Chemical & Process Technology

Process engineering design involve preliminary equipment sizing during initial conceptual phase. It is mainly to identify the magnitude of major equipment potentially install in a plant. This is rather important during conceptual phase as equipment dimensioning will provide sufficient key information for budgetary costing which possibly provide direction in Process Engineering Design. 

Recommended :
- Subscribe FREE - Chemical Engineering
- Tips on Succession in FREE Subscription

Process simulation is commonly conducted for all phases of design e.g. Preliminary Design, Basic Design, Front-End Design, Detailed Design, etc. Process simulation enable production of heat and material balance and provide basic process parameters for equipment specification and sizing. Conventionally equipment sizing is conducted manually and vendor preliminary sizing program / software. Transfer of process parameters to vendor software or spreadsheet will require time and effort and also subject to erroneous risk of data transfer. Therefore Process Simulation provider have taken extra effort to provide additional equipment sizing utilities in the Process Simulator to aid Process Engineer to identify system capacity and rule out technical not feasible process option. ASPEN HYSYS have done the same to assist user.

The following document is a HYSYS SIZING guide which provide information in using Sizing Utilities and provide the theories and equations used in the sizing Utilities. It is particularly important for an HYSYS Sizing Utilites user have clear understanding of the utilities background and limitation.

Download

Related Topics

• Simulation of Gas Power Plant Using HYSYS
• HYSYS Simulation of MEA Based CO2 Removal
• Correct model and thermo package in Amine system simulation using HYSYS
• Incompatibility HYSYS Version & Its File...What to do ?
• Adjusted Method For Compressor Settle Out (with Vapor & Liquid) Using HYSYS
• Simple Method For Compressor Settle Out (Vapor Only) Using HYSYS
• HYSYS related

Indian Chemical Industry is one of the oldest industry in India. It plays crucial role & contributes significantly towards industrial and economical growth of the nation.

Until 1991, India had a closed economy and chemical manufacturing was largely controlled by licensing regulations. Indian chemical industry has evolved over the years into producing high quality and reasonably priced products. Indian chemicals and chemical-based products are exported all over the world. Intensive efforts in the areas of research and development have resulted in development of technologically sound, environmentally confirming and economically viable products by the chemical industry in India.   

Across the world, the chemicals industry is undergoing the process of globalization, consolidation, product innovation and cost rationalization. This has resulted in a steady shift of manufacturing from western countries to Asia-mainly India, China and West Asia. Due to this there is an increase in the domestic chemical production and exports, with  increasing foreign investment.

Indian chemical industry possesses a well-built and diversified base with its operations in many areas such as pharmaceuticals, insecticides and pesticides, and paints. The growth rate of this industry is comparatively higher than all other manufacturing sectors in India. This industry is labor-intensive and therefore human resource is a vital aspect of this industry.

Global chemical market is approximately USD 1700 bn. The area wise breakup is given below. Global chemical industry growth rate is 2-3%

Country - USD Bn (year 2007)
*************************
Western Europe - 731    
N. America - 374
S. America - 68  
Asia - 442
Rest - 85*************************
Total - 1698  

Huge investments are taking place in China and the Middle East. Our major competitors are China, Taiwan, Korea and the Gulf while major export markets are EU and USA.

Market size of indian chemical industry is given below

Indian chemical industry has a share of 14% in indian industry and is the largest single industry segment. 80% of India’s chemical industry is located at Gujrat and indian chemical industry is growing at the rate of 12 -13% per annum.

The industry serves the basic need of many different industry verticals like natural gas, water, oil, metals, minerals, air, oil, etc and all these verticals eventually bring into marketplace an array of products, almost 70000. Although domestic performance is well, Indian chemical industry has to face stiff competition in international market



The strengths of Indian Chemical Industry 

• Long private sector history in textile chemicals, colourants, leather chemicals, et
• It is aggressively competitive overseas
• Scope to grow for indian market (per capita consumption is very low)
• Large pool of skilled manpower is available
• English is commonly spoken language
• Intellectual Property Right enhance the confidence of investors
• Aggressive cost management and use of  knowledge engineering
• Joint venture possible
• Contract manufacturing / research possible
• Consolidation and integration
• Outsourcing of services possible
• Product and application development possible
• Chemical Science in China and India is strong in Polymer, Organic Chemistry and Process Engineering

This industry plays a pivotal role in agricultural and development sectors. Many other sectors, like engineering, automotive, consumer durables and food processing also depend on this sector in a big way. Investment opportunity in this industry is more than US$ 75bn in next 10 years

The spread of chemical industry is as follows: Private Limited Company  69%, Public Limited  Company   12%,   Partnership  11%,   Propriyory  08%.

Problems faced by Indian Chemicals Industry

• Lack of scale
• Huge investment and long gestation
• Major threats are from Korea, Taiwan, China and Gulf
• Mindset is largely for trading and not partnering
• Absence of Infrastructure
• Fluctuating prices of crude oil
• Scarcity of capital
• Low investment in R&D.(32nd rank )
• High taxation
• High capital , raw materials and utility cost , hence less competitive
• Highly fragmented
• Presence of many MNC

Most of these problems can be solved by Process Intensification (Read more in Process Intensification".
 


P.J. Lakhapate is a Chemical Engineer from UDCT, Mumbai (1975) & has completed a Post Graduation in systems management from J. Bajaj Institute, Mumbai. He is a lead assessor for ISO-9000. He  received Quality Award from Chemtex Engg of India Ltd,Powai. He has travelled U.S.A., Brazil, Russia, Kuwait, Saudi Arabia. He has written more than 40 articles & published in national & international magazines. He is distinguished member of expert committee group (for PUMPS & VALVES ) of NATIONAL ADVISORY COUNCIL. He has to his credit a work experience of more than 35 years. He is working as a consultant.
Email  : plakhapate@rediffmail.com

Thanks to P.J. Lakhapate.
by JoeWong 

Related Topic

• Process Intensification
• ASPEN PIPESYS MANUAL
• Useful Documentation for AFSA / FLARENET...
• Useful Documentation for UNISIM... 
• Useful Documentation for HYSYS ...
  

Process Intensification (PI) is a revolutionary approach to process and plant design, development and implementation. It presents significant scientific challenges to chemists, biologists and chemical engineers while developing innovative systems and practices which can offer drastic reduction in chemical and energy consumptions, improvements in process safety, decreased equipment volume and waste formation and increased conversions and selectivity towards desired product(s). In addition they can offer relatively cheaper and sustainable process option.

Here one must note that development of a new chemical route or a change in composition of a catalyst, no matter how dramatic the improvements they bring to existing technology, do not qualify as process intensification.

Process Intensifying Equipment

Monolythic Catalytic Reactor
Monolithic substrate used today for catalytic  applications are  metallic or non metallic bodies providing a multitude of  straight narrow channels of  defined uniform cross sectional shapes To ensure sufficient porosity and enhance the catalytically active surface, the inner walls of the monolith channels usually are covered with a thin layer of wash   coat, which acts as the support for the catalytically active species.

The advantages of Monolithic Reactors are as follow.                            

• Low pressure drop
• High mass transfer  area
• Low space requirement
• Low cost
• Better Selectivity
• Better Safety
• Less Environmental problems

Micro-Reactors
Micro-reactors are chemical reactors of extremely small dimensions that usually have a sandwich-like structure consisting of a number of slices (layers) with micro-machined channels (10-100 micron in dia.). The layers perform various functions, from mixing to catalytic reaction, heat exchange, or separation

Higher values of heat transfer coefficient values upto 20000 W/m2K are reported. Hence highly exothermic reactions can be easily carried out .This is very useful for toxic or explosive reactants / products. The chan¬nels in the plates of micro-channel heat exchangers are usually around 1 mm or less wide, and are fabricated via silicon micromachining, deep X-ray lithography, or non-lithographic micromachining

Spinning Disk Reactors (SDR)
For fast and very fast liquid-liquid reactions like sulphonation, nitration , polymerization (styrene)    involving high heat of reactions,  this type of reactor is developed by Newcastle University. In SDRs, a very thin (typically 100 micron) layer of liquid moves on the surface of a disk spinning at up to approximately 1,000 rpm. At very short residence times (typically 0.1 s), heat is efficiently removed from the reacting liquid at heat-transfer rates reaching 10,000 W/m2K. SDRs currently are being commercialized.

Static Mixer Reactors

Supersonic Gas-Liquid Reactor
Praxair Inc. developed this type of reactor for fast and very fast processes for gas/liquid systems and it employs a supersonic shockwave to disperse gas into very tiny bubbles in a supersonic in-line mixing device.

Recommended :
Subscribes to FREE Hydrocarbon Processing

The Jet Impingement Reactor
An apparatus to allow reaction in liquid phase. The apparatus is a vessel having a baffle. There are openings in the baffle through each of which liquid passes as jet. Neighboring openings are sufficiently close to allow impingement of the jet thereby allowing for the reaction of liquids. This is useful for immiscible liquids. e.g. Nitration of aromatic compound with aqueous solution , manufacture of Nitroglycerine etc.

NORAM Engineering and Constructors (Vancouver, BC) uses this system of specially configured jets and baffles to divide and remix liquid streams with high intensity.

This type of reactor is suitable for  gas – liquid  system  and can be used for  Amination, Alkylation, Carbonylation, Chlorination, Ethoxylation, Hydrogenation, Nitrilation, Oxidation , Phosgenation etc. The Buss loop reactor has been successfully used for hydrogenation, amination and sulphonation.

Rotor/stator mixers, which are aimed at processes requiring very fast mixing on a micro scale, contain a high-speed rotor spinning close to a motionless stator. Fluid passes through the region where rotor and stator interact and experiences highly pulsating flow and shear. In-line rotor/stator mixers resemble centrifugal pumps and, therefore, may simultaneously contribute to pumping the liquids.

HIGEE technology intensifies mass-transfer operations by carrying them out in rotating packed beds in which high centrifugal forces (typically 1,000 g) occur. This way, heat and momentum transfer as well as mass transfer can be intensified. The rotating-bed equipment can be used in absorption, extraction, distillation and also can be utilized for reacting systems (especially, those that are mass-transfer limited). It potentially can be applied to other phase combinations including three-phase gas/liquid/solid systems. e.g. Absorption of  CO2, H2S  using  Di-ethanol Amine

Another example is the filtering centrifuge-cum-dryer. The centrifuge combines these operations for a pesticide/herbicide/pharmaceutical product with recycle of the solvent used for crystallization. This saves on floor area, operators, conveying, drying equipment, etc.  Centrifuge for liquid- liquid separation are already in use.

HIGEE packed bed replaces towers up to 50-60 ft tall and can process up to 250 tons of water per hour. The size of the equipment is about 6 ft tall.. The deoxygenated water is required for oil well injection to enhance oil well production. This could also be used for boiler water deaeration Dow Chemicals have used these columns for stripping of hypochlorous acid from brines

Lower value of g will affect the convection currents. This in turn may affect growth of the crystals in crystallization. Lowering effect of g can be obtained by providing bottom entry in the crystallization vessel.

Plate Heat Exchangers, Spiral Plate Heat Exchangers, Capillary Tube Type Shell and Tube type heat exchangers are already used as reactors .

There are several other type of reactors such as Biofilm Annular Reactor ,  Oscillating  Flow Reactors, Drip Flow reactor etc  can be used to improve the performance

The reactor concept aims to achieve an indirect coupling of energy necessary for endothermic reactions and energy released by exothermic reactions, without mixing of the endothermic and exothermic reactants, in closed-loop reverse flow operation. Periodic gas flow reversal incorporates regenerative heat exchange inside the reactor. This reactor is used for SO2 oxidation, total oxidation of hydrocarbons in off-gases, and NOx reduction.

It is a distillation column filled with catalytically active packing. In the column, chemicals are converted on the catalyst while reaction products are continuously separated by fractionation (thus overcoming equilibrium limitations). The catalyst used for reactive distillation usually is incorporated into a fiberglass and wire-mesh sup¬porting structure, which also provides liquid redistribution and disengagement of vapor. Structured catalysts, such as Sulzer's KATAPAK,

The membrane enable in-situ separation of catalyst particles from reaction products. thus itself becoming a highly selective reaction-separator It also can be applied for a controlled distributed feed of some of the reacting species, either to increase overall yield or selectivity of a process (e.g., in fixed-bed or fluidized-bed membrane reactors or to facilitate mass transfer (e.g., direct bubble-free oxygen sup¬ply or dissolution in the liquid phase via hollow-fiber membranes ).

Reactive extruders used in the polymer industries enable reactive processing of highly viscous materials without re¬quiring the large amounts of solvents. Popular twin-screw extrud¬ers offer effective mixing, can operate at high pres¬sures and temperatures, plug-flow characteristics, and capability of multi-staging. New types of extruders with catalyst immobilized on the surface of the screws may allow carrying out three-phase catalytic reactions.

Eastman Chemicals successfully changed the methyl acetate plant. The process involves the esterification of methanol with acetic acid in presence of catalyst, removal of water of reaction, distillation of product and recovery and recycle of excess reactants. There are as many as six distillation columns that have been replaced by single multifunctional distillation column. Imagine the reduction of number of reboilers, condensers, pumps, etc. The heat input and rejection is practically only at two points.

Here, integration of chemical reaction and electric power generation takes place (Simultaneous gas/solid reaction and comminution in a multifunctional reactor also has been investigated).

Isothermal reactor crystallizer cooler operation gives higher P2O5 recovery efficiency, superior sulfate control. The P2O5 content of gypsum is 0.7%, phosphoric acid concentration 28%. This gigantic single vessel, combining,  reactor, crystallizer and cooler, (12 meter dia, 1300 M3 volume) occupies less space, requires fewer moving parts and is substantially less expensive to build, operate, clean and maintain than conventional installations, thereby substantially reducing capital and operating costs.

Here the membrane serves as a permeable barrier between the gas and liquid phases. By using hollow-fiber membrane modules, large mass-transfer areas can be created,

This offers operation independent of gas and liquid flow rates, without entrainment, flooding, channeling, or foaming The technique is widely considered as an alternative to reverse osmosis and evaporation. Membrane distillation basically consists of bringing a volatile component of a liquid feed stream through a porous membrane as a vapor and condensing it on the other side into a permeate liquid. Temperature difference is the driving force of the process. Main advantages of membrane distillation are

Here a selective adsorbent is added to a distillation mixture. This increases separation ability and may present an attractive option in the separation of azeotropes or close-boiling components. Adsorptive distillation can be used, for the removal of trace impurities in the manufacturing of fine chemicals; it may allow switching some fine-chemical processes from batch wise to continuous operation.

Ultrasound is used as a source of energy for formation of micro- bubbles in the liquid medium of reaction. These cavities can be thought of as high energy micro-reactors. Their collapse creates micro-implosions with very high local energy release (temperature rises of up to 5,000 K and negative pressures of up to 10,000 atm are reported ). This may have various effects on the reacting species, from homolytic bond breakage with free radicals formation, to fragmentation of polymer chains by the shockwave in the liquid surrounding the collapsing bubble. This is still at development stage.

A novel high-temperature reactor in which solar energy is absorbed by a cloud of reacting particles to supply heat directly to the reaction site has been studied. Experiments with two small-scale solar chemical reactors in which thermal reduction of MnO2 took place also are reported. Other studies describe, the cyclo-addition reaction of a carbonyl compound to an olefin carried out in a solar furnace reactor and oxidation of 4-chlorophenol in a solar-powered fiber-optic cable reactor.

Microwave heating can make some organic syntheses proceed up to 1,240 times faster than by conventional techniques. Microwave heating also can enable energy-efficient in-situ desorption of hydrocarbons from zeolites used to remove volatile organic compounds.

Electric fields can augment process rates and control droplet size for a range of processes, including painting, coating, and crop spraying. In these processes, the electrically charged droplets exhibit much better adhesion properties. In boiling heat transfer, electric fields have been successfully used to control nucleation rates. Electric fields also can enhance processes involving liquid/liquid mixtures, in particular liquid/liquid extraction where rate enhancements of 200-300% have been reported.

Gliding Arc technology, that is, plasma generated by formation of gliding electric discharges. These discharges are produced between electrodes placed in fast gas flow, and offer a low-energy alternative for conventional high-energy-consumption high-temperature processes. Example include: methane transformation to acetylene and hydrogen, destruction of N2O, reforming of heavy petroleum residues, CO2 dissociation, activation of organic fibers, destruction of volatile organic compounds in air, natural gas conversion to synthesis gas, and SO2 reduction to elemental sulfur.

SCF is any substance at a temperature and pressure above its critical point. It can diffuse through solids like a gas, and dissolve materials like a liquid. In addition, close to the critical point, small changes in pressure or temperature result in large changes in density, allowing many properties of a supercritical fluid to be "fine-tuned".

Many of the physical and transport properties of a SCF are intermediate between those of a liquid and a gas. Diffusivity in an SCF, falls between that in a liquid and a gas; this suggests that reactions that are diffusion limited in the liquid phase could become faster in a SCF phase. Also Compounds that are largely insoluble in a fluid at ambient conditions can become soluble in the fluid at supercritical conditions. Conversely, some compounds that are soluble at ambient conditions can become less soluble at supercritical conditions. SCFs have been investigated for systems, including enzyme reactions, Diels-Alder reactions, organo-metallic reactions, heterogeneously catalyzed re¬actions, oxidations, and polymerizations.

Cryogenic techniques involving distillation or distillation combined with adsorption, today are used almost exclusively for production of industrial gases, may in the future prove attractive for some specific separations in manufacturing bulk or fine chemicals.

This is a well known example where several equipment are put together to make compact ,energy efficient equipment.

• Safety - As per Cell for Industrial Safety and Risk Analysis (CISRA) the major cause of accident is STORAGE. When size of the  process equipment is reduced , operating inventory will be reduced.
• Health - The fugitive emissions will be reduced due to smaller equipment size. This  will improve the health of the society in general. Environment Better efficiency /yield leads to less rejection to environment hence less pollution.
• Quality - It is possible to get desired quality of products
• Energy - Due to higher energy efficiency, leads to enhanced production
• Cost - Less due to less raw material, catalyst, labour, utility and space requirement

Following photos indicate how old plant (above) will look like after Process Intesification implementation (below) .This is how more production, better quality can be obtained from less energy, less space, less cost






Implementation of Process Intensification (PI)
May consider following actions for PI implementation.

• Utilise existing facilities / human resources efficiently
• Develop new modern facilities
• Connect all scientific research institutes
• Allocate  separate funds for R&D
• Provide favorable environment for R&D
• Develop platform for Industry –Academy interaction
• Develop patent laws in accordance with global practices. 
• Create awareness 
• Provide incentives in the form of awards

P.J. Lakhapate is a Chemical Engineer from UDCT, Mumbai (1975) & has completed a Post Graduation in systems management from J. Bajaj Institute, Mumbai. He is a lead assessor for ISO-9000. He  received Quality Award from Chemtex Engg of India Ltd,Powai. He has travelled U.S.A., Brazil, Russia, Kuwait, Saudi Arabia. He has written more than 40 articles & published in national & international magazines. He is distinguished member of expert committee group (for PUMPS & VALVES ) of NATIONAL ADVISORY COUNCIL. He has to his credit a work experience of more than 35 years. He is working as a consultant

Email  : plakhapate@rediffmail.com

Thanks to P.J. Lakhapate.
by JoeWong 

 Related Topic

• ASPEN PIPESYS MANUAL
• Useful Documentation for AFSA / FLARENET...
• Useful Documentation for UNISIM... 
• Useful Documentation for HYSYS ...
  

The basic principle of the Combined Cycle is by burning gas in a gas turbine (GT) produces electric power by a coupled generator and routing hot exhaust gases through a water-cooled heat exchanger produces steam, which can be turned into electric power with a coupled steam turbine and generator.

Recommended :
Subscribes to FREE Hydrocarbon Processing

This set-up of Gas Turbine, waste-heat boiler, steam turbine and generators is called a combined cycle. This type of power plant is being installed in increasing numbers round the world where there is access to substantial quantities of natural gas. This type of power plant produces high power outputs at high efficiencies and with low emissions. It is also possible to use the steam from the boiler for heating purposes so such power plants can operate to deliver electricity alone

Efficiencies are very wide ranging depending on the lay-out and size of the installation and vary from about 40-56% for large new natural gas- fired stations. Developments needed for this type of energy conversion is only for the gas turbine. Both waste heat boilers and steam turbines are in common use and well-developed, without specific needs for further improvement.

The primal objective of this report is to show the efficiency into simulate a Gas Power Plant with Combined Cycle technology with HYSYS software; and to optimize the process to get the biggest possible economic benefit, making changes in the feed variables of the combined cycle plant. The data of this project are based on the document of the Department of Energy of United States.

Read more in "Simulation of Gas Power Plant"

Download

Related Topics

• HYSYS Simulation of MEA Based CO2 Removal
• Correct model and thermo package in Amine system simulation using HYSYS
• Incompatibility HYSYS Version & Its File...What to do ?
• Adjusted Method For Compressor Settle Out (with Vapor & Liquid) Using HYSYS
• Simple Method For Compressor Settle Out (Vapor Only) Using HYSYS
• HYSYS related

Aspen PIPESYS integrates powerful capabilities for single and multiphase pipeline flow modeling into Aspen HYSYS. Aspen PIPESYS enables users to:

If you found any documents related to ASPEN PIPESYS and/or available FREE for all, you are encourage to share within our community. You may drop a note via email or comment. Please include your nickname.

Related Topic

• Incompatibility HYSYS Version & Its File...What to do ?
• Adjusted Method For Compressor Settle Out (with Vapor & Liquid) Using HYSYS
• Simple Method For Compressor Settle Out (Vapor Only) Using HYSYS
• Saturate Dry Gas With Water in HYSYS Using SATURATE Extension
• Saturate Dry Gas With Water in HYSYS

Aspen product including HYSYS and FLARENET used to have English interface. Nevertheless, engineer and operators from certain countries are normally not used to English language and this lead to many error in understanding and operation of Aspen products. Typical countries are China, Japan, Korean, Brazil, Latin American countries, etc.

Aspen aware of this issue and has taken a big step in making their product interface using 9 different languages. There are

Recommended :
Tips on Succession in FREE Subscription
Subscribes to FREE Hydrocarbon Processing


Aspen Flare System Analyzer, AFSA (formerly FLARENET) enables engineers to perform steady-state design, rating, or debottlenecking of single or multiple flare and vent systems. AFSA may calculate minimum sizes for new flare systems or evaluate alternatives to remove bottlenecks in existing relief networks and can be used to identify potentially dangerous relief scenarios during design phase or current operational scenarios.


Similar to "Useful Documentation for HYSYS ...", following are compilation of documents related to AFSA or FLARENET. If you found any documents related to AFSA or FLARENET and/or available FREE for all, you are encourage to share within our community. You may drop a note via email or comment. Please include your nickname.

• FLARENET 2004 - Getting Started Guide
• FLARENET 2006 - Getting Started Guide
• AFSA V7 - Getting Started Guide
• AFSA V7 - Reference Manual
  
• Depressuring - Save Some Time in HYSYS - FLARENET Iteration
• How to Merge Several FLARENET Models into Single Model ?

Related Topic

• Useful Documentation for HYSYS ...
• Useful Documentation for UNISIM...
• How to Merge Several FLARENET Models into Single Model ?
• Depressuring - Save Some Time in HYSYS - FLARENET Iteration
• ProMax from BR&E - Renowed Process Simulator in Gas Treating Industry

This is a continuous post from "Useful Documentation for UNISIM..."... With the feedback from readers, the original has been updated to include more valuable information.

UNISIM, another most user friendly Process simulator for process system designer. It enables process designer / engineers to create steady-state and dynamic models for plant design, process system performance monitoring, real plant troubleshooting, operational improvement, business planning and asset management.

Following are additional part :

• UNISIM Design - Installation Guide
• UNISIM Design - User Guide
• UNISIM Design - Operations Guide
• UNISIM Design - Customization Guide
• UNISIM Design - Tutorial and Application
• UNISIM Design - Simulation Basis
• UNISIM Design - Dynamic Modeling
• UNISIM Design - OLGA Link
• UNISIM Design - OLGA Link User Guide
• UNISIM Design - OLI Interface Reference
• UNISIM Clean Fuels Package User Guide
• UNISIM Design - PIPESYS - Get Started
• UNISIM Design - PIPESYS - User Guide
• UNISIM Design - PIPESYS - Tutorial

Complete list in Useful Documentation for UNISIM...

Related Topic

• Useful Documentation for HYSYS ...
• How to Merge Several FLARENET Models into Single Model ?
• Depressuring - Save Some Time in HYSYS - FLARENET Iteration
• ProMax from BR&E - Renowed Process Simulator in Gas Treating Industry

Subscribes to FREE Hydrocarbon Processing

UNISIM, another most user friendly Process simulator for process system designer. It enables process designer / engineers to create steady-state and dynamic models for plant design, process system performance monitoring, real plant troubleshooting, operational improvement, business planning and asset management. UNISIM has almost same display and approach as in HYSYS (from user friendly perspective). If you are familiar with HYSYS, you are certainly know how to operate UNISIM in the 1st attempt to use.



Objective
The mains objective of this post is to compile a complete listing of UNISIM related DOCUMENTATION. This activity intended :

* Educate UNISIM user in operation of UNISIM and making full use of UNISIM via these documentations
* Easy & FREE access to all UNISIM related documentations via a single platform and interface
* Information sharing among the UNISIM user within our community

This post IS NOT intended to share any copyrighted documents and IS NOT host & distribute any documents to the public. It mainly to share the location of documentation available FREE in internet via links.

Benefits to Developer
This post partially and indirectly promote and advertise UNISIM to public and it potentially increase awareness of UNISIM and increase conversion rate. HONEYWELL, the owner of UNISIM is technically support all registered UNISIM user via UNISIM Support team. Nevertheless it only provide support to genuine licensed & registered UNISIM user.

Similar to "Useful Documentation for HYSYS ...", following are compilation of documents related to UNISIM. If you found any documents related to UNISIM and/or available FREE for all, you are encourage to share within our community. You may drop a note via email or comment. Please include your nickname.

• UNISIM Design - Installation Guide
• UNISIM Design - User Guide
• UNISIM Design - Operations Guide
• UNISIM Design - Customization Guide
• UNISIM Design - Tutorial and Application
• UNISIM Design - Simulation Basis
• UNISIM Design - Dynamic Modeling
• UNISIM Design - OLGA Link
• UNISIM Design - OLGA Link User Guide
• UNISIM Design - OLI Interface Reference
• UNISIM Clean Fuels Package User Guide
• UNISIM Design - PIPESYS - Get Started
• UNISIM Design - PIPESYS - User Guide
• UNISIM Design - PIPESYS - Tutorial

UNISIM Design Tutorials
The Tutorials section of this guide presents you with independent tutorial sessions. Each tutorial guides you step-by-step through the complete construction of a UNISIM Design simulation. The tutorial(s) you choose to work through will likely depend on the simulation topic that is most closely related to your work, your familiarity with UNISIM Design, and the types of simulation cases you anticipate on creating in the future.


UNISIM Tutorial
UNISIM (very similar to HYSYS) is a program used to design chemical plants. It is built around:

• a library of the physical properties of a large number of chemical species
• a set of subroutines to estimate the behavior of many types of plant equipment (heat exchangers, reactors, etc.)
• a graphical user interface to accept specifications for the case, and display results

The user describes the process in terms of pieces of equipment interconnected by process streams, and the program solves all the mass/energy/equilibrium equations, taking into consideration the specified design parameters for the units. In this tutorial, you will be introduced to some of the basic features of UniSim. Once you have completed this tutorial, it is highly recommended that you attempt to work through the advanced tutorial (available for download on the course webpage), as it will introduce you to additional unit operations and features. Upon completion of both tutorials, you will be well-prepared to dig into the plant optimization assignments.

Related Topic

• Useful Documentation for HYSYS ...
• How to Merge Several FLARENET Models into Single Model ?
• Depressuring - Save Some Time in HYSYS - FLARENET Iteration
• ProMax from BR&E - Renowed Process Simulator in Gas Treating Industry

Nowadays Oil & gas, LNG, Petrochemical, Refinery plant capacity are large and some time a few design centers are working together to manage the project during design phase. The project may splits into several large units and each design center will design their own units. The design include flare system modeling using FLARENET.

Several design center will generate their own FLARENET models and upto one point of time, all models may required to merge in order to check the overall flare system performance. Some steps presented in thmay be used to merge several FLARENET models into single model using built in utility in FLARENET.

Since the release of "Simple Method For Compressor Settle Out Using HYSYS", some readers of Chemical & Process Technology raised a question. The proposed method has considered all in VAPOR, how shall this method apply in case of present of VAPOR and LIQUID in Compressor Suction drum and Air Cooler Downstream ?

It is correct that the simple method is simplified version for VAPOR only Settle out condition. Nevertheless, minimum adjustment to the method enable the method to be used for condition with VAPOR and LIQUID. First refer to following image.

Step 1 : Compressor Suction. Estimate physical volume of vapor (Vv1) and liquid (Vl1).

Step 2a : Compressor Suction. Separate Compressor Suction Inlet (stream 1) with 2-phases (vapor & Liquid) with Separator unit operation.

Step 2b : Copy Compressor Suction Inlet Vapor (stream 2) condition and composition to a new stream Actual Compressor Suction Inlet Vapor ((stream 4). Adjust Mass flow of this stream until the Actual Volumetric Flow equal to Vv1.

Step 2c : Copy Compressor Suction Inlet Liquid (stream 3) condition and composition to a new stream Actual Compressor Suction Inlet Liquid (stream 5). Adjust Mass flow of this stream until the Actual Volumetric Flow equal to Vl1.

Step 2d : Mix Actual Compressor Suction Inlet Vapor (stream 4) and Actual Compressor Suction Inlet Liquid (stream 5) to form Compressor Suction (stream 6).

Normally the Compressor Discharge stream is superheated and no liquid is expected.

The remaining steps are same as "Simple Method For Compressor Settle Out Using HYSYS" by adjusting Settle Out Cond Actual Volumetric Flow same as Vv1+Vl1+V2+Vv3+Vl3.

Recommended :
Subscribe FREE - Processing Magazine

Compressor emergency blowdown is commonly initiated after compressor system shutdown. The compressor shutdown will also lead to Compressor System Suction shutdown valve (SDV) and Discharge SDV to shut close and the anti-surge and/or capacity control valve open. Compressor discharge with high pressure and hot, air cooler and downstream high pressure and cold and suction vessel low pressure and cold will be settled-out prior to blowdown.

Settle-out of compressor system can be conducted using HYSYS. The main concept is constant mass and volume before and after settle-out. It is assumed the settle out is carried out adiabatically.

Wetting a dry gas using 3-phase Separator unit operation in HYSYS has been discussed in "Saturate Dry Gas With Water in HYSYS". It is a simple but ordinary way and useful. Aspen HYSYS (previously Hyprotech) has generated a simple extension called SATURATE extension to perform same function. See below image.


Locate SATURATE Extension
The SATURATE extension does not come with HYSYS installation file. It can be downloaded from ASPENTECH Support Website. Click here to locate the HYSYS extension. (for register user only).

Register & Access SATURATE Extension
Once the SATURATE extension is downloaded, it shall be registered in HYSYS. Unzip the saturate.edf and saturate.dll files to a convenient directory on your hard disk. Go to Tools … Preferences, then choose the Extensions tab, click the Register an Extension button, then navigate to the location of the saturate.dll file. Local Administrator privileges are required in order to register an extension. The Saturate Stream Unit extension should then appear under the Extensions category of the Add Operation window. (Accessible via Flowsheet … Add Operation, or by pressing F12.)


Obtain Water Content
Once the SATURATE extension is open, above tab will be shown. Just set the the unit to lb/mmcf at Standard condition, the water content in lb/mmscf can be found.

Find Under Saturate Water Content
If one to find the Water Content at 80% Humidity, just simply change the Humidity input to 80. Water content at under saturate condition will be shown.

Applicability
This extension only support HYSYS 2.4.1 onwards.



Related Topic

• Saturate Dry Gas With Water in HYSYS
• Useful Documentation for HYSYS ...
• Depressuring - Save Some Time in HYSYS - FLARENET Iteration
• Control System Development with HYSYS Dynamic Simulation
• Bug in ASPENTECH HYSYS 2006 Dynamic Depressuring Fisher Valve model
• How to apply valve equation in HYSYS Depressuring ?
• Catalytic Distillation Process Simulation using HYSYS

A loyal reader in Chemical Process Technology raised a question. I have a dry gas composition. As the gas is produced from reservoir, it is saturated with water. How to simulate in the HYSYS simulator ? How to calculate water content in wet gas ?

Recommended :
Subscribe FREE - Plant Services

From hydrocarbon - water equilibrium analysis, you will find that as you increase water content in dry gas, the water will mix with dry gas until the dry gas is saturated with water. Once it is saturated with water, any addition of water into the water saturated gas (normally called wet gas) will knock-out as free water in aqueous phase. This can be easily modeled in any process simulator like HYSYS.

Below image shows Dry gas stream is mix with Water in a 3-phase Separator unit operation. To saturate the Dry gas with water, the only requirement is increase the Free Water flow until the aqueous flow (Free Water) starts to knock off free water. In this case, an ADJUST unit is used to adjust the water flow until zero flow.


To find water content (in lb/mmscf), first check out the Water Mass Flow in Wet gas from composition, change the basis to mass flow. See following image.



Then find the Molar flow in MMSCFD. See following image.


In above example, the Water Mass Flow is 1233.6 kg/h (2719.6 lb/h) and Molar Flow is 1005 mmscfd. Thus,

Water content = (2719.6 x 24) / 1005 = 64.93 lb Water / mmscf Gas.

If you have better method, let us know.

Related Topic

• Useful Documentation for HYSYS ...
• Depressuring - Save Some Time in HYSYS - FLARENET Iteration
• Control System Development with HYSYS Dynamic Simulation
• Bug in ASPENTECH HYSYS 2006 Dynamic Depressuring Fisher Valve model
• How to apply valve equation in HYSYS Depressuring ?
• Catalytic Distillation Process Simulation using HYSYS