Practical Exercise No.

Objective:
Hot water at 250 C and 1000psig is used to heat a cold stream of water in a shell and tube heat
exchanger. The inlet temperature and pressure of cold stream is 25C and 130 psig. The outlet
temperatures of the cold and hot streams are 150 and 190 C. If the flow rate of the hot stream
is 100kg/hr determine the flow rate of the cold stream passing through heat exchanger.
Description:
We’ve to simulate shell and tube heat exchanger to heat up a cold water stream using a hot
water stream. The parameters of both the streams are provided as:
Hot Water: F=100kg/hr Tin=2500C Tout =1900C P=1000psig
Cold Water: F=? kg/hr Tin = 250C Tout=1500C P=130psig
We’ve to determine the flowrate of cold water stream to achieve the required outlet
temperature
Procedure:
1. Select the component water from component list.
2. Add Peng-Robinson as the fluid package.
3. Enter the simulation environment and add a heat exchanger.
4. Add four material streams as Cin and Cout & Hin and Hout and connect them to shell and
tube side respectively.
5. In parameters section specify the pressure drop for both the sides as 10psi.
6. In worksheet section specify the conditions for each stream as described above.
7. Run the simulation and results will be available.
8. Click on Cout stream and from the dialog box appearing select show table to see stream
parameters.

Results and Conclusions:

The temperature of pump discharge was found to be 55.22kg/hr.
 Practical Exercise No.4
Objective:
To develop process simulation and perform heat integration of a natural gas processing plant
in Aspen HYSYS.

Description:
The processing plant is set up on Aspen using mixer, separator, heat exchanger, cooler and
LTS Separator. Heat integration encompasses the retrieval and utilization of heat that was
previously dissipated. For instance, heat can be transferred from vapors to cool gas by
employing a recycled stream from a separator, facilitated by a heat exchanger. The vapors
undergo cooling through a distinct cooler.

Procedure:
1) Select the components C1-C4, N2 gas and CO2 from the component list.
2) Add Peng-Robinson as the fluid package.
3) Under the simulation environment, add mixer whose inlets are Feed 1 and Feed 2, outlet
is Mixed Out and enter the given conditions and composition.
4) Then add a separator whose inlet in Mixed Out and outlet are Sep Vap and Sep Liq.
5) Next, add a heat exchanger with the pressure drop on both the shell side and tube side to
be 10 psi. The shell inlet and outlet are LTS Vap and Sales Gas respectively and tube inlet
and outlet are Sep Vap and Cool Gas respectively.
6) Insert a Cooler whose inlet is Cool Gas and outlet is Cold Gas. Set temperature of cool
gas = 32 F, temperature of cold gas = 10 F and ∆P = 10 psi.
7) Add a LTS separator whose inlet in Cold Gas and outlet streams are LTS Vap and LTS
Liq.
8) Complete the simulation and verify until its converged.

Results:
The above-mentioned process is simulated on the Aspen HYSYS and the results are shown
below.
Discussions:
The experiment has taught us how to realistically design a process which is energy efficient
using heat integration.
 Practical Exercise No.5
Objective:
To meet the pipeline hydrocarbon dew point specification and find the net heating value of
the product of a natural gas processing plant in Aspen HYSYS.

Description:
The processing plant is set up on Aspen using mixer, separators, heat exchangers and a
distillation column unit. A natural gas processing plant serves as a purification facility for
raw natural gas, aiming to remove impurities and other substances, guaranteeing the gas's
suitability for transportation through pipelines. The dew point, which signifies the
temperature at which specific components of the gas transition from a gaseous to a liquid
state, is a crucial parameter in this process.

Procedure:
1) Repeat steps of Practical Exercise No.4 ie. select the components, add fluid package,
under the simulation environment, add the process streams along with duty and attach
them to the respective equipment mentioned in the question.
2) After adding a mixer, separator, heat exchanger, cooler and LTS separator, add another
mixer whose inlet streams are Sep Liq and LTS Liq and outlet stream is Tower Feed.
3) At the end, attach the distillation unit and start by specifying the data and stream names.
4) Then move on to the next tab for more specifications to be entered.
5) Verify the connections until the simulation is fully converged.

Results:
The above-mentioned process is simulated on the Aspen HYSYS and the results are shown
below.
Discussions:
Adjustments to temperature, vapor fraction will not impact the remaining flowsheet.
However, modifications to the Sales Gas will influence the dew point due to the mole
balance.
 Practical Exercise No.6
Objective:
To simulate a depropanizer for the removal of propane from the liquid separated from the
rich gas of a natural gas processing plant in Aspen HYSYS.

Description:
The processing plant is set up on Aspen using mixer, separators, heat exchangers and a
distillation column unit. In a natural gas processing plant, a distillation column is introduced
to extract propane from the liquid separated from the rich gas.

Procedure:
1) Repeat steps of Practical Exercise No. 5 ie. select the components, add fluid package,
under the simulation environment, add the process streams along with duty and attach
them to the respective equipment mentioned in the question.
2) After adding a mixer, separator, heat exchanger, cooler, LTS separator, mixer and
distillation column and start by specifying the data and stream names.
3) Then move on to the next tab for specification of reboiler and condenser.
4) Select Reboiler configuration = once through and set Condenser Pressure = 200 psia
and Reboiler Pressure = 205 psia.
5) Lastly, input Vapor rate= 2 MMSCFD and Reflux ratio= 1.
6) After the data is entered, add a new spec and define its specifications under the spec
tab. Enter name of the spec as Propane Fraction, spec value = 0.02, liquid and
composition in mole fraction.
7) Lastly, deactivate the overhead vapor spec rate and activate the new spec added which
is the Propane fraction.
8) Verify the connections until the simulation is fully converged.

Results:
The above-mentioned process is simulated on the Aspen HYSYS and the results are shown
below.
Discussions:
The converged temperature profile is displayed in the upper right corner of the view. To view
the pressure or flow profiles, appropriate radio buttons can be selected. A detailed stage
summary of the feed and products' composition and flows can be accessed by moving to the
Column Profiles page on the Performance tab.
 Practical Exercise No. 7

Objective:
To define the reaction kinetics of glycol production in Aspen HYSYS.
Description:
We’ve to add the components for conversion of propylene oxide to propylene glycol and
define the kinetics for the reaction to study the effect of different parameters on the reaction.
The reaction is defined as:
Propylene Oxide + Water → Propylene Glycol
C3H6O + H2O → C3H8O
A = 1.7e13 E = 32400 BTU/lbmol
Procedure:
1. Select the component water, propylene oxide and propylene glycol from component list.
2. Add UNIQUAC as the fluid package.
3. Go to reaction and click on add reaction and select kinetic type.
4. Define the reaction i.e. add the components with stoichiometric coefficients and add the
kinetics of the reaction as described.
5. Change the forward order of water to zero.
6. Select propylene oxide as the base component as it is the limiting product and select
combined liquid as phase.
7. Add the reaction to property package to ensure that the reaction takes place in the
simulation.
Results and Conclusions:
The kinetics of reaction were added in the model which helps building a more robust model
and study the effect of different parameters on the reaction more accurately.
 Practical Exercise No. 8

Objective:
To simulate the process of glycol production using CSTR in Aspen HYSYS.
Description:
We’ve to simulate conversion of propylene oxide to propylene glycol as per the kinetics for
the reaction and obtain parameters such that the conversion for that conversion will be 85% -
95%. The reaction kinetics and equations for the reaction are as follows:
Propylene Oxide + Water → Propylene Glycol
C3H6O + H2O → C3H8O
A = 1.7e13 E = 32400 BTU/lbmol
The feed conditions of propylene oxide and water are as follows:
Water: F=150lbmol/h T=750F P=1.1atm
Propylene Oxide: F=11000lb/h T=750F P=16.7psia
Procedure:
1. Select the component water, propylene oxide and propylene glycol from component list.
2. Add UNIQUAC as the fluid package.
3. Go to reaction and click on add reaction and select kinetic type.
4. Define the reaction i.e. add the components with stoichiometric coefficients and add the
kinetics of the reaction as described.
5. Change the forward order of water to zero.
6. Select propylene oxide as the base component as it is the limiting product and select
combined liquid as phase.
7. Add the reaction to property package to ensure that the reaction takes place in the
simulation.
8. Enter the simulation environment and add a mixer.
9. Define the inlet streams to mixer as water and prop oxide and the outlet as mixed feed.

10. Add a CSTR and define its volume as 280 cubic feet, liq vol% as 85% and outlet as CSTR
outlet & CSTR vent.
11. Add the reaction to CSTR
Results and Conclusions:
The conversion achieved for volume of 280ft3 was found to be 33%.
 Practical Exercise No. 9

Objective:
To learn the petroleum characterization method in HYSYS that will convert laboratory
analyses of condensates, crude oils, petroleum cuts and coal tar liquids components.
Description:
In this experiment, the characterization of petroleum is done through process simulation
software called Aspen HYSYS. The approach includes non-ideal distillation models which
integrate laboratory information such as density, molecular weight, API gravity, and true
boiling point (TBP) in order to construct a consistent pseudo component model.
Procedure:
1. Select the desired in component list.
2. Add Peng-Robinson as the fluid package.
3. Go to oil manager, click on input assay and then add.
4. Select TBP from the assay data types drop-down list.
5. Choose the input composition from the light ends drop-down menu.
6. Click the bulk props button and enter the standard density and molecular weight.
7. Click the composition cell and input the composition for each component.
8. Click the calculate button and then press output blend and then add.
9. Select Assay 1 from the available assays and then click add.
10. Click the Install Oil tab to start the oil installation process.
11. Enter the oil's name in the stream name column.
Results and Conclusions:
 F/OBEM 01/18/00

NED University of Engineering & Technology

Department of Chemical Engineering
Course Code & Title: CH-401 (Process Modeling and Simulation)
Laboratory Session No. Date:_____________
Assessment Rubric for Software-based Lab-Level
Extent of Achievement
Below
Criterion Average Good Very Good Excellent
Average
(1) (2) (3) (4)
(0)
Complete
No Incorrect Understands Understands
understanding of
Problem understanding of understanding some aspects of major aspects of
all aspects of the
Understanding the problem of the problem the problem the problem
problem
statement. statement. statement. statement.
statement.
Ability to
Able to Perfect
Marginal ability properly
No ability to moderately articulation and
Problem Data to properly articulate data
articulate data articulate data formulation of
Articulation & articulate data from problem
from problem and formulate the the data from the
Formulation from problem statement with
statement. problem problem
statement. minor
statement. statement.
shortcomings.
Skills to use Not able to use Uses basic
Uses advanced Uses advanced Exhibits full use
basic and any commands command from
commands with commands of all commands
advanced of the software graphical
help. without help. of the software.
commands used. interface icons.
Exact solution
No proper Understandable
methodology for
solution Incorrect Solution solution
Problem using
methodology for solution methodology methodology
Solution engineering
using methodology apparent to a with least
Methodology software
engineering implemented. certain extent. possibility of
followed with
software. error.
valid solution.
Used some of the Used most of the
Did not use time Rarely use time time well but time effectually Used time wisely
Time to focus on and engage in occasionally but sometimes and focused well
Management completing the completing the distract others gets distracted to complete
task/activities tasks / activities while completing from completing tasks/activities
tasks/activities tasks/activities
Provided Provided Provided
inaccurate, Provided relatively accurate and
incomplete somewhat accurate report. complete reports
Final Result No report for the
reports of the accurate report A generic result of the project
and Reporting project.
project with with brief without the with unique and
incorrect discussion. setup of valid applicable
results. assumptions. results.

Student’s Name:_________________ Roll No.:__________________

Total Score = Instructor’s Signature: