UniSim® Plate-Fin

Exchanger Modeler
(referred to as UniSim® PFE)

Reference Guide
Copyright
Release 451

The information in this help file is subject to change over time. Honeywell may make
changes to the requirements described. Future revisions will incorporate changes, including
corrections of typographical errors and technical inaccuracies.

For further information please contact

Honeywell
130 Dufferin Ave., Suite 1001
London, Ontario
N6A 5R2
Telephone: (519) 679-6570
Facsimile: (519) 679-3977

Copyright Honeywell 2017. All rights reserved.

Prepared in Canada.
 Table of Contents
1 Introduction ......................................................... 1-1
1.1 Overview ........................................................ 1-3
1.2 UniSim® PFE Calculation Engines ....................... 1-4
1.3 Exchanger Geometries ...................................... 1-5
1.4 Design Calculations .......................................... 1-5
1.5 Heat Transfer and Pressure Drop ........................ 1-6
1.6 Property Data Sources ...................................... 1-6
1.7 Thermosyphons ............................................... 1-6
1.8 Output Options ................................................ 1-7
1.9 Documentation ................................................ 1-7

2 Using UniSim® PFE............................................... 2-1

2.1 Overview ........................................................ 2-3
2.2 The Start up Screen ......................................... 2-4
2.3 Running UniSim® PFE ...................................... 2-5
2.4 UniSim® PFE Icons .......................................... 2-6

3 Data Input ............................................................ 3-1

3.1 Overview ........................................................ 3-3
3.2 Input Screens .................................................. 3-3
3.3 Process Data Input ........................................... 3-5
3.4 Geometry Data Input ........................................ 3-6
3.5 Other Data Input.............................................. 3-7
3.6 Input Units ...................................................... 3-7
3.7 Using Help ...................................................... 3-9
3.8 Finding Input Items ........................................ 3-10
3.9 The Input File ................................................ 3-11
3.10 Default Input Data File .................................... 3-12
3.11 Input Errors and Warnings............................... 3-13

4 Output .................................................................. 4-1

4.1 Overview ........................................................ 4-3
4.2 Output Screens ................................................ 4-3
4.3 Output Files..................................................... 4-4
4.4 Error / Warning Message Log ............................. 4-7

i
 4.5 Other Output ................................................... 4-7

5 Physical Properties............................................... 5-1

5.1 Overview ........................................................ 5-3
5.2 Properties Input ............................................... 5-5
5.3 Properties Data Input (Old Style) ....................... 5-8
5.4 Mixture Calculations (Old Style) ....................... 5-11
5.5 Property Databanks ........................................ 5-14
5.6 Importing Properties & Process Data ................. 5-15
5.7 Importing from UniSim® Design ...................... 5-17
5.8 Importing from a Properties Package ................ 5-18
5.9 Properties Output ........................................... 5-19
5.10 Pressure Dependence ..................................... 5-20

6 Other Facilities ..................................................... 6-1

6.1 Overview ........................................................ 6-3
6.2 User Fin Databank ............................................ 6-3
6.3 Project File Structure ........................................ 6-3

7 Examples .............................................................. 7-1

7.1 Overview ........................................................ 7-3
7.2 Case 1 Design.................................................. 7-3

ii
 Introduction 1-1

1 Introduction

1.1 Overview ....................................................................................... 3

1.2 UniSim® PFE Calculation Engines .................................................. 4

1.3 Exchanger Geometries ................................................................... 5

1.4 Design Calculations ....................................................................... 5

1.5 Heat Transfer and Pressure Drop................................................... 6

1.6 Property Data Sources ................................................................... 6

1.7 Thermosyphons ............................................................................. 6

1.8 Output Options .............................................................................. 7

1.9 Documentation .............................................................................. 7

1-1
 Introduction 1-3

1.1 Overview
UniSim® PFE can perform a range of calculations on plate-fin heat
exchangers, either simple two-stream exchangers, or complex ones
with multiple streams. The basic calculation options are:

UniSim® PFE Calculation Modes

Simulation This determines the heat load, pressure changes and
outlet conditions for each stream in the exchanger, based
on an exchanger you specify, and given stream inlet
conditions.
Layer by Layer As for normal simulation, but on a layer by layer rather
Simulation than stream by stream basis. This option lets you assess
the stacking pattern in which layers of the various streams
are arranged.
Thermosyphon This determines the performance of an exchanger, with a
geometry you specify, with one stream operating as a
thermosyphon. The exchanger can either be internal to
the column or outside it and connected via pipework. You
can specify either the head of liquid driving the
thermosyphon flow, or the thermosyphon stream flowrate,
leaving the program to calculate the one you do not
specify.
Design This will produce a “first shot” design of a heat exchanger
to meet a heat load duty and pressure drop limits, which
you specify for each stream. This should be a useful
indication of what a specialist manufacturer would
provide. A final design of a plate-fin exchanger must,
however, come from a manufacturer, who can use
proprietary finning and specialist design and
manufacturing techniques.
Crossflow Exchanger For single or multipass, including thermosyphon.

UniSim® PFE’s User Interface presents a structured approach to data

input. The software can run at various levels of detail, and is
extensively supported by Help Text. A range of outputs are produced,
in both tabular and graphical form. There is an Exchanger Diagram,
available in the input for performance calculations, so that you can
check that the data you have provided is correct, or in the output from
design calculations.

1-3
1-4 UniSim® PFE Calculation Engines

1.2 UniSim® PFE Calculation

Engines
UniSim PFE contains four calculation engines:

Calculation
Use
Engine
Design Engine For ‘first-shot’ design
Simulation For general performance simulation including
Engine thermosyphons and exchangers with high
numbers or crossflow passes.
Layer-by-layer For detailed simulation on a layer-by-layer
Engine basis.
Crossflow Engine For simulating crossflow designs of plate-fin
exchangers (including crossflw reboilers)
where a limited number of crossflow passes
are used.

These calculation engines use one User Interface, which allows the
user to select the calculation engine required. The input data required
for these engines varies slightly, but there are no incompatibilities. The
output formats are all very similar.

1-4
 Introduction 1-5

1.3 Exchanger Geometries

UniSim® PFE allows for the following aspects of plate-fin exchanger
geometry:

Exchanger Geometries
Overall Stream entry and exit at any point along the
Geometry exchanger.
Inlet and outlet distributors .
Internal re-distribution into otherwise empty
layers.
Partial draw-off of a stream.
Nozzles.
Change of main fin type at points along the
exchanger length.
Exchangers in parallel.
Exchangers in series (in Design, if needed).
Internal and external thermosyphon reboilers.
Layer patterns, including allowance for double
or triple banking.
Empty layers.
Performance evaluation with some streams
switched off.
Distributors End entry/exit - Full end, central end, at side.
Side entry/exit - Diagonal, mitred, indirect.
Hardway.
Single- or twin-headed distributors.
Finning Plain.
Perforated.
Serrated (lanced or multi-entry).
Wavy (herringbone).
Unfinned.
Correlations for fin performance.
Option to supply manufacturer’s performance
data.

1.4 Design Calculations

The Design Engine in UniSim PFE offers a ‘first shot’ design capability.
It will produce a design based purely on the required inlet and outlet
process conditions for each stream, or you can specify certain aspects
of the exchanger, for example the fins or distributors to be used, and
leave the program to complete the design.

While this ‘first shot’ approach should in many cases give a reasonable
approximation to what a plate fin manufacturer might suggest, you
should be aware that sometimes there may be significant differences.
For a more realistic design, you would need to select proprietary fins

1-5
1-6 Heat Transfer and Pressure Drop

and use proprietary fin performance data from a manufacturer. For

complex multi-stream exchangers, specifying the distributor types and
constraining the number of layers for certain streams can also lead to
improvements on the design produced by the Design Engine.

1.5 Heat Transfer and

Pressure Drop
UniSim® PFE can perform heat transfer and pressure drop calculations
on single or two-phase streams, involving sensible heating or cooling,
boiling or condensation, or any combination of these. Streams can be
either pure components, or multicomponent mixtures.

Facilities are provided whereby you can modify the heat transfer
coefficients and pressure gradients calculated by UniSim® PFE, either
by scaling them, or replacing them with specified values.

UniSim® PFE calculates fin efficiencies, allowing for local thermal

conduction along the fin metal to the parting sheet. It can also allow
for longitudinal thermal conduction in the parting sheets and sidebars,
transferring heat from the hot to the cold end of the exchanger.

1.6 Property Data Sources

UniSim® PFE offers a range of options for providing the physical
property information needed for heat transfer and pressure drop
calculations. If you have stream property information available, this can
be input directly, or imported provided it is in the correct format. If the
stream is a mixture of known composition, UniSim® PFE can perform
vapour liquid equilibrium and mixture calculations to determine the
stream properties. This can be done using the UniSim® Thermo
package which has data for over 1000 components.

See Chapter 5 - Physical Properties of this Manual for more

information on the various properties options and methods.

1.7 Thermosyphons
For thermosyphons, UniSim® PFE has methods for calculating both
frictional and gravitational pressure changes in the inlet and outlet
pipework connecting the exchanger to the column. You can simplify
each line to an equivalent length, allowing for bends, diameter changes

1-6
 Introduction 1-7

and generalised flow restrictions.

UniSim® PFE will either determine the thermosyphon stream flowrate,

consistent with the driving pressure head you specify, or evaluate the
head needed to drive a particular flowrate. It will tabulate the pressure
changes in all the components of the circuit, as well as providing full
information about exchanger performance.

For the condensing stream in a thermosyphon, you can specify a

number of options, with either its flow, inlet pressure or exit quality
(vapour mass fraction) adjusting to conform to the calculated heat
load. In a cryogenic flow driven by a turbine, the condensing stream
operating pressure usually adjusts itself to give complete condensation
in supplying the required heat load.

1.8 Output Options

UniSim® PFE produces a number of different types of output
information. Some are in the form of output screens; information can
be tabulated, plotted and printed out. Other information is available as
output files, which you can examine via the User Interface. The Find
facility helps to locate text within these files. You can control the
amount of information they contain using flags in the program input.

UniSim® PFE also includes an extensive set of error and warning

messages, to provide clear information on what is required, if you omit
vital data, or provide unusual or inconsistent input.

Chapter 4 - Output of this Manual gives more detailed information on

the program output.

1.9 Documentation
UniSim Heat Exchanger supplies the following manuals on the Software
media:
• UniSim® Heat Exchangers User Guide;
(these two are generic to all programs)
• Program Getting Started;
• Program Reference Guide.

This Reference Guide provides basic information on using the

program, its capabilities, the required input data (see Chapter 3 -
Data Input), and the results (see Chapter 4 - Output). Chapter 5 -
Physical Properties covers the range of options for providing the
information needed to run the program.

1-7
1-8 Documentation

Also contained in this manual is a set of standard examples (see

Chapter 7 - Examples) for you to work through. These examples
illustrate a range of exchanger calculations that can be performed using
UniSim® PFE, and show you the various methods of inputting the
relevant data.

When appropriate, this Manual includes the UniSim® PFE input and
output screens to help with explanations. Since UniSim® PFE is being
continuously developed, there may be minor discrepancies between
what you see on your computer, and the screens shown in this manual.
The discrepancies may relate to layout, or to numerical values, but
should not be taken as indicating any problem.

See the UniSim® PFE Getting Started Manual for information on the
set of QA data that is included with the program. The QA data are
input data sets to help ensure that UniSim® PFE is functioning properly.
These sets should be run in UniSim® PFE and then checked that the
results are the same (within the limits of computer accuracy) as the
corresponding output files, which are also provided.

The Help Text is the most extensive documentation available for

UniSim® PFE. It is available whenever you are running the program, or
can be loaded separately. There are direct links to appropriate Help
To load the Help Text topics for every input item, and from many other places in the program.
when you are not running
UniSim® PFE, double click
on PFE.CHM in the main The technical methods used in UniSim® PFE are proprietary. These
UniSim PFE directory. methods are described in Design Reports DR50, DR62 and in a range
of Research Reports.

1-8
 Using UniSim® PFE 2-1

2 Using UniSim® PFE

2.1 Overview ....................................................................................... 3

2.2 The Start up Screen ....................................................................... 4

2.3 Running UniSim® PFE.................................................................... 5

2.4 UniSim® PFE Icons ........................................................................ 6

2-1
 Using UniSim® PFE 2-3

2.1 Overview
The normal procedure when running UniSim® PFE is to set up input
data representing a particular case, to run the case, and to examine the
results. If you come back to a case, which you have run previously,
you can examine the results without needing to run the program again.
You can very easily make changes to a case and re-run it. After making
changes, you can decide whether to save them for future reference, or
simply to Run the changed case, see what the results are, and then
decide whether to save it. You can also save a case part way through
providing input, so you can come back later and complete it.

Facilities are provided for you to provide a descriptive title for each run,
to number a run, and to add a number of lines of comments giving
further information.

Further information on the data input is provided in Chapter 3 - Data

Input of this guide, and on output in Chapter 4 - Output. Extensive
Help Text is available when running the program. This covers not only
the details of input and output, but also the use of the User Interface
and on plate-fin exchangers in general.

Figure 2.1

The Welcome screen is displayed, which contains a list of recently

used input files, and gives you the option of opening an Existing file,
or starting a New one. Select the New button, and you will be taken to
the Start up screen where you can begin inputting data for a new
example.

You can save an example at any point during data input, or after you
have run it. When you next start UniSim® PFE, you will see it in the list
of recently used files, and can double click on it to select it. If you want

2-3
2-4 The Start up Screen

to find a previous input file which does not appear in the recently used
list, click on Open. When you open an input file, UniSim® PFE will also
open all the associated output files, if any, produced by a previous run.

When you have your UniSim® PFE file loaded, you can start a
(different) new case, using the New command under the File menu.
Selecting New will clear any existing data and set up default data.
Return to a different existing case by using the Open command under
the File menu.

Regardless of the method you choose to begin a new case, the screen
available is the Start up screen, shown in Figure 2.2. You can return
You can also use the key
<Shift>+<F1> to return to that screen at any point by selecting Start up under the Input
to the Start up screen. menu.

When you start an existing case, you will not be taken to the Start up
screen, but for a simulation case you will be shown the Exchanger
Diagram, (Geometry Preview screen), if available, while for a design
case you will be shown the Process Data input screens. You will also
see the Run Title, to remind you of the case you have selected. The
Exchanger Diagram can also be accessed at any time from the View
menu or by clicking on the appropriate toolbar button. For the diagram
to be available, you must have provided the basic information on where
each stream enters and leaves the exchanger. It will also show
View Geometry Diagram information on main fin number and distributor and nozzle layout,
icon provided you have supplied the relevant input information.

2.2 The Start up Screen

Figure 2.2

The Start up screen is important because it ensures that you are

shown a set of input options consistent with what you want to do. You

2-4
 Using UniSim® PFE 2-5

must set the items on the Start up screen, or accept the defaults, and
click on OK before you can enter any other data.

The most important item is the Calculation Mode. The default is

Simulation Engine, but you can reset it to Design Engine or Design
Engine - Thermosyphon, or Layer-by-Layer Engine, or Crossflow
Engine. As with all input items, press <F1> to see the Help Text, if
you are not sure what the options mean or what you should do.

It is always important to specify the number of streams in the

exchanger.

The Number of Fins to be Directly Input should be set if you are

going to provide information on fin geometry or performance in the
input. It can be left blank if you are doing a simple design (when
UniSim® PFE will select all the fin information), or if you are going to
get all your fin data from a fin databank.

Basic Input Mode is a facility which limits the number of input items
you can see. If you are a new user, setting it may help you get an
overview of the most important items and options in the UniSim® PFE
input. If you set it, you can return to the Start up screen at any time
and unset it, to gain access to the full range of input. If you save your
data while using Basic Mode and then reopen the case later, it will
again be displayed in Basic Mode.

The Equipment Item Number and the Job Title are optional input,
but it is recommended that you provide them for future reference.

Click on OK to gain access to the input screens for your new case.

2.3 Running UniSim® PFE

When you have prepared your data input (see Chapter 3 - Data
Input) you must Run one of the calculation engines to generate
results. You can run the calculation engine corresponding to the
calculation type you specified either by:
• clicking on the Run icon;
• selecting Calculate All under the Run menu or
• pressing <F4> on the keyboard.
Run icon The Run menu also lets you run calculation engines other than the one
you specified under Calculation Mode on the Start up screen. You
will be asked for confirmation first.

A window will appear detailing the progress made as the calculation is

run. See Figure 2.3. Sometimes this will be too rapid to follow in

2-5
2-6 UniSim® PFE Icons

detail, but it can be useful for UniSim® PFE cases that take more than a
few seconds to run. A message appears when the calculation is
complete, and the Results Summary window, and/or the Error/
Warning Log appears. See the Chapter 4 - Output for more details..

Figure 2.3

The Run Progress window records the file that is being run. If the
extension is .PFEI, you are running the case you just opened, without
having made any changes to it. If the file extension is .PFEA, you are
running the edited copy of your original input file, having made changes
to it.

2.4 UniSim® PFE Icons

Figure 2.4

UniSim® PFE has a toolbar containing a number of icons, which can be

clicked on as short-cuts to the frequently performed program
operations. The meaning of each icon is displayed as a ToolTip after the
cursor has been left positioned on it for a second or two. When toolbar
icons are referenced in this manual, an image of the icon will often
appear in the margin adjacent to the relevant paragraph. The following

2-6
 Using UniSim® PFE 2-7

table gives a brief description of each of the available icons.

Name Icon Function

New Create a new case.

Open Locate and open an existing

case.

Save Save the active case.

Preview Input View the input data file.

File

Find Input Item Open the Find Item view.

Geometry Open the Geometry input form.

Advanced Open the Advanced Geometry

Geometry input form.

Process Open the Process Data input

form.

Fins Opens the Fin Geometry and

Performance Data input form.
Only accessible if Numbers of
Fins specified on the Start up
screen is greater than zero.
Options Opens the Options input form.

Physical Open the Physical Properties

Properties input form.

Run Run the UniSim® PFE

calculations.

View Geometry View the Geometry Diagram.

Diagram

Help Open the UniSim® PFE Help

Text.

Exit Exit UniSim® PFE.

The Help Text provides more information on all the operations

described above.

2-7
 Data Input 3-1

3 Data Input

3.1 Overview ....................................................................................... 3

3.2 Input Screens ................................................................................ 3

3.3 Process Data Input ........................................................................ 5

3.4 Geometry Data Input ..................................................................... 6

3.5 Other Data Input ........................................................................... 7

3.6 Input Units .................................................................................... 7

3.7 Using Help ..................................................................................... 9

3.8 Finding Input Items......................................................................10

3.9 The Input File ...............................................................................11

3.10 Default Input Data File ...............................................................12

3.11 Input Errors and Warnings .........................................................13

3-1
 Data Input 3-3

3.1 Overview
UniSim® PFE has a number of data input forms (screens), each
comprising several tabbed pages. These are found under the Input
menu. The contents of each page vary slightly according to the
Calculation Type (Design, Simulation or Thermosyphon etc.) you
have specified.

Data is input either by typing in values, or selecting from a drop-down

list. You do not need to fill in all the data input items, only those that
sufficiently describe the case under consideration. If you are only
interested in thermal performance, you can omit information on
distributors and nozzles, but you should remember that the calculated
pressure drop will not then allow for these items. All the items
controlling the details of the calculation, or outputs can be omitted.
Program defaults will then be used.

If you are unsure what a data item means, position the cursor on that
item and press <F1>. You will be shown the Help Text on that item,
which can show diagrams, define defaults, and let you explore other
relevant information. It can point you to assumptions made by the
program, and to what use is made of an input item during UniSim® PFE
calculations.

For a full description of each item, and a listing of all possible items,
use the Help Text. For more information on Physical Properties,
both input and output, see Chapter 5 - Physical Properties.

Some input items have checks on them to prevent you from inputting
inappropriate values. For simulation cases, use the Exchanger
Diagram (View menu) to ensure you have specified the exchanger
layout correctly. A complete and systematic check on input is made
when you run UniSim® PFE calculations. You will be shown a list of any
errors and warnings produced.

3.2 Input Screens

Under the Input menu you will see a list of input screens, each of
which consists of a set of tabbed pages. The screens and their tabbed

3-3
3-4 Input Screens

pages are as follows.

Views Tabbed Pages

Geometry Basic Geometry.
Layer Pattern.
Layer Definition.
Thermosyphons.
Stream Geometry.
Distributors and Nozzles.
Pass Lengths.
Advanced Geometry Extra Main Fins.
Redistributors.
Substreams.
Layer Flow Distribution.
Inter-pass Details.
Process Process.
Process Constraints.
Process - Exchanger.
Fins Fin Geometry.
Fin Performance.
Options Comments to go on Output.
Output Options.
Calculation Options.
Physical Properties These screens have a different layout
from the other screens, and are
described in Chapter 5 - Physical
Properties.

Figure 3.1 shows a typical example of an input view.

Figure 3.1

Some screens/tabbed pages are only used for certain Calculation

Modes. They sometimes have a different set of items on them,
depending on the Calculation Mode. In the Basic Input option, a
reduced set of screens, with a reduced set of input items on them is
displayed. This may make it easier for you to find your way around the

3-4
 Data Input 3-5

input, if you are unfamiliar with the program.

3.3 Process Data Input

Some information on the Process tabbed pages must always be
provided, but many of the items on the forms may be optional or
alternatives. In Design Mode, UniSim® PFE needs sufficient
information to be able to work out both inlet and required outlet
conditions for each stream. In performance modes, only the inlet
conditions are needed, but it is valuable also to supply estimated outlet
conditions, since the program can then compare calculated outlet
conditions with your expectations.

Figure 3.2

An example of alternative inputs might be the inlet conditions for a

multicomponent stream with two phase entry. These can be defined
either by the inlet temperature, or by the inlet quality (vapour mass
fraction). Other alternatives apply primarily in Design mode. Stream
heat loads can either be supplied explicitly, or derived from the mass
flowrate and inlet and outlet conditions. In Design mode, if you
provide more data than necessary for a stream, UniSim® PFE will
undertake consistency checks, and warn you of any discrepancies.

Discrepancies tend to arise when the sources of your Process and

Property data are different. For example, if you get your Properties
data from UniSim Thermo, then there may be minor discrepancies
from values for the same substance from other sources. This applies
particularly to T-h-x (Temperature-enthalpy-quality) Properties
Data. Though the discrepancies are often equivalent to less than a
degree in temperature, they sometimes represent a substantial fraction
of heat load. They may be circumvented by appropriate input. For

3-5
3-6 Geometry Data Input

example, for a stream which must condense completely, it may be best

to specify the Outlet Quality (=0.0) rather than the Outlet
Temperature, which may not correspond exactly to the Bubble Point
Temperature from internal calculations.

The best method of preventing discrepancies is to obtain process and

properties data from the same source.

The Process Constraints and Process - Exchanger screens only

Note that Process data need input if you want to make special modifications to the calculations
can also be imported,
along with Properties
performed.
data, from a PSF file. See

3.4 Geometry Data Input

Chapter 5 - Physical
Properties.

A significant number of input screens relate to the geometric

configuration of the exchanger and related equipment. Several are only
required in special circumstances. The Thermosyphon screen is only
required for thermosyphon calculations. Distributor information is
usually only needed in performance modes if you want distributor
pressure losses to be calculated.

Layer pattern information must be supplied when you are running the
Layer-by-Layer Engine, but is optional for Simulation and
Crossflow Engines, and is not used in the Design Engine.

The main difference in geometry input is between Design mode

calculation, and the other modes. In the other modes, you should
generally specify as much information as you have available to describe
the exchanger, both its size and layout.

In Design mode, all the geometry information can be omitted. You

can, however, supply partial geometry information, and the program
will determine the remainder, consistent with the part you have
supplied. For example, you could specify distributor types and
orientations, leaving the program to determine their size and location.
You could specify that certain fin types be used (plain, serrated etc.) or
even that certain specific fins be used, for some or all of the streams.

3-6
 Data Input 3-7

3.5 Other Data Input

Properties information must always be provided. This is described in
Chapter 5 - Physical Properties.

Options input can normally be left set to default values, unless you
want to modify the basis of the calculations, or suppress or switch on
certain outputs. A special option in Design mode lets you ignore some
or all of the geometry data input. This can be useful if you have an
exchanger geometry defined, but want to explore the effects of a
redesign to new process conditions

3.6 Input Units

The various parts of UniSim® PFE input can each be in one of five sets
of units. The three basic ones are:
• SI (mm, deg C, kJ/kg etc.);
• British/US customary (inches, deg F, BTU/lb etc.);
• Metric (mm, deg C, kCal/kg etc.)

The application allows for data to be entered in a range of alternative

units of measure. On each input item where units are accepted, access
is given via a button at the left of the field, to a list of relevant units.
The display is always in a consistent set of units. This could be one of
the standard unit sets, or a customised unit set.

To specify a customised unit set, enter the Preferences option under

the File menu and then select Display Units. One of the existing unit
sets must first be cloned and then each unit of measure can be

3-7
3-8 Input Units

customised to use one of the units of measure provided.

Figure 3.3

The unit of measure for the display is selected via the drop down list at
the top of the main data input screen.

When the data is saved or passed on to the calculation engine to run

the case, it will be saved in one of the three pre-defined unit sets. You
are able to choose how the data is saved, by using the Engine Units

3-8
 Data Input 3-9

view under Preferences.

Figure 3.4

3.7 Using Help

The Help Text in UniSim® PFE is the definitive source of information
on Program Input, and on other aspects of the program. The Help
Text is kept fully up to date with every release.

Manuals, as supplied on the Software media, give an

overview of facilities and options, and full information on
installation. For specific information on how to use the
program facilities, use the Help text.

UniSim® PFE Help can be accessed at any point using the Help menu,
or during input, you can press <F1> to go directly to help on the item
where the cursor currently points.

The Help Text provides information on data input, how to use the
User Interface, the program output, and on errors and warnings.
There is also general information on plate-fin heat exchangers, and the

3-9
3-10 Finding Input Items

reasons for choosing particular design features.

Figure 3.5

You will also find information on UniSim® PFE capabilities, new features
in the latest version, and contact points for user support.

3.8 Finding Input Items

If you need to specify information on some aspect of a UniSim® PFE
case, and do not know where to find the relevant input screen, then
look up the item in the Help Text index using the Search facility. Try
alternative descriptions if you cannot at first find what you expect.

When you have found the Help Text relevant to the particular input
item, you will see that there is an input item identifier at the bottom of
the Help window. This takes the form of a Line number and Item
number in the input file. For example Inlet Temperature is 204.1,
meaning item 1 one line 204 (there can be up to 6 items on a line).
See Figure 3.6

To find a particular item, use the Find Item command under the View
menu. When you type in a line number, you will be shown the list of
items on that line. If you click on a particular item, you will either be
taken to the input screen where it occurs, or get an indication that it is

3-10
 Data Input 3-11

Figure 3.6

only visible with some other Calculation Type setting. For Physical
Properties input, you will just be taken to the main properties screen,
and may need to investigate subsidiary screens yourself.

Some Error and Warning messages give line and item numbers. You
can use the Find Item facility to identify the item more fully, and go to
the input screen where you can amend it.

3.9 The Input File

When you provide UniSim® PFE input, it is used to generate an input
file, which has a simple layout, and contains all the information you
have provided. The file consists of a set of lines, each identified by a
number occupying the first three characters, and followed by up to six
items of data. When only some of the items on a line are present,
asterisks (*) are used to indicate omitted items.

The data lines are gathered together into ‘blocks’, with a related set of
line numbers. The following table lists the data type and their
respective number ranges.

Data Type Range

Program Options 001-099
Geometry 101-199
Process 201-299
Stream Properties 301-399
Component Properties 401-499
Fin 701-799

The first line in each block identifies the block, and the units of the
input data. Some data blocks are repeated, for example there is a

3-11
3-12 Default Input Data File

Process block, and at least one Properties block, for each stream.

A full listing of all possible input data items is given in the Help Text.
The Help Text on individual items indicates the line number (and
position on the line).

You can preview the Input data file, before it is run, under the View
menu.

The User Interface normally holds an internal version of the input file,
which is modified in response to changes you make in the input, and
which is used when you ask for UniSim® PFE calculations to be Run.
You have the option of saving this internal version of the input file, at
any stage. You will be explicitly offered the option of saving it, for
example on Exit from the program. If you do not save it, any initial
version of your input file will be left unaltered.

Both the saved input file and the current internal version may contain
data which is not relevant to the current calculation mode. No data are
lost when you change the Calculation Mode.

3.10 Default Input Data File

You can, if you wish, set up a default input data file, which is called up
whenever you ask for a New input data file. This can contain any
amount of pre-set input data. You can set up several such files, and
have the option of selecting from among them when you run UniSim®
PFE.

To set up such a default file, create a partial input data file in the usual
way, and save it with an appropriate name. Then select Preferences,
under the File menu, and select the Files tabbed page. Select your
default file under the Default File option.

When you use such a default input file, you should be careful to do a
Save As (under the File menu) to give an appropriate name to your
new datafile, different from the name of your default file. To select a
different default input data file, go the File menu, then Preferences
and Files and make your selection. Then select File menu, then New,
to initiate a new data file based on your new default.

3-12
 Data Input 3-13

3.11 Input Errors and

Warnings
If some mal-operation occurs when you are using the UniSim® PFE
User Interface, or if you have provided data, which the Interface
cannot interpret, then an information message screen will appear. You
will need to click on this, and take appropriate action before you can
continue.

In some circumstances, some of these input warnings from the User

Interface may appear to be repeated, as you make use of various
different parts of the User Interface. This can be annoying, if the
message relates to something you judge not to be relevant, or to
something you plan to correct shortly. To prevent such warnings being
displayed, select the File menu, then Preferences, and choose the
General tabbed page. This lets you switch off various categories of
warning messages from the Interface. See Figure 3.7.

Figure 3.7

It should be emphasised that this facility does not affect the more
stringent checks performed when you Run the UniSim® PFE
calculations. Error and Warning messages on running cannot be
suppressed, and are always sent to a special message log, as well as
being incorporated in the main lineprinter output. Chapter 4 - Output.

3-13
 Output 4-1

4 Output

4.1 Overview ....................................................................................... 3

4.2 Output Screens .............................................................................. 3

4.3 Output Files ................................................................................... 4

4.4 Error / Warning Message Log ........................................................ 7

4.5 Other Output ................................................................................. 7

4-1
 Output 4-3

4.1 Overview
Running the UniSim® PFE calculations produces a number of different
types of output. These can be viewed using the Output menu. When
you stop working on an example, all the key output files remain in
place, so you can view the output again, once you re-enter a case you
have previously worked on.

This chapter gives an overview of the various outputs you can inspect,
to help you find particular details you may be interested in. A more
detailed description of all the outputs is available in the Help Text.
See Output in the Help Text contents screen.

4.2 Output Screens

You can select from a set of output screens, which contain the main
results and information used to generate them.
• Results Summary.
• Full Results.
• Specified Duty.
• Temperature Profiles.
• Other Profiles.
• Stream Details.
• Thermosyphon Details.
• Geometry - Overall.
• Geometry - Streams.
• Geometry - Distributors.
• Exchanger Diagram.
• Zig-zag Diagram.
• Fin Geometry.
• Fin Performance.
• Alternative Designs.

Not all these outputs will be available. For example the Zig-zag is only
produced if you have supplied a layer pattern input, Alternative
Designs and Specified Duty are only shown in Design mode.

There are also screens where you can review, in tabular or graphical
form, the physical property data used for each stream.
• Stream Properties.
• T-h-x.
• Stream Compositions.

Figure 4.1 shows the Results Summary screen, which appears

automatically at the end of a run, providing that the initial input

4-3
4-4 Output Files

Figure 4.1

checking has been successful.

If any warning or related messages have been produced, the Error/

Message Log will be written on top of the Results Summary, so you
should read this first, to check that there are no problems with the data
used to generate the Results.

The contents of the Results Summary screen depend on the

calculation mode. In Design mode, this is geometric information on
the best design found. In Simulation and Thermosyphon modes, the
key results are process data, particularly the calculated outlet
conditions, and for Thermosyphons, the flowrates.

The Results Summary screen also records the number of error and
warning messages, and most importantly, whether a design met
various design constraints, or whether a simulation calculation
converged.

The Full Results output uses Internet Explorer, or your equivalent

HTML viewer, and has Topic Headings to give you direct access to
various parts of the results. The information shown is that in the
Lineprinter output file, the most comprehensive output.

4.3 Output Files

Some of the UniSim® PFE output is directed to files. The User
Interface has a File View facility when you select these outputs under
the Output menu. This applies to the following files.
• The Brief Output.
• The Lineprinter Output.

4-4
 Output 4-5

Figure 4.2

• The 80-column Output.

• The Physical Properties Output.

The Lineprinter output is the most comprehensive set of results from

UniSim® PFE. It is up to 132 characters wide. When you run the
UniSim® PFE calculations from the User Interface, by default all the
possible components of the Lineprinter output are produced. See
Figure 4.3 for an example of this output.

4-5
4-6 Output Files

Figure 4.3

If you would like a more limited version, go to the Input menu, then
Options, then Output Options to switch off any parts you do not
want. Then re-run the program to generate the reduced file.

In some cases, there are also Output Options for various output
tables to be extended, or repeated, but these are rarely of interest after
a successful run.

The 80-column output is usually a more restricted version of the

Lineprinter output, but after design calculations, it can contain a
record of why various design choices were made. The Brief Output
contains similar information to the Results Summary screen.

For each of the above, you will see an option for printing out the file.
You can also select part of a file - click and drag with the mouse - and
then copy this to the clipboard. You can paste the clipboard contents
into a text viewer/editor such as Notepad, or a word processor
application, and then print the selected text from there.

4-6
 Output 4-7

One of the most useful features of the File View facility is a Find
button. If you want more information on some aspect of an exchanger,
for example, nozzles, vibration checks, clearances, baffles, just click on
Find, then type the relevant word. Use Find Next if the first
occurrence is not what you want. The Find is not case sensitive.

4.4 Error / Warning Message

Log
When you run UniSim® PFE calculations, an extensive set of checks is
performed on the data you have provided, and then further checks are
made as the program continues its operation. These checks result in
Error and Warning messages, which are collected together in a file
and which also appear in the main record of the run, the Lineprinter
output. The messages file will often be the first thing you see when you
have run UniSim® PFE.

Errors are normally fatal, in that UniSim® PFE has identified some
fundamental inconsistency in your data, or a lack of vital data, which
means that it cannot continue further with its calculations.

Warnings occur if a value you have supplied is outside an expected

range. For example an Inlet Temperature of 20K, which is not
impossible, but unlikely. Warnings also occur if there is an
inconsistency in your data, for example if you specify an inlet quality,
which is different from that deduced from your inlet temperature. They
also occur if your exchanger has some unexpected feature, such as
triple banking in the layer pattern.

With any such warnings, you should check the input data, to confirm
that it is as you intended, and amend it if necessary.

4.5 Other Output

When UniSim® PFE calculations are run, a file called the INTOUT file is
produced. Its extension is .PFEF and it contains all the data needed by
the Output screens. You can’t view this file from the Interface, or
suppress its output.

After a Design calculation, you can go to the File menu, and click on
Create Simulation Case, to be given the option of creating a
UniSim® PFE input file for a Stream-by Stream Simulation. You will
be asked for a name for the new file (by default based on the current
name, but terminating in ‘s’) and have the option of selecting from the
Alternative Designs table for the design of interest.

4-7
 Physical Properties 5-1

5 Physical Properties

5.1 Overview ....................................................................................... 3

5.1.1 Properties Data Input ............................................................... 3
5.1.2 Properties Used ....................................................................... 4

5.2 Properties Input ............................................................................ 5

5.2.1 Setting a Data Source............................................................... 6
5.2.2 Get Properties ......................................................................... 7
5.2.3 Rules for Direct Property Input................................................... 7

5.3 Properties Data Input (Old Style) .................................................. 8

5.3.1 Input Directly .......................................................................... 9
5.3.2 User Databank........................................................................11
5.3.3 Single Component Stream........................................................11
5.3.4 Components: Calculation of the Properties of a Mixture ................11

5.4 Mixture Calculations (Old Style) ...................................................11

5.5 Property Databanks ......................................................................14

5.6 Importing Properties & Process Data ...........................................15

5.6.1 Importing PSF Files .................................................................15

5.7 Importing from UniSim® Design...................................................17

5.8 Importing from a Properties Package ...........................................18

5.9 Properties Output .........................................................................19

5.10 Pressure Dependence .................................................................20

5-1
 Physical Properties 5-3

5.1 Overview
A wide range of options are provided for providing the physical property
data needed by this program. The user interface contains the
UniSim® Thermo package, which contains data for over 1000
substances and a range of methods for determining vapour liquid
equilibrium and mixture properties, and can be used to set up tables of
property data for each stream.

The calculation engine contains the UniSim Heat Exchanger Physical

Properties Package (PPP), which contains facilities for checking and
interpolating the tables of property data.

Physical Properties Options are common to most UniSim

Heat Exchanger programs. Examples in this section are
based on a two stream heat exchanger, but the description
applies also to UniSim Heat Exchanger programs where the
number of streams is one (e.g. UniSim® PPL) or more than
two (e.g. UniSim® PFE, UniSim® FPH).

5.1.1 Properties Data Input

There are two separate properties options under the Input menu:

Physical Properties
This lets you define a stream data source (components and methods)
for the UniSim® Thermo databank, and then calculate a table of
stream properties, which can be used as program input. It also lets
you directly input property data tables, or modify those just calculated.
Section 5.2 - Properties Input gives more details.

Physical Properties (Old Style)

This gives you access to all the facilities which were in UniSim Heat
Exchanger programs before the UniSim® Thermo databank was
included.

Use of the newer style input, with the UniSim® Thermo package
gives you more control. This lets you set up, check and if necessary
revise properties data before running the program. Except for the
special case when you provide direct input, the old style input only sets
up the properties data tables data when the program is run.

5-3
5-4 Overview

5.1.2 Properties Used

A set of Property Data comprises liquid properties, vapour properties
and T-h-x data as appopriate. The data required are as follows:

Property Data
Liquid Temperature for liquid properties.
Liquid Density.
Liquid Specific Heat.
Liquid Viscosity.
Liquid Thermal Conductivity.
Surface Tension (for two-phase
streams, optional).
Vapour Temperature for vapour properties.
Vapour Density.
Vapour Specific Heat.
Vapour Viscosity.
Vapour Thermal Conductivity.
T-h-x Data Temperature for T-h-x.
Specific Enthalpy [h].
Quality (vapour mass fraction) [x].

Sets of 1-24 liquid data points, 1-24 vapour data points and 2-26 T-h-
x points are used. Although separate sets of temperatures can in
principle be used for each of the three subsets, when UniSim®
Thermo is used the liquid and vapour temperatures are identical with
the relevant ones for T-h-x.

The properties need not relate explicitly to the process

conditions in the equipment through which the system flows
in any way. Data can be extrapolated as well as interpolated
if necessary. It is, however, clearly sensible that the
properties cover a broadly similar temperature range to that
in the equipment, as major extrapolations are likely to be
less accurate than interpolations.

5-4
 Physical Properties 5-5

5.2 Properties Input

Properties input using UniSim® Thermo normally involves:
• Setting up one or more data Sources.
• Selecting a data source for each stream, then defining the
composition, temperatures and pressures for the properties data
tables.
• Generating the property data tables, using Get Properties.

There are, however, four special data sources also provided:

• Direct Input - you type the numbers in yourself, copy them from
a spreadsheet, or modify values already calculated by UniSim®
Thermo. See Section 5.2.1 - Setting a Data Source below.
• Not set here - meaning that one of the options under Physical
Properties (old style) is used. See Section 5.3 - Properties
Data Input (Old Style).
• Air or Water - a special setting under which air or water data are
obtained from UniSim Thermo at run time. No further settings
for the stream are necessary.

The data source options, and calculated property tables are shown in
the main Physical properties screen.

Figure 5.1

5-5
5-6 Properties Input

5.2.1 Setting a Data Source

A Data Source defines the components in a stream, and the VLE and
properties methods to be used. For a new case you will normally first
click on Add to set up a new Data Source. You can then select a set
of components from the master list, and add them to the list for the
Data Source. A Search facility lets you find components in the list
more easily, searching on either name or formula. Many components
can be identified under a variety of synonyms. The form ‘*abc’ can be
searched on, to find the string ‘abc’ preceded by other characters.

Figure 5.2

To define a data source, it is necessary to select property calculation

methods, (the Property Package) as well as a set of components.

If you selected a Stream Type on the main properties input form, then
a default Property Package will be selected. You can, however,
change the package used, from a selection including Peng Robinson,
SRK, NRTL, and variants on these. A brief description of each is given
on screen.

When both components and Property Package are set, the box at the
bottom right turns green and reads Ready. You can then close this
screen, and on the main Properties input screen, the new Data
Source is available to be selected for any stream.

5-6
 Physical Properties 5-7

5.2.2 Get Properties

Get Properties calculates properties at one or more pressure levels,
using a set of temperature points. Using the Options facility lets you
either define a temperature range and a number of points (from which
the temperature points are determined automatically) or you can
choose to specify the temperatures to be used explicitly. A
temperature range and set of pressures are initialised from any process
information you provide where possible.

Get Properties causes the spreadsheet of property data to be filled in

automatically. If a stream is two phase within or near the range of
defined temperatures, property data at the bubble and dew point are
added in.

After properties have been calculated you can delete individual data
points (data columns). You can explore the effect of changing the
Property Package, used using Edit to revise the Data Source.

Once data has been generated, you can change the Data Source to
Direct Input and edit individual property values, though this is not
recommended.

5.2.3 Rules for Direct Property

Input
Data for Two Phase streams must always contain the dew and bubble
points, if these points are within the range of data you supply. If they
are outside the range of data provided, they will be estimated by
extrapolation of T-h-x data. When data are provided, the highest
Enthalpy point with Quality 0 is assumed to be the bubble point, and
the lowest Enthalpy point with Quality 1 is assumed to be the dew
point. Points need not be provided in any particular order, but are
sorted into order of increasing enthalpy by the PPP when the
calculation is Run.

The facility to supply the specific enthalpy and molecular weight of

individual phases is available via the Show Phase Enthalpies and
Molecular Weights check-box, on the Options screen. These are
always optional inputs.

For Single Phase streams data need only be input for one phase.
Specific enthalpy data are optional, as they can be found by integrating
specific heats.

5-7
5-8 Properties Data Input (Old Style)

A set of Stream Properties data you specify should all relate to the
same pressure, typically some mean pressure within the exchanger.
You can supply a second set of stream data at a different pressure,
permitting the program to allow for the pressure dependence of
properties. Such dependence is sometimes significant, particularly for
thermosyphons, or if there is a very close temperature approach
between streams. For the UniSim PPL program, pressure dependence
is mandatory. See Section 5.10 - Pressure Dependence for more
information.

5.3 Properties Data Input

(Old Style)
Figure 5.3

The Old Style physical properties input gives access to all the facilities
that were present prior to the introduction of Thermo. Many of these
facilities are associated with the fact that, unlike UniSim® Thermo
options, with many old-style options you cannot see the properties until
you have run the Calculation Engine.

The master screen for old style input is shown in Figure 5.3. Using
this, Physical Property information can be supplied in a number of ways.

5-8
 Physical Properties 5-9

You can:
• Input Stream Properties directly. You can either type them, or
import them from a PSF file. See Section 5.6 - Importing
Properties & Process Data.
• Identify data from a User Databank. The calculation engine will
read data from this databank when it runs.
• For a single component stream, get the data for a limited
number of components directly from the UniSim Thermo
supplied with the program.
• Tell the program the stream components and composition, and
get it to calculate the properties.

The Data Source item on the main Physical Properties input screen
allows you to select the various options. You should also set the Phase
before supplying further data. A two-phase stream means that it can
be either single phase or two phase, depending on the temperature.

If you have previously set up properties data using UniSim® Thermo,

or the corresponding direct input (see Section 5.2 - Properties
Input), you will see the Data Source set to Approximately. You can
change the Data Source to Direct Input, and view and edit the
properties data, but you will not be able to access it again using the
main Properties Input.

5.3.1 Input Directly

If you set the Data Source to Input Directly, you can then click on
the Property Table button to open a view, shown in Figure 5.4,

5-9
5-10 Properties Data Input (Old Style)

where you can enter the properties.

Figure 5.4

If you have previously imported data from a PSF file, you will be able to
see what you have imported.

You need to specify the properties indicated above for one or both
phases. For Two-phase streams you also supply T-h-x data.
Although you can supply data at up to 24 temperature points, this is
potentially tedious if you are typing the data in, and you are most likely
to use this method when you have only one or two data points
available, for example at an exchanger inlet and outlet.

If you wish you can use different sets of temperatures for the Liquid,
Two-phase (Enthalpy + Quality) and Vapour Properties. You
should normally fill in the data tables from the left, without leaving
gaps, though this is not strictly necessary.

For Single Phase streams, T-h-x data are not usually input, as they
can be found by integrating specific heats. If, however, you do want to
input Enthalpies for a Single Phase stream, click on Show T-h-x,
and that T-h-x part of the input table will become available.

Heat Load data, rather than Specific Enthalpies, can be specified. If

you supply a heat load, you must also specify the flowrate to which it
relates.

You can supply Compressibilities instead of Vapour densities. Use

5-10
 Physical Properties 5-11

the click-box to specify this option.

The rules for direct property input are as defined in Section 5.2.3 -
Rules for Direct Property Input. The additional facilities available
under Old Style input are as follows.

5.3.2 User Databank

If you have previously set up data in a user databank, then when you
set Data Source to User Databank, you will see a list of the datasets
in this bank under the Code drop-down box. All you need to do is select
which of them you want. See Section 5.5 - Property Databanks.

5.3.3 Single Component Stream

UniSim Heat Exchanger programs come with UniSim Thermo. If your
stream is a single component in this bank, all you have to do is identify
the component in the Code drop-down box. This gives direct access to
a limited number of components for compatibility with previous
versions.

5.3.4 Components: Calculation of

the Properties of a Mixture
You must specify the Mixture Composition (mass or molar) and
identify the Components. The program will calculate a full set of
Stream Properties. The methods used are not as advanced as in
Process Simulators or specialist properties software packages. See
Section 5.4 - Mixture Calculations (Old Style) for more
information.

5.4 Mixture Calculations (Old

Style)
Mixture calculations determine the properties of a stream given its
components and composition. If the stream is two phase, then VLE
(vapour liquid equilibrium) calculations must be performed to
determine the bubble and dew point temperatures and the
compositions of the individual phases at intermediate temperatures.
Given the phase compositions, mixing rules can be applied to

5-11
5-12 Mixture Calculations (Old Style)

determine each stream property from the corresponding component

properties.

With the Old Style input, mixture calculations are performed when the
calculation engines run.

From the main Properties input screen, set the Data Source for the
stream concerned to Components, and then click on the Specify
Mixture button. The Specify Mixture screen, Figure 5.7, lets you
define the temperature range over which mixture properties should be
calculated, or amend the calculation methods or results.

Figure 5.5

For a Two Phase stream, you can select the method to be used for
VLE calculations, SRK or Ideal. There is also a facility called T-h-x
Override, whereby you can control the results of the VLE calculations.
At the basic level, you can simply specify all the temperatures at which
you want the calculations performed. You can also request that any
calculated bubble and dew points (temperatures and optionally
enthalpies), be modified to conform to pre-set values. More
information on all these options is given in the Help Text, accessed by
using the Help button at the bottom of the page.

All the inputs on the Specify Mixture screen are optional, but you
must use it to access the Define Components and Define
Compositions screens, via the appropriate buttons.

From the Define Components screen, Figure 5.6, you can identify
each component, and where data for it is to be obtained. Click on Add

5-12
 Physical Properties 5-13

Component until the correct number are identified. The number

should be the total number of components in all such mixtures. If the
same component occurs in more than one stream, it need only be
counted once. There is no need to include those components which
only occur in pure component streams.

Figure 5.6

If you are accessing components select internal databank and identify

the component in the Code drop-down box.

You can also select from a User Databank of component data (if you
have set one up previously), or you can choose to Input Directly.
Selecting Input Directly as the Data Source enables the Property
Table button. If clicked the screen for direct input of component
properties is opened. The properties needed for each component are
similar to those required for a stream, but the Liquid Properties are
saturation line values, and the Vapour Properties are ideal gas
values, that is values in the low pressure limit.

Each component can be identified as Liquid only, Vapour only, or Two

Phase. It is normally safe to leave the components set to Two Phase,
but if a stream is Single Phase, you can obviate the need for VLE
calculations by specifying all the components to be Single Phase as
well. For a Two Phase stream you can specify some of the
components (incondensibles) as Vapour-only if you wish, but not as
Liquid-only. With the SRK method, (see later) it is best to leave all
components set as Two Phase.

5-13
5-14 Property Databanks

When you have defined components, click on the Specify

Composition button on the Define Components screen or back on
the Specify Mixture screen. On the Compositions screen, see
Figure 5.7, enter the compositions, as fractions, flows or percentages.
Identify whether you are supplying Mass or Molar values.

Figure 5.7

5.5 Property Databanks

The program contains the UniSim® Thermo databank for physical
properties.

The UniSim® Thermo databank contains data for over 1000

substances, and is accessed via the User Interface to set up tables of
Physical Properties data as part of the program input. To see the list of
substances in UniSim® Thermo, go to the Physical Properties input
screen, and click on Add in the Data Source box.

The UniSim® Thermo databank includes software for performing

vapour liquid equilibrium (VLE) and mixture calculations, using a
variety of methods. This includes interaction parameters appropriate to
each of the methods offered. In principle the UniSim® Thermo
package can be linked to a variety of Properties databanks, but as
supplied with UniSim Heat Exchanger programs, only the Honeywell
databank is available.

Properties from UniSim® Thermo will depend on the equation of state

used in the properties method selected, even for pure components.

You can set up a User Databank with the properties of any

components which you may frequently need to access. The structure of
the databank is very similar to that of the Component blocks of an
Input file. The Help Text gives full details.

5-14
 Physical Properties 5-15

You can also set up a User Databank containing the properties of

streams. The User Interface lets you add the properties of any
stream to such a databank. Use the Output to Databank check-box
on the Properties Output Options screen (via the main Properties
input screen). You are advised to run the program first without this
check-box set, to ensure that the stream properties produced are
acceptable. Then re-run the program with the check-box set. Make
sure that the stream has a meaningful name you will recognise in
future. When you have put one or more sets of stream data in the
userbank, on subsequent runs you can select User Databank as the
Data Source on the main Properties input screen using the Code
drop-down box, select from among the previously established data.

The User Databanks of stream and component data are files. Specify
their location by selecting Preferences, under the File menu on the
Files tab, specify the appropriate tab.

5.6 Importing Properties &

Process Data
There are three ways you can import properties and process data into
the case you are running:
• Import a PSF file (set up by a Process Simulator);
• Import from UniSim® Design (if this is available);
• Generate and Import a PSF setup using your company’s own
physical properties software while you are using this UniSim
Heat Exchanger program (if an interface has been written).

5.6.1 Importing PSF Files

PSF files are files containing process and/or property information for
one or more streams. They can be generated by Process Simulators,
and have the file extension .PSF. It is normally best to import PSF data
before entering any other process or properties data.

The data from a PSF file go directly into your input file. The import
facility can be accessed via either the Input or the File menus. The
first step is to identify the particular PSF file from which you want to
import data. You will then be taken to the Import PSF Data screen.

5-15
5-16 Importing Properties & Process

Figure 5.8

If the PSF file has been prepared specifically for the exchanger you are
interested in, you may simply be able to click on OK. You can, however,
use the Import PSF Data screen to direct only part of the information
from a PSF file into the input file.

You can:
• View the stream Names, Number and Inlet/Outlet
Temperatures in the file;
• Import data for some streams but not others;
• Import Process data, or only Property data, or both;
• Import data at any selection of pressure levels (PSF files often
contain properties data at the Inlet, Outlet and Mean Pressures
in the exchanger);
• Change the stream Number when you import data.

The Import facility shows you the stream names and inlet/outlet
temperatures in the PSF file. The temperature units of the display can
be reset by clicking on the box in the top right hand corner.

The PSF file itself is largely in basic SI units, and when

imported to the input file the data can be viewed in whatever
units have been set for process and property data.

The Import To column shows the Stream Number to which data will
be imported. This is initially set to the Stream Number from the PSF
file, but you can reset it to a different number if you wish, or if it is
necessary for the program. You can set it to ignore, enabling you to
import data for only one stream (or fewer than all the streams for
multi-stream exchangers). You cannot set two stream numbers to be
the same.

5-16
 Physical Properties 5-17

The Use Properties column lets you select which pressure levels in a
PSF file to use for Properties data. If there are data for three
pressure levels, you can select two (upper and lower), one (middle
level), or you can opt for a special selection.

If you want to import the properties data but not the process data, click
on Separate Process and Properties, and you will see that the
Import To column is divided in two. The left hand part relates to
Process data, the right hand one to Properties. You can set either
one to Ignore, so that only the other is imported.

Normally, when you import Process and/or Properties data for a

PSF file layout and
contents are defined in the stream, any data you have already entered for that stream is
Help Text. overwritten. You can however, cause the Properties data to be added
to any data currently present, provided that it relates to a different
pressure. Use the Merge with Existing Data check-box.

Click on OK to transfer the Process/Properties data selected from

the PSF file to the input file. Select Process or Properties (old style)
under the Input menu to see what has been imported.

5.7 Importing from UniSim®

Design
If you can run the UniSim® Design Process simulator on your
computer, you can select an exchanger in a UniSim® Design case, and
import the data directly into your UniSim Heat Exchanger program.
The exchanger can also be a UniSim® Design LNG block, when
appropriate.

Though this facility is available within most UniSim Heat

Exchanger programs, it is clearly only directly useful when
the UniSim Heat Exchanger program is for equipment
corresponding to a UniSim® Design exchanger.

Select Import from UniSim® Design under either the Input or File
menu and you will be presented with a screen to select an existing
UniSim® Design case.

UniSim® Design will then be started, load the chosen case and the
import interface will generate a list of all heat exchangers within that
case. You can select an exchanger, and for each stream in that
exchanger, the temperatures and pressures will be shown.

You can revise the temperatures and pressures. If you then select OK,

5-17
5-18 Importing from a Properties

Figure 5.9

UniSim® Design will perform the flashes needed to generate the data
for a PSF file. You can then review and select from the data as for a
normal PSF import.

5.8 Importing from a

Properties Package
There is an option for importing properties and process data by
accessing your company’s own physical properties software while you
are running an UniSim Heat Exchanger program. If this facility has been
made available, the Import from Other Package command under the
File menu will be active.

When you select this option, you are asked to provide input on stream
inlet/outlet conditions, stream compositions and components, and
possibly also on the methods to be used, and the temperature/pressure
range of data to be set up. When you have supplied the necessary
information, a PSF file will be generated, and you will be taken to the
PSF import facility, where you can opt to import the data you have
created into the input file of your UniSim Heat Exchanger program.

To set up a facility to import data from your company’s own physical

properties software you must write an interface to this property
package and register it so that your UniSim Heat Exchanger program
will recognise it. You

5-18
 Physical Properties 5-19

must create an executable with project name Properties Package and

a class name PSFFileGen.

The Help Text provides detailed information on the structure of the

interface, and on the contents of the PSF file it must generate.

5.9 Properties Output

The Physical Properties Package can be used to generate two types
of output. The first is in file format, the second in Windows format. All
the output relates to tables of property values which are set up at the
beginning of the program, and subsequently interpolated during heat
transfer and pressure drop calculations.

The first type of output can be either held in a separate file, or directed
to the main Lineprinter file. The separate file is the default. If you
want it in the main Lineprinter output, or turned off, select this on the
Output Options screen, using the Options command under the Input
menu.

Putting the Physical Properties output in the Lineprinter file means

that you will be able to see it in the Full Results output, in programs
with this facility.

The contents of the file format Physical Properties output can be set
via the Properties Output Options screen, accessed from the main
Physical Properties (old style) input screen. The output is in four
parts:
• Input data for each stream/pressure level;
• Table of properties for each stream/pressure level;
• Stream/phase compositions for each stream/pressure level;
• Table of properties for each component.

The third and fourth items are only relevant where mixture calculations
have been performed. Only the second item is produced by default.
See the Help Text for more information on the contents of the various
parts of the output. A further option, accessible via Output, lets you
output stream data to a stream properties databank (see Section 5.5 -
Property Databanks).

The second type of Physical Properties Package output, in Windows

format, is not yet available in all UniSim Heat Exchanger programs.
When it is available, you will see Stream Properties and T-h-x as
Output menu items.

Stream Properties gives the properties of each phase in both tabular

and graphical forms. The graphical form has a range of options. The

5-19
5-20 Pressure Dependence

default is to plot all properties relative to their maximum value, so you

can immediately see if any property does not have a smooth variation.
This can be very useful for identifying typographical errors if you have
input the properties data yourself.

T-h-x gives tabular or graphical presentations of the temperature,

specific enthalpy and quality (vapour mass fraction) for each stream.
The graphical version also shows a set of interpolated points, so that
you can see the way properties data (input or calculated) is interpreted
when it is interpolated during heat transfer calculations.

5.10 Pressure Dependence

The effect of pressure on properties is most likely to be significant in
the changes it produces in vapour density, and in dew and bubble
points, which may be important when there is a close temperature
approach between streams. Allowing for pressure dependence is
optional in most UniSim Heat Exchanger programs (it is mandatory in
UniSim PPL).

The normal way of ensuring pressure dependence is allowed for is to

provide properties data at two pressure levels.

If you are using the program to calculate stream properties for a

mixture of known composition, then it is very simple to define two
pressure levels in the properties input. This normally happens by
default when you are using UniSim® Thermo. If you are using
Physical Properties (old style) input you will need to use the Add
Pressure key. You must then specify the pressure for each level (if you
only have one level, you can use a default pressure). You should select
the pressures to span the range expected in the exchanger.

You can specify data at more than two pressure levels for a stream if
you wish. This is unlikely to be necessary if the stream pressure
change is less than 30% of the (absolute) inlet pressure.

When data are available at only one pressure, the PPP can, if specified,
estimate an allowance for pressure dependence, using the Clausius
Clapeyron equation. This will be less accurate for wide boiling range
mixtures. To allow for pressure dependence in such cases, use the
check-box on the main Physical Properties (old style) input screen.

If you are supplying pre-calculated properties data at two pressures,

you should use specific enthalpies, not heat loads, and ensure that the
enthalpies have a consistent zero.

If the properties data you have available are not isobaric data, but

5-20
 Physical Properties 5-21

contain some inherent pressure dependence, for example from inlet to

outlet, then in many cases you can use this data with relatively minor
inaccuracies. You should not select Pressure Dependence in such
cases. Data with an inherent pressure dependence are, however, not
acceptable for two-phase streams that are pure substances, or
azeotropes, or for which the change in saturation temperature due to
pressure changes is comparable with, or larger than, the isobaric
boiling range.

5-21
 Other Facilities 6-1

6 Other Facilities

6.1 Overview ....................................................................................... 3

6.2 User Fin Databank ......................................................................... 3

6.3 Project File Structure..................................................................... 3

6-1
 Other Facilities 6-3

6.1 Overview
This chapter introduces you to some of the other facilities, which are
available with UniSim® PFE.

6.2 User Fin Databank

You can set up a databank containing fin geometry and performance
information for any fins where you have this information, both
distributor fins and main fins. Each fin is identified by a number in the
range 100 to 9999. To identify that a particular fin is used in some
part of an exchanger it is simply necessary to specify its number at the
appropriate place in the input data, as an alternative to lower
numbered fins (1 upwards) for which data must be provided in the
main input.

The Fin Databank is a text file. Its layout is essentially the same as
that of the fin data within the input data file. The Help Text gives more
information. When you create a fin databank file, you should name it
FINDAT, without any file extension, and place it in the program
directory

6.3 Project File Structure

A UniSim® PFE project is initially set up as an input file. The various
files are outlined in the following table.

File Name Description

name.PFEI UniSim® PFE input file, where name is the
name of the project. After you have run the
project, some or all of the following files will
also have been set up.
name.PFEF The so-called INTOUT file, containing all the
main input and results. The format of this file
is described in a document on the Program
media. All the UniSim® PFE result Windows,
which you can view under Output, take data
from this file. You can use this file as a source
of information for in-house software, if you
wish.
name.PFEL The Lineprinter output file.
name.PFET The 80-column output file.
name.PFEE The Error/Warning Messages file.
name.PFEV The Brief Summary output file.
name.PFEP The Physical Properties output file.

6-3
6-4 Project File Structure

When you run calculations from the User Interface, all these output
files are set up by default. You can switch off most of the other files if
required. Click on the Input menu, select Options, then the Output
Options tabbed page, and you will see drop-down boxes controlling
these outputs.

You cannot switch off the .PFEF file, which is needed for the main
output screens, or the Error/Warning Log.

The file extension .PFEA is used for an edited copy of the input data.
This is the version stored internally by the User Interface, which you
can run without saving. If you save the file, the main input,
name.PFEI is updated. The .PFEA file is not preserved when
UniSim® PFE is shut down.

6-4
 Examples 7-1

7 Examples

7.1 Overview ....................................................................................... 3

7.2 Case 1 Design ................................................................................ 3

7-1
 Examples 7-3

7.1 Overview
The following examples will guide you through the various ways in
which UniSim® PFE can help you with assessing or designing plate fin
heat exchangers. The examples concentrate on a relatively simple case
for a notional cryogenic duty with three streams. Plate-fin exchangers,
of course, very often have a much larger number of streams, but once
you understand what is needed for each stream, it is no more difficult
to supply it for many streams. You are shown first how to produce a
‘first shot’ design, then how to undertake a basic UniSim® PFE
Simulation, and finally how to perform a more detailed layer by layer
calculation.

The other simplification in the examples is that stream physical

property data are obtained using the internal databank. In reality it is
often critically important to get accurate property information for
cryogenic processes using plate-fin exchangers, so it is best to
generate these properties outside of UniSim® PFE, and set up tables of
property data in the input file, either directly, or by importing via a PSF
File. Because of the large amounts of data involved, none of the
examples use these methods. More information on importing data is
given in the Help Text.

All the examples relate to brazed aluminium exchangers. UniSim® PFE

can simulate plate-fin type exchangers made of stainless steel or other
materials, but the design facility should not be used for such
exchangers unless you are aware of the very different
manufacturingconstraints, which apply.

7.2 Case 1 Design

The first example is a simple gas-gas exchanger in which an air stream
is cooled in succession by two cold nitrogen streams. It is required to
design a plate fin exchanger for this duty. The stream conditions are as
follows:

Stream Air (1) Nitrogen (2) Nitrogen (3)

Total mass flow kg/h 15000 12000
Inlet temperature K 300 120 210
Outlet temperature K 125 200 290
Inlet pressure bar 10 3 2.5
Allowed pressure drop bar 0.5 0.3 0.3

Start up UniSim® PFE (see introduction). Select the New button on the

7-3
7-4 Case 1 Design

Welcome screen, and the Start up screen will appear.

Figure 7.1

7.2.1 Start Up
1. Set the Calculation Mode to Design, and set the Number of
Streams to 3. Leave the fins set to 0, since you do not need to
specify any input about fins in simple design cases.
2. Click on the Basic Mode check-box, since this is a simple example,
with no need for any less common inputs.
3. Fill in a Job Title, such as Simple Example Number One, and an
Equipment Item Number such as Ex1, then click on OK.

7.2.2 Process Data

The Process Data Input screen will appear. The first thing to note is
the units, which are set to SI/deg C. The information supplied has
temperatures in Kelvin, so the units must be changed.
1. Click on the Units box, and you will see a form where the units for
all the various sections of input can be specified. (This screen can
also be accessed via Preferences under the File menu).
2. Change the Process & Properties data units to SI/deg. K. None
of the other input sections are relevant to this example, so their
units need not be changed. When you change units, you are offered
the option of converting the existing inputs. Since no data have yet
been provided, answering either Yes or No is acceptable.
3. Clicking on OK on the units takes you back to the Process data
screen.

7-4
 Examples 7-5

4. Enter the information for the streams 1 to 3, using the values in the
table at the beginning of the example.

The flow of air has not been specified, but this is not a
problem, since it will be evaluated via a heat balance when
the program is run. Similarly, no heat loads need be input,
since they will be evaluated from flowrates and input and
outlet temperatures.

Since plate-fin exchangers normally handle clean fluids, fouling

resistances are assumed to be zero.
5. Click on OK to save the Process data.

7.2.3 Stream Definition

Having specified the process conditions, it is next necessary to define
the streams. This can be done using UniSim® Thermo.
1. Under the Input menu, click on Physical Properties.
2. For stream 1 click on < Air > as the Stream Data Source.
3. Click on the tab for stream 2. Click on Add to set a new data source
Note with item 2 - air and
water are treated as and you will be taken to the Data Source screen.
special substances, 4. Set the stream name to N2/stream 2, and the Stream Type to
requiring only this simple
setting. Air/Other Gas.
5. You will see a list of components. Begin typing Nitrogen in the
Match box and you will see the list of components reduce. When
Nitrogen is visible, click on it then click Add, to move the list of
components on the right hand side of the screen.
6. You should see the box at the lower right of the window turn green
and display Ready. If you click on the Property Package tab, you
will see that a default has been set appropriate to the stream type
you entered. Close the Data Source screen.
7. On the main Properties screen, click on the data source Gas 1 that
you have just set. You will see that a composition of 1.0 is set
automatically, as this is a single component screen.
8. Click on Get Properties. Pressure Level and Temperature
Range information is required before properties can be calculated.
These should have been set by default. You could set/revise them if
required. They should cover the range relevant to the stream, but
need not match inlet or outlet conditions exactly. You should see the
Properties Table filled with data for stream 2. You should see that
two pressure levels have been set up by default. Clicking on either
one shows the data at that level.

7-5
7-6 Case 1 Design

9. Click on the table for stream 3. Select the same data source as for
stream 2 (both streams are nitrogen). Check the pressure levels
and temperature range (click on Options) are correct for stream 3.
Revise them if necessary. Click on Get Properties to generate
tables of property data as before.
10. Close the Physical Properties screen, retaining the property data
you have generated.

7-6
 Index
Numerics Finning 1-5
Fins 3-4
80-column Output 4-5
Full Results 4-3
A
G
Advanced Geometry 3-4
Geometry 3-4
Alternative Designs 4-3
Geometry - Distributors 4-3
B Geometry - Overall 4-3
Geometry - Streams 4-3
Basic Input Mode 2-5 Geometry Data Input 3-6
Brief Output 4-4
Bubble Point Temperature 3-6 H
C Heat Transfer and Pressure Drop 1-6
Help Text 1-8, 3-9
Calculation Engines 1-4
Calculation Modes I
Design 1-3
Importing from a Properties Package 5-18
Layer by Layer Simulation 1-3
Importing Properties and Process Data 5-15
Simulation 1-3
Importing PSF Files 5-15
Thermosyphon 1-3
Input Directly 5-9
Components
Input Errors and Warnings 3-13
Calculation of the Properties of a Mixture
Input File 3-11
5-11
Input Items - Finding 3-10
D Input Screens
Advanced Geometry 3-3
Data Input 3-1, 3-7 Exchanger Geometry 3-3
Databank 5-11 Fins 3-3
Default Input Data File 3-12 Options 3-3
Design 1-3 Physical Properties Data 3-3
Design Calculations 1-5 Process 3-3
Distributors 1-5 Input Units 3-7
Documentation 1-7 Introduction 1-1
E J
Equipment Item Number 2-5 Job Title 2-5
Error / Warning Message Log 4-7
Errors and Warnings 3-13 L
Examples 7-1
Layer by Layer Simulation 1-3
Exchanger Diagram 1-3, 4-3
Lineprinter Output 4-4
Exchanger Geometries 1-5
Distributors 1-5 M
Finning 1-5
Mixture Calculations 5-11
Overall Geometry 1-5
Mixture Calculations (Old Style) 5-11
F
N
Fin Geometry 4-3
Number of Fins to be Directly Input 2-5
Fin Performance 4-3
Find 1-7
Finding Input Items 3-10

I-1
I-2

O S
Options 3-4 Simulation 1-3
Other Facilities 6-1, 7-1 Single Component Stream from NEL40 5-11
Outlet Temperature 3-6 Specified Duty 4-3
Output 4-1 Start up Screen 2-4
Output - Other 4-7 Stream Compositions 4-3
Output Files Stream Details 4-3
80-column Output 4-4 Stream Properties 4-3
Brief Output 4-4
T
Lineprinter Output 4-4
Physical Properties Output 4-4 Temperature Profiles 4-3
Output Options 1-7 Thermosyphon 1-3
Output Screens 4-3 Thermosyphon Details 4-3
Overall Geometry 1-5 Thermosyphons 1-6
Overview 1-3 T-h-x 4-3
P U
Physical Properties 3-4, 5-1, 5-3 UniSim Design 5-17
Physical Properties (Old Style) 5-3 UniSim PFE Icons 2-6
Physical Properties Output 4-5 User Databank 5-11
Pressure Dependence 5-20 User Fin Databank 6-3, 7-3
Process 3-4 User Interface 1-3, 1-7
Process Data Input 3-5 Using UniSim PFE 2-1
Bubble Point Temperature 3-6
Outlet Temperature 3-6 V
T-h-x (Temperature-enthalpy-quality) View Geometry Diagram 2-4
Properties Data 3-5
Profiles - Other 4-3 W
Project File Structure 6-3 Warning Messages 3-13
Properties Data 3-5 Welcome Screen 2-3
Properties Data Input 5-3, 5-8
Properties Data Input (Old Style) 5-8 Z
Properties Input 5-5 Zig-zag Diagram 4-3
Properties Output 5-19
Properties Package - Importing 5-18
Properties Used 5-4
Property Data
Liquid 5-4
T-h-x Data 5-4
Vapour 5-4
Property Data Sources 1-6
Property Databanks 5-14
PSF Files 5-15
R
Results Summary 4-3
Run 2-5
Running UniSim PFE 2-5

I-2