Introduction to Process Modeling using Aspen HYSYS (Includes Sustainability Module)

• 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 

• 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
• Aspen HYSYS User Certification exam (included in the course fee)

• 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
• EHY2102 Aspen HYSYS Petroleum Refining: Process Modeling and Optimization for Refinery Unit Operations
• EHY2351 Modeling Heavy Oil & Gas Production and Facilities Using Aspen HYSYS Upstream

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 and Emissions Manager to perform emissions calculations - Sustainability Focus 
• 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 
• Identify steps to perform CO2 emissions tracking, Carbon Fee, Utility Consumption and Cost calculations - Sustainability Focus 
• 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 
• Learn how to assign process utilities to energy streams to see usage at stream level - Sustainability Focus 
• 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 
• Recognize how “Pinch technology” is used to minimize energy use and optimize heat exchangers - Sustainability Focus 
• 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  
• Carbon capture and storage example of carbon capture using DEPG (physical solvents) and MEA (chemical solvents) - Sustainability Focus 
• Dynamic modeling capabilities for Acid Gas Columns in v12  - Sustainability focus 
• 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 

Appendix 

• Blue hydrogen Example – SMR to produce hydrogen rich gas 
• Green hydrogen Example – Alkaline electrolysis system 
• Biofuels Example – Production of green diesel with vegetable oil  
• Biofuels Example – Production of green diesel with waste cooking oil