| Preface |
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xvii | |
| The Book Theme |
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xix | |
| About the Author |
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xxi | |
| What Do You Get Out of This Book? |
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xiii | |
| Who Should Read This Book? |
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xxv | |
| Notes for Instructors |
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xxvii | |
| Acknowledgment |
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xxix | |
| About the Companion Website |
|
xxxi | |
| 1 Introducing Aspen Plus |
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1 | (48) |
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1.1 What Does Aspen Stand For? |
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1 | (1) |
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1.2 What is Aspen Plus Process Simulation Model? |
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2 | (1) |
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1.3 Launching Aspen Plus V8.8 |
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3 | (1) |
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1.4 Beginning a Simulation |
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4 | (10) |
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14 | (1) |
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1.6 Specifying the Property Method |
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15 | (8) |
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1.7 Improvement of the Property Method Accuracy |
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23 | (15) |
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38 | (2) |
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40 | (1) |
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1.9 A Good Flowsheeting Practice |
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40 | (1) |
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1.10 Aspen Plus Built-In Help |
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40 | (1) |
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1.11 For More Information |
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40 | (9) |
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Homework/Classwork 1.1 (Pxy) |
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41 | (1) |
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Homework/Classwork 1.2 (DeltaGmix) |
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42 | (1) |
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Homework/Classwork 1.3 (Likes Dissolve Likes) as Envisaged by NRTL Property Method |
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42 | (2) |
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Homework/Classwork 1.4 (The Mixing Rule) |
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44 | (5) |
| 2 More on Aspen Plus Flowsheet Features (1) |
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49 | (22) |
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49 | (1) |
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2.2 Entering and Naming Compounds |
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49 | (2) |
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51 | (2) |
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2.4 The "Simulation" Environment: Activation Dashboard |
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53 | (1) |
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2.5 Placing a Block and Material Stream from Model Palette |
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53 | (1) |
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2.6 Block and Stream Manipulation |
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54 | (2) |
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2.7 Data Input, Project Title, and Report Options |
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56 | (2) |
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2.8 Running the Simulation |
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58 | (3) |
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2.9 The Difference Among Recommended Property Methods |
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61 | (1) |
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2.10 NIST/TDE Experimental Data |
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62 | (9) |
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Homework/Classwork 2.1 (Water-Alcohol System) |
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65 | (1) |
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Homework/Classwork 2.2 (Water-Acetone-EIPK System with NIST/DTE Data) |
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66 | (3) |
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Homework/Classwork 2.3 (Water-Acetone-EIPK System Without NIST/DTE Data) |
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69 | (2) |
| 3 More on Aspen Plus Flowsheet Features (2) |
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71 | (28) |
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3.1 Problem Description: Continuation to the Problem in
Chapter 2 |
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71 | (1) |
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3.2 The Clean Parameters Step |
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71 | (3) |
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3.3 Simulation Results Convergence |
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74 | (2) |
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76 | (2) |
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78 | (4) |
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3.6 Adding Stream Conditions |
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82 | (1) |
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3.7 Printing from Aspen Plus |
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83 | (1) |
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3.8 Viewing the Input Summary |
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84 | (1) |
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85 | (2) |
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87 | (1) |
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3.11 Adding a Flash Separation Unit |
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88 | (2) |
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3.12 The Required Input for "Flash3"-Type Separator |
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90 | (1) |
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3.13 Running the Simulation and Checking the Results |
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91 | (8) |
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Homework/Classwork 3.1 (Output of Input Data and Results) |
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92 | (1) |
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Homework/Classwork 3.2 (Output of Input Data and Results) |
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93 | (1) |
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Homework/Classwork 3.3 (Output of Input Data and Results) |
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93 | (1) |
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Homework/Classwork 3.4 (The Partition Coefficient of a Solute) |
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93 | (6) |
| 4 Flash Separation and Distillation Columns |
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99 | (32) |
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99 | (1) |
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4.2 Adding a Second Mixer and Flash |
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99 | (2) |
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4.3 Design Specifications Study |
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101 | (5) |
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Exercise 4.1 (Design Spec) |
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105 | (1) |
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4.4 Aspen Plus Distillation Column Options |
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106 | (1) |
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4.5 "DSTWU" Distillation Column |
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107 | (4) |
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4.6 "Distl" Distillation Column |
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111 | (2) |
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4.7 "RadFrac" Distillation Column |
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113 | (18) |
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Homework/Classwork 4.1 (Water-Alcohol System) |
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120 | (5) |
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Homework/Classwork 4.2 (Water-Acetone-EIPK System with NIST/DTE Data) |
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125 | (2) |
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Homework/Classwork 4.3 (Water-Acetone-EIPK System Without NIST/DTE Data) |
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127 | (1) |
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Homework/Classwork 4.4 (Scrubber) |
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128 | (3) |
| 5 Liquid-Liquid Extraction Process |
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131 | (24) |
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131 | (1) |
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5.2 The Proper Selection for Property Method for Extraction Processes |
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131 | (5) |
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5.3 Defining New Property Sets |
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136 | (1) |
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5.4 The Property Method Validation Versus Experimental Data Using Sensitivity Analysis |
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136 | (6) |
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5.5 A Multistage Extraction Column |
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142 | (4) |
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146 | (3) |
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149 | (6) |
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Homework/Classwork 5.1 (Separation of MEK from Octanol) |
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149 | (1) |
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Homework/Classwork 5.2 (Separation of MEK from Water Using Octane) |
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150 | (1) |
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Homework/Classwork 5.3 (Separation of Acetic Acid from Water Using Isopropyl Butyl Ether) |
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151 | (1) |
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Homework/Classwork 5.4 (Separation of Acetone from Water Using Trichloroethane) |
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151 | (1) |
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Homework/Classwork 5.5 (Separation of Propionic Acid from Water Using MEK) |
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152 | (3) |
| 6 Reactors with Simple Reaction Kinetic Forms |
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155 | (42) |
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155 | (1) |
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6.2 Defining Reaction Rate Constant to Aspen Plus® Environment |
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155 | (2) |
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6.3 Entering Components and Method of Property |
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157 | (2) |
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6.4 The Rigorous Plug-Flow Reactor (RPLUG) |
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159 | (2) |
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6.5 Reactor and Reaction Specifications for RPLUG (PFR) |
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161 | (6) |
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6.6 Running the Simulation (PFR Only) |
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167 | (1) |
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167 | (1) |
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6.7 Compressor (CMPRSSR) and RadFrac Rectifying Column (RECTIF) |
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168 | (3) |
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6.8 Running the Simulation (PFR + CMPRSSR + RECTIF) |
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171 | (1) |
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172 | (1) |
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6.9 RadFrac Distillation Column (DSTL) |
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172 | (2) |
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6.10 Running the Simulation (PFR + CMPRSSR + RECTIF + DSTL) |
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174 | (1) |
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6.11 Reactor and Reaction Specifications for RCSTR |
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175 | (4) |
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6.12 Running the Simulation (PFR + CMPRSSR + RECTIF + DSTL + RCSTR) |
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179 | (2) |
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180 | (1) |
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6.13 Sensitivity Analysis: The Reactor's Optimum Operating Conditions |
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181 | (7) |
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188 | (9) |
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Homework/Classwork 6.1 (Hydrogen Peroxide Shelf-Life) |
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189 | (3) |
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Homework/Classwork 6.2 (Esterification Process) |
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192 | (2) |
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Homework/Classwork 6.3 (Liquid-Phase Isomerization of n-Butane) |
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194 | (3) |
| 7 Reactors with Complex (Non-Conventional) Reaction Kinetic Forms |
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197 | (32) |
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197 | (2) |
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7.2 Non-Conventional Kinetics: LHHW Type Reaction |
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199 | (1) |
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7.3 General Expressions for Specifying LHHW Type Reaction in Aspen Plus |
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200 | (2) |
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7.3.1 The "Driving Force" for the Non-Reversible (Irreversible) Case |
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201 | (1) |
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7.3.2 The "Driving Force" for the Reversible Case |
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201 | (1) |
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7.3.3 The "Adsorption Expression" |
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202 | (1) |
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7.4 The Property Method: "SRK" |
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202 | (1) |
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7.5 Rplug Flowsheet for Methanol Production |
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203 | (1) |
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7.6 Entering Input Parameters |
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203 | (2) |
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7.7 Defining Methanol Production Reactions as LHHW Type |
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205 | (11) |
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7.8 Sensitivity Analysis: Effect of Temperature and Pressure on Selectivity |
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216 | (3) |
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219 | (10) |
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Homework/Classwork 7.1 (Gas-Phase Oxidation of Chloroform) |
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220 | (2) |
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Homework/Classwork 7.2 (Formation of Styrene from Ethylbenzene) |
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222 | (3) |
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Homework/Classwork 7.3 (Combustion of Methane Over Steam-Aged Pt-Pd Catalyst) |
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225 | (4) |
| 8 Pressure Drop, Friction Factor, ANPSH, and Cavitation |
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229 | (22) |
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229 | (1) |
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8.2 The Property Method: "STEAMNBS" |
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229 | (1) |
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8.3 A Water Pumping Flowsheet |
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230 | (1) |
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8.4 Entering Pipe, Pump, and Fittings Specifications |
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231 | (6) |
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8.5 Results: Frictional Pressure Drop, the Pump Work, Valve Choking, and ANPSH Versus RNPSH |
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237 | (5) |
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238 | (4) |
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8.6 Model Analysis Tools: Sensitivity for the Onset of Cavitation or Valve Choking Condition |
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242 | (5) |
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247 | (4) |
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Homework/Classwork 8.1 (Pentane Transport) |
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247 | (1) |
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Homework/Classwork 8.2 (Glycerol Transport) |
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248 | (1) |
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Homework/Classwork 8.3 (Air Compression) |
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249 | (2) |
| 9 The Optimization Tool |
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251 | (18) |
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9.1 Problem Description: Defining the Objective Function |
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251 | (1) |
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9.2 The Property Method: "STEAMNBS" |
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252 | (1) |
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9.3 A Flowsheet for Water Transport |
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253 | (1) |
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9.4 Entering Stream, Pump, and Pipe Specifications |
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253 | (3) |
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9.5 Model Analysis Tools: The Optimization Tool |
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256 | (4) |
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9.6 Model Analysis Tools: The Sensitivity Tool |
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260 | (3) |
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263 | (1) |
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264 | (5) |
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Homework/Classwork 9.1 (Swamee-Jain Equation) |
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264 | (1) |
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Homework/Classwork 9.2 (A Simplified Pipe Diameter Optimization) |
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264 | (1) |
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Homework/Classwork 9.3 (The Optimum Diameter for a Viscous Flow) |
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265 | (1) |
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Homework/Classwork 9.4 (The Selectivity of Parallel Reactions) |
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266 | (3) |
| 10 Heat Exchanger (H.E.) Design |
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269 | (32) |
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269 | (1) |
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10.2 Types of Heat Exchanger Models in Aspen Plus |
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270 | (2) |
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10.3 The Simple Heat Exchanger Model ("Heater") |
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272 | (2) |
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10.4 The Rigorous Heat Exchanger Model ("HeatX") |
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274 | (5) |
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10.5 The Rigorous Exchanger Design and Rating (EDR) Procedure |
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279 | (15) |
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10.5.1 The EDR Exchanger Feasibility Panel |
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279 | (15) |
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10.5.2 The Rigorous Mode Within the "HeatX" Block |
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294 | (1) |
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10.6 General Footnotes on EDR Exchanger |
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294 | (3) |
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297 | (4) |
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Homework/Classwork 10.1 (Heat Exchanger with Phase Change) |
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297 | (1) |
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Homework/Classwork 10.2 (High Heat Duty Heat Exchanger) |
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298 | (1) |
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Homework/Classwork 10.3 (Design Spec Heat Exchanger) |
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299 | (2) |
| 11 Electrolytes |
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301 | (24) |
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11.1 Problem Description: Water De-Souring |
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301 | (1) |
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11.2 What Is an Electrolyte? |
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301 | (1) |
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11.3 The Property Method for Electrolytes |
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302 | (1) |
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11.4 The Electrolyte Wizard |
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302 | (8) |
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11.5 Water De-Souring Process Flowsheet |
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310 | (1) |
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11.6 Entering the Specifications of Feed Streams and the Stripper |
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311 | (4) |
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315 | (9) |
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Homework/Classwork 11.1 (An Acidic Sludge Neutralization) |
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316 | (1) |
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Homework/Classwork 11.2 (CO2 Removal from Natural Gas) |
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317 | (4) |
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Homework/Classwork 11.3 (pH of Aqueous Solutions of Salts) |
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321 | (3) |
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Appendix 11.A Development of "ELECNRTL" Model |
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324 | (1) |
| 12 Polymerization Processes |
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325 | (36) |
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12.1 The Theoretical Background |
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325 | (4) |
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12.1.1 Polymerization Reactions |
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325 | (1) |
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326 | (1) |
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12.1.3 Ethylene Process Types |
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327 | (1) |
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12.1.4 Reaction Kinetic Scheme |
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327 | (1) |
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327 | (1) |
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328 | (1) |
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12.2 High-Density Polyethylene (HDPE) High-Temperature Solution Process |
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329 | (2) |
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12.2.1 Problem Definition |
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330 | (1) |
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12.2.2 Process Conditions |
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330 | (1) |
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12.3 Creating Aspen Plus Flowsheet for HDPE |
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331 | (7) |
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12.4 Improving Convergence |
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338 | (1) |
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12.5 Presenting the Property Distribution of Polymer |
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339 | (4) |
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343 | (8) |
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Homework/Classwork 12.1 (Maximizing the Degree of HDPE Polymerization) |
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344 | (1) |
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Homework/Classwork 12.2 (Styrene Acrylonitrile (SAN) Polymerization) |
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345 | (6) |
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Appendix 12.A The Main Features and Assumptions of Aspen Plus Chain Polymerization Model |
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351 | (5) |
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Appendix 12.A.1 Polymerization Mechanism |
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351 | (1) |
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Appendix 12.A.2 Copolymerization Mechanism |
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351 | (1) |
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Appendix 12.A.3 Rate Expressions |
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352 | (1) |
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Appendix 12.A.4 Rate Constants |
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352 | (1) |
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Appendix 12.A.5 Catalyst Preactivation |
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352 | (1) |
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Appendix 12.A.6 Catalyst Site Activation |
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352 | (1) |
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Appendix 12.A.7 Site Activation Reactions |
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353 | (1) |
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Appendix 12.A.8 Chain Initiation |
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353 | (1) |
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Appendix 12.A.9 Propagation |
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353 | (1) |
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Appendix 12.A.10 Chain Transfer to Small Molecules |
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354 | (1) |
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Appendix 12.A.11 Chain Transfer to Monomer |
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354 | (1) |
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Appendix 12.A.12 Site Deactivation |
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354 | (1) |
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Appendix 12.A.13 Site Inhibition |
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354 | (1) |
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Appendix 12.A.14 Cocatalyst Poisoning |
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355 | (1) |
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Appendix 12.A.15 Terminal Double Bond Polymerization |
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355 | (1) |
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Appendix 12.A.16 Phase Equilibria |
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355 | (1) |
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Appendix 12.A.17 Rate Calculations |
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355 | (1) |
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Appendix 12.A.18 Calculated Polymer Properties |
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356 | (1) |
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Appendix 12.B The Number Average Molecular Weight (MWN) and Weight Average Molecular Weight (MWW) |
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356 | (5) |
| 13 Characterization of Drug-Like Molecules Using Aspen Properties |
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361 | (18) |
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361 | (1) |
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362 | (1) |
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13.3 Creating Aspen Plus Pharmaceutical Template |
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363 | (1) |
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13.3.1 Entering the User-Defined Benzamide (BNZMD-UD) as Conventional |
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363 | (1) |
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13.3.2 Specifying Properties to Estimate |
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364 | (1) |
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13.4 Defining Molecular Structure of BNZMD-UD |
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364 | (6) |
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13.5 Entering Property Data |
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370 | (3) |
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13.6 Contrasting Aspen Plus Databank (BNZMD-DB) Versus BNZMD-UD |
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373 | (2) |
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375 | (4) |
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Homework/Classwork 13.1 (Vanillin) |
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375 | (1) |
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Homework/Classwork 13.2 (Ibuprofen) |
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376 | (3) |
| 14 Solids Handling |
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379 | (30) |
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379 | (1) |
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14.2 Problem Description #1: The Crusher |
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379 | (1) |
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14.3 Creating Aspen Plus Flowsheet |
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380 | (7) |
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14.3.1 Entering Components Information |
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380 | (1) |
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14.3.2 Adding the Flowsheet Objects |
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381 | (1) |
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14.3.3 Defining the Particle Size Distribution (PSD) |
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382 | (3) |
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14.3.4 Calculation of the Outlet PSD |
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385 | (2) |
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Exercise 14.1 (Determine Crusher Outlet PSD from Comminution Power) |
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386 | (1) |
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Exercise 14.2 (Specifying Crusher Outlet PSD) |
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386 | (1) |
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14.4 Problem Description #2: The Fluidized Bed for Alumina Dehydration |
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387 | (1) |
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14.5 Creating Aspen Plus Flowsheet |
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387 | (6) |
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14.5.1 Entering Components Information |
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387 | (1) |
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14.5.2 Adding the Flowsheet Objects |
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388 | (1) |
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14.5.3 Entering Input Data |
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389 | (2) |
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391 | (2) |
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Exercise 14.3 (Reconverging the Solution for an Input Change) |
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392 | (1) |
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393 | (8) |
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Homework/Classwork 14.1 (KCl Drying) |
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393 | (3) |
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Homework/Classwork 14.2 (KCl Crystallization) |
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396 | (5) |
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Appendix 14.A Solids Unit Operations |
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401 | (1) |
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Appendix 14.A.1 Unit Operation Solids Models |
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401 | (1) |
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Appendix 14.A.2 Solids Separators Models |
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401 | (1) |
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Appendix 14.A.3 Solids Handling Models |
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402 | (1) |
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Appendix 14.B Solids Classification |
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402 | (1) |
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Appendix 14.C Predefined Stream Classification |
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403 | (1) |
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Appendix 14.D Substream Classes |
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404 | (1) |
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Appendix 14.E Particle Size Distribution (PSD) |
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405 | (1) |
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Appendix 14.F Fluidized Beds |
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406 | (3) |
| 15 Aspen Plus® Dynamics |
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409 | (78) |
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409 | (1) |
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410 | (1) |
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15.3 Preparing Aspen Plus Simulation for Aspen Plus Dynamics (APD) |
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411 | (5) |
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15.4 Conversion of Aspen Plus Steady-State into Dynamic Simulation |
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416 | (7) |
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15.4.1 Modes of Dynamic CSTR Heat Transfer |
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417 | (5) |
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15.4.2 Creating Pressure-Driven Dynamic Files for APD |
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422 | (1) |
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15.5 Opening a Dynamic File Using APD |
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423 | (1) |
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15.6 The "Simulation Messages" Window |
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424 | (1) |
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15.7 The Running Mode: Initialization |
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425 | (1) |
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15.8 Adding Temperature Control (TC) Unit |
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426 | (4) |
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15.9 Snapshots Management for Captured Successful Old Runs |
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430 | (1) |
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15.10 The Controller Faceplate |
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431 | (3) |
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15.11 Communication Time for Updating/Presenting Results |
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434 | (1) |
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15.12 The Closed-Loop Auto-Tune Variation (ATV) Test Versus Open-Loop Tune-Up Test |
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434 | (2) |
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15.13 The Open-Loop (Manual Mode) Tune-Up for Liquid Level Controller |
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436 | (7) |
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15.14 The Closed-Loop Dynamic Response for Liquid Level Load Disturbance |
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443 | (5) |
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15.15 The Closed-Loop Dynamic Response for Liquid Level Set-Point Disturbance |
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448 | (2) |
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15.16 Accounting for Dead/Lag Time in Process Dynamics |
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450 | (1) |
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15.17 The Closed-Loop (Auto Mode) ATV Test for Temperature Controller (TC) |
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451 | (8) |
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15.18 The Closed-Loop Dynamic Response: "TC" Response to Temperature Load Disturbance |
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459 | (3) |
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15.19 Interactions Between "LC" and "TC" Control Unit |
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462 | (2) |
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15.20 The Stability of a Process Without Control |
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464 | (2) |
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15.21 The Cascade Control |
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466 | (2) |
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15.22 Monitoring of Variables as Functions of Time |
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468 | (4) |
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15.23 Final Notes on the Virtual (DRY) Process Control in APD |
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472 | (6) |
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478 | (9) |
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Homework/Classwork 15.1 (A Cascade Control of a Simple Water Heater) |
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478 | (4) |
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Homework/Classwork 15.2 (A CSTR Control with "LMTD" Heat Transfer OPTION) |
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482 | (1) |
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Homework/Classwork 15.3 (A PFR Control for Ethylbenzene Production) |
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|
483 | (4) |
| 16 Safety and Energy Aspects of Chemical Processes |
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487 | (36) |
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487 | (1) |
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487 | (1) |
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16.3 The "Safety Analysis" Environment |
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488 | (2) |
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16.4 Adding a Pressure Safety Valve (PSV) |
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490 | (6) |
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16.5 Adding a Rupture Disk (RD) |
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496 | (4) |
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16.6 Presentation of Safety-Related Documents |
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500 | (1) |
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16.7 Preparation of Flowsheet for "Energy Analysis" Environment |
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501 | (5) |
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16.8 The "Energy Analysis" Activation |
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506 | (4) |
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16.9 The "Energy Analysis" Environment |
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|
510 | (2) |
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16.10 The Aspen Energy Analyzer |
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|
512 | (11) |
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Homework/Classwork 16.1 (Adding a Storage Tank Protection) |
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513 | (5) |
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Homework/Classwork 16.2 (Separation of C2/C3/C4 Hydrocarbon Mixture) |
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518 | (5) |
| 17 Aspen Process Economic Analyzer (APEA) |
|
523 | (42) |
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17.1 Optimized Process Flowsheet for Acetic Anhydride Production |
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523 | (2) |
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17.2 Costing Options in Aspen Plus |
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|
525 | (6) |
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17.2.1 Aspen Process Economic Analyzer (APEA) Estimation Template |
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525 | (2) |
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17.2.2 Feed and Product Stream Prices |
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527 | (1) |
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17.2.3 Utility Association with a Flowsheet Block |
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528 | (3) |
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17.3 The First Route for Chemical Process Costing |
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|
531 | (1) |
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17.4 The Second Round for Chemical Process Costing |
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532 | (27) |
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17.4.1 Project Properties |
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533 | (2) |
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17.4.2 Loading Simulator Data |
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|
535 | (2) |
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17.4.3 Mapping and Sizing |
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|
537 | (7) |
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17.4.4 Project Evaluation |
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|
544 | (2) |
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17.4.5 Fixing Geometrical Design-Related Errors |
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546 | (3) |
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549 | (1) |
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17.4.7 Capital Costs Report |
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|
550 | (1) |
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17.4.8 Investment Analysis |
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|
551 | (8) |
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Homework/Classwork 17.1 (Feed/Product Unit Price Effect on Process Profitability) |
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|
555 | (1) |
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Homework/Classwork 17.2 (Using European Economic Template) |
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556 | (1) |
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Homework/Classwork 17.3 (Process Profitability of Acetone Recovery from Spent Solvent) |
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556 | (3) |
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559 | (6) |
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Appendix 17.A.1 Net Present Value (NPV) for a Chemical Process Plant |
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559 | (1) |
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Appendix 17.A.2 Discounted Payout (PAYBACK) Period (DPP) |
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560 | (1) |
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Example 17.1 (Uniform Cash Flow) |
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561 | (1) |
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Example 17.2 (Non-Uniform Cash Flow) |
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561 | (1) |
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Appendix 17.A.3 Profitability Index |
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561 | (1) |
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562 | (1) |
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Appendix 17.A.4 Internal Rate of Return (IRR) |
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562 | (1) |
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Appendix 17.A.5 Modified Internal Rate of Return (MIRR) |
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|
563 | (7) |
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|
563 | (2) |
| 18 Term Projects (TP) |
|
565 | (30) |
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18.1 TP #1: Production of Acetone via the Dehydration of Isopropanol |
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|
565 | (4) |
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18.2 TP #2: Production of Formaldehyde from Methanol (Sensitivity Analysis) |
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|
569 | (1) |
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18.3 TP #3: Production of Dimethyl Ether (Process Economics and Control) |
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|
570 | (4) |
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|
570 | (2) |
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18.3.2 Process Dynamics and Control |
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572 | (2) |
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18.4 TP #4: Production of Acetic Acid via Partial Oxidation of Ethylene Gas |
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|
574 | (1) |
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18.5 TP #5: Pyrolysis of Benzene |
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575 | (1) |
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18.6 TP #6: Reuse of Spent Solvents |
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575 | (1) |
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18.7 TP #7: Solids Handling: Production of Potassium Sulfate from Sodium Sulfate |
|
|
576 | (1) |
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18.8 TP #8: Solids Handling: Production of CaCO3-Based Agglomerate as a General Additive |
|
|
577 | (1) |
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18.9 TP #9: Solids Handling: Formulation of Di-Ammonium Phosphate and Potassium Nitrate Blend Fertilizer |
|
|
577 | (1) |
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18.10 TP #10: "Flowsheeting Options" | "Calculator": Gas De-Souring and Sweetening Process |
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|
578 | (4) |
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18.11 TP #11: Using More than One Property Method and Stream Class: Solid Catalyzed Direct Hydration of Propylene to Isopropyl Alcohol (IPA) |
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|
582 | (4) |
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18.12 TP #12: Polymerization: Production of Polyvinyl Acetate (PVAC) |
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586 | (2) |
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18.13 TP #13: Polymerization: Emulsion Copolymerization of Styrene and Butadiene to Produce SBR |
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|
588 | (2) |
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18.14 TP #14: Polymerization: Free Radical Polymerization of Methyl Methacrylate to Produce Poly(Methyl Methacrylate) |
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|
590 | (2) |
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18.15 TP #15: LHHW Kinetics: Production of Cyclohexanone-Oxime (CYCHXOXM) via Cyclohexanone Ammoximation Using Clay-Based Titanium Silicalite (TS) Catalyst |
|
|
592 | (3) |
| Index |
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595 | |
