A V E V A ™ T R A I N I N G

Lab Manual
Version 2020
May 2020

Introduction to AVEVA™
PRO/II™ Simulation
INFORMATION IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE.

Copyright © 2020 AVEVA™ Group plc and its subsidiaries. All rights reserved.
 Table of Contents 3

Table of Contents
Chiller Plant – Part 1 ................................................................................................................... 4

Chiller Plant – Part 2 ................................................................................................................. 17

Chiller Plant – Part 3 ................................................................................................................. 23

Chiller Plant – Part 4 ................................................................................................................. 28

Debutanizer with Assay ............................................................................................................ 39

Debutanizer with Petroleum Components .............................................................................. 49

Light Ends Fractionation Train ................................................................................................ 58

Naphtha Assay – Part 1 ............................................................................................................ 68

Naphtha Assay – Part 2 ............................................................................................................ 75

Naphtha Assay – Part 3 ............................................................................................................ 80

Phase Envelope ........................................................................................................................ 84

Rigorous Heat Exchanger ........................................................................................................ 90

Specifications and Defines ...................................................................................................... 95

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4 Chiller Plant – Part 1

Chiller Plant – Part 1

OVERVIEW
You will build a simulation of the process shown below. This is part of a typical chiller plant in
natural gas processing. However, for the purpose of this exercise the actual process is
unimportant, as the goal is to familiarize you with the basic steps required to build a simulation
in the software. In subsequent parts of this example, you will add additional sections of the plant
to this simulation.
Use the Peng-Robinson thermodynamic method with the Petroleum Correlations for the
Transport Properties.

Figure 1: PFD of Chiller Plant – Part 1

The process and equipment data are given in Table 1 and 2.

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Table 1: Feed Stream Data

Component Alias Name Mole %

Nitrogen N2 1.00

Carbon Dioxide CO2 1.60

Methane C1 72.5

Ethane C2 11.5

Propane C3 6.75

i-Butane iC4 1.25

n-Butane nC4 3.00

i-Pentane iC5 0.55

n-Pentane nC5 1.10

C6+ (Petroleum Component) - 0.75

C6+ Properties Metric English

NBP 100 C 210 F

Gravity 690 kg/m3 73 API

Feed Conditions Metric English

Total Flowrate (Vap. Vol.) 1.00e+6 m3/day 40 MM SCFD

Temperature 50 C 120 F

Pressure 1410 kPag 205 psig

Table 2: Equipment Data and Operating Conditions

Unit Description Data Metric English

D-1 Scrubber Pressure 1400 kPag 203 psig

Temperature 30 C 85 F

C-1 Compressor Outlet Pressure 4150 kPag 600 psig

Adiabatic Efficiency 72% 72%

HX-1 Cooler Hotside: Process Stream

Outlet Temperature 45 C 110 F

Pressure Drop 35 kPa 5 psi

Coldside: Utility Air

Inlet Temperature 25 C 80 F

Outlet Temperature 38 C 100 F

D-2 Knockout Drum Flash drum with no change of -- --

pressure or duty.

* PUMP P-1 data is on the next page.

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6 Chiller Plant – Part 1

P-1 Pump Outlet Pressure 3800 kPag 550 psig

Pump Efficiency 65% 65%

SOLUTION STEPS

Step 1 Create a New Simulation

• Under the File tab, select New.

Note that several buttons (i.e. Component Selection, Thermo, Run) have red borders. This
indicates that data is required before the simulation can be run. When you have satisfied the
input requirements, the red borders will disappear.

Step 2 Modify the Input Units of Measure (UOM)

• Under the Input tab (or the Express tab), select green-bordered Units Of Measure
to verify the units of measure used in this simulation.
The default UOM basis is English. To change to another system of units, click
Initialize from UOM Library.

Note: It is important to use a consistent set of units throughout. In this example, choose
your preferred UOM (Metric or English) and check each data entry item to ensure that it
matches the input data given in the tables above.

• In this example you will use gauge pressure units. Change the Pressure unit to the
required option by selecting from the drop-down list.
o For Metric units, select Kilopascal (gauge).
o For English units, select Pound/inch^2 (gauge).
• Click OK to save the change.

Notice that the border of Units Of Measure is now blue, indicating that you have
modified the default data.

Step 3 Define the Components

• Select Input | red-bordered Component Selection.
• Type in the component name or alias and use the <Enter> key or click Add ->.

Note: Alternatively, you can click on Select from Lists to search for desired components.

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 Chiller Plant – Part 1 7

• Enter data for the petroleum component C6+ by clicking Petroleum.

• Enter its Normal Boiling Point, gravity data, and name, and click OK.
Note that only two of the three parameters are required for petroleum component
definition as shown in Figure 2.

Figure 2: Petroleum Components (English units)

Note that in the main Component Selection window, Petroleum and the list of selected
components now have blue borders, as shown in Figure 3.

Figure 3: Component Selection

• Click OK.

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8 Chiller Plant – Part 1

Step 4 Select the Thermodynamic Method

• Select Input | red-bordered Thermo.
• Under Category, select Most Commonly Used.
• Under Primary Method, select Peng-Robinson.
• To add your method selection to Defined Systems, double-click on Peng-
Robinson, or click Add ->.
• Set the Default System to PR01.
• To specify the transport property methods, click Modify | Transport Properties.
• From the Transport System drop-down list, select Petroleum Correlations as
shown in Figure 4.

Figure 4: Transport Properties

• Click OK to PFD to save the entered data and return to the PFD.

Step 5 Build the Process Flow Diagram (PFD)

When developing a PFD, it is important to build the flowsheet gradually and check the
results at each stage. In this case, we suggest you add the feed stream, the scrubber
D-1, and its product streams.

If the PFD palette is not already visible, select View | Show or Hide PFD Palette to open it.

• On the PFD palette under the General tab, select the FLASH unit icon. A pointer
with a box and flash drum attached appears.
• Click the area of the flowsheet to set the position of the unit.

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 Chiller Plant – Part 1 9

• To add the streams connected to the FLASH, on the PFD palette, click Streams.
• Click once on the flowsheet to fix the starting point of the stream, move the mouse
to extend the stream line, then click again to fix the end point of the stream.

Note that the pointer now has an S attached to it, denoting stream mode. All
available exit ports appear on each unit once you select Streams.
Required exit ports are red and optional exit ports are green.
After your first click, only the available feed ports are shown in red or green.

Note: Although not critical in this example, it is good practice to connect the FLASH DRUM
hydrocarbon liquid product to the side port and to reserve the bottom port for a decanted
water or second liquid product.

• To exit stream mode, right-click or press the <Esc> key.

Once you have attached the streams the model should look as shown below:

Note: It is also good practice to rename the unit operations and the streams according to
the PFD or P&ID. In this example, please use the names as shown in Figure 1.
Alternatively, you can select Options | Drawing Defaults | General, then check the
Request Unit/Stream Names option.

• Double-click on the FLASH unit and enter the required data.

• The First Specification is Pressure and the Second Specification is
Temperature.

Note: As you return to the PFD after entering the unit operation data, its unit identifier has
changed from red (data missing) to black (data satisfied).

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Step 6 Define the External Feed Stream

Double-click on the feed stream INLET_GAS and confirm that the Stream Type is
Composition Defined.
• Enter the stream’s Thermal Condition:
o Select Temperature as the first specification, and enter the value depending
on the UOM system chosen.
o Select Pressure as the second specification and enter the value.
• Click Flowrate and Composition.
• Select Total Fluid Flowrate and enter the value.

Note: You will need to locally override the default flowrate dimensional units (mol/hr). To do
this, click the Total Fluid Flowrate field, click UOM at the top of the window, and change
the basis to Vap. Vol. and the units to those specified in the input data. Click Change Units.
See Figures 5 and 6 below for the case with English UOM.

Figure 5: Convert UOM’s

• Enter the individual component mole percentages into the component grid. You can
move down the list using the <Tab> key. After entering the composition data, check
that the total equals 100 as shown in Figure 6.

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Figure 6: Flowrate and Composition (English units)

• Click OK to PFD to save the entered data and return to the PFD.

Note: If compositions are written elsewhere (e.g. Excel), you may use the Copy and Paste
feature by utilizing the Copy and Paste buttons located to the left (as shown in Figure 6).
When using, confirm the first cell is selected.

Once the external feed stream is defined, it is a good idea to check that the data entered
is correct. One way to do this is to select the stream (with a single click), then select Tools
| Flash Stream. This will flash the stream and generate the output as shown in Figure 7.

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12 Chiller Plant – Part 1

Metric Units English Units

Figure 7: Flash Stream Results (Default Browser Format)

If your results differ, check your input data for the stream, particularly the UOM and the phase
basis for the volumetric flowrate.

• Before continuing, save the simulation as CHILL1.prz.

Step 7 Add the Remaining Unit Operations to the PFD

• Using the PFD palette, select and arrange the unit operations as shown in Figure 1:

On the PFD palette, you will find the FLASH DRUM under General, the SIMPLE HEAT
EXCHANGER under Heat Exchangers, and the COMPRESSOR and the PUMP under
Pressure Change.

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• Once you have added the additional units, draw the streams on the flowsheet to
connect the units. The completed PFD should now look like Figure 1.

After you finish building the flowsheet, the labels of all the internal streams are black and the
available ports of all the units are green. In addition, the labels of the newly added units have
red borders, because data must be inputted.
On the PFD palette, note that the border of the Streams button is black, indicating that you
have entered all necessary data for this function.
To exit the stream connection mode, right-click or click on the Streams button. Streams will turn
gray, indicating that the mode is no longer active.

Step 8 Enter Operating Conditions for Each Unit Operation

• Double-click on each unit and enter the required data.
• Enter data for FLASH drum D-2:
o The First Specification is Pressure Drop and the Second Specification is
Duty. The duty of an adiabatic flash is zero.
• Enter data for HEAT EXCHANGER HX-1.

Note: By default, the tube side stream is the hot side and the shell side stream is the cold
side. Here this means that the utility stream is the cold side. You can click on Process
Stream to access Heat Exchanger – Process Streams from where you could change the
stream allocations, if the reverse were true.

• For the Hot Side, enter the Pressure Drop.

• Click Specification to open the heat exchanger Specifications window.
• Select Hot Product Temperature from the list and enter the value.

Figure 8: Heat Exchanger Specifications (English units)

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14 Chiller Plant – Part 1

• Click OK to return to the Heat Exchanger window.

• Click Cold Side Utility Stream and enter the appropriate data.

Figure 9: Cold Side Utility Stream (English units)

• Close the Heat Exchanger windows and return to the PFD.

• For PUMP P-1, enter the Outlet Pressure and Pump Efficiency data.
• For COMPRESSOR C-1, enter the Outlet Pressure and Adiabatic Efficiency.

When you have entered all the data, there should not be any red on the flowsheet. All stream
and unit labels should have black borders. If any of the unit or stream labels has a red border,
check for missing data.

• Save the simulation before continuing.

Step 9 Run the Simulation and View the Results

• Run the simulation by clicking Run.

You have already checked that your feed stream input data is correct, but let’s also check that
outlet stream 6 is correct.

• Select stream 6. Then Output | Data Review Window (or right-click | Data Review
Window) which will generate a property table for stream 6 (shown in Figure 10).

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Metric Units English Units

Figure 10: Data Review Window for Stream 6

Note: Before continuing, make sure PUMP P-1 produces a result of 1.71 kW (2.44 HP).

Step 10 Flowsheet Status

Heat Exchanger HX-1

After running the simulation, HEAT EXCHANGER HX-1 shows a message in the
Flowsheet Status window (Run | Status) as shown in Figure 11.

Note: At this point, heat and material balances are solved. Messages or Warnings occur
due to physical measurements or other situations the user needs to be aware. In some
cases, a change in inputs is desirable.

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16 Chiller Plant – Part 1

Figure 11: Flowsheet Status window

Zones analysis is useful for locating temperature pinches and phase changes that occur within
the heat exchanger. Calculation of the average temperature driving force using the conventional
logarithmic mean temperature difference (LMTD), derived from terminal temperature
differences, will not be accurate when phase changes occur. So, including the zones analysis
function is needed for an accurate lmtd calculation.

To clear this status:

• Open HEAT EXCHANGER HX-1’s Data Entry window.
• Click Zones Analysis.
• Select Include Zones Analysis.
• Click OK to PFD.
• Run the simulation.
Run the simulation again. The status has cleared.

Step 11 Save and Close the Simulation

You will use this simulation as the basis for Chiller Plant – Part 2.
• To save, File | Save.
• To close, File | Close.

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Chiller Plant – Part 2

OVERVIEW
Continue to build the chiller plant. Since you have already entered the units of measure,
thermodynamic method, components, and feed stream data in Part 1, you will not need to add
this data again.
Figure 1 shows the completed PFD for Chiller Plant - Part 2.

Figure 1: PFD of Chiller Plant – Part 2

The new equipment data and operating conditions are provided in Table 1.

Table 1: Equipment Data and Operating Conditions

Unit Description Data Metric English

Hotside Pressure Drop 35 kPa 5 psi

Gas to Gas
HX-2 Coldside Pressure Drop 35 kPa 5 psi
Exchanger
Approach Temp (Hot In - Cold Out) 5.5 C 10 F

Hotside Pressure Drop 35 kPa 5 psi

HX-3 Chiller Coldside refrigerant saturated liquid propane Temperature -30 C -22 F
Hotside Outlet Temp -25 C -13 F

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D-3 Cold Separator Adiabatic Separation with no pressure change -- --

V-1 Valve Outlet Pressure 1690 kPag 245 psig

SOLUTION STEPS

Step 1 Open the Existing Simulation

Use the previous example, CHILL1.prz as the basis for this exercise.
• Select the Start icon and select CHILL1.prz from the Most Recently Used list. Or
select File | Open and select file CHILL1.prz.
• Select File | Save As and save the file as CHILL2.prz.

Step 2 Add to the Process Flow Diagram

• Using Figure 1 as a guide, add units HX-2, HX-3, D-3, and V-1 to the flowsheet.

• Connect the vapor product stream from D-2 to HX-2.

• Add the remaining streams to the flowsheet and ensure that the unit names and
stream numbers are as illustrated in Figure 1.

Step 3 Enter Operating Conditions for Each New Unit Operation

• Open the new units (HX-2, HX-3, D-3, and V-1) and enter their data.

For HEAT EXCHANGER HX-3 (Chiller), click Utility Stream and choose Refrigerant as the
Utility Type. Select C3 from the Component list and enter the saturation temperature (as
shown in Figure 2).

Note: The refrigerant utility, used in unit HX-3, considers only latent heat effects, so the
refrigerant inlet and outlet conditions are a saturated liquid and a saturated vapor,
respectively.

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Figure 2: Cold Side Utility Stream (English units)

After inputting all needed data, there should not be any red borders on the flowsheet. All stream
and unit labels should have black borders. If any of the unit or stream labels has a red border,
double-click the unit operation and check the data.

• Save the simulation by clicking on Save.

Step 4 Run the Simulation and View the Results

• Run the simulation.
• Right-click on the cold separator overhead Stream 10 and select View Results
(Mass Units). The stream is all vapor.

Note: Clicking on View | Recycle and Reference Stream will highlight in green any
recycle or reference streams in the model. In this case, Stream 10 will be flagged as
a recycle stream.

• Generate an output report by selecting Output | Generate Text Report.

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20 Chiller Plant – Part 2

Look at Heat Exchanger HX-3 report in Figure 3.

• Find the flowrate of the refrigerant as you will use this rate as an initial estimate in
Part 3 of this exercise:

Metric Units English Units

Figure 3: Heat Exchanger HX-3 Results

Note: Some calculations, such as the utility calculations for the heat exchanger, are
performed during output generation and cannot be viewed by clicking View Text
Results.

Step 5 Flowsheet Status

After running the simulation, HEAT EXCHANGER HX-2 shows one message and one
warning, while HEAT EXCHANGER HX-3 shows a message (as shown in Figure 4).

Note: At this point, heat and material balances are solved. Messages or Warnings occur
due to physical measurements or other situations the user needs to be aware. In some
cases, a change in inputs is desirable.

Messages are considered as more informative notes, although it may suggest changes.
Warnings are considered as notes worth changing; in addition, the unit operation in question
will display in yellow. If you do not want to show warnings in yellow, you may suppress the
yellow temporarily.

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Figure 4: Flowsheet Status

Heat Exchanger HX-2

For HX-2, we notice the two statuses:
1) **warning** The lmtd correction factor (ft) has been set to 0.0001.
2) **message** The calculated lmtd is not accurate as one of the sides is undergoing
phase change and zones analysis is not specified. Zones analysis is included
automatically for accurate lmtd calculation.
For the warning, the software resets the lmtd correction factor to 0.0001, because a larger area
is needed to make a temperature change. When the figuration uses the default of 2 tube / 1
shell pass, an unreasonable amount of area is needed to use this configuration for the heat
exchanger.
Now, if we increase the tube and shell passes to 4 tube / 2 shell or 6 tube / 3 shell, the heat
exchanger area is more reasonable, a temperature change can be attained, and the warning is
eliminated.
For the message, we have learned why this occurs and how to clear this specific message in
Chiller Plant – Part 1. Including the zones analysis allows for an accurate lmtd calculation,
since there is a phase change.

To clear both statuses:

• Open HEAT EXCHANGER HX-2’s Data Entry window.
• Click Configuration.
o Set Tube Passes to 4 and set Shell Passes to 2.
o Click OK.
• Click Zones Analysis.

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22 Chiller Plant – Part 2

o Select Include Zones Analysis.

o Click OK to PFD.

Heat Exchanger HX-3

To clear this status:
• Open HEAT EXCHANGER HX-3’s Data Entry window.
• Click Zones Analysis.
o Select Include Zones Analysis.
o Click OK to PFD.
Run the simulation again. The statuses have cleared.

Step 6 Save and Close the Simulation

You will use this simulation as the basis for Chiller Plant – Part 3.
• To save, File | Save.
• To close, File | Close.

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Chiller Plant – Part 3

OVERVIEW
Continue to build the chiller plant. Suppose that the refrigerant for the chiller HX-3 consists of a
mixture rather than pure propane. You want to determine the flowrate of that mixture required to
maintain a fixed process stream (hotside) outlet temperature. Instead of using the Heat
Exchanger refrigerant utility, which is designed for use with single components, you now must
introduce a refrigerant stream, with the correct composition, and use a Controller to determine
the refrigerant flowrate.
Figure 1 shows the completed PFD.

Figure 1: PFD of Chiller Plant – Part 3

The refrigerant stream and equipment data are shown in Tables 1 and 2.

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24 Chiller Plant – Part 3

Table 1: Refrigerant Stream Composition Data

Component Alias Name Mole%

Ethane C2 2.5

Propane C3 97

i-Butane IC4 0.5

Feed Conditions Metric English

Pressure 80 kPag 11.5 psig

Thermal Condition Bubble Point

Table 2: Equipment Data and Operating Conditions

Unit Description Data Metric English

HX-3 Chiller Cold product liquid fraction 0 0

Hotside Pressure Drop 35 kPa 5 psi

Coldside Pressure Drop 0 kPa 0 psi

CN1 Controller Stream 9 Specification -25 °C -13 °F

(Temperature)

SOLUTION STEPS

Step 1 Open the Existing Simulation

• Use the previous example, CHILL2.prz, as the basis for this exercise.
• Save as CHILL3.prz.

Step 2 Change the Flowsheet Configuration

• Add a Controller unit to the flowsheet (PFD palette | Utilities).
• Remove the utility stream on Heat Exchanger HX-3 by double-clicking on the unit
and deactivating the check box for the utility stream.
• Add inlet and outlet streams to the cold side of HX-3.
• Name the inlet stream 50 and the outlet stream 51, respectively.

Step 3 Enter the Stream Data

• Enter the flowrate, composition, and define the thermal conditions for stream 50.
Even though the flowrate of this stream is going to be calculated by the controller, you must
enter a flowrate here. This not only satisfies the data requirements of the window but also
serves as an initial estimate.
• Use the propane refrigerant rate from the previous example as the initial flowrate for
this stream: 15,891 kg/hr (36,790 lb/hr). Ensure that the UOM is correct.

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Step 4 Enter the Unit Data

HEAT EXCHANGER HX-3

• Change the specification for HEAT EXCHANGER HX-3 so that the new refrigerant
stream exits at its dew point:
o Select the Cold Product Liquid Fraction specification and set the value to
0.00.
We have already learned that many exchangers will give us a Flowsheet Status message to use
the Zones Analysis. Let’s be proactive and request the zones to be calculated.
• Click Zones Analysis.
o Select Include Zones Analysis.
o Click OK to PFD.

CONTROLLER CN1
• Double-click on the CONTROLLER to open the Feedback Controller window.
You want to vary stream 50 flowrate so that the temperature of stream 9 is as shown
in Table 2.
In the Specification section of the Feedback Controller window:
• Click on Parameter.
• Choose stream 9 (hotside outlet stream for HEAT EXCHANGER HX-3) as the
stream to specify.
• Click on Parameter in the Parameter window (see Figure 2).

Figure 2: Controller - Parameter Window

• Select Temperature and click OK to return to the Feedback Controller window.

• Enter the temperature provided as the value of the hotside outlet temperature.
In the Variable section:
• Click on Parameter.
• Choose stream 50 as the stream to vary.
• Click on Parameter and select Flowrate as the variable.

When complete, the Feedback Controller window will look like Figure 3 below.

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Figure 3: Completed Feedback Controller Window (English units)

• Click OK to save the entries and return to the flowsheet.

• Save the simulation before continuing.

Step 5 Run the Simulation and View the Results

• Run the simulation.
• Create a STREAM PROPERTY TABLE to examine the inlet refrigerant stream 50
and outlet stream 51 conditions using the Property Label List. To do this, select
Output | Stream Property Table.

Metric Units

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English Units

Figure 5: Refrigerant Stream Results

• Figure 6 below shows the calculated data for stream 13 from a Stream Property
Table using the Comp. Molar Rates Property List.
• Make sure your results match before proceeding.

Metric Units English Units

Figure 6: Stream 13 Stream Property Table

Step 6 Save and Close the Simulation

You will use this simulation as the basis for Chiller Plant – Part 4.
• To save, File | Save.
• To close, File | Close.

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28 Chiller Plant – Part 4

Chiller Plant – Part 4

OVERVIEW
Continue to build the chiller plant. Add a Column and a Compressor. Use Mixers to combine the
plant liquid and vapor streams each into single product streams.

Figure 1: PFD of Chiller Plant – Part 4

Table 1: Equipment Data

Stabilizer Column T-1

Actual number of trays 22

Overall Tray Efficiency 55%

Feed location Tray 1

Metric English

Top Tray Pressure 1380 kPag 200 psig

Column Pressure Drop 17 kPa 2.5 psi

Bottom Product TVP 1620 kPag 235 psig

Compressor C-2

Outlet Pressure 4150 kPag 600 psig

Adiabatic Efficiency 73 % 73%

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SOLUTION STEPS

Step 1 Open the Existing Simulation

Use the previous example, CHILL3.prz, as the basis for this example.
• Open CHILL3.prz and save as CHILL4.prz.

Step 2 Add to the Process Flow Diagram

• Place a COMPRESSOR, two MIXERS and a COLUMN on the PFD.
• Connect the streams as shown in Figure 1.
• Name the units and streams appropriately.
When you place the COLUMN, you will be asked to give the number of theoretical trays and to
state whether the COLUMN has a condenser and a reboiler.

Note: Table 1 gives actual trays and tray efficiency. From this you must calculate the
number of theoretical trays in the body of the column. To calculate the theoretical number of
trays, multiply the actual number of trays and the overall tray efficiency (22*55% = 12
stages). The kettle Reboiler is simulated as a theoretical stage, and thus is stage 13. This
column has no condenser, so uncheck the Condenser check box.

Step 3 Enter the Unit Data

Mixers require no data. Enter the COMPRESSOR data from the table.

• Double-click on the COLUMN. Check that Number of Stages is correct and that the
default selections for Algorithm and Calculated Phases are appropriate to your
simulation.
• Click Pressure Profile and enter the Top Tray Pressure and the Pressure Drop for
the entire COLUMN.
• Click Feeds and Products to set the feed tray number. Check that the default entry
for the Phase of each product is correct.

Estimate the rate of the overhead product. You can make a good guess from the results of the
previous run using Figure 2 as a guide. You could also use the Define function, assuming that
the overhead stream consists of all the Nitrogen through Methane from the column feed.
To access the Define function, click the data entry field for the overhead rate, and click Define
at the top of this window.
Note that the Define refers to stream 13, which is the column feed (and not the overhead rate).
Also, the Define assumes that the components N2 to C1 were initially selected as Components
in order of increasing volatility.

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Figure 2: Overhead Flowrate Definition (English units)

• Click Reboiler to check that Kettle (Conventional) has been selected.

• Click Initial Estimates to select the Conventional initial estimate generation
method.
• Click Performance Specifications to enter the true vapor pressure specification.
o If not already checked, check the Add Specifications and Variables box.
o In the Specifications grid, click on Parameter, choose the bottoms stream
15, and select Vapor Pressure from the Parameter list and True Vapor
Pressure from the Vapor Pressure list.
o Click OK to return to the Specifications and Variables window and enter the
appropriate value.
o If not already entered, in the Variables grid, click on Parameter, choose
Column and select Heat Duty of the Reboiler from the lists.
o The completed window is shown in Figure 3.

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Figure 3: Bottoms True Vapor Pressure Specification (English units)

• Click OK to return to the PFD and save the simulation.

Step 4 Run the Simulation

• Run the simulation.
For METRIC users, observe that PUMP P-1 has a warning. In Step 6, you will be
provided instruction to clear this warning.

Note: If at any time a simulation fails (particularly a complex simulation with column(s) or
recycles), it is advised to Restore Input Data if the model has already been run (Input |
Restore Input Data).

Step 5 View the Results

• Select the column. Right click and select the View Excel Results option to generate
the fixed format Excel summary of the column as shown in Figure 4.
• Check the reboiler duty required to meet the liquid product specification.

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Metric Units

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English Units

Figure 4: Column T-1 Profile Summary

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34 Chiller Plant – Part 4

• To setup the plot output to Excel, select Options | Plot and select SIMSCI or Excel.
In this example, we will use SIMSCI.

• To generate the plot, select Output | Generate Plot.

• Plot Overview of Temperature and Flowrates for T-1 (Column), shown in Figure 5.
You may view the plot directly on the PFD.
As you make changes to the simulation, this plot will automatically update. You can transfer this
plot to Excel by right-clicking the plot and selecting Export to Excel.

Metric Units

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 Chiller Plant – Part 4 35

English Units

Figure 5: Column T-1 Plot

• Double-click on COLUMN T-1.

• Click Print Options.

Figure 6: Column T-1 Data Entry Window

• In Column Print Options, check Tray Loading Summary and KGTower/FRI Data
in XML File.

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36 Chiller Plant – Part 4

Figure 7: Column Print Options Window

• Run and generate output.

• The additional output requested will now be available in Tools | Spreadsheet |
Distillation under the TrayLoadingReport tab in Excel.

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 Chiller Plant – Part 4 37

Figure 8: Tray Loading Report from Distillation Report (English units)

Step 6 Flowsheet Status

After running the simulation when using METRIC units, PUMP P-1 shows a warning (as
show in Figure 9).

This warning is due to the feed being very close the bubble point line. In the METRIC version, it
just moves over into mixed phase region, hence the warning at the pump.
A check (adding a bubble point flash) showed the mixtures bubble point at 1397 kPag to be
30.31 C, and the pump inlet is 33.11 C.
In the ENGLISH version, the mixture’s bubble point at 202.5 psig is 86.5 F, and the pump inlet
is 86.49 F, so just in the liquid region.

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38 Chiller Plant – Part 4

Figure 9: Flowsheet Status for METRIC units only

AVEVA™ Training
 Debutanizer with Assay 39

Debutanizer with Assay

OVERVIEW
A debutanizer removes C4 and lighter components from a mixed Naphtha and LPG feed
stream. The Naphtha feed has been changed, and you must ensure that the column can still
meet the process requirements such as product recoveries and column duties. The column
must recover 99% of the C4 components in the overhead product, and the overhead should
also contain a maximum of 1% of the C5’s in the column feed.

Figure 1: Debutanizer Process

Simulation Objectives
1) Calculate the duties of the condenser and reboiler to achieve these operating objectives.
2) Calculate the reflux ratio and rate.
3) Create a Unit Operation Property Table to show the column operating conditions and a
Stream Property Table to show the process material balance.

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40 Debutanizer with Assay

Table 1: LPG Feed Data

Metric English

Temperature 40°C 100°F

Pressure 19 bar 275 psia

Flowrate (Liq. Vol.) 11 m3/hr 70 bbl/hr

Component Mole %

H2 0.3

H2S 0.2

C1 0.7

C2 5.5

C3 28.5

IC4 11.7

NC4 49.0

IC5 4.1

Table 2: Naphtha Feed Data

Metric English

Temperature 40°C 100°F

Pressure 19 bar 275 psia

Flowrate (Liq. Vol.) 90 m3/hr 560 bbl/hr

ASTM D86 Data

Liquid Volume % °C °F

0 40 104

5 62 144

10 70 158

30 91 196

50 109 228

70 120 248

90 140 284

95 155 311

100 165 329

Average Specific Gravity = 0.75

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 Debutanizer with Assay 41

Table 2: Naphtha Feed Data (cont.)

Lightends Data

(10% Liquid Volume)

Component Mole %

C3 0.07

IC4 0.21

NC4 0.42

IC5 3.24

NC5 6.06

Table 3: Equipment Data and Operating Conditions

Unit Description Data Metric English

PREHEAT Flash Temperature 160°C 320°F

Pressure Drop 0.5 bar 6 psi

DEBU Column Condenser Type Bubble

Reboiler Type Kettle

Feed Location Tray 18

Condenser Pressure 13 bar 185 psia

Top Tray Pressure 13 bar 190 psia

Column Pressure Drop 0.5 bar 4 psi

SOLUTION STEPS

Step 1 Define Input Units of Measurement (UOM)

• Select Input | Units Of Measure to set the default units of measure.
• Select your preferred UOM based on the information provided and use consistent
UOM throughout. Check the temperature, pressure, and liquid volume flowrate units
for consistency with the input data.

Note: For Metric units, set Pressure to bar (abs).

Step 2 Define the Components

• Select Input | Component Selection to open the Component Selection window.
• Add all of the pure components.

Reminder: Don’t forget to add NC5, which is listed under the Lightends Data in Table 2.

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42 Debutanizer with Assay

Step 3 Select the Thermodynamic Method

• Select Input | Thermodynamic Data
• From the list of Most Commonly Used methods, select Soave-Redlich-Kwong.

Step 4 Build the Flowsheet

• Add a FLASH DRUM and COLUMN on the PFD.
• Connect streams, as shown in Figure 1.

Note: When connecting the OVHD stream, connect it to the liquid port of the condenser.

Step 5 Define the Feed Streams

LPG Feed
• Double-click on the LPG feed stream and enter the data from Table 1 into the
Stream Data window. Note that the flowrate is in liquid volume units.

Naphtha Feed
• Double-click on the NAPHTHA feed stream and enter the data from Table 2 into the
Stream Data window.
• Under Stream Type, select Petroleum Assay.
• Click Flowrate and Assay to define the assay.
• Enter the flowrate and then click Define/Edit Assay to open the Assay Definition
window. Note that the flowrate is in liquid volume units.

To enter assay data:

• Select ASTM D86 as the Distillation type.
• Select Specific Gravity as the Gravity Data option and enter 0.75.
• Using the default D86 settings, enter the boiling point curve.

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 Debutanizer with Assay 43

Figure 2: Assay Definition Window (English units)

To enter lightends data:

• Click Lightends and check the Assay lightends information for stream
NAPHTHA box.
• Enter the Specification of Total Lightends Flowrate as a Percent of Assay on
a Liquid Volume basis, then enter the composition of each lightend.

Figure 3: Assay Lightends Data Window

Introduction to AVEVA™ PRO/II™ Simulation

44 Debutanizer with Assay

• Check the Normalize Component Flowrates based on Specified Total

Flowrate box as the supplied composition does not sum to 1.0 or to 100.

Step 6 Specify Unit Operating Conditions

Flash – PREHEAT
The flash drum simulates the mixed feed preheat. Enter the appropriate values from Table 3
depending on the chosen UOM.

Column – DEBU
• Open COLUMN DEBU’s Data Entry Window.
Pressure Profile
• Click Pressure Profile and enter the Top Tray Pressure and the Column Pressure
Drop. The Condenser Pressure will be defined in the Condenser data entry
window.
Feeds and Products
• Click Feeds and Products and specify the Feed Tray as 18.
• Supply an estimate for either the overhead or bottoms product.
o A numerical value can be provided but a better method that will work under a
wide range of column feed condition changes is to use the DEFINE feature.
o With the cursor in the Overhead Product Rate data entry field, click Define at
the top of the window and set the overhead rate as all of the C4 and lighter
components in the column feed as shown in Figure 4.

Figure 4: OVHD Flowrate Definition (English units)

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 Debutanizer with Assay 45

Reboiler
The default reboiler type is a Kettle reboiler.
• Open Reboiler to view the available options and additional data that can be
provided.
Condenser
The condenser will automatically be set to Bubble Temperature, because you
connected the product to the overhead liquid port.
• Click Condenser window and specify the condenser pressure.
Initial Estimates
This is a conventional column with condenser and reboiler.
• Click Initial Estimates, and for the Initial Estimate Generation, select the
Conventional method. No other estimates are required.
• Click No to use the reflux estimate as a specification.
Performance Specifications
• Click Performance Specifications.
o Enter the following Specifications:
1) Set the C4s recovery in the overhead to be 99%
2) Set the C5s recovery in the overhead to be 1%
o Vary the reboiler and condenser duties to meet these specifications

Figure 5: Column Performance Specifications (English units)

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46 Debutanizer with Assay

Step 7 Run Simulation and Generate Output

• Select Run | Run + Output to solve the simulation and generate the output.

Step 8 View the Results

As the column has converged with the required recovery specifications, it can clearly cope with
the new feed. The calculated values for the specifications, along with the duties and the reflux
ratios, are shown in the column output.

• Generate the text report (Output | Generate Text Report).

In addition, create your own Unit Ops property table for the column displaying the reflux ratio
and duties.

Add a Unit Op Property Table

• Select Options | UnitOps Lists
• Under the Unit Type drop-down list, select Column. This will display the default
Column property list.
• Add Column Reflux Ratio and Column Reflux Rate (Mass) to the property list.
• Adjust the number of significant digits that are shown past the decimal by editing the
format field for each property. For example, reduce the number of significant digits
for Temperature and Pressure.
• Click Save As and save under a unique name.
• Add a UNIT OP PROPERTY TABLE on the flowsheet.
• Double-click on the table and select the new table you created.
• Add the column DEBU from Available Units to Displayed Units.

Add a Stream Property Table

• Add a STREAM PROPERTY TABLE on the flowsheet.
• Double-click on the table and select the Material Balance List.
• Include all flowsheet feeds and products in the table.

The Unit Op Property Table and Stream Property Table are shown below for both UOM.

Metric Units

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 Debutanizer with Assay 47

English Units

Figure 6: Unit Op Property Tables for Column DEBU

Metric Units

Introduction to AVEVA™ PRO/II™ Simulation

48 Debutanizer with Assay

English Units

Figure 7: Material Balance List Stream Property Tables

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 Debutanizer with Petroleum Components 49

Debutanizer with Petroleum Components

OVERVIEW
A debutanizer removes C4 and lighter components from a mixed Naphtha and LPG feed
stream. The Naphtha feed has been changed, and you must ensure that the column can still
meet the process requirements such as product recoveries and column duties. The column
must recover 99% of the C4 components in the overhead product, and the overhead should
also contain a maximum of 1% of the C5’s in the column feed.

Figure 1: Debutanizer Process

Simulation Objectives
4) Calculate the duties of the condenser and reboiler to achieve these operating objectives.
5) Calculate the reflux ratio and rate.
6) Create a Unit Operation Property Table to show the column operating conditions and a
Stream Property Table to show the process material balance.

Introduction to AVEVA™ PRO/II™ Simulation

50 Debutanizer with Petroleum Components

Table 1: LPG Feed Data

Metric English

Temperature 40°C 100°F

Pressure 19 bar 275 psia

Flowrate (Liq. Vol.) 11 m3/hr 70 bbl/hr

Component Mole %

H2 0.3

H2S 0.2

C1 0.7

C2 5.5

C3 28.5

IC4 11.7

NC4 49.0

IC5 4.1

Table 2: Naphtha Feed Data

Metric English

Temperature 40°C 100°F

Pressure 19 bar 275 psia

Flowrate (Liq. Vol.) 90 m3/hr 560 bbl/hr

Component Mole %

C3 0.1

IC4 0.2
NC4 0.5

IC5 3.8

NC5 7.0

Cut1 4.0

Cut2 9.2

Cut3 17.8

Cut4 41.0

Cut5 16.4

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 Debutanizer with Petroleum Components 51

Table 3: Petroleum Component Information (Metric units)

Component NBP (°C) Specific Gravity MW

Cut1 47 0.72 73.6

Cut2 58 0.728 78.4

Cut3 79 0.743 87.9

Cut4 115 0.767 106.1

Cut5 155 0.793 128.8

Table 4: Petroleum Component Information (English units)

Component NBP (°F) API Gravity MW

Cut1 117 65.1 73.6

Cut2 137 62.9 78.4

Cut3 175 59 87.9

Cut4 239 53 106.1

Cut5 312 46.9 128.8

Table 5: Equipment Data and Operating Conditions

Unit Description Data English English

PREHEAT Flash Temperature 160°C 320°F

Pressure Drop 0.5 bar 6 psi

DEBU Column Condenser Type Bubble

Reboiler Type Kettle

Feed Location Tray 18

Condenser Pressure 13 bar 185 psia

Top Tray Pressure 13 bar 190 psia

Column Pressure Drop 0.5 bar 4 psi

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52 Debutanizer with Petroleum Components

SOLUTION STEPS

Step 1 Define Input Units of Measurement (UOM)

• Select Input | Units Of Measure to set the default units of measure.
• Select your preferred UOM based on the information provided and use consistent
UOM throughout. Check the temperature, pressure and liquid volume flowrate units
for consistency with the input data.

Note: For Metric units, set Pressure to bar (abs).

Step 2 Define the Components

• Select Input | Component Selection to open the Component Selection window.
• Add all of the pure components.

Reminder: Don’t forget to add NC5, which is listed under Table 2.

• Create 5 new petroleum components using the NBP, Gravity, and MW information
provided in Table 3 or 4.

Step 3 Select the Thermodynamic Method

• Select Input | Thermodynamic Data
• From the list of Most Commonly Used methods, select Soave-Redlich-Kwong.

Step 4 Build the Flowsheet

• Add a FLASH DRUM and COLUMN on the PFD.
• Connect streams, as shown in Figure 1.

Note: When connecting the OVHD stream, connect it to the liquid port of the condenser.

Step 5 Define the Feed Streams

LPG Feed
• Double-click on the LPG feed stream and enter the data from Table 1 into the
Stream Data window. Note that the flowrate is in liquid volume units.

Naphtha Feed
• Double-click on the NAPHTHA feed stream and enter the data from Table 2 into the
Stream Data window. Note that the flowrate is in liquid volume units.

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 Debutanizer with Petroleum Components 53

Step 6 Specify Unit Operating Conditions

Flash – PREHEAT
The flash drum simulates the mixed feed preheat. Enter the appropriate values from Table 5
depending on the chosen UOM.

Column – DEBU
• Open COLUMN DEBU’s Data Entry Window.
Pressure Profile
• Click Pressure Profile and enter the Top Tray Pressure and the Column Pressure
Drop. The Condenser Pressure will be defined in the Condenser data entry
window.
Feeds and Products
• Click Feeds and Products and specify the Feed Tray as 18.
• Supply an estimate for either the overhead or bottoms product.
o A numerical value can be provided but a better method that will work under a
wide range of column feed condition changes is to use the DEFINE feature.
o With the cursor in the Overhead Product Rate data entry field click Define at
the top of the window and set the overhead rate as all of the C4 and lighter
components in the column feed as shown in Figure 2.

Figure 2: OVHD Flowrate Definition (English units)

Introduction to AVEVA™ PRO/II™ Simulation

54 Debutanizer with Petroleum Components

Reboiler
The default reboiler type is a Kettle reboiler.
• Open Reboiler to view the available options and additional data that can be
provided.
Condenser
The condenser will automatically be set to Bubble Temperature, because you
connected the product to the overhead liquid port.
• Click Condenser window and specify the condenser pressure.
Initial Estimates
This is a conventional column with condenser and reboiler.
• Click Initial Estimates and for the Initial Estimate Generation, select the
Conventional method. No other estimates are required.
• Click No to use the reflux estimate as a specification.
Performance Specifications
• Click Performance Specifications.
o Enter the following Specifications:
1) Set the C4s recovery in the overhead to be 99%
2) Set the C5s recovery in the overhead to be 1%
o Vary the reboiler and condenser duties to meet these specifications.

Figure 3: Column Performance Specifications (English units)

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 Debutanizer with Petroleum Components 55

Step 7 Run Simulation and Generate Output

• Select Run | Run + Output to solve the simulation and generate the output.

Step 8 View the Results

As the column has converged with the required recovery specifications, it can clearly cope with
the new feed. The calculated values for the specifications, along with the duties and the reflux
ratios, are shown in the column output.

• Generate the text report (Output | Generate Text Report).

In addition, create your own Unit Ops property table for the column displaying the
reflux ratio and duties.

Add a Unit Op Property Table

• Select Options | UnitOps Lists
• Under the Unit Type drop-down list, select Column. This will display the default
Column property list.
• Add Column Reflux Ratio and Column Reflux Rate (Mass) to the property list.
• Adjust the number of significant digits that are shown past the decimal by editing the
format field for each property. For example, reduce the number of significant digits
for Temperature and Pressure.
• Click Save As and save under a unique name.
• Add a UNIT OP PROPERTY TABLE on the flowsheet.
• Double-click on the table and select the new table you created.
• Add the column DEBU from Available Units to Displayed Units.

Add a Stream Property Table

• Add a STREAM PROPERTY TABLE on the flowsheet.
• Double-click on the table and select the Material Balance List.
• Include all flowsheet feeds and products in the table.

The Unit Op Property Table and Stream Property Table are shown below for both UOM.

Metric Units

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56 Debutanizer with Petroleum Components

English Units

Figure 4: Unit Op Property tables for Column DEBU

Metric Units

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 Debutanizer with Petroleum Components 57

English Units

Figure 5: Material Balance List Stream Property Tables

Introduction to AVEVA™ PRO/II™ Simulation

58 Light Ends Fractionation Train

Light Ends Fractionation Train

OVERVIEW
In this example, you will simulate light ends fractionation with tray hydraulics in the columns.
As part of this task, you will specify the following:
• Size each column for valve trays through the Tray Hydraulics/Packing window.
• Use I/O (Inside-Out) as the distillation algorithm for the column calculations.
• Use Conventional as the Initial Estimate Generation method.
• Vary the column duties to meet the specifications given in Table 4.
• Similar to the Chiller Plant exercises, use the Peng-Robinson thermodynamic
method with Petroleum Correlations (Modify | Transport Properties).

Figure 1: Light Ends Fractionation Train

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 Light Ends Fractionation Train 59

Table 1: Feed Streams Composition Data

Stream 19 – Chiller Plant Liquids 60 – Royal Gas Liquids

Component Composition Mole % Composition Mole %

Nitrogen 0.0015 0.015

Carbon dioxide 0.41 0.265

Methane 0.35 0.60

Ethane 23.57 18.74

Propane 32.21 32.99

i-Butane 7.58 11.70

n-Butane 19.25 22.49

i-Pentane 3.79 1.50

n-Pentane 7.65 7.20

C6+ 5.19 4.5

C6+ Properties Metric English

NBP 99C 210F

Gravity 690 kg/m3 73 API

Table 2: Feed Streams Flow & Thermal Condition Data

Stream 19 – Chiller Plant Liquids

Metric English

Temperature 38 °C 92 °F

Pressure 3900.0 kPag 550 psig

Rate 271 kg-mol/hr 600 lb-mol/hr

Stream 60 – Royal Gas Liquids

Temperature 38 °C 100 °F

Pressure 4240 kPag 600 psig

Rate 303 kg-mol/hr 670 lb-mol/hr

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60 Light Ends Fractionation Train

Table 3: Column Data

Column Name T-2 Deethanizer

Condenser Type Partial

Metric English

Condenser Pressure 2930 kPag 410 psig

Top Tray Pressure 2960 kPag 415 psig

Column Pressure Drop 34 kPa 5 psi

Theoretical Stages 24

Feed Location Tray 13

Column Name T-3 Depropanizer

Condenser Type Subcooled, Fixed Temperature

Metric English

Condenser Pressure 1760 kPag 240 psig

Condenser Temperature 43 °C 110 °F

Top Tray Pressure 1790 kPag 245 psig

Column Pressure Drop 34 kPa 5 psi

Theoretical Stages 23

Feed Location Tray 11

Column Name T-4 Debutanizer

Condenser Type Subcooled, Fixed Temperature

Metric English

Condenser Pressure 790 kPag 100 psig

Condenser Temperature 43 °C 110 °F

Top Tray Pressure 825 kPag 105 psig

Column Pressure Drop 34 kPa 5 psi

Theoretical Stages 26

Feed Location Tray 14

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 Light Ends Fractionation Train 61

Table 4: Column Specifications

T-2 Deethanizer

C3 overhead product composition 2 mol %

C2/C3 mole ratio in bottom product 0.025

T-3 Depropanizer

C4s overhead product composition 2 mol %

C3 bottom product composition 2 mol %

T-4 Debutanizer

IC5 overhead product composition 0.25 liq vol %

NC4 bottom product composition 1 liq vol %

Table 5: Valve Operating Conditions

Outlet Pressure

Unit Metric English

Valve V-2 3030 kPag 425 psig
Valve V-3 1890 kPag 260 psig
Valve V-4 1000 kPag 130 psig

SOLUTION STEPS
• Build the flowsheet.
Note that the components and thermodynamics are the same, so you could start with one of the
earlier chiller plant models to save having to re-enter this data.
In addition, we suggest building the model stage-wise: adding one column at a time, ensuring
the model converges and the results look reasonable before adding the next column.

Hint: You will need to provide a flowrate estimate for one product in each column in the
Feeds and Products data entry window. Use the DEFINE feature to provide these
estimates.
The default Unit Operation Property Table summary of the calculated duties for the column
condensers and reboilers can be seen in Figure 2.

Metric Units

Introduction to AVEVA™ PRO/II™ Simulation

62 Light Ends Fractionation Train

English Units

Figure 2: Column Condenser & Reboiler Duties

The Material Balance List stream property table for key streams is shown in Figure 3 below.

Figure 3: Material Balance SPT for Key Streams

For column T-2, plot Vapor and Liquid Compositions of ethane and propane on a single plot.
To do this:
• Select Output | Generate Plot.
• Under Units for Selection, select T-2 (Column).
• Under Available Plots, select Vapor and Liquid Compositions.
• Click Options.
• On line 1, select Vapor as the Phase. Then select C2 as the Starting Component
and the Ending Component.
• On line 2, select Liquid as the Phase. Then select C2 as the Starting Component
and the Ending Component.
• On line 3, select Vapor as the Phase. Then select C3 as the Starting Component
and the Ending Component.

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 Light Ends Fractionation Train 63

• On line 4, select Liquid as the Phase. Then select C3 as the Starting Component
and the Ending Component.
• Click Plot.
• Compare your results as shown in Figure 4.

For column T-3, plot the Separation Factor of the light (C3) and heavy components (IC4 to
NC4). To do this:
• Select Output | Generate Plot.
• Under Units for Selection, select T-3 (Column).
• Under Available Plots, select Separation Factor.
• Click Options.
• Under Separation Factor Light Key, select C3 as the Starting Component and the
Ending Component.
• Under Separation Factor Heavy Key, select IC4 as the Starting Component and
select NC4 as the Ending Component.
• Click Plot.
• Compare your results as shown in Figure 5.

For column T-4, plot the Overview of Temperature and Flowrates. To do this:
• Select Output | Generate Plot.
• Under Units for Selection, select T-4 (Column).
• Under Available Plots, select Overview of Temperature and Flowrates.
• Click Plot.

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64 Light Ends Fractionation Train

Figure 4: Mole Fractions of Ethane and Propane in Column T-2

Figure 5: Separation Factor in Column T-3

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 Light Ends Fractionation Train 65

Figure 6: Overall Temperature and Flowrate Profiles in Column T-4

Tray Sizing
When sizing a column (unless the user specifies a flooding factor), the software will use its own
default settings.
These defaults vary depending on the column diameter as shown:

Table 6: Column Diameter and Flooding Factor

Diameter Range
Flooding Factor
Metric English

0 to 609.6 mm 0 to 2 ft 70

609.6 to 1219 mm 2 to 4 ft 75

1219 to 3060 mm 4 to 10 ft 78

3060 to 15 240 mm 10 to 50 ft 80

As the tray loading may vary throughout a column, you may see a range of different column
sizes calculated by the software.
Examining the tray sizing results, the Next Largest Diameter for T-3 indicates that tray
diameters in the range of 1372 to 1676 mm (54 to 66 inches) are required, so an overall column
diameter of 1676 mm (66 inches) would be adequate.
Similarly for T-4, the software calculates a Next Largest Diameter of 1219 to 1372 mm (48 to
54 inches), thus a 1372 mm (54 inch) diameter column would be adequate.

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66 Light Ends Fractionation Train

Examining the tray sizing results for T-2, the range in the Next Largest Diameter is from 914
mm (36 inches) at the feed tray to 1829 mm (72 inches) as shown in the text output report
below (Figure 7).
Many decisions are made in the design of distillation columns; most determined by economics
and company practice.
The point of this exercise is to confirm that the products can be separated with three reasonable
columns. However, the final process design may be quite different.

Metric Units

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 Light Ends Fractionation Train 67

English Units

Figure 7 : Column T-2 Tray Sizing Results

Introduction to AVEVA™ PRO/II™ Simulation

68 Naphtha Assay – Part 1

Naphtha Assay – Part 1

OVERVIEW
Enter the assay data for the Naphtha Feed described below and generate a set of petroleum
components. Also, create a plot of the calculated TBP curve and component cuts. The light
ends make up 5% of the total liquid volume. Use the Soave-Redlich-Kwong (SRK)
thermodynamic method to model the system.
To represent the boiling curve more closely, increase the number of pseudocomponents by
using twenty-one 10°C (18°F) cuts from 30°C to 240°C (80°F to 460°F).
The feed condition and assay data are given in Tables 1 and 2.
Table 1: Naphtha Feed D86 Data

Metric English

LV% °C °F

3 32 90

5 52 125

10 90 195

30 121 250

50 138 280

70 154 310

90 199 390

95 214 418

98 221 430

Average Gravity 0.762 Sp Gr 54.2 °API

Fluid Flowrate 450 kg/hr 1000 lb/hr

Temperature 38 °C 100 °F
Pressure 101.3 kPa 1 atm

Table 2: Naphtha Feed Light Ends

Component Alias Name Molar Composition

Isobutane iC4 0.7

n-Butane nC4 2.15

Isopentane iC5 0.86

n-Pentane nC5 3.58

Total 5% Liquid Volume

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 Naphtha Assay – Part 1 69

SOLUTION STEPS
• Create a new simulation by selecting File | New.

Step 1 Modify the Input Units of Measure

• Select Input | green-bordered Units Of Measure
• Change the UOM basis, if needed, by clicking on Initialize from UOM Library
• Once a basis has been selected, make any specific modifications using the individual
drop down lists.
If you have modified UOM, notice that the border of the UOM button is now blue.

Step 2 Define the Components for the Light Ends

• Select Input | red-bordered Component Selection
• Click Select from Lists
• Under Component Databank, select Hydrocarbon Lightends
• Select the components from the list displayed in the order shown in Table 2.

Step 3 Select the Thermodynamic Method

• Select Input | red-bordered Thermodynamic Data
• From the Most Commonly Used Category, select Soave-Redlich-Kwong

Step 4 Build the Process Flow Diagram

• On the PFD palette, click on the red-bordered Streams button and add a stream to
the PFD.

Step 5 Modify the Assay Characterization Data

To represent the boiling curve more closely, you must increase the number of
pseudocomponents by using twenty-one 10°C (18°F) cuts from 30°C to 240°C (80°F to 460°F).

• Select Input | Assay Characterization

• Click Modify Primary Set
o Change the Minimum Temperature for First Interval to 30°C (80°F).
o In the first row, enter 240°C (460°F) as the Maximum Temperature for
Interval and 21 as the Number of Pseudocomponents in Interval.
o Leave the default data for the second and third intervals as they are.
o Click OK.
• Click Characterization Options
o Under Distillation Boundaries, change the Initial point from its default of
1% to 3%.
o Click OK to PFD.

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70 Naphtha Assay – Part 1

Step 6 Define the Assay Stream

• Double-click on the stream and change the Stream name to NAPHTHA_FEED.
• Under Stream Type, select Petroleum Assay.
• Click Flowrate and Assay.
• Enter the Fluid Flowrate.

To define a new assay:

• In the Stream Data – Flowrate and Assay window, click Define/Edit Assay.
• Select ASTM D86 and enter the distillation data in the grid.
You can use the <Tab> key to move from cell to cell in the grid.
• Select the appropriate Gravity Data option and enter the average value.

Figure 1: Stream Data – Assay Definition (English units)

To enter the lightends composition:

• In the Assay Definition window, under Additional Data, click Lightends.
• Check the Assay lightends information for stream NAPHTHA_FEED box.
• Enter the molar composition of each component in the grid.
• Select Percent of Assay and enter 5 as the Liquid Volume percent.
• Because the lightends compositions do not add up to 1 or 100, you must check the
Normalize Component Flowrates Based on Specified Total Flowrate box.
• Click OK.

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 Naphtha Assay – Part 1 71

Figure 2: Stream Data – Assay Lightends Data

• Back in the Stream Data window, enter the Temperature and Pressure values.
• Click OK.
• When asked whether you want to generate the pseudocomponents now or at a later
time, click No.

Step 7 Generate the Pseudocomponents

• You can generate the pseudocomponents at any time. To do this, select Input |
Generate Assay Components.

• To view the list of pseudocomponents, select Input | Component Selection.

• To look at the petroleum property data generated for the pseudocomponents,

generate an output report (Output | Generate Text Report).

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72 Naphtha Assay – Part 1

Metric Units

English Units

Figure 3: Petroleum Property Data Generated for the Pseudocomponents

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 Naphtha Assay – Part 1 73

Step 8 Generate the Plot

• Double-click stream NAPHTHA_FEED.
• Click Flowrate and Assay | Define/Edit Assay | View Curve
• View the results as shown in Figure 3 below.

Metric Units

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74 Naphtha Assay – Part 1

English Units

Figure 4: Assay Processing Plot

Step 9 Save and Close the Simulation

You will use this simulation as the basis for Naphtha Assay – Part 2.
• To save, File | Save.
• To close, File | Close.

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 Naphtha Assay – Part 2 75

Naphtha Assay – Part 2

OVERVIEW
In this exercise, you will use the assay stream you created in NAPHTH1.prz and manipulate it
using two flash drums. The first flash drum predicts the temperature at which 80 mole % of the
feed is recovered in the vapor. The second flash drum predicts the quantity of liquid that drops
out when a temperature drop is imposed on that vapor.

Figure 1: PFD of Naphtha Assay – Part 2

Table 1: Equipment Data and Operating Conditions

Unit Description Data Metric English

F1 Flash Drum Pressure 81 kPa 0.8 atm

80/20 vapor/liquid (molar basis split)

F2 Flash Drum Temperature Drop 10°C 18°F

Pressure Drop 10 kPa 0.1 atm

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76 Naphtha Assay – Part 2

SOLUTION STEPS

Step 1 Open and Save the Simulation

• Open simulation NAPHTH1.prz and save it under a new name: NAPHTH2.prz.

Step 2 Build the Process Flow Diagram

• Add two flash drums to the PFD and connect as shown in Figure 1.
• Connect the stream NAPHTHA_FEED to the first flash drum.
• Add the remaining streams to the flowsheet and ensure that the unit names and
stream numbers are as illustrated in Figure 1.

Step 3 Enter Unit Operating Conditions

• Enter the unit data from Table 1 into both flash drums.

Flash – F1
• Enter the Pressure and Vapor Mole Fraction.
The completed window for Flash F1 is shown in Figure 2 below.

Figure 2: Completed Flash Drum Window for F1 (English units)

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 Naphtha Assay – Part 2 77

Flash – F2
Because a temperature drop is specified, the temperature of Flash F2 is unknown until the first
flash has executed, thus you cannot enter an absolute value at this time.
You can, however, enter a relative value using the Define function as shown in Figure 3. Notice
that when this is set up, the word DEFINED appears in the Temperature field.

Figure 3: Completed Flash Drum Window for F2 (English units)

• To accomplish the above, click the Temperature field, click Define.

• In the Definition window, check the Set Up Definition box.
• To set up a temperature drop specification click on = and select = Parameter –
Parameter from the list.
• For the first Parameter, select the Temperature of Stream F1VAPOR (the feed
stream to the second flash drum).
• For the second Parameter, select Constant and enter the temperature difference
value in the box.

The completed Definition window is shown in Figure 4.

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78 Naphtha Assay – Part 2

Figure 4: Completed Definition Window for F2 (English units)

Step 4 Add a Stream Property Table

• Add a STREAM PROPERTY TABLE.
• Double-click and choose to display a Short Property List for all the streams in the
flowsheet.

Note: Configure the Stream Property Table by selecting Options | Stream Property Lists.

Step 5 Run the Simulation and View the Results

• Run the simulation.
• Observe the temperatures, pressures and flowrates. Verify that they accurately
reflect the specifications you entered.

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 Naphtha Assay – Part 2 79

Figure 4: Short Property Table

Step 7 Save and Close the Simulation

You will use this simulation as the basis for Naphtha Assay – Part 3.
• To save, File | Save.
• To close, File | Close.

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80 Naphtha Assay – Part 3

Naphtha Assay – Part 3

OVERVIEW
Using the assay stream and flashes from NAPHTH2, you will now examine the effects of
varying the vapor/liquid split in the first flash drum on the duty of the second flash drum.
Run case studies at vapor fractions from 80% (the base case) to 40% in 10% increments.

SOLUTION STEPS

Step 1 Open and Save the Simulation

• Open simulation NAPHTH2.prz and save it under a new name: NAPHTH3.prz.

Step 2 Enter Case Study Data

• Select Input | Case Study to open Case Study Parameters and Results.
• Check the Define Case Study box.
• In the first row of the Parameters field, click PARAM1 to rename the parameter to
F1SPLIT.
• Click Parameter and select Flash F1.
• Click Parameter and select Vapor Mole Fraction.
• Specify 5 cycles and a step size of –0.1.
• In the first row of the Results field, click RESULT1 to rename the result to F2DUTY.
• Click Parameter and select Flash F2 and Duty.

Figure 1 shows the completed Case Study Parameters and Results window.

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 Naphtha Assay – Part 3 81

Figure 1: Completed Case Study Parameters Window (English units)

• Click OK to return to the PFD.

Step 3 Run the Simulation

• Click Run to run the simulation.

Step 4 View Output in a Tabular Format

• Select Output | Tables to open the Case Study Tables window.
• Enter table name NAPHTHA3 in the first row, then click Data.
• Click Columns to change the default to Display cycles in Rows.
• Move the variables you want to appear in the table from the Available Variable(s)
list to the Selected Variable(s) list.
o In this case, click Add All.
• Click View Table to view the results.

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82 Naphtha Assay – Part 3

Figure 2: Case Study Results in a Tabular Format

Step 5 View Output in a Graphical Format

Define a plot that shows the change in F2 duty with the change in F1 split.
• Select Output | Plots to open the Case Study Plots window.
• Enter plot name NAPHTHA3B in the first row, then Data.
• Highlight F1SPLIT from the Available Variable(s) list and X-Axis from the next list.
• Enter a label in the Label/Legend field, if desired.
• Click Update, then Add ->
• Highlight F2DUTY from the Available Variables list and Y-Axis#1 in the next list.
• Enter a label in the Label/Legend field, if desired.
• Click Update, then Add ->

Figure 3: Case Study – Plot Definition Window

• To view the plot, click Preview Plot.

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 Naphtha Assay – Part 3 83

Metric Units

English Units

Figure 4: F2 Duty as a Function of F2 Liquid/Vapor Ratio

• Save and close the simulation.

Introduction to AVEVA™ PRO/II™ Simulation

84 Phase Envelope

Phase Envelope

OVERVIEW
In this example, we want to examine the characteristics of the gas in the receiving vessel so that
you can make a decision about the pressure required to maximize the amount of liquid
condensed.
To do this, generate a Phase Envelope curve for the natural gas stream shown in Table 1. In
addition, generate lines of constant liquid mole fraction at 5%, 10%, and 15%.
At an ambient temperature of 50°F (10°C), what pressure will be needed to maximize the
production of liquid?
Table 1: Feed Data

Stream NAT_GAS
Component Mole %

C1 82
C2 7
C3 4
IC4 2
NC4 2
nC5 (represents iC5 and heavier) 3
Flowrate 45 kg-mol/hr 100 lb-mol/hr
Pressure 175 bar 2500 psia
Temperature 65C 150°F

Optional
• Another way to maximize the liquid rate is with an optimizer.

Hint: Add a flash drum onto feed stream.

SOLUTION STEPS

Step 1 Create a New Simulation

• Create a new simulation by selecting File | New.

Step 2 Enter Stream Data

• Define the components and enter the data for the stream.

Step 3 Select Thermodynamic Method

• Use the SRK thermodynamic method.

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 Phase Envelope 85

Step 4 Build the Process Flow Diagram

• Place a stream on the PFD and name it NAT_GAS.
• Enter stream data.

Step 5 Add Phase Envelope to the Flowsheet

• On the PFD Palette under the Utilities tab, add a Phase Envelope to the flowsheet.
• Double click on the Phase Envelope unit operation.
• For line 1, select stream NAT_GAS and do not enter a value for liquid mole fraction.
• For line 2, select stream NAT_GAS and enter 0.05 for liquid mole fraction.
• For line 3, select stream NAT_GAS and enter 0.10.
• For line 4, select stream NAT_GAS and enter 0.15.
• Under Plot Options, select Comparison for all four entries.
• For Comparison Plot Symbol enter 1, 2, 3 and 4.
• Click OK to PFD.

Step 6 Run the Simulation and Generate the Phase Envelope Plot
• Run the simulation.
• Select Output | Generate Plot.
• Select PH1 (Phase Envelope) and click Plot to display the phase envelope (see
Figure 1).

Step 7 Plot Alternatives (Optional)

• The above can also be accomplished by highlighting the stream and selecting Tools
| Phase Envelope.
• To create the charts as Excel Workbooks, select Options | Plot Setup. Then in the
drop-down list, select Excel.

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86 Phase Envelope

Step 8 Observe the Generated Plot

Metric Units

English Units

Figure 1: Pressure vs. Temperature Phase Envelope

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 Phase Envelope 87

Notice the locations of:

• cricondentherm (point with maximum temperature)
• cricondenbar (point with maximum pressure)
• Critical point (where bubble- and dew point lines meet) are also indicated.
• Dew and bubble point lines respectively to the right and left of the critical point
• The requested lines of constant liquid mole fraction at 5%, 10% and 15% shown
inside of the actual envelope. Note that the 5% curve is very close to the dew point
line.
To maximize the production of liquid at an ambient temperature of 10°C (50°F), a pressure of
roughly 90 bar (1300 psia) is needed.

Step 9 Add a Flash Drum and an Optimizer (Optional)

Flash – F1
• For the First Specification, enter a Pressure of 25 bar (363 psia).
• For the Second Specification, enter a Temperature of 10°C (50°F).
• Click Product Phases.
o For S1, select Vapor.
o For S2, select Liquid.

When complete, the Flash Drum window will look like Figure 2 below.

Figure 2: Completed Flash Drum Window (English units)

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88 Phase Envelope

Optimizer – OP1
• For the Objective, select Maximize.
• Create the Objective Function.
o Click Parameter.
o Select Stream S2.
o Click Parameter | Flowrate | All Components.
• Create the Variables.
o Click Parameter.
o Select Flash F1 Pressure within the range of 100 to 3600 psia (5 to 250 bar).
o Check the Active box for the variable.
• Click Options.
o Set the Minimum Relative Change in Objective Function to 0.0005.

When complete, the Optimizer window will look like Figure 3 below

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 Phase Envelope 89

Figure 3: Completed Optimizer Window

Table 2: Results of Optimizer OP1

Metric English

Liquid Rate 4.63 kg mol/hr 10.3 lb mol/hr

Pressure 91.4 bara 1325.3 psia

Introduction to AVEVA™ PRO/II™ Simulation

90 Rigorous Heat Exchanger

Rigorous Heat Exchanger

OVERVIEW
You want to increase the throughput of the exchanger and need to calculate the shellside outlet
temperature under the new conditions.
This exercise is to be performed in two parts:
A. Determine the fouling of the heat exchanger under its current operating conditions
which yields a shell side outlet temperature of 72C (161F)
B. Using the fouling results from Part A, change the calculation mode. Now, instead of
having the software determine the fouling factor as done in Part A, you will input the
calculated fouling factor from Part A, change the heat exchanger calculation mode to
PREDICTIVE, and update the inlet stream conditions allowing the HXRig to compute
the stream outlet conditions
The flowsheet, stream, and process data are provided below. Use the SRK thermodynamic
system and modify the Transport Properties to Petroleum Correlations.

Figure 1: PFD of a Rigorous Heat Exchanger

Table 1: Feed Stream Data

Component TUBE_IN SHELL_IN

Mole % Mole %
NC4 15 4
IC5 14 15
NC5 16 16
NC6 22 25
NC7 13 15
NC8 20 25
Temperature 21C 70F 104C 220F
Pressure 14 bar 195 psia 10 bar 135 psia
Current Flowrate – Part A 250,000 kg/hr 550,000 lb/hr 225,000 kg/hr 500,000 lb/hr
Increased Flowrate – Part B 275,000 kg/hr 606,000 lb/hr 295,000 kg/hr 660,000 lb/hr

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 Rigorous Heat Exchanger 91

Table 2: Heat Exchanger Data

Type AES, Horizontal, Countercurrent

Metric English
Area 215 m2 2293 ft2
Tube length 6m 20 ft
Tube OD 19 mm 0.75 in
Tube BWG 14 14
Tube, number of 600 600
Tube pattern 60° 60°
Tube pitch 31.75 mm 1.25 in
Tube Material Carbon Steel Carbon Steel
Shell Material Carbon Steel Carbon Steel
Shell ID 914 mm 36 in
Baffle type Single Single
Baffle cut 0.30 0.30
Baffle center spacing 600 mm 24 in
Shell nozzle ID 200 mm 8 in
Tube nozzle ID 200 mm 8 in

SOLUTION STEPS

Part A
Determine the actual fouling of the HEAT EXCHANGER under current operating conditions. In
this part of the exercise, you require a shellside outlet temperature of 72°C (161°F).

Step 1 Select the Units of Measurement

• Select the appropriate set of units of measurement. This problem can be solved in
English or Metric units of measure.

Step 2 Select Components

• Add the pure components listed in Table 1.

Step 3 Select a Thermodynamic Method

• Select the Soave-Redlich-Kwong equation of state.
• Click Modify, then Transport Properties.
• Change the Transport System to Petroleum Correlations.

Step 4 Build the Process Flow Diagram

• Place a RIGOROUS HEAT EXCHANGER unit with feed and product streams on the
PFD.

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92 Rigorous Heat Exchanger

• Name the unit and streams to match Figure 1.

• Save the simulation as HXRIG_A.prz.

Step 5 Enter Stream and Unit Data

• Enter stream data from Table 1.
• Double-click on the HEAT EXCHANGER and enter the data from Table 2 into the
Heat Exchanger window.
• In this example, the shellside outlet temperature is given, and we want to determine
the fouling resistance.
o For the Calculation Type, select Shell Outlet Temperature, and enter the
value in the Temperature field.

Figure 2: Rigorous Heat Exchanger Window (English units)

• Click Configuration to check that the TEMA Type, Orientation, and Configuration
are correct.
o Keep the default settings. You do not need to change anything.
• Click Tubes to enter the tube data in the Tube Data window.
o Note that the Tube Sheet Thickness data field has a default value and is
outlined in green. This means that, if you do not enter a value, the software
calculates one using TEMA methods.
• Click Baffles to enter baffle data. Cut can be entered as a percentage or a fraction.
• Click Film Coefficients and set the Tube Side Fouling Resistance to 0.

In this example, you want the software to calculate an overall fouling resistance to meet the
specification. You could supply values for both the tubeside and a shellside fouling resistances
and have the software adjust them to meet the performance specification.

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 Rigorous Heat Exchanger 93

However, for simplicity, it is easier to set the Tube Side Fouling Resistance to 0 and allow the
software to report the calculated overall resistance as the required shellside resistance.
• Click Materials to check that the materials of construction defaults are appropriate to
this exchanger.
• Click Print Options to check the Extended box to request an additional data sheet
with information about stream properties, heat exchanger configuration, and
hydrodynamics.
• Click Nozzles to enter the nozzle data.
• Click OK to save the entries.

Step 6 Run the Simulation

• Save the file and run the simulation.

Step 7 View the Results

• Select Output | Generate Text Report.
• Make a note of the required shellside fouling resistance as this will be used in Part B.
• This is the value shown as FOULING RESIST (REQD)

Figure 3: Heat Exchanger Results – Part A

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94 Rigorous Heat Exchanger

Part B
Using the fouling results, you have calculated in Part A, rate the existing fouled exchanger for
the increased throughput.

Step 1 Open and Save the Simulation

• Open the simulation named HXRIG_A.prz and save it under a new name,
HXRIG_B.prz.

Step 2 Modify Stream Flowrates

• Increase flowrates as shown in Table 2.

Step 3 Change the Calculation Mode

• Double-click on the HEAT EXCHANGER.
• In the Rigorous Heat Exchanger main window, change the Calculation Type to
Rating (Predictive).
• Click Film Coefficients, and enter the new value for the Shell Side Fouling
Resistance calculated in Part A.

Step 4 Run the Simulation

• Save the file and run the simulation.

Step 5 View the Results

• Select Output | Generate Text Report
• Note the Shell Side exit temperature should be 76.3°C (168.8°F), plus or minus
calculation tolerances.

Step 6 Review
• The idea of this exercise was:
o In Part A, to identify the actual fouling resistance factor based on plant
measurements. In other words, Part A tells us how fouled the existing heat
exchanger really is.
o In Part B, using the calculated fouling resistance factor, we can now simulate
the exchanger in predictive mode.

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 Specifications and Defines 95

Specifications and Defines

OVERVIEW
The process shown in Figure 1 preheats a stream that is fed to a distillation column. The flash
drum vaporizes 40 mole percent of the feed, and the heat exchanger further heats the flash
drum liquid. Both the flash drum and heat exchanger have 7 kPa (1 psi) pressure drops. A total
of 1.1 MM KJ/hr (1.0 MM BTU/hr) is available to the process.
Find the liquid fraction and temperature of the PROD stream and the two duties.
Table 1 shows the feed composition and condition.
Use the NRTL thermodynamic system (single liquid phase), and modify the default Vapor
Enthalpy and Vapor Density methods with SRKM (SRK-Modified Panag.-Reid).

Figure 1: Preheat Process

Hint: As the stream feeding heat exchanger, HX, is being heated it needs to be defined in
the heat exchanger unit operation as the Cold Side.

Table 1: Feed Stream Data

Stream Feed
Component Mole%

Toluene 80
MEK 19
Water 1

Temperature 88C 190°F

Pressure 140 kPa 20 psia
Flowrate 45 kg-mol/hr 100 lb-mol/hr

Hint: Use one stream specification and one Define.

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96 Specifications and Defines

SOLUTION STEPS
In order to vaporize 40% of the feed, a product specification has to be entered into the flash
drum.

The duty available to the heat exchanger is 1.1 MM KJ/hr (1 MM Btu/hr) minus the duty the flash
drum requires to vaporize 40% of its feed. Since the flash duty is unknown before the run, you
cannot assign a value to the heat exchanger’s duty. Instead, you should have the software
calculate the FLASH duty, and use the define feature to pass the calculated flash duty to the
heat exchanger.
The heat exchanger’s Define statement will have the form:
Heat Exchanger HX Duty in 10^6 KJ/hr = 1.1 - Flash Drum Duty
Heat Exchanger HX Duty in 10^6 BTU/hr = 1.0 - Flash Drum Duty

Table 2 summarizes the results.

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Table 2: Results of MEK/Toluene Preheat

Metric English

Flash Duty 0.777 MKJ/hr 0.740 MM BTU/hr

Heat Exchanger Duty 0.323 MKJ/hr 0.260 MM BTU/hr

PROD Temperature 112.9°C 233.7°F

PROD Molar Liquid Fraction 0.6428 0.6988

Introduction to AVEVA™ PRO/II™ Simulation