Koya University

Faculty of Engineering
Department of Chemical Engineering
Fourth Stage/2022-2023

Process Simulation
The Applications of Engineering Simulation Software
In Chemical Engineering

Instructor
Mr. Ribwar K. Abdulrahman
Prepared by:
Safeen Yaseen Ja’far
Submitted on
25/10/2022
 Table of Content
Abstract ......................................................................................................................................................... 1
1. Introduction .............................................................................................................................................. 2
1.1 Introduction to Simulation .................................................................................................................. 2
1.2 A brief History of Simulation and Simulation Software ..................................................................... 2
2. Literature Review & Methodology ........................................................................................................... 3
2.1 What is Simulation and Simulation Software? ................................................................................... 3
2.2 Types of Simulation ............................................................................................................................ 3
2.3 Advantages of Simulation................................................................................................................... 3
2.4 How is Simulation Performed? ........................................................................................................... 4
2.5 Common Simulator Software for Engineering Simulation ................................................................. 6
2.6 Applications of Simulation Software in Chemical Engineering ......................................................... 7
2.6.1 Aspen Plus and Aspen HYSYS .................................................................................................... 7
2.6.2 ProMax ........................................................................................................................................ 8
2.6.3 ChemCAD ..................................................................................................................................... 9
2.6.4 PRO II........................................................................................................................................... 9
3. Results .................................................................................................................................................... 10
4. Discussion .............................................................................................................................................. 11
5. Conclusion .............................................................................................................................................. 11
6. References.............................................................................................................................................. 11
Abstract

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1. Introduction
1.1 Introduction to Simulation

A simulation is an imitation of the dynamics of a real-world process or system over time. Although
simulation could potentially still be done “by hand,” nowadays it almost always implicitly requires
the use of a computer to create an artificial history of a system to draw inferences about its
characteristics and workings (Leonelli, 2021).

A simulation is a model that mimics the operation of an existing or proposed system, providing
evidence for decision-making by being able to test different scenarios or process changes. This
can be coupled with virtual reality technologies for a more immersive experience. Simulations can
be used to tune up performance, optimize a process, improve safety, testing theories, training staff
and even for entertainment in video games! Scientifically modelling systems allows a user to gain
an insight into the effects of different conditions and courses of action. Simulation can also be used
when the real system is inaccessible or too dangerous to assess or when a system is still in the
design or theory stages (TWI, 2022).

1.2 A brief History of Simulation and Simulation Software

The history of computer simulation dates back to World War II when two mathematicians Jon Von
Neumann and Stanislaw Ulam were faced with the puzzling problem of behavior of neutrons. Hit
and trial experimentation were too costly and the problem was too complicated for analysis. Hence,
the Roulette wheel technique was suggested by the mathematicians. The basic data regarding the
occurrence of various events were known, into which the probabilities of separate events were
merged in a step by step analysis to predict the outcome of the whole sequence of events. With
the remarkable success of the techniques on neutron problem, it soon became popular and found
many applications in the business and industry. The power of simulation as a tool became evident
in the middle 90s.Challenges were faced by companies like Universal Data Systems. The hurdle
was to convert the entire plant to a hybrid flow-shop where an individual unit would be sent to the
next operation as soon as it was completed at the current operation. One serious reservation for
this change was the impact on finished goods inventory. (UH.EDU, 2022)

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2. Literature Review & Methodology

2.1 What is Simulation and Simulation Software?

Definition of Simulation: Modelling and simulation are a discipline for developing a level of
understanding of the behavior of the parts of a system, and of the system as a whole. Modelling
and simulation are very much an art. One can understand about riding a bicycle from reading a
book. To really learn to ride a bicycle, one must actively practice with a bicycle. Modelling and
simulation follow much the same principle (Jana, 2011).

https://books.google.iq/books?id=46EIuf2ycdYC&source=gbs_navlinks_s

Why to use models?

To fly a simulator is safer and cheaper than the real airplane. For precisely this reason, models are
used in industry commerce and military: it is very costly, dangerous and often impossible to make
experiments with real systems. Provided that models are adequate descriptions of reality (they are
valid), experimenting with them can save money, suffering and even time (Arsham, 2015).

http://home.ubalt.edu/ntsbarsh/simulation/sim.htm#rwis

2.2 Types of Simulation

Simulation can be broken down into three overarching types, as follows:

▪ Discrete Event Simulation: Modelling a system as it progresses through time, for example;
factory operations (stamping, turning, milling), traffic analysis (roads, networks, queues)
▪ Dynamic Simulation: Modelling a system as it progresses through space, for example; machine
kinematics, human ergonomics, aerodynamic testing, virtual prototyping.
▪ Process Simulation: Modelling physical interactions between two or more systems, for
example; in-service product modelling, in-manufacture product modelling, weather forecasting.

2.3 Advantages of Simulation

There are a range of advantages to be gained through the use of simulation, including:
▪ Less Financial Risk: Simulation is less expensive than real life experimentation. Simulation
allows you to test theories and avoid costly mistakes in real life.
▪ Exact Repeated Testing: A simulation allows you to test different theories and innovations time
after time against the exact same circumstances.

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▪ Examine Long-Term Impacts: A simulation can be created to let you see into the future by
accurately modelling the impact of years of use in just a few seconds.
▪ Gain Insights for Process Improvement: The benefits of simulation are not only realised at the
end of a project. Improvements can be integrated throughout an entire process by testing
different theories.
▪ Assess Random Events: A simulation can also be used to assess random events such as an
unexpected staff absence or supply chain issues.

Definition of (Simulator) Simulation Software: Simulation software is based on the process of

modeling a real phenomenon with a set of mathematical formulas. It is, essentially, a program that
allows the user to observe an operation through simulation without actually performing that
operation. Simulation software is used widely to design equipment so that the final product will be
as close to design specs as possible without expensive in process modification (Mahmud, Soetanto
and Town, 2018).

https://doi.org/10.1016/B978-0-12-809597-3.00518-6

2.4 How is Simulation Performed?

Simulations may be performed manually. Most often, however, the system model is written either
as a computer program (for an example click here) or as some kind of input into simulator software
(Arsham, 2015).

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 Figure 2.1: The main Steps of Modeling and Simulation Procedure

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2.5 Common Simulator Software for Engineering Simulation

We have many of programs which can be use to design chemical and physical processes from
any industry, So, we can mention some of these as below you see in the list:

Table 2.1: List of most known process simulators (Haydary, 2019)

Name Source Type Website

Aspen Plus Aspen Technology Inc. Steady State www.aspentech.com
Ten Canal Park
Cambridge, MA 02141-
2201, USA
Aspen Dynamics Aspen Technology Inc. Dynamic www.aspentech.com
Ten Canal Park
Cambridge, MA 02141-
2201, USA
Aspen HYSY Aspen Technology Inc. Steady State and www.aspentech.com
Ten Canal Park Dynamic
Cambridge, MA 02141-
2201, USA
PRO/II and dynamics SimSci-Esscor 5760 Steady State and www.simsci.com
Fleet Street Dynamic
Suite 100, Carlsbad CA
92009,USA
UniSim Design Honyewell Steady State and www.honeywell.com
300-250 York Street Dynamic
London,Ontario N6A
6K2, Canada
ChemCAD Chemstation Inc. 2901 Steady State www.chemstations.net
Wicrest, Suite 305
Houston
TX 77251-1885, USA
DESIGN II WinSim Inc. Steady State www.winsim.com
P.O.Box 1885
Houston,
TX 77251-1885, USA
gPROM PSE Process Systems Steady State
Enterprise Limited 26–
28 Hammersmith Grove
London
W6 7HA
United Kingdom

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https://books.google.iq/books?id=hbR-DwAAQBAJ&source=gbs_navlinks_s

2.6 Applications of Simulation Software in Chemical Engineering

To know some information or details about these Programs/software we can deals with them in
the internet. So, we will talk about four of them in the next sub-section below.

2.6.1 Aspen Plus and Aspen HYSYS

ASPEN is an acronym of Advanced System for Process ENgineering. It is based on a flowsheet

simulation. Notice that Aspen was replaced by Aspen Plus® in latest versions. A flowsheet
simulation is a computer software that is used to quantitatively model a chemical processing plant,
which, In general, a chemical process consists of chemical components, or different species, that
are subject to physical or chemical treatment, or both. The goal of applying such treatment steps
is basically to add a value or convert the raw, cheap material(s) into valuable, final finished products
(gold). The physical treatment steps may include mixing, separation (de-mixing), such as
absorption, distillation, and extraction, and heating/cooling with or without a phase change (Al-
Malah, 2016).

https://books.google.iq/books?id=UvHzDAAAQBAJ&source=gbs_navlinks_s

What Does Aspen Hysys Use For?

Aspen HYSYS is a market-leading process modeling tool for conceptual design, optimization,
business planning, asset management, and performance monitoring for oil & gas production, gas
processing, petroleum refining, and air separation industries. Aspen HYSYS is a core element of
Aspen Tech's aspen ONE® Engineering applications. It has vast importance for chemical engineers
to simulate a process [1]. Some of the very intuitive capabilities include a highly interactive process
flow diagram for building and navigating through large simulations. It has efficient workflow for
process design, equipment sizing, and preliminary cost estimation [2]. The program also provides
a very flexible and easy to use distillation column modeling environment. Additionally, the
interactive nature of HYSYS enables users to build and use their models quickly and effectively.
Aspen HYSYS offers a comprehensive thermodynamics foundation for accurate calculation of
physical properties, transport properties, and phase behavior for the oil & gas and refining
industries. Comprehensive library of unit operation models including distillation, reactors, heat
transfer operation, rotating equipments, controllers and logical operations in both the steady state
and dynamic environments [3].

Applications of ASPEN HYSY

Hysys is mainly for oil and gas process industry but it’s expanded to various industries for
simulation as:

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− Petroleum Industry.
− Oil refinery.
− Heavy chemical industry.
− Petrochemical industry.
− Natural gas process plant.
− Synthesis Gas Production.
https://www.researchgate.net/publication/281608946_HYSYS_Simulation_of_Chemical_Process_
Equipment

Figure 2.2
https://www.researchgate.net/publication/326377217_Hydrodesulfurization_unit_for_natural_gas_
condensate_Simulation_based_on_Aspen_Plus_software

2.6.2 ProMax

ProMax is a multifaceted process simulation software package that is made by engineers for
engineers. It is designed to optimize gas processing, refining, and chemical facilities. With the
newest version we have emphasized sustainable technologies such as green hydrogen, renewable
natural gas, renewable diesel, and carbon-capture. The new Data Exchange feature allows
read/write access to your historian to monitor your plant operations and calculate valuable
performance information. Our goal is to support our clients in reducing emissions to help build a
more sustainable future that will equip future generations to succeed (BR&E, 2022).

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2.6.3 ChemCAD

ChemCAD is an integrated suite of intuitive chemical process simulation software that fits into the
chemical engineering workflow and supercharges an engineer's efficiency. Perhaps most
significantly, it continues to evolve to meet the ever-expanding needs of chemical engineers
(Chemstations, 2020).

Benefits:

• Highly customizable, flexible, and affordable.

• All modules work within a single graphical user interface for seamless interaction.

• Adapts to how you approach engineering challenges.

• Appealing graphics and reports are easy to export to third-party software.

• Easily integrates into chemical engineering computing environment.

• Personalized technical support second to none.

2.6.4 PRO/II

AVEVA PRO/II Simulation optimizes plant performance by improving process design and
operational analysis, and performing engineering studies. Designed to perform rigorous heat and
material balance calculations for a wide range of chemical processes, AVEVA PRO/II Simulation
offers a wide variety of thermodynamic models to virtually every industry.

Application of PRO/II

AVEVA PRO/II Simulation can be used in virtually every industry, including oil and gas production,
refining, petrochemicals, chemicals, pharmaceuticals, and polymer plant modelling.

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3. Results

In general, it can be said that Aspen Plus is better tool for chemical process design such as fine
chemistry, chemicals, pharma, etc., whilst HYSYS is best for hydrocarbon, petrochemical,
petroleum operations such as natural gas, liquified gases, crude oil etc.

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4. Discussion

5. Conclusion

6. References

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