Jordan University of Science & Technology

Chemical Engineering Department

CHE454 -COMPUTER APPLICATIONS LAB FOR CHEMICAL ENGINEERS – Fall 2020/2021

Module #4: Separators

Learning Outcomes: At the end of this Lab, you should be able to:
1- Introduce the concept of the absorption process
2- Install the column and define the sub-flow sheet in HYSYS.
3- Operate an absorber operation in HYSYS to model the absorption process.
4- Simulate three types of absorbers in HYSYS:
a. Absorber
b. Refluxed absorber
c. Re-boiled absorber
5- Determine the column design parameter

1. Theory:
➢ Packed columns are used in chemical industry to absorb a gas from a mixture of gases or strip a
volatile substance from a liquid. The columns are, usually, countercurrent gas-liquid contactors in
which gas flows upward and liquid downward. To provide large interfacial area for mass transfer
between gas and liquid, the columns are filled with packing.

➢ Design of the column involves estimation of diameter of the column and height of the packing
required for specified separation. The diameter is determined from flooding characteristics of the
column and, the height is found from mass transfer characteristics of the packing and the gas-liquid
system.

➢ Flooding depends on pressure drop across the column, it being higher at the bottom and lower at
the top to allow the gas to flow upward. The gas flow is usually turbulent and in a dry column, the
pressure drop rises with gas flow with an exponent of 1.8 to 2.0 - a typical feature of turbulent
flow. The pressure drop rises with an increasing flow of liquid because liquid fills up the column
and the space for gas flow is reduced. Up to the loading point, the pressure drop follows the same
relation as in dry run. Beyond the loading point, the pressure drop rises rapidly with gas flow and
the liquid hold up in the column also rises.

➢ Tower height is determined by packing characteristics, namely, interfacial area, and mass transfer
coefficient of the gas-liquid system and extent of separation.

𝑧
𝐻𝑂𝐺 =
𝑁𝑂𝐺
Where,

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Z≡ height of the column (m)
HOG≡ theoretical overall height of gas-phase transfer unit (m)

𝑚𝐺
𝐻𝑂𝐺 = 𝐻𝐺 + ∗ 𝐻𝐿
𝐿
NOG ≡ is a function only of compositions and depends on the operating conditions, e.g., G, L, T, P.
It is defined as

(𝑦𝐴𝑜 − 𝑦𝐴𝑖 )
𝑁𝑂𝐺 =
(𝑦𝐴 − 𝑦𝐴∗ )𝑙𝑚
HG≡ height of gas-phase transfer unit (m)
m ≡ slope of equilibrium line
G, L ≡ gas and liquid flow rates, respectively (kmol.m2s)
HL ≡ liquid phase transfer unit (m)

2. Sub-flow sheet and column installation

The Column (absorption and distillation) is a special type of sub-flow sheet in HYSYS. A sub flow sheet
contains equipment and streams, and exchanges information with the parent flow sheet through the
connected internal and external streams. From the main simulation environment, the Column appears as
a single, multi-feed multi-product operation. In many cases, you can treat the column in exactly that
manner.

2.1 Main Flowsheet / Subflowsheet Concept

Consider a simple Vapor-Liquid Absorber in which you wish to remove CO2 from a gas stream using
H2O as the solvent. A typical approach to setting up the problem would be as follows:

1. Create the gas feed stream, Feed Gas, and the water solvent stream, Water In, in the main
flowsheet.

2. Select the Absorber button from the Object Palette and provide the stream names, number of
trays, pressures and estimates. You must also provide the names of the outlet streams, Clean Gas
and Water Out.
3. Run the Column from the main flowsheet Column property view.
When you connected the streams to the tower, HYSYS created internal streams with the same names. The
Connection Points or "Labels" serve to connect the main flowsheet streams to the subflowsheet streams
and facilitate the information transfer between the two flowsheet. For instance, the main flowsheet stream
WaterIn is "connected" to the subflowsheet stream WaterIn.

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 Figure 1

Note that the connected streams do not necessarily have the same parameters - all specified values will
be identical, but calculated stream variables may be different depending on the Fluid Packages and
Transfer Basis.

When working in the main build environment, you "see" the Column just as any other unit operation, with
a property view containing parameters such as the number of stages and top and bottom pressures. If you
change one of these parameters, the subflowsheet will recalculate (just as if you had selected the Run
button); the main flowsheet will also recalculate once a new column solution is reached.

However, if you are inside the Column subflowsheet build environment, you are working in an entirely
different flowsheet. To make a major change to the Column such as adding a reboiler, you must enter the
Column subflowsheet build environment. When you enter this environment, the main flowsheet is put on
"hold" until you return.

2.2 Advantages of having column subflowsheet

Having a Column sub-flow sheet provides a number of advantages:
➢ Isolation of Column Solver
➢ Optional use of different Property Packages
➢ Construction of custom templates
➢ Ability to solve multiple towers simultaneously.

2. 2.1: Isolation of column solver

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One advantage of the Column build environment is that it allows you to make changes and focus on the
Column without requiring a recalculation of the entire flowsheet. When you enter the Column build
environment, HYSYS clears the desktop by caching all views that were open in the parent flowsheet. Then
the views that were open when you were last in the Column build environment are re-opened.

2.2.2: optional use of different property package

HYSYS allows you to specify a unique Fluid Package for the Column subflowsheet. Here are some
instances where a separate Fluid Package is useful:

1. If a column does not use all of the components used in the main flowsheet, it is often advantageous
to define a new Fluid Package with only the components that are necessary. This will speed up the
column solution.

2. In some cases, a different Fluid Package may be better suited to the column conditions. For
example, you may want to redefine Interaction Parameters such that they are applicable for the
operating range of the column.

3. In Dynamic mode, different columns may operate at very different temperatures and pressures.
With each Fluid Package, you may define a different Dynamic model whose parameters can be
regressed in the appropriate temperature and pressure range, thus, improving the accuracy and
stability of the dynamic simulation.

3. Column Conventions, specifications and types (absorbers only)

3.1 HYSYS Column Conventions

✓ Column TRAY SECTIONS,
✓ Overhead CONDENSERS
✓ Bottom REBOILERS

All above are defined as individual unit operations. Condensers and Reboilers are not numbered stages,
as they are considered to be separate from the Tray Section.

The following are some of the conventions, definitions and descriptions of the basic columns:

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 Table 1

3.2 Column Default Replaceable Specifications

Replaceable specifications are the values which the Column convergence algorithm is trying to meet.
When you select a particular Column template, or as you add side equipment, HYSYS creates default
specifications. You may use the specifications that HYSYS provides, or replace these specifications with
others more suited to your requirements.

The available default replaceable specifications are dependent on the Basic Column type (template) that
you have chosen. The default specifications for the four basic column templates are combinations of the
following:

1- Overhead vapor flowrate

2- Distillate flowrate
3- Bottoms flowrate

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 4- Reflux ratio
5- Reflux rate

The provided templates contain only pre-named internal streams (streams which are both a feed and
product). For instance, the Reflux stream, which is named by HYSYS, is a product from the Condenser
and a feed to the top tray of the Tray Section.

Note:- The pressure for a tray section stage, condenser or reboiler can be specified at any time on the
Pressures page of the Column property view.

3.3 Absorber Templates (Types)

The first step in installing a Column is deciding which type you want to install. The most basic Column
types are:

3.3.1 Absorber

The only unit operation contained in the Absorber is the TRAY SECTION, and the only streams are the
overhead vapor and bottom liquid products. A schematic representation of the Absorber appears to the
left.
There are no available specifications for the Absorber, which is the base case for all tower configurations.
The conditions and composition of the column Feed stream, as well as the operating pressure; will define
the resulting converged solution. The converged solution includes the conditions and composition of the
Vapor and Liquid Product streams.

Note (1):- The Liquid-Liquid Extraction Template is identical to the Absorber Template
Note (2):- The remaining Column templates have additional equipment, thus increasing the
number of required specifications.

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 Figure 2

3.3.2 Reboiled Absorber

The Reboiled Absorber template consists of a tray section and a bottom reboiler. Two additional streams
connecting the REBOILER to the TRAY SECTION are also included in the template (see figure 3).
When you install a Reboiled Absorber (i.e. add only a REBOILER to the Tray Section), you increase the
number of required specifications by one over the Base Case. As there is no overhead liquid, the default
specification in this case is the overhead vapor flow rate

Figure 3

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 3.3.3 Refluxed Absorber

The Refluxed Absorber template contains a TRAY SECTION and an overhead CONDENSER (partial or
total). Additional material streams associated with the Condenser are also included in the template. For
example, the vapor entering the Condenser from the top tray is named to Condenser by default, and the
liquid returning to the Tray Section is the Reflux.

When you install a Refluxed Absorber, you are adding only a CONDENSER to the base case. Specifying
a partial condenser increases the number of required specifications by two over the Base Case. The default
specifications are the overhead vapor flow rate and the side liquid (Distillate) draw. Specifying a total
condenser results in only one available specification, since there is no overhead vapor product

Either of the overhead vapor or distillate flow rates may be specified as zero, which creates three possible
combinations for these two specifications. Each combination defines a different set of operating
conditions. The three possible Refluxed Absorber configurations are listed below:

➢ Partial condenser with vapor overhead but no side liquid (distillate) draws.
➢ Partial condenser with both vapor overhead and distillate draws.
➢ Total condenser (with distillate but no vapor overhead draw).

Figure 4

4. Columns (Absorbers) Tabs

4.1 Design Tab

4.1.1 Connections page (Main Flowsheet)

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The main flowsheet Connections page allows you to specify the name and location of feed streams, the
number of stages in the tray section, the stage numbering scheme, condenser type, names of the Column
product streams and Condenser/Reboiler energy streams. Note that the streams shown in this view reside
in the parent or main flowsheet; they do not include Column sub flowsheet streams, such as the Reflux or
Boil-up. In other words, only feed and product streams (material and energy) are displayed on this page.

Figure 5

Note: - The appearance of the Connections page will vary depending on the template you are using.

4.1.2 Connections page (Column Runner)

In the connection page, All Feed and Energy Streams, as well as the associated stage, are displayed in the
left portion of the Connections page. Liquid, Vapor and Water Product streams and locations are displayed
on the right hand side of the page.

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 Figure 6

4.1.3 Monitor Page

The Monitor page is primarily used for editing specifications, monitoring Column convergence and
viewing Column profile plots. An input summary and a view of the initial estimates can also be accessed
from this page.

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 Figure 7

Profile Group

During the column calculations, a profile of temperature, pressure or flow will be displayed and updated
as the solution progresses. Select the appropriate radio button to display the desired variable versus tray
number profile.

Specifications Group

✓ Each specification, along with its specified value, current value, weighted error and status is shown
in the Specifications group.
✓ You can change a specified value by typing directly in the associated Specified Value cell.
Specified values can also be viewed and changed on the Specs and Specs Summary pages. Any
changes made in one location will be reflected across all locations.
✓ Double clicking on a cell within the row for any listed specification will open its property view.
In this view, you define all the information associated with a particular specification. Each
specification view has three tabbed pages: Parameters, Summary and Spec Type. This view can
also be accessed from both the Specs and Specs Summary pages.
✓ Further details are outlined in following Specification Property View sub section

4.1.4 Specs Page

Adding and changing Column specifications is straightforward. If you have created a Column based on
one of the templates, HYSYS already has default specifications in place. The type of default specification

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depends on which of the templates you have chosen (see the Default Replaceable Specifications sub
section in Section 3.2) for more details.

Figure 8

Specification Property View

Shown below is a typical property view of a specification. In this view, you define all the information
associated with a particular specification. Each specification has three tabbed pages:

1. Parameters, Summary, and Spec Type. This example shows a component recovery specification
which requires the Stage Number, Spec Value, and Phase type when a Target Type of Stage is
chosen.

Figure 9

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 2. Summary tab is used to supply tolerances and define whether the specification is Active or simply
an Estimate.

3. The Spec Type tab can be used to define specifications as Fixed/ Ranged and Primary/Alternate.
By default, all specifications are initially defined as Fixed and Primary. Advanced solving options
available in HYSYS allow the use of both Alternate and Ranged Spec types.

Figure 10

4.1.5 Specs Summary Page

The Specs Summary page lists all Column specifications available along with relevant information. This
specification information is shared with the Monitor and Specs Summary pages. Altering information in
one location will automatically update across all other locations.

Figure 11

4.1.6 Subcooling Page

The Subcooling page allows you to specify Subcooling for products coming off the condenser of your
column. You can specify the condenser product temperature or the degrees to sub-cool. For columns
without condensers, such as absorbers, this page requires no additional information.

4.1.7 Notes Page

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The Notes page provides a text editor where you can record any comments or information regarding the
Column unit operation or pertaining to your simulation, in general.

4.2 Parameters Tab

4.2.1 Profiles Page

✓ The Profiles is used to show the column pressure profile and to provide estimates for the
temperature, net liquid and net vapor flow for each stage of the column. You can input tray
estimates in the Temperature, Net Liquid and Net Vapor or view the values calculated by HYSYS.
✓ Use the radio buttons in the Flow Basis group to select the flow type you want displayed in the
Net Liquid and Net Vapor columns: Molar, Mass or Volume. The graph on the right hand side of
Figure 12 depicts the pressure profile across the column.

Figure 12

4.2.2 Estimates Page

✓ The Estimates page is used to view and provide composition estimates. Estimates are NOT a
requirement for convergence.
✓ Estimates are NOT required for column convergence.
✓ To see the initial estimates generated by HYSYS, press the View Initial Estimates button on the
Monitor page.

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 Figure 13

4.2.3 Efficiencies Page

✓ The Efficiencies page allows you to specify Column stage efficiencies on an overall or component-
specific basis. Efficiencies for a single stage or a section of stages may easily be specified.
✓ HYSYS uses a modified Murphree stage efficiency. All values are initially set to 1.0, which is
consistent with the assumption of ideal equilibrium or theoretical stages.
✓ If this assumption is not valid for your column, you have the option of specifying the number of
actual stages and changing the efficiencies for one or more stages.
✓ The data table on the Efficiency page gives a stage-by-stage efficiency summary. Note that the
efficiencies are fractional, i.e. an efficiency of 1.0 corresponds to 100% efficiency.
✓ Overall stage efficiencies may be supplied by selecting the Overall radio button in the Efficiency
Type group, and entering values in the appropriate cells.

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 Figure 14

4.2.4 Solver Page

✓ We will discuss only the Solving Method

Solving Method

Figure 15

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The table below, which is displayed below the drop down list, provides explanations for each method:

Table 2

4.3 Rating Tab

The Rating tab has four pages:

1. Tray Sections,
2. Vessels,
3. Equipment
4. Pressure Drop

Table (3) in the next page summarizes the 4 pages:

Table 3

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 4.4 Worksheet Tab

The Worksheet tab contains a summary of the information contained in the stream property view for all
the streams attached to the unit operation. The Conditions, Properties, and Composition pages contain
selected information from the corresponding pages of the Worksheet tab for the stream property view.
The PF Specs page contains a summary of the stream property view’s Dynamics tab.

4.5 Performance Tab

4.5.1 Summary Page

The Summary Page gives a tabular summary of Column stage temperatures, pressures, flows and duties.

Figure 16

4.5.2 Results Page

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 Figure 17

On the Results page, you can view various column profiles or refinery assay curves in a graphical or
tabular format.
1- Column profile
2- Feeds/Products
3- Plots
4- Cond./reboiler if applicable

Tray by Tray Properties Group

To view a column profile, follow this generalized procedure:

1- Select a profile from the list in the Tray by Tray Properties group. The choices include:
Temperature, Pressure, Flow, MW, Dens, Visc., Composition, K Value and Light/Heavy Key.

2- Specify the stage tray flow basis by selecting the appropriate radio button: Net or Total. Where the
net basis only includes interstage flow and the total basis includes draw and pump around flow.

3- In the Column Tray Ranges group, select the appropriate radio button:

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 Table 4

4- After selecting a tray range, click either the View Graph or View Table button to display a plot or
table respectively.

Figure 18

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 5. Solved Example: Absorption Column Design Using HYSYS
This example introduces the use of HYSYS to model a continuous gas absorption process in a packed
column.
Problem statement: CO2 is absorbed into propylene carbonate in a packed column. The inlet gas stream
is 20 mol% CO2 and 80 mol% methane. The gas stream flows at a rate of 2 m3/s and the column operates
at 60 °C and 60.1 atm. The inlet solvent flow is 2000 kmol/hr.
Use HYSYS to determine:
1- The concentration of CO2 (mole %) in the exit gas stream,
2- The column height (m) and
3- The column diameter (m).

1. Selecting the component

You need to add Methane (CH4), Carbon dioxide (CO2) and Propylene carbonate into your
simulation.
Figure 19

2. Selecting a ‘Fluid Package’:

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 Figure 20

3. Entering the Simulation Environment.

4. Setting up the Simulation Environment:

By placing the mouse over each icon on the object palette, one can see what each icon represents. Click
and select the icon that says “Absorber”, which looks like this,
After selecting the “Absorber” icon, click on the PFD window to insert the absorption column into the
simulation environment. By default, HYSYS names it as “T-100”. Double-click on “T-100” to open up
the ‘Absorber Column Input Expert’ window. Name the streams that connect to the column. To name a
stream, click within the box corresponding to that stream and type the name (e.g. Solvent In, Gases In,
Gases Out etc.). Name all the streams as indicated in figure 21.

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 Figure 21

Only when all the streams are labeled, the 'Next' button is activated. Click ‘Next’.
The window changes to the one that requires the pressure at the top and the bottom of the column. Enter
both pressures as 60.1 atmospheres (please note that the pressure unit is ‘kPa’ by default – You need to
change it to ‘atm’ by selecting from the list of units on the drop-down menus at the top-right corner of the
window.
No matter what units you use to represent pressure HYSYS converts it into ‘kPa’ and shows the value in
‘kPa’.
After entering the pressures of the top and the bottom, click on ‘Next’. This will change the window to
one where the estimates of the temperature of the column top and bottom are asked for. Enter both
temperatures as 60 °C. Then click on the ‘Done’ button. By clicking on the done button, HYSYS will
bring up a window pertaining to the column (It is actually a schematic of the column). Please note that it
shows 10 stages (trays). Later we will see how to change those “trays” to “packing”. For now, close that
window and return to PFD.

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 Figure 22

5. Defining stream component specifications:

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 Figure 23

Figure 24

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 Figure 25

6. Running the simulation:

On the PFD, double click on "T-100". When the column window pops up, click on the “Run” button
located near the bottom of the window. The red “Un-converged” box should turn to green “Converged” if
all the above procedure was followed.

However, the results that are obtained at this point do not represent a true model for our gas
absorption column because the simulation was run using trays, not packing. Now, let’s see how
to replace trays with packing.

7. Changing Trays to Packing:

• Go to the ‘Internals’ menu and select ‘Active Internal Section, whether all of internal or specific
section of the column’.
• Click on the ‘Add New button. A tray-sizing Row should pop up. Then select Internal Type as
“Packing”.
• When ‘Packed’ is selected, a drop-down menu box will appear in the window. Scroll the drop-
down menu box for the desired packing type. For this case choose, Generic Raschig Rings
(Ceramic) ¼ inch. You should not worry if your selection doesn’t show up on the drop-down menu
box.

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 Figure 26

• Now close this window and go to the ‘PFD’ window. Double-click on ‘T-100’ and run the
simulation again.

8. Getting the design parameters:

• Now, click on the ‘Performance’ tab and select “Internals Results”. Then click on ‘View Button’
In the section results, you can see the diameter and the height of the section.

Figure 27

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 • Enter these values on your note book. Now, go back to the PFD window and double-click on the
“Gases Out” stream and note the composition of CO2.

Figure 28

9. New Run:
To change the solvent flow rate, go back to the PFD window and double-click on the blue line that says
‘Solvent In’. Change the flow rate from 2000 kmol/hr to 2500 kmol/hr. Run the simulation and sees how
the column dimension and exit concentration of CO2 have changed. You will notice that the exit
concentration of CO2 decreases significantly with the increase in the inlet solvent flow rate but the column
dimensions do not change appreciably. Record these values in your answer sheet!

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