Introduction to Process Modeling using Aspen Plus

Course Id:  EAP101   |   Duration:  3.00 day(s)   |   CEUs Awarded:  2.1   |   Level:  Introductory

Course Objective

  • Learn how to build flowsheet simulation models to analyze steady-state processes using Aspen Plus.
  • Learn how to simulate and troubleshoot the basic Unit Operation models and full process models.
  • Develop the foundation skills for process design, debottlenecking, and optimization.

Course Overview

  • Develop the skills and techniques required for modeling new and existing processes in steady state.
  • Build and troubleshoot flowsheet simulations with distillation columns, reactors, heat exchangers, pressure changers, and separators.
  • Reduce process design time by evaluating various plant configurations.
  • Determine optimal process conditions for new or existing processes and help de-bottleneck processes.

Benefits

  • Gain the practical skills and knowledge to begin modeling new and existing processes.
  • Learn some practical techniques for building and troubleshooting flowsheet simulations.
  • Reduce process design time by testing various plant configurations.
  • Determine optimal process conditions to improve current processes.

Audience

  • Engineers new to Aspen Plus who need basic training to get started Aspen Custom Modeler®
  • Users who need exposure to steady-state simulation as preparation for using Aspen Plus Dynamics®

Approach

  • Instruction on basic topics.
  • Discussion about the general approach and the key elements for successful simulations.
  • Instructor-guided demonstrations of features.
  • Hands-on workshops that apply learned concepts.
  • Detailed course notes and answer keys.

Prerequisites

A background in chemical engineering or industrial chemistry

Subsequent Courses

  • EAP201 Select and Use the Right Physical Property Models for Process Simulations
  • EAP202 Model and Analyze Batch Processes using Aspen Plus 
  • EAP2211 Modeling Processes with Equation Oriented Methods using Aspen Plus
  • EAP301 Aspen Plus: Real Time Modeling and Optimization 
  • EAP2411 Use Dynamic Simulations to Improve Operations with Aspen Plus

Class Schedule

Class Agenda

EAP101: Introduction to Process Modeling using Aspen Plus

Introduction to Flowsheet Simulation

  • Introduce general flowsheet simulation concepts and Aspen Plus features
  • Review the benefits of process modeling using Aspen Plus
  • Discuss the approaches to flowsheet simulations
The User Interface
  • Become comfortable and familiar with the Aspen Plus graphical user interface
Properties Environment
  • Develop a working knowledge of the Aspen Plus Properties Environment
  • Learn to enter Components and Property Method for a process flowsheet 
  • Review the save options for Aspen Plus models 
  • Workshop: Build a Simulation Flowsheet – Properties Environment
Simulation Environment
  • Develop a working knowledge of the Aspen Plus Simulation Environment 
  • Build  a process flowsheet and enter stream and block information in an Aspen Plus simulation
  • Run the simulation 
Flowsheet Results
  • Review features for viewing simulation results
  • Discuss options to enhance flowsheet output
  • Workshop: Build a Simulation Flowsheet – Simulation Environment
Unit Operation Models
  • Review major types of unit operation models
  • Explore flowsheet handling techniques
Distillation Column Rating
  • Enter the minimum input required for the RadFrac fractionation model
  • Implement design specifications, stage efficiencies and column sizing
  • Workshop: Set up a methanol – water distillation tower model, implement efficiencies and size the column
Modeling Heat Exchangers
  • Review the Aspen Plus models used for modeling Heat Exchangers
  • Explore Activated Exchanger Analysis for heat exchanger design
  • Workshop: Compare the simulation of a heat exchanger using three methods: two Heaters connected with a Heat stream, a Heater using a Utility, and a rigorous HeatX
Modeling Chemical Plant – Ethylene Oxide Production Workshop
  • Apply acquired skills to build an Ethylene Oxide production flowsheet 
  • Workshop: Create a flowsheet to model an Ethylene Oxide production process
Physical Properties
  • Key considerations in choosing a property method and review physical property parameters
  • Learn how to choose an appropriate Property Method to represent single chemical or mixture
  • Workshop: Simulate a two-liquid phase settling tank 
Sensitivity Analysis
  • Become familiar with referencing flowsheet variables (accessing variables) which is used in sensitivity analysis, design specifications, calculator blocks and optimization
  • Use a sensitivity analysis to study relationships between process variables
  • Workshop: Use a Sensitivity Analysis to Study the Effect of a Recycle on Reactor Composition
Design Specification
  • Introduce the use of design specifications to meet process design requirements
  • Workshop: Use a Design Specification to Set the Feed Composition to a Reactor
Calculator Blocks
  • Introduce use of Microsoft Excel and Fortran Calculator blocks for flowsheet calculations.
  • Workshop: Use a Calculator block to set Ethylene to CO2 conversion in a reactor
Modeling Reactors (Simple and Rigorous)
  • Introduce the various classes of reactor models available
  • Explore  details of the balanced based reactors
  • Review details of the equilibrium and kinetic based reactors
  • Workshop: Compare the uses of different reactor types to model an ethyl-acetate reactor
Modeling Pumps, Compressors, Valves and Pipes (Pressure Changers)
  • Introduce unit operation models used to change pressure, such as Pumps and Compressors, and those which model pressure drop, such as Pipes and Valves
  • Workshop: Add pressure changer unit operations to the Ethylene Oxide flowsheet
Improving Flowsheet Convergence
  • Introduce the idea of convergence blocks, tear streams and flowsheet sequences
  • Workshop: Converge a flowsheet and review results
Process Improvement with Activated Analysis
  • Review Activated Energy Analysis and Activated Economic Analysis tools for process improvement
  • Investigate opportunities to improve energy efficiency and carbon footprint of the Ethylene Oxide flowsheet
  • Workshop: Perform a cost analysis on the Ethylene Oxide flowsheet using Activated Economic Analysis

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.