Refinery Process Modeling using Aspen HYSYS and Aspen HYSYS Petroleum Refining

Course Id:  EHY150   |   Duration:  5.00 day(s)   |   CEUs Awarded:  3.5   |   Level:  Introductory


Course Objective

Learn to build, navigate and optimize process simulations using Aspen HYSYS and Aspen HYSYS Petroleum Refining. Learn efficient use of different HYSYS functions to build steady-state refinery process simulations. Leverage the intuitive solving capabilities and other key features of Aspen HYSYS and Aspen HYSYS Petroleum Refining that allow for rapid flowsheet construction for petroleum refining processes. Reactor models available: Cat Cracker for FCC units, Hydrocracker for multi-bed hydroprocessing units, Reformer for naphtha reforming units, ISOM for C5 isomerization, HBED for single bed hydroprocessor units, Delayed Coker and Visbreaker for furnace units.

Course Overview

  • Learn to build, navigate and optimize process simulations using Aspen HYSYS and Aspen HYSYS Petroleum Refining
  • Learn efficient use of different HYSYS functions to build steady-state refinery process simulations

Benefits

  • Leverage the intuitive solving capabilities and other key features of Aspen HYSYS and Aspen HYSYS Petroleum Refining that allow for rapid flowsheet construction for petroleum refining processes
  • Use the Workbook and Flowsheet interfaces for quick and effective modeling
  • Discover how multi-flowsheet integration can streamline and organize simulation efforts
  • Explore a variety of means of reporting simulation results
  • Gain confidence in modeling distillation and fractionation columns
  • Improve the convergence characteristics of columns and flowsheets; troubleshoot common problems
  • Perform Case Studies to determine the optimum operating points for a process
  • Learn the different options for defining and managing crude oil assay information and properties
  • Use a Petroleum Shift Reactor to create a simplified Delayed Coker reactor model
  • Learn how to create refinery reactor templates - Fluidized Catalytic Cracking (FCC) Reactor, Hydrocracker Reactor and Catalytic Reformer

Audience

  • New engineering graduates/technologists who will be using Aspen HYSYS in their daily work
  • Process engineers doing refinery 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 refining industry
  • Detailed course notes
Please note this course includes selected content from the following courses:
  •  EHY101: Aspen HYSYS: Process Modeling
  •  EHY2102: Aspen HYSYS Petroleum Refining: Process Modeling and Optimization for Refinery Unit Operations
If you have previously attended either EHY101 or EHY2102 some of the content covered in this course will be redundant.

Prerequisites

A background in chemical/process engineering or in the petroleum refining industry.

Subsequent Courses

This course serves as a prerequisite for many of the more advanced courses.

  • EHY121: Building MS Excel User Interfaces for Aspen HYSYS Simulations Using Aspen Simulation Workbook
  • EHY202: Aspen HYSYS: Advanced Process Modeling Topics
  • EHY223: Aspen HYSYS Dynamics: Introduction to Dynamic Modeling
  • EHY2311: Developing Automation Solutions for Aspen HYSYS
  • EHY2611: Heat Transfer Modeling Using Aspen HYSYS
  • EHY150: Refinery Process Modeling using Aspen HYSYS and Aspen HYSYS Petroleum Refining

Class Schedule

Class Agenda

EHY150: Refinery Process Modeling using Aspen HYSYS and Aspen HYSYS Petroleum Refining

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

Oil Characterization and HP Separation
  • Introduce the HYSYS Oil Manager and the oil characterization process
  • 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

Reporting in Aspen HYSYS
  • Survey common result reporting techniques in Aspen HYSYS
  • Generate Microsoft Excel reports from the Aspen 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

De-Butanizer and De-Propanizer
  • 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
  • Introduce a template file to an existing simulation
  • Workshop: Model the De-Butanizer and De-Propanizer columns from a gas-oil processing train

Pre-Heat Train
  • Utilize the Heat Exchanger model in Aspen HYSYS
  • Use the Pipe Segment operation to model single and multi-phase fluid flow
  • Introduce the Balance and Adjust mathematical operations
  • Workshop: Using a variety of heat transfer, separation, and piping unit operations, construct a raw crude pre-heat train flowsheet

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: Atmospheric Crude Column - Construct, run, manipulate, and analyze an atmospheric crude distillation column

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: Vacuum Tower & Heat Integration - Construct and analyze a vacuum distillation tower; simulate heat integration to reduce energy usage within an overall crude processing system

Getting Started with HYSYS Petroleum Refining Assays
  • Introduce Aspen HYSYS Petroleum Refining
  • Outline the workflow for starting an Aspen HYSYS Petroleum Refining Simulation
  • Discuss Petroleum Assay input options
  • Apply HYSYS Petroleum Refining assays to a process flowsheet
  • Workshop: Add assay data with petroleum properties and install into a flowsheet material stream; discover methods to import assay data into Aspen HYSYS from external sources

Petroleum Feeder
  • Introduce the unit operations associated with Aspen HYSYS Petroleum Refining
  • Add a Petroleum Feeder unit operation to an Aspen HYSYS Petroleum Refining simulation
  • Describe how the Petroleum Feeder can be used to setup feeds as blends and/or cuts of petroleum assays
  • Workshop: Introduce a Petroleum Feeder to a flowsheet and explore petroleum stream physical properties

Petroleum Distillation Column
  • Model an atmospheric crude column using the Petroleum Distillation Column unit operation
  • Review the setup options and analyze the results of the Petroleum Column model
  • Calibrate a Petroleum Distillation Column to match plant data
  • Calibrate a Petroleum Distillation Column using a rigorous Aspen HYSYS distillation column model
  • Workshop: Simulate a Petroleum Distillation Column and review calibration techniques to tune the model to operational data

Refinery Reactors
  • Review refinery reactor capabilities in Aspen HYSYS V8.4
  • Introduce the Delayed Coker and Visbreaker reactor models

Petroleum Yield Shift Reactor
  • Perform efficient reactor modeling by using data tables with the Petroleum Yield Shift Reactor
  • Manipulate product yields and properties using linear shift relations
  • Workshop: Use a Petroleum Shift Reactor to create a simplified Delayed Coker reactor model

Assay Manipulator and Product Blender
  • Use the Assay Manipulator operation to adjust petroleum properties
  • Mix petroleum material streams using the Product Blender
  • Optimize Petroleum Blender products using the HYSYS SQP Optimizer
  • Workshop: Modify petroleum properties using the Assay Manipulator; mix and optimize assay blends using the Product Blender

Fluidized Catalytic Cracking (FCC) Reactor
  • Create an Aspen FCC (Fluidized Catalytic Cracking) template
  • Calibrate an FCC model using a variety of data sets
  • Import an FCC into a HYSYS Petroleum Refining flowsheet and integrate it with other unit operations
  • Workshop: Create an FCC template file and use it to test a variety of operational parameters; calibrate an FCC and introduce it to an Aspen HYSYS Petroleum Refining flowsheet

Atmospheric Crude Column Optimization
  • Use the Derivative Analysis tool to define optimization variables and process constraints for an atmospheric crude column optimization
  • Create a HYSYS Spreadsheet to define an optimization objective function
  • Run the Hyprotech SQP Optimizer
  • Workshop: Use the SQP optimizer in Aspen HYSYS Petroleum Refining to determine the optimal operating conditions for an atmospheric crude column.

FCC Optimization Using Aspen PIMS
  • Overview of refinery planning and scheduling using Aspen PIMS
  • Discuss association between Aspen HYSYS Petroleum Refining and Aspen PIMS via sample business cases
  • Discuss the transfer of data from Aspen HYSYS to Aspen PIMS for on-demand adjustments to refinery planning models
  • Brief review of Aspen PIMS workflow
  • Workshop: Review the process for making Aspen HYSYS model data readable by Aspen PIMS; run default and modified Aspen PIMS cases to optimize an FCC unit

Hydrocracker Reactor
  • Learn how to create and configure an Hydrocracker reactor template
  • Understand how to calibrate a Hydrocracker model based on measured data
  • Simulate a Hydrocracker and run either standalone or within an Aspen HYSYS Petroleum Refining flowsheet
  • Workshop: Build a new Hydrocracker reactor template and calibrate it using provided data; install a Hydrocracker into an Aspen HYSYS Petroleum Refining model

Catalytic Reformer
  •  Learn how to create and configure a Catalytic Reformer template
  •  Understand how to calibrate a Catalytic Reformer model based on measured data
  •  Simulate a Catalytic Reformer and run either standalone or within an Aspen HYSYS Petroleum Refining flowsheet
  •  Workshop: Build a new Catalytic Reformer reactor template and calibrate it using provided data; install a Catalytic Reformer into an Aspen HYSYS Petroleum Refining model

Delayed Cooker
  •  Learn how to create and configure a Delayed Coker model
  •  Simulate a Delayed Coker Model with Rigorous Fractionator within an Aspen HYSYS Petroleum Refining flowsheet
  •  Understand how to calibrate a Delayed Coker model based on measured data

Visbreaker
  •  Learn how to create and configure an Visbreaker model
  •  Simulate a Visbreaker Model with Rigorous Fractionator within an Aspen HYSYS Petroleum Refining flowsheet
  •  Understand how to calibrate a Visbreaker model based on measured data

Additional Topics
  •  Review HYSYS Petroleum Refining components and light ends handling
  •  Discuss petroleum properties calculation, tracking and transition
  •  Identify different refinery reactors for required feeds, product transition, and solver settings

Best Practices & Troubleshooting
  •  Discover Activated Analysis for continuous evaluation of economics, energy usage, and equipment design
  •  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 and column models
  •  Workshop: Troubleshoot a series of Aspen HYSYS simulations and implement various best practices to get these simulations to solve properly

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.