Beruflich Dokumente
Kultur Dokumente
1
September 2001
Copyright (c) 1981-2001 by Aspen Technology, Inc. All rights reserved.
Aspen Plus®, Aspen Properties®, Aspen Engineering Suite, AspenTech®, ModelManager, the aspen leaf logo and
Plantelligence are trademarks or registered trademarks of Aspen Technology, Inc., Cambridge, MA.
All other brand and product names are trademarks or registered trademarks of their respective companies.
This manual is intended as a guide to using AspenTech's software. This documentation contains AspenTech
proprietary and confidential information and may not be disclosed, used, or copied without the prior consent of
AspenTech or as set forth in the applicable license agreement. Users are solely responsible for the proper use of the
software and the application of the results obtained.
Although AspenTech has tested the software and reviewed the documentation, the sole warranty for the software
may be found in the applicable license agreement between AspenTech and the user. ASPENTECH MAKES NO
WARRANTY OR REPRESENTATION, EITHER EXPRESSED OR IMPLIED, WITH RESPECT TO THIS
DOCUMENTATION, ITS QUALITY, PERFORMANCE, MERCHANTABILITY, OR FITNESS FOR A
PARTICULAR PURPOSE.
Corporate
Aspen Technology, Inc.
Ten Canal Park
Cambridge, MA 02141-2201
USA
Phone: (1) (617) 949-1021
Toll Free: (1) (888) 996-7001
Fax: (1) (617) 949-1724
URL: http://www.aspentech.com
Division
Design, Simulation and Optimization Systems
Aspen Technology, Inc.
Ten Canal Park
Cambridge, MA 02141-2201
USA
Phone: (617) 949-1000
Fax: (617) 949-1030
Contents
Separators 2-1
Flash2 Reference ..............................................................................................................2-2
Flowsheet Connectivity for Flash2 ......................................................................2-2
Specifying Flash2.................................................................................................2-3
EO Usage Notes for Flash2..................................................................................2-3
Flash3 Reference ..............................................................................................................2-4
Flowsheet Connectivity for Flash3 ......................................................................2-4
Specifying Flash3.................................................................................................2-5
Decanter Reference ..........................................................................................................2-6
Flowsheet Connectivity for Decanter...................................................................2-6
Specifying Decanter .............................................................................................2-7
EO Usage Notes for Decanter ..............................................................................2-9
Sep Reference.................................................................................................................2-10
Flowsheet Connectivity for Sep .........................................................................2-10
Columns 4-1
DSTWU Reference ..........................................................................................................4-3
Flowsheet Connectivity for DSTWU...................................................................4-4
Specifying DSTWU .............................................................................................4-4
Distl Reference.................................................................................................................4-5
Flowsheet Connectivity for Distl .........................................................................4-5
Specifying Distl....................................................................................................4-6
SCFrac Reference.............................................................................................................4-7
Flowsheet Connectivity for SCFrac .....................................................................4-7
Specifying SCFrac................................................................................................4-8
RadFrac Reference ...........................................................................................................4-9
Reactors 5-1
RStoic Reference..............................................................................................................5-3
Flowsheet Connectivity for RStoic ......................................................................5-3
Specifying RStoic.................................................................................................5-4
EO Usage Notes for RStoic..................................................................................5-6
RYield Reference .............................................................................................................5-7
Flowsheet Connectivity for RYield......................................................................5-7
Specifying RYield ................................................................................................5-8
EO Usage Notes for RYield .................................................................................5-8
REquil Reference .............................................................................................................5-9
Flowsheet Connectivity for REquil......................................................................5-9
Specifying REquil ..............................................................................................5-10
RGibbs Reference ..........................................................................................................5-11
Flowsheet Connectivity for RGibbs...................................................................5-11
Specifying RGibbs .............................................................................................5-12
References ..........................................................................................................5-15
RCSTR Reference ..........................................................................................................5-16
Flowsheet Connectivity for RCSTR ..................................................................5-16
Specifying RCSTR.............................................................................................5-17
RPlug Reference.............................................................................................................5-20
Flowsheet Connectivity for RPlug .....................................................................5-20
Specifying RPlug................................................................................................5-22
RBatch Reference...........................................................................................................5-24
Flowsheet Connectivity for RBatch ...................................................................5-24
Specifying RBatch..............................................................................................5-25
Manipulators 7-1
Mult Reference.................................................................................................................7-2
Flowsheet Connectivity for Mult .........................................................................7-2
Specifying Mult....................................................................................................7-2
EO Usage Notes for Mult.....................................................................................7-3
Dupl Reference.................................................................................................................7-4
Flowsheet Connectivity for Dupl .........................................................................7-4
Specifying Dupl....................................................................................................7-5
EO Usage Notes for Dupl.....................................................................................7-5
ClChng Reference ............................................................................................................7-6
Flowsheet Connectivity for ClChng.....................................................................7-6
Specifying ClChng ...............................................................................................7-6
Analyzer Reference ..........................................................................................................7-7
Flowsheet Connectivity for Analyzer ..................................................................7-8
Specifying Analyzer.............................................................................................7-8
EO Usage Notes for Analyzer..............................................................................7-8
Feedbl Reference..............................................................................................................7-9
Selector Reference..........................................................................................................7-10
Flowsheet Connectivity for Selector ..................................................................7-10
Specifying Selector ............................................................................................7-10
EO Usage Notes for Selector .............................................................................7-11
Qtvec Reference .............................................................................................................7-12
Flowsheet Connectivity for Qtvec......................................................................7-12
Specifying Qtvec ................................................................................................7-12
Measurement Reference.................................................................................................7-14
xii • About This Manual Aspen Plus 11.1 Unit Operation Models
Technical Support
World Wide Web For additional information about AspenTech
products and services, check the AspenTech World Wide Web
home page on the Internet at: http://www.aspentech.com/
Technical resources AspenTech customers with a valid license
and software maintenance agreement can register to access the
Online Technical Support Center at
http://support.aspentech.com/
This web support site allows you to:
• Access current product documentation
• Search for tech tips, solutions and frequently asked questions
(FAQs)
• Search for and download application examples
• Submit and track technical issues
• Send suggestions
• Report product defects
• Review lists of known deficiencies and defects
Registered users can also subscribe to our Technical Support e-
Bulletins. These e-Bulletins are used to proactively alert users to
important technical support information such as:
• Technical advisories
• Product updates and Service Pack announcements
Contacting Customer Customer support is also available by phone, fax, and email for
Support customers with a current support contract for this product. For the
most up-to-date phone listings, please see the Online Technical
Support Center at http://support.aspentech.com.
The following contact information was current when this product
was released:
Hours
Support Centers Operating Hours
North America 8:00 – 20:00 Eastern Time
South America 9:00 – 17:00 Local time
Europe 8:30 – 18:00 Central European time
Asia and Pacific Region 9:00 – 17:30 Local time
Aspen Plus 11.1 Unit Operation Models About This Manual • xiii
Phone Support Phone Numbers
Centers
North 1-888-996-7100 Toll-free from U.S., Canada, Mexico
America 1-281-584-4357 North America Support Center
(52) (5) 536-2809 Mexico Support Center
South (54) (11) 4361-7220 Argentina Support Center
America (55) (11) 5012-0321 Brazil Support Center
(0800) 333-0125 Toll-free to U.S. from Argentina
(000) (814) 550-4084 Toll-free to U.S. from Brazil
8001-2410 Toll-free to U.S. from Venezuela
Europe (32) (2) 701-95-55 European Support Center
Country specific toll-free numbers:
Belgium (0800) 40-687
Denmark 8088-3652
Finland (0) (800) 1-19127
France (0805) 11-0054
Ireland (1) (800) 930-024
Netherlands (0800) 023-2511
Norway (800) 13817
Spain (900) 951846
Sweden (0200) 895-284
Switzerland (0800) 111-470
UK (0800) 376-7903
Asia and (65) 395-39-00 Singapore
Pacific (81) (3) 3262-1743 Tokyo
Region
xiv • About This Manual Aspen Plus 11.1 Unit Operation Models
Fax Support Centers Fax Numbers
North America 1-617-949-1724 (Cambridge, MA)
1-281-584-1807 (Houston, TX: both Engineering and
Manufacturing Suite)
1-281-584-5442 (Houston, TX: eSupply Chain Suite)
1-281-584-4329 (Houston, TX: Advanced Control Suite)
1-301-424-4647 (Rockville, MD)
1-908-516-9550 (New Providence, NJ)
1-425-492-2388 (Seattle, WA)
South America (54) (11) 4361-7220 (Argentina)
(55) (11) 5012-4442 (Brazil)
Europe (32) (2) 701-94-45
Asia and Pacific (65) 395-39-50 (Singapore)
Region (81) (3) 3262-1744 (Tokyo)
This chapter describes the unit operation models for mixing and
splitting streams. The models are:
Model Description Purpose Use For
Mixer Stream mixer Combines multiple Mixing tees. Stream mixing operations.
streams into one Adding heat streams. Adding work streams
stream
FSplit Stream splitter Divides feed based on Stream splitters. Bleed valves
splits specified for
outlet streams
SSplit Substream splitter Divides feed based on Stream splitters. Perfect fluid-solid separators
splits specified for
each substream
Aspen Plus 11.1 Unit Operation Models Mixers and Splitters • 1-1
Mixer Reference
Use Mixer to combine streams into one stream. Mixer models
mixing tees or other types of mixing operations.
Mixer combines material streams (or heat streams or work
streams) into one stream. Select the Heat (Q) and Work (W) Mixer
icons from the Model Library for heat and work streams
respectively. A single Mixer block cannot mix streams of different
types (material, heat, work).
Use the following forms to enter specifications and view results for
Mixer:
Use this form To do this
Input Enter operating conditions and flash convergence
parameters
Block Options Override global values for physical properties,
simulation options, diagnostic message levels, and
report options for this block
Results View Mixer simulation results
Dynamic Specify parameters for dynamic simulations
Flowsheet
Connectivity for
Mixer Material
(2 or more) Material
Water (optional)
Heat
Heat
(2 or more)
1-2 • Mixers and Splitters Aspen Plus 11.1 Unit Operation Models
Heat Streams
Work
Work
(2 or more)
Aspen Plus 11.1 Unit Operation Models Mixers and Splitters • 1-3
Mixer performs an adiabatic calculation on the product to
determine the outlet temperature, unless Mass Balance Only
Calculations is specified on the Mixer BlockOptions
SimulationOptions sheet or the Setup SimulationOptions
Calculations sheet.
EO Usage Notes for All features of Mixer are available in the EO formulation, except
Mixer the features which are globally unsupported.
1-4 • Mixers and Splitters Aspen Plus 11.1 Unit Operation Models
FSplit Reference
FSplit combines streams of the same type (material, heat, or work
streams) and divides the resulting stream into two or more streams
of the same type. All outlet streams have the same composition and
conditions as the mixed inlet. Select the Heat (Q) and Work (W)
FSplit icons from the Model Library for heat and work streams
respectively. Use FSplit to model flow splitters, such as bleed
valves.
FSplit cannot split a stream into different types. For example,
FSplit cannot split a material stream into a heat stream and a
material stream.
To model a splitter where the amount of each substream sent to
each outlet can differ, use an SSplit block. To model a splitter
where the composition and properties of the output streams can
differ, use a Sep block or a Sep2 block.
Use the following forms to enter specifications and view results for
FSplit:
Use this form To do this
Input Enter split specifications, flash conditions
and calculation options, and key components
associated with split specifications
Block Options Override global values for physical
properties, simulation options, diagnostic
message levels, and report options for this
block
Results View split fractions for outlet streams, and
material and energy balance results
Flowsheet
Material
Connectivity for (2 or more)
Material
FSplit (any number)
Aspen Plus 11.1 Unit Operation Models Mixers and Splitters • 1-5
Heat
Heat (2 or more)
(any number)
Work
Work (2 or more)
(any number)
1-6 • Mixers and Splitters Aspen Plus 11.1 Unit Operation Models
When FSplit has more than one inlet, you can do one of the
following:
• Enter the outlet pressure on the FSplit Input FlashOptions sheet
• Let the outlet pressure default to the minimum pressure of the
inlet streams
To split heat streams or work streams Specify the fraction of the
combined inlet heat or work for each outlet stream except one.
FSplit puts any remaining heat or work in the unspecified outlet
stream to satisfy energy balance.
EO Usage Notes for The features listed below are not supported in equation-oriented
FSplit formulation. However, the capabilities are still available for the EO
solution strategy via the Perturbation Layer.
• Specifications which result in renormalized split fractions
during sequential-modular calculations
• Features which are globally unsupported
Aspen Plus 11.1 Unit Operation Models Mixers and Splitters • 1-7
SSplit Reference
SSplit combines material streams and divides the resulting stream
into two or more streams. Use SSplit to model a splitter where the
split of each substream among the outlet streams can differ.
Substreams in the outlet streams have the same composition,
temperature, and pressure as the corresponding substreams in the
mixed inlet stream. Only the substream flow rates differ. To model
a splitter in which the composition and properties of the
substreams in the output streams can differ, use a Sep block or a
Sep2 block.
Use the following forms to enter specifications and view results for
SSplit:
Use this form To do this
Input Enter split specifications, flash conditions,
calculation options, and key components associated
with split specifications
BlockOptions Override global values for physical properties,
simulation options, diagnostic message levels, and
report options for this block
Results View split fractions of each substream in each outlet
stream, and material and energy balance results
Flowsheet
Connectivity for Material
Material (2 or more)
SSplit
(any number)
Material Streams
1-8 • Mixers and Splitters Aspen Plus 11.1 Unit Operation Models
You can specify mole or mass flow rate for one of the following:
• The entire substream
• A subset of components in the substream
You can specify the flow rate of a component in a substream of an
outlet stream. To do this, define a key component and specify the
flow rate for the key component. Similarly, you can specify the
flow rate for a group of components in a substream of an outlet
stream. To do this, define a key group of components and specify
the total flow rate for the group (the sum of the component flow
rates).
Substreams in outlet streams have the same composition as the
corresponding substream in the mixed inlet stream. For this reason,
when you specify the flow rate of a key, the total flow rate of the
substream in the outlet stream is greater than the flow rate you
specify.
When SSplit has more than one inlet, you can do one of the
following:
• Enter the outlet pressure on the Input FlashOptions sheet.
• Let the outlet pressure default to the minimum pressure of the
inlet streams.
The composition, temperature, pressure, and other substream
variables for all outlet streams have the same values as the mixed
inlet. Only the substream flow rates differ.
Aspen Plus 11.1 Unit Operation Models Mixers and Splitters • 1-9
1-10 • Mixers and Splitters Aspen Plus 11.1 Unit Operation Models
CHAPTER 2
Separators
Material
(any number)
Water (optional)
Heat Liquid
(optional)
Material Streams
Material
(any number)
1st Liquid
Heat 2nd Liquid
(optional)
Material Streams
Heat Exchangers
Cold Inlet
Material Streams
F Shell
G Shell
Split Flow
H Shell
J Shell
Divided Flow
X Shell
Cross Flow
TEMA Shell Types
Shell to Bundle
Clearance
Shell Dimensions
Baffle Geometry Calculation of shell-side film coefficient and pressure drop require
information about the baffle geometry within the shell. Enter baffle
geometry on the Geometry Baffles sheet.
HeatX can calculate shell-side values for both segmental baffle
shells and rod baffle shells. Other required information depends on
the baffle type. For segmental baffles, required information
includes:
• Baffle cut
• Baffle spacing
• Baffle clearances
For rod baffles, required information includes:
• Ring dimensions
• Support rod geometry
The next two figures show the baffle dimensions. The Baffle Cut
in the Dimensions for Segmental Baffles figure is a fraction of the
shell diameter. All clearances are diametric.
Rod Diameter
Tube Geometry Calculation of the tube-side film coefficient and pressure drop
require information about the geometry of the tubebank. HeatX
also uses this information to calculate the heat transfer coefficient
from the film coefficients. Enter tube geometry on the Geometry
Tubes sheet.
You can select a heat exchanger with either bare or low-finned
tubes. The sheet also includes fields for:
• Total number of tubes
• Tube length
• Tube diameters
• Tube layout
• Tube material of construction
The next two figures show tube layout patterns and fin dimensions.
30 45 60 90
Tube
Tube Pitch Tube Tube
Pitch Pitch Pitch
Triangle Rotated Rotated Square
Square Triangle
Direction of Flow
Tube Layout Patterns
Fin Thickness
Fin Height
Fin Dimensions
Nozzle Geometry Calculations for pressure drop include the calculation of pressure
drop in the exchanger nozzles. Enter nozzle geometry on the
Geometry Nozzles sheet.
Model Correlations HeatX uses open literature correlations for calculating film
coefficients and pressure drops. The next four tables list the model
correlations.
Tube-side Heat Transfer Coefficient Correlations
Mechanism Flow Regime Correlation References
Single-phase Laminar Schlunder [1]
Turbulent Gnielinski [1]
Boiling - Steiner/Taborek [2]
vertical tubes
Boiling - Shah [3, 4]
horizontal tubes
Condensation - Laminar Nusselt [5]
vertical tubes Laminar wavy Kutateladze [6]
Turbulent Labuntsov [7]
Shear-dominated Rohsenow [8]
Condensation - Annular Rohsenow [8]
horizontal tubes Stratifying Jaster/Kosky method [9]
If R = 1, then:
P∗ 2
F=
2 − P ∗ (2 − 2 )
(1 − P ∗ ) ln ∗
2 − P (2 + 2 )
If R=1, then:
P
P∗ =
P − NP + N
Where:
P = Thermal effectiveness for the overall heat
exchanger:
(temp. increase of cold fluid)/(inlet T hot fluid –
inlet T cold fluid)
N = Number of shells in series
Reference
Cold Water
Outlets (optional)
inlet At least one material stream on the hot side, unless a load
stream is used.
At least one material stream on the cold side, unless a load
stream is used.
outlet One outlet stream for each inlet stream.
One water decant stream for each outlet stream (optional).
Load Streams
$LNGQ03
$LNGQ02 $LNGQ04
$LNGHTR
S1 S2
LNGIN MHEATER LNGOUT
Example of MHeatX Computational Structure
Hot Outlet
Cold Outlet
Cold Water (optional)
Material Streams
Hot Outlet
Heat
(optional)
inlet Inlet heat stream (optional)
outlet Outlet heat stream (optional)
Specifying HxFlux You have to specify inlet hot stream temperature or temperature
from a reference stream, and inlet cold stream temperature or
temperature from a reference stream. You also have to specify four
of the following variables:
• Outlet hot stream (temperature or temperature from a reference
stream)
• Outlet cold stream (temperature or temperature from a
reference stream)
• Duty, duty from a reference heat stream, or inlet heat stream
• Overall heat transfer coefficient
• Heat transfer area
You can select the flow direction for either counter-current or co-
current flow. When there is an inlet heat stream or when the duty is
Hot Outlet
Cold Outlet
Cold Water (optional)
Material Streams
Columns
N Bottoms
Heat Heat
(optional) (optional)
Material Streams
N Bottoms
Heat Heat
(optional) (optional)
Material Streams
Feed
Bottoms
Material Streams
Stream-1 Stream-1
P3 P2
Stream-2
Stream-2 P3
P4 Feed Stream-3
Feed P4
Stream-3 Stream-4
P5 P5
Stream-4
n-1
Vapor
Mixed feed to
stage n
Liquid
n-1
Mixed feed to
stage n n
When the Feed Convention is On-Stage, both the liquid and vapor
portions of a feed flow to the stage you specify.
Columns Without You can specify the column configuration on the Setup
Condensers or Reboilers Configuration sheet.
If the column has no Then specify On sheet
Condenser None for Setup Configuration
Condenser
Reboiler None for Setup Configuration
Reboiler
Reboiler Handling RadFrac can model two reboiler types:
• Kettle
• Thermosyphon
A kettle reboiler is modeled as the last stage in the column on the
Setup Configuration sheet. Select Kettle for reboiler. By default,
RadFrac uses a kettle reboiler. To specify the reboiler duty, enter
Nstage - 1
Reboiler
Bottoms (B)
Thermosyphon Reboiler
Where:
K = Equilibrium K value
x = Liquid mole fraction
y = Vapor mole fraction
Eff v = Vaporization efficiency
i = Component index
j = Stage index
To specify vaporization or Murphree efficiencies, enter the number
of actual stages on the Setup Configuration sheet. Then use the
Efficiencies form to enter the efficiencies.
For three-phase calculations, the vaporization and Murphree
efficiencies you enter apply equally to the following equilibrium
by default:
• Vapor-liquid1 (VL1E)
• Vapor-liquid2 (VL2E)
You can use the Efficiencies form to enter separate efficiencies for
VL1E and VL2E. You cannot enter separate efficiencies for VL1E
and VL2E when you specify equilibrium reactions or when using
Murphree efficiencies.
You can use any of these efficiencies to account for departure from
equilibrium. But you cannot convert from one efficiency to the
other. Magnitudes of the efficiencies can be quite different. You
should manipulate the Murphree efficiency to match the operating
data when:
• Efficiency is unknown
• Actual column operating data are available
Where:
m = Design specification number
∧
G = Calculated value
G = Desired value
G* = Scaling factor
w = Weighting factor
The algorithm that manipulates the variables to minimize Φ does
not depend on matching particular variables with corresponding
design specifications. You should carefully select the manipulated
variables and design specifications. Make sure that each
manipulated variable has a significant effect on at least one design
specification.
The number of design specifications must be equal to or greater
than the number of manipulated variables. If there are more design
specifications than manipulated variables, assign weighting factors
to reflect the relative importance of the specifications. The larger
the weighting factor, the more nearly a specification will be
satisfied. Scale factors normalize the errors, so that different
specification types are compared on a consistent basis.
When a value of a manipulated variable reaches a bound, that
bound is active. If a problem has no active bounds and the same
number of manipulated variables as design specifications, then Φ
will approach zero (within some tolerance) when all specifications
are satisfied.
If there are active bounds or more design specifications than
manipulated variables, RadFrac minimizes Φ . The weighting
factors determine the relative degree to which the design
specifications are satisfied.
Top Stage
Vapor Distilate
or Condenser
Heat Duty 1
(optional) Heat
Liquid Distillate (optional)
Water Distillate (optional)
Feeds Side Products (optional)
n-1
Vapor
Mixed feed
to stage n
Liquid
Mixed feed n
to stage n
n+1
Where:
K = Equilibrium K value
x = Liquid mole fraction
y = Vapor mole fraction
Eff v = Vaporization efficiency
( )
Fm = G$ m − Gm / Gm** = 0
G$ − G
2
Φ = ∑wm **
m G
Where:
m = Design specification number
G$ = Calculated value
G = Desired value
G ** = Scaling factor
w = Weighting factor
Initialization Use Initialization Method on the Convergence Methods sheet to
choose the initialization method.
MultiFrac has two initialization procedures:
• Standard
• Crude
Standard is appropriate for most systems. You must enter at least
the top and bottom temperature estimates for each column.
Crude invokes a special initialization procedure designed for
petroleum refining and ethylene plant primary fractionator/quench
tower applications. This procedure is designed for systems
consisting of a main column connected to any number of
sidestrippers. If you specify the following information on the
Columns Setup and/or Columns FlowSpecs forms, you do not need
to provide estimates:
• All stripper bottoms flow rates
• Either the distillate or bottoms flow rate of the main column
Otherwise, you must enter at least the top and bottom temperature
estimates for each column. You may enter profile estimates on the
Columns Estimates form to enhance convergence. Temperature
estimates are usually adequate. Highly nonideal systems may
require composition estimates.
Physical Properties Use the BlockOptions form to override the global physical
property method. You can specify a single property method on the
BlockOptions form. MultiFrac uses this property method for all
stages in all columns.
Use the Columns Properties form to specify physical property
methods when you use a separate property method for an
inlet One heat stream per stage for the main column (optional)
One heat stream per pumparound heater/cooler (optional)
One heat stream per stripper reboiler (optional)
One heat stream per stripper bottom liquid return (optional)
outlet One heat stream per stage for the main column (optional)
One heat stream per pumparound heaters/cooler (optional)
One heat stream per stripper reboiler (optional)
One heat stream per stripper bottom liquid return (optional)
PetroFrac uses an inlet heat stream as a duty specification for all
stages except the condenser, reboiler, pumparounds, and stripper
bottom liquid return.
If you do not give sufficient operating column specifications on the
Setup Configuration sheet, PetroFrac uses a heat stream as a
specification for the condenser and reboiler.
If you do not give two specifications on the Pumparounds
Specifications sheet, PetroFrac uses a heat stream as a specification
for pumparounds.
If you do not give two specifications for the bottom liquid return
on the Strippers Setup LiquidReturn sheet, PetroFrac uses a heat
stream as a specification.
If you give two specifications on the Setup Configuration sheet or
Pumparounds Specifications sheet, PetroFrac does not use the inlet
heat stream as a specification. The heat stream supplies the
required heating or cooling.
Use optional outlet streams for the net heat duty of the condenser,
reboiler, and pumparounds. The value of the outlet heat stream
equals the value of the inlet heat stream (if any) minus the actual
(calculated) heat duty.
Main Column The main column can have any number of inlet streams. It can also
have up to three product streams per stage (one vapor, one
hydrocarbon liquid, and one free water).
Side Strippers The side strippers can have a steam feed. They must have a liquid
bottoms product. You can use a heat stream as the heat source for
the reboiler. If you do not specify the reboiler duty, bottoms flow
rate, and steam feed, PetroFrac uses the heat stream as a duty
specification.
Optionally, the stripper liquid bottoms may be partially returned to
the main column. To specify a bottom liquid return, you must enter
two specifications on the Strippers Setup LiquidReturn sheet.
n-1
Vapor
Mixed feed
to stage n
Liquid
n-1
Mixed feed
n
to stage n
n+1
Heat
Feed
Main Column
Feed Furnace
Feed
Furnace
Where:
K = Equilibrium K value
x = Liquid mole fraction
y = Vapor mole fraction
Eff v = Vaporization efficiency
Eff M = Murphree efficiency
i = Component index
j = Stage index
To specify vaporization or Murphree efficiencies, enter the number
of actual stages on the Setup Configuration sheet and Strippers
Setup Configuration sheet as Number of stages. Then use the
Heat (optional)
Bottom Segment N
Heat (optional)
or Reboiler Heat
Duty (optional)
Bottoms or
Interconnecting Streams
Segment n-1
Vapor
Mixed Feed to
Segment n Liquid
Segment n
Liquid
Mixed Feed to
Segment n
Segment n
Vapor
Segment n + 1
Equilibrium Stages RateFrac can model both equilibrium stages and nonequilibrium
segments in the same column. Use the Columns
EquilibriumSegments form to specify the location of equilibrium
stages. When all stages are equilibrium, you can obtain the same
results using RateFrac as you can using RadFrac, MultiFrac, or
PetroFrac with ideal stages.
Reactive Systems RateFrac can handle kinetically controlled reactions and
equilibrium reactions in both liquid and vapor phases. Chemical
reactions can be of any type, including:
• Simultaneous
• Consecutive
• Parallel
• Forward
• Reverse
For kinetically controlled reactions, the kinetics can be defined by
one of the following:
• Built-in power law expressions
• User-supplied Fortran subroutines
For equilibrium reactions, the chemical reaction equilibrium
constant can be defined either in terms of user-supplied
coefficients for a temperature-dependent polynomial, or can be
computed from the reference state free energies of participating
components.
RateFrac can model electrolyte systems using both the apparent
and the true component approaches.
( ScinL )
−1/ 2
( )
0 .4
k in = 0.0051 a pd p
gµ L aω µ L
The correlation for the gas phase binary mass transfer coefficient
is:
g RT g
0 .7
G
( Sc ) ( a )
−2
k in = 5.23 g 1/ 3
pd p
p g
in
a p in
D a u
{ [
a ω = a p 1 − exp − 145
. Re L
0.1
FrL − 0.05We L
0 .2
(σ σ ) c
−0.75
]}
Where:
2
L aρ L2 L
Re L = FrL = We L =
a pµ L gρ 2L , a p σρ L
,
and:
L = Binary mass transfer coefficient for the binary
k in
pair i and n in the liquid phase (m/sec)
ρL = Density of liquid (kg/m )
3
g = 2
Acceleration due to gravity (m/sec )
µL = Viscosity of liquid (Newton-sec/m )
2
2
L = Liquid superficial mass velocity (kg/m /sec)
aw = Wetted interfacial area (m interfacial area/m
2 3
packing volume)
T
g = Gas phase temperature (K)
2
G = Gas superficial mass velocity (kg/m /sec)
µg = Viscosity of gas mixture (Newton-sec/m )
2
( ) ( Re ) ( v ) 0.05 ( ScinL )
0.68 0.09 0.5
ShinL = 125.4 Re g L
The correlation for the gas phase binary mass transfer coefficients
is:
( ) ( Re ) ( ϖ) 0.39 ( Scing )
0.87 0.13 0.5
Shing = 9.93 Re g L
( ) ( Re )
0.37
( ϖ) 0.52
0.25
a = 0.27 Re g L
Where:
L g
k in ad k in ad µL µg
Sh = L
in Sh = g
in ScinL = Scing =
ρ L D in ρ g D in ρ L D in ρ g D in
L g L g
, , , ,
Ld Gd W
Re L = Re g =
µL , µg ϖ = d
,
and:
2
L = Liquid mass velocity (kg/m /sec) (Velocity is
based on tower active area.)
d = Geometric parameter of unit length (m)
µL = Viscosity of liquid mixture (Newton-sec/m )
2
2
G = Gas mass velocity (kg/m /sec) (Velocity is
based on tower active area.)
µg = Viscosity of gas mixture (Newton-sec/m )
2
Where:
L = Binary mass transfer coefficient for the binary
k in 2
pair i and n in the liquid phase (kg mole/m
/sec)
2 2
a = Interfacial area (m interfacial area/m tower
active area)
L = Binary Maxwell-Stefan diffusion coefficient
D in 2
for the binary pair i and n (m /sec)
F = µ g ρ1g/ 2 kg 1/2 / sec / m1/2
F-Factor =
µg = Gas volumetric flow per unit active area (m
3
2
/sec/m )
ρg = Density of gas mixture (kg/m )
3
2
L = Liquid molar velocity (kg mole/m /sec)
(Velocity is based on active area.)
tL = Liquid residence time = 0.9998hL Z L / QL (sec)
hL = Liquid holdup =
0.04191 + 0.19hw + 2.4545QL − 0.0135 F ( m )
ZL = Liquid flow path length (m)
QL 3
= Liquid flow per average path width (m
/sec/m)
The product of the gas phase binary mass transfer coefficient and
interfacial area is given by the correlation:
( D ) (1030 F − 867 F )
g 0.5 2
k in a =
g in
h L 0.5
Where:
L = Binary mass transfer coefficient for the binary
k in 2
pair i and n in the liquid phase (kg mole/m
/sec)
2 2
a = Interfacial area (m interfacial area/m tower
active area)
L = Binary Maxwell-Stefan diffusion coefficient
D in 2
for the binary pair i and n (m /sec)
F = µ g ρ g 1/ 2 ( kg 1/ 2 / sec / m1/ 2 )
F-Factor =
µg = Gas volumetric flow per unit active area (m
3
2
/sec/m )
2
L = Liquid molar velocity (kg mole/m /sec)
(Velocity is based on active area.)
tL = Liquid residence time = 0.9998hL Z L / QL (sec)
hL = 0.04191 + 0.19hw + 2.4545QL − 0.0135 F ( m )
Heat Transfer RateFrac calculates the heat transfer coefficients, using the
Coefficients Chilton-Colburn analogy (King, 1980).
The heat transfer coefficient is given by:
htc
k av ( Sc) =
2/3
Cpmix
Where:
k av = Average binary mass transfer coefficients
(kg mole/sec)
Sc = Schmidt number
inlet One material stream for the initial charge; any number of
optional material streams for intermediate charges; any
number of optional material streams for continuous feeds
outlet One material stream for final column contents; one material
stream for final main accumulator contents; one material
stream for the final contents of optional additional
accumulators; any number of optional streams for
intermediate dump products; any number of optional
pseudo-product streams.
Specifying BatchFrac BatchFrac numbers stages from the top down, starting with the
condenser. The distillation operation is represented by a series of
sequential operation steps. BatchFrac performs a total reflux
calculation at the beginning of the first operation step.
BatchFrac has two types of data specifications:
• Column setup
• Column operation
Column Setup Setup specifications define the column you are modeling, but they
do not define its operation. These specifications include:
Nstage
L1 Phase L2 Phase
Material Streams
inlet One material stream to the first (top) stage, rich in the first
liquid phase (L1)
One material stream to the last (bottom) stage, rich in the
second liquid phase (L2)
One material stream per intermediate stage (optional)
outlet One material stream for L1 from the last stage
One material stream for L2 from the first stage
Up to two side product streams per stage, one for L1 and
one for L2 (optional)
Specifying Extract Extract can operate in one of the following ways:
• Adiabatically (default)
• At a specified temperature
• With specified stage heater or cooler duties
You must specify:
• Number of stages
• Feed and product stream stage locations
• Side product stream phase and mole flow rate
• Pressure profile
The first liquid phase (L1) flows from the first stage to the last
stage. The second (L2) flows in the opposite direction. You must
identify the key components in each phase using L1-Comps and
L2-Comps on the Setup form. Extract can treat phase L1 as the
solvent/extract phase or the feed/raffinate phase.
Reactors
This chapter describes the unit operation models for reactors. The
models are:
Model Description Purpose Use For
RStoic Stoichiometric Models stoichiometric Reactors where reaction kinetics are unknown or
reactor reactor with specified unimportant but stoichiometry and extent of reaction
reaction extent or are known
conversion
RYield Yield reactor Models reactor with Reactors where stoichiometry and kinetics are
specified yield unknown or unimportant but a yield distribution is
known
REquil Equilibrium Performs chemical and Reactors with simultaneous chemical equilibrium
reactor phase equilibrium by and phase equilibrium
stoichiometric
calculations
RGibbs Equilibrium Performs chemical and Reactors with phase equilibrium or simultaneous
reactor with phase equilibrium by phase and chemical equilibrium. Calculating phase
Gibbs energy Gibbs energy equilibrium for solid solutions and vapor-liquid-
minimization minimization solid systems.
RCSTR Continuous Models continuous One-, two, or three-phase stirred tank reactors with
stirred tank stirred tank reactor rate-controlled and equilibrium reactions in any
reactor phase based on known stoichiometry and kinetics
RPlug Plug flow reactor Models plug flow One-, two-, or three-phase plug flow reactors with
reactor rate-controlled reactions in any phase based on
known stoichiometry and kinetics
RBatch Batch reactor Models batch or semi- One-, two-, or three-phase batch and semi-batch
batch reactor reactors with rate-controlled reactions in any phase
based on known stoichiometry and kinetics
RCSTR, RPlug, and RBatch are kinetic reactor models. Use the
Reactions Reactions form to define the reaction stoichiometry and
data for these models.
You do not need to specify heats of reaction, because Aspen Plus
uses the elemental enthalpy reference state for the definition of the
Water (optional)
Material
Material Streams
Where:
∆P = Change in number of moles of component P due to
reaction
∆A = Change in number of moles of component A due to
reaction
In the numerator, real represents changes that actually occur in the
reactor. Aspen Plus obtains this value from the mass balance
between the inlet and outlet.
In the denominator, ideal represents changes according to an
idealized reaction scheme. This scheme assumes that no reactions
are present, except for the reaction that produces the selected
component from the reference component. Therefore, the
denominator indicates how many moles of P are produced per
mole of A consumed in an ideal stoichiometric equation, or:
∆P υ
∆A = P
Ideal υ A
Water (optional)
Material
Heat Heat
(optional) (optional)
Material Streams
Heat
(optional)
Material Material
Material Material
Material Coolant
(optional)
Flowsheet Reactor with Coolant Stream
Material Streams
Product
Reactor
Optional Flowsheet product Flowsheet
Stream for transferred Stream for
Continuous Feed once each Reactor
cycle Product
RBatch Reactor Configuration—No Vent Case
Feed Vent Vent
Holding Tank Accumulator Holding Tank
Pressure Changers
This chapter describes the unit operation models for pumps and
compressors, and models for calculating pressure change through
pipes and valves. The models are:
Model Description Purpose Use For
Pump Pump or hydraulic Changes stream Pumps and hydraulic turbines
turbine pressure when the
power requirement is
needed or known
Compr Compressor or turbine Changes stream Polytropic compressors, polytropic positive
pressure when power displacement compressors, isentropic
requirement is needed compressors, isentropic turbines
or known
MCompr Multistage compressor Changes stream Multistage polytropic compressors,
or turbine pressure across multiple polytropic positive displacement
stages with intercoolers. compressors, isentropic compressors,
Allows for liquid isentropic turbines
knockout streams from
intercoolers
Valve Valve pressure drop Models pressure drop Control valves and pressure changers
through a valve
Pipe Single segment pipe Models pressure drop Pipe with constant diameter (may include
through a single fittings)
segment of pipe
Pipeline Multiple segment Models pressure drop Pipeline with multiple lengths of different
pipeline through a pipe or diameter or elevation
annular space
Use Pump, Compr, and MCompr models when energy-related
information such as power requirement is needed or known.
Material
(any number)
Water (optional)
Work
(optional)
Material Streams
NPSHR =
N ss
Where:
NPSHR = Net Positive Suction Head Required
N = Pump shaft speed (rpm)
Q = Volumetric flow rate at the suction conditions
N ss = Suction specific speed
A1 = π × d 12 / 4
Where:
Flowc = Flow coefficient
Q = Volumetric flow rate
A1 = Cross-sectional area of discharge throat
d1 = Diameter of discharge throat
u = Impeller tip speed
The diameter of throat and diameter of impeller are related by the
following empirical equation:
d1
N s = 5500
Diam
Where:
Ns = Specific speed at the best efficiency point
Diam = Diameter of impeller
Water (optional)
Material
Material Streams
For compression:
s
hout − hin
ηs =
hout − hin
Applying the gas law PV = ZRT and using the average point for
each interval, given the number of intervals between P1 and P2,
subpath i for head developed can be written as:
Pi
HEAD i = R( ZT ) av ln 2i
P1
n-Method
From Cooler
Stage Compressor Heat
K-1 Stage K (optional)
Stage K
Work
(optional)
Knockout
Stage K
Water
(optional)
Material Streams
inlet At least one material stream for the first compressor stage
One or more material streams for stages after the first
(optional). These streams enter the intercooler before the
stages you specify.
outlet One material stream leaving the last compressor stage
Either one optional knockout material stream for each
intercooler for the liquid formed, or one optional global
knockout for the liquid formed in all intercoolers
Either one optional water decant stream for each
intercooler, or one optional global water decant stream
For compression:
Material Streams
with ΣK = K1 + K2 + K B1 − K B2
Where:
2 2 4
d2 d2 d
K1 = 0.5 1 − 2 . 1 − 2
K 2 = 10 K B1 = 1−
D1 D2 D1
, , ,
4
d
K B2 = 1 −
D2
and:
Fp = Piping geometry factor
Cυ = Valve flow coefficient
N2 = Numerical constant (based on the units of
measure)
d = Valve diameter
K1, K 2 = Resistance coefficients of the inlet and outlet
fittings
K B1 , K B2 = Bernoulli coefficients for the inlet and outlet
fittings
D1 = Inlet pipe diameter
D2 = Outlet pipe diameter
If the valve and pipe fittings diameters are different and you wish
to include the effect of the additional head loss on the valve flow
F f = 0.96 − 0.28
Pc
Where:
FL = Pressure recovery factor
Ff = Liquid critical pressure ratio factor
Fk = Ratio of specific heats factor
XT = Pressure drop ratio factor
Pin = Inlet pressure
Pυ = Vapor pressure at inlet
Pc = Critical pressure at inlet
dPlc = Limiting pressure drop, liquid phase
dPvc = Limiting pressure drop, vapor phase
For multi-phase streams, Valve takes the limiting pressure drop for
choked flow to be the smaller of dPlc and dPvc . Flow in the valve is
choked when the pressure drop exceeds this limiting pressure drop.
Valve displays the choking status of the valve if you check the
Check for Choking box on the Input CalculationOptions sheet.
Cavitation Index The likelihood of cavitation in a valve is measured by the
cavitation index. Aspen Plus calculates the cavitation index as
(Instrument Society of America, 1985):
P − Pout
K c = in
Pin − Pv
Where:
Kc = Cavitation index
Pin = Inlet pressure
Pout = Outlet pressure
Material
Material Streams
Material
Pipeline Streams
Material Streams
Beggs and Brill Slip and flow regimes are considered with this method. Friction
Correlation factor and holdup correlations depend upon flow regime and pipe
inclination. It is suitable for all inclinations, including vertical flow
downward.
Dukler Correlation The Hughmark holdup method should be used with this pressure
drop method. The Dukler method was developed from field data
using air-water mixtures in 1-inch pipes. It tends to over-predict
frictional pressure drop. It is recommended in a design manual
published jointly by the AGA and API.
Hagedorn-Brown The Hagedorn-Brown correlation considers slip between phases,
Correlation but flow regime is not considered. It uses the same correlations for
liquid holdup and friction factor for all flow regimes. It is an old
method that works well for conventional oil wells. It is suitable for
vertical upward flow, but not downward. It is generally
recommended for gas wells, and is based on data obtained from
U.S. Gulf Coast oil wells with 2-3/8 inch and 2-7/8 inch tubing.
Lockhart-Martinelli The Lockhart-Martinelli correlation is one of the oldest pressure
Correlation drop correlations. It does not consider pressure drop due to
acceleration. The method treats the vapor and liquid phases
separately and uses a correction factor to find the 2-phase pressure
gradient. Our implementation assumes turbulent gas and liquid
phase flow.
Orkiszewski Correlation The Orkiszewski correlation considers slip and flow regimes. The
friction factor and holdup correlation depend on the flow regime. It
is suitable for vertical flow upward, but not downward. It is
generally reliable for oil wells. It may exhibit problems for oil
wells with high water cuts or high total gas to liquid ratios. It can
significantly underpredict pressure drop for higher rate and higher
pressure wells (Beggs and Brill/1984).
Manipulators
Material Streams
Material Material
(any number)
Heat Heat
(any number)
Work Work
(any number)
Material Streams
Train 1
Dupl Selector
Train 2
Example of modeling alternate simulation trains with a Selector block
EO Usage Notes for All features of Selector are available in the EO formulation, except
Selector the features which are globally unsupported.
Solids
Heat
(optional)
Heat
(optional)
Where:
ρc = Density of crystal (kg/m3)
Bo
n = o
o
G ,
and B = kb G MT R
o i j k
Work (optional)
Material Streams
Where:
Bik = Breakage function. Fraction of particles originally in
size interval i that end up in size interval k
Fij = Flow rate of feed in the size interval i and particle
size distribution j
Pk = Flow rate of solid in size interval k
Si = Selection function. Fraction of feed particles in size
interval i to be crushed at the outlet diameter β
β = Crusher outlet diameter (Maximum Particle
Diameter field)
i = Size interval counter within a PSD
j = PSD counter for multiple size distribution
If the inlet stream contains no liquid, then Crusher assumes dry
crushing, and power requirements increase by 34%.
You can enter tabular values for the breakage ( Bik ) function on the
Input BreakageFunction sheet and for the selection ( S i ) function
on the Input SelectionFunction sheet, or let Crusher use the built-in
tables (U.S. Bureau of Mines, 1977) (see the following two tables).
Ratio of product Feed size/solids outlet diameter >1.7 Feed size/solids outlet
size to feed size diameter <1.7
Primary and Secondary Crushing operations are usually performed in stages. The reduction
Crushers ratio is the ratio of the maximum diameter of feed particles to
product particles. The reduction ratio in crushers ranges from 3 to
6 per stage. Feed particles are fed to the primary crushers. Outlet
particles from the primary crushers are reduced further by the
secondary crushers.
POWER =
( )
0.01 X F − X P × BWI × FLOWT
XF × XP
Where:
POWER = Required power (Watt)
XF = Diameter larger than 80% of feed particle mass
(m)
XP = Diameter larger than 80% of product particle
mass (m)
BWI = Bond work index
FLOWT = Total solids mass flow rate (kg/s)
For dry crushing, power requirement increases by 34%.
Where:
E = Work required to reduce a unit weight of feed with
80% passing a diameter X F microns to a product
with 80% passing a diameter X P microns
Ei = Bond work index, that is, the work required to
reduce a unit weight from a theoretical infinite size
to 80% passing a diameter of 100 micrometers
The Bond work index is a semi-empirical parameter that depends
on the properties of the material processed. The Bond work indices
have been measured experimentally for a wide range of materials,
Underflow
Material Streams
Where:
Si = Selection function. The fraction of feed particles in
size range i that passes over the screen into the
overflow product
Fij = Flow rate of feed in size range i and particle size
distribution attribute j
Selection Function and Screen calculates the selection function for a certain size interval
Separation Strength as:
1
Si = for d p < S o
[(
exp A 1 − d p S o )]
Si = 1 for d p ≥ S o
Where:
dp = Particle diameter
So = Size of screen opening
A = Separation strength
The default value of the screen separation strength, A, is a function
of the size of the screen opening. Screen has four built-in functions
(U.S. Bureau of Mines, 1977) for all possible combinations of
screen types (see the table, Screen Separation Strength/Screen Size
Correlation):
• Upper level dry
• Lower level dry
• Upper level wet
• Lower level wet
Material Streams
Where:
∆Pf = Final pressure drop across collected dust and filter
cloth
∆Pi = Pressure drop of the clean bag
C = Dust concentration
K = Dust resistance coefficient
Vo = Air to cloth ratio (gas velocity through the cloth)
Vo
The air to cloth ratio is:
Q
Vo =
( N cell − N shake ) Abag N bag
Where:
Q = Volumetric flow rate of the gas
N cell = Number of cells
N shake = Number of cells being cleaned
Abag = Total filter surface of all bags
N bag = Number of bags per cell
Where:
dp = The average particle size in microns
2
The units for K are (inches of water)/(lbs dust/ft of area)(ft/min
velocity).
∑∑Sη ij ij
flow rate of solids removed from the inlet
ηo = =
j i
Total inlet flow rate of solids total inlet flow rate of solids
Where:
Sij = Flow rate of solid j in size increment i
In FabFl, the separation efficiency is a function of the particle
diameter of the solids. For large particles (greater than 10
micrometers in diameter), fractional collection efficiency ( ηi ) is
1.0. For particles smaller than 10 micrometers, efficiency
decreases rapidly.
ηi When
1.0 ( d p ) av > 10 µm
(d ) 1µm < (d p ) av < 10 µm
0.0011 p av 0.989
(d ) ( d p ) av < 1µm
0.495 p av 0.495
You also can enter efficiency as a function of particle sizes on the
Input Efficiency sheet to override the built-in correlations.
References Air Pollution Engineering Manual, Public Health Service
Publication No. 999-AP-40, pp. 106-135, Washington D.C.,
DHEW (1967).
Billings, C.E. and Wilder, J., Handbook of Fabric Filter
Technology, Vol. I, NIIS PB 200648.
Solids
Material Streams
Where:
Co = Concentration of solids in inlet gas
Ci = Concentration of solids in outlet cleaned gas
Qo = Inlet gas flow rate
E = Outlet emission rate of solids in the cleaned gas
Cyclone attains higher separation efficiencies with particles that
are 5 to 10 microns or greater in diameter. For particles smaller
than 5 microns, Cyclone efficiency decreases. Even with large
particles, it is difficult to obtain a collection efficiency greater than
95%.
The annular shaped volume Vs above the exit duct to midlevel of the
entrance duct is:
π( s − a / 2 ) ( Dc2 − De2 )
Vs =
4
Cyclone Diameter Cyclone calculates the diameter of the body of the cyclone Dc as:
0 . 454
Qρ2f (1 − b / Dc )
Dc = 0.0502 × 2.2
µ(ρ p − ρ f ) ( a / Dc ) (b / Dc )
Where:
Q = Overflow gas flow rate
ρf = Density of the fluid
µ = Viscosity of gas fluid
ρp = Density of the particles
In this empirical equation, units are:
Unit type Unit
Length Feet
Mass Pounds
Time Seconds
Dimension Ratios Use the Input Dimensions sheet to enter the dimensions of a
cyclone when Mode=Simulation and Type=User-Specified. If you
specify Type=User-Specified Ratios, you can use the Input Ratios
sheet to enter dimension ratios (dimension / cyclone diameter) for
a cyclone.
b De
s
a h
B
Cyclone Geometry
∆p * = Pressure drop
∆p = Pressure drop with clean gas
β ,γ = Constants depending on the material
inlet One stream for solids with at least one solids substream
One stream for the atomized liquid
outlet One stream for the cleaned gas
One stream for the liquid with solid particles
( )
2ρl Vt 2 Ql
∆p = 1 − x 2 + x 4 − x 2
gc Qg
Where:
ρl = Density of the liquid
Vt = Relative velocity of gas to liquid at the throat
gc = Conversion factor in Newton's law of motion
Ql = Liquid to gas volume flow rate
Qg
Where:
lt = Throat length
CD = Drag coefficient, as a function of the Reynolds
number (Dickinson and Marshall, 1968) N Re .
24
C D = .22 + (1 + 015 0.6
. N Re )
N Re
=
∑ Sη i i
Solids
Material Streams
Cnvs ( X s − L)q ps E c C
ηov = 1 − exp
Cnvo 3πµdWV
Where:
Cnvs = Particle concentration at X s
Cnvo = Particle concentration at inlet
Xs = Point at which all particles have acquired a
saturation charge
L = Plate length
q ps = Particle saturation charge
Ec = Collecting field strength ( = 0.25( Eo ))
Where:
VB = Breakdown voltage
f = Roughness factor of wire
To = Atmospheric temperature
Po = Atmospheric pressure
T = Temperature
P = Pressure
The particle concentration at the point where the particles first
have saturation charge, Cnvs is:
0.212( k + 2) 0.8 E c Ws w − E o ro
Cnvs =
kd 2 0.427 Ws w E c + 2 E o ro (0.533 Ws w − ro )
Where:
k = Dielectric constant ( = ε / ε o )
Pressure Drop ESP calculates the pressure drop across the precipitator as:
∆p = 45.5 ρ g Vg2
Where:
ρg = Gas density
Vg = Gas velocity
Required Power The power required (White, H. J., 1963) Pw to meet a specified
separation efficiency is:
Pw = 52.75 ln(1 − ηov ) Q
Where:
Q = Volumetric gas flow rate
Gas Velocity The models used in ESP are valid for inlet gas velocities ranging
from 0.5 to 3 m/s. Outside this range, transport by turbulent
diffusion becomes more significant than by electrostatic force and
large errors should be expected.
Particle Diameter You can use ESP to model the separation of fine particles with
diameters ranging from 0.01 to 10 microns. ESP is accurate when
the inlet particle concentration is high
(≥ 1011 particles / m 3 or 0.1 kg / m 3 ). If the concentration is too
low, the model tends to overestimate the separation efficiency.
References Crawford, M., Air Pollution Control Theory, Chapter 8:
Electrostatic Precipitation, p. 298-358. McGraw-Hill, New York,
1976.
White, H.J., Industrial Electrostatic Precipitation, 204, pp. 91-92
(1963).
Solids
Material Streams
R
Where f is the volumetric ratio of underflow to feed flow (see
Material Split).
The reduced efficiency is obtained from the following equation:
d
3
E ′ = 100 1 − exp − − 0.115
d50
Where:
d = Diameter of the solid particles to be separated
d 50 = Particle diameter for which 50% of feed passes
through underflow
= tan
Di2 α Q(σ − ρ ) 2
Where:
Q = Volumetric flow rate at inlet
Dc = Chamber diameter
Di = Inlet diameter
n = Power of R in the tangential velocity distribution
function
α = Inlet velocity loss coefficient
σ = Density of solid
Rf = Underflow rate/feed rate
θ = Cone angle
ρ = Density of liquid
µ = Viscosity of liquid
Material Split HyCyc splits the feed according to the following empirical
correlation (Moder, J.M. and Dahlstrom, D.A., 1952):
Du 4.4 −.44
S =β ( ) Q
Do
Where:
2
Where:
α = Inlet velocity loss coefficient
Vi = Inlet velocity
Dc = Diameter of the hydrocyclone
n = Exponent of radial dependence
R = Radius
For most cases, α and n are determined experimentally to be 0.45
and 0.8. These two variables are then used to determine d 50 .
Dimension Ratios Common hydrocyclones have the following ranges of dimension
ratios (dimension/chamber diameter):
Inlet diameter: 1/7 to 1/3
Length: 4 to 12
Overflow 1/8 to 1/2.3
diameter:
Underflow 1/10 to 1/5
diameter:
Cone angle: 9 deg. to 20 deg.
Pressure Drop For the pressure drop correlation to be valid (overflow
diameter/underflow diameter) should be 0.6 to 2.0. HyCyc uses the
empirical pressure drop correlation (Dahlstrom, D.A., 1954):
Q
0 .5
= 6.38 ( Do × Di ) 0.9
H
Where:
Do
Du
Hydrocyclone Dimensions
Solids
Material Streams
If you enter the particle size distribution (PSD) of the inlet solid
stream, CFuge calculates the average particle diameter, so you do
not need to enter average diameter on the Input FilterCake sheet.
Feed
Solids
Material Streams
Material Streams
inlet One stream for the solids particles with an entrained liquid
One stream for the washing liquid
outlet One stream for the washed solids particles
One stream for the washing liquid and entrained liquid
from the inlet solids stream
Heat Streams
E= S
x IN − xOUT
L
Where:
S
x IN = Mass fraction of dissolved components in the
entrained liquid of the inlet solids stream
S
xOUT = Mass fraction of dissolved components in the
entrained liquid of the outlet solids stream
L
x OUT = Mass fraction of dissolved components in the outlet
liquid stream
Bypass Fraction The bypass fraction is the fraction of liquid in the feed that
bypasses the mixing, when mixing efficiency is less than 1. It is
calculated as:
liquid − to − solid ratio specified for SWash
Bypass fraction = (1 − mixing efficiency) ×
liquid − to − solid ratio in inlet solids stream
1
Feed To Product From
Underflow Overflow
(optional) (optional)
Washing
Underflow Liquid
(Bottom feed)
Material Streams
E= S
x IN − xOUT
L
Where:
S
x IN = Mass fraction of dissolved components in the
entrained liquid of the total inlet solids stream to
stage n.
S
x OUT = Mass fraction of dissolved components in the
entrained liquid of the total outlet solids stream from
stage n.
L
x OUT = Mass fraction of dissolved components in the outlet
liquid stream from stage n.
Medium Temperature The duty for each stage is calculated according to the following
equations:
Qi = UAi (Tcalci − Tmed i )
Where:
Qi = Heat duty for stage i
UAi = Product of heat transfer coefficient and area for
stage i
Tcalci = Calculated outlet temperature of stage i
Tmed i = Temperature of the heat transfer medium at stage i
User Models
This chapter describes the models that allow you to add custom
extensions to Aspen Plus.
User and User2 allow you to write your own unit operation models
as Fortran subroutines. These subroutines must follow the
guidelines described in the Aspen Plus User Models reference
manual. User2 can also be used with a unit operation model written
as an Excel spreadsheet. User3 allows you to use custom or
external models with equation-oriented formulations. The models
are:
Model Description Purpose Use For
User User-defined unit Model a unit operation using a Unit operations with four (or fewer)
operation model user-supplied Fortran subroutine inlet and outlet streams
User2 User-defined unit Model a unit operation using a Unit operations with no limit on
operation model user-supplied Fortran subroutine. number of streams
User3 User-defined or Run built-in models from RT- Unit operations with equation-
external unit-operation Opt, Aspen EO models from the oriented formulations
model PML model library, or models
written by a user that may contain
proprietary models
ACMUser3 Aspen Custom Models a unit operation using Unit operation models created with
Modeler models Aspen Custom Modeler Aspen Custom Modeler
Hierarchy blocks allow you to organize complex flowsheets in a
hierarchical manner. When a user model template containing
multiple blocks is placed on a flowsheet, it automatically appears
inside a Hierarchy block. See the Aspen Plus User Guide, chapter
16, for more information on creating these templates. You may
also use Hierarchy blocks directly, without using a template.
Model Description Purpose Use For
Hierarchy Hierarchical structure Create a hierarchical structure to Container for other blocks
organize complex flowsheets.
Material Streams
Pressure Relief
Q = (credit factor )34,500 Area 0.82 , the default credit factor being 1
Where:
υ = Specific volume of stream
p = Static (flowing) pressure of stream
G = Mass flow rate per unit area
f = Friction factor
D = Inside diameter of pipe
L = Equivalent pipe length
g = Acceleration due to gravity
sin Φ = Vertical rise/equivalent pipe length
Φ represents the physical angle of the pipe with respect to the
horizontal only if the equivalent pipe length is the same as the
physical flow path length (that is, only pipe, no fittings or other
resistances). The potential energy term in the equation assumes
that the vertical elevation is distributed evenly along the entire
equivalent length.
Equation (6) provides the means to calculate the flow rate through
a perfect nozzle given the upstream stagnation pressure and the
proper p-v relationship (which is isentropic). As one integrates (6)
Aspen Plus 11.1 Unit Operation Models Advanced Distillation Features • A-1
Sizing and Rating for Trays and
Packings: Overview
Aspen Plus has extensive capabilities to size, rate, and perform
pressure drop calculations for trayed and packed columns. Use the
following Tray/Packing forms to enter specifications:
• TraySizing
• TrayRating
• PackSizing
• PackRating
These capabilities are available in the following column unit
operation models:
• RadFrac
• MultiFrac
• PetroFrac
You can choose from the following five commonly-used tray
types:
• Bubble caps
• Sieve
• Glitsch Ballast®
• Koch Flexitray®
• Nutter Float Valve
Aspen Plus can model a variety of random packings. You can also
use any of the following types of structured packings:
• Goodloe®
• Glitsch Grid®
• Norton Intalox Structured Packing
• Sulzer BX, CY, Mellapak, and Kerapak
• Koch Flexipac, Flexeramic, Flexigrid
• Raschig Super-Pak and Ralu-Pak
For sizing and rating calculations, Aspen Plus divides a column
into sections. Each section can have a different tray type, packing
type, and diameter. The tray details can vary from section to
section. A column can have an unlimited number of sections. In
addition, you can size and rate the same section with different
types of trays and packings.
A-2 • Advanced Distillation Features Aspen Plus 11.1 Unit Operation Models
The calculations are based on vendor-recommended procedures
whenever these are available. When vendor procedures are not
available, well-established literature methods are used.
Aspen Plus calculates sizing and performance parameters such as:
• Column diameter
• Flooding approach or approach to maximum capacity
• Downcomer backup
• Pressure drop
These parameters are based on:
• Column loadings
• Transport properties
• Tray geometry
• Packing characteristics
You can use the computed pressure drop to update the column
pressure profile.
Single-Pass and You can use the column models in Aspen Plus to:
Multi-Pass Trays • Size one- and two-pass trays
• Rate trays with up to four passes
Schematics of one-, two-, three-, and four-pass trays are shown in
the next four figures. Aspen Plus performs and reports rating
calculations for all panels.
When specifying Weir heights, cap positioning, and number of
valves:
For Specify
One-pass tray A single value
Two-pass tray Up to two values, one for each panels A and B
Three-pass tray Up to three values, one for each panel (A, B and C)
Four-pass tray Up to four values, one for each panel (A, B, C and D)
The values for the number of caps and number of valves applies
for each panel. For example, two-pass trays have two A panels for
tray AA, and two B panels for tray BB. Therefore, the number of
caps per panel is the number of caps per tray divided by two.
Similar consideration is necessary for three- and four-pass trays.
If you specify only one value for multi-pass trays, that value
applies to all panels.
Aspen Plus 11.1 Unit Operation Models Advanced Distillation Features • A-3
When specifying downcomer clearance and width:
For Specify
One-pass tray A single value for the side downcomer
Two-pass tray Up to two values, one for the side downcomer, one for
the center downcomer
Three-pass tray Up to two values, one for the side downcomer, one for
the off-center downcomer
Four-pass tray Up to three values: one for the side downcomer, one
for the center downcomer, and one for the off-center
downcomer
Column Diameter
Outlet Weir Length
DC-WTOP
WEIR-HT
DC- DC-HT
WBOT
DC-CLEAR
A One-Pass Tray
A-4 • Advanced Distillation Features Aspen Plus 11.1 Unit Operation Models
Column Diameter
CTR. DC
CTR. DC
DC-WTOP
Below
~ ~
WEIR-HT Panel A Tray AA
DC- Side
WBOT DC-HT
Downcomer
DC-
DC-CLEAR WTOP Panel B Tray BB
DC-HT Center
DC- Downcomer
WBOT
DC-CLEAR
~ ~ ~~
A Two-Pass Tray
Aspen Plus 11.1 Unit Operation Models Advanced Distillation Features • A-5
Column Diameter
OFF-CTR.DC
OFF-CTR.DC
DC-WTOP DC-WTOP
WEIR-HT
Panel A. B. C.
DC-HT DCOF
DC-WBOT
DC-WTOP
DC-
CLEAR B A Panel C. B. A.
Panel A. B. C.
A B C
A Three-Pass Tray
A-6 • Advanced Distillation Features Aspen Plus 11.1 Unit Operation Models
Column Diameter
OFF-CTR.DC OFF-CTR.DC
CTR.DC
DC-WTOP DC-WTOP
WEIR-HT
Panel A. B.
DC-HT
DC-WBOT DC-WBOT
DC-
CLEAR D D C Panel C. D.
DCOF
A B B A Panel A. B.
A Four-Pass Tray
Modes of Operation Aspen Plus provides two modes of operation for trays:
for Trays • Sizing
• Rating
In either mode, you can divide a column into any number of
sections. Each section can have a different column diameter, tray
type, and tray geometry. You can re-rate or re-design the same
section with different tray types and/or packings.
Aspen Plus performs the calculations one section at a time. In
sizing mode, the column model determines tray diameter to satisfy
the flooding approach you specified for each stage. The largest
diameter is selected.
Aspen Plus 11.1 Unit Operation Models Advanced Distillation Features • A-7
In rating mode, you specify the column section diameter and other
tray details. For each stage, the column model calculates tray
performance and hydraulic information such as flooding approach,
downcomer backup, and pressure drop.
Flooding Calculations For bubble caps and sieve trays, Aspen Plus provides two
for Trays procedures for calculating the approach to flooding. The first
procedure is based on the Fair method. The second uses the Glitsch
procedure for ballast trays. This procedure de-rates the calculated
flooding approach by 15% for bubble caps and by 5% for sieve
trays. All other hydraulic calculations are based on the Fair and
Bolles methods. You can also supply your own calculation
procedure:
= Specify On form
Flooding calculation method = USER TraySizing or TrayRating
Subroutine name UserSubroutines
For valve trays (Glitsch Ballast, Koch Flexitray, and Nutter Float
Valve trays), Aspen Plus uses procedures from vendor design
bulletins.
Two versions of vendor design bulletins are available for Koch
Flexitray:
• Bulletin 960
• Bulletin 960-1
You can use the Convergence form to specify which bulletin to use
for all TraySizing and TrayRating sections for a block. You can
specify which bulletin to use for each section. This specification
overrides the block-wise specification. For valve type S, AO, and
TO in the TrayRating sections, Aspen Plus always uses Bulletin
960-1 internally, regardless of the block-wise specification. For all
other cases, the default is Bulletin 960.
For Nutter Float Valve trays, two versions of curve fitting are
provided for curves in the vendor design bulletin:
• Aspen90
• Aspen96
Aspen96 is recommended. Use the Convergence form to specify
which version to use.
A-8 • Advanced Distillation Features Aspen Plus 11.1 Unit Operation Models
RadFrac uses cap diameter only for tray type CAPS. Valid entries
Bubble Cap Tray
are:
Layout
Cap Diameter Default Weir Height
Nominal Size, in 3 4 6
Cap
U.S. Standard gauge 16 16 16
OD, in 2.999 3.999 5.999
ID, in 2.875 3.875 5.875
Height overall, in 2.500 3.000 3.750
Number of slots 20 26 39
Type of slots Trapezoidal Trapezoidal Trapezoidal
Slot width, in
Bottom 0.333 0.333 0.333
Top 0.167 0.167 0.167
Slot height, in 1.000 1.250 1.500
Height shroud ring, in 0.250 0.250 0.250
Riser
U.S. Standard gauge 16 16 16
OD, in 1.999 2.624 3.999
ID, in 1.875 2.500 3.875
Material Stainless Steel
Nominal size, in 3 4 6
Standard heights, in
0.5-in skirt height 2.250 2.500 2.750
1.0-in skirt height 2.750 3.000 3.250
1.5-in skirt height 3.250 3.500 3.750
Riser-slot seal, in 0.500 0.500 0.500
Cap areas, in
Aspen Plus 11.1 Unit Operation Models Advanced Distillation Features • A-9
Riser 2.65 4.80 11.68
Reversal 4.18 7.55 17.80
Annular 3.35 6.38 14.55
Slot 5.00 8.12 14.64
Cap 7.07 12.60 28.30
Area ratios
Reversal/riser 1.58 1.57 1.52
Annular/riser 1.26 1.33 1.25
Slot/riser 1.89 1.69 1.25
Slot/cap 0.71 0.65 0.52
Pressure Drop Normally, RadFrac, MultiFrac, and PetroFrac treat the stages you
Calculations for enter as equilibrium stages. You must enter overall efficiency to:
Trays • Convert the calculated pressure drop per tray to pressure drop
per equilibrium stage
• Compute the column pressure drop
If you do not enter overall efficiency, these models assume 100%
efficiency. If you specify Murphree or vaporization efficiency, you
should not enter overall efficiency. RadFrac, MultiFrac, and
PetroFrac will treat the stages as actual trays.
Foaming Calculations Suggested values for Ballast trays are:
for Trays Service System Foaming Factor
Non-foaming systems 1.00
Fluorine systems 0.90
Moderate foamers, such as oil 0.85
absorbers, amine, and glycol
regenerators
Heavy foamers, such as amine and 0.73
glycol absorbers
Severe foamers, such as MEK units 0.60
Foam stable systems, such as caustic 0.30
regenerators
Suggested values for Flexitrays are:
Service System Foaming Factor
Depropanizers 0.85-0.95
Absorbers 0.85
Vacuum towers 0.85
Amine regenerators 0.85
Amine contactors 0.70-0.80
High pressure deethanizers 0.75-0.80
Glycol contactors 0.70-0.75
A-10 • Advanced Distillation Features Aspen Plus 11.1 Unit Operation Models
Suggested values for Float valve trays are:
Service System Foaming Factor
Non foaming 1.00
Low foaming 0.90
Moderate foaming 0.75
High foaming 0.60
Packed Columns The calculations for packings are based on the height equivalent of
a theoretical plate (HETP). HETP=packed height/number of
stages. The HETP is required. You can provide it using one of the
following methods:
• Enter it directly on the PackSizing or PackRating forms
• Enter the packing height on the same form
Packing Types and Aspen Plus can handle a wide variety of packing types, including
Packing Factors different sizes and materials from various vendors.
For random packings, the calculations require packing factors.
Aspen Plus stores packing factors for the various sizes, materials,
and vendors allowed in a databank. If you provide the following
information, Aspen Plus retrieves these packing factors
automatically for calculations:
• Packing type
• Size
• Material
You may specify the vendor on the PackSizing or PackRating
form.
Is the vendor
specified? Aspen Plus uses
Yes The packing factor published by the vendor
No A value compiled from various literature sources
You can enter the packing factor directly to override the built-in
values. Aspen Plus uses the packing type to select the proper
calculation procedure.
Literature Sources
Aspen Plus 11.1 Unit Operation Models Advanced Distillation Features • A-11
The column models have two modes of operation for packing:
Modes of Operation
for Packing • Sizing
• Rating
In either mode, you can divide a column into any number of
sections. Each section can have different packings. You can re-rate
or re-design the same section with different packings and/or tray
types. Aspen Plus performs the calculations one section at a time.
In sizing mode, Aspen Plus determines the column section
diameter from:
• The approach to the maximum capacity
• A design capacity factor you specify
You can impose a maximum pressure drop per unit height (of
packing or per section) as an additional constraint. Once
Aspen Plus has determined the column section diameter, it re-rates
the stages in the section with the calculated diameter.
In rating mode, you specify the column diameter. Aspen Plus
calculates the approach to maximum capacity and pressure drop.
Maximum Capacity Aspen Plus provides several methods for maximum capacity
Calculations for calculations. For random packings you can use:
Packing Method For this type of packings
Mass Transfer, Ltd. (MTL) 1 MTL
Norton 2 Norton IMTP
Koch 3 Koch
Raschig 4 Raschig
Eckert All other random packings
For structured packings, Aspen Plus provides vendor procedures
for each type. If you specify the maximum capacity factor,
Aspen Plus bypasses the maximum capacity calculations.
The definition of approach to maximum capacity depends on the
type of packings.
For Norton IMTP and Intalox structured packings, approach to
maximum capacity refers to the fractional approach to the
maximum efficient capacity. Efficient capacity is the operating
point at which efficiency of the packing deteriorates due to liquid
entrainment. The efficient capacity is approximately 10 to 20%
below the flood point.
For Sulzer structured packings (BX, CY, Kerapak, and Mellapak),
approach to maximum capacity refers to the fractional approach to
maximum capacity. Maximum capacity is the operating point at
which a pressure drop of 12 mbar/m (1.47 in-water/ft) of packing
A-12 • Advanced Distillation Features Aspen Plus 11.1 Unit Operation Models
is obtained. At this condition, stable operation is possible, but the
gas load is higher than that at which maximum separation
efficiency is achieved.
The gas load corresponding to the maximum capacity is 5 to 10%
below the flood point. Sulzer recommends a usual design range
between 0.5 and 0.8 for approach to flooding.
For Raschig random and structured packings, approach to
maximum capacity refers to the fractional approach to maximum
capacity. Maximum capacity is at the loading point.
For all other packings, approach to maximum capacity refers to the
fractional approach to the flood point.
Because there are different definitions for approach to maximum
capacity, sizing results are not on the same basis for packings from
different vendors, even when you use the same value for approach
to maximum capacity. Direct performance comparison of packings
from different vendors is not recommended.
The capacity factor is:
ρV
CS = VS
ρ L − ρV
Where:
CS = Capacity factor
VS = Superficial velocity of vapor to packing
ρV = Density of vapor to packing
ρL = Density of liquid from packing
References
1 Cascade Mini-Ring Design Manual (Tokyo: Dodwell &
Company, Ltd., 1984).
2 Intalox High-Performance Separation Systems, Bulletin IHP-1
(Akron: Norton Company, 1987).
3 McNulty, K.J., "Hydraulic Model for Packed Tower Design."
Paper presented at the American Institute of Chemical
Engineers Spring Meeting in Houston, 1993.
4 Billet, R., and Schultes, M., "Modeling of Packed Tower
Performance for Rectification, Absorption and Desorption in
the Total Capacity Range." Paper presented at the 3rd Korea-
Japan Symposium On Sep. Tech., October 25-27, 1993 in
Seoul, Korea.
Aspen Plus 11.1 Unit Operation Models Advanced Distillation Features • A-13
Pressure Drop For random packings, Aspen Plus provides several built-in
Calculations for methods to compute the pressure drop.
Packing Vendor Pressure drop method
MTL Vendor 1
Norton Vendor procedure 2,3,4
Koch Vendor procedure 5
Raschig Vendor procedure 6
Not specified Eckert GPDC 7, Norton GPDC 2,3,4, Prahl GPDC 8, Tsai
GPDC 9
If you specify the vendor, Aspen Plus uses the vendor procedure. If
you do not specify the vendor, you can choose one of four different
pressure drop methods. If you do not specify a method, Aspen Plus
uses the Eckert generalized pressure drop correlation (GPDC).
For structured packings, vendor pressure drop correlations are
available for all packings:
Packing type Pressure drop method
Goodloe Vendor procedure 10
Glitsch Grid Vendor procedure 11
Norton Intalox Structured Packings Vendor procedure 12
Sulzer BX, CY, Mellapak, and Kerapak Vendor procedure 13
Super-Pak and Ralu-Pak Vendor procedure 6
Koch Flexipac, Flexeramic, and Flexigrid Vendor procedure 14
References
1 Cascade Mini-Ring Design Manual (Tokyo: Dodwell &
Company, Ltd., 1984).
2 Dolan, M.J. and Strigle, R.F., "Advances in Distillation
Column Design," CEP, Vol.76, No.11 (November 1980), pp.
78-83.
3 Intalox High-Performance Separation Systems, Bulletin IHP-1
(Akron: Norton Company, 1987).
4 Intalox Metal Tower Packing, Bulletin IM82 (Akron: Norton
Company, 1979).
5 McNulty, K.J., "Hydraulic Model for Packed Tower Design."
Paper presented at the American Institute of Chemical
Engineers Spring Meeting in Houston, 1993.
6 Billet, R., and Schultes, M., "Modeling of Packed Tower
Performance for Rectification, Absorption and Desorption in
the Total Capacity Range" Paper presented as the 3rd Korea-
Japan Symposium On Sep. Tech., October 25-27, 1993 in
Seoul, Korea.
A-14 • Advanced Distillation Features Aspen Plus 11.1 Unit Operation Models
7 Fair, J.R. et al., "Liquid-Gas Systems," Perry’s Chemical
Engineers’ Handbook, R.H. Perry and D. Green, ed., 6th ed.
(New York: McGraw Hill, 1984), pp. 18-22.
8 McNulty, K.J. and Hsieh, C.L., "Hydraulic Performance and
Efficiency of Koch Flexipac Structured Packings." Paper
presented at American Institute of Chemical Engineers Annual
Meeting in Los Angeles, 1982.
9 Tsai, T.C., "Packed Tower Program Has Special Features," Oil
and Gas Journal, Vol. 83 No. 35 (September, 1985), p. 77.
10 Goodloe, Bulletin 520A (Dallas: Glitsch, Inc., 1981).
11 Glitsch Grid-Grid/Ring Combination Bed, Bulletin No. 7070
(Dallas: Glitsch, Inc., 1978).
12 Norton Company, private communication, 1992.
13 Spiegel, L. and Meier, W., "Correlations of the Performance
Characteristics of the Various Mellapak Types." Paper
presented at the 4th International Symposium of Distillation
and Absorption, Brighton, England, 1987.
14 McNulty, K.J., "Hydraulic Model for Packed Tower Design."
Paper presented at the American Institute of Chemical
Engineers Spring Meeting in Houston, 1993.
Liquid Holdup Aspen Plus performs liquid holdup calculations for both random
Calculations for and structured packings. For Raschig packings, Aspen Plus uses
Packing the vendor procedure is used. The required parameters are void
fraction and surface area. If you do not provide these parameters,
Aspen Plus will retrieve them from the built-in databank.
For other packings, Aspen Plus uses the Stichlmair correlation.
The Stichlmair correlation requires these parameters:
• Packing void fraction and surface area
• Three Stichlmair correlation constants
When Stichlmair correlation is used, Aspen Plus provides these
parameters for a variety of packings in the built-in packing
databank. If these parameters are missing for a particular packing,
Aspen Plus will not perform liquid holdup calculations for that
packing.
You can also enter these parameters to provide missing values, or
to override the databank values.
Pressure Profile You can update the pressure profile using:
Update • Computed pressure drops for the rating mode of both trays and
packings
• The sizing mode of packings
Aspen Plus 11.1 Unit Operation Models Advanced Distillation Features • A-15
If you choose to update the pressure profile, the column models
solve the tray or packing calculation procedures simultaneously
with the column-describing equations. For updating the pressure
profile during calculations check Update Section Pressure Profile
on the following forms:
• TrayRating
• PackSizing
• PackRating
Also, you can fix the pressure at the top or bottom of the column
and you can specify this option on the above forms. The stage
pressures become additional variables. Aspen Plus uses the
pressure specifications given on the Pres-Profile form to:
• Initialize the column pressure profile
• Fix the pressure drop of stages for which the pressure profile is
not updated
Physical Property Several physical properties that are not normally used for heat and
Data Requirements material balance calculations are required for column sizing and
rating. These properties are:
• Liquid and vapor densities
• Liquid surface tension
• Liquid and vapor viscosities
The physical property method that you specify for a unit operation
model must be able to provide the required properties. In addition,
the physical property parameters needed to calculate the required
properties must be available for all components in the column. See
the descriptions of properties in the Aspen Plus User Guide,
Chapter 8, for details on specifying physical property methods and
determining property parameter requirements.
References Fair, J.R., et al., "Liquid-Gas Systems," Perry’s Chemical
Engineers’ Handbook, R.H. Perry and D. Green, ed. 6th ed., New
York: McGraw Hill, 1984.
Ballast Tray Design Manual, Glitsch, Inc. Bulletin No. 4900, 3rd
ed. Dallas, 1980.
Smith, B.D., "Tray Hydraulics: Bubble Cap Trays" and "Tray
Hydraulics: Perforated Trays," Design of Equilibrium Stage
Processes, New York: McGraw Hill, 1963, pp. 474-569.
Koch Flexitray Design Manual, Koch Engineering Co., Inc.
Bulletin No. 90, Wichita.
Ballast Tray Design Manual, Glitsch, Inc. Bulletin No. 4900, 3rd
ed. Dallas, 1980.
A-16 • Advanced Distillation Features Aspen Plus 11.1 Unit Operation Models
Koch Flexitray Design Manual, Koch Engineering Co., Inc.
Bulletin No. 90, Wichita.
Nutter Float Valve Design Manual, Tulsa: Nutter Engineering Co.,
1976.
Stichlmair, J., et al., "General Model for Prediction of Pressure
Drop and Capacity of Countercurrent Gas/Liquid Packed
Columns," Gas Separation and Purification, Vol. 3 (1989), p. 22.
Aspen Plus 11.1 Unit Operation Models Advanced Distillation Features • A-17
Column Targeting
The Aspen Plus Column Targeting tool offers capabilities for
thermal and hydraulic analysis of distillation columns. During
design or retrofit analysis of a process, these capabilities can be
exploited to identify the targets for appropriate column
modifications in order to:
• Reduce utilities cost
• Improve energy efficiency
• Reduce capital investment (by improved driving forces)
• Facilitate column debottlenecking
These capabilities are available for the following distillation
column models:
• RadFrac
• MultiFrac
• PetroFrac
Column Targeting The thermal analysis capability is useful in identifying design
Thermal Analysis targets for improvements in energy consumption and efficiency.
This capability is based on the concept of minimum
thermodynamic condition for a distillation column. The minimum
thermodynamic condition pertains to thermodynamically reversible
column operation. In this condition, a distillation column would
operate at minimum reflux, with an infinite number of stages, and
with heaters and coolers placed at each stage with appropriate heat
loads for the operating and equilibrium lines to coincide. In other
words, the reboiling and condensing loads are distributed over the
temperature range of operation of the column. The stage-enthalpy
(Stage-H) or temperature-enthalpy (T-H) profiles for such a
column therefore represent the theoretical minimum heating and
cooling requirements in the temperature range of separation. These
profiles are called the Column Grand Composite Curves (CGCCs).
The Aspen Plus Column Targeting tool generates the CGCCs
based on the Practical Near-Minimum Thermodynamic Condition
(PNMTC) approximation (Dhole and Linnhoff). The enthalpies
used in plotting the CGCCs are calculated at a given stage of the
column by assuming that the equilibrium and operating lines
coincide at this stage. This approximation takes into account the
losses or inefficiencies introduced through practicalities of column
design (such as pressure drops, multiple side-products, side
strippers, etc.), while preserving the meaning of the CGCC. The
equations for equilibrium and operating lines are solved
simultaneously at each stage for designated light key and heavy
A-18 • Advanced Distillation Features Aspen Plus 11.1 Unit Operation Models
key components. The Aspen Plus Column Targeting tool has a
built-in capability to select light key and heavy key components for
each stage of the column.
The CGCCs are helpful in identifying the targets for potential
column modifications. These modifications include:
• Feed location
• Reflux ratio modifications
• Feed conditioning (heating or cooling)
• Side condensing or reboiling
An additional capability is provided through exergy analysis. The
exergy profiles are plotted by calculating the exergy loss at each
stage of the column, taking into account all entering and leaving
material and heat streams. In general, the exergy loss profiles can
be used as a tool to examine the degradation of potential work
availability (irreversibility) in a distillation column due to:
• Momentum loss (pressure driving force)
• Thermal loss (temperature driving force)
• Chemical potential loss (mass transfer driving force)
Column Targeting The hydraulic analysis capability is useful in understanding how
Hydraulic Analysis the vapor and liquid flow rates in a distillation column compare
with the minimum (corresponding to the PNMTC) and maximum
(corresponding to flooding) limits. For packed and tray columns,
jet flooding controls the calculation of vapor flooding limits. For
tray columns, parameters such as downcomer backup control the
liquid flooding limits. Hydraulic analysis can be used to identify
and eliminate column bottlenecks.
Specifications for For RadFrac, MultiFrac, and PetroFrac, the column targeting
Column Targeting thermal and hydraulic analysis capabilities can be activated by
and Hydraulic using the corresponding option buttons on the Report Property
Analysis Options forms.
Method for selecting light and heavy key components for the
PNMTC calculations has to be specified. The component K-values
based method is used as default.
To calculate the maximum vapor and liquid flow rates due to
flooding, you must specify tray or packing rating information for
the entire column. In addition, you can specify allowable flooding
factors (as fraction of total flooding) for flooding limit
calculations. The allowable limit for vapor flooding can be
specified on the TrayRating | Design/Pdrop or PackRating |
Design/Pdrop sheets. The allowable limit for liquid flooding (due
to downcomer backup) can be specified on the TrayRating |
Downcomers sheet. The default values are 85% for the vapor
Aspen Plus 11.1 Unit Operation Models Advanced Distillation Features • A-19
flooding limit and 50% for the liquid flooding limit. The liquid
flooding limit specification is available only if the downcomer
geometry is specified.
Selection of Key Results of the column targeting analysis depend strongly on the
Components selection of light key and heavy key components. The Aspen Plus
Column Targeting tool provides the following four methods for
judicious selection of these key components:
Method Use When
User defined Allows you to specify the light key and heavy key
components.
Based on Selects the light key and heavy key components
component split- on the basis of component split-fractions in
fractions column product streams. This method is best
suited for sharp or near-sharp splits.
Based on Selects the light key and heavy key components
component K- on the basis of component K-values. This method
values is best suited for sloppy splits.
Based on column Selects the light and heavy key components on the
composition basis of composition profiles. In principle, this
profiles method is similar to the K-value based method. It
is best suited for sloppy splits and it is, in general,
inferior to the K-value based method.
These methods can be chosen for the distillation models on the
following sheets:
Model Form
RadFrac Report Targeting Options
MultiFrac Columns Report Targeting Options
PetroFrac Report Targeting Options
Strippers Report Targeting Options
The associated parameters for each method can be chosen on the
following sheets:
Model Form
RadFrac Report Targeting Specifications
MultiFrac Columns Report Targeting Specifications
PetroFrac Report Targeting Specifications
Strippers Report Targeting Specifications
Selection of Key This method allows the user to define column sections and light
Components: User key and heavy key components for each section. If the sections
Defined defined do not cover the entire column, extrapolations are used. If
the selection of key components is inconsistent with the separation
in the column, the column targeting calculations are skipped. In
A-20 • Advanced Distillation Features Aspen Plus 11.1 Unit Operation Models
both cases, appropriate warning messages are written to the control
panel and to the history file.
We highly recommend that you run the simulation and inspect the
column split-fractions, composition profiles, and component K-
values before using this method to designate key components.
Selection of Key In this method the column is divided into sections bounded by its
Components Based on product streams. For each section, the key components are selected
Component Split- based on the component split-fractions in its bounding product
Fractions streams as:
Component Mole- Component Split - Designation
Fraction Fraction
In the section bottom- In the section top-product Light key
product > Composition > Minimum split-fraction
tolerance
In the section top- In the section bottom- Heavy key
product > Composition product > Minimum split-
tolerance fraction
If there is more than one light key component for a column section,
the heaviest of these components is selected as the light key.
Similarly, in case of multiple heavy keys for a column section, the
lightest is selected as the heavy key. These selections are made
based on the component K-values.
If light key and/or heavy key components cannot be selected for a
column section, appropriate extrapolations are used. If these
extrapolations do not produce a meaningful selection, column
targeting calculations are skipped. In both cases, appropriate
warnings are written to the control panel and to the history file.
The default values for the parameters used in this method are:
Parameter Default Value
Minimum split-fraction 0.9
Composition tolerance 1e-6
K-value tolerance 1e-5
These parameters can be manipulated to adjust the key selection.
This method also allows for components to be excluded from key
selection throughout the entire column.
This method should be used for columns with sharp or near-sharp
splits. Therefore, we highly recommend that you run the
simulation and inspect the column split-fractions and composition
profiles before choosing this method and adjusting its parameters.
Aspen Plus 11.1 Unit Operation Models Advanced Distillation Features • A-21
Selection of Key In this method key components are selected based on their K-
Components Based on values on each stage as:
Component K-Values Component Mole- Component K-value Designation
Fraction
> Composition > 1+K-value Light key
tolerance tolerance
> Composition < 1-K-value tolerance Heavy key
tolerance
If light key and/or heavy key components cannot be selected for a
stage, the components selected for the stage above are used. If
these extrapolations do not represent a meaningful selection,
column targeting calculations are skipped. In both cases,
appropriate warnings are written to the control panel and to the
history file.
The default values for the parameters used in this method are:
Parameter Default Value
Composition tolerance 1e-6
K-value tolerance 1e-5
These parameters can be manipulated to adjust the key selection.
This method also allows for components to be excluded from key
selection throughout the entire column.
Note that to represent the separation on each column stage, this
method selects a group of components as light key and another
group of components as heavy key. It is therefore, most suited for
columns with sloppy splits. It is also the default key selection
method.
Selection of Key This method is similar to the K-value based method except that the
Components Based on component composition profiles in the column are used instead of
Column Composition their K-values. You can specify the composition tolerance and the
Profiles stage span (the number of stages above and below the current stage
that are used to evaluate the composition profile). The default
values of these parameters are:
Parameter Default Value
Composition tolerance 1e-6
Stage span 2
These parameters can be manipulated to adjust the key-selection.
This method also allows for components to be excluded from key
selection throughout the entire column.
If light key and/or heavy key components cannot be selected for a
stage, the components selected for the stage above are used. If
these extrapolations do not represent a meaningful selection,
A-22 • Advanced Distillation Features Aspen Plus 11.1 Unit Operation Models
column targeting calculations are skipped. In both cases,
appropriate warnings are written to the control panel and to the
history file.
This method is also suited for sloppy splits and may be used
instead of the K-value based method.
Using Column The column targeting results can be viewed on the following sheets
Targeting Results for the three distillation column models:
Model Form
RadFrac Profiles Key Components
Profiles Thermal Analysis
Profiles Hydraulic Analysis
MultiFrac Columns Profiles Key Components
Columns Profiles Thermal Analysis
Columns Profiles Hydraulic Analysis
PetroFrac Profiles Key Components
Profiles Thermal Analysis
Profiles Hydraulic Analysis
Strippers Profiles Key Components
Strippers Profiles Thermal Analysis
Strippers Profiles Hydraulic Analysis
The CGCCs, the exergy loss profile, and the hydraulic analysis
profiles can be plotted using the PlotWizard.
The thermal analysis results provide a practical approach to
identifying and implementing potential modifications to the
column design. The following order of review for column
modifications, based on inspection of the CGCCs, is
recommended:
1 Feed location (appropriate placement)
2 Reflux ratio modification (reflux ratio vs. number of stages)
3 Feed conditioning (heating or cooling)
4 Side condensing or reboiling
Let us briefly discuss each modification with the help of a
distillation column that separates a mixture of n-heptane and n-
octane from heavier hydrocarbons (n-nonane, n-decane, and n-
pentadecane).
Aspen Plus 11.1 Unit Operation Models Advanced Distillation Features • A-23
Parameter Design 1
No. of stages 15
Reflux ratio 7.668
Feed location 3
Feed temperature 100 C
Condenser duty -28.30 MW
Condenser 141.03 C
temperature
Reboiler duty 41.00 MW
Reboiler temperature 205.61 C
Side condenser duty –
Side condenser –
temperature
Side reboiler duty –
Side reboiler –
temperature
The design parameters of importance for the base case design
(Design 1) of this column are summarized below:
• Feed Location
• Reflux Ratio Modification
• Feed Conditioning
• Side Condensing or Reboiling
Feed Location Inspection of the CGCC can identify any anomalies or distortions
due to inappropriate feed placement. Normally, such distortions
will be apparent as significant projections at the feed location
(pinch point) on the Stage-H CGCC. This is due to a need for extra
local reflux to compensate for the inappropriate feed placement.
A feed introduced too high up in the column will show a sharp
enthalpy change on the condenser side on the Stage-H CGCC and
should be moved down. Similarly, a feed introduced too low in the
column will show a sharp enthalpy change on the reboiler side on
the Stage-H CGCC and should be moved up the column.
A correctly placed feed not only removes the distortions in the
Stage-H CGCC but also results in reduced condenser and reboiler
duties.
The Stage-H CGCC for Design 1 of our distillation column is
shown in the following figure. It clearly shows a distortion on the
condenser side at the pinch point (stages 2 and 3). Therefore, the
feed must be moved down the column. The figure also shows the
CGCC for Design 2, where the feed is moved down to stage 7.
A-24 • Advanced Distillation Features Aspen Plus 11.1 Unit Operation Models
Comparison of the design parameters also reveals a slight
reduction in the condenser and reboiler duties.
Parameter Design 1 Design 2
No. of stages 15 15
Reflux ratio 7.668 7.668
Feed location 3 7
Feed temperature 100 C 100 C
Condenser duty -28.30 MW -28.02 MW
Condenser 141.03 C 140.58 C
temperature
Reboiler duty 41.00 MW 40.74 MW
Reboiler temperature 205.61 C 205.91 C
Side condenser duty – –
Side condenser – –
temperature
Side reboiler duty – –
Side reboiler – –
temperature
Aspen Plus 11.1 Unit Operation Models Advanced Distillation Features • A-25
Reflux Ratio Modification The horizontal gap between the T-H CGCC pinch point and the
ordinate represents the scope for reduction in heat duties through
reduction in reflux ratio. As the reflux ratio is reduced (while
increasing the number of stages to preserve the separation), the
CGCC will move towards the ordinate, thus reducing both the
condenser and reboiler loads.
The T-H CGCC for Design 2 of our distillation column is shown in
the following figure. This figure also identifies the scope for
reduction in condenser and reboiler duties by reducing the reflux
ratio.
A-26 • Advanced Distillation Features Aspen Plus 11.1 Unit Operation Models
Comparison of the design parameters for Design 2 and Design 3
reveals the energy savings achieved by reducing the reflux:
Parameter Design 2 Design 3
No. of stages 15 30
Reflux ratio 7.668 1.227
Feed location 7 14
Feed temperature 100 C 100 C
Condenser duty -28.02 MW -4.48MW
Condenser 140.58 C 140.58 C
temperature
Reboiler duty 40.74 MW 17.20 MW
Reboiler temperature 205.91 C 205.91 C
Side condenser duty – –
Side condenser – –
temperature
Side reboiler duty – –
Side reboiler – –
temperature
Aspen Plus 11.1 Unit Operation Models Advanced Distillation Features • A-27
Feed Conditioning Scope for adjustment of feed quality can be identified from sharp
enthalpy changes on the Stage-H or T-H CGCC.
A feed that is excessively sub-cooled will show a sharp enthalpy
change on the reboiler side of the CGCC. The extent of this change
determines the approximate feed heating duty required. Similar
arguments also apply for feed cooling. Changes in the heat duty of
feed pre-heaters or pre-coolers will lead to similar duty changes in
the column reboiler or condeser loads, respectively.
The Stage-H CGCC for Design 3 of our distillation column is
shown in the following figure. The enthalpy change on the reboiler
side is noticeably sharper. Therefore, our design can benefit from
addition of a feed pre-heater.
A-28 • Advanced Distillation Features Aspen Plus 11.1 Unit Operation Models
Design 4 adds a feed pre-heater with a duty of 2.34 MW. The
comparison of the design parameters for Design 3 and Design 4 is
shown in the following table:
Parameter Design 3 Design 4
No. of stages 30 30
Reflux ratio 1.227 1.227
Feed location 14 14
Feed temperature 100 C 123.19 C
Condenser duty -4.48 MW -4.50 MW
Condenser 140.58 C 140.80 C
temperature
Reboiler duty 17.20 MW 14.87 MW
Reboiler temperature 205.91 C 205.73 C
Side condenser duty – –
Side condenser – –
temperature
Side reboiler duty – –
Side reboiler – –
temperature
Note that feed preheating not only reduces the reboiler duty but
also reduces the temperature levels at which the hot utility (for the
reboiler and for the pre-heating the feed) needs to be supplied.
Side Condensing or Feed conditioning is normally preferred to side condensing or side
Reboiling reboiling, as such modifications are external to the column and
potentially at a more convenient temperature level.
The scope for side condensing or side reboiling can be identified
from the area beneath or above the CGCC pinch point (area
between the ideal and actual enthalpy profiles). If a significant area
exists, say below the pinch, a side-condenser can be placed at an
appropriate temperature level. This allows heat removal from the
column using a cheaper cold utility. A similar converse argument
applies to scope for placing a side reboiler.
Aspen Plus 11.1 Unit Operation Models Advanced Distillation Features • A-29
The T-H CGCC for Design 4 is as shown below:
As shown by the red lines, we can reduce the area on the reboiler
side of the CGCC by using a side reboiler at stage 22 with a duty
of about 6.5 MW (Design 5). The T-H CGCC for Design 5 is
shown in the following figure:
A-30 • Advanced Distillation Features Aspen Plus 11.1 Unit Operation Models
The following table shows the comparison of design parameters
for Design 4 and Design 5:
Parameter Design 4 Design 5
No. of stages 30 30
Reflux ratio 1.227 1.227
Feed location 14 14
Feed temperature 123.19 C 123.19 C
Condenser duty -4.50 MW -4.50 MW
Condenser 140.80 C 140.91 C
temperature
Reboiler duty 14.87 MW 8.37 MW
Reboiler temperature 205.73 C 205.64 C
Side condenser duty – –
Side condenser – –
temperature
Side reboiler duty – 6.5 MW
Side reboiler – 184.49 C
temperature
Aspen Plus 11.1 Unit Operation Models Advanced Distillation Features • A-31
Note that, the addition of the side reboiler, not only reduces the
main reboiler duty but also reduces the temperature levels at which
the hot utility (for the main reboiler and for the side reboiler) needs
to be supplied.
Exergy analysis provides a supplementary tool in identifying the
above design modification targets. For example, the exergy loss
profiles for Design 3 and Design 4 of our distillation column are
shown below:
Note that the high exergy loss at the feed stage for Design 3 (due to
the sub-cooled feed) has been reduced substantially in Design 4 by
pre-heating the feed.
The hydraulic analysis results show how the vapor and liquid flows
in the column compare with the minimum and maximum limits.
This comparison can be used separately or in conjunction with the
thermal analysis results for removing possible bottlenecks in
distillation columns.
For example, let us consider that Design 2 of our distillation
column contains single pass sieve trays of 4.25 m diameter. The
A-32 • Advanced Distillation Features Aspen Plus 11.1 Unit Operation Models
hydraulic analysis results for vapor flow through the column are as
shown:
For stages 22 to 29, the vapor flow through the column exceeds the
flooding limit. This is a bottleneck, which can possibly be removed
by increasing the column diameter for this bottom section of the
column. Note that the sharp increase in the vapor flow at the feed
stage (stage 14) is due to the liquid part of the feed at this stage.
Therefore, another option to remove the bottleneck is to decrease
the amount of liquid fraction of the feed to the column by pre-
heating it. This is exactly what we did in Design 3.
Aspen Plus 11.1 Unit Operation Models Advanced Distillation Features • A-33
The hydraulic analysis results for vapor flow through the column
for Design 3 are as shown below:
A-34 • Advanced Distillation Features Aspen Plus 11.1 Unit Operation Models
Index
sum-rates: 4-20, 4-24, 4-39, 4-40
A Algorithms: 4-20, 4-24, 4-25, 4-26, 4-39, 4-
40, 4-53, 10-18
Absorbers 4-57
analysis
MultiFrac: 4-28
hydraulic A-18
RadFrac: 4-9
thermal A-18
RateFrac 4-57, 4-58
ASME method
Absorbers: 4-9, 4-28
Compr: 6-9
ACM
MCompr: 6-15
Using with Aspen Plus: 9-8
ASME method: 6-9, 6-15
ACM: 9-8
Aspen Custom Modeler
ACMUser3
Using with Aspen Plus: 9-8
flowsheet connectivity: 9-8
Aspen Custom Modeler: 9-8
Overview: 9-8
Azeotropic distillation
specifying: 9-8
RadFrac: 4-20
ACMUser3: 9-8
Azeotropic distillation: 4-20
Aerotran
flash specifications: 3-26
B
flowsheet connectivity: 3-25
overview: 3-25 Baffle geometry
physical properties: 3-26 HeatX: 3-12
solids: 3-26 Baffle geometry: 3-12
specifying: 3-26 Baghouses
Aerotran: 3-25, 3-26 FabFl: 8-18
Air separation resistance coefficients: 8-20
MultiFrac: 4-28 separation efficiency: 8-21
RadFrac: 4-21 Baghouses: 8-18, 8-20, 8-21
Air separation: 4-21, 4-28 Ballast trays
Air-cooled heat exchangers values: A-10
Aerotran: 3-25 Ballast trays: A-10
Air-cooled heat exchangers: 3-25 Batch distillation
Algorithms BatchFrac: 4-78
convergence: 4-20, 4-24, 4-25, 4-26, 4-39, Batch distillation: 4-78
4-40, 4-53 Batch fractionation
dynamic scenario: 10-18 BatchFrac: 4-78
inside-out: 4-24, 4-40 Batch fractionation: 4-78
Newton: 4-20, 4-24, 4-39, 4-40 Batch reactors
nonideal: 4-20, 4-24 RBatch: 5-24
standard: 4-24, 4-39, 4-40 Batch reactors: 5-24