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Steady State Simulation Using Aspen Hysys

Designing Distillation System Using Hysys

y Objective:
y Become comfortable and familiar with various
distillation column models in Hysys and use of sizing
module

Distillation Models
Four models are available which can be used to model
and design industrial fractionation system
y Distillation Column

Model with Condenser and Reboiler in-built


Used for conventional solvent separation

y Refluxed Absorber

Model with Condenser and no Reboiler

Distillation Model

(Continue.)

y Absorber
Model without Condenser and Reboiler
Used for absorber or stripper

y Reboiled Absorber
Model with Reboiler and no Condenser
Used to model reboiled stripping or absorber

Tutorial 3 De-Methaniser

y Build a flowsheet in Hysys to model De-Methaniser


Name

Feed1

Feed 2

Temperature

-95 deg C

-85 deg C

Pressure

2275 kPa

2290 kPa

Flowrate

1620 kmol/hr

215 kmol/hr

Components

Mole fraction

Mole Fraction

N2

0.0025

0.0057

CO2

0.0048

0.0029

C1

0.7041

0.7227

C2

0.1921

0.1176

C3

0.0706

0.0750

i-C4

0.0112

0.0204

N-C4

0.0085

0.0197

i-C5

0.0036

0.0147

N-C5

0.0020

0.0102

C6

0.0003

0.0037

C7

0.0002

0.0047

C8

0.0001

0.0027

Tutorial 3 De-Methaniser Study


y Study Feed Streams

2 Feed Streams contain Methane and heavier vapours


Also contain traces of non condensables N2 and CO2
Feed conditions low temp and high pressure
Decide Thermodynamic System
Which are key components?
What are boiling points of methane and ethane
Configure streams in simulation and study their state (liq/vap)
Can methane be separated by flashing to lower pressure? To
study using a simple flash
Need distillation column

De-Methaniser To Decide Column inputs


y To Decide Column Inputs

What type of column? Fractionator / Stripper / Rectifier?


No need of condenser why?
Number of theoratical stages based on difficulty of separation
Column top pressure and pressure drop per stage
Feed Locations
y Feed-1 at top stage to provide reflux
y Feed-2 at stage 4

Configure column specs y Reboiler Duty


y Distillate Rate

Provide Temperature Estimates

Tutorial 3 De-Methaniser

Column flowsheet details

Ex Duty
Heat Flow
Stream
Feed 1
Feed 2
Ex Duty

2.1e+06

Feed Stage
1
4
2

Temperature Estimates
Top
-68 C
Bottom
27 C
Main TS
Number of Stages
10
Top Stage Pressure
2275
Bottom Stage Pressure
2310
Distillate Rate
1338

Property : Peng Robonson


kPa
kPa
kmol/hr

kJ/hr

Tutorial 3 De-Methaniser

Answer Followings..

y What is mole fraction of methane in overhead?


:______________

Add design specification to get 95 % (mole) of


methane in overhead. You have to add Column
Component Fraction spec from Specs page and
deactivate distillate flowrate.
y What is mole fraction of methane in overhead?
:______________
y What is flowrate of overhead product? :______________

Tutorial 4 De-Ethaniser
y Add pump to transfer bottom product of De-Methaniser to DeEthaniser column with following data
In This cell
Connections
Inlet
Outlet
Energy
Worksheet
DC2 Feed Pressure

Enter
DC1 Btm
DC2 Feed
P=100-HP
2790 kPa

Tutorial 4 De-Ethaniser

(Continue)

y De-Ethaniser is modeled using Distillation column with


following details
In This cell
Connections
Name
No. of stages
Feed stream/Stage
Overhead Vapour Product
Overhead Liquid Product
Bottom Liquid Outlet
Reboiler Duty
Condenser Duty

Enter
DC2
14
DC2 Feed / 6
DC2 Ovhd
DC2 Dist
DC2 Btm
DC2 Reb Q
DC2 Cond Q

Tutorial 4 De-Ethaniser
In This cell
Pressures
Condenser
Condenser Delta P
Reboiler
Temperature Estimates
Condenser
Reboiler
Specifications
Overhead Vapour Product
Distillate Rate
Reflux Ratio

(Continue)

Enter
2725 kPa
35 kPa
2792 kPa
-4 C
95 C
320 kmol/hr
0 kmol/hr
2.5 (Molar)

Answer this
What is flowrate of C2 and C3 in DC2 Btm?
C2 _____________, C3_______________, Ratio C2/C3 ________________

Tutorial 4 De-Ethaniser

(Continue)

y Add design specification to maintain ratio of C2/C3 to 0.01,


deactivating Ovhd Vap Rate. Select Column Component
Ratio as specification type with following information
In This Cell
Name
Stage
Flow Basis
Phase
Spec Value
Numerator
Denominator

Enter
C2/C3
Reboiler
Mole Fraction
Liquid
0.01
Ethane
Propane

What is the flowrate of DC2 Ovhd ? : _____________________

Tutorial 5 Methanol Water Separation

Feed:
63.2 wt% Water
36.8 wt% Methanol
Total flow = 120,000 lb/hr
Pressure 18 psia
Saturated liquid

Desired Purity of Products:


99.95 wt% methanol in the distillate
99.90 wt% water in the bottoms

Tutorial 5 Methanol Water Separator Study


y Study Feed and Required Column Specs

Decide Thermodynamic System


Any Azeotrope between Methanol Water?
What are boiling points of Methanol and Water?
What type of column? Fractionator / Stripper / Rectifier?
Number of theoratical stages based on difficulty of separation
Column top pressure and pressure drop per stage
Feed Location
Configure column specs y Distillate Rate
y Reflux Ratio

Tutorial 5 Methanol Water Separation


Part A:
y Perform a rating calculation of a Methanol tower using the
following data:
Column specification:
38 trays (40 stages)
Feed tray = 23 (stage 24)
Total condenser
Top stage pressure = 16.1 psia
Pressure drop per stage = 0.1 psi
Distillate flowrate = 1245 lbmol/hr
Molar reflux ratio = 1.3
Feed:
63.2 wt% Water
36.8 wt% Methanol
Total flow = 120,000 lb/hr
Pressure 18 psia
Saturated liquid
Use the NRTL Property Method

Tutorial 5 Methanol Water Separation (Continue)


Part B:
y Set up design specifications within the column so the following
two objectives are met:
99.95 wt% methanol in the distillate
99.90 wt% water in the bottoms

y What are condenser and reboiler duty?


Condenser Duty :_________
Reboiler Duty :___________
y What is reflux ratio ? :______________________

Tutorial 5 Methanol Water Separation (Continue)


Part C:
y Perform the same design calculation after specifying
a 60% Murphree efficiency for each tray.
y How do these efficiencies affect the condenser and
reboiler duties of the column?
Part D:
y Perform a tray sizing calculation for the entire column,
given that Bubble Cap trays are used.
What is column diameter required for this separation ? : _____________