Bicol University College of Engineering

Department of Chemical Engineering

SY 2021-2022

ChE Design 2:
Introduction to Process Simulation

Engr. Sandino Michael Angelo G. Aguilar, ChE

Email: [email protected]
Objectives
• To learn how to prepare Process Simulation and create
a Heat and Material Balance for a Unit Process or
overall plant.
• Able to apply theoretical knowledge of different Unit
operations to actual plant operations
• To teach student how to apply engineering
judgement, pick-up data/information from various
sources.
Process Simulation
• Simulation (Upstream Work) – downstream activities rely on simulation
results for engineering works.
• Heat and Material Balance is obtained from Process Simulations /
Modelling
• Related process design activities are dependent from simulation results.
• Reliability of simulation means reliable data for downstream disciplines
(i.e Mechanical Engrs, Instrument Engrs, Static Equipment Engrs, Rotary
Engrs, etc)

WRONG SIMULATION DATA GREATLY IMPACTS SCHEDULE,

MANPOWER ALLOCATION AND COST IN AN ENGINEERING
PROJECT
Workflow of Process Eng’g
(Basic Design)
Process
Design Study of Design
Process Document
Basis Configurations
No

Yes Heat and

Process Opt
Material
Simulation ?
Balances

Hydraulic Process
Equipment Preparation
Calculation for Flow
Sizing/Rating of PFD
Main Rotary Diagram

Material
Equipment
Selection
Plot List

Plan Detailed Preparation

Hydraulics of P&ID
(Process,
Utility)

Pump/
Equipment Equipment
Compressor
Datasheets List
Datasheet
Piping/Process & Utility
Instrumentation Flow
Instrument Diagram Diagram
Datasheet
PROCESS SIMULATIONS (Common Tools)
LICENSED / COMMERCIAL
Aspen HYSYS

Aspen PLUS

PROII
ProMax

OPEN SOURCE/FREE
DWSIM
COCO Simulator
Overall Steps for PROCESS SIMULATIONS

SUPPLY
CHECK THE SELECT THE RUN OPTIMIZE,
DEFINE THE BUILD PROCESS
UNIT OF THERMODYNAMIC SIMULATION, EXTRACT
COMPONENTS PFD UNIT
MEASURE METHOD/PACKAGE VERIFY HMB
DATA
PROCESS SIMULATIONS (Thermo Guide)
 About DWSIM
• Developed by Daniel Medeiros
• DWSIM is a free-source simulator that is
capable of steady-state, dynamic state
operation, vapor-liquid, V-L-L, Solid-
Liquid and aqueous electrolyte DM’s Background:
• Chemical Engineer specialized in Process Engineering,
equilibrium processes with the following with sixteen years of experience on the Petroleum
Thermodynamic models and Unit Industry working as a Process Engineer. Has
experience with design, modeling, simulation,
Operations evaluation and operation of petroleum and natural
• Latest Version: v7.4.0 (March 2022) •
gas processing / transportation facilities.
Creator and developer of DWSIM
Download link: Download DWSIM – DWSIM – The Open (http://dwsim.inforside.com.br), an award-winning
Source Chemical Process Simulator (inforside.com.br) Chemical Process Simulator for Windows, Linux,
macOS, Android and iOS.
• Specialties: process simulation, design and
optimization, software development
 • Non-polar gases at low pressure (< 10 atm)
➢Use Raoult’s Law Property Package. It assumes
that both phases are ideal.
• Non-polar gases at high pressures (>10 atm)
PROCESS ➢Use EOS models line Peng-Rebonsin, Soave-
Redlick Kwong and PRSV2
SIMULATIONS • Polar gases at high pressures (> 10 atm)
(DWSIM) ➢Use PSRV2, check if available parameters are
present in DWSIM. If now, use PR or SRK.
• Systems with high H2 content
➢Use Chao-Seader, Grayson-Streed or Lee-Kesler
Plocker Model.
 • Air Separation / Refrigeration systems
➢ Use CoolProp or FPROPS Property Package
• Steam / Water simulations
> Use Steam Tables Property Packages
PROCESS • Polar chemicals
➢ Use activity coefficient models like NRTL or
SIMULATIONS UNIQUAC. If no interaction paramaters, use
Modified UNIFAC (NIST).
(DWSIM) • Salt/Water systems
➢ Use Seawater Property Package
• Aqueous Electrolytes
> Use LIQUAC, Extended UNIQUAC, Electrolyte
NRTL or Reaktoro Package
Unit Operations (DWSIM)
• Pressure Changers

• Separator/Tanks

• Mixers/Splitters
Unit Operations (DWSIM)
• Exchangers

• Reactors

• Columns
Unit Operations (DWSIM)
• Solids

• Logical Blocks
For Dynamic Simulation (DWSIM)
• Indicators

• Controllers
Other Functions (DWSIM)
• For Material Streams • For Vessel Sizing
Other Functions (DWSIM)
• Tools:
• Hypothetical Component Generator,
• Bulk C7+/Distillation Curves Petroleum
• Characterization, Petroleum Assay Manager
• Reactions Manager
• Compound Creator
• Process Analysis and Optimization:
• Sensitivity Analysis Utility
• Multivariate Optimizer with bound constraints
• Extras:
• Support for Runtime Python Scripts
• Plugins
• CAPE-OPEN Flowsheet
Try Example 8.1 of 7th ed Intro to ChE Thermo
(Van Ness, Smith & Abbott)
Steam generated in a power plant at a pressure of 8,600 kPa and a
temperature of 500oC is fed to a turbine. Exhaust from the turbine
enters a condenser at 10 kPa, where it is condensed to a saturated
liquid, which is then pumped to a boiler.
Pump and Turbine efficiency : 0.75
Power cycle rate : 80,000 kW
DWSIM Simulation
DWSIM Simulation: Heat and Material balance
MATERIAL BALANCE

ENERGY BALANCE
(Equipment Power Requirements)
Reference Book vs Simulation Results
Parameters VSA DWSIM % error
Cycle Efficiency 0.2961 0.2962 0.034

Steam rate (kg/s) 84.75 84.69 0.071

Net work (kW) 80,000 80,000.9 0.0011

Qboiler (kW) 270,200 270,063 0.051

Qcondenser (kW) 190,200 190,062 0.073

Condenser outlet / Pump inlet temp (oC) 45 45.81* 1.8

Saturated temp of water at 10 kPa is 45.81oC

 Chemical Engineering Design
(Gavin Towler & Ray Sinnot)

Computer Methods in
Chemical Engineering by Nayef
Read more on Ghasem
(Patterned from HYSYS Sim)

Process Design Basis and

Process Design Guide
Bicol University College of Engineering
Department of Chemical Engineering
SY 2021-2022

ChE Design 2:
Introduction to Process Simulation

Engr. Sandino Michael Angelo G. Aguilar, ChE

Email: [email protected]