Introduction to Process Modeling using Aspen HYSYS

Course Id:  EHY101   |   Duration:  3.00 day(s)   |   CEUs Awarded:  2.1   |   Level:  Introductory

Course Objective

The design and operation of a process facility typically necessitates that various engineering analyses be performed.  Engineers must be able to predict process operating conditions, as well as execute optimization studies to meet their project goals.  Aspen HYSYS has the capability to model complex process facilities, and assist engineers in finding the operating conditions that will maximize the value of plant assets (without exceeding plant design limits, e.g. available utilities).  This technology can reduce capital costs by providing accurate thermophysical data for equipment sizing, and by enabling the user to perform sophisticated calculations that would be impractical with less-capable technologies

Course Overview

Build, navigate and optimize steady state simulation models using Aspen HYSYS. Utilize a wide variety of unit operation models and calculation tools to model process equipment. Use templates and sub-flowsheets to streamline and organize simulation models. Explore different means of reporting simulation results, including the use of the Aspen Simulation Workbook.

Benefits

  • Leverage the intuitive solving capabilities and other key features of Aspen HYSYS that allow for rapid flowsheet construction 
  • Discover how multi-flowsheet integration can streamline and organize simulation efforts
  • Explore a variety of means of reporting simulation results
  • Evaluate the performance of existing equipment by leveraging the equipment rating capabilities of Aspen HYSYS
  • Improve the convergence characteristics of columns and flowsheets; troubleshoot common problems
  • Perform Case Studies to determine the optimum operating points for a process 

Audience

  • New Engineering graduates/technologists who will be using Aspen HYSYS in their daily work
  • Process engineers doing process design and optimization projects and studies
  • Plant engineers checking plant performance under different operating conditions
  • R&D engineers and researchers using Aspen HYSYS for process synthesis

Approach

  • Instruction on basic topics
  • An experienced instructor will select an appropriate order in which to present the modules
  • Discussion about the general approach and the key elements for successful simulations
  • Instructor-guided demonstrations of features
  • Hands-on workshops using examples from the petroleum processing industry
  • Detailed course notes

Prerequisites

A background in chemical/process engineering, the oil/gas industry, or in petroleum refining

Subsequent Courses

Develop additional expertise with these recommended courses:

  • EHY202 Advanced Solutions using Aspen HYSYS
  • EHY223 Aspen HYSYS Dynamics: Introduction to Dynamic Modeling
  • EHY121 Building MS Excel User Interfaces for Aspen HYSYS Simulations Using Aspen Simulation Workbook

Class Schedule

Class Agenda

EHY101: Introduction to Process Modeling using Aspen HYSYS

Aspen HYSYS Process Simulation Overview

  • Identify the benefits of process simulation
  • Describe the capabilities of Aspen HYSYS
  • Introduce the Aspen HYSYS graphical user interface and organizational structure
Getting Started
  • Enter necessary elements to fully define a Fluid Package
  • Specify required parameters in order to execute flash calculations and fully define material streams
  • Modify and set desired units of measure
  • Review stream analysis options
  • Workshop: Introduce basic concepts necessary for creating simulations in Aspen HYSYS
Propane Refrigeration Loop
  • Add and connect unit operations to build a flowsheet
  • Use available tools to manipulate the user interface
  • View and customize the Aspen HYSYS Workbook
  • Convert a simulation case to a template
  • Workshop: Build and analyze a propane refrigeration loop
Refrigerated Gas Plant
  • Utilize the Heat Exchanger model in Aspen HYSYS
  • Introduce mathematical operations, starting with the Balance and Adjust
  • Add a Template file to an existing simulation
  • Workshop: Model a simplified version of a refrigerated gas plant and incorporate multiple flowsheet architecture
Reporting in Aspen HYSYS
  • Survey common result reporting techniques in Aspen HYSYS
  • Generate Excel reports from the HYSYS Workbook
  • Use the Report Manager to create custom unit operation and stream reports
  • Discover how to report non-standard physical properties in your material streams
  • Introduce Data Tables as an option to create customized simulation results tables
  • Provide a brief introduction to Aspen Simulation Workbook, enabling integration between Microsoft Excel and Aspen HYSYS
Oil Characterization and HP Separation
  • Introduce the Aspen HYSYS Oil Manager and Assay Management features and how they are used for assay characterization
  • Perform Spreadsheet calculations in Aspen HYSYS
  • Use the Case Study feature to run flowsheet-wide scenarios
  • Workshop: Use the Assay Management tools to characterize a crude assay, then employ the Spreadsheet and Case Study features to determine how Gas-Oil Ratio (GOR) varies with operating pressure
Two Stage Compression
  • Introduce the Recycle operation in Aspen HYSYS
  • Recognize suitable locations for a Recycle operation
  • Enter compressor curves to determine head and efficiency as a function of inlet flow
  • Workshop: Utilize the Recycle operation to build a two stage compression flowsheet; define and activate compressor curves thus modeling a HYSYS compressor with real-world data
Heat Exchanger Rating
  • Review the available heat transfer unit operations in Aspen HYSYS
  • Compare and contrast the applicability and operation of different heat exchanger models
  • Implement Aspen Exchanger Design & Rating (EDR) for rigorous heat exchanger calculations within Aspen HYSYS
  • Introduce the Activated Exchanger Analysis feature for continuous heat exchanger study and design
  • Workshop: Use a Rating model to determine if an existing heat exchanger will meet desired process specifications; design and rate a heat exchanger using the EDR interface inside Aspen HYSYS
Best Practices & Troubleshooting
  • Discover Activated Analysis for continuous evaluation of economics, energy usage, equipment design, and dynamic modeling
  • Identify best practices for using Aspen HYSYS
  • Investigate reasons why a simulation may produce poor results or errors
  • Use suggested tips to debug a variety of simulations
  • Workshop: Troubleshoot a series of Aspen HYSYS simulations and implement various best practices to get these simulations to solve properly
Gas Gathering and Crude Pre-Heat Train
  • Use the Pipe Segment operation to model single and multi-phase fluid flow
  • Introduce Pipe Segment Flow Assurance capabilities to ensure short and long-term viability of pipelines
  • Workshop Gas Gathering (O&G Focus): Use the Pipe Segment and its built-in Flow Assurance tools to model and study a piping network in Aspen HYSYS
-Or-
  • Workshop Crude Pre-Heat Train (Refinery Focus): Using a variety of heat transfer, separations, and piping unit operations, construct a raw crude pre-heat train flowsheet
NGL Fractionation and Atmospheric Crude Column
  • Introduce Aspen HYSYS column models and templates
  • Use the Input Expert to add and define a distillation column
  • Add and manipulate column specifications to meet process objectives
  • Include column side operations for additional distillation configuration options
  • Workshop NGL Fractionation (O&G Focus): Model a two column natural gas liquids (NGL) fractionation train
-Or-
  • Workshop Atmospheric Crude Column (Refinery Focus): Construct, run, manipulate, and analyze an atmospheric crude distillation column
Gas Dehydration and Vacuum Tower & Heat Integration
  • Review methods for saturating a hydrocarbon stream with water in Aspen HYSYS
  • Use the Hydrate Formation Analysis to calculate hydrate formation temperatures and pressures
  • Build a vacuum distillation tower with side draws and pump arounds
  • Apply the Recycle operation as a flowsheet-building tool appropriate for a variety of simulations
  • Workshop Gas Dehydration (O&G Focus): Model a typical gas dehydration unit and study gas saturation, hydrate formation conditions, and unit operation performance throughout the model
-Or-
  • Workshop Vacuum Tower & Heat Integration (Refinery Focus): Define and analyze a vacuum distillation tower; simulate heat integration to reduce energy usage within an overall crude processing system

Optional Exercises and Extra Materials (Time Permitting)

Acid Gas Package
  • Introduce the Acid Gas Property Package
  • Workshop: Model an acid gas sweetening process using diethanolamine
Liquefied Natural Gas (LNG) Plant
  • Use the LNG Exchanger operation to simulate multi-pass heat exchangers
  • Utilize the Sub-Flowsheet to build a modularized process flowsheet
  • Workshop: Model an LNG production process

Aspen Technology, Inc. awards Continuing Education Units (CEUs) for training classes conducted by our organization. One CEU is granted for every 10 hours of class participation.