Lesson #1: hysys

Fluid package:

Use any EOS, not pv=nrt

If there is any electrolytes or polar molecules present among the feed materials, use activity
coefficient model couple with equation of state. Eg:
NRTL-PR

Lesson #2: hysys

Pressure across the plant - try not to set P across the plant to fall below 3-4 bars, except at feed
to storage tanks (raw materials) and products.
If P falls below that..install compressor or pumps.

Lesson #3: hysys

Reactors:

for early stage of simulation..use conversion reactor. If the simulation is successful for the whole
plant, you may change to other reactors that need kinetic data. Then you can do optimisation of
P & T for your reactor to achieve the highest yeild of products.
use 1 reaction set for 1 reactor only. Many reactions can be attached to 1 reaction set
if you have more than 1 reaction in a reactor, make sure you ranked them according to conversion
priority. The rank no 1 is the main reaction usually.
choose the limiting reactant as base. You may set overall as the phase even if you know it takes
place at liq phase. It is highly affected by your process condition.

LESSON #4: Phases in pipelines.

Please make sure no two phases present in the pipeline. We want to avoid it because it creates
rigourous control of the flow
LESSON #5: Phase separator.

Set the inlet to the phase separator at bubble point condition..i.e. V/F fraction is set to 0.

LESSON #6: Distillation column.

inlet feed also set to bubble point condition. V/F = 0.

at monitor spec, set the parameters you want..i.e. products at top and bottom stream. NEVER set
reflux ratio as the active ir required spec

LESSON #6: Distillation column

However, after done with no (2), always check your reflux ratio to acceptable range.
Pfeed > P reboiler > P condensor.
If the temp.@ condensor = -ve, check for condensed vapour, e.g. H2, HCl etc. Then choose partial
condensor to vent out dissolved light components.
If T@reboiler is very high, reduce the Pressure of the column. then the T can be reduced.
Check decomposition T of your products and materials. We do not want to operate DC which
later destroys all components.
Operate DC at T < decomposition T. Reduce P to achieve that. Its ok to do it at vacuum condition.
I.e. P < 1bar.

LESSON#6..DC cont..

If products spec at top and bottom strean of DC still cannot be achieved, try play around with the
no of trays. In general, efficiency of DC can be increased by increasing no of trays.

LESSON#7..Pressure Drop

Across HX - about 35 to 50kPa

Across cstr - can use change of rho.g.height
across bubble bed or fluidized bed..use pressure drop eqn in particle tech book. (Can't
remember).
 Rule of thumb for Pressure drop across equipment = 2% of inlet P. ( But use with care..for high
overall P system).

LESSON #8. Product purity.

Make sure you know your market demand for product purity before you decide your product
purity.
please make sure your product sent to storage tank fulfill this product purity demand.
product purity measure = in mass fraction, NOT mole fraction. Thus very very important to
present your overall PFD in mass fraction.
check for products/raw materials compound in your waste stream. Make sure they are in small
amount. Increase the efficiency of your separation system if too many products/raw materials
are found in your waste stream.

LESSON #9. recycle stream.

Connect your recycle streams after you have completed your simulation.
include purge stream..make it visible even the flow is zero.
discharge the recycle stream to a storage tank. From the storage tank connect the stream to a
mixer and mix with fresh feed.
the purity of the recycle stream has to be close to the fresh feed purity. Do not recycle if the
separated raw materials contains other materials from the reactions. Increase the separation
efficiency of the recyclable materials.

LESSON #10. Discharge process conditions

discharge temps of either waste streams or products streams has to be at low temperatures,
max 50 -60 oC.
should be also stored at lower pressure, i.e. about 1-3 bar..unless required by the system.

Q#1: Possible problem:

1. wrong setting of base reactant: choose limiting reactant correctly

2. ratio between excess and limiting reactant feed too large. Refer to lit review or try n error.
 3. if there are more than 1 reactions, the conv % between the main reaction and side reactions are
not the same.
Eg: system with 2 reaction equations and overall conv% of 80%, try set co% = 80% for 1st eqn
and set co% = 20% for the 2nd eqn.
3c) Then at the result tab of the reactor, look for the conversion for each of the reaction.
3d) do try and error of the %conv to achieve mol of output which you will always obtain from
patern.
3e) use Adjust function to iterate the conv% of both reactions to achieve the desired mole
output of components.
3f) for each equations, you should be able to see the values of extent of reactions. Try to
prove values in your mass balance.

Q#3: DC monitor spec.

1) Reflux ratio is never our interest. We dont really care how much it is as long as you achieve product
purity you want.
2) But after convergence, make sure you check your reflux ratio..if gives RR = 1 X 10E-6 then you
know this is not possible. Check from literature acceptable values for RR.
3) Item no 2a-2c, you can play around with it..Eg: change the phases at both reboiler or condensors,
either you want to specify at tray no1 or the last tray, or at the distillate or bottom streams.
Play around with total no of trays as well.
add one more spec. Any products you think will be at top or bottom streams.
eg separation of comp A, B and C.
specify comp A at top with comp fraction 0.99.
set comp B at bottom stream with comp fraction 0.99
comp C: comp fraction 0.05 at condensor.

Q#5: the principle of flash drum/ phase separator.

it works just by the principle of pressure drop. When we set the entrance to the flash drum at
bubble point condition, the most volatile comp is ready to vapourise due to change of pressure.
 lower pressure in the separator causes the volatile component to vapourise and separated from
the liq stream.
The myth of flash separate commonly used by students is to separate two phases already in the
pipe line. Which is NOT right. We shouldn't allow two phases to be present in a pipe line.

Q#6. Materials in solid form.

you need to crystallise the material from the liq form. Which in this case you actually need a
crystalliser.
to crystallise the liq you need solubility data of the component in the solvent, which is very tricky
to determine. Tricky but possible to determine.

Q#7. Clarifier simulation.

So far hysys doesn't have any clarifier or thickener in their library.

You can include block diagram in you pfd and write a little of coding for this equipment
use component splitter..i think this is ok for clarifier as it doesn't require any Qin or Qout from
the tank. But of course you have to justify the use of component splitter as a replacement to
clarifier/thickener in your report.

Q#8 press filter: It is available in v02 or aspern..solid simulation. But not sure the one you have is the right
version. Also can use component splitter as a replacement. But justify in report.

EXTRAS

Aiman eh220B: Dulu kita guna conversion rxctor je sbb takda kinetics data

Nornizar Anuar: Limiting reactant set apa?

Aiman eh220B: Since rxn dia polymerzation ada 1 reactant je

Nornizar Anuar: Conversion berapa %?

Aiman eh220B: Tetrafluoroethylene

Aiman eh220B: 80% coversion based on journa

Nornizar Anuar: Yg 20% lagi tu remain as tetra ke kat output stream?

Aiman eh220B: Aahh unreacted

Aiman eh220B: Dalam hysys comp library takda untuk ptfe

Aiman eh220B: Jadi kitorg set as apa tuu "imaginary" component

Nornizar Anuar: Hypothetical

Nornizar Anuar: Kat reactor kan kena set eqn.

Nornizar Anuar: So ptfe tu ikut eqn of desired MW lah kan?

Aiman eh220B: Yupp betul tu

Aiman eh220B: Kitorg set MW weight utk ptfe

Aiman eh220B: Dkt hypothetical comp punya section

Aiman eh220B: Pastu dkt reactor dia produce ptfe ikut specification tu

Nornizar Anuar: Ok..thanks..