Part II

Chemical Plant Simulation

using Aspen Plus
 Aspen Plus Simulation of
Chemical Plants

4 1 .
INTRODUCTION

In the last three chapters, we have studied in detail the simulation of individual
processes, such as flash drum, dryer, chemical reactor, distillation column including
petroleum refining process, absorber, stripper and liquid-liquid extraction unit, using
Aspen Plus software. Here, by a 'chemical plant' we mean a chemical process
integrated with several single process units. The chemical process industries usually
include flash chamber, mixer, splitter, heat exchanger, pump, compressor, reactor,
fractionator, ilter and so on. It is easy to simulate even a large chemical plant by the
f

use of Aspen software package.

In the present chapter, the simulation of two chemical process flowsheets is
discussed. They are a distillation train and a vinyl chloride monomer (VCM)
manufacturing unit. After thoroughly reading this chapter and simulating the solved
examples in hand, we will be able to use Aspen Plus flowsheet simulator for solving a
wide variety of chemical plants. To improve the flowsheet simulation skills, it is
recommended to solve the problems given in the exercise.

4 2 . ASPEN PLUS SIMULATION OF A DISTILLATION TRAIN

Problem statement

A hydrocarbon stream H is supplied at 50C and 2.5 atm. The pump Pi discharges the
feed F at 10 atm. In Table 4.1 the component-wise low rates are tabulated for stream H.
f

The schematic representation of the complete process integrated with a pump and
ive DSTWU column models (Cl, C2, C3, C4 and C5) is shown in Figure 4.1.
f

189

Copyrk
190 PROCESS SIMULATION AND CONTROL USING ASPEN

TABLE 4.1

Component F/ouj rate (kmol/hr)

10
35
50
130
200
180
200
n-C .
5

pi C1 C2 C3 C4 cs

FIGURE 4.1 A lowsheet of a distillation train.

f

For Aspen Plus simulation of the distillation train, required information are given
in Table 4.2.

TABLE 4.2

Column Condenser Reboiler

(abbreviation) pressure (aim) pressure (atm)
Deethanizer (CD 9 9
Depropanizer (C2) 5 6
Deisobutanizer (03) 4 4
Debutanizer (04) 3 3
Deisopentanizer (05) 2 2

All distillation models have total 20 theoretical stages (including condenser and
reboiler) and a total condenser. For the light key (LK) and heavy key (HK), we expect
99.9% and 0.1% recovery, respectively, in the distillate of all columns. Using the Peng-
Robinson property method, simulate the distillation train and report the compositions
of all distillation products.

Simulation approach
From the desktop, select Start button followed by Programs, AspenTech, Aspen
Engineering Suite, Aspen Plus Version and finally Aspen Plus User Interface. Then
choose Template option in the Aspen Plus Startup dialog (see Figure 4.2).

Copyrighled malarial
 \SI'KN PWB SIMULATION OP CHKMK \l PLANTS 191

hmbj_lj__bJ'ii mmLii-jd .3 J.i.'isim i. :

si

In ro..-

AM n i.tu.

1 1"
-
.' I 1 «

FIGURE 4.2

As wo hit OK button, the following window appears (sec Figure 13). Based on the
units used in the problem statement we select General with Metric Uliits,
,

in-i
.

1»

1- . l-.

<- r< mil I-'

.- J - .

.
I
_
J I"-
1

I '

FIGURE 4 3
192 PROCESS SIMULATION AND CONTROL USING ASPEN
'

Press OK and obtain the Connect to Engine dialog. Select Local PC as Server type
and click OK. Actually, this step is specific to our installation (see Figure 4.4).

Connect to Engine

Server type:

User Info

Node name:

User name;

Password;

Working directory:

Save as Delaull Connection

OK ] ExB Help

FIGURE 4.4

Creating flowsheet
The next screen represents a Process Flowsheet Window. Add a pump by selecting the
Pressure Changers tab from the Model Library toolbar. Moreover, in the library, select
the Columns tab and then choose DSTWU model to include five such columns
consecutively on the flowsheet. Notice that to incorporate a block click on the ,

appropriate icon and then place the block on the process flowsheet by clicking with the
cross hairs somewhere on the flowsheet background. Right click to de-select the block.
Now we need to interconnect the blocks and add the inlet as well as outlet streams.
Select Material STREAMS on the left of the toolbar at the bottom In the next, as we .

move the cursor to the process flowsheet window several red and blue arrows appear
,

around the blocks. The red arrows indicate required streams and the blue arrows are
optional. In the previous chapters, we have learned how to connect the feed and product
streams with a single block.
Let us observe Figure 4.5 to know how to interconnect the two blocks by a stream.
Here, first we wish to interconnect the pump PI with the column Cl using the feed
stream F. Right-click with highlighting feed block select Reconnect Destination and
,

then move the cursor to click on an arrow that is fed to the column Cl.

m o
-

QD-o
SOD-*

r ]-o

PI Cl

FIGURE 4.5
 ASPEN PLUS SIMU1.ATION OF CHEMICAL PLANTS 193

We can select Reconnect Source instead of Reconnect Destination if we modify

Figure 4.5 to Figure 4.6.
j3L D1

B1 c>

C1

FIGURE 4.6

By the same way, interconnect remaining blocks. Renaming all blocks as well as
incoming and outgoing streams, finally we have the screen shown in Figure 4.7. To
rename a particular stream (or block), first select it, then right-click, next select Rename
Stream (or Rename Block) and finally enter the appropriate name.

Re E« Vto» On Took tin Uban Whfen Help

H _J iU _l J

kl

5","*,s Oirwu o ai
, SCfuc PMiofioc BMefiai Boictfuc
C |iFold».mo»IVilH HUM fw»llr»J

FIGURE 4.7

The status indicator in the bottom right of the window, shown in Figure 4.7, says
Required Input Incomplete indicating that the process flowsheet is complete and input
data are required to enter for running the simulation.
194 PROCESS SIMULATION AND CONTROL USING ASPEN

Configuring settings
As we hit Next icon and then click on OK, the following window pops up (see Figure 4.8).
Remember that in the Data Browser, we need to enter information using data input
forms at locations where there are red semicircles. As we inish a section, a blue

f
checkmark appears.

» r- -i'iv
-

life ,

FIGURE 4.8

It is always a good practice to represent a simulation problem with entering a title.

In the Tattle field, enter 'Simulation of a Distillation Train'. Note that we may change
the input/output data units under Units of measurement (see Figure 4.9).

I r i-l I 17 -i.gi i «(i

V-H

-
id* ~ ' . -

figur: m 9

The next window (see Figure 4.10) includes the Aspen Plus accounting information ,

as given below, required at some installations.

 ASPEN PLUS SIMULATION OF CHEMICAL PLANTS 195

User name: AKJANA

Account number: IIT-KGP
Project ID CHEMICAL
Project name: DT

-
o- i S *
MM -

FIGURE 4.10

If we want the streams results summary sheet to display mole fractions select ,

Report Options under Setup folder to the left Under the Stream tab select 'Mole' as ,

Fraction basis (see Figure 4 11) .

n fT7

-
- .
i i
-

*- . -

-
»

u>U>i

.
2}' I -
n .
- .« <

FIGURE 4.11
196 PROCESS SIMULATION AND CONTROL USING ASPEN

Specifying components
In the subsequent step, use the Data Browser menu tree to navigate to the Components/
Specifications sheet. It is shown in Chapter 1 how to define components in the component
input form. Here, we have this table as shown in Figure 4.12.

ffc E* *p. ftw To* R»

i r l-l .l- fT >i -"Pi I iai

g :.r.: Fopui

C2
CJ

C*

IU
cs
.

*
!S
*

_
j wy tm
1: - . .

_
J O pOa**
.

i i r
id

5 -.
_
| > M<MVnt«« -J

FIGURE 4.12

Specifying property method

In the list on the left , choose Properties/Specifications to obtain the property input form.
A property method includes the models and methods to calculate the physical properties,
such as vapour-liquid equilibrium coeficient enthalpy and density. For the example ,

plant, set PENG-ROB base property method by scrolling down (Figure 4 13). .

5* C*, T** P« U , Wnajt. tt*

I 3

J DM
.
3

PT

FIGURE 4.13
 ASPEN PLUS SIMULATION OF CHEMICAL PLANTS -f 197

Note that there is no compulsion to use only a single thermodynamic property

method for all processes in a chemical plant. Aspen software provides an option to
choose different property methods for different processes. To do so select Block Options! ,

Properties under a particular model of Blocks folder in the list on the left and then
choose the suitable property method.

Specifying stream Information

The Streams/H/Input/Specifications sheet appears with the Data Browser menu tree in the
left pane. Entering the given data for stream H, we obtain the sheet as shown in Figure 4.14.

j T-i i-i r>

-
'
i-w I'M -

3
"

3 j. a. -j],. ,. j

tti»» .rtl.m '-if

2j twi- m*.

' ". : ww. r w sit.

FIGURE 4.14

Specifying block information

As we hit Next button the block input form appears. The deethanizer column is specified
,

with the given data as shown in Figure 4.15.

arn<tv*\
* & V- tm, r , m

31i£iai _U *iB| 51 nl-mi*!<l

.
_
1 "

: ; £

it:

6 :

imua h** m tffl

FIGURE 4.15
198 PROCKSS SIMULATION AND CONTROL USING ASPEN

Subsequently, the filled input forms are shown in Figures 4.16(a), (b), (c) and (d)
for other four DSTWU columns.

fir. Prt Ubfwy WMM

-
LT-

tap u**

neb*.

»>y ctnponent Condentei ipertcalun!

(a

Ct«p fo
1 F
-

Rww jo O
T

C3

O St*: G<t<-C-.

r>n»m

] .JtdiJ Trim

FIGURE 4.16(a)

J iiiJ JZi J
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iJ~_
|0 IrcU 3Mt I HJilJ -3 U
_
j V- n CdaimxtOebor* j Convagervt
.
) .an d Ptuiite

i pi
a Wumbe.
- tjf
j
Reba» fT
_

.
U B3 r Reftw .aha
*
6-
-
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1
.
U K
I J W
Ccrrp fic<
_

.
0 02 3]
_1 M
'

-
_
j W
j _, D£

Reow (0 CO)
S M Cl

jfi : .

ftco- It* cm
RMI
t

P»u

I I Sob* I UMModrt t

k
Km-

Fv H* cm F"

FIGURE 4.16(b)
 ASPEN PLUS SIMULATION OF CHEMICAL PLANTS 199

Si ioj _U 51 riKifci- l-M 3) _J_JjiJ ji) 5j

i _
J «
(7 ll**c»*

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Zl r i »>-
S H
-

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-

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-

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as

I HMtKfaan | Colm | Rucmt | Pimm*!

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CH
MM
M- FSptr SSpM
C iFMiStavPUtn NUN fi«w*Jkci41

FIGURE 4.16(c)

Pta Jrav

ffiimii
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CondEnia f

u «
J w
_

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J .
-

- I

f" HMra/lrfi-"nan || f[«*jit

Mraeon || Hn.f
.
Him rp., | Coupni | RmcV<. | Prwtti.Ch»»n | tWiMi t Set* | UtpUM* |
-
CM
Hp
flflUMS ' U** V , *

C a(*t«J r tI> HUN ,«*«rJKmvwa u

FIGURE 4 16(d) .

Click on Afert and specify the pump (PI) outlet by providing the discharge pressure
of 10 atm (see Figure 4.17).
200 PROCESS SIMULATION AND CONTROL USING ASPEN

FU Jtnry Wndov. I Ms

HA
L TJ i i
-
J2J

"

r Preci.ie "iciMie

r Pt«tiu>«(Mo
"

I I 3
) <Jfti«mr* (kthnjs condhoni

Saiw

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£0 MM

Sw&wjm -1

j <Ch« 'il-IA=r'Ari j 1 JAcw | -J U- q Tern} Atpei> Pk» - Simi

FIGURE 4.17

The status bar in the window, shown in Figure 4.17, includes a message of Required
Input Complete; it reveals that to run the simulator, sufficient data have been provided.
But there is no such restriction that we cannot specify the process with more input
information. Again, as we click on Next, Aspen Plus shows a message under the heading
of Required Input Complete as shown in Figure 4.18.

J T -
1-1. I pr H jsn l -iai

/Specifcaliooij CflfcOalKr. OsHjw ] flaihOphor.t

wni
D>38
(? Ptmp
0 EWSK
j Rtcnc
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3
3
P Result
_
J

ro-jcertrterma'eincxJ To no'rr roi ed»i ijncd »

Al Mea ' c fx :- Hm - * Osu .>: -- (Mnu.
Ptnp.

I W ci
-
ai c;
j a o
.
ai «
.
a pi

EOCorwOpten

-
Q -

iM
. 9 -m *

FIGURE 4.18
 ASPEN PLUS"' SIMULATION OF CHEMICAL PLANTS 201

Notice that if there are no red semicircles in the left it can be said that the data,

entry for running the Aspen simulator is complete.

Running the simulation
As we approve the simulation run, the Control Panel, displayed in Figure 4 19, .
shows
the progress of the flowsheet simulation in addition to a message o[ Results Available .

1
.

B a
B O
B w
Z '
93 us states; ~. Jt mu tjxll huz - jjtkt:

n a = c» n

z. =i3»i arc:

lice* a Bsmi: csrta

fi" -

"
. v. ex. -vOS

FIGURE 4.19

Viewing results
Choose Results Summary /Streams in the column at the left side and obtain the
compositions of all distillation products as shown in Figure 4.20.
We may save the work by choosing File/Save As/...using the menu list on the top.
W< tan give a name of the file whatever we like. Note that if we click on Stream Table,
the results summary table is incorporated in the Process Flowsheet Window, as shown
in Figure 4 21.
.

Viewing input summary

If we wish to have the systematic input information, press Ctrl + Alt + I on the keyboard
or select Input Summary from the View pulldown menu (see Figure 4*22).
In order to create a report file (*.rep) for the present problem, we may follow the
approach presented in Chapter 1 It is worthy to mention that the report file contains
.

all necessary information on the solved Aspen Plus problem including given process ,

data and computed results

202 PROCESS SIMULATION AND CONTROL USING ASPEN

3 >bJ.'<IP~~3»l-i g|

C- « 1 J .
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e tUi sm 1 TOTB 1 nuif 1m muff
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FIGURE 4.20

i MIBlJBI
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FIGURE 4.21

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 ASPEN PLUS SIMULATION OF CHEMICAL PLANTS 203

rrrvJ |t«i1«t<«i of a DUinUtlon TrtU

MCW-aetrr i<ol( -OtNSrrr- tuol' c-ji

'

voilM-CM otir*-!

for Inpm: Ho1«

Stream report ct xnltiwi: «o1t fli

SOLIDS 1MMCAMIC

W-SDUKCS Wll / -QOWWS SOLIDS INOtMMC

CI C2M I
( 1 ClHt
1C4 C4H10-2 i
' ' C4N10-1 /
IC1 CSH12-; '
ici cvai-i /
MCt CftfU-1

LCMMKT
1LOW C» I«l-e4 O'JT-O) Bl
.LOCK C4 IWt} O'.n-.oi M
ukk ci in-c; out-03 el

FIGURE 4.22

43
. ASPEN PLUS SIMULATION OF A VINYL CHLORIDE MONOMER
(VCM) PRODUCTION UNIT
Problem statement

The process flow diagram for Aspen Plus simulation of the vinyl chloride monomer
manufacturing plant is shown in Figure 4 23. The flowsheet has been developed based .

on the VCM production technology reported in a book by Seider et al (1998). .

O-fcmi

O-feu

BB 66 B7

F10

[purge]-o

FIGURE 4.23 A flowsheet of a vinyl chloride monomer production unit .

204 PROCESS SIMULATION AND CONTROL IISINO ASRKN

Pure ethylene, stored as a gas at 70oF and 1000 psia, with a flow rate of 20 tons/hr ,

and pure chlorine, stored as a liquid at 70oF and 150 psia, with a flow rate of 50 tons/hr
enter the mixer block Bl operated at 2 atm. The mixer outlet Fl then goes to the
reactor B2 run at 363 K and 1.5 atm. In this stoichiometric reactor (RStoic), the following
chlorination reaction occurs with 98% conversion of ethylene to 1, 2-dichloroethane:
C2H4 + Cl2 -> C2H4C12
ethylene chlorine dichloroethane
In the next, mixer B3 operated at 1.4 atm allows the mixing of the recycled stream
F12 with the reactor product F2. The outlet stream F3 is then condensed fully to liquid
phase in block B4 at 298 K before being pumped to an evaporator. The pump B5 has
discharged the liquid at 26 atm. The evaporator B6 performs the phase change operation
and then the vapour temperature is increased in the same unit to 515 K. In the
subsequent step, stream F6 is introduced in the reactor B7 (RStoic) in which the
following pyrolysis reaction occurs:
C2H4C12 -> C2H3C1 + HC1
dichloroethane VCM hydrogen chloride
The dichloroethane is converted to VCM and it takes place spontaneously at 773 K
and 25 atm with 65% conversion. To reduce carbon deposition in the heat exchanger,
the hot vapour stream leaving the reactor is quenched in block B8 yielding a saturated
vapour stream at 443 K. Quencher effluent stream F8 is condensed to liquid phase in
block B9 at 279 K and then fed to a DSTWU column B10 as stream F9. In the next ,

Stream F10 is introduced in another DSTWU column Bll. The first column mainly
separates HC1 from other components, while the second column purifies VCM from the
rests. Both the distillation columns have 10 theoretical stages (including condenser
and reboiler) and a total condenser along with the specifications shown in Table 4.3.
,

TABLE 4.3

% Recovery of LK/HK in distillate Pressure (atm)

Block Light key (LK) Heavy key (HK) Condenser Reboiler

B10 99.9% of HC1 0.1% of VCM 20 22

Bll 99.9% of VCM 0.1% of dichloroethane 75 .
8

Finally block B12 (FSplit) splits stream Fll to ensure the recycling of 99.999% of
Fll as F12 stream to mixer B3. A purge stream is introduced to prevent accumulation
of unreacted components.
Using the POLYSRK property method simulate the complete plant to compute the
,

composition of all streams.

Simulation approach
To start Aspen Plus package select Aspen Plus User Interface under Programs. When
,

the Aspen Plus window pops up choose Template and click on OK. In the next, select
,

Polymers with Metric Units (see Figure 4.24) and press OK button.
 ASPEN PLUS SIMULATION OF CHEMICAL PLANTS 205

- . . r .ii.-i.*. Ti 3 . i i .rj 3 a
i : ; : I -i

-.

-
:

HZ]

FIGURE 4.24

Click OA" when the Aspen Plus engine window appears to obtain a blank Process
Flowsheet Window.

Creating flowsheet
We can develop the process flow diagram (see Figure 4.25) by incorporating the following

IpF -I- I I- IT MCI I m ti

ED
413

? 4f

FIGURE 4.25
206 PROCESS SIMULATION AND CONTROL USING ASPEN

built-in process units available in the Aspen Plus Model Library:

two mixers (Bl and B3)
two Stoic' type reactors (B2 and B7)
four 'Heater1 type heat exchangers (B4, B6, B8 and B9)
1

one Tump type pressure changer (B5)

two T TWIT type columns (BIO and BID
'

one TSplit type splitter (B12)

All the blocks and streams are renamed according to the problem definition.
The status message directs us to provide the input information required to run the
complete Aspen Plus simulation program. In the subsequent sections, we will fill up
several input forms one by one.

Configuring settings
After creating the flowsheet for the VCM manufacturing unit hit Next button followed ,

by OK to open the Setup /Specifications / Global sheet. In the following the first screen , ,

shown in Figure 4.26(a), includes the Title of the present project as Simulation of a
VCM Production Unit' and the next screen displayed in Figure 4.26(b), shows the ,

Aspen Plus accounting information as given below .

User name: AKJANA

Account number: SAY X
Project ID: ANYTHING
Project name: AS YOU LIKE

ft* Edl ««. Dal* TotU f*jr. linry Wndw Help

DNBi L _ - JMjaj jg| dvlfeM M n>i -j -1 |h| a| -4 M a|

© SjtuIblco Cf
|SiT«iabon oi a VCM PieducUon Urd
itm&iB Gfcbal jetting,
_

O irouldars fwiT 3
Input mods

v Sf>ec/>awrn
Sueam das:
31
Flovbuc 3
it Jj Pew Oiar»a*fo
3

r Um see

£1 Cvre-ljdi
it; O Parw

> r j Mntof 4t "i Tents -J

5Tft£*MS
ssft.

FIGURE 4.26(a)
 ASPEN PLUS SIMUI.ATION OF CHEMICAL PLANTS 207

Qi BI _
LJ *j«J .] r5h-|ftl»N|w| mj rj J_iilj _J J
I r -i-1-i Fir -
t lei, I i«l MhJ

Mi*

FIGURE 4.26(b)

We wish to have streams results summarized with mass fraction basis that is not
set by default. Accordingly, we choose Mass' fraction basis in the Report Options/
'

Stream sheet under Setup folder (see Figure 4.27).

«. Ea '< W Tm> V< -tat, AWl- -*k

DIQ*IHI
'

J .
1 - M|
11 >id illF-Z]»J iJ _

OKI to U rciM r. ffMaitcV

P Hbi

P Ir-imi .«! no >» j tKW,

I .1

FIGURE 4 27
208 PROCESS SIMULATION AND CONTROL USING ASPEN

Specifying components
The components that are involved in the monomer manufacturing process are ethylene
(C2H4), chlorine (CI2), 1,2-dichloroethane (C2H4C12), vinyl chloride (C2H:iCl} and hydrogen
chloride (HC1). In order to get a blank component input form, choose Components/
Speciftcatiojis in the left pane of the Data Browser window. Defining all species in the
Selection sheet, we have Figure 4.28.

1 (ComponaO Spooftoiioni . Dal a Bnnrasr) ma

Data Tods fkn Plot Library Window Hdp

510*101 _
Tii.J J
JT _1_M.

_
Setjr
Selection] Pelidftum | Noraiorivenliona! j-/Dalabanl s |
Soedicatona
0 Smjiaion Options Define comp«*nli
Q Slrean- Class Componerit ID Type Comconent name Foirtiula

::h4 Conventtonal ETHYLENE C2H4

J/) UrUs-S«S
CL2 Conventional IHLORINE ri;
( Custom Unrts
Q Report C ions C2H4CL2 Conventional 1 2-DICHL0R0ET r :h4
.
.
Cemporwrti Conventional VINYL-CHLORIDE C2H3CL

HCI Conventional HYDROGEN CHLC HCI

Lg l-End Propert.es >

*
Jj Petrc Cha cterzatoi
FieudoccmocneiTts

I t-'enf - Comps
iMFJCGrtupi
'

1 Conp-Groops
.
J/] Comp-Ltsts
_
j Fo ert
PfOpefti«

| Stocks
'

1 Reaoons ElecWEatd UsetDelmed

'

I Corv-ergence
'

1 Flowsheeling Oplons
'

j Modd -ViaSyas Toots

EOCorrfgurabon

z1
fif Miyeu/Splittets | Sepaialoi Heat Exchargeti ] Columns ) Reactots ) Ptestute Changei: ] Manpulatots j SoWs ) Usei Modeit ]

Matei.at
STREAMS ' »m FSpS SSpK
ForHe*j.pn»j Fl C\. gFtAlfla\Aip«nPliji 11 1 NUM fiML«<! tTua netwowK
'.
ami s - jjChapter4 1*00 | Oiapler I - Mero | T) Uidii Teimi I* | Aspen f\j» - VCM [| Aspen Plus « 9 C . '656
FIGURE 4.28

Specifying property method

In the subsequent step choose Properties/Specifications to set the property method.
,

As mentioned in the problem statement accordingly select POLYSRK base method ,

under POLYMER process type (see Figure 4.29).

Specifying stream information

From the Data Browser ,
choose Streams folder and see the name of all input, output
and intermediate streams. However, we have to provide information for only two input
streams, C2H4 and CL2 which are fed to the mixer block Bl. Figures 4.30(a) and (b) ,

show the filled stream input forms.

 ASPEN PLUS SlMULVnON OF CHEMICAL PLANTS 209

IM tp ... .' i ~ . .

f
CirftUl .-I i c|g| ni-«-|fcl%l-3M ml I M "I ?l -I _
Li

"

in fHMM
f

a
o

IT

VtBUKi
- -

. - M

FIGURE 4.29

|i*lB|
-
J L
"

3 "! M -1 ""1
10 Ci . I

|-«i.pr. 3 pw=-3P -3
IB 1 - f
fS5
ED
- "

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FIGURE 4.30(a)
 ASPEN PLUS SlMULVnON OF CHEMICAL PLANTS 209

IM tp ... .' i ~ . .

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FIGURE 4.30(a)
 '

210 PROCESS SIMULATION AND CONTROL USING ASI KN

n. ton Pirn Stn.l*>on 1 [SlrBM C.L3 WATEBIAL) kyU IMa ttowwrl -

Data Tools Ruti rlol

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STREAMS 1 FSpia SS|*
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: NUM Rt»ju«ed ir<x£ TTC0ncJ«»t
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FIGURE 4.30(b)

Specifying block information

Unlike stream information , we need to input required data for all blocks of the process
flow diagram. As stated earlier the flowsheet of the VCM plant consists of two mixers, ,

two reactors, four heat exchangers one pump, two distillation columns and one splitter. ,

Although discussed during the Aspen Plus simulation of different single process units
in the preceding chapters, we must remember the following points when we fill up the
block input forms.

To simulate a mixer model, at least provide the pressure data and valid phases.
In the simulation of the reactor model coefficients should be negative for ,

reactants and positive for products .

In the Vapour fraction field of a heater model put 0 to indicate bubble point ,

and 1 to indicate dew point. For subcooled liquid and superheated vapour, use
Flash specifications.
The windows, shown in Figures 4.31(a) to 4.31(n) display the block-wise information
using the input forms.
 ASPEN PLUS SIMULATION OF CHEMICAL PLANTS T

f* e* d*»
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 1"
212 PROCKSS SIMULATION AND CONTROL USING ASPKN

jag|y| I I ite|ll8| ffj aMfkltKH H 2J-Liil)-2J iil -I J

Read arts

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STREAMS M t. FSpS SSpH

forHab press F1

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Aapen Pk> CH4 SeC 4

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FIGURE 4.31(d)
 ASPEN PLUS SIMULATION OF CHEMICAL PLANTS 213

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214 * PROCESS SIMULATION AND CONTROL USING ASPEN

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FIGURE 4.31(g)

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 ASPEN PLUS SIMULATION OF CHEMICAL PLANTS 215

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216 PROCESS SIMULATION AND CONTROL USING ASPEN
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 ASPKN PLUSIM SIMUI.VriON OF CHEMIC-VI PL\NTS 217

uMiei | i ibj I nhlit Hhi J

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FIGURE 4 31(n)
 '

218 PROCESS SIMULATION AND CONTROL USING ASPEN 1 M

Running the simulation

As we press Next button, Aspen Plus displays a message as shown in Figure 4.32. Since
the data entry is fully complete, the simulator seeks user permission to run the program.

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STREAMS 1 Mew SSpi -

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FIGURE 4.32

As we hit O-K button on the message the Control Panel window appears as displayed ,

in Figure 4.33. It usually shows errors warnings, convergence status, etc. ,

gaBSBEsai
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FIGURE 4.33
 ASPEN PLUS SIMULATION OF CHEMICAL PLANTS 219

Viewing results
Choose Results Summary /Streams in the column at the left side and rearrange the table to
get the results in the form as shown in Figure 4.34 Save the work positively at this moment. .

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FIGURE 4.34

Viewing input summary

To obtain the input information of the present project, select Input Summary from the
View dropdown menu (see Figure 4 35). .

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FIGURE 4.35
220 PROCESS SIMULATION AND CONTROL USING ASPEN

SUMMARY AND CONCLUSIONS |

In the previous chapters, we have studied the steady state simulation of a large variety of
individual process units using Aspen Plus package. In the present chapter, several chemical
processes have been assembled to develop the chemical plants and those plants have
been simulated subsequently. The solved examples include a distillation train and a vinyl
chloride monomer unit. In the second example, the loop is closed by a recycle stream,
whether in the irst unit, there is no such complicacy. However, the straightforward
f

approach to simulate a lowsheet is that after developing the process low diagram in the
f

f
lowsheet window of Aspen Plus, we can simply use Next button for data entry. As we
f

receive the message of Required Inpu t Completey we can move on to run the simulation.
In the next two chapters, we will study the process dynamics and closed-loop control of
low-driven as well as pressure-driven processes using Aspen Dynamics package.
f

PROBLEMS|
4
. 1 A hydrocarbon stream with component-wise low rates, shown in Table 4.4, enters
f
the isentropic compressor at 120oF and 1 atm. The compressor has discharged the
vapour stream at 3 atm.
TABLE 4.4

Component Flow rate (kmol/hr)

10
95
150
n -C4 25
/i-C3 10
n-C 100
6

The complete process lowsheet for lashing and stripping operation is shown in
f

Figure 4.36. The lash drum (Flash2) runs at 1250F and 2.8 atm. The stripper
f

(STRIP2) has total 6 stages (including condenser and reboiler) and bottoms to
feed ratio (mole basis) is 0.8. The feed stream to the stripper is introduced above
the top stage and the pressure throughout the column is 2 atm.

V24

I 0 1

COMPRESS FLASH STHiPPER

FIGURE 4.36 A flowsheet for flashing and stripping operation .

CopyHghlod material
 ASPEN PLUS SIMUIJUION OF CHKMICAL PLANTS 221

Using the UNIQUAC property method, simulate the plant to compute the product
compositions and flow rates.
4 2 A ternary mixture, as shown in Table 4.5, is fed as stream H at 100oF and 290
.

psia to a pump Pi employed to increase 20 psi pressure.

TABU 4.5

Component Flow rale (Ibmol/hn

500

300

"
r 11, 10

The stripper (STRIP2) has total 100 stages (including condenser and reboilen
with a reboiler duty of 107 Btu/hr Stream F enters above 70th stage and Stream
R) mien above 1st stage. The top stage pressure of the stripper is 280 psia
with a stage pressure drop of 0.5 psi The intercolumn pump P2 has increased
25 psi pressure The RECT column has total 120 stages (including condenser
and reboileri with a reflux ratio (mole basis) of 10 and a bottoms to feed ratio
'mole basis) of 0.6. Stream Dl enters below 120th stage. In the simulation,
consider condenser pressure of 275 psia with a pressure drop of 5 psi and a
stage pressure drop of 0.1 psi (see Figure 4.37).

0
-
0

PI 8TRIP2 ' w"

FIGURE 4 .
37 A flowsheet of a propylene-propane mixture separation process

Applying the RK-Soavc thormodynamit mod* I

(a; simulate the above propylene propane mixer Beparation plant and report the
product compositions, and
(by perform the seneitivity aaalysifl to observe the effect of the second column
efficiency varied from 20'/. to 10091 on the propylene mole fraction in the
distillate
222 PROCESS SIMULATION AND CONTROL USING ASPEN

4 . 3 The hydrogenation of aniline produces cyclohexylamine in a CSTR according to

the following reaction:
CgHgNH;, + 3H2 -) CgHnNHs
aniline hydrogen cyclohexylamine
To simulate the aniline hydrogenation process using Aspen Plus, we develop the
process flow diagram as exhibited in Figure 4.38.

FA
S-o
C>-I ANILINE

El
PUMP

CD-
C>-| HYDROGEN I-I

CSTR

COMPRESS

FIGURE 4.38 A flowsheet for aniline hydrogenation.

The reactor model (RCSTR) operates at 580 psia and 2480F, and its volume is
1200 t3 (75% liquid). For the liquid-phase reaction, the inlet streams have the
f

specifications, shown in Table 4.6.

TABLE 4.6

Stream Temperature Pressure Flow rate

(0F) (psia) (Ibmol/hr)
ANILINE (pure aniline) 95 100 150

HYDROGEN (pure hydrogen) 12 100 600

Both pump and compressor (isentropic) have discharged the fluids at 585 psia.
Data for the Arrhenius law are given as:
Pre-exponential factor = 5x 105 m3/kmol . s
Activation energy = 20,000 Btu/lbmol
[CJ basis = Molarity
Use the SYSOPO base property method in the simulation. The reaction is irst-
f

order in aniline and hydrogen. The reaction rate constant is defined with respect
to aniline. Simulate the process and compute the component mole fractions in
the liquid product and the vent stream.
4 . 4 The process flow diagram for an azeotropic distillation process is shown in
Figure 4.39. The technique involves separating close boiling components
(acetic acid and water) by adding a third component (vinyl acetate), called an

Copyrighted material
 ASPEN PLUS SIMULATION OF CHEMICAL PLANTS 223

entrainer, to form a minimum boiling azeotrope which carries the water overhead
and leaves dry product (acetic acid) in the bottom. The overhead vapour is
condensed and then separated in the decanter into two liquid phases: the organic
phase and aqueous phase.
DECANTER

1 VA-RICHh
DIST
VA

1 FEEDf

HW-RICHh

AA

RADFRAC

FIGURE 4.39 A flowsheet of an azeotropic distillation process .

A feed stream, namely FEED, enters above 15th stage of the azeotropic distillation
column at 330oF and 90 psia in addition to the flow rates, shown in Table 4.7.
TABLE 4.7

Component Flow rate (Ibmol/hr)

acetic acid 2700
water 500

The entrainer, VA (vinyl acetate), with a flow rate of 455 Ibmol/hr enters above
12th stage of the column at 200oF and 100 psia. The azeotropic column (RadFrac)
has the following specifications:
Number of stages (including condenser and reboiler): 55
Condenser type: total
Valid phases: vapour-liquid-liquid
Reflux ratio (mole basis): 4
Bottoms rate: 2700 Ibmol/hr
Condenser pressure: 66 psia
Column pressure drop: 12 psi
Key component in the second liquid-phase: water
Stages to be tested for two liquid-phases: 1 to 55
The specifications for the decanter model are noted below:
Pressure: 50 psia
Temperature: 110oC
Key component in the second liquid-phase: water
Using the NRTL RK thermodynamic model simulate the process to compute the
-

component-wise product flow rates.

224 PROCESS SIMULATION AND CONTROL USING ASPEN

4 . 5 A hydrocarbon stream H is at 50C and 2.5 atm. The pump has discharged the
liquid feed F at 5 atm. The component-wise low rates are shown in Table 4.8 for

f
stream H.
TABLE 4.8

Component Flow rate (kmol/hr)

35

C3 50
i-C, 130
n-C 200
4

' -

c5 180
n-C5 200

n-C 5
6

In Figure 4.40 the schematic representation of a hydrocarbon separation process

integrated with a Pump, three DSTWU columns (Cl, C2 and C3) and two RadFrac
(RECT) columns (CR1 and CR2) is shown.

DRl DR2

CR2

CRT
BR2|-0

BRI
G1

PUMP
h
C2
C3

B3 | C1 B2}<>

FIGURE 4.40 A flowsheet of a hydrocarbon separation process .

AH DSTWU fractionators have total 20 stages (including condenser and

reboiler) and two RECT models have 10 stages (including condenser and reboiler)
with no reboiler. The specifications, shown in Tables 4.9(a) and (b) are required ,

for simulating the process.

 «PEN PLUS SIMULXTION OF CHKMICAL PLANTS 225

TABLE 4.9(a)

* Recovery of LK/HK in distillate Pressure (atm)

Block Lighi key Heavy kev Condenser (type) Reboiler

IK (HK)

Cl 99 of r»-C4 1% of i-CB 4 (partial condenser with 4

all vapour distillate)
C2 99* of t-C4 21 of n-C4 1 5 (total condenser)
.
15 .

C3 99* of 1-C5 4* of n-C5 3 (total condenser) 3

TABLE 4.9(b)

Block Condenser Distillate to feed ratio Pressure

(type) (mole basis) (atm)

CR1 Partial vapour 02 .

2

CR2 Total 05 .
15

Applying the Peng-Robinson property method, simulate the separation process

to compute the flow rates and compositions of all product streams.
4
. 6 An inlet Stream H supplied at SOT and 300 psia is compressed to 4000 psia by
the use of an isentropic compressor Bl. Stream H has component-wise flow rates,
shown m Table 4.10.
TABLE 4.10

Component Flow rate (Ibmol/hr)

mtrogen 100
hydrogen 300
ammonia 0
carbon dioxide 1

A flow diagram for the ammonia process (Finlayson 2006) is shown in Figure 4.41.
,

B '

m-<
H -

0 H"

ED-0

Bl B2 B3 84

FIGURE 4 41 A flowsheet of an ammonia process

226 PROCESS SIMULATION AND CONTROL USING ASPEN

Stream Fl is mixed with the recycle stream F8 in a mixer block B2 operated at

4000 psia. Before introducing into the reactor, the mixer efluent F2 is heated in

f
block B3 to 900oF at 4000 psia. Note that the reactor (RGibbs) B4 runs at 900oF
and 3970 psia. In the next, the reactor outlet F4 is cooled in a heat exchanger
B5 operated at 80oF and 3970 psia. The flash drum (FIash2) B6 produces Streams
Bl and F6 at 80oF and 3970 psia. In the subsequent step, Stream F6 enters the
splitter (FSplit) B7 and 0.01% of it is used as purge. Finally, an isentropic
compressor B8 has discharged Stream F8 to the mixer block B2 at 4000 psia.
Using the NRTL thermodynamic model and the Newton's iteration method (from
the Data Browser, choose Convergence/Conu Options), simulate the ammonia
process to compute the component-wise low rates and compositions of all streams.

f
REFERENCES |
Finlayson, B.A. (2006), Introduction to Chemical Engineering Computing, 1st ed., Wiley
Interscience, New Jersey.
Seider, W.D., J.D. Seider and D.R. Lewin (1998), Process Design Principles: Synthesis,
Analysis, and Evaluation, 1st ed., John Wiley & Sons, New York.

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