THE TEN COMMANDMENTS

DISTILLATION COLUMNOF
PROCESS SIMULATION
MODELING

Thursday, 23 Jan 2025

Title Layout
STARTING SOON

Subtitle
Ir. Rafil Elyas
Founding Owner and
Principal Engineer,
East One-Zero-One Sdn Bhd
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Introduction: Fauzi

Terminal
Front End,
operations and
Feasibility, Due
Master of modifications,
Undergraduate FEED Diligence,
Business new business Solution Consulting,
Chemical EPC LNG Financial
Administration for terminals Technical Account
Engineering Regasification, Modeling
National Upstream LNG Planning, Process
(2002) Refinery, LNG
University of McDermott Regasification, Digitalization Road Map
Institut Chemicals Regasification,
Singapore Oil and Southeast Asia
Teknologi Worley Refinery, Power
(2014) Chemical Aspen Technology
Bandung Plant
Terminals
Advisian
Vopak

https://www.linkedin.com/in/fauzidjauhari/ TheCurious.Engineer
 Founding Owner and Principal Engineer, East One-Zero-One Sdn Bhd (East101)

Ir. Rafil Elyas is the Founder and Principal Engineer of East One-Zero-One Sdn Bhd
(East101), a Malaysian company specializing in process simulation-based
solutions for the oil and gas industry.

With over 35 years of experience, he has worked extensively on optimizing

production systems, pipelines, refineries, and petrochemical facilities.

Rafil’s expertise includes simulation technologies, flow assurance, compressor

surge studies, and carbon capture projects. He is the co-author of Chemical
Ir. Rafil Elyas
Founding Owner and
Engineering Process Simulation (Elsevier) and delivers training programs to equip
Principal Engineer, engineers with practical simulation skills.
East One-Zero-One Sdn Bhd
He holds a BSc in Chemical Engineering from Syracuse University, NY, USA, and is
a Registered Professional Engineer with BEM. A Chartered Engineer and Fellow of
IChemE, Rafil serves as IChemE Malaysia Chair and is a member of the BEM
Engineering Accreditation Council. He also mentors future engineers as an
adjunct lecturer and industrial advisor at several Malaysian universities.

MySep Pte Ltd | TheCurious.Engineer 9

The Ten Commandments of Process
Simulation
Ir Rafil Elyas
Owner and Principal Engineer
East101
 EAST 101 WHO WE ARE

The Company The Team

• Founded in 2003 • Team Size 15
• Kuala Lumpur (Engineering, R&D) ⚬ Principal Engineers
⚬ Latitude: North 3.088454 ⚬ Process Engineers
⚬ Longitude: East 101.54772 • Skill Sets
• Houston (Sales & Service) ⚬ Advanced Process Solutions
• Ghana (Sales & Services) based on Process Simulation
• Nottingham (Sales & Services) ⚬ Software Development
• Brisbane (Sales) ⚬ Machine Learning & AI
• Jakarta (Sales)
• Thailand (Sales)
 EAST101 ACROSS THE ASSET LIFECYCLE
New Detailed Commissioni
FEED Operations
opportunity Design ng

Transient Downstream Operational Excellence Knowledge Transfer

Simulation based Analysis Specialist Solutions

• Centrifugal Compressor Surge • Heat Exchanger Design, • Gas Field Production • Workshops
Analysis Troubleshooting and Optimization Forecasting • Steady State Simulation
• Rigorous Blowdown Analysis • LNG cryogenic refrigeration • Operator Training Simulators, Course
• Heat Management Analysis troubleshooting powered by dynamic models • Dynamic Simulation and
• Heat Exchanger Tube Rupture • Refinery and Petrochemical Plant • Performance Monitoring Process Controls Course
Analysis Design, Optimization and Retrofit Applications • Introduction to Machine
• Water Hammer Analysis • Separation Column • Machine learning & AI Learning & AI
Debottlenecking and Solutions • Subject Matter Expert
Troubleshooting • Predictive Online Corrosion Development Program
• Steam Boiler and Header System Monitoring Solutions • Engaged learning
Controls Analysis • Custom Software • Model Handover Training
• Energy Accounting and Development
Optimization
• Pressure Protection

Minimizing unknowns with simulation technology

 EAST101 ACROSS THE ASSET LIFECYCLE
New Detailed Commissioni
FEED Operations
opportunity Design ng

Transient Downstream Operational Excellence Knowledge Transfer

Simulation based Analysis Specialist Solutions

• Centrifugal Compressor Surge • Heat Exchanger Design, • Gas Field Production • Workshops
Analysis Troubleshooting and Optimization Forecasting • Steady State Simulation
• Rigorous Blowdown Analysis • LNG cryogenic refrigeration • Operator Training Simulators, Course
• Heat Management Analysis troubleshooting powered by dynamic models • Dynamic Simulation and
• Heat Exchanger Tube Rupture • Refinery and Petrochemical Plant • Performance Monitoring Process Controls Course
Analysis Design, Optimization and Retrofit Applications • Introduction to Machine
• Water Hammer Analysis • Separation Column • Machine learning & AI Learning & AI
Debottlenecking and Solutions • Subject Matter Expert
Troubleshooting • Predictive Online Corrosion Development Program
• Steam Boiler and Header System Monitoring Solutions • Engaged learning
Controls Analysis • Custom Software • Model Handover Training
• Energy Accounting and Development
Optimization
• Pressure Protection

Minimizing unknowns with simulation technology

 EAST101 ACROSS THE VALUE CHAIN
FROM PORE…

…TO SHORE & MORE

OUR CLIENTS
 OUR CLIENTS
Operating Companies Engineering Companies FPSO Companies
Module Overview
1) Why use process simulation?
2) 10 Commandments of Process Simulation
Module Objective
• Understand the role of a simulation tool in process engineering
• Have a good grasp of some best practices before starting a simulation,
and what a simulator can and cannot do for you
 O&G Asset Lifecycle
Where does Process Simulation come in?
New
Opportunity

✓ Feasibility studies
Decline ✓ Conceptual design FEED
✓ Process
✓ Equipment sizing
• Capacitance
✓ Decommissioning
• Power
studies
• Duty
✓ Equipment lists
✓ Preliminary operability
Computation / ✓ HAZOP
✓ Debottlenecking Simulation ✓ Detailed equipment sizing,
Extension / studies heights, volumes, valve Detailed Design
Revamp ✓ Equipment sizes
engineering ✓ Operability
• Controls
• Methods
✓ Performance
monitoring
✓ Optimization
✓ Planning ✓ Operator Training

Operation ✓ Troubleshooting Construction

Commissioning
Start Up
Why use Process Simulation?
• As an engineer, once you’ve understood the objective, and what
mathematical relationships are required to get your solution - you want the
fastest and most accurate way to get there.
I.e., nobody wants to do iterative calculations by hand!

• However, there is no 1-size-fits-all. No simulator can cover every aspect of

a real-life phenomenon as it would be too complicated to solve.
We need to know the underlying principles, constraints and assumptions
to select the appropriate simulator.
Why use Process Simulation?
However, warning: GIGO! YOU are the problem solver; the simulator is just a tool!

Hence, we will cover some Commandments when using simulation in the next section.
10 Commandments of Process Simulation
1 You must:
Understand your OBJECTIVE
• You build a simulation model to meet an objective.
• Your model must be purpose built. No single mathematical model can
represent all fluids and processes.
10 Commandments of Process Simulation
1 You must:
Understand your OBJECTIVE

APPLICATION
Q) Should you use a simple short-cut distillation model or a rigorous tray-by
tray distillation model in your simulation?
10 Commandments of Process Simulation
1 You must:
Understand your OBJECTIVE

APPLICATION
Q) Should you use a simple short-cut distillation model or a rigorous tray-by
tray distillation model in your simulation?
It depends, a simplified unit operation may be acceptable for a preliminary
flowsheet’s mass and energy balance.
10 Commandments of Process Simulation
2 You must:
Identify your process or SYSTEM ENVELOPE for your model’s boundaries
• Sketch your system out BY HAND. Very important! This allows you to get
FAMILIAR with the process quickly.
• Draw an envelope around your system. Identify all the in/outgoing material
and energy streams as the boundaries for your model.
10 Commandments of Process Simulation
2 You must:
Identify your process or SYSTEM ENVELOPE for your model’s boundaries
APPLICATION
1kg/h Air

Tank 1
1kg/h Air
100kg/h Water
120kg/h Water

Pump 1

You were building your simulation model from given HMB data, and you
notice something strange, according to HMB there is more water exiting the
pump than entering the tank! What might be the problem?
10 Commandments of Process Simulation
2 You must:
Identify your process or SYSTEM ENVELOPE for your model’s boundaries
APPLICATION

1kg/h Air
Initial Boundary
New Boundary

1kg/h Air Tank 1 Pump Min. Flow 20kg/h

Recycle line
100kg/h Water Water

100kg/h Water
120kg/h
Water

Pump 1

In this HMB the minimum flow valve is open, which recycles some flow from
the pump. It was not considered in the initial model’s boundaries.
10 Commandments of Process Simulation
3 You must:
IMAGINE the MECHANISM happening physically in real life
• Engineers and scientists need great imaginations!
• You must be able to describe the mechanisms behind the
system/phenomena you’re studying.
10 Commandments of Process Simulation
3 You must:
IMAGINE the MECHANISM happening physically in real life
APPLICATION

Q: Designing a valve in your simulator, after specifying the inlet and the pressure drop
across the valve, you notice a large temperature drop after the valve. Are your simulation
results correct or is there something wrong with your input?
YES, it is expected real behaviour! This is the Joule-Thompson effect, temperature drops
due to pressure drop. A valve is Isenthalpic. (Note it cools most of the time, but it may heat
up depending on conditions).
10 Commandments of Process Simulation
4 You must:
Translate the physical model to a MATHEMATICAL model
• Use the fundamentals you’ve gained from:
• Thermodynamics
• Transport phenomena
• Reaction engineering
• And all the other classes you took in between playing video games and
partying in university!
• What models are available in your simulator?
10 Commandments of Process Simulation
4 You must:
Translate the physical model to a MATHEMATICAL model
APPLICATION
You want to study if there is the possibility of water hammer (or liquid
pressure surge) occurring in your water distribution system. You already
have a HYSYS model built to optimize the process flow for this area, can you
repurpose your model to perform this study?
10 Commandments of Process Simulation
4 You must:
Translate the physical model to a MATHEMATICAL model
APPLICATION
You want to study if there is the possibility of water hammer (or liquid
pressure surge) occurring in your water distribution system. You already
have a HYSYS model built to optimize the process flow for this area, can you
repurpose your model to perform this study?
NO, HYSYS has limitations in performing hydraulic computations that
involve momentum balances, you would need some other software e.g.
PIPENET.
Common Tasks and Typical Software
– which to use?
Multiphase Steady state hydraulic
General Flowsheet Pipeline programs. Pipeflo,
Heat and Pipesim, OLGA
simulators – PROII, Sizing
Material HYSYS, ASPEN+,
Balance UniSim Pro/II, VMGSim

Heat
Exchanger
Heat transfer
Thermal applications, HTRI, EDR
Valve Vendor’s manuals, Sizing /
property prediction Rating
Sizing packages

Flare
Flarenet, Visual Flare System
Sizing

Piping, liquid Single liquid phase

surge, water models. SPS-Stonor,
hammer Flowmaster Flow OLGA, LedaFlow,
Assurance COMPASS
 Common Tasks and Typical Software
Multiphase Steady state hydraulic
General Flowsheet Pipeline programs. Pipeflo,
Heat and Pipesim, OLGA
simulators – PROII, Sizing
Material HYSYS, ASPEN+,

What software
Balance UniSim Pro/II, VMGSim

Heat

Valve
should I use?
Vendor’s manuals,
Exchanger
Thermal
Sizing /
Heat transfer
applications, HTRI, EDR
property prediction Rating
Sizing packages

Flare
Is HYSYS better than Flarenet, Visual Flare System
Sizing

Piping, liquid Single liquid phase

PROII?
surge, water models. SPS-Stonor,
hammer Flowmaster Flow OLGA, LedaFlow,
Assurance COMPASS
10 Commandments of Process Simulation
5 You must:
Identify the COMPONENTS involved and their interactions
• Understand how they’ll be interacting with each other.
• When you know this, you will know what sort of fluid packages (property
estimation methods) you will need and what sort of hypothetical
components you may need to create.
• Does your system have azeotropes?
• Association/dissociation? Complexes?
10 Commandments of Process Simulation
6 You must:
Know the CONTEXT of your Feed streams to characterize them correctly
• Characterize accordingly, e.g., Gas analyses using a GC are generally on a
water free (dry) basis. Do you need to saturate the stream?
• Do you need to recombine streams with water to meet some specification
at some stipulated temperature and pressure?
• Analyze all the data that you want to input into your model!
100MMscfd Gas
Using composition
directly from lab data
(GC analysis)

Gas Wells Inlet Separator

0 kg/h Water
10 Commandments of Process Simulation
7 You must:
Know your Components’ Boiling Points
• Arrange them in ascending boiling point order so you can get an idea of
volatility. You can do quick and dirty material balances by knowing this.
• WATCH OUT FOR POLAR MOLECULES and HYDROGEN BONDS!
AZEOTROPES!
• For example: Components Boiling Points (°C)
Ethane -88.6
Propane -42.1
n-Butane -0.5
n-Pentane 36.2
n-Hexane 68.8
10 Commandments of Process Simulation
8 You must:
Keep track of the UNITS OF MEASURE (UOM) in all your calculations
• Even if you’re doing a calculation on a dirty napkin, show the UOM!
• UOM errors can be deadly and are VERY EASILY AVOIDABLE!
10 Commandments of Process Simulation
9 You must:
Always Perform a Simple Material and Energy Balance FIRST
• Do this by HAND to get an order of magnitude feel for the quantities of
material you’ll be working with.
10 Commandments of Process Simulation
9 You must:
Always Perform a Simple Material and Energy Balance FIRST
APPLICATION
10 Commandments of Process Simulation
9 You must:
Always Perform a Simple Material and Energy Balance FIRST
APPLICATION

ALWAYS
DO A MATERIAL TechSupport01

BALANCE FIRST!
10 Commandments of Process Simulation
10 You must:
Plot the PHASE ENVELOPE for important streams
• This should be a reflex for all chemical engineers
• Paste the phase envelope up in your workspace!
• Check for dew points
• Identify regions of retrograde behavior
10 Commandments of Process Simulation
10 You must:
Plot the PHASE ENVELOPE for important streams
APPLICATION
10 Commandments of Process Simulation
10 You must:
Plot the PHASE ENVELOPE for important streams
APPLICATION

8,000
kPa

2,962
kPa
SUMMARY: 10 COMMANDMENTS OF PROCESS
SIMULATION
1) Understand your OBJECTIVE
2) Identify your process or SYSTEM ENVELOPE for your model’s boundaries
3) IMAGINE the MECHANISM happening physically in real life
4) Translate the physical model to a MATHEMATICAL model
5) Identify the COMPONENTS involved and their interactions
6) Know the CONTEXT of your Feed Streams to characterize them correctly
7) Know your Components’ BOILING POINTS
8) Keep track of the UNITS OF MEASURE (UOM) in all your calculations
9) Always Perform a Simple Material and Energy Balance FIRST
10) Plot the PHASE ENVELOPE for important streams
Additional Tips
• Analyze all the INPUT data that you want to input into your model!
• After all this tips to build your model, VALIDATE and verify your model and
simulation before any case studies. Perform some sensitivity checks.
• COMMUNICATE and explain any methods and assumptions used in your
documentation, so that the reader understands the limitations of what
decisions the model be used for.
Thank you!
• Q&A
• [email protected]
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