Process Modeling & Simulation Lab Report
Experiment # 06:
Procedure:
1. I Start the Aspen HYSYS software and select the "New" option to initialize a
blank simulation environment for the assigned problem.
2. In the Properties environment, navigate to the "Component Lists" folder in the left pane to
prepare for adding the chemical components required for the gas stream.
3. I accessed the "Component Lists" folder and searched the HYSYS databanks to set up the
simulation. From there, I added the required components: Ethane, Propane, i-Butane, and
n-Butane.
4. I navigated to the "Fluid Packages" folder to assign a property package for the simulation.
From the available options, I selected "Peng-Robinson" to accurately model the
thermodynamic behavior of the selected gas components.
5. I switched to the Simulation environment and added a compressor unit to the main
flowsheet. I then configured its connections by defining the "inlet", "outlet", and "comp Q"
energy streams.
6. I accessed the Parameters tab under the compressor's Design section to review its
operating specifications. This allowed me to verify key variables such as the adiabatic
efficiency, calculated duty, and pressure change.
7. I opened the Worksheet tab for the compressor to check the Conditions of the inlet and
outlet streams. This allowed me to verify the changes in temperature, pressure, and flow
rates across the equipment.
8. I accessed the Composition section under the compressor's Worksheet tab to verify the gas
mixture. This allowed me to confirm the mole fractions of Ethane, Propane, i-Butane, and
n-Butane for both the inlet and outlet streams.
9. I added a Cooler unit to the flowsheet and configured its connections. I assigned the
compressor's "outlet" as the inlet, "w" as the energy stream, and "cool gas" as the cooling
outlet stream.
10. I navigated to the Parameters section under the Cooler's Design tab to set the pressure
drop (Delta P) to 0.0000 bar. This allowed the system to successfully calculate the required
cooling duty and the resulting temperature change (Delta T).
11. I added a Separator unit to the flowsheet and configured its connections by setting "cool
gas" as the inlet stream. I then defined the vapor outlet as "top" and the liquid outlet as
"bottom" to collect the separated phases.
12. I accessed the Parameters section under the Separator's Design tab to configure the
vessel's pressure settings. I set the pressure drop (Delta P) for both the inlet and vapour
outlet to 0.0000 bar.
13. I navigated to the Composition section under the Separator's Worksheet tab to review the
final separation results. This allowed me to verify the calculated mole fractions for each
component in both the top vapor and bottom liquid streams.
14. I accessed the Conditions section under the Separator's Worksheet tab to evaluate the final
physical properties of the streams. This allowed me to determine the exact temperature,
pressure, and mass flow rates for both the separated top vapor and bottom liquid products.
15. I reviewed the fully assembled main flowsheet to visually verify that the compressor,
cooler, and separator were properly interconnected with all necessary material and energy
streams.
16. I examined the flowsheet specifically focusing on the compressor unit (Ch-13) to confirm
that its inlet, outlet, and energy streams were correctly placed and established.
17. I examined the updated flowsheet to ensure the compressor and cooler units were properly
connected. This visual verification confirmed that the gas stream routed correctly from the
compressor's outlet into the cooler.
Results:
The Aspen HYSYS simulation established the mass flow rates for the separated product streams:
the top vapor stream flows at 1070 kg/hr, while the bottom liquid stream flows at 3312 kg/hr.
Additionally, the software successfully computed the final component compositions (mole
fractions) for ethane, propane, i-butane, and n-butane within both the vapor and liquid phases.
Discussion:
This practical exercise highlighted the method for evaluating essential process parameters such
as component compositions and flow rates across standard industrial stages like compression,
cooling, and phase separation. Constructing a process flow diagram (PFD) in Aspen HYSYS
enables the accurate calculation of previously unknown variables, including the cooler's outlet
temperature, the compressor's discharge pressure, and the phase separator's output conditions.
Utilizing simulation software enhances overall process efficiency and conserves time by allowing
users to observe how modifying specific operating conditions impacts the entire system.