs
through the tubes. This is due to the corrosive nature of the rich amine.
 Fouling resistance can be user-specified for side A and side B of the exchanger. Go to the Connections tab
to determine which fluid is on side A and which is on side B.

67
68
ProMax Additional Exercises
Exercise 17: REFRIGERATION LOOP
Use the Propagation Terminal in ProMax to determine the required
refrigerant flow. Inlet Conditions
Temperature 80°F [27°C]
PROCESS INFORMATION Pressure 300 psia
[20.7 bar]
 Use 100% propane as the refrigerant.
Flow Rate 33 sgpm
 Compress to 250 psia {17.25 bar], then cool to 120°F {48°C]. [125 lpm]
 Expand to 35 psia {2.4 bar] across the valve.
 Use 10 MMBtu/h [2.93 MW] for the Q-Load stream in this Composition Mole %
example. Propane 99.973
Methyl Mercaptan 0.027

QUESTIONS
1. What is the required flow rate of propane, and the compressor HP?

Exercise 18: ETHYLENE GLYCOL INJECTION

Prevent solids when processing a 0.7 gravity gas using EG. Inlet Conditions
PROCESS INFORMATION Temperature 110°F [43°C]
Pressure 1000 psia [69 bar]
 Circulate 500 lb/h [225 kg/h] EG solution. Flow Rate 25 MMSCFD
 Operate the LTS at -5°F [-20.5°C]. [29,500 sm^3/h]
 Heat the LTS liquids temperature to 30°F [0°C] so emulsions
Composition Mole%
forming at low temperature will separate in the oil/glycol
separator. Methane 86.05
Ethane 6.06
 Operate the oil/glycol separator at 265 psia [18.3 bar].
Propane 3.39
 Regenerate the EG solution to 80 wt% using an atmospheric
regenerator. A reflux ratio of 0.15 is sufficient. i-Butane 0.84
 Sales gas temperature leaving the gas/gas exchanger is 100°F n-Butane 1.36
[38°C]. n-Pentane 2.30
100% water saturated

QUESTIONS
1. What is the solids formation temperature of the low temperature separator feed?
2. What is the water dew point (or freeze out temperature) of the sales gas?

69
Exercise 19: MIXED AMINES
Sweet Gas with < 0.5 mol% CO2 and 100 ppm (mol) H2S.

PROCESS INFORMATION Inlet Conditions

Temperature 100°F [38°C]
 Use 100 sgpm [375 lpm] of 30 wt% MDEA / 15 wt% DEA . Pressure 500 psia [35 bar]
 Absorber: 21 real trays, ∆P = 4 psi [0.25 bar] , D=3.5 ft [1.1 m], Flow Rate 25 MMSCFD
weir height = 3 in [5 cm], tray spacing = 2 ft [0.6 m]. [29,500 sm^3/h]
 Stripper: 20 real trays, operating P=24.4 psia [1.6 bar], ∆P = 5
Composition Mole %
psi [0.3 bar], condenser = 120°F [49°C], reboiler = 5.5 MMBtu/h
[1.6 MW]. H2S 0.1
 Flash tank operates at 80 psia [5.5 bar]. CO2 3.3
Methane 72.4
Ethane 13.3
QUESTIONS Propane 7.5
1. What is the rich amine loading? n-Butane 2.7
2. What is the makeup rate of water, MDEA, and DEA? n-Hexane 0.7
3. What is the liquid residence time on a tray in the absorber? 100% water saturated

Exercise 20: ACTIVATED MDEA FOR ACID GAS REMOVAL

Compare sweetening results using activated MDEA with the results using basic MDEA.

PROCESS INFORMATION
 Process set-up is identical to Exercise 3:Simple MDEA Sweetening Unit; the unsolved version of this
exercise is identical to the solved version of Exercise 3:
 Add piperazine as a component in the Environment, then modify the Make-up/Blowdown block to
maintain 3% piperazine in addition to the 40% MDEA.

QUESTIONS
1. How does the H2S and CO2 absorption compare? What caused the results to shift this way?

70
Exercise 21: PHYSICAL SOLVENT ACID GAS REMOVAL
Achieve a Sweet Gas with 3% CO2 using a DEPG.

PROCESS INFORMATION Inlet Conditions

Temperature 95°F [35°F]
 The flash tanks should operate at 250 psia, 25 psia and 5 psia Pressure 950 psia [65.5 bar]
[17.5 bar, 1.75 bar, and 0.34 bar] . Flow Rate 9 MMSCFD
 The first flash vapor is compressed and mixed with the inlet . [10.600 sm^3/h]
 Circulate 325 sgpm [1230 lpm] of DEPG (make-up pure DEPG).
Composition Mole%
 Chill the lean solvent down to 45°F [7°C] before entering the
contactor. Methane 65
CO2 35
100% water saturated
QUESTION
1. Try various chiller temperatures to see how this affects the
treated gas and acid gas compositions.

Exercise 22: MERCAPTAN REMOVAL FROM LPG USING NAOH

Simulate mercaptan removal using a caustic solution.
Inlet Conditions
PROCESS INFORMATION Temperature 80°F [27°C]
Pressure 300 psia [20.7 bar]
 Use 1 sgpm [4 lpm] of 10 wt% NaOH solution; assume
Flow Rate 33 sgpm [125 lpm]
there is residual methyl mercaptan in the caustic of
Composition Mole %
0.01 wt%.
 The caustic solution should be cooled to 80°F [27°C]. Propane 99.973
 Specify a two stage LLE column. Methyl Mercaptan 0.027

QUESTIONS
1. What percent recovery of CH3S is achieved in the absorber?
2. What is the liquid viscosity of the lean caustic solution feeding the column?

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Exercise 23: CO2 REMOVAL USING NAOH
Simulate CO2 removal using a caustic solution. Inlet Conditions
PROCESS INFORMATION Temperature 100°F [38°C]
Pressure 165 psia [11.4 bar]
 Use 5 sgpm [19 lpm] of 7 wt% NaOH solution. Flow Rate 15 MMSCFD
 Select the Caustic property package. [17700 sm^3/h]
Composition Mole %
QUESTIONS CO2 0.1
Nitrogen 10
1. Using the ionic info analysis information, determine how
Hydrogen 11
much Na2CO3 will be formed.
2. What is the CO2 content of the fuel gas in ppm? Methane 40
3. What is the respective CO2 contents when the NaOH Ethylene 17
circulation is decreased to 4 sgpm [15 lpm], then 3 sgpm Ethane 16
[11 lpm]? Propylene 0.8
4. What is the liquid viscosity of the rich caustic solution? Propane 3.9

Exercise 24: MEA FLUE GAS CO2 CAPTURE

Reduce CO2 to <1% mol in an inlet flue gas stream.
Inlet Conditions
PROCESS INFORMATION Temperature 125°F [52°C]
Pressure 16 psia [1.1 bar]
 The gas is first treated in a 3-stage “Ideal Stage” caustic Flow Rate 50 MMSCFD
SO2 scrubber (10 sgpm [38 lpm] of 10% wt NaOH]. [59,000 sm^3/h]
 A 4-stage TSWEET Kinetics absorber uses 2 ft. [0.6 m]
Composition Mole %
spacing and 2 in. [5 cm] weirs.
H2O 11.8
 Circulate 1300 sgpm [295 lpm] of 28.2 wt% MEA; cool to
CO2 12.8
125°F [52°C].
O2 5.6
 Strip with 0.8 lb/gal [0.1 kg/L] of 60 psia [4.1 bar]
N2 69.8
saturated steam, and a 120°F [49°C] condenser. The
regenerator operates at 10 psig [0.7 barg]. SO2 0.01

QUESTIONS
1. Why is the scrubber required?
2. Why does the cooler not need to keep the amine 10°F [5°C] above the feed gas temperature?

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Exercise 25: FRACTIONATION TRAIN
Fractionate the liquids from a demethanizer into ethane, propane, butanes, and a C5+ condensate.

PROCESS INFORMATION
 Deethanizer

a. An initial guess is required for column convergence; Inlet Conditions

use 99% ethane recovery in the top.
Temperature 80°F
b. The column operates at 300 psia [20.7 bar] with a
[27°C]
∆P=7psi [0.5 bar].
Pressure 500 psia
c. Ethane product exits at a 65°F [18.3C] condenser
[34.5 bar]
temperature.
d. Specify a 0.04 C2/C3 ratio in the bottoms product. Flow Rate 2400 lb-mol/h
[1080 kg-mol/h]
 Depropanizer
Composition Mole %
a. The exchanger cools the feed to 180°F [82°C]. Methane 0.63
b. The column operates at 205 psia [14.1 bar] with a ∆P= Ethane 49.00
3psi [0.25 bar]. Propane 27.00
c. Use a reflux ratio of 2. i-Butane 4.15
d. 99.9% of the C3 is to be recovered in the vapor. n-Butane 7.60
e. Use an initial guess of 98% i-C4 recovery in the i-Pentane 2.20
bottoms. n-Pentane 2.14
 Debutanizer n-Hexane 3.80
n-Heptane 0.60
a. The condenser is sub-cooled to 160°F [71°C]. Benzene 0.12
b. Column pressure is 150 psia [10.3 bar] with a ∆P= 5 psi Toluene 0.17
[0.4 bar]. Ethylbenzene 0.009
c. Recover 99.9 mol% n-C4 in the overhead product. p-Xylene 0.13
d. Use a boil-up ratio of 4. Nitrogen 0.051
e. Use an initial guess of 99.9 mol% recovery of i-c5 in
CO2 2.40
the bottoms.
 Butane Splitter

a. The column operates at 135 psia [9.3 bar] with a

∆P= 20psi [1.5 bar].
b. Use a total condenser with the i-Butane product sub-
cooled to 70°F [21°C].
c. Use a boil-up ratio of 11.5.
d. The bottoms product purity specification is 97.5 mol%
n-C4.

QUESTIONS
1. What is the ethane recovery in the deethanizer?
2. What is the propane recovery in the depropanizer?
3. What is the RVP of the C5+ split?
4. What is the temperature difference between stages 2 and 60 of the butane splitter?

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Exercise 26: ENVIRONMENTAL BTEX CALCULATIONS
Build the following flowsheet which represents a field production and separation facility.

PROCESS INFORMATION
Inlet HC Conditions
 In “Project Options”, set Atmospheric Pressure to 11.3 psia
Temperature 115°F [46°C]
[0.78 bar].
Pressure 1000 psig [69 barg]
 Use the Peng-Robinson property package in the
Environment. Add the components listed in the inlet Flow Rate 1.04 MMSCFD
composition and H2O. [1225 sm^3/h]
 Water rate is 0.5 sgpm [2 lpm]. Inlet HC Composition Mole %
 The inlet mix goes through a choke valve and line heater and Methane 90.2
then enters the high pressure separator at 875 psig [60.3 bar] Ethane 6.3
and 95°F [35°C]. Set the line heater pressure drop to 0. Propane 1.2
 The sample line contains material that will be sampled for i-Butane 0.06
extended GC analysis. n-Butane 0.08
 The liquids leave the condensate tank at 0 psig [0 bar]. Do n-Pentane 0.13
not set pressure drop in the condensate tank. n-Hexane 0.15
n-Heptane 0.5
n-Octane 0.2
n-Nonane 0.17
n-Decane 0.73
Benzene 0.03
Toluene 0.13
Ethylbenzene 0.012
m-Xylene 0.137

QUESTIONS
1. What is the molecular weight of the inlet HC feed?
2. How much heat in BTU/h must be supplied to the line heater?
3. What mole fraction of the HP Flash feed left as a vapor?
4. How many barrels/day of liquid condensate are produced?
5. What is the API gravity of the condensate?
6. How many tons/yr of BTEX leave with the condensate tank emissions? Use the “Sum Components”
ProMax Property Stencil.
7. Prepare a Phase Envelope Analysis of the Sales Gas. What are the critical temperature and pressure?
8. Select the “Hydrate Curve” option in the phase envelope from the previous question. At what
temperature will hydrates form if this stream remains at 875 psig [60.3 bar]?
9. What are the Reid Vapor Pressure (RVP) and True Vapor Pressure (TVP) of the condensate?
10. Using a combustion analysis, determine the rate of oxygen required (lbmol/h) to completely combust the
emissions stream.

74
Exercise 27: SIMPLE SOUR WATER STRIPPER
This unit is used to remove several contaminants from utility water before sending it to waste water treatment. Here,
we will simulate a sour water stripper with a thermosyphon and an overhead condenser.

PROCESS INFORMATION
 The pump outlet pressure is 40 psig [3.8 bar]. Use 65% pump efficiency. Inlet Conditions
 The Sour Water enters the Stripper at 190°F [90°C]. Temperature 95°F
 The stripper has 7 ideal stages, and should be an Equilibrium column type. [35°C]
 The top stage is 8 psig [1.5 bar] and the column has a 1 psi [0.06 bar] Pressure 0.3psig
pressure change. [1.05 bar]
 The Condenser outlet temperature is 185 °F [93°C].
Flow Rate 545 sgpm
 For stripping, a thermosyphon is used to heat and return 70% of the [120 m3/h]
bottoms. This stream is 15% vaporized through the exchanger.
 The Air Cooler lowers the stripped sour water temperature to 110°F Composition Mass %
[43°C]. NH3 0.55
 The column may require a pump-around duty estimate. Give this initial H2S 1.2
guess for the thermosyphon loop as a “Pump-around Estimate” column Phenol 0.1
specification. HCN 0.001
 After setting up the simulation, insert a Property Table to display the H2O 98.149
temperatures, pressures, flow rates, and compositions of the Sour Water,
Stripped Water, Stripper Overheads streams.

QUESTIONS
1. Determine the pump’s head and required horsepower.
2. What are the end-point approach temperature, and Effective UA in the Feed Effluent Exchanger?
3. What is the Stripper bottoms temperature?
4. What is the recovery of H2S and NH3 in the Stripper Overhead?
5. What is the pH of the Sour Water from Tankage and the cooled Stripped Sour Water?
6. The pressure drop in the Stripper Overheads is to be maintained below 5 psi/100 ft of horizontal length.
Using schedule 40 pipe, what diameter is required? What is the actual ∆P and velocity?
7. What is the critical point for the Stripper Overhead?

75
Exercise 28: AIR COOLER RATING
Using the heat exchanger specification sheet on page 77, rate the fin fan heat exchanger used to cool the lean amine
before entering the amine contactor.

PROCESS INFORMATION
 This will require creating a second side to the exchanger by connecting a second single-sided exchanger
to the first via a common energy stream.
 “Air” is not a component in ProMax, and must be created from its constituent components – at a
minimum nitrogen and oxygen, and additionally water, argon, carbon dioxide and other lesser
components, if desired.
 The rating option is available once the exchangers have been connected with a common energy stream
(or if the single-sided air cooler icon is replaced with a double-sided exchanger). This option is found in
the Project Viewer of the heat exchanger under the Process Data Tab at the bottom. Check the box for
“Enable Rating”, and select the correct exchanger type from the drop-down list. Once this box is
checked, a new tab appears in the Project Viewer for “Rating”.

QUESTIONS
1. What is the calculated pressure drop for the process stream?
2. How can the heat exchanger rating be exported to an .hexr file?

76
77
Additional Help & Troubleshooting
8.1. BASIC SPECIFICATIONS FOR PROMAX BLOCKS
Each block within ProMax gives the user some freedom to specify what is occurring around that block. There are many
possibilities of what can be specified within and around each type of block, not all of which are covered here. The
following is a list of the most common types of specifications:

 Inlet Streams The user must fully specify inlet streams. This generally means providing these 4 pieces of
information: Temperature, Pressure, Flow Rate (molar, mass, or volumetric flow), and composition.

 Pumps/Compressors/Expanders: An efficiency and outlet pressure are the most common specifications.

 Heat Exchangers: A pressure drop is required within every heat exchanger. For multi-sided exchangers a
pressure drop is required for each side. Along with the pressure drop, a single or double-sided heat exchanger
allows for one temperature-related specification to be set. Most commonly one of the outlet temperatures
is set but in some cases a duty or Minimum End Approach Temperature may be set instead.

 Separator: A pressure drop or outlet pressure is required. If an energy stream is attached to a separator
(such as with a condenser) then an outlet temperature can also be set.

 Valves: An outlet pressure (most common) or pressure drop must be specified.

 Columns: Columns are allowed 1 specification for every energy source to the column (Reboiler, Condenser,
etc.). The specifications the user chooses to use will vary greatly depending on the process. For a complete
list of available specifications, see page 13. Regardless of configuration, all columns need a user-specified
pressure profile.

 Process Recycles: Process recycles allow the user to estimate what is happening at a particular point in the
process to allow ProMax to iterate towards the final solution. For process recycle blocks, the recycle outlet
stream must be completely user-specified just like an inlet stream (temperature, pressure, flow rate,
composition).

 Q (Energy) Recycles: Energy recycles require the user to estimate how much energy is being recycled. This
energy estimate is user-specified within the block itself.

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8.2. GENERAL GUIDELINES FOR DIAGNOSING ERRORS
 If a block is bright red, it means the block is missing one or more connections. Check the
Connections tab to determine which connections need to be made before the block can be
solved.

 If a stream is bright red, it means the stream is missing a specification.

 Check to make sure that all inlet streams going to an unsolved block are green, meaning they are converged. A
block will not solve if any of its inlet streams are not solved.

 Click the “Warnings” button in the ProMax Ribbon to bring up a list of all the errors and warnings currently in
the ProMax project. The Warnings list should always be checked, even if the simulation is fully converged.

 The Message Log records information about convergence each time the user clicks to Execute. When
troubleshooting, make sure to look at the most recent information at the bottom of the Message Log by right-
clicking in the log and selecting “Page End”.

 Most “Errors” prevent a simulation from converging. “Warnings” appear when the simulation has converged
but there are certain parts of the simulation that are outside normal operations or normal simulation practices.
Thus, the user can determine whether or not a warning needs to be addressed.

Interpreting ProMax monikers in Message Log error messages

Every object & property within ProMax has a “moniker” that acts as an identifier for that object (similar to a web
address). Error messages include the object moniker where the error occurred. Each moniker follows this pattern:

ProMax:ProMax!Project every moniker begins with this reference meaning it is an object found in a ProMax
project

Flowsheets!Gas Processing the moniker mentions which flowsheet it is looking at (a flowsheet named “Gas
Processing” in this case).

PStreams!16 this portion mentions which object the moniker is referring to (a process stream
named “16” in this case). PStream stands for process stream. QStream refers to
energy stream, and Block refers to any block.

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8.3. COMMON ERRORS & WARNINGS
Generic Block Errors

This error means that a block is overspecified. Common causes of over-specification:

 Exchanger: Outlet temperatures specified for both outlets of an exchanger OR both an outlet temperature
and Minimum End Approach Temperature specified.
 Pump: Outlet temperature and pressure specified, along with an efficiency or power inside the pump

Columns

Inside a column, at the very bottom of the Project Viewer, it will say “Under Specified” when there are degrees of
freedom available to the column that have not been used.

This error occurs when the pressure profile has not been configured within the tower. This means that on the Stages
grouping within the Process Data tab either a pressure change or top/bottom stage pressures need to be set.

OR

OR

OR

A column turns yellow (meaning it is approximating a solution).

These errors mean the column could not find a solution. First, verify that all the column inlet streams and column
specifications are correct. If these are all correct, go to the Convergence tab within the column and try changing the
Enthalpy Model, then the Inner Loop Model. Sometimes using a different model can find a solution when the default
did not.

80
If none of these combinations work, click the “Delete Last Solution” button and try again to execute the column.
Adding a K Damping factor (0-10) can help with oscillation issues. Checking the “Boston-Sullivan Kb” option or
changing the MESH Method can also help with convergence. Lastly, the max number of iterations can be increased
by going to the “Solver” grouping under the Convergence tab.

This warning occurs when an amine absorber is run as the incorrect column type. On the Process Data tab in the
Column grouping, make sure “TSWEET Kinetics” is selected for the Ideal Stage Column Type.

This warning occurs when an amine stripper is run as the incorrect column type. On the Process Data tab in the
Column grouping, make sure “TSWEET Stripper” is selected for the Ideal Stage Column Type.

OR

All columns are required to have vapor entering on the bottom stage of the column. Similarly, all columns must have
liquid feeding into the top stage of the column.

This error message means a duty estimate is required for a column pumparound loop. If duty is added to a
pumparound by a heat exchanger (other than the condenser) or pump, an estimate may be required for the total
pumparound duty amount. This estimate can be made within the column by adding a “Pump-around Estimate”
specification. Estimate a negative duty if energy is being removed from the loop.

Heat Exchangers
Always check inside the exchanger to make sure a Pressure Drop is specified. If it is a double-sided exchanger, then it
will require a Pressure Drop on both sides of the exchanger.

81
This error message means there is a temperature cross in the heat exchanger, indicating that the specified heat
transfer is thermodynamically impossible. While the heat exchanger (and model) will converge, any attempt to rate
the exchanger will fail. Adjust any duty or outlet temperature specification until there is no longer a negative approach
temperature for the exchanger.

Pumps

This error occurs when ProMax calculates a pump efficiency greater than 100%. This usually occurs when the user
specifies an outlet temperature from the pump. Generally, it is recommended that the user not specify the
temperature coming out of a pump but instead specify an efficiency inside the pump which will allow ProMax to
calculate the outlet temperature.

Recycles

This error message means that the recycle block was not able to converge to a solution after performing the set
maximum number of iterations. The first thing to do is verify that there is a reasonable estimate in the recycle block
outlet stream. The maximum number of iterations can be increased inside the Recycle block under the Solver grouping
on the Converge tab.

Simple Solvers

This error message indicates that a variable written into the Solver/Specifier equation is undefined. This means either
a) the variable has not been added to the Measured/Independent Variable list or b) the name written in the equation
does not match the name given to the Measured/Independent Variable. Make sure the variable is listed and that the
names match, keeping in mind that names are case-sensitive and no spaces are allowed in the name.

This error message indicates that a Solver initial guess has not been set. Inside the solver, make sure an initial estimate
has been put into the Calculated Value cell. ProMax will adjust this initial guess until it reaches a solution.

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Solver/Recycle Priorities
When there is more than one solver and/or recycle in a simulation, priorities tell ProMax the order in which to solve
the different solvers/recycles. ProMax will solve from the highest priority on down. Poor priority order can lead to
much longer convergence times and even prevent a simulation from solving. Consider the following:

 Give higher priorities to solvers that come first in sequence. Example: solvers/recycles on an amine unit
should solve before (and therefore have higher priorities than) solvers/recycles on a downstream
dehydration unit.

 Nested, inner loops should be solved before outer loops. Example: solvers within a recycle loop should
solve before the loop recycle block.

 The exact number value of a priority is unimportant; it is only the comparison of priorities from highest to
lowest that matters. Example: if a recycle has a priority of 10 and a solver has a priority higher than 10 (11,
20, 100, etc.), ProMax will solve the solver and then the recycle.

 A list of solvers/recycles in a project, including their priorities, is found in the Solver Summary within the
Project Viewer.

Streams

This error means that either the temperature or pressure being calculated for the specified stream is outside the
maximum/minimum allowable values in ProMax. The most common cause is a duty within an exchanger that is
impossibly high for the given stream’s flow rate.

OR

These warnings appear for any stream that is near or below a temperature where hydrates could form. Similar
warning messages appear for ice and dry ice formation. This means that solids could potentially form at this part of
the process and the user should consider running at higher temperatures, removing water (or CO2 for dry ice) from
the system, or injecting a hydrate inhibitor such as methanol or ethylene glycol.

83
8.4. WEB TUTORIALS
At www.bre.com, an ever-expanding library of web tutorials is available to demonstrate common ProMax applications.
These videos include explanations of each block in ProMax, how-to videos on different ProMax tools, discussions on
commonly simulated processes, and much more.

Some pertinent videos for those wanting to learn the basics of ProMax are listed below.

ProMax Tools
 Simple Specifier
 ProMax Solver
 Scenario Tool Basics
 Creating User Values – Ambient Temperature Example
 Single Oils

Common Processes
 Amine Sweetening Initial Design
 Pipeline Model
 Separator Sizing

Additional Tips
 What’s New in ProMax 4.0
 Streams & Blocks Tips
 Column Convergence Tips
 Selecting Components in a ProMax Environment
 Selecting a Property Package in a ProMax Environment
 Solver Summary Table
 Project Options

BRE 101 Exercise Demonstrations

 BRE 101 - Exercise 1 (Simple Gas Plant Part 1)
 BRE 101 - Exercise 1 (Simple Gas Plant Part 2)
 BRE 101 - Exercise 1 (Simple Gas Plant Questions)
 BRE 101 - Exercise 3 (Simple MDEA Sweetening Part 1)
 BRE 101 - Exercise 3 (Simple MDEA Sweetening Part 2)
 BRE 101 - Exercise 4 (Export/Append)

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8.5. VISIO HOTKEYS
Standard Microsoft hotkeys are available within any ProMax project. In addition, a user also has the ability to create
custom hotkeys through VBA programming.

Below is a summary of commonly used Visio hotkeys (based on Visio 2016):

Ctrl + A Select All

Ctrl + D Duplicate Selected Shape (creates a new, blank shape)

Ctrl + C Copy and Paste Selected Shape(s)

Ctrl + V (user-defined properties in a stream will be copied along with the

stream but internal block info will not be copied with the block)

Ctrl + H Flip Shape Horizontal

Ctrl + J Flip Shape Vertical

Ctrl + S Save File

Ctrl + 3 Toggle to/from Connector Mode

Ctrl + 2 Toggle to/from Text Mode

Ctrl + X Delete Selected Shape(s)

Ctrl + L Rotate Selected Shape Counterclockwise

Ctrl + R Rotate Selected Shape Clockwise

Ctrl + Click Select Multiple Shapes

Ctrl + Wheel Zoom In / Out

Shift + Wheel Scroll Flowsheet Right / Left

Shift + Arrow Nudge Selected Object Right/Left/Up/Down

85