3.1 Introduction Aspen Plus provides several blocks that are suitable for, but not limited to, material balance only calculations. They are the stream splitter, the mixer, and the simple separator blocks. Additionally, the stoichiometric reactor, which will be covered in Chapter Ten, is also very useful for material balance- only calculations. These blocks are especially important since when they are combined to form a simple process model, the results are useful as an initial cost estimate for a rigorous model of a process. In some cases, such calculations are used as the basis for design. Aspen Plus also provides two blocks with general utility in various aspects of simulation. The stream duplicator block enables, for example, the execution of duplicate processes with different thermodynamics and parameters but the same feeds. The stream multiplier enables all elements of an input stream to be modified by a calculated multiplier subject to the specification of a block output, such as the composition of a component in an output stream.
3.2 Mixer/Splitter Blocks
The blocks Mixer, Fsplit, and Ssplit are available from the Aspen Plus model palette shown on the bottom of the Aspen Plus displays under the Mixers/Splitters tab as shown in Figure 3.1.
Figure 3.1 Library of mixers/splitters.
3.2.1 The Mixer Block
The Mixer block combines an arbitrary number of input streams and produces a single stream by simple material balance. If the no heat balance option is chosen, no other input is required. An example is shown in Figure 3.2. Figure 3.2 The Mixer block. If Fi and hi represent the flow rate and enthalpy/mole of stream i, the material balance and energy balance are as follows:
3.1
3.2 When energy balances are selected, it is necessary to specify the outlet stream's pressure or the pressure drop across the block. If no pressure is specified, the block uses the lowest pressure of the feed streams. Additionally, the allowable phases of the output stream must also be specified. Since the output stream is of known composition and pressure and its molar enthalpy is calculated with Equation 3.2, its state is defined, and therefore, an adiabatic flash yields its temperature.
3.2.2 The Fsplit Block
The Fsplit block is designed to divide a single stream, or a mixture of streams of known state, that is, flow rate, composition temperature, and pressure, into an arbitrary number of product streams with identical states. Note that since the state is known, the enthalpy/mole is calculable. A choice of product stream split fraction (based on the sum of the flow rates of the feed streams), mass or molar flow rate, volumetric flow rate, or flow rate of a component may be made. If there are n product streams, specifications for any n − 1 streams must be made. Figure 3.3 shows an example of an Fsplit block. Figure 3.3 The Fsplit block. When the model is executed, all the feed streams are mixed and the combined flow rate, composition, and molar enthalpy are computed. It is important to note that any of the block's product specifications can be converted into product stream split fractions. This provides the basis for describing equations of the model. For example, if the molar flow rate of component i in stream j, , is specified, the split fraction αi can be calculated by Equation 3.3:
3.3
where fi is the combined feed flow of component i. Componential material
balances are as follows. Let F and h represent the total flow rate and the molar enthalpy of the combined feed streams, and Pi, and αi, the flow rate and split fraction of the product streams. Since there are n product streams, then n − 1 split fraction material balance equations, each described by Equation 3.4, may be written for the product streams.
3.4 The flow rate of the last product stream is calculated by an overall material balance shown in Equation 3.5.
3.5
The combined feed molar enthalpy, h, is assigned to each product stream. The pressure of all of the product streams is identical and is either specified on the Flash tab or if not specified the lowest input stream pressure is used and thus all product streams are at the same state. If the energy balance option is used for the simulation, the temperature of a product stream is calculated by an adiabatic flash. The Ssplit block available from the model palette, except for input format, has the same functionality as Fsplit. 3.3 The Simple Separator Blocks The blocks Sep and Sep2 are available from the Aspen Plus model palette shown at the bottom of the Aspen Plus displays under the Separators tab as shown in Figure 3.4.
Figure 3.4 Library of separators.
3.3.1 The Sep Block
When the Sep model is executed, all the feed streams are mixed and the combined flow rate, composition, and molar enthalpy are computed. The block permits the assignment of the flow rates or componential split fraction of each component in each of the n − 1 product streams, based on the combined feeds. The composition of the nth stream is calculated by overall material balance. An example of a Sep block is shown in Figure 3.5.
Figure 3.5 The Sep block.
As part of the blocks' input specifications, there is a tab Outlet Flash, which enables a user to specify the state of each outlet stream. A flash of each stream establishes their molar enthalpies and facilitates the calculation of the block energy balance. See Examples/duplicator example. Since Sep is a typical sequential modular block, for an n component, m product stream configuration, with the temperature and pressure of the feeds and products specified, a degree of freedom analysis shows that for a material balance-only application there are n * m unknowns. If n * (m − 1) products are associated with a specification such as the fraction of the sum of the feeds of a component exiting in a particular stream, n unknowns remain to be calculated by a material balance, thus the composition of all streams are calculable. For the energy balance calculation, there is one additional unknown per product stream, that is, molar enthalpy. Since the composition temperature and pressure of each stream is known at the conclusion of the material balance calculations, an adiabatic flash produces the molar enthalpy of all streams and an overall energy balance can be performed. If represents the quantity of component i in feed stream k, then the amount of component i entering the block, Fi, is given by Equation 3.6, where l is the number of feed streams.
3.6
If the split fraction of a particular component i, in stream j, , is given, the
quantity of component i leaving the block in stream j, is given by Equation 3.7.
3.7 Alternatively, the quantity of component i leaving the block in stream j, can be directly specified. The variables in the equations do not depend on each other and thus the solution where not uniquely specified as in Equation 3.7 is direct.
3.3.2 The Sep2 Block
The Sep2 block is designed to model a simple two-product separator such as a distillation or extraction process. Similarly to the Sep model, when a Sep2 block is executed, all the feed streams are mixed and the combined flow rate, composition, and molar enthalpy are computed. For n product streams, the block permits the assignment of the flow rates or componential split fraction of each component in each product stream of n − 1 streams, based on the combined feeds. The Sep2 model, however, provides more flexibility in specification than the Sep block does. The additional allowed specs are overall stream split, that is, ratio of flow of a product stream to the sum of the flows of the feed streams, and mole or mass fraction of a component in a product stream. The composition of the nth stream is calculated by overall material balance. An example of a Sep2 block is shown in Figure 3.6. Figure 3.6 The Sep2 block. Unlike the Sep block, there is interdependency between some of the block specifications. Equations 3.6 and 3.7 describe the specifications of the Sep block, which apply to the Sep2 block, but the other Sep2 specifications involve interaction between the variables. The mole fraction specification as given in Equation 3.8 is an example. If represents the specified mole fraction of component i in product stream j, where l is the number of components, then
3.8
Equation 3.8 applies. An equation similar to Equation 3.8 that describes the total flow specification is shown in Equation 3.9, where βj is the overall split fraction of stream j to the sum of flows of all p feeds, Fm represents the sum of the flows of all components in feed stream m, and l represents the number of components.
3.9
Note that the flows of the components may not be known a priori as in the Sep block; therefore, the solution of a set of simultaneous equations is required in which the unknowns are the individual component flows of product streams. Like the Sep block, there is a tab Outlet Flash that enables a user to specify the state of each outlet stream. A flash of each stream establishes their molar enthalpies and facilitates the calculation of the block energy balance.
3.4 Some Manipulator Blocks
Manipulators can be found in the Aspen Plus model palette under the tab “Manipulators” shown in Figure 3.7. The only manipulators considered here are the stream duplicator and stream multiplier blocks.
Figure 3.7 Library of manipulators.
3.4.1 The Dupl Block
The duplicator example illustrating the solution of the same problem with both the Sep and Sep2 blocks is shown in Figure 3.8. Details are given in Examples/DuplicatorExample. Upon execution, streams 2 and 3 are identical to stream 1.
Figure 3.8 Duplicator block example.
A feed of 100 lb mol/h of methanol, 200 lb mol/h, and 300 lb mol/h is to be separated into an overhead product of 100 lb mol/h with composition 0.95 mole fraction methanol and 0.04 mole fraction ethanol. The column, operating at 14.7 psi, is to be simulated twice, once with a Sep and once with a Sep2 block. A Duplicator block is to be used to feed both columns. No energy balances are employed. Figures 3.9–3.11 show the specifications for both separator blocks.
Figure 3.9 Sep specifications.
Figure 3.10 Sep2 specifications.
Figure 3.11 Sep2 specifications. Figure 3.12 shows that identical results are obtained; however, the use of Sep would not be straightforward if it were in the middle of a process where the feed was not known a priori.
Figure 3.12 Duplicator example results.
3.4.2 The Mult Block
The Multiplier block contains a user-specified parameter that multiplies the sum of all the flow rates in the block's feed by a specified value or by a value calculated from another part of the process. An example of the use of the Multiplier block is shown in Figure 3.13. In this example, stream 1, the feed to the Mult block, is specified but, stream 2, the feed to the rest of the process, is unknown. In this case, a process quantity such as the flow rate of a component in a stream, for example, stream 8, will be targeted to achieve a user-specified value. A design specification, described in detail in Chapter Five, is used to manipulate the value of the multiplier parameter, operating on stream 1, so that stream 2 attains a value such that the desired flow rate of the component in stream 6 is obtained. Figure 3.13 The Mult block.
3.5 Workshops Workshop 3.1a Three streams are to be mixed. Their specifications are given in Table 3.1. Use the material balance-only option. The property option to be used is Chao–Seader. Solve the flowsheet. The components are propane, n- butane, n-pentane, and n-hexane. Stream specifications are given in Table 3.1. Be sure that mole flow and mole fractions are selected in the stream report. Table 3.1 Stream Specifications for Workshop 3.1a Stream/Component Temperature Pressure Flow Rate (lb Vapor (°F) (psi) mol/h) Fraction 1 200 300 C3 20 NC4 30 NC5 30 NC6 20 2 250 400 C3 30 NC4 30 NC5 20 NC6 20 3 200 0.5 C3 50 NC4 0 NC5 30 NC6 20 Workshop 3.1b Repeat Workshop 3.1a using material and energy balances. What do you observe? Is your solution correct? Workshop 3.2a Three streams are to be fed to an Fsplit block used to emulate a distillation column with a side stream. The process specifications are given below. Use the option “material balance and energy balances.” There will be three product streams: D, SS, and B. The property option to be used is Chao–Seader. The component list and stream specifications are the same as in Workshop 3.1a. Make the following specifications : 1. 50% of the combined feeds are to be directed to stream D. 2. 50 lb mol/h of NC4 will exit in stream SS. Solve the flowsheet. Is something wrong? What? Why? Workshop 3.2b Change Workshop3.2a such that 20 lb mol/h of NC4 exits in stream SS. Solve the flowsheet. What do you observe? Workshop 3.3a A two-feed, two-product distillation column operating at 1 atm is to be simulated using the Sep2 block. The system components are methanol, water, and normal hexane. You may assume that the system thermodynamics can be represented by an ideal vapor phase and the UNIFAC correlation for the liquid phase. The componential flow rates of the first feed are 50 lb mol/h of methanol and 100 Ib mol/h of water and is a saturated liquid at 14.696 psi. The second feed flow rate is 150 Ib mol/h of pure n-hexane at 120 °F and 14.696 psi. Both feeds are at 1 atm and are saturated liquids. The column performance specifications are as follows: 1. One half of the methanol fed is to be recovered in the overhead product. 2. 99% of the water fed is recovered in the overhead product. 3. 99% of the n-hexane fed is recovered in the bottom product. Set up the problem and solve. Workshop 3.3b The specifications 2 and 3 are to be changed as follows: 2. The mole fraction of water in the overhead product is 0.788. 3. The mole fraction of n-hexane in the bottom product is 0.85. Modify Workshop 3.3a and solve. Workshop 3.3c The specification 2 above is to be changed as follows: 2. The mole fraction of water in the overhead product is 0.8. Modify Workshop 3.3b and solve. 3.3c Solve by hand. What do you observe? Workshop 3.3d The specification 2 above is to be changed as follows: 2. The mole fraction of water in the overhead product is 0.75. Modify Workshop 3.3c and solve. 3.3d What do you observe?
3.6 Workshop Notes
Workshop 3.1b Care must be taken with the specifications of the allowable phases in the product. If there is a possibility that the resulting state is a mixture of phases, it must be specified on the Flash Options/Valid phases data entry location. Workshop 3.2a The specifications stated in the problem have not been achieved. It is recommended that the problem be solved manually. This will show that a negative flow of one of the products results. This is an improperly specified problem. Workshop 3.2c A satisfactory solution is obtained. Workshop 3.3a A satisfactory solution is obtained. Workshop 3.3b A satisfactory solution is obtained. Workshop 3.3c A satisfactory solution is not obtained. A manual material is given below using the following nomenclature: f1, f2, f3 are the combined feed flow rates of methanol, water, and n- hexane respectively. d1, d2, d3 are the componential distillates. b1, b2, b3 are the componential bottoms. 3.3c The material balance equations are then as follows:
The first specification results in d1 = b1 = 25. Simultaneous solution of the
remaining four equations and substituting the known values for d1 and b1 yield the following results:
Since there is a negative flow for d3, n-hexane in the distillate, a physically unrealistic solution, the specifications are improper. Workshop 3.3d A satisfactory solution is obtained as a result of the change in the overhead specification for water.
