Operating Unit Models

Lesson
Objectives

We will look at the main models of operating units

We use methods for processing the flow chart

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9-1
Types of Operating Unit Models

Reference :

models, see the

online Help Aspen Plus
Reference | Unit Operation
Models Reference Manual

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Mixers/Splitters . Faucets / Splitters

Mixer
Merges multiple threads together.
Adiabatic. Can Change Pressure

Fsplit
Separates one (or more) streams at
multiple points. Specify a stream or
fraction for each output. The line-up
remains the same

Ssplit
A separator of substreams – solids from a
liquid. Separates one (or more) streams at
multiple points. Specify a thread or fraction for
each substream in each output stream.

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9-2
Separators. Separators
Vapor Vapor

Liquid 1
Liquid 1
Liquid 2
Liquid Liquid 2

Flash2 Flash3 Decanter

Specify two operating conditions, for example, T, P,
enthalpy.
Uses phase equilibrium to compute output streams

Sep & Sep2

Component Separators
Separates one (or more) streams at multiple
points. Give a flow or fraction for each
component in each output stream.

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Heat Exchangers. Heat exchangers

Heater
Single-flow heat exchanger (cooling as well). Specify
the output conditions, e.g. T or load and pressure

HeatX
Two-flow t/o. Parameters:
- Shortcut (user specifies
performance)
- Rigorous*: Shell & Tube, Kettle
Reboiler, Thermosyphon, Air-Cooled, and
Plate

MHeatX
Multi-flow heat exchange between any number of
streams. Used for air separation processes,
production of liquefied natural gas, olefins....

* Separate license required

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9-3
Distillation Columns. Distillation Columns

The main operating unit of the distillation column is called RADFRAC

– Precise geometry calculation and design for individual columns
– Distillation columns, absorbers, strippers, extraction and azeotropic distillation,
Reaction Distillation LT ENDS

– The separation rate in the tower is known to be limited by the rates of mass
transfer and heat transfer

Other types:
– PetroFrac for Refinery Columns
– Extract for Slurry-Liquid Extraction
– Multifrac for simultaneous solution of several columns
– BatchSep for periodic processes (in the Batch Models tab on the Model Palette)
– ConSep for Conceptual Design of Distillation Columns

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Reactors. Reactors (1)

RStoic
Stoichiometric reactor. Determine the reactions and the
degree of reaction or conversion.

RYield
Specify the output composition. The outgoing mass flow rate
corresponds to the incoming one. (Used to decompose coal)

REquil & RGibbs

It assumes a chemical equilibrium based on the
minimization of Gibbs energy. In the case of REQUIL,
reactions are indicated, if Rgibbs, then no. (RGibbs are
often used for combustion and solids reactions)

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9-4
Reactors. Reactors (2)

RCSTR, RPlug & RBatch

Kinetic reactors, where users give correlations of
kinetic data.
RCSTR = Continuous Stirring RPlug = Flow
Reactor
Rbatch = batch reactor

Fluidbed
Simulates fluid bed operations in which reactions are coupled
to solids
Located in the Solids tab of the Model Palette panel

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Pressure Changers. Pressure-changing equipment.

2
Pump
1
Pumps & Hydraulic Turbines

3 Compr
Compressors or expanders using simple
characteristics or flow curves
4

MCompr
5 6 Multistage compressors

Valve
Valve. Uses either a simple specification or is
selected from the manufacturer's list of valves

Pipe or Pipeline
7 8 Multiphase pipe model. The pipe is a single segment, i.e.
one diameter and one height difference. A pipeline has
multiple segments connected together

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9-5
Manipulators. Manipulators (1)
Mult (multiplier)
Multiply the flow rate by the factor set by the
user to scale or scale the diagrams
Dupl (duplicator)
PROD1
Copy the stream to any number of output
FEED PROD2
streams with the same flow rate
DUPL
PROD3

ClChng (class changer)

FEED PRODUCT
Link partitions or blocks that use different thread
classes

Analyzer
Requests a report on the properties of
the stream

FEED1
Selector
FEED2 PRODUCT Switch between different incoming streams to
test different flowsheet scenarios
FEED3

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Manipulators. Manipulators (2)

Design-Spec
DSNSPEC
Allows the user to set a specific value for a
computed flowsheet by controlling a predefined
input variable

Calculator
Allows the user to write equations in a Microsoft
Excel spreadsheet or Fortran syntax to be
executed by Aspen Plus

Transfer
Allows the user to copy the values of process
variables from one part of the diagram to another

Note: All of these blocks can also be created from the Navigation Pane

By default, these blocks do not appear in the On/Off diagram in the Flowsheet | Modify, the
Display Options group

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9-6
Types of Solid Phase Operating Units (Solids)
In Aspen Plus, there are two categories of operating units that calculate the
solid phase:

Solids Models:
•
• Models Processing Solids, Crushing, and Model
Classifications
• Particulate Formation: Crystallization, Granulation and
Agglomeration

Solids Separator Models:

• Liquid-Solid Phase Separation Models
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Custom Models

Custom models can be added to Aspen Plus in 4 ways:

– Using Excel
– Fortran Interface
– Cape Open interface (e.g. C++ or VB)
– Custom Models from Aspen Custom Modeler (ACM)

– For Fortran, C++ or VB, Intel Visual Fortran, Visual C++ or Visual Basic, compilers are required
– Starting with V9, a compiler is not required to export ACM models to Aspen Plus!

– Flowsheet Objects: Flows, Single Operations, Other Hierarchy Blocks

– Out-of-Schematic Objects: Design Specifications, Calculator Blocks, Convergence Blocks
– The structure of the data in the hierarchical block is similar to that of the top-level

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9-7
 Batch Models. Batch Models

BatchProcess
Hierarchy Sub-Flowsheet for batch unit operations
Hierarchical Subcircuit for Periodic Block
Operations

BatchSep
Precise Operation Model for Batch Distillation

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Batch Modeling in Aspen Plus

, built-
in graph and
strip charts

Establish
flow
chart as a batch
process

The turquoise
frame indicates
that the current
area is A subset of the
process single
operations
available in the
scheme
environment

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9-8
A continuous model diagram can include a Batch Sub-
flowsheets
The model solves sequentially on the left
rightwards
The top-level
schema is declared The BatchProcess submodel is
continuous solved dynamically by integration
Can contain a
submodel of
BatchProcess

BatchProcess subcircuit Continuous model BatchProcess sub-flowsheet

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Operating Units in Batch Diagram

Supported Not supported

an
independent batch scheme;

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9-9
BatchOp Unit Operation Model

General Purpose Operations

– Batch reaction
– Batch crystallization

CHARGE

PRODUCT
CONT FEED COND DRAW

Detailed description in EAP202 Modeling Batch Processes using Aspen Plus

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Copy/Paste Functions
(1)
You can copy and paste schematic features while maintaining the integrity of the source

– Select a block or thread

– Select Copy in the Home panel, or right-click Copy to make a copy of the objects in the selected square
– Alternatively, select Copy Special to include other source data, such
, such as Components, Properties, Design Specs, Calculators, etc., in
the copy function

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9 - 10
Copy/Paste Functions
(2)
– Use the Cut function in the right-click menu to copy the object to the clipboard and delete it in one step
– Select Paste to paste the selected object
– The Resolve ID Conflicts dialog box appears when two or more objects have the same name. You must correct
the names before inserting the objects into the current one

In addition to using menu items, you can also use Ctrl-C to copy, Ctrl-X to cut an object, and Ctrl-
V to paste.

You can copy the same objects from one simulation to another

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"Find Object" function

Limit your
search by Pattern Match When
selecting an Entering a Name
object type

Click "Name" to navigate to that

feature in the default diagram or
RMC (right-click) on an
form for objects that are not
object to navigate to the
displayed in the diagram
schematic layout, input
form, or results

Activate by right-clicking on the diagram ,then Find Object ( or by pressing Ctrl F) or

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9 - 11
 RadFrac – Minimum Input Required

Objectives of
the section

Recognize the minimum required input data for a RadFrac model

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10 - 1
Precise multi-stage separation using
RadFrac

Vapor-to-liquid or vapor-liquid-liquid phases are modeled for:

– Conventional Distillation
– Absorption, reboiler absorption
– Stripping, stripping – rayballer
– Azeotropic distillation
– Reactive Distillation

Configuration Options
– Any amount of raw materials
–
– General Fluid Pumping and Circulating Irrigation (Pumparounds)
– Any number of heaters
– Any number of decanters

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RadFrac Wiring Diagram

Vapor Distillate

Top-Stage or 1
Heat (optional)
Condenser Heat Duty
Liquid Distillate
Water Distillate (optional)
Feeds Reflux
Side Products (optional)

Heat (optional) Pseudo Streams (optional)

Pumparound
(optional)
Heat (optional) Feed (optional)

Decanter
Heat (optional) Boil-up Return Product

N-stage
Bottom Stage or Heat (optional)
Reboiler Heat Duty

Bottoms

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10 - 2
RadFrac Demo

OVHD

RadFrac Features of
Flow = 1000 lbmol/hr Partial-Vapor
T = 190°F Condenser Kettle
P = 315 psia Reboiler
FEED COLUMN 15 Stages (Total)
Reflux Ratio = 1.5 (mole)
Mole fractions Distillate to feed ratio = 0.6
C1: 0.26 Column pressure = 315 psia
C2: 0.09
C3: 0.25 BTMS
nC4: 0.17
nC5: 0.11
nC6: 0.12

Use the RKS-BM Property Package Filename: RADFRAC DEMO.

BKP

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Specify:
– Calculation Type
– Number of plates
– Condenser & Reboiler
Configurations
– Active phases
– Convergence
– Operational Characteristics
– Columns

Important: The calculation type can be set up as equilibrium or

velocity-based

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10 - 3
RadFrac Stream Input

Specify:
– The plate on which the raw material arrives
– Method of feeding raw materials to the plate
– Above-Stage
– On-Stage
– On-Stage-Liquid
– On-Stage-Vapor
– Decanter
(only for three-phase
calculations)
– Product flows from the top and bottom plates
– Side Products

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Feed Convention
Above-Stage
On-Stage
(default)
Ln- Vn- Ln- Vn-
2 1 2 1

n-1 n-1

Vfeed
Ln- V
Raw Ln-1 V
Material
Pre-Flash 1

Lfeed Raw
Material n
n
L Vn+
L Vn+ 1
1
Above-Stage: RadFrac introduces a material flow between adjacent plates - part of the liquid flows to the predetermined dish, and part of
the steam goes to the top dish

On-Stage-Liquid and On-Stage-Vapor are the same as On-Stage, but no separation is ever performed with these characteristics.
The raw material is calculated in full in the specified phase.

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10 - 4
RadFrac Pressure Settings (1)
Pressure Value on the First
Specify one of: Plate
Can represent the pressure of
– Upper or Lower Disc Pressure Pressure the entire tower if the differential
pressure is not known
– Profile
– Differential Pressure

You can specify the pressure

to delete information about
On each plate or the
entire column

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RadFrac Setu Pressure Settings (2)

The pressure profile option
allows pressure to be applied
for any stage in the tower

Plate pressure is not

introduced linearly
interpolated or
extrapolated
from the set values

Differential
pressure allows
you to specify
Differential pressure for any range of trays
in the tower

The pressure of the top plate

is necessary
Enter for this option

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10 - 5
RadFrac Results
Results from the tab
«Results»

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RadFrac. Plotting results

the results for the following operations:

– Assay Data Analysis
– Physical Property Analysis
– Data Regression Analysis
– Profiles for all individual models, including RadFrac, MultiFrac, and PetroFrac
– Sensitivity Analysis

Navigate to a feature of interest via the Navigation Pane to plot

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10 - 6
Charting (1)

Select Custom

information if required, e.g. phases,

components, etc.

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Charting(2)

Use the Design and Format tabs on the toolbar to adjust charts

Note: The display of the feed depends on what is selected on the chart

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10 - 7
 Using the Plotting Tool's plotting feature, plot the change

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Workshop: Methanol Synthesis Tower Simulation with

RadFrac

• Learn how to set up a RadFrac unit with minimal background information

• Task 1 - Add Component List and Select Property Package

• Task 2 - Enter Flow and Block Characteristics
• Task 3 - Fix the model to remove warnings

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10 - 8
 Methanol Synthesis Tower Simulation
with RadFrac
Seminar
The files can be found in the folder: RadFrac

Objectives of the seminar

In this workshop, you will simulate the methanol/water distillation process using a
RadFrac unit. You'll learn how to set up the RadFrac block and define flow connections,
enter the minimum information required, and run and view the results of the block.

The workshop contains the following objectives:

• Task 1 - Add Component List and Select Property Package

• Task 2 - Enter Flow and Block Characteristics
• Task 3 - Fix the model to remove warnings

Task 1 - Add Component List and Select Property Package

Because you'll start with a new simulation, you'll start by defining the Properties
environment before moving into the Simulation modeling environment

11 - 1
1. Start Aspen Plus V10 and create a new model with the General with English
Units template.

2. In Components – Specifications | Component ID of the partition, type WATER and

METHANOL.

3. Click on the Methods folder in the Navigation Pane and select NRTL-RK as Base
method.

Tip: Change the method filter from COMMON to ALL. Not all property
methods are listed when the method filter is set to COMMON.

4. Click on the Next button to check the available binary interaction options or go to
Methods | Parameters | Binary Interaction | NRTL.

5. Click on the Next button. The Properties Input Complete window will appear to
indicate that all minimum inputs have been completed. Select Go to Simulation
environment and click OK.

11 - 2
 Task 2 - Enter Flow and Block Characteristics

6. From the Model Palette, in the Columns tab, select the RadFrac block and place it
on the diagram. Enter the name COLUMN.
7.

Click on the Material Streams label on the block palette and connect the stream to
the feed port of the RadFrac unit. Name the stream FEED. Do the same for the
liquid distillate and lower streams and name them DIST and BTMS, respectively.

11 - 3
8. Click Next or double-click on the FEED stream to open the input form. Select
Pressure and Vapor Fraction for Flash Type, enter the following conditions:

Specification Value
Pressure 18 psia
Vapor Fraction 0
Total flow rate 120,000 lb/hr
Water mass fraction 0.632
Methanol mass fraction 0.368

9. Click Next or double-click on the RadFrac block to access the

block specifications. Enter the following specifications:

Setup options Value

Number of stages 40
Condenser type Total
Operation Specifications Value
Distillate rate 1,245 lbmol/hr
Reflux ratio (mole basis) 1.3

11 - 4
10. Go to the Streams tab and enter 24 as the feed stage number.

11. Click on the RadFrac Pressure tab and enter the following specifications:

Specification Value
Stage 1 / Condenser pressure 16.1 psia
Stage pressure drop for the rest of the column 0.1 psia

11 - 5
12. Go to the Home panel and press Run.

Question: Have you received a warning message

message)?

Task 3 - Correct model that

Remove warnings

13. The warning message indicates that the flow pressure of the FEED is lower than that
of the pressure supply stage 24. In practice, this can lead to a backflow in the other
direction. Go to the RadFrac COLUMN | Profiles | TPFQ to see the pressure at all
stages and confirm the warning.

Results Value
FEED stream pressure 18 psia
COLUMN stage 24 pressure 18.4 psia

11 - 6
14. To mitigate the warning, go to the main table, double-click the thread FEED
and specify the pressure 19 psia.

15. Press the Reset button on the Home ribbon panel to reinitialize the simulation.

16. Click the Run button to start the simulation with the new specifications.

Q: What is the duty of Condenser and Reboiler in RadFrac?

Tip: Go to Blocks |COLUMN | Results | Summary to see the condenser/reboiler results.

QUESTION: What is the mass fraction of methanol in the distillate?

QUESTION: What is the mass fraction of water on the bottom plate?

Tip: Go to Blocks | COLUMN | Profiles to view temperature, pressure, flows
and compositions on all plates (Stages).

11 - 7
17. In the RadFrac Results tab, go to Home ribbon | Plot to plot the results.

18. Save your file as MEOH-COL MIN INPUT. BKP

11 - 8
Notes:

11 - 9
 Model a Methanol Tower Using
RadFrac Solution
Files can be found in folder: RadFrac

Task 2
QUESTION: Do you get any

warning message? After running the

simulation, you get the message:

WARNING: FEED PRESSURE IS LOWER THAN STAGE PRESSURE

Task 3
QUESTION: What are the Condenser and Reboiler duties on

the RadFrac? The heat duty of the Condenser is -4.325e7

BTU/hr.

The heat duty of the Reboiler is 4.484e7 BTU/hr.

QUESTION: What is the mass fraction of methanol in

the distillate? The mass fraction of methanol in the

distillate is 0.999758.

QUESTION: What is the mass fraction of water in the bottoms? The mass fraction of water in
the bottoms is 0.946518

11 - 10