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Aspen Plus & Aspen

Dynamic Workshop
Driven by Innovation

By: Dinie Muhammad

Presentation Outline
Part 1: Introduction to Aspen Plus
Introduction to AspenONE
Introduction to Flowsheet simulation

What is Aspen Plus?


What Aspen Plus can do?
Aspen Plus extension- Aspen Dynamic
Steady state and Dynamic model dilemma
How Aspen can help me with my research?

Part 2: Before starting with Aspen Plus


Process know how
Process Analysis

Property Method

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Presentation Outline
Part 3: Getting Started with Aspen Plus
Distillation column design
Aspen Analysis

Binary Analysis
Azeotrope Analysis
Design Specs
Sensitivity Analysis
Optimization
Part 4: From Aspen Plus to Aspen Dynamic
Part 5: Aspen Dynamic with Matlab

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PART 1:
INTRODUCTION TO ASPEN

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Introduction to AspenONE
Developed by AspenTech Inc.
Integrated simulation software to implement best practices for:
Process design and modelling
Optimization engineering
Production management
Supply chain operation
Advanced process control

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General Simulation Problem


What is the composition of stream PRODUCT?
RECYCLE

REACTOR
COOL
FEED
REAC-OUT

To solve this problem, we need:

COOL-OUT

SEP

PRODUCT

Material balances
Energy balances
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Flowsheet Simulation
What is flowsheet simulation?
Use of a computer program to quantitatively model the characteristic
equations of a chemical process
Uses underlying physical relationships
Mass and energy balance

Equilibrium relationships
Rate correlations (reaction and mass/heat transfer)

Predicts
Stream flowrate, compositions, and properties
Operating conditions
Equipment sizes

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Flowsheet simulation

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Approaches to Flowsheet Simulation


Sequential Modular
Each unit operation block is solved in a certain sequence
Aspen Plus is a sequential modular simulation program

Equation Oriented
All equations are solved simultaneously
Aspen Custom Modeler (formerly SPEEDUP) is an equation oriented

simulation program

Combination
Aspen

Dynamics (formerly DynaPLUS) uses the Aspen Plus


sequential modular approach to initialize the steady state simulation
and the Aspen Custom Modeler (formerly SPEEDUP) equation
oriented approach to solve the dynamic simulation

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Sequential-Modular
Approach
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Equation Oriented
Approach
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Advantage of Simulation
Reduces plant design time
Allows designer to quickly test various plant configurations

Helps improve current process


Answers what if questions
Determines optimal process conditions within given constraints
Assists in locating the constraining parts of a process

(debottlenecking)

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Good Flowsheeting Practice


Build large flowsheets a few blocks at a time.
This facilitates troubleshooting if errors occur.

Ensure flowsheet inputs are reasonable.


Check that results are consistent and realistic.

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What is Aspen Plus?


Steady state computer-aided chemical process simulation tool

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Aspen Plus Inputs


Choose
Thermodynamic
Models
Specify
Chemical
Components

Process
Flowsheet
Design

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Specify Feed
Conditions

Aspen Plus
Process
Simulation
Model Inputs

Specify
Operating
Conditions

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What Aspen Plus can do?


Flowsheet (default): process simulation (SA and optimization)
Data Regression: fitting data to existing models in Aspen

Property Display: show properties of a components in Aspen Pluss


database
Property Analysis: estimating physical and thermodynamic properties
Assay Data Analysis: analyze assay data (petroleum application)
Property Plus: prepare property package for Aspen Custom Modeler

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Aspen Plus in Process Design & Development

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Aspen Plus Extension: Aspen Dynamic


Dynamic modeling tool for plant operations and process design
Enables users to study and understand the dynamics of real plant
operations
Exported from Aspen Plus steady state model

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Aspen Dynamic Overview

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Adding Dynamic Data


Data is required to calculate the following:
Vessel geometry (required for vessel volume)

Vessel initial filling (used for starting liquid holdup)


Process heat-transfer method
Equipment heat transfer options
Equipment heat capacity
Environmental heat transfer

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Steady state vs. Dynamic dilemma


Steady state
All properties are steady
(not changing over time).
Can be used to study
different steady state
conditions for a specific
range of properties either at
operating conditions or offdesign conditions.

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Dynamic
Ability to model the time
varying behaviour of a
system (changing over time)
Used to analyse the
dynamic behaviour
(response) of complex
systems.

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Advantages of Steady State Simulation


Immediate answers to system condition variation
Determine results at specific conditions

Quick what if in design, sensitivity and optimization studies

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Advantages of Dynamic Simulation


Determine behaviour of plant/system over complete operating range:
start up, shut down, accident scenarios, transition between different
states and disturbances occurrence (what if behaviour)

Can identify in advance if the operating problems occurred


Facilitate the design for control and optimization of process
components to ensure optimum system behaviour, even during off
design and transient behaviour
Design and commission control systems using simulations and just
fine tune during actual installations
Dynamic integrated simulations can help to identify bottlenecks,
inefficiencies and safety risks that are not identifiable with steady-state
or segregated simulation
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Application for SS and Dynamic Simulation

Mcmillan, G. K. (2006). Modeling and Simulation of Processes. In "Process Control And Optimization" (B. G. Liptk, ed.), Vol. 2. CRC Press, Boca Raton, FL.

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How Aspen can help me with my research?


Another option for first principle model (FPM)
Simulation and validation of complex chemical process

Sensitivity analysis and optimization study of process


Study nonlinearity and multiplicity behavior in process
Using Aspen Dynamic & Matlab Simulink for control scheme design

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PART 2:
BEFORE STARTING WITH
ASPEN PLUS

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Process know how


Aspen Plus is not a magic box
All the process inputs (e.g. sizing and process condition) must based
on facts or heuristic justification
A preliminary study of process design in recommended

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Process Analysis
Used to generate simple property diagrams to validate physical property
models and data
Understand the behavior of the process
Diagram Types:
Pure component, e.g. Vapor pressure vs. temperature
Binary, e.g. TXY, PXY

Ternary residue maps

Select Analysis from the Tools menu to start Analysis

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Aspen Property Method


A collection of thermodynamic models and methods used to
calculate physical properties.
Choice of model types depends on degree of non-ideal behavior and
operating conditions
Users can modify existing Property Methods or create new ones

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Case Study - Acetone Recovery


Correct choice of physical property models and accurate physical
property parameters are essential for obtaining accurate simulation
results.

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Ideal vs. Non-Ideal Behavior


What do we mean by ideal behavior?
Ideal Gas law and Raoults law

Which systems behave as ideal?


Non-polar components of similar size and shape

What controls degree of non-ideality?


Molecular interactions

e.g. Polarity, size and shape of the molecules


How can we study the degree of non-ideality of a system?
Property plots (e.g. TXY & XY)

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Comparison of EOS and Activity Models

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Common Property Methods


Equation of State Property Methods
PENG-ROB
RK-SOAVE

Activity Coefficient Property Methods


NRTL
UNIFAC
UNIQUAC
WILSON

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Choosing a Property Method - Review

References:
Aspen Plus User Guide, Chapter 7, Physical
Property Methods, gives similar, more detailed
guidelines for choosing a property Method.

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PART 3:
GETTING STARTED WITH
ASPEN PLUS

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Aspen User Interface


Run ID

Title Bar
Menu Bar

Next Button Tool Bar

Select Mode
button

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Model
Library

Model Menu
Tabs

Status Area
Process
Flowsheet
Window

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Case Study
Design a distillation process to separate isobutane and propane so
that the impurity target in distillate is 2 wt% and in bottom is 1 wt%

Feed:
Propane (40%)
Isobutane (60%)
Flowrate: 100 kg/h
Temperature: 322 K (48.85C)
Pressure: ?
Feed at Stage 16
Reflux ratio = 2
Number of Stages = 32 (reboiler + sump)
Number of Trays = 30
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Overview of case study


C3 0.98 wt%
iC4 0.02 wt%
C3 0.4 wt%
iC4 0.6 wt%

C3 0.01 wt%
iC4 0.99 wt%
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How to begin?
Develop the distillation
column system
Specify the C3 and iC4
in component selection
Choose a suitable
property method

Define feed condition

Specify a reasonable
operating condition

Run and check the


results
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Columns - Shortcut

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Columns - Rigorous

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Develop the distillation column system


Valve (pressure
changer library)

Pump (pressure
changer library)
Distillation column
RadFrac (separator library)
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Connect all the blocks

Connect all the red input and


output (primary stream)
Select material stream to insert
stream in the flowsheet
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A complete distillation system


P12
FEED

V12

DIST

C1

V1
Rename all
the blocks
and streams

P11
BOTM

V11

Click the NEXT button


and this dialog menu
will appeared. Click OK
to proceed.
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Fill the specification menu

Select unit measurement


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Note:
You can also use your own set of unit
by using Unit-Sets option under the
Setup Menu

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Edit Report Options

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Click the NEXT button

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Specify the component

Click the NEXT button


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Use the Find


button to search
the components
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Select the property method

Select Chao-Seader
property method

Click the NEXT button


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Define the FEED stream

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How to calculate the pressure in FEED?


Cooling water at condenser is expected to be at 305 K (31.85C)
Heuristic temperature different for heat transfer in condenser is 20 K

Therefore, the reflux drum temperature is ~ 325 K


Vapor pressure for C3 at 325 K is ~ 14 atm
Assume the pressure drop in the V1 is 5 atm
So, FEED stream pressure > 19 atm
In this case, FEED pressure is selected at 20 atm

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Distillation column setup (Configuration)

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Distillation column setup (Stream)

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Distillation column setup (Condenser)

Heuristic pressure
drop in column =
0.0068 atm

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Click the NEXT button

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Pump 11 and Pump 12 Setup

Click the NEXT button


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Use pressure increase


6 atm for all pump
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V1 Setup

Use outlet
pressure option
= 14.2 atm

Choose Liquid-Only
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Click the NEXT button

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V12 and V13 Setup

Use Pressure
drop option
= 3 atm

Choose Liquid-Only
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Click the NEXT button

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Run the simulation

Click OK to run the simulation

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The simulation run complete

Result completed normally

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Status Indicators

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Check the results (Stream summary>>Streams)


Select the
wanted
streams

The overall
result is still
not achieve
target

Adjust to
STREAMS
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Redesign: RR = 3
Operating condition for RR is changed from 2 to 3
Reinitialize the simulation and Run again

Reinitialize button

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Check the results (Stream summary>>Streams)

Separation
target achieved

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Analysis Using Aspen Plus


Binary Analysis This tool will examine and plot the binary
interaction between components.
Azeotrope Analysis To determine whether the mixture is azeotrope
mixture or not
Design Spec - This tool will help the user to achieve the production
target by varying the specified operating condition.
Sensitivity Tool This tool will help the user to analysis the effect of
specified operating condition over a certain region towards the
production target.

Optimization This tool will produce the optimized value for the
operating condition in order to achieve the desired production target.
This tool will automatically change the selected operating value to an
optimized value after Run.
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ANALYSIS:
BINARY ANALYSIS

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Find Binary Analysis Menu

Access the Binary Analysis


Menu under Tools Menu

Click OK to continue

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Binary Analysis Menu

Select type
of analysis

Select Unit
and list/range
for Pressure
variation

Select basis
component

Property
Method

Click GO to
start analysis

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Analysis Result
Txy Graph

Use Plot Wizard


to plot other type
of graphs e.g. xy
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Full
results
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ANALYSIS:
AZEOTROPE ANALYSIS

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Azeotrope Analysis Menu

Select the menu

In this case, consider a feed of water and


isopropane mixture to be analyzed. Here,
the property method selected is SRK

Mixture Block
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Menu
Click the desired
component

Select the
Pressure basis

Finally, click the


Report option to
get the analysis

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Select Property
method and
mixture phase

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Azeotrope Report

Azeotrope exist!
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The xy graph

azeotrope point

xy graph of water and isopropane mixture (from Binary Analysis)


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ANALYSIS:
DESIGN-SPEC

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Choose the Design-Spec Menu

Design Spec and


Vary (below) menu
in the explorer

Create new ID
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Design Spec Tab Information


Specification define the target to be achieve in the simulation e.g.
99% composition in distillate stream
Components specify the target component
Feed/Product Streams - specify the target components stream

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Specification Tab
Select type
of target

Specify target
value

In this case, a mass purity target of 0.99% is desired

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Click the NEXT button

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Components Tab

Select the target


component from
available
components

Propone is selected as the target component

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Click the NEXT button

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Feed/Product Streams Tab

Specify the target


stream from the
available streams

Since the C3 product stream is at the top, thus


the distillate stream is selected
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Click the NEXT button

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Vary Menu: To specify the varying variable for


Design-Spec

Vary Menu
Create new ID

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Specification Tab
Select the varying variable
to be used. Must be a
variable from the specified
operating conditions

Select a reasonable
lower and upper
bound

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Click the NEXT button

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Run the simulation

Click OK to start the simulation

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Check result in Vary Menu


Select the
Results Tab

The final value of RR to achieve


99%C3 purity is 2.87

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ANALYSIS:
SENSITIVITY STUDY

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Select: Sensitivity Study

Select the Sensitivity


option from Model
Analysis Tool

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Sensitivity Study Tab Information


Define: The user need to define the variable to be used as the
production/simulation target.
Vary: Choose the a variable from the specified operating conditions
to be varied over selected region.
Tabulated: Choose how the data will be tabulated. Usually, varied
operating conditions vs. target value responses

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Insert new variable

Click New and enter a name


for the target variable

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Select the target variable

In this case, we want


to specify the C3 mass
concentration in the
distillate stream as the
Target variable

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Click the NEXT button

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Select the Vary Variable

Use search option


to find the RR

In this case, the Reflux


ratio (RR) is selected to be
the Vary variable. The RR
variable can be selected by
specify C1 (the column)
under Block-Var (Block
variables).

Specify range: Lower and Upper boundary.


Specify the number of point to be plotted
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Tabulate the variables


Click Fill variables button
as Aspen will automatically
tabulated all the variables.

Click the NEXT


button and OK
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Check result

Choose Results. Make sure all the


result is completed and converged
(blue tick on the explorer)

Results summary
for C3 composition
by varying RR

Full results is
available here
under S-1 label

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How to plot results in Aspen

Select the RR column


in results summary

Click Plot from menu bar.


Specify as X-axis.
Repeat the same procedure for C3 result. Finally,
click the Display Plot under the same Plot menu
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The Sensitivity analysis results

The figure show the effects of varying


the RR towards C3 composition.
Based on the figure, the best RR value
to achieve the highest C3 purity would
be around RR=4

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ANALYSIS:
OPTIMIZATION

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Select Optimization Menu

Optimization menu

Click New to
create a new ID

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Define Tab

Click New to define a


New optimization value

Enter the target variable


name and Click OK

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Define the Target variable

Specify the Target


variable
The optimization target variable is C3
mass purity in the distillate stream

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Click the NEXT button

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Objective & Constraints Tab


Specify the previously defined
variable name in the Define Tab

Select max
or min
Constraint can also be
specified in the
Constraint Menu

C3 composition is optimized to find the max purity

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Vary Tab
Specify number of
varying variable

Select and specify


the varying variable

Specify lower and


upper boundary

RR is varied from 0.5 to 5 to find the max


mass purity for C3 distillate product

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Click the NEXT button

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Run the simulation

Click OK to start the simulation

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Check the results: Final C3 composition

Final value shows the max C3 distillate


product composition can be achieved
within the specified boundary

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Check the results: New optimized RR value

The optimized RR value in


the C1 Results Summary

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PART 4: FROM ASPEN PLUS


TO ASPEN DYNAMIC
Steady State to Dynamic Simulation

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Using the same example:


A commonly used heuristic is to set these holdups to allow for 5 min of
liquid holdup when the vessel is 50% full, based on the total liquid
entering or leaving the vessel (Luyben, 2006)
100% full = 10 minutes of volume flowrate
From Hydraulic Tab:
Reflux drum volume = 0.00800586 m3/min (10min) = 0.0801 m3
Sump volume = 0.00216335 m3/min(10min) = 0.0216 m3

*Please refer to slide18 &19 for explanation on dynamic properties


Luyben, W. L. (2006). "Distillation Design and Control using Aspen Simulation," Wiley, New York.

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From Hydraulic Tab: Stage 1 => Reflux drum


volume i.e. sum of Reflux and distillate flowrate

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From Hydraulic Tab: Stage 32 => sump level i.e.


liquid entering reboiler from bottom tray

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Calculate the vessel geometry

Reflux drum: L = 0.9718m; D = 0.3239 m


Sump: L = 0.6279 m; D = 0.2093 m
L=length; D=diameter
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Vessel Geometry

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Entering the dynamic properties

Click this button to enter


the dynamic properties

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Click the NEXT button

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Enter the dynamic properties in the column


configuration: Reflux drum and Sump Sizing

Enter the calculated


Length and Diameter for
Reflux Drum and Sump

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Click the NEXT button

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Entering the properties for Hydraulic


calculation inside the column

Choose Rigorous
Tray Calculation

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Click the NEXT button

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Additional Info
Simple Tray: Using simple tray hydraulics equation relates the liquid
flow rate from a tray to the amount of liquid on the tray. Here, the
Francis weir equation for a single pass tray is used.

Rigorous: The pressure drop across the tray is calculated by the


same rigorous methods used for the steady-state simulation. The
Francis weir equation is used to model the hydraulics based on the
number of passes and tray geometry specified in the steady-state
simulation.

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Tray Rating

Since we are using Rigorous Tray


Calculation, we need to specify the Tray
Rating (so that Aspen Plus can perform the
pressure drop calculation along the trays)

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Specify Tray Rating

Click New and enter


any ID number

Select Tray Rating


menu under the C1

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Specify Tray Rating


Enter the starting stage = 2
and End stage = 31
(In Aspen Plus; Stage1 =
Condenser and Stage 32 =
Reboiler)
Enter the tray diameter, Tray type,
Tray spacing and weir heights

Note: Default value for


Tray spacing = 0.6069 m
weir heights = 0.05 m

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Pressure Drop profile

In order for the Aspen Plus to


calculate and update the Pressure
Drop profile inside the column, this
box must be tick

Click the NEXT button and RUN the simulation


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Export to Dynamic (Flow Driven)

Click this icon for export our model


into dynamic state (flow driven).
A menu will pop up to rename and
save the model. Just click OK.

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Additional Note:
Aspen provide two type of dynamic simulation i.e. flow driven and
pressure driven. The icon for pressure driven simulation is just next to
the flow driven in the menu. In the author experience, flow driven
simulation is much simpler to develop compared to the pressure
driven. Once the simulation is completed with no error, the simulation
is ready to be export to the dynamic states in flow driven.
However, for pressure driven, all the pressure inside the streams in
steady state model must be control by using pump or valve and its
pressure must appropriate. There are also problem (depends) with
irregular pressure drop inside the column and inconsistence pressure
in feed and recycle stream. Use the Pressure checker icon to check
the pressure within the SS model. Refer Process Simulation and
Control Using Aspen by AK Jana.
Pressure Checker
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Find the saved file .dyn file


Click the saved file from previous
menu. Generally, the file is saved
in the same folder as the SS
simulation file

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Entering Aspen Dynamic (or Custom Modeler)

Choose the state


of simulation:
Dynamic or
Steady-state. Run
Initialization at
before starting
dynamic
simulation

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If all goes right, you should get


this figure. Notice that in Aspen
Dynamic, the basic controller is
already implemented. These
control loops are important to
operate the column properly.
Click this set of
icons to
run/pause/rewind
(or restart) the
simulation

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Additional Info:
For distillation system, there are 3 major control loop that are
essential to operate the column:1.

Top / Condenser Pressure control loop control energy balance

2.

Reflux drum Level control loop control mass balance (top)

3.

Sump Level control loop control mass balance (bottom)

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See simulation result


Run the simulation.
Right click top product
stream. Select Forms
and click TPFmPlot

During running
the simulation,
this panel will
show the latest
calculation step

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Results in real time form

This panel
display the
mass flowrate,
pressure and
temperature for
the top product
stream in real
time. Use Zoom
Full option for
clearer plot.

Although the graph is


not steady, notice that
the difference (in each
parameter) is very small.
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Specify custom parameter (e.g. Propane purity in top


product stream)

#2 Name form
and choose Plot
option

#1 Select Tool in
the top menu.
Click New Form

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#3 The plot
figure with no Y
axis value

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Specify
parameter
(e.g. Propane purity in top
Specifycustom
specific
parameter
product stream)
#4 Right click top stream and
choose Results in the Forms option

#5 From Results Table, drag the


highlighted row (Propane purity) into
the Y axis of the plot. The final figure
should be like the one on the left. Run
the simulation in dynamic mode.

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Specify custom parameter (e.g. Propane purity in top


product stream)
#6 We can now know the
Propane composition in
Distillate Stream in real time

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PART 5: ASPEN DYNAMIC


WITH MATLAB SIMULINK

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Getting Started with Aspen-Matlab


Basically, AspenTech had made a collaboration with Mathworks to
develop the AMS simulation system to connect Aspen Dynamic with
Matlab Simulink

However, there might be some compatibility issues regarding Aspen


and Matlab version. Please refer to Aspen Help. Based on the author
experiences:
Aspen V7.2 compatible with Matlab 2009
Aspen V7.3 compatible with Matlab 2010

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Use Aspen Dynamic Examples


As an example, we are using the Simulink file in the Aspen Dynamic
Examples
Find the Aspen Dynamic instillation folder. Inside the folder, find the
Examples folder. Inside the example folder, click the Simulink folder;
C:\Program Files\AspenTech\Aspen Plus Dynamics V7.2\Examples
Click the MCH file (Simulink) as shown below:

Note: MCH is a simulation


of extractive distillation of
methylcyclohexane and
toluene using phenol as
an entrainer.

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127

The MCH simulation in Simulink

AM-Simulation
Block
Notice that there are 4 control loops
that are controlling the MCH column.
Now, input s form the Aspen Dynamic
(via AMS Block) is supplied to the
controller block. Then, the controller
action is computed in Simulink and
returned back to the Aspen Dynamic
for further action.
D. Muhammad & AspenTech, 2013

A step input
block act as the
disturbance

128

Configure AMSimulation Block


Click the AMSimulation Block
to open this menu

Use Browse to
find the .dynf
(Aspen Dynamic)
file
Click Connect
to link with Aspen
Dynamic

Input & Output represent the variables


that being used in the AMS Block. Input
refer to the input that is supplied to the
Aspen Dynamic model (e.g. MV or DV).
Output refer to the process variable (i.e.
PV) that is produced from the model.
D. Muhammad & AspenTech, 2013

MCH Model in
Aspen Dynamic
129

AMSimulation file
Follow the link

Before begin the Aspen-Matlab


simulation, it is advised that we
copy the AMSimulation file (mfile format) into the current
working folder (in Matlab) . The
file is generally located inside
the AMSystem folder in the
Aspen installation folder.

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130

Running the simulation


Scope
Aspen
Dynamic

Simulink

Click RUN button in the Simulink to run the


simulation
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131

How they work?

AM-Simulation

Compute and provide


controller action
(decide the MV)

Matlab
Simulink
D. Muhammad & AspenTech, 2013

Provide simulation
data and result
(present the PV)

Aspen
Dynamic
132

What happen?
Based on the previous figure (after running the simulation), Matlab
Simulink had provided the initial Input (SS or initial value) for the
Aspen Dynamic Model. Then, the input is processed (or calculated) by
Aspen Dynamic to provide the current process variable (PV) values.
The process variables is send back to Simulink environment via AMS
Output.
Based on the output that we had selected (in the AMS box), the
output will provide the latest PV for Simulink Matlab to calculate its
next MV. The new MV is then supplied back to the Aspen Dynamic via
AMS Input and so on.
One of the ways to set the initial value for the Aspen Dynamic is by
using the unit delay box in Matlab Simulink.

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133

Simulation Time
In the author opinion, it is important to synchronize the Aspen
Dynamic and Matlab Simulink simulation time.
This can be done via RUN (in the menu bar) >> Run Option or select
F9.

Adjust the time


units to match
both simulation
time

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134

Simulation model vs. predictive model

u(k)

Simulation Model
(Aspen Dynamic)

y(k)

u(k)

Predictive
Model

y(k+1)

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135

Special Thanks
Assoc. Prof Dr. Norashid Bin Aziz (USM)
Assoc. Prof Dr. Zainal Bin Ahmad (USM)

Imam Mujahidin Iqbal, Msc (USM)


Process Control Research Group (PCRG) USM

D. Muhammad & AspenTech, 2013

E: annursi@gmail.com

136

END OF PRESENTATION

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137

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