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Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Preparing a Steady-State Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Debutanizer Column Specifics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Development of a Control Scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Preparation of Flowsheet for Dynamic Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Implementing and Sizing Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Activating Dynamic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Column Equipment Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Adding and Specifying Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Strip Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Execution of Dynamic Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Implementing Disturbances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Jump Start: Using Aspen HYSYS Dynamics with Columns
Introduction
Columns are an integral part of most processes. They are used to separate components in mixtures where the material
exiting columns often have stringent purity and flow constraints to maintain. It is also important to maintain flow through
columns to ensure safety.
For these reasonsand more, control schemes are usually implemented on columns in order to ensure that variables
such as temperature, pressure, and flow at critical points throughout the column remain constant. Control schemes also
help to maintain product purity and flow, ensuring that acceptable materials exit the column.
In order to obtain working simulation for a column in steady-state operation, Aspen HYSYS can be used. To obtain a
simulation of a column with an implemented control scheme, Aspen HYSYS Dynamics should be utilized. Using both
of these programs in concert provides a comprehensive summary of how a column will perform under varying plant
conditions and perturbations to the columns normal steady-state operation.
This guide will begin with a brief walkthrough of the process for setting up a steady-state column model. The steps
required towards developing and implementing a working control scheme, and studying column dynamic response using
Aspen HYSYS Dynamics, will then be outlined.
Four Aspen HYSYS files come compressed with this guide. The file Debutanizer SS Starter.hsc is the steady-state
simulation for the debutanizer column. Debutanizer Solution RefluxBoilup1 Control Case.hsc is a dynamics-ready file.
This guide will show the steps necessary to add the control equipment to the steady-state debutanizer file that is present
in the LV-1 control case.
In addition, two other alternative control scheme HYSYS files are included. These files are Debutanizer Solution
RefluxBottoms Control Case.hsc and Debutanizer Solution DistillateBoilup Control Case.hsc. The Aspen HYSYS
flowsheet for each of these files and a short description of the control schemes are included in the conclusion section of
this guide.
This document is not meant to be used as a stand-alone reference document. We recommend that a range of other
resources be called upon to give the user a comprehensive view of how to use Aspen HYSYS Dynamics. These may
include:
AspenTech support website (support.aspentech.com) this website has a wealth of information on the use of
AspenTech products and provides answers to frequently asked questions.
AspenTech courseware available in on-line and in-person versions
AspenTech business consultants
This document will show how to prepare a column and analyze its response to varying conditions using Aspen HYSYS
Dynamics. It assumes that the user has Aspen HYSYS V8.0 or higher installed on his or her computer and a functional
process design completed, as well as a very basic knowledge of dynamic simulation using Aspen HYSYS Dynamics.
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Jump Start: Using Aspen HYSYS Dynamics with Columns
For the purposes of this Jump Start Guide, a complete dynamic simulation of a column will be demonstrated utilizing
a previously completed steady-state Aspen HYSYS process involving a debutanizer column. The process developed is
shown in Figure 1.
Vent
Feed2
Reb Duty
Debutanizer
C5+
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Jump Start: Using Aspen HYSYS Dynamics with Columns
Additional required column specifications of the reflux ratio, butane recovery from the condenser, and C5 exiting the
reboiler can be made in the Specs window. For the particular debutanizer column in this guide, the butane recovery is
96.25% and the C5+ in the condenser is set at 2.5%, which makes the percentage of C5+ in the bottoms 97.5%. From
these parameters, Aspen HYSYS calculates a reflux ratio of 3.697 and a molar reflux flow of 777.0 lbmole/hr. Figure 3
shows the Specs window and the setting up of the butane recovery in the condenser.
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Jump Start: Using Aspen HYSYS Dynamics with Columns
Once a steady-state column has been solved in Aspen HYSYS, the user can then continue to develop a control scheme
and add dynamic equipment to the flowsheet in order to begin a dynamic simulation using Aspen HYSYS Dynamics.
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Jump Start: Using Aspen HYSYS Dynamics with Columns
In order to develop an appropriate control scheme, the differentials in temperature between stages were studied under
the column profiles. Stage 5 through stage 11 all have high temperature differentials. For the purposes of this guide, stage
6 was chosen for implementation of the control scheme described in the following section.
Feed1 Flow Feed2 Flow Tray 6 Temperature Mass Fraction i-C5 in Condenser Duty Reboiler Duty
(lb/hr) (lb/hr) (F) Butanes Stream (Btu/hr) (Btu/hr)
The temperature on tray 6 in the debutanizer increased and decreased according to a respective increase or decrease of
the flowrate of the Feed1 stream. Also, with an increase in the flowrate of Feed1, an increase in the i-C5 mass fraction and
decrease of condenser and reboiler duty was observed. For these reasons, the control scheme described in the following
section should be implemented.
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Jump Start: Using Aspen HYSYS Dynamics with Columns
Vent
Valves VLV-100, VLV-101, VLV-102 and VLV-103 need to be sized. This is done by clicking on the Rating tab in the
valve window and then clicking the Size Valve button in the bottom left of the window.
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Jump Start: Using Aspen HYSYS Dynamics with Columns
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Jump Start: Using Aspen HYSYS Dynamics with Columns
In a similar fashion, check the flow specification box for the streams Vent and Reflux. Reflux is located within the
column subflowsheet environment. Also ensure that no dynamic specifications are checked for streams Feed1 and
Feed2.
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Jump Start: Using Aspen HYSYS Dynamics with Columns
To size the trays for the column, open the Tray Section window and then double click the named Tray/Packed Section,
shown in Figure 9. This will open the sizing form for that tray section.
Enter a tray diameter of 4.5 ft, a tray spacing of 1.8 ft, a Weir height of 0.15 ft, and a Weir length of 4.0 ft to complete tray
sizing.
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Jump Start: Using Aspen HYSYS Dynamics with Columns
Tuning
Controller Process Variable Source Output Target Object Action Range
Parameters
After implementing the control scheme from the above table, the flowsheet should then appear as Figure 10 displays
below. For Cond PC and Column TC the control valves on the duty streams need energy ranges specified. To do this, open
the form for the controller and then click on the button labeled Control Valve... at the bottom right of the form. For the
condenser duty, choose a Direct Q duty source instead of From Utility Fluid. For both duty streams control valves,
specify a minimum flow of 1 btu/hr and a maximum flow of 1*107 btu/hr.
Cond PC
Column TC
Cond LC
Reboiler LC
SS Specs
Vent
Cond
Feed1 Duty
FIC
Butanes
To Feed1 Feed1 VLV-102 Butane
VLV-100
Product
Feed2
To Feed2 VLV-101 Reb Duty
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Jump Start: Using Aspen HYSYS Dynamics with Columns
Strip Charts
Strip charts help users to view the results of dynamic simulation to disturbances. Four strip charts are automatically
available under the Dynamics tab once the control scheme is implemented. These strip charts show the liquid percent
level in the condenser and reboiler versus time, the two feed mass flows versus time, condenser pressure and column
stage 6 temperature versus time, and the composition in the Butanes product stream versus time. These strip charts
can be found by clicking the Strip Charts button under the Dynamics header in the ribbon, then selecting the desired
graph, shown in Figure 11.
Figure 12. Navigating to the Dynamics Tab from the Main Ribbon and Running a Dynamic Simulation
If the steps in this guide are followed, the Dynamics Assistant will indicate that there are changes suggested before
running the dynamic simulation. The suggested changes would revert some of the set up steps listed in this guide. Simply
press No when prompted to run the dynamic simulation.
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Jump Start: Using Aspen HYSYS Dynamics with Columns
Implementing Disturbances
Some process modification suggestions to view dynamic response for the control scheme implemented include:
Change the feed flowrate
Change the feed composition
Change the temperature setpoints
Change the pressure setpoints
Change both temperature and pressure setpoints
To change the composition or feed flowrates, once the dynamic simulation has been initialized, the feed streams
definition worksheet can be opened by double clicking the appropriate stream. Then, the streams flow or composition
can be modified. Additionally, flow controller setpoints can be modified to initiate disturbance in the simulation.
To change the setpoints for either temperature or pressure, the controllers Parameters tab can be used or the face
plate for a controller can be opened by double clicking the appropriate controller and selecting the Face Plate option,
shown in Figure 13.
Figure 13. Changing the Setpoint and Opening a Face Plate for a Controller
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Jump Start: Using Aspen HYSYS Dynamics with Columns
In the Parameters tab, the setpoint can be manually typed to the desired value. If the face plate is used, the setpoint can
be modified by dragging the red arrow highlighted in Figure 14.
To test the implemented control scheme, a dynamic simulation was run. After letting the process come to steady-state
operation, the flowrate of the stream To Feed1 was increased from 18,000 lb/hr to 28,000 lb/hr. The control response
was evident in the Feed Flows strip chart, shown below in Figure 15.
Figure 15. Feed Flows Strip Chart from Dynamic Simulation of Debutanizer
The increased flow to 28,000 lb/hr to the column can be seen, as well as a small perturbation to the Feed 2 stream from
the steady-state value of 9000 lb/hr.
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Jump Start: Using Aspen HYSYS Dynamics with Columns
Additional strip charts showing the dynamic response for the simulation can be generated for the temperature on tray 6
of the column and condenser vessel pressure. This strip chart is shown in Figure 16.
Figure 16. Strip Chart Showing Tray 6 Temperature and Condenser Pressure
It can be observed that both the temperature and condenser pressure show fluctuations when the column feed
experienced disturbancebefore each parameter returned to its original value due to the control response.
Figure 17 shows another strip chart for the liquid level percent present in the reboiler and condenser.
Figure 17. Strip Chart Showing Liquid Percent Level in Condenser and Reboiler
For this strip chart, neither the liquid level percent in the reboiler nor the condenser fully reaches its steady-state value of
50% before the feed flow disturbance is activated. However, upon control response, the liquid levels both move towards
their steady-state values.
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Jump Start: Using Aspen HYSYS Dynamics with Columns
Conclusion
Dynamic simulation is a very powerful tool that allows users to view how processes will behave when deviations from
steady-state operation occur. Aspen HYSYS Dynamics is the premier dynamic simulator, combining the simulation power
of Aspen HYSYS with the ability to view rigorous dynamic process response.
Aspen HYSYS Dynamics is especially effective for its use in viewing column dynamic response and exploring various
control schemes to limit steady-state operation deviations in columns. The control scheme shown in this guide is a
reflux-boilup control. Reflux-boilup control responds well to feed disturbances. The reflux flow rate controls the distillate
composition while the heat input to the reboiler controls the bottoms composition.
Other suggestions for control schemes to be implemented on the debutanizer column, as well as the scheme shown in
this guide, are included in Table 3.
Figure 18 shows the flowsheet of Aspen HYSYS file Debutanizer Solution DistillateBoilup Control Case.hsc, which is
an example of Distillate-Boilup control. This Aspen HYSYS file was downloaded along with this guide and is available for
examination and modification inside of Aspen HYSYS and Aspen HYSYS Dynamics.
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Jump Start: Using Aspen HYSYS Dynamics with Columns
To Feed 2
Vent
P/F Specs Pressure Cond PC
P/F Specs Flow
Pressure 198.5 psig
Cond LC Molar Flow 0.0
To Feed 1
Column TC
P/F Specs Pressure
Pressure 199.2 psig Reboiler LC Key Compositions
Vent
Feed 2 FC
Butane Product
Cond Duty P/F Specs Pressure
Distillate-Boilup control is effective for columns operating at high reflux. The distillate flow rate controls the distillate
composition while the heat input to the reboiler controls the bottoms composition.
Figure 19 shows the flowsheet of the Aspen HYSYS file Debutanizer Solution RefluxBottoms Control Case.hsc, which
is an example of Reflux-Bottoms control. This file was also downloaded in conjunction with this guide.
Reflux-Bottoms control is effective when the boilup ratio of a column is high. The reflux controls distillate composition
while the bottoms flow controls the bottoms composition.
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Jump Start: Using Aspen HYSYS Dynamics with Columns
To Feed 2
Vent
P/F Specs Pressure Cond PC
P/F Specs Flow
Pressure 198.5 psig Cond LC
Molar Flow 0.0
To Feed 1
Column TC
P/F Specs Pressure
Pressure 199.2 psig Reboiler LC Key Compositions
Vent
Feed2 FC
Butane Product
Cond Duty P/F Specs Pressure
Butanes Butane Pressure 182.6 psig
To Feed2 Feed2 VLV-102 Product
VLV-100
Liquid Product
To Feed1 Feed1 P/F Specs Pressure
VLV-101
Pressure 186.9 psig
Reb Duty
Feed 1 FC C5+ Liquid Product
Debutanizer VLV-103
In-depth exploration of these control schemes, as well as others that would be appropriate for a users specific process,
ultimately leads to safer and more profitable column operation.
Additional Resources
Public Website:
www.aspentech.com/products/aspen-hysys-dynamics.aspx
Online Training:
www.aspentech.com/products/aspen-online-training
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About AspenTech
AspenTech is a leading supplier of software that optimizes process manufacturingfor energy, chemicals,
pharmaceuticals, engineering and construction, and other industries that manufacture and produce
products from a chemical process. With integrated aspenONE solutions, process manufacturers can
implement best practices for optimizing their engineering, manufacturing, and supply chain operations.
As a result, AspenTech customers are better able to increase capacity, improve margins, reduce costs,
and become more energy efficient. To see how the worlds leading process manufacturers rely on Worldwide Headquarters
AspenTech to achieve their operational excellence goals, visit www.aspentech.com.
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