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Aspen HYSYS and Process Modeling



This training program provides participants with the skills to effectively use Aspen HYSYS software for process simulation and modeling. It enables participants to address real-world engineering challenges and enhance process performance.

Program Objectives:

At the end of this program, participants will be able to:

  • Gain proficiency in building, navigating, and optimizing process simulations using Aspen HYSYS, including advanced steady-state simulations.

  • Utilize various HYSYS functions efficiently to construct comprehensive process flowsheets, leveraging intuitive solving capabilities for rapid model development.

  • Explore multi-flowsheet integration to streamline and organize simulation efforts effectively, using Workbook and Flowsheet interfaces for quick modeling.

  • Enhance convergence characteristics of columns and flowsheets, troubleshoot common issues, and improve simulation accuracy.

  • Utilize Aspen HYSYS's rating capabilities to evaluate the performance of existing equipment and determine optimum operating points through case studies.

  • Learn pipeline hydraulics calculations essential for assessing sizing requirements in gas gathering systems.

  • Discover effective methods for reporting simulation results, including the use of Microsoft Excel VB macros, to communicate findings efficiently.

Targeted Audience:

  • Process Engineers with Process simulation experience.

  • New engineering graduates/technologists who will be using Aspen HYSYS in their daily work.

  • Process engineers doing process design and optimization projects and studies.

  • Plant engineers checking plant performance under different operating conditions.

  • R&D engineers and researchers using Aspen HYSYS for process synthesis.

Program Outlines:

Unit 1:

Propane Refrigeration Loop:

  • Add and connect operations to construct a simple flowsheet.

  • Use the graphic interface to manipulate flowsheet objects and provide a clearer representation of the process.

  • Understand how to process information has propagated both forwards and backward.

  • Convert simulation cases to templates.

  • Build and analyze a propane refrigeration loop simulation.

Unit 2:

Refrigerated Gas Plant:

  • Install and converge heat exchangers.

  • Use logical operations: Adjust and Balance.

  • Model a simplified version of a refrigerated gas plant.

Unit 3:

NGL Fractionation Train:

  • Model distillation columns with the assistance of the Column Input Expert.

  • Manipulate column specifications to better represent process constraints.

  • Evaluate utility requirements using the Process Utility Manager.

  • Model a two-column natural gas liquid (NGL) recovery plant.

Unit 4:

Oil Characterization and HP Separation:

  • Introduce Oil Characterization in Aspen HYSYS.

  • Use the Aspen HYSYS Spreadsheet and Case Study functionality.

  • Use the Oil Environment to characterize a crude assay and then employ the Case Study and Spreadsheet operation to determine how the Gas Oil Ratio (GOR) varies with pressure.

Unit 5:

Gas Gathering System:

  • Simulate a gas gathering system located on varied terrain using the steady-state capabilities of Aspen HYSYS.

  • Use the pipe segment and the Hydraulics subflowsheet to model a piping network in Aspen HYSYS.

Unit 6:

Two-Stage Compression:

  • Introduce the use of the recycling operation.

  • Recognize suitable recycling locations.

  • Implement performance curves for rotating equipment.

  • Utilize the recycle operation to build a two-stage compression flowsheet; define and activate compressor curves.

Unit 7:

Natural Gas Dehydration with TEG:

  • Review the recommended methods to saturate single-phase and two-phase hydrocarbon streams.

  • Discuss the implications of hydrate formation and the different means available to avoid hydrate problems.

  • Model a typical TEG dehydration unit.

  • Model a typical TEG dehydration unit and determine water dew point for the dry gas; use the hydrate utility to investigate the effects of methanol injection on hydrate inhibition.

Unit 8:

Rating Heat Exchangers:

  • Review heat transfer calculation models in Aspen HYSYS.

  • Configure a shell and tube heat exchanger to use a built-in Rating model.

  • Integrate rigorous Exchanger Design and Rating (EDR) calculations into an Aspen HYSYS flowsheet.

  • Use a Rating model to determine if an existing heat exchanger will meet process specifications; design and rate a heat exchanger using the EDR interface inside Aspen HYSYS.

Unit 9:

Troubleshooting / Best Practices:

  • Introduce best practices for product integration and automation.

  • Investigate the reasons why a simulation may produce poor results, consistency errors, etc.

  • Identify appropriate thermodynamic models for common processes.

  • Use suggested tips to debug simulations and columns.

  • Troubleshoot existing Aspen HYSYS cases; recognize common problem areas in an Aspen HYSYS case.

Unit 10:

Reporting in Aspen HYSYS:

  • Create a variety of customized reports using newly added functionality in the Report Manager.

  • Access free Excel utilities designed to extract simulation data.

  • Use Aspen Simulation Workbook to deploy models in Microsoft Excel.

  • Use the Report Manager, Excel utilities, and Aspen Simulation Workbook to obtain custom reports.

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