Objectives

 choose an appropriate tear stream

 successfully install a stream recycle loop
Preview

 Stream Recycle
– Tear Stream Selection
– Tear Stream Installation
– Tear Stream(s) Convergence

 Problem 7 - Multi-stage Separation

Recycle

 Gives the ability to insert a Tear Stream (a stream with temporary

specifications)
 Adjusts Tear Stream specifications until converged solution is obtained
 Recommendations for Recycle Installation:
– Select a Tear Stream
– With the simulator in Hold mode..
– Break the Tear Stream
– Insert Recycle Block
– Connect recycle stream(s)
– Return simulator to GO mode
Recycle
 Recycle iteration is as follows:
1) Outlet stream of the Recycle block is used to solve the flowsheet up
to the inlet stream of the Recycle block
2) Calculated values of the inlet are then compared to those of the outlet
3) Based on the differences, values in the inlet are modified and passed
to the outlet stream
4) The above steps repeat until the values in the inlet matches those in
the outlet within specified tolerance

Flowsheet
Recycle

 Tolerance values specified on the Parameters page serve as

multipliers for HYSYS’ internal convergence tolerance
 Lower values for the multipliers correspond to tighter tolerances
Recycle
 Numerical page contains options related to the Acceleration Method used
by the Recycle Block to modify the values it passes from the inlet to the
outlet streams
 Calculation Mode (for simulations with multiple Recycle Blocks)
– Nested option:
Each recycle block is solved individually whenever it is encountered during the
calculations
– Simultaneous option:
Recycle blocks are solved simultaneously (used when flowsheet contains multiple inter-
connected recycle loops)
Recycle

 User must select the location of a Tear Stream in a recycle loop

 Choose the Tear Stream(s) to minimize the number of recycles
 Choose the Tear Stream(s) to minimize the number of recycle
variables (i.e. as many variables as possible already specified)
 Choose a stable Tear Stream (i.e. a stream in which fluctuations in
the recycle stream have a minimal effect)
 Rules of Thumb for location of a Tear Stream:
– Downstream of Mixers
– Upstream of Splitters and Separators
– Common streams on multiple, nested loops
Problem 1-Multi Stage Separation

 A staged stabilization process, shown in the attached PFD, separates a feed stream
(see below) into gas and liquid products. Three stages of separation occur at 260,
80, and 20 psia to stabilize the crude. A crude heater is provided before the second
o
stage in order to meet a crude vapor pressure spec of 15 psia at 100 F.
The flash gas from the separators is fed to a three-stage centrifugal compressor
with a final stage discharge pressure of 750 psia. The first two compressor stages
ride off the two lower pressure separation stages. The discharge from each
o
compressor stage is cooled to 100 F and sent to a scrubber whose liquid is recycled
to one of the separator stages. The first-stage scrubber liquid is recycled to the low
pressure separator, while the second and third-stage scrubber liquids are recycled
to the intermediate pressure separator.
Assume a 5 psi pressure drop across each cooler and the crude heater, and that
the adiabatic efficiency of the compressor is 0.7125.
 Feed Composition
Problem 1

 Targeted PFD
Strategy

 We will set up the problem flowsheet from scratch

 set up simulation basis - Peng-Robinson
 set up feed stream
 incrementally build flowsheet and assume a suitable outlet
temperature for the heater block outlet stream.
 Set up recycle stream blocks and connect the inlet and outlet streams.
Leave the outlet streams from the recycle block ‘hanging’.
 After the simulator has converged, connect the recycle output streams to
the appropriate mixer block.
Strategy

 Once the simulator has converged with the recycle streams connected, set
up an ADJUST block to meet the crude TVP specification.
 The adjust block will vary the heat duty of the heater. Set up a cold
properties utility that will reference the crude outlet stream. The adjust
block can now access the TVP of the crude stream referenced in this
utility.
Questions

 Where will we put the Recycle Streams?

 Outlet crude heater temperature?
 Gas Flowrate?
 Liquid Flowrate?
Key Concepts Review

 Recycle streams are needed whenever you require an input

stream that is yet to be calculated further downstream in the
flowsheet.

 Simulation strategy: Set up flowsheet without recycle outlets

connected to compute initial guesses.

 Hook up recycle outlet streams after initial values are

obtained.
Problem 1 – Detail Steps

 File, New, Case

Detail Steps

 From Component List, click Add

Problem 1 – Detail Steps

 Component List View, Add Pure

Problem 1 – Detail Steps

 Add Hypo group

Problem 1 – Detail Steps

 Add Hypothetical component

Problem 1 – Detail Steps

 Change hypo component name

Problem 1 – Detail Steps

 Estimate Unknown props

Problem 1 – Detail Steps

 Blue fonts are inputs, red fonts are estimated

Problem 1 – Detail Steps

 Close Hypothetical Input tabular, back to Components tab

Problem 1 – Detail Steps

 Click View
Problem 1 – Detail Steps

 Select Hypothetical
Problem 1 – Detail Steps

 Add Hypo Group to the list, or one by one

Problem 1 – Detail Steps

 Close Component List View, Click Fluid Pkgs

Problem 1 – Detail Steps

 Select Peng - Robinson

Problem 1 – Detail Steps

 ..then Enter Simulation Environment

Problem 1 – Detail Steps

 File, Save As
Problem 1 – Detail Steps

 Save
Problem 1 – Detail Steps

 Tools, Preferences, Variables

Problem 1 – Detail Steps

 Select Unit in Available Unit Sets

Problem 1 – Detail Steps

 Click Object Palette or press F4

Problem 1 – Detail Steps

 Click Material Stream on Object Palette

Problem 1 – Detail Steps

 Double click, Worksheet, Composition. Enter the mole

fractions
Problem 1 – Detail Steps

 Change the composition basis

Problem 1 – Detail Steps

 Enter the mole flow for each component

Problem 1 – Detail Steps

 Worksheet, Conditions, 135 degF in Temperature, 1050 psia

in Pressure
Problem 1 – Detail Steps

 Click separator on Object Palette

Problem 1 – Detail Steps

 Design, Connections
Problem 1 – Detail Steps

 Enter 790 psi in Parameters, Delta P

Problem 1 – Detail Steps

 Or we can enter 260 psia in Pressure

Problem 1 – Detail Steps

 Close Flash_1 form

Problem 1 – Detail Steps

 Click heater
Problem 1 – Detail Steps

 Double click on heater, enter labels

Problem 1 – Detail Steps

 Enter 5 psi in Delta P or enter 255 psia in Pressure

Problem 1 – Detail Steps

 Assume 200 degF as outlet heater temperature. This value

will be adjusted later to achieve crude vapor pressure of 15
psia (liquid outlet Flash_3)
Problem 1 – Detail Steps

 This will appear

Problem 1 – Detail Steps

 Add Mixer
Problem 1 – Detail Steps

 Add Labels
Problem 1 – Detail Steps

 Close Mixer and add separator

Problem 1 – Detail Steps

 Enter labels
Problem 1 – Detail Steps

 Enter Delta P of 175 psi or enter 80 psia in Pressure

Problem 1 – Detail Steps

 Close Flash_2 form and add mixer

Problem 1 – Detail Steps

 Enter labels
Problem 1 – Detail Steps

 Close Feed_F3 form, add separator

Problem 1 – Detail Steps

 Enter labels
Problem 1 – Detail Steps

 Worksheet, conditions, enter 20 psia in Pressure

Problem 1 – Detail Steps

 Close Flash_3 form and add compressor

Problem 1 – Detail Steps

 Enter labels
Problem 1 – Detail Steps

 Enter adiabatic efficiency of 72%

Problem 1 – Detail Steps

 Enter 80 psia as discharge pressure

Problem 1 – Detail Steps

 Close Comp_1 form and add Mixer

Problem 1 – Detail Steps

 Enter labels
Problem 1 – Detail Steps

 Close Mixer_3 form and add Cooler

Problem 1 – Detail Steps

 Enter labels
Problem 1 – Detail Steps

 Enter 5 psi in Delta P OR 75 psia in Pressure

Problem 1 – Detail Steps

 Enter 100 degF in Feed_F4 Temperature

Problem 1 – Detail Steps

 Close Cool_1 form and add Separator

Problem 1 – Detail Steps

 Enter labels
Problem 1 – Detail Steps

 Close Flash_4 form and add Compressor

Problem 1 – Detail Steps

 Enter labels
Problem 1 – Detail Steps

 Enter adiabatic efficiency 72% and 260 psia as discharge

pressure
Problem 1 – Detail Steps

 Close Comp_2 form and add Mixer

Problem 1 – Detail Steps

 Enter labels
Problem 1 – Detail Steps

 Close Mixer_4 form and add Cooler

Problem 1 – Detail Steps

 Enter labels
Problem 1 – Detail Steps

 Enter 5 psi in Delta P OR 255 psia in Pressure

Problem 1 – Detail Steps

 Enter 100 degF in Feed_F5 Temperature

Problem 1 – Detail Steps

 Close Cool_2 form and add Separator

Problem 1 – Detail Steps

 Enter Labels
Problem 1 – Detail Steps

 Close Flash_5 form and add Compressor

Problem 1 – Detail Steps

 Enter labels
Problem 1 – Detail Steps

 Enter adiabatic efficiency of 72% and 750 psia as discharge

pressure
Problem 1 – Detail Steps

 Close Comp_3 form and add Cooler

Problem 1 – Detail Steps

 Enter labels
Problem 1 – Detail Steps

 Enter 5 psi in Delta P OR enter 745 psia in Feed_F6

Pressure
Problem 1 – Detail Steps

 Enter 100 degF in Feed_F6 Temperature

Problem 1 – Detail Steps

 Close form and add separator

Problem 1 – Detail Steps

 Enter Labels
Problem 1 – Detail Steps

 Close Flash_6 and add mixer

Problem 1 – Detail Steps

 Enter Labels
Problem 1 – Detail Steps

 Close form
Problem 1 – Detail Steps

 Define Recycle_1 & Recycle_2. Initially take Recycle_1 is the same as

Liq_Return stream, and Recycle_2 is the same as Liq_F4
Problem 1 – Detail Steps

 Click Define from Other Stream on Recycle_1. Select

Liq_Return. Do similarly to Recycle_2
Problem 1 – Detail Steps

 This will appear

Problem 1 – Detail Steps

 Mix Recycle_1 with Outlet_Heater in Mixer_1

Problem 1 – Detail Steps

 Mix Recycle_2 with Liq_F2 using Mixer_2

Problem 1 – Detail Steps

 This will appear and add 2 recycle

Problem 1 – Detail Steps

 Enter labels. Select Recycle_1 in Outlet

Problem 1 – Detail Steps

 Enter Labels. Select Recycle_2 in Outlet

Problem 1 – Detail Steps

 This will appear. Calculation converged

Problem 1 – Detail Steps

 Flowsheet is completed and simulator is converged. Now we

will calculate the outlet heater temperature which gives crude
(Liquid Outlet Flash_3) vapor pressure of 15 psia. Use
Adjust.
 Before running the Adjust operation, we have to show crude
vapor pressure variable in stream utility
Problem 1 – Detail Steps

 Attachments - Utilities
Problem 1 – Detail Steps

 Click Create
Problem 1 – Detail Steps

 Select Cold Properties

Problem 1 – Detail Steps

 Add Adjust
Problem 1 – Detail Steps

 Enter Labels
Problem 1 – Detail Steps

 Select Variables on Adjusted Variables

Problem 1 – Detail Steps

 This will appear

Problem 1 – Detail Steps

 Select Var on Targeted Variables

Problem 1 – Detail Steps

 Enter 15 psia in Specified Target Value

Problem 1 – Detail Steps

 Enter solving parameters

Result Checking
Result Checking

 True Vapor Pressure : 14.9912 psia

 Outlet heater temperature : 144.33 degF
Result Checking

 Gas Flowrate is 7125.8 lbmole/hr

 Crude Flowrate is 62695 barrel/day
Problem 2 – Gas Compression

 Gas from field will be increased its pressure in a Gas Compression Plant.
Gas will enter a separator to separate liquids (assume pressure drop = 0
across the separator). Outlet gas pressure will be increased to 1000 psia
using compressor with adiabatic efficiency of 72.5%
 Due to high temperature of compressor outlet gas, cooler is needed
(pressure drop = 10 psi across cooler). Outlet temperature is set to a point
which methane content in gas outlet is 80% (mole fraction)
 Gas outlet cooler then be separated in a discharge scrubber (assume
pressure drop = 0). To get more gas, the liquid is recycled to the inlet of
Gas Compression Plant
Problem 2 – Gas Compression

 Data
Questions

 Where will we put the recycle stream?

 Outlet cooler temperature?
 Gas flowrate (lbmole/hr) from the plant?
 Flowrate (lbmole/hr) of recycle stream?
Problem 2 – Detail Steps

 File, New, Case

Problem 2 – Detail Steps

 Add components
Problem 2 – Detail Steps

 Add pure
Problem 2 – Detail Steps

 Use Peng – Robinson

Problem 2 – Detail Steps

 Save as Problem_2
Problem 2 – Detail Steps

 Use Training Unit Set

Problem 2 – Detail Steps

 Add material stream, enter composition

Problem 2 – Detail Steps

 Enter stream conditions

Problem 2 – Detail Steps

 Add separator
Problem 2 – Detail Steps

 Enter labels
Problem 2 – Detail Steps

 Add compressor
Problem 2 – Detail Steps

 Enter lables
Problem 2 – Detail Steps

 Enter adiabatic efficiency of 72.5% and discharge pressure

Problem 2 – Detail Steps

 Add cooler
Problem 2 – Detail Steps

 Enter labels
Problem 2 – Detail Steps

 Enter 10 psi in Delta P OR enter 990 psia in Feed Sep_2

pressure
Problem 2 – Detail Steps

 Enter initial value of 50 degF outlet cooler temperature

Problem 2 – Detail Steps

 Close form and add separator

Problem 2 – Detail Steps

 Enter labels
Problem 2 – Detail Steps

 Close form and add material stream

Problem 2 – Detail Steps

 Name the stream Liq_Recy

Problem 2 – Detail Steps

 Click Define from Other Stream. Select Recycle

Problem 2 – Detail Steps

 Make Liq_Recy as inlet to Separator_1

Problem 2 – Detail Steps

 Close form and add recycle

Problem 2 – Detail Steps

 Enter labels
Problem 2 – Detail Steps

 Not converged. What happened?

Problem 2 – Detail Steps

 Add Adjust operation

Problem 2 – Detail Steps

 Name : Adjust
Problem 2 – Detail Steps

 Adjusted variables, select var

Problem 2 – Detail Steps

 Target Variable, Select Var

Problem 2 – Detail Steps

 This will appear, enter 0.8 in Specified Target Value

Problem 2 – Detail Steps

 Enter solving parameters

Problem 2 – Detail Steps

 This will appear. Converged.

Result Checking

 Outlet cooler temperature : 9.03 degF

Answers

 Recycle location : Liquid outlet separator-2

 Outlet cooler temp : 9.0301 degF
 Plant gas flowrate : 123.72 lbmole/hr
 Recycle flowrate : 2.202 lbmole/hr