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Aspen Plus Chemical Engineering Applications

by: Al-Malah, Kamal I. M.

Aspen Plus Chemical Engineering Applications

by: Al-Malah, Kamal I. M.

ISBN 13:
9781119131236
ISBN 10:
1119131235
Edition: 1st
Format: Hardcover
Copyright: 10/24/2016
Publisher: Wiley
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Aspen Plus Chemical Engineering Applications > ISBN13: 9781119131236

Summary

Facilitates the process of learning and later mastering Aspen Plus® with step by step examples and succinct explanations
Step-by-step textbook for identifying solutions to various process engineering problems via screenshots of the Aspen Plus® platforms in parallel with the related text
Includes end-of-chapter problems and term project problems
Includes online exam and quiz problems for instructors that are parametrized (i.e., adjustable) so that each student will have a standalone version
Includes extra online material for students such as Aspen Plus®-related files that are used in the working tutorials throughout the entire textbook

Author Biography

Kamal Al-Malah, is professor of chemical engineering at Higher Colleges of Technology, United Arab Emirates and former chairman of the chemical engineering department at the University of Hail in Saudi Arabia. He holds B.S., M.S., and Ph.D. degrees in chemical/biochemical engineering. Dr. Al-Malah graduated from Oregon State University in 1993 and his area of specialty deals with mathematical modeling, optimization, simulation, and computer-aided design. Professor Al-Malah is Windows-based software developer and MATLAB® book author

Preface xvii

The Book Theme xix

About the Author xxi

What Do You Get Out of This Book? xxiii

Who Should Read This Book? xxv

Notes for Instructors xxvii

Acknowledgment xxix

About the Companion Website xxxi

1 Introducing Aspen Plus 1

1.1 What Does Aspen Stand For? 1

1.2 What is Aspen Plus Process Simulation Model? 2

1.3 Launching Aspen Plus V8.8 3

1.4 Beginning a Simulation 4

1.5 Entering Components 14

1.6 Specifying the Property Method 15

1.7 Improvement of the Property Method Accuracy 23

1.8 File Saving 38

Exercise 1.1 40

1.9 A Good Flowsheeting Practice 40

1.10 Aspen Plus Built-In Help 40

1.11 For More Information 40

Homework/Classwork 1.1 (Pxy) 41

Homework/Classwork 1.2 (ΔG_mix) 42

Homework/Classwork 1.3 (Likes Dissolve Likes) as Envisaged by NRTL Property Method 42

Homework/Classwork 1.4 (The Mixing Rule) 44

2 More on Aspen Plus Flowsheet Features (1) 49

2.1 Problem Description 49

2.2 Entering and Naming Compounds 49

2.3 Binary Interactions 51

2.4 The “Simulation” Environment: Activation Dashboard 53

2.5 Placing a Block and Material Stream from Model Palette 53

2.6 Block and Stream Manipulation 54

2.7 Data Input, Project Title, and Report Options 56

2.8 Running the Simulation 58

2.9 The Difference Among Recommended Property Methods 61

2.10 NIST/TDE Experimental Data 62

Homework/Classwork 2.1 (Water–Alcohol System) 65

Homework/Classwork 2.2 (Water–Acetone–EIPK System with NIST/DTE Data) 66

Homework/Classwork 2.3 (Water–Acetone–EIPK System Without NIST/DTE Data) 69

3 More on Aspen Plus Flowsheet Features (2) 71

3.1 Problem Description: Continuation to the Problem in Chapter 2 71

3.2 The Clean Parameters Step 71

3.3 Simulation Results Convergence 74

3.4 Adding Stream Table 76

3.5 Property Sets 78

3.6 Adding Stream Conditions 82

3.7 Printing from Aspen Plus 83

3.8 Viewing the Input Summary 84

3.9 Report Generation 85

3.10 Stream Properties 87

3.11 Adding a Flash Separation Unit 88

3.12 The Required Input for “Flash3”-Type Separator 90

3.13 Running the Simulation and Checking the Results 91

Homework/Classwork 3.1 (Output of Input Data and Results) 92

Homework/Classwork 3.2 (Output of Input Data and Results) 93

Homework/Classwork 3.3 (Output of Input Data and Results) 93

Homework/Classwork 3.4 (The Partition Coefficient of a Solute) 93

4 Flash Separation and Distillation Columns 99

4.1 Problem Description 99

4.2 Adding a Second Mixer and Flash 99

4.3 Design Specifications Study 101

Exercise 4.1 (Design Spec) 105

4.4 Aspen Plus Distillation Column Options 106

4.5 “DSTWU” Distillation Column 107

4.6 “Distl” Distillation Column 111

4.7 “RadFrac” Distillation Column 113

Homework/Classwork 4.1 (Water–Alcohol System) 120

Homework/Classwork 4.2 (Water–Acetone–EIPK System with NIST/DTE Data) 125

Homework/Classwork 4.3 (Water–Acetone–EIPK System Without NIST/DTE Data) 127

Homework/Classwork 4.4 (Scrubber) 128

5 Liquid–Liquid Extraction Process 131

5.1 Problem Description 131

5.2 The Proper Selection for Property Method for Extraction Processes 131

5.3 Defining New Property Sets 136

5.4 The Property Method Validation Versus Experimental Data Using Sensitivity Analysis 136

5.5 A Multistage Extraction Column 142

5.6 The Triangle Diagram 146

References 149

Homework/Classwork 5.1 (Separation of MEK from Octanol) 149

Homework/Classwork 5.2 (Separation of MEK from Water Using Octane) 150

Homework/Classwork 5.3 (Separation of Acetic Acid from Water Using Isopropyl Butyl Ether) 151

Homework/Classwork 5.4 (Separation of Acetone from Water Using Trichloroethane) 151

Homework/Classwork 5.5 (Separation of Propionic Acid from Water Using MEK) 152

6 Reactors with Simple Reaction Kinetic Forms 155

6.1 Problem Description 155

6.2 Defining Reaction Rate Constant to Aspen Plus^® Environment 155

6.3 Entering Components and Method of Property 157

6.4 The Rigorous Plug-Flow Reactor (RPLUG) 159

6.5 Reactor and Reaction Specifications for RPLUG (PFR) 161

6.6 Running the Simulation (PFR Only) 167

Exercise 6.1 167

6.7 Compressor (CMPRSSR) and RadFrac Rectifying Column (RECTIF) 168

6.8 Running the Simulation (PFR + CMPRSSR + RECTIF) 171

Exercise 6.2 172

6.9 RadFrac Distillation Column (DSTL) 172

6.10 Running the Simulation (PFR + CMPRSSR + RECTIF + DSTL) 174

6.11 Reactor and Reaction Specifications for RCSTR 175

6.12 Running the Simulation (PFR + CMPRSSR + RECTIF + DSTL + RCSTR) 179

Exercise 6.3 180

6.13 Sensitivity Analysis: The Reactor’s Optimum Operating Conditions 181

References 188

Homework/Classwork 6.1 (Hydrogen Peroxide Shelf-Life) 189

Homework/Classwork 6.2 (Esterification Process) 192

Homework/Classwork 6.3 (Liquid-Phase Isomerization of n-Butane) 194

7 Reactors with Complex (Non-Conventional) Reaction Kinetic Forms 197

7.1 Problem Description 197

7.2 Non-Conventional Kinetics: LHHW Type Reaction 199

7.3 General Expressions for Specifying LHHW Type Reaction in Aspen Plus 200

7.3.1 The “Driving Force” for the Non-Reversible (Irreversible) Case 201

7.3.2 The “Driving Force” for the Reversible Case 201

7.3.3 The “Adsorption Expression” 202

7.4 The Property Method: “SRK” 202

7.5 Rplug Flowsheet for Methanol Production 203

7.6 Entering Input Parameters 203

7.7 Defining Methanol Production Reactions as LHHW Type 205

7.8 Sensitivity Analysis: Effect of Temperature and Pressure on Selectivity 216

References 219

Homework/Classwork 7.1 (Gas-Phase Oxidation of Chloroform) 220

Homework/Classwork 7.2 (Formation of Styrene from Ethylbenzene) 222

Homework/Classwork 7.3 (Combustion of Methane Over Steam-Aged Pt–Pd Catalyst) 225

8 Pressure Drop Friction Factor ANPSH and Cavitation 229

8.1 Problem Description 229

8.2 The Property Method: “STEAMNBS” 229

8.3 A Water Pumping Flowsheet 230

8.4 Entering Pipe, Pump, and Fittings Specifications 231

8.5 Results: Frictional Pressure Drop, the Pump Work, Valve Choking, and ANPSH Versus RNPSH 237

Exercise 8.1 238

8.6 Model Analysis Tools: Sensitivity for the Onset of Cavitation or Valve Choking Condition 242

References 247

Homework/Classwork 8.1 (Pentane Transport) 247

Homework/Classwork 8.2 (Glycerol Transport) 248

Homework/Classwork 8.3 (Air Compression) 249

9 The Optimization Tool 251

9.1 Problem Description: Defining the Objective Function 251

9.2 The Property Method: “STEAMNBS” 252

9.3 A Flowsheet for Water Transport 253

9.4 Entering Stream, Pump, and Pipe Specifications 253

9.5 Model Analysis Tools: The Optimization Tool 256

9.6 Model Analysis Tools: The Sensitivity Tool 260

9.7 Last Comments 263

References 264

Homework/Classwork 9.1 (Swamee–Jain Equation) 264

Homework/Classwork 9.2 (A Simplified Pipe Diameter Optimization) 264

Homework/Classwork 9.3 (The Optimum Diameter for a Viscous Flow) 265

Homework/Classwork 9.4 (The Selectivity of Parallel Reactions) 266

10 Heat Exchanger (H.E.) Design 269

10.1 Problem Description 269

10.2 Types of Heat Exchanger Models in Aspen Plus 270

10.3 The Simple Heat Exchanger Model (“Heater”) 272

10.4 The Rigorous Heat Exchanger Model (“HeatX”) 274

10.5 The Rigorous Exchanger Design and Rating (EDR) Procedure 279

10.5.1 The EDR Exchanger Feasibility Panel 279

10.5.2 The Rigorous Mode Within the “HeatX” Block 294

10.6 General Footnotes on EDR Exchanger 294

References 297

Homework/Classwork 10.1 (Heat Exchanger with Phase Change) 297

Homework/Classwork 10.2 (High Heat Duty Heat Exchanger) 298

Homework/Classwork 10.3 (Design Spec Heat Exchanger) 299

11 Electrolytes 301

11.1 Problem Description: Water De-Souring 301

11.2 What Is an Electrolyte? 301

11.3 The Property Method for Electrolytes 302

11.4 The Electrolyte Wizard 302

11.5 Water De-Souring Process Flowsheet 310

11.6 Entering the Specifications of Feed Streams and the Stripper 311

References 315

Homework/Classwork 11.1 (An Acidic Sludge Neutralization) 316

Homework/Classwork 11.2 (CO₂ Removal from Natural Gas) 317

Homework/Classwork 11.3 (pH of Aqueous Solutions of Salts) 321

Appendix 11.A Development of “ELECNRTL” Model 324

12 Polymerization Processes 325

12.1 The Theoretical Background 325

12.1.1 Polymerization Reactions 325

12.1.2 Catalyst Types 326

12.1.3 Ethylene Process Types 327

12.1.4 Reaction Kinetic Scheme 327

12.1.5 Reaction Steps 327

12.1.6 Catalyst States 328

12.2 High-Density Polyethylene (HDPE) High-Temperature Solution Process 329

12.2.1 Problem Definition 330

12.2.2 Process Conditions 330

12.3 Creating Aspen Plus Flowsheet for HDPE 331

12.4 Improving Convergence 338

12.5 Presenting the Property Distribution of Polymer 339

References 343

Homework/Classwork 12.1 (Maximizing the Degree of HDPE Polymerization) 344

Homework/Classwork 12.2 (Styrene Acrylonitrile (SAN) Polymerization) 345

Appendix 12.A The Main Features and Assumptions of Aspen Plus Chain Polymerization Model 351

Appendix 12.A.1 Polymerization Mechanism 351

Appendix 12.A.2 Copolymerization Mechanism 351

Appendix 12.A.3 Rate Expressions 352

Appendix 12.A.4 Rate Constants 352

Appendix 12.A.5 Catalyst Preactivation 352

Appendix 12.A.6 Catalyst Site Activation 352

Appendix 12.A.7 Site Activation Reactions 353

Appendix 12.A.8 Chain Initiation 353

Appendix 12.A.9 Propagation 353

Appendix 12.A.10 Chain Transfer to Small Molecules 354

Appendix 12.A.11 Chain Transfer to Monomer 354

Appendix 12.A.12 Site Deactivation 354

Appendix 12.A.13 Site Inhibition 354

Appendix 12.A.14 Cocatalyst Poisoning 355

Appendix 12.A.15 Terminal Double Bond Polymerization 355

Appendix 12.A.16 Phase Equilibria 355

Appendix 12.A.17 Rate Calculations 355

Appendix 12.A.18 Calculated Polymer Properties 356

Appendix 12.B The Number Average Molecular Weight (MWN) and Weight Average Molecular Weight (MWW) 356

13 Characterization of Drug-Like Molecules Using Aspen Properties 361

13.1 Introduction 361

13.2 Problem Description 362

13.3 Creating Aspen Plus Pharmaceutical Template 363

13.3.1 Entering the User-Defined Benzamide (BNZMD-UD) as Conventional 363

13.3.2 Specifying Properties to Estimate 364

13.4 Defining Molecular Structure of BNZMD-UD 364

13.5 Entering Property Data 370

13.6 Contrasting Aspen Plus Databank (BNZMD-DB) Versus BNZMD-UD 373

References 375

Homework/Classwork 13.1 (Vanillin) 375

Homework/Classwork 13.2 (Ibuprofen) 376

14 Solids Handling 379

14.1 Introduction 379

14.2 Problem Description #1: The Crusher 379

14.3 Creating Aspen Plus Flowsheet 380

14.3.1 Entering Components Information 380

14.3.2 Adding the Flowsheet Objects 381

14.3.3 Defining the Particle Size Distribution (PSD) 382

14.3.4 Calculation of the Outlet PSD 385

Exercise 14.1 (Determine Crusher Outlet PSD from Comminution Power) 386

Exercise 14.2 (Specifying Crusher Outlet PSD) 386

14.4 Problem Description #2: The Fluidized Bed for Alumina Dehydration 387

14.5 Creating Aspen Plus Flowsheet 387

14.5.1 Entering Components Information 387

14.5.2 Adding the Flowsheet Objects 388

14.5.3 Entering Input Data 389

14.5.4 Results 391

Exercise 14.3 (Reconverging the Solution for an Input Change) 392

References 393

Homework/Classwork 14.1 (KCl Drying) 393

Homework/Classwork 14.2 (KCl Crystallization) 396

Appendix 14.A Solids Unit Operations 401

Appendix 14.A.1 Unit Operation Solids Models 401

Appendix 14.A.2 Solids Separators Models 401

Appendix 14.A.3 Solids Handling Models 402

Appendix 14.B Solids Classification 402

Appendix 14.C Predefined Stream Classification 403

Appendix 14.D Substream Classes 404

Appendix 14.E Particle Size Distribution (PSD) 405

Appendix 14.F Fluidized Beds 406

15 Aspen Plus^® Dynamics 409

15.1 Introduction 409

15.2 Problem Description 410

15.3 Preparing Aspen Plus Simulation for Aspen Plus Dynamics (APD) 411

15.4 Conversion of Aspen Plus Steady-State into Dynamic Simulation 416

15.4.1 Modes of Dynamic CSTR Heat Transfer 417

15.4.2 Creating Pressure-Driven Dynamic Files for APD 422

15.5 Opening a Dynamic File Using APD 423

15.6 The “Simulation Messages” Window 424

15.7 The Running Mode: Initialization 425

15.8 Adding Temperature Control (TC) Unit 426

15.9 Snapshots Management for Captured Successful Old Runs 430

15.10 The Controller Faceplate 431

15.11 Communication Time for Updating/Presenting Results 434

15.12 The Closed-Loop Auto-Tune Variation (ATV) Test Versus Open-Loop Tune-Up Test 434

15.13 The Open-Loop (Manual Mode) Tune-Up for Liquid Level Controller 436

15.14 The Closed-Loop Dynamic Response for Liquid Level Load Disturbance 443

15.15 The Closed-Loop Dynamic Response for Liquid Level Set-Point Disturbance 448

15.16 Accounting for Dead/Lag Time in Process Dynamics 450

15.17 The Closed-Loop (Auto Mode) ATV Test for Temperature Controller (TC) 451

15.18 The Closed-Loop Dynamic Response: “TC” Response to Temperature Load Disturbance 459

15.19 Interactions Between “LC” and “TC” Control Unit 462

15.20 The Stability of a Process Without Control 464

15.21 The Cascade Control 466

15.22 Monitoring of Variables as Functions of Time 468

15.23 Final Notes on the Virtual (DRY) Process Control in APD 472

References 478

Homework/Classwork 15.1 (A Cascade Control of a Simple Water Heater) 478

Homework/Classwork 15.2 (A CSTR Control with “LMTD” Heat Transfer OPTION) 482

Homework/Classwork 15.3 (A PFR Control for Ethylbenzene Production) 483

16 Safety and Energy Aspects of Chemical Processes 487

16.1 Introduction 487

16.2 Problem Description 487

16.3 The “Safety Analysis” Environment 488

16.4 Adding a Pressure Safety Valve (PSV) 490

16.5 Adding a Rupture Disk (RD) 496

16.6 Presentation of Safety-Related Documents 500

16.7 Preparation of Flowsheet for “Energy Analysis” Environment 501

16.8 The “Energy Analysis” Activation 506

16.9 The “Energy Analysis” Environment 510

16.10 The Aspen Energy Analyzer 512

Homework/Classwork 16.1 (Adding a Storage Tank Protection) 513

Homework/Classwork 16.2 (Separation of C2/C3/C4 Hydrocarbon Mixture) 518

17 Aspen Process Economic Analyzer (APEA) 523

17.1 Optimized Process Flowsheet for Acetic Anhydride Production 523

17.2 Costing Options in Aspen Plus 525

17.2.1 Aspen Process Economic Analyzer (APEA) Estimation Template 525

17.2.2 Feed and Product Stream Prices 527

17.2.3 Utility Association with a Flowsheet Block 528

17.3 The First Route for Chemical Process Costing 531

17.4 The Second Round for Chemical Process Costing 532

17.4.1 Project Properties 533

17.4.2 Loading Simulator Data 535

17.4.3 Mapping and Sizing 537

17.4.4 Project Evaluation 544

17.4.5 Fixing Geometrical Design-Related Errors 546

17.4.6 Executive Summary 549

17.4.7 Capital Costs Report 550

17.4.8 Investment Analysis 551

Homework/Classwork 17.1 (Feed/Product Unit Price Effect on Process Profitability) 555

Homework/Classwork 17.2 (Using European Economic Template) 556

Homework/Classwork 17.3 (Process Profitability of Acetone Recovery from Spent Solvent) 556

Appendix 17.A 559

Appendix 17.A.1 Net Present Value (NPV) for a Chemical Process Plant 559

Appendix 17.A.2 Discounted Payout (PAYBACK) Period (DPP) 560

Example 17.1 (Uniform Cash Flow) 561

Example 17.2 (Non-Uniform Cash Flow) 561

Appendix 17.A.3 Profitability Index 561

Example 17.3 562

Appendix 17.A.4 Internal Rate of Return (IRR) 562

Appendix 17.A.5 Modified Internal Rate of Return (MIRR) 563

Example 17.4 563

18 Term Projects (TP) 565

18.1 TP #1: Production of Acetone via the Dehydration of Isopropanol 565

18.2 TP #2: Production of Formaldehyde from Methanol (Sensitivity Analysis) 569

18.3 TP #3: Production of Dimethyl Ether (Process Economics and Control) 570

18.3.1 Economic Analysis 570

18.3.2 Process Dynamics and Control 572

18.4 TP #4: Production of Acetic Acid via Partial Oxidation of Ethylene Gas 574

18.5 TP #5: Pyrolysis of Benzene 575

18.6 TP #6: Reuse of Spent Solvents 575

18.7 TP #7: Solids Handling: Production of Potassium Sulfate from Sodium Sulfate 576

18.8 TP #8: Solids Handling: Production of CaCO3-Based Agglomerate as a General Additive 577

18.9 TP #9: Solids Handling: Formulation of Di-Ammonium Phosphate and Potassium Nitrate Blend Fertilizer 577

18.10 TP #10: “Flowsheeting Options” | “Calculator”: Gas De-Souring and Sweetening Process 578

18.11 TP #11: Using More than One Property Method and Stream Class: Solid Catalyzed Direct Hydration of Propylene to Isopropyl Alcohol (IPA) 582

18.12 TP #12: Polymerization: Production of Polyvinyl Acetate (PVAC) 586

18.13 TP #13: Polymerization: Emulsion Copolymerization of Styrene and Butadiene to Produce SBR 588

18.14 TP #14: Polymerization: Free Radical Polymerization of Methyl Methacrylate to Produce Poly(Methyl Methacrylate) 590

18.15 TP #15: LHHW Kinetics: Production of Cyclohexanone-Oxime (CYCHXOXM) via Cyclohexanone Ammoximation Using Clay-Based Titanium Silicalite (TS) Catalyst 592

Index 595

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Aspen Plus Chemical Engineering Applications

Aspen Plus Chemical Engineering Applications

9781119131236

1119131235

Summary

Author Biography

Table of Contents

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