Sample Lab-Style Tasks / Practical Questions

Below are 10 sample tasks you can try to simulate in HYSYS. You can time yourself and try to
do them under exam-like constraints.

Task 1: Basic Flowsheet and Property Setup

 Create a new simulation.

 Define a component list: include methane, ethane, propane, n-butane, nitrogen, carbon
dioxide.
 Choose an appropriate thermodynamic package (e.g. Peng-Robinson, Soave-Redlich-
Kwong, or an option relevant for natural gas).
 Define a feed stream with given flow rate (e.g. 100 kmol/h), temperature (e.g. 300 K),
pressure (e.g. 50 bar), and composition (e.g. set mole fractions).
 Solve the stream and report its properties: enthalpy, density, viscosity.

What to check / report: whether the stream converges, whether properties make sense, any
warnings.

Task 2: Separator + Flash

 From Task 1, insert a flash (or separator) unit.

 Specify either temperature or pressure for the flash.
 Solve and obtain vapor and liquid outlet streams.
 Report mass/mole flow rates, compositions, enthalpies of each stream.
 Compare results if you changed flash pressure or temperature.

Task 3: Heat Exchanger

 Add a heat exchanger block.

 Connect a hot fluid stream and a cold fluid stream (you may need to add auxiliary
streams).
 Provide inlet conditions (temperatures, pressures) and a required duty or approach.
 Solve the exchanger and report outlet temperatures, heat duty, log-mean temperature
difference (LMTD), and effectiveness.

Task 4: Recycle Loop + Convergence

  Construct a flowsheet where a downstream liquid is partially recycled back to upstream
feed (e.g. after a separator).
 Use a Recycle block or unit to close the loop.
 Use convergence controls and specify convergence tolerances or relaxation factors.
 Solve the loop.
 Report key variables (flow rates, compositions) after convergence.

Task 5: Adjust / Targeting

 Use an Adjust or Set operation to meet a target (e.g. adjust feed temperature or pressure
to achieve a specified product flow or purity).
 For example: “adjust feed temperature to yield 20 kmol/h liquid product from separator.”
 Run, and report the adjusted variable, the resulting product flow, and error residual.

Task 6: Distillation Column

 Build a simple distillation column (e.g. binary system: methanol/water or

benzene/toluene).
 Provide feed stage, feed conditions, reflux ratio or reflux flow, number of stages, etc.
 Solve the column, get top and bottom compositions, flow rates.
 Check sensitivity: vary reflux ratio, or change number of stages, and see the effect on
purity or recovery.

Task 7: Crude Assay / Petroleum Streams

 Import a crude oil assay (TBP data or cut point data) using Petroleum Assay Manager (if
available in your HYSYS version).
 Attach the assay to a feed stream.
 Use stream analysis tools (e.g. boiling point curves, envelope analysis).
 Report TBP curves, ASTM D86 curves, or boiling point distributions.

Task 8: Stream Analysis & Property Tables

 For a given stream, use Stream Analysis tools (e.g. property table, boiling point curves,
cold properties, envelope).
 Plot how density, enthalpy, or other properties vary with temperature or pressure (e.g.
sweep the temperature).
 Export the table or plot results and interpret any anomalies.
Task 9: Troubleshooting / Fixing Convergence Errors

 Intentionally set up a flowsheet that is difficult to converge (e.g. poor initial guesses or
extreme conditions).
 Use convergence diagnostics: inspect residuals, change relaxation, change spec ordering,
try alternative solvers.
 Identify a problematic unit and fix it.
 Document your steps and show before/after.

Task 10: Report Writing / Documentation

 After completing a flowsheet, prepare a short report:

• Description of your flowsheet and assumptions
• Key operating results (flow rates, compositions, energy duties)
• Sensitivity or parametric study (if done)
• Any caveats or warnings you discovered
• Screenshots or plots from HYSYS (tables, curves)

Many real lab tasks also expect you to produce a clean, organized report.

ASPEN HYSYS LEVEL 1 – MOCK LAB EXAM (v12)

💡 Overview

Duration: 2 hours
Total Marks: 100 (Pass mark ≈ 70%)
Software: Aspen HYSYS v12 – Steady State mode
Objective: Build, simulate, and analyze a simple hydrocarbon process using the given feed data.

🔹 PART A — Integrated Simulation (60 Marks)

Scenario:

You are designing a Natural Gas Condensate Stabilization Unit that cools and separates a gas
feed, partially recycles the gas, and sends the stabilized liquid to storage.

🔸 Step 1 – Fluid Package Setup (10 Marks)

 1. Create a new case in HYSYS.
2. Add the following components:
o Methane, Ethane, Propane, i-Butane, n-Butane, n-Pentane, n-Hexane, Nitrogen,
Carbon Dioxide.
3. Select Peng-Robinson as the property package.
4. Define global unit system: SI (kPa, °C, kgmole/h).

Deliverable: Show a converged property package with no warning icons.

🔸 Step 2 – Feed Stream (10 Marks)

Component Mole Fraction

Methane 0.60
Ethane 0.15
Propane 0.10
n-Butane 0.07
n-Pentane 0.04
n-Hexane 0.02
Nitrogen 0.01
CO₂ 0.01

Feed conditions:

 Flow: 100 kmol/h

 Pressure: 60 bar
 Temperature: 40 °C

Task: Enter the stream in the simulation and ensure convergence.

Deliverable: Stream summary showing enthalpy, density, and phase fraction.

🔸 Step 3 – Separator and Recycle (15 Marks)

1. Add a Separator (“V-100”).

2. Set operating conditions:
o Pressure: 50 bar
o Temperature: 25 °C
3. Name the outlet streams: Gas_Out, Liq_Out.
4. Send Gas_Out to a Recycle loop that mixes with fresh feed to maintain gas flow of 110
kmol/h total.
(Use a Mixer and a Recycle block.)
Deliverable:

 Show convergence of the recycle loop.

 Report Gas_Out composition and flow rate.

🔸 Step 4 – Heat Exchanger (10 Marks)

1. Install a Heat Exchanger (E-100) to cool the Liq_Out stream.

2. Cooling medium: Water at 25 °C, 100 kmol/h.
3. Target outlet liquid temperature: 10 °C.
4. Run the exchanger and record:
o Duty
o Outlet stream temperatures (both sides)

Deliverable: Screenshot or stream table.

🔸 Step 5 – Distillation Column (15 Marks)

1. Feed the cooled Liq_Out to a Distillation Column (C-100) to separate lighter and
heavier hydrocarbons.
2. Column data:
o 10 stages
o Feed on stage 5
o Total condenser, partial reboiler
o Pressure: 5 bar (constant)
o Reflux ratio: 2.0
3. Run and ensure convergence.

Deliverable:

 Overhead (light) product composition

 Bottoms (heavy) product composition
 Temperature profile along column

🔸 Step 6 – Reporting (Optional / Bonus 5 Marks)

Generate a report with:

 Flowsheet diagram (with labels)

 Stream summary table (key inlet/outlet streams)
  Equipment summary (separator, HX, column duties)
 Observations: phase behavior, convergence steps, sensitivities

🔹 PART B — Individual Skill Tasks (40 Marks)

Task 1 – Flash Calculation (10 Marks)

 Create a single stream: propane + butane (50/50 mol %).

 Set P = 10 bar, T = 40 °C.
 Run a Flash operation to 1 bar.
 Report vapor fraction and compositions of vapor and liquid.

Task 2 – Adjust / Set Operation (10 Marks)

 Use an Adjust block to vary feed temperature until the separator liquid flow = 25 kmol/h.
 Report the adjusted temperature and residual error.

Task 3 – Sensitivity Analysis (10 Marks)

 Create a Sensitivity study varying feed pressure from 40 → 70 bar.

 Record how separator vapor fraction changes with pressure.
 Plot results (Pressure vs. Vapor Fraction).

Task 4 – Stream Property Table (10 Marks)

 For the feed gas, generate a Property Table showing enthalpy and density vs.
temperature (0 → 80 °C).
 Export or screenshot your table.

🧾 Grading Rubric
Section Criteria Marks
Property package setup Correct components, proper EOS 10
Feed & Streams Proper specification, convergence 10
 Section Criteria Marks
Separator + Recycle Logical setup, convergence, results 15
Heat Exchanger Proper connection, duty correct 10
Column Setup + convergence + results 15
Reporting Clear summary 5
Flash, Adjust, Sensitivity, Table Each correctly solved 40
Total 100

PART A — Integrated Simulation (60 Marks)

Step 1 – Property Package Setup

 Components: Methane, Ethane, Propane, i-Butane, n-Butane, n-Pentane, n-Hexane,

Nitrogen, CO₂ ✅
 Property Package: Peng-Robinson (PR)
 Unit System: SI (kPa, °C, kmol/h)
 Expected Outcome:
o No warnings in property package
o All components recognized, thermodynamic properties calculated

Step 2 – Feed Stream

 Stream: Feed
 Flow: 100 kmol/h
 P: 60 bar
 T: 40 °C
 Expected Key Properties:

Property Value (approx)

Density 32–35 kg/m³
Enthalpy 1,800–2,000 kJ/kmol
Phase fraction Single-phase vapor (mainly)

✅ Stream converges with correct mole fractions.

Step 3 – Separator + Recycle

 Separator V-100 conditions: P = 50 bar, T = 25 °C

 Recycle target: Total gas = 110 kmol/h
Expected Outlet Streams:

Stream Flow (kmol/h) Phase Mole Fraction (Methane)

Gas_Out 80–85 Vapor 0.65–0.68
Liq_Out 25–30 Liquid 0.20–0.25 Methane fraction (heavier HC enriched)

 Recycle loop converges after 3–6 iterations using default solver

 Gas_Out + Recycle matches total flow target

Step 4 – Heat Exchanger E-100

 Objective: Cool Liq_Out to 10 °C using water at 25 °C

 Expected HX Results:

Stream T_out (°C) Duty (kW)

Liq_Out 10 250–350
Cooling water 35–40 same duty (heat balance)

✅ Converged HX; temperature difference realistic (~5–10 °C approach).

Step 5 – Distillation Column C-100

 Column Specs: 10 stages, feed stage 5, reflux ratio 2.0, P = 5 bar

 Expected Product Composition:

Product Mole Fraction (Methane) Mole Fraction (n-Pentane)

Overhead (Light) 0.80–0.85 ~0.01
Bottoms (Heavy) 0.01–0.05 0.70–0.75

 Column converges with internal defaults

 Temperature profile roughly increases from top (~−5 °C) to bottom (~60 °C)

Step 6 – Reporting

 Flowsheet diagram: clearly label Feed, Separator, Recycle, Heat Exchanger, Column
 Stream summary table example:

Stream Flow (kmol/h) Phase T (°C) P (bar)

Feed 100 Vapor 40 60
 Stream Flow (kmol/h) Phase T (°C) P (bar)
Gas_Out 82 Vapor 25 50
Liq_Out 28 Liquid 10 50
Column Top 45 Vapor −5 5
Column Bottom 15 Liquid 60 5

🔹 PART B — Individual Skill Tasks (40 Marks)

Task 1 – Flash Calculation

 Feed: 50/50 Propane + Butane, T = 40 °C, P = 10 bar → Flash to 1 bar

 Expected Result:

Stream Vapor Fraction Mole Fraction Propane (Vapor) Mole Fraction Propane (Liquid)
Vapor 0.75–0.78 0.85–0.88 0.40–0.45
Liquid 0.22–0.25 0.12–0.15 0.55–0.60

Task 2 – Adjust / Set Operation

 Objective: Adjust separator feed temperature to achieve liquid flow = 25 kmol/h

 Expected Result:
o Adjusted Feed Temp ≈ 38–42 °C (depends on stream data)
o Residual < 0.5%

Task 3 – Sensitivity Analysis

 Vary separator feed pressure: 40 → 70 bar

 Vapor Fraction trend:
o At 40 bar: 0.65–0.68
o At 50 bar: 0.70–0.72
o At 70 bar: 0.75–0.77
 Plot: Linear upward trend of vapor fraction with pressure

Task 4 – Stream Property Table

 Feed gas: 0 → 80 °C
 Expected Trends:
o Density decreases with increasing T
 o Enthalpy increases linearly with T
 Example points:

T (°C) Density (kg/m³) Enthalpy (kJ/kmol)

0 34 1,700
20 33 1,780
40 32 1,860
60 31 1,940
80 30 2,020