ConsortiumofReaction/Separation / p Prosess

ProcessSimulationusingAspenDynamics
Speaker:JianKai Cheng() DeptofChem.Eng. NationalTaiwanUniversity

Agenda
Introduction Dynamic Data in Aspen Plus Running Simulation in Aspen Dynamics Distillation with RadFrac Reactors Tasks Process Control

Introduction
AspenDynamicsisatoolintheAspenEngineeringSuit fordynamicsimulationofflowsheets
AspenPlus: SteadyState,BasisforAspenDynamics simulations AspenDynamics: Runningofftheshelfmodelsbasedib AspenPlusflowsheet

WorkflowwithAspenDynamics
Build steady state flowsheet in Aspen Plus Prepare flowsheet for Dynamic simulation Add dynamic data Export simulation Load simulation in Aspen Dynamics Build control system, system add disturbance

ExampleofWorkflow
What happens if operating conditions change?

ExampleofWorkflow
1. Create the simulation flowsheet in Aspen Plus
Properties, components, stream, blocks, Develop the flowsheet

2. Enter the dynamic information in Aspen Plus 3 Export the simulation to Aspen Dynamics 3. 4. We have a dynamic model for our flowsheet
Apply disturbances Change control system Etc

DynamicDatainAspenPlus
IntroductiontoAspenDynamics

LessonObjectives
Describethedatarequiredtocreateadynamic simulationinputfromAspenPlusflowsheet

AccessingthedynamicDataForms
Clickdynamictoolbuttontoactivatedynamicdata forms

AddingDynamicData
Dataisrequiredtocalculatethefollowing: Vesselgeometry Vesselinitialfillage Processheattransfermethod

VesselGeometry
Vesseltype
Instantaneous
Defaulttyperequirednoinputvesselgeometry.

Vertical Horizontal

Vesselgeometry
Headtype Diameter Length

Headtype

VesselInitialCondistion

CreatetheAspenDynamicsFiles
Export
Creates and saves the Aspen Dynamics Problem file (*.dynf) Creates and saves the Aspen Plus Properties Definition (* (*.appdf) appdf) required for the properties calculations

Send to
Exports then automatically starts Aspen Dynamic and loads the exported problem files
Runid#.dynf Runid#.appdf

WhatisExportedtoAspenDynamics
Thefollowingobjectsareexported:
Components Properties StreamandBlock(Supportedmodelonly)

Thefollowingobjectsarenotexported:
Specification p Calculator

TypesofDynamicSimulations
Th There are t two types t of f dynamic d i simulations: i l ti

Flow-driven
Flowrate is not controlled by pressure differences Useful for a first approach of dynamic behavior of the processes Good for liquid processes

Pressure driven
Flowrate is controlled by pressure differences More realistic, the system must be setup, pumps and compressors must be installed whenever necessary necessary.

MessagesWhileExportingtheSimulation
Alwaysanalyzethemessagewhileexportingthe simulationastheyarereallyimportant Warning:Somethingyoushouldreallycheck!
Example:
Flashvesselfullofliquid Phasetype

(Fatal)Error:Thesimulationcannotbeexportedor usedwithoutcorrectiveaction
Pressuredrop

TypesofMessagesDuringExporting
FatalError
UseofanyAspenPlusfeature,whichisnotsupportin Aspendynamics Anyresults,whichareinconsistentwithadynamic simulation, i l ti e.g.,problem bl with ithRadFrac R dF pressureprofile fil

Error
Ablockthatisnotsupport
Note:Ifaflowsheet includesanunsupportedblock,itwillstillbe exportedbutamessagewillbeoutputabouttheunsupported block

Warning
Anythingwhichcouldcauseaprobleminthedynamic simulation,e.g.,negativeorzeropressuredropinvalves

WhatisExportingtoAspenDynamics
Thefollowingobjectsareexported
Component Properties Streamandblock

Thefollowingobjectsarenotexported
Specification p Calculatorblocks

Workshop: AddingDynamicData
Buildthesteadystateflowsheet

RunningSimulationinAspenDynamics

IntroductiontoAspenDynamics

LessonObjectives
Reviewthebasicconceptsinrunningthesimulation Explainhowtorunandpause Showhowtodisplaytheresults CompleteWorkshop

AspenDynamicsGraphicalInterface

SimulationExplorer
Displaythecontentofthesimulation
ComponentList:Componentsandphysical property Globals:Optionsforthesimulation Flowsheet:Blocksandstreamsonthe flowsheet Libraries: Lib i Library Lib of fmodels d l Diagnostics:Informationonresultion

RunMode
Selectsthetypeofsimulation AspenDynamicsistypicallyusedwithDynamicand Initializationrunmode Initializationrun:
Solvesequationsofthesystemattime0tofindthe valuesofthefreevariables

Dynamicrun:
Firstitdoesaninitializationrunattime0 Theintegrates,stepbystep,equationsofthesystem Reportsresultsateachcommunicationinterval

RunControl

To start or continue the simulation (Run button) o run u step step-by-step by step To To pause the simulation (Pause button) To go back to a time 0 (Re-start button) To go back to a timed snapshot (Rewind button)

RunOptions

Communication interval

Pause Time

Time units for display

SolverOptions
Selectstheparametersfor numericalmethods Importsettingonintegrator sheet InitialIntegrationstep MinimumIntegrationstep Defaultvaluesare appropriatefortheother setting

ExampleofATable

SpecificationsandValuesofVariables
Fixed:Specifythevalueofthevariablefor thecalculation Free:ValueiscalculatedbyAspenPlus Initial:Specifythevalueofthevariableat time0 OriginalvaluesarefromtheAspenPlussimulation Youcansavenewstartingpointsincurrentresults sectionsorinsnapshots.

CreatePlotsandTables
1. 2. 3. 4. 5. Click the new form button Select the option, click OK Open a table/plot Click the name of the variable Hold down the left mouse button to drag it and drop it on the form 6. Right Click to change its its properties 7. The table/plot is defined in Flowsheet folder

Workshop: RunningAspenDynamics
Explorethemainstepsonhowtorunasimulation:
Experimentwithpredefinedplotsandtables Createplotsandtables Rewind,Restart

DistillationwithRadFrac

IntroductiontoAspenDynamics

LessonObjectives
OverviewofRadFraccapabilities DynamicforminAspenPlus ModelandSpecificationsofexportedto:
ShowhowAspenPlusdataandresultsareused ReviewsomespecificdetailsofAspenDynamics assumptions p

CompleteworkshopadRadFrac

RadFraccapabilities
Dynamic RadFrac may be used in the same applications as steady-state model In I dynamic d i mode. d R RadFrac dF models d l th the pressure d drop across each stage due to the head of liquid and vapor flow resistance Stage hydraulics are also modeled Reactive Distillation:
Reaction-Dist Reaction type: equilibrium reactions are not supported User reaction type us supported

DynamicDatainAspenPlus
Heattransferoption
Condenser Reboiler

Sizeandinitialcondition
Refluxdrum Sump p Decanter

Hydraulics:Selectionofpressuredropandholdup calculationforthestages

DynamicData SurgeVolumes(1)
Condensers C d and d reboiler b il holdups h ld are typical i l surge volume. l Heuristics: 5 min residence time for condensers and reboilers 20-30 min for a decanter

Ex. Overhead vapor rate=5577 lb/hr and L = 29 lb/ft 3 lb 1ft 3 1hr V = 5577 5min 2 = 32ft 3 hr 29lb 60min

Liquid Volume Fraction = 0.5

DynamicData SurgeVolumes(2)
Aspectratio(L/D)rangesfrom1to4generally
Atypicalvalueof2isoftenused

Volume =

D 2L
4

D 2 2D
4

D3
2

OptionsforHydraulics
Simple Trays: Uses simple correlation for trays p Packing: g Uses simple p correlation for Simple packing Rigorous: Uses the same correlation as tray rating or packing rating Model includes weeping for trays if vapor flow becomes too low

Rigorous Tray and Packing Rating Option

To complete form, you need to select the option update pressure profile in the tray rating or packing rating section

Control
Example showing default controllers for a simple column
Pressure Controller

Level Controlle

Workshop: DistillationColumn
HeterogeneousAzeotropic Distillation
1. 2. 3. 4. BuildsteadystatedesigninAspenPlus Adddynamicdata Trydynamicsimulation Changeconditionoftheprocess

Reactors

IntroductiontoAspenDynamics

LessonObjectives
PresentthereactormodelssupportedbyAspen Dynamics
RCSTR RPlug

Workshop

RCSTR
Perfectlymixedreactor Onlykineticreactionsaresupported Youneedtoconvertequilibriumreactionintotwo kineticreactions(forwardandreverse)
AspenDynamicsmodelenablestheoutletflowofeach phasetobemanipulated p p independently p y Formultiplephases,reactorsprefertouseseparateoutlet streamsinAspenPlus

Itispossibletoreconnecttheliquidandthevapor streaminAspen p Dynamics y

RPlug
Plugflowisdiscretized intoanumberoffixedsize elements Supportliquid,vapor,liquidvaporandliquidliquid vaporphaseoptions Onlykineticreactionsaresupported
Youneedtoconvertequilibriumreactionintotwokinetic reactions(forwardandreverse)

Heattransfereffectbetweencatalystandprocess fluidismodeled

RPlug inDynamicSimulations
Aspendynamicsusesaonedimensional,firstorder finitedifferenceschemetosolvethepartial equationsfortheRPlug reactor.Thefinitesizeof eachelementmaycauseacertainamounterror Reducetheerrorbyincreasingthennumberoffinite differenceelementsfromthedefaultvalueof10
RPlug Report/ProfilesheetinAspenPlus

Workshop: RCSTRandRPlug
ComparedifferenttransferoptionsinRCTRand RPlug

Tasks
IntroductiontoAspenDynamics

LessonObjectives
Exposethepurposeoftasks Explainsyntaxoftaskinstructions Workshop

TaskTheory
A task is a set of instructions that define a sequence of actions taking place during a dynamic simulation
Change the value of some variables, write message You can create as many tasks as you like

The tasks can be

Event-driven tasks: triggered by a predetermined simulation time, a logical becoming true Callable Tasks: called from another task

TaskLanguage
You need to end statements with a semi colon (;) y to access a variable within a: Syntax
Blocks: Blocks(block name).<Variable name>
Ex: Block(C130).Level

Stream: Stream s(block name).<Variable name>

Ex: Stram(FEED).FmR

Compile task: Short cut-Function key F8

FlowsheetofTasks
Tocreateaflowsheet task:
1. 2. 3. 4. 5. DoubleclickAddTask Definetaskname Entertaskinsructions Compile Activatetaskifeventdriven
inactive active callable task error task

CallableTaskSyntax
Syntax
TASK TaskName (ParameterList) TaskStatement ; END

Call
CALL TaskName (ParameterList)

EventDrivenTasktoStartatSpecifiedTime
Syntax
TASK TaskName T kN RUNS AT time i TaskStatement ; END

time:apostive realvaluerepresentingasimulation time

EventDrivenTasktoStartOnEvent
Syntax
TASK TaskName RUNS ONCE WHEN condition TaskStatement ; END TASK TaskName RUNS WHEN condition TaskStatement ; END

Condition:
time==value(synonymofRUNSATvalue) expression1 >,<.==.<>,>=,<=expression2

AssignmentandRamps
Assignment:Tochangethevalueofafixedvariable Unitsofmeasurecanbespecifiedbetweenbraces{}
variable: value {unit};

Ramp:Toincrease/decreaseavariabletotarget value al ewith ithlinearorsineshapedrampofspecified duration

RAMP (variable: value, finalvalue, duration); SRAMP (variable: value, finalvalue, duration);

WAITStatement
WAITFOR:Suspendstheexecutionofthetaskuntil conditionismet.Executionwillcontinuefromthe nextstatement
WAIT FOR condition; ;

WAIT: Suspendstheexecutionofthetaskforthe numberoftimeunitsrepresentedbyRealExpression. Executionwillcontinuefromthenextstatement

WAIT duration;

RESTARTStatement
RESTARTAFTER:Endstheexecutionofatask.Thetaskwill thenrestartafterthenumberoftimeunits representedby RealExpression Executionwillcontinuefromthefirst RealExpression. statementafterstartcondition. task Thetaskwill RESTARTWHEN:Endstheexecutionofatask. restartwhentheconditionistrue.Executionwillcontinue fromthefirststatementafterstartcondition. RESTART:Endstheexecutionofatask.Thetaskwillrestart. Executionwillcontinuefromthefirststatementafterstart condition.

Process Control
IntroductiontoAspenDynamics

LessonObjectives
Learn about the Aspen Dynamics process control models Become familiar with the PIDincr controller Auto-generated generated PIDincr Controller Auto
Pressure Level Temperature

ProcessControlModels
Dynamicslibrary controlmodels

ControlSignal
ControlSignal
Streamtypetoconnectcontrollertothe otherobjects

PIDControlModels
Two models: T d l PIDi PIDincr and d PID PIDincr: Incremental or velocity PID controller
More realistic, close to DCS Auto-tune feature

PID: Positional controller

Backward compatibility

Control
Toobtaingoodresultsthatcanbetransferredtoa realcontrolsystem,itisimportantthatyou accuratelymodeltheloopdynamics Itisparticularlyimportanttomodellagsanddead timesinthecontrolloop

TypicalControlLoopElementTimeConstant
Foranysensor,the h responseof fmeasurementisnotinstantaneous.Itis morerealistictoincludemeasurementlags. Typical items: number time (minutes) type _____________________________________________________ T Temperature Liquid Li id 2 0 0.5 Fi First order d l lag Gas 3 1 First order lag Composition GC 1 3-10 Dead time _____________________________________________________

PIDincrControllerFacePlate
Cascade mode switch Manual mode switch Percent toggles display b/w process unit and % Configuration form Plot form

Auto mode switch Tuning g controller parameters

PIDincrBlockConfiguration: TuningandRanges

[rang OP ] [ gain with units ] = [ gain] [range PV ]

PIDincrControllerAction
Direct:
Whenthemeasuredvariable increase,themanipulated variableshouldbe increased

Indirect:
Whenthemeasuredvariableincrease,themanipulated variableshouldbedecreased

PIDincrInitializeValueButton
U Used dthe h currentvalues l of fthe h measured dvariables i bl andmanipulatedvariabletoinitializecontroller parameters
ThevaluefortheoperatorSPchangestothevalueofthe measuredvariable ThevaluefortheOPchangestothevalueofthe manipulatedvariable Processvariableandoutputrangeschangedto0to2times thevalue
Exception: Exception Forvalveposition position,therangeisspecifiedto0and100%

Typically,youusethisonlyonce,whenyoucreate thePIDincrblock

AutoGeneratedControllers (FlowDrivenMode)
Controller Added When Measured V i bl Variable Pressurein P i vessel Liquidlevel Manipulated Variable Vaporoutlet V tl t moleflowrate Liquidoutlet massflowrate Duty

Pressure

Vaporholdup V h ld ismodeled Liquidholdup ismodeled CSTRblock

Level

Temperature

Temperature

AutoGeneratedControllers (PressureDrivenMode)
During the export, it checks for valves connected on liquid and vapor outlets
If a valve block is present, the controller will manipulated the valve position
Pressure control with vapor outlet Liquid level with liquid outlet

If no valve block is present present, the controller is still created so that you can select another appropriate p in Aspen p Dynamics y variable to manipulate

Autotuning relayfeedbacktest

Remark: 1. Generate sustained oscillation in a controlled manner. 2. Ku=4h/a and Pu are readily available. 3. Set the controller using Ziegler-Nichols type of tuning.

Stepresponse
First order plus dead time model (FOPDT) 0.5e s G (s) = = s + 1 2s + 1 IMC Tuning: K p e Ds

=max(1.7D,0.2 ) 2 + D Kc K p = 2 I = + D / 2
Kc = ?

I = ?

Workshop p:
ControlSystemofHeterogeneousAzeotropic Distillation

SettemperatureController SetconcentrationController Tunecontrollerparameters

CascadeControlandRationControl

Reference
http://support.aspentech.com/ , 2006- SteadyStateto Dynamic.

FurtherStudy
1. Luyben,W.L.;Tyreus,B.D.;Luyben,M.L.Plantwide Process Control,McGrawHill,NewYork,1999. 2 Luyben, 2. L b W. W L. L Plantwide Pl t id Dynamic D i Simulators Si l t i inCh Chemical i l andProcessingandControl,MarcelDekker:NewYork,2002. 3 Luyben, 3. Luyben W. W L. L DistillationDesignandControlUsingAspen Simulation,WILEYInterscience:NewYork,2006.

THANK HAN YOU!