186 Process Simulation using HYSYS

Solution:

Follow the step-by-step instructions to solve the problem.

1- Open a new case.

Tutorial 3
Separation Processes

Problem 1 Shortcut Distillation

A column is used to separate propane from a mixture of hydrocarbons (ethane to n-hexane).
The condenser is in full reflux condition and pressures in condenser and reboiler are 248 and
252 psia, respectively. Reflux ratio is 6.06. Feed enters to the column at 225 ºF and 250 Psia
with molar flow rate of 1000 lbmole/hr. Solve the column using shortcut operation. The
2- Add a new component list. composition of feed is shown bellow:
Composition of Feed
Component Molar flow rate (lbmole/hr)
Ethane 30
Propane 200
n-Butane 370
n-Pentane 350
n-Hexane 50
188 Process Simulation using HYSYS Tutorial 3 Separation Processes 187

5- Select the Fluid Package (Make sure selecting Component List -1in the component list). 3- Select the components from the Components list and then close the active window by
clicking on cross button (all process components should be entered in this step).

6- Add a new Fluid Package. 4- The cross button is not seen on the figure and you could move the active window to see
the cross button in order to close it.
190 Process Simulation using HYSYS Tutorial 3 Separation Processes 189

9- Drag a material stream to the PFD and change its name to feed, and then enter its 7- Select the Peng Robinson or SRK equation of state from Property Package.
temperature and pressure in the Worksheet/Conditions Page.

8- Close the Fluid Package by clicking on cross button. After this step, it is possible to
10- Save the simulation work (e.g., problem-1). import/export the Fluid Package. Then enter to Simulation Environment.
192 Process Simulation using HYSYS Tutorial 3 Separation Processes 191

13- Double click on Shortcut and enter inlet, outlet and energy streams. Change the top 11- In the Worksheet/Composition page, click the Edit button, enter molar flow rate of the
product phase to Vapor. components, (make sure to select mole flow) then click OK. Close the active window to
return to PFD.

14- In the Design/Parameters page, enter propane as a light key in the bottom and n-butane as
a heavy key in the distillate (0.0001 mole fractions). Also enter the condenser and 12- Select a Shortcut operation from object palette and drag it to the PFD.
reboiler pressures.
194 Process Simulation using HYSYS Tutorial 3 Separation Processes 193

Problem 2 Distillation Column 15- Finally, enter the reflux ratio.

Consider a stream of light hydrocarbons fed to a column at 100 ºC and
10 atm with a molar flow rate of 1150 kmole/hr. The column has 18 trays and the feed
enters on the 8th tray. Pressures in condenser and reboiler are 7 and 12 atm, respectively, and
the reflux ratio is 2. Condenser is in the full reflux condition. Simulate the column, if the
recovery of ethane in distillate is 99 % and recovery of i-butane in bottom is 100 %. The feed
composition is shown at the table below:

Component Mole fraction

Methane 0.1
Ethane 0.4
Propane 0.2
i-Butane 0.15
n-Butane 0.15

16- Properties of column could be seen in the Performance page (e.g., minimum number of
trays, actual number of trays and optimal feed stage).
196 Process Simulation using HYSYS Tutorial 3 Separation Processes 195

3- Select the components from the Components list and then close the active window by Solution:
clicking on cross button (all process components should be entered in this step).
Follow the step-by-step instructions to solve the problem.
1- Open a new case.

4- The cross button is not seen on the figure and you could move the active window to see
the cross button in order to close it.

2- Add a new component list.

198 Process Simulation using HYSYS Tutorial 3 Separation Processes 197

7- Select the Peng Robinson or SRK equation of state from Property Package. 5- Select the Fluid Package (Make sure selecting Component List -1in the component list).

8- Close the Fluid Package by clicking on cross button. After this step, it is possible to 6- Add a new Fluid Package.
import/export the Fluid Package. Then enter to Simulation Environment.
200 Process Simulation using HYSYS Tutorial 3 Separation Processes 199

11- In the Worksheet/Composition page, click the Edit button, enter the composition, and 9- Drag a material stream to the PFD and change its name to feed, and then enter its
then click OK. Close the active window to return to PFD. temperature, pressure and the molar flow rate in the Worksheet/Conditions Page.

12- Select a distillation column from the object palette (F4) and drag it to the PFD. 10- Save the simulation work (e.g., problem-2).
202 Process Simulation using HYSYS Tutorial 3 Separation Processes 201

15- Click on Next button. Since the condenser and reboiler temperatures are optional, it is 13- Double click on Column and enter inlet, outlet and energy streams. Select Full Rflx for
not necessary to enter these parameters in this problem. condenser type. Change the number of trays to 18 and the feed inlet stage to 8th tray.

16- Click on Next button, enter the reflux ratio and click the Done button. 14- Click on Next button. Enter the condenser and reboiler pressures.
204 Process Simulation using HYSYS Tutorial 3 Separation Processes 203

19- Select the Design/ Specs page. 17- The column specification page is now shown.

20- Add a new column specification. Choose the Column Component Recovery in the
Column Specification types menu and click on the Add spece(s) button. 18- Go to the Design/Monitor page. As shown, the degree of freedom is 1.
206 Process Simulation using HYSYS Tutorial 3 Separation Processes 205

23- Add another spec. Select the Column Component Recovery button. Enter 1 for recovery 21- Define 0.99 recovery for the ethane in distillate. The degree of freedom becomes zero.
of i-butane in bottom stream. The degree of freedom is -1. The column is over-specified.

24- One specification should be removed to bring the degree of freedom to zero in order to
solve the column. Go back to the Monitor page and deactivate the reflux ratio button. 22- Close the active window and run the column.
The column runs automatically.
208 Process Simulation using HYSYS Tutorial 3 Separation Processes 207

Problem 3 Ammonia Production 25- Various combination of specifications could be chosen to run the column (for all cases,
In an ammonia plant, the feed gas (74 % H2, 24.5 % N2, 1.2 % CH4, and 0.3 % Ar in mole) at the degree of freedom should be zero to solve the column), e.g., choose the Component
300 °F and 500 psi enters to a catalytic reactor. The reaction N 2  3H 2 o 2 NH 3 is carried Recovery-2 and the Reflux Ratio and run the column.
out in the reactor at T=930 °F and P=200 atm. The 65 % of the N2 is converted in the reactor.
The products of reaction are refrigerated to separate 75 % of NH3 product per pass. The
remaining process stream is recycled back after being purged. Assume a total feed of 100
lbmole/hr and no pressure drop in the mixer. Simulate the process with Peng-Robinson
equation of state for the case when the purge fraction is 10 %.

26- The column is now simulated using those specifications.

210 Process Simulation using HYSYS Tutorial 3 Separation Processes 209

3- Select the components from the Components list and then close the active window by Solution:
clicking on cross button (all process components should be entered in this step).
Follow the step-by-step instructions to solve the problem.
1- Open a new case.

4- The cross button is not seen on the figure and you could move the active window to see
the cross button in order to close it.
2- Add a new component list.
212 Process Simulation using HYSYS Tutorial 3 Separation Processes 211

7- Select the Peng Robinson or SRK equation of state from Property Package. 5- Select the Fluid Package (Make sure selecting Component List -1in the component list).

8- Close the Fluid Package by clicking on cross button. After this step, it is possible to
import/export the Fluid Package. Click on the Reaction button. 6- Add a new Fluid Package
214 Process Simulation using HYSYS Tutorial 3 Separation Processes 213

11- Select components from the drop down menu and then enter stoichiometry of components 9- Go to the Add Rxn button to enter the reaction data.
(negative for reactants and positive for products). The balance error should be zero.

10- Select the Conversion Reaction and then click on the add Reaction.button.
12- Click on the Basis button, select Base Component from drop down menu and enter the
conversion for the base component (65 %).
216 Process Simulation using HYSYS Tutorial 3 Separation Processes 215

15- Click on the Add FP button (This makes the reaction accessible for simulation) 13- Close the active window and return to the following window: The reaction Rxn-1 is
added. Add a reaction set by clicking on the Add Set button.

16- Click on Add Set to Fluid Package Button

14- In the Active List, select Rxn-1 from the drop down menu. Check mark the set and close
the active window.
218 Process Simulation using HYSYS Tutorial 3 Separation Processes 217

19- Go to the Variables button, select Field and close the window. 17- The Basis-1 property model is now added to the Fluid Package. Then Enter to
Simulation Environment.

20- Drag a material stream to the PFD and change its name to feed. Enter its temperature,
pressure and molar flowrate in the Worksheet/Conditions Page. 18- Go to Tools/Preference to change the Unit Set to Field.
220 Process Simulation using HYSYS Tutorial 3 Separation Processes 219

23- Drag another stream named R* to the PFD. Define it like feed stream. 21- Save the simulation work (e.g., problem-3).

22- Enter the mole fractions of the components in Worksheet/Composition Edit page. Click
24- Enter 0 for molar flow rate of R* (Open-loop simulation). Close the active window. OK. The stream is now solved. Close the active window to return to PFD.
222 Process Simulation using HYSYS Tutorial 3 Separation Processes 221

27- Select a Compressor from the object palette and drag in to the PFD. 25- Select a Mixer from the object palette (F4) and drag it to the PFD.

28- Double click on Compressor and enter inlet, outlet and energy streams. 26- Double click on mixer and enter inlet and outlet streams. It is solved immediately. Close
the active window and return to PFD.
224 Process Simulation using HYSYS Tutorial 3 Separation Processes 223

31- Double click on Heater and enter inlet, outlet and energy streams. 29- Go to the Worksheet and enter 200 atm as the pressure of outlet stream. The Compressor
is solved. Close the active window.

32- On the Design/Parameters page enter 0 for Delta P.

30- Select a Heater from the object palette and drag in to the PFD.
226 Process Simulation using HYSYS Tutorial 3 Separation Processes 225

35- Double click on Reactor and enter the inlet, outlet and energy streams. 33- Go to the Worksheet page and enter 930 ºF for the outlet stream temperature. At the
beginning, the Heater acts as a cooler. However, after the recycle stream completion, it
will work as a Heater, because of the higher flow rate. Close the active window.

36- Go to the Reaction page and select the reaction set from the Reaction Set drop down.
34- Select a Conversion reactor from the object palette and drag it to the PFD.
228 Process Simulation using HYSYS Tutorial 3 Separation Processes 227

39- Double click on the Splitter to enter the inlet, outlet and energy streams. 37- Go to Worksheet and enter 930 ºF for the outlet stream temperature.

40- Go to the Design/Splits page and enter 0.25 for ammonia and 1 for the other components
as the fraction to Overhead. Therefore, 75 % of ammonia is separated as a pure product. 38- Select a Component splitter from the object palette and drag in to the PFD.
230 Process Simulation using HYSYS Tutorial 3 Separation Processes 229

43- Double click on the Tee and enter the inlet and outlet streams. 41- Go to Worksheet and enter 930 ºF and 200 atm for both outlet streams. The Splitter is
now solved. Close the active window.

44- On the Design Parameters page, enter 0.9 for a Recycled Flow Ratio (stream R) and 42- Select a Tee from the object palette and drag it to the PFD.
close the active window.
232 Process Simulation using HYSYS Tutorial 3 Separation Processes 231

47- If the Recycle reached to its iteration limit without converging, click Continue. 45- Select a Recycle operation from the object palette and drag it to the PFD.

48- The process is now simulated. 46- Double click on Recycle and enter the inlet and outlet streams.