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Aspen HYSYS Simulation Module

Simulation is the tool every process engineer should be conversant with.
REALCHEM provides the necessary training for you to understand the
simulation tool and help you to gain confidence to use it yourself. You can
spend sufficient time learning and practicing the tool with guidance from

Process Design and Simulation

Process simulation is used for the design, development, analysis, and
optimization of technical processes and is mainly applied to chemical plants
and chemical processes, but also to power stations, and similar technical
facilities. Process simulation is a model-based representation of chemical,
physical, biological, and other technical processes and unit operations in
software. Basic prerequisites are a thorough knowledge of chemical and
physical properties of pure components and mixtures, of reactions, and of
mathematical models which, in combination, allow the calculation of a
process in computers.
Aspen HYSYS is a comprehensive process modeling tool used by the worlds
leading oil and gas producers, refineries, and engineering companies for
process simulation and process optimization in design and operations.
Why simulation software knowledge is important:
For the design of various components in any plant/facility, Process
Simulations are performed:

To solve Mass and Energy Balance using in-built Mathematical Models.

To obtain the Flow Rates, Compositions and Thermo Physical Properties

of process streams at its various operating conditions.

To Predict Phase behavior of Fluids.

Simulations are also performed to detect abnormal conditions like:

Formation of hydrates by hydrocarbons due to fall in Pressure &


Fall in temperature below Hydrocarbon or Water- Dew Point.

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Flashing of liquids across Control Valves or Drain Valves, etc.

Condensation of Vapors due to cooling.

Latent heat data required at relieving conditions (Temperature and

Pressure) for Safety Valve Sizing calculations.

Time behavior of inventory streams during Depressurization.

Minimum temperatures during Venting from High Pressure

Atmosphere, which may affect material selection upstream
downstream of vent valve (inclusive).


User can easily do steady state &dynamic process modeling in Aspen

Application of Steady state simulators:

Process design (to determine the process conditions required to

produce the desired product)

Process equipment design (to size the equipment required to produce

the desired product)

Process design optimization (to determine the optimum configuration

of equipment and maximize energy recovery)

Process Optimization (to determine changes to the current operating

conditions that can either reduce operating costs or Increase

Process simulation software describes processes in flow diagrams where unit

operations are positioned and connected by product streams. The software
has to solve the mass and energy balance to find a stable operating point.
The goal of a process simulation is to find optimal conditions for an examined
process. This is essentially an optimization problem which has to be solved in
an iterative process.
Process simulation always uses models which introduce approximations and
assumptions but allow the description of a property over a wide range of
temperatures and pressures which might not be covered by real data. Models
also allow interpolation and extrapolation - within certain limits - and enable
the search for conditions outside the range of known properties.

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The development of models for a better representation of real processes is

the core of the further development of the simulation software. Model
development is done on the chemical engineering side but also in control
engineering and for the improvement of mathematical simulation
techniques. Process simulation is therefore one of the few fields where
scientists from chemistry, physics, computer science, mathematics, and
several engineering fields work together.
A lot of efforts are made to develop new and improved models for the
calculation of properties. This includes for example the description of
Thermo physical properties like vapor pressures, viscosities, caloric
data, etc. of pure components and mixtures
Properties of different apparatuses like reactors, distillation columns,
pumps, etc.
Chemical reactions and kinetics
Environmental and safety-related data

Two main different types of models can be distinguished:

1. Rather simple equations and correlations where parameters are fitted
to experimental data.
2. Predictive methods where properties are estimated.
The equations and correlations are normally preferred because they describe
the property (almost) exactly. To obtain reliable parameters it is necessary to
have experimental data which are usually obtained from factual data banks
or, if no data are publicly available, from measurements.
Using predictive methods is much cheaper than experimental work and also
than data from data banks. Despite this big advantage predicted properties
are normally only used in early steps of the process development to find first
approximate solutions and to exclude wrong pathways because these
estimation methods normally introduce higher errors than correlations
obtained from real data.
Process simulation also encouraged the further development of
mathematical models in the fields of numeric and the solving of complex

The history of process simulation is strongly related to the development of
the computer science and of computer hardware and programming
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languages. First working simple implementations of partial aspects of

chemical processes have been made in the 1970 where, for the first time,
suitable hardware and software (here mainly the programming languages
FORTRAN and C) have been available. The modeling of chemical properties
has been started already much earlier, notably the cubic equation of states
and the Antoine equation are developments of the 19th century.

Steady state and dynamic process simulation

Initially process simulation was used to simulate steady state processes.
Steady-state models perform a mass and energy balance of a stationary
process (a process in an equilibrium state) but any changes over time had to
be ignored. Dynamic simulation is an extension of steady-state process
simulation whereby time-dependence is built into the models via derivative
terms i.e. accumulation of mass and energy. The advent of dynamic
simulation means that that the time-dependent description, prediction and
control of real processes in real time have become possible. This includes the
description of starting up and shutting down a plant, changes of conditions
during a reaction, holdups, thermal changes and more.
Dynamic simulations require increased calculation time and are
mathematically more complex than a steady state simulation. It can be seen
as a multiply repeated steady state simulation (based on a fixed time step)
with constantly changing parameters.
Dynamic simulation can be used in both an online and offline fashion. The
online case being model predictive control, where the real-time simulation
results are used to predict the changes that would occur for a control input
change, and the control parameters are optimized based on the results.
Offline process simulation can be used in the design, troubleshooting and
optimization of process plant as well as the conduction of case studies to
assess the impacts of process modifications.
The topics covered in this module are:


HRS (4 weeks)

Introduction to HYSYS Software

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HYSYS User Interface


Defining the Simulation Basis


Selecting a Unit Set


Adding a Stream


Flash Calculations


Adding Utilities


The Stream Property Value

1.10 Additional Exercises

1.11 Optimization in HYSYS
1.12 Set and Adjust Logic Operations
1.13 Flash Calculation
1.14 PFD Preparation
1.16 Oil Manager / Characterization
1.17 Pipe Sizing and Pressure Drop in HYSYS
REALCHEM offers different courses for you to learn how to use Aspen
HYSYS. If you want to work as a process engineer in any process engineering
firm or any operation industry, then you should have good knowledge of
Aspen Hysys software.

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