- Facilitates the process of learning and later mastering Aspen Plus® with step by step examples and succinct explanations
- Step-by-step textbook for identifying solutions to various process engineering problems via screenshots of the Aspen Plus® platforms in parallel with the related text
- Includes end-of-chapter problems and term project problems
- Includes online exam and quiz problems for instructors that are parametrized (i.e., adjustable) so that each student will have a standalone version
- Includes extra online material for students such as Aspen Plus®-related files that are used in the working tutorials throughout the entire textbook
Table of Contents:
Preface xvii
The Book Theme xix
About the Author xxi
What Do You Get Out of This Book? xxiii
Who Should Read This Book? xxv
Notes for Instructors xxvii
Acknowledgment xxix
About the Companion Website xxxi
1 Introducing Aspen Plus 1
1.1 What Does Aspen Stand For? 1
1.2 What is Aspen Plus Process Simulation Model? 2
1.3 Launching Aspen Plus V8.8 3
1.4 Beginning a Simulation 4
1.5 Entering Components 14
1.6 Specifying the Property Method 15
1.7 Improvement of the Property Method Accuracy 23
1.8 File Saving 38
Exercise 1.1 40
1.9 A Good Flowsheeting Practice 40
1.10 Aspen Plus Built-In Help 40
1.11 For More Information 40
Homework/Classwork 1.1 (Pxy) 41
Homework/Classwork 1.2 (ΔGmix) 42
Homework/Classwork 1.3 (Likes Dissolve Likes) as Envisaged by NRTL Property Method 42
Homework/Classwork 1.4 (The Mixing Rule) 44
2 More on Aspen Plus Flowsheet Features (1) 49
2.1 Problem Description 49
2.2 Entering and Naming Compounds 49
2.3 Binary Interactions 51
2.4 The “Simulation” Environment: Activation Dashboard 53
2.5 Placing a Block and Material Stream from Model Palette 53
2.6 Block and Stream Manipulation 54
2.7 Data Input, Project Title, and Report Options 56
2.8 Running the Simulation 58
2.9 The Difference Among Recommended Property Methods 61
2.10 NIST/TDE Experimental Data 62
Homework/Classwork 2.1 (Water–Alcohol System) 65
Homework/Classwork 2.2 (Water–Acetone–EIPK System with NIST/DTE Data) 66
Homework/Classwork 2.3 (Water–Acetone–EIPK System Without NIST/DTE Data) 69
3 More on Aspen Plus Flowsheet Features (2) 71
3.1 Problem Description: Continuation to the Problem in Chapter 2 71
3.2 The Clean Parameters Step 71
3.3 Simulation Results Convergence 74
3.4 Adding Stream Table 76
3.5 Property Sets 78
3.6 Adding Stream Conditions 82
3.7 Printing from Aspen Plus 83
3.8 Viewing the Input Summary 84
3.9 Report Generation 85
3.10 Stream Properties 87
3.11 Adding a Flash Separation Unit 88
3.12 The Required Input for “Flash3”-Type Separator 90
3.13 Running the Simulation and Checking the Results 91
Homework/Classwork 3.1 (Output of Input Data and Results) 92
Homework/Classwork 3.2 (Output of Input Data and Results) 93
Homework/Classwork 3.3 (Output of Input Data and Results) 93
Homework/Classwork 3.4 (The Partition Coefficient of a Solute) 93
4 Flash Separation and Distillation Columns 99
4.1 Problem Description 99
4.2 Adding a Second Mixer and Flash 99
4.3 Design Specifications Study 101
Exercise 4.1 (Design Spec) 105
4.4 Aspen Plus Distillation Column Options 106
4.5 “DSTWU” Distillation Column 107
4.6 “Distl” Distillation Column 111
4.7 “RadFrac” Distillation Column 113
Homework/Classwork 4.1 (Water–Alcohol System) 120
Homework/Classwork 4.2 (Water–Acetone–EIPK System with NIST/DTE Data) 125
Homework/Classwork 4.3 (Water–Acetone–EIPK System Without NIST/DTE Data) 127
Homework/Classwork 4.4 (Scrubber) 128
5 Liquid–Liquid Extraction Process 131
5.1 Problem Description 131
5.2 The Proper Selection for Property Method for Extraction Processes 131
5.3 Defining New Property Sets 136
5.4 The Property Method Validation Versus Experimental Data Using Sensitivity Analysis 136
5.5 A Multistage Extraction Column 142
5.6 The Triangle Diagram 146
References 149
Homework/Classwork 5.1 (Separation of MEK from Octanol) 149
Homework/Classwork 5.2 (Separation of MEK from Water Using Octane) 150
Homework/Classwork 5.3 (Separation of Acetic Acid from Water Using Isopropyl Butyl Ether) 151
Homework/Classwork 5.4 (Separation of Acetone from Water Using Trichloroethane) 151
Homework/Classwork 5.5 (Separation of Propionic Acid from Water Using MEK) 152
6 Reactors with Simple Reaction Kinetic Forms 155
6.1 Problem Description 155
6.2 Defining Reaction Rate Constant to Aspen Plus® Environment 155
6.3 Entering Components and Method of Property 157
6.4 The Rigorous Plug-Flow Reactor (RPLUG) 159
6.5 Reactor and Reaction Specifications for RPLUG (PFR) 161
6.6 Running the Simulation (PFR Only) 167
Exercise 6.1 167
6.7 Compressor (CMPRSSR) and RadFrac Rectifying Column (RECTIF) 168
6.8 Running the Simulation (PFR + CMPRSSR + RECTIF) 171
Exercise 6.2 172
6.9 RadFrac Distillation Column (DSTL) 172
6.10 Running the Simulation (PFR + CMPRSSR + RECTIF + DSTL) 174
6.11 Reactor and Reaction Specifications for RCSTR 175
6.12 Running the Simulation (PFR + CMPRSSR + RECTIF + DSTL + RCSTR) 179
Exercise 6.3 180
6.13 Sensitivity Analysis: The Reactor’s Optimum Operating Conditions 181
References 188
Homework/Classwork 6.1 (Hydrogen Peroxide Shelf-Life) 189
Homework/Classwork 6.2 (Esterification Process) 192
Homework/Classwork 6.3 (Liquid-Phase Isomerization of n-Butane) 194
7 Reactors with Complex (Non-Conventional) Reaction Kinetic Forms 197
7.1 Problem Description 197
7.2 Non-Conventional Kinetics: LHHW Type Reaction 199
7.3 General Expressions for Specifying LHHW Type Reaction in Aspen Plus 200
7.3.1 The “Driving Force” for the Non-Reversible (Irreversible) Case 201
7.3.2 The “Driving Force” for the Reversible Case 201
7.3.3 The “Adsorption Expression” 202
7.4 The Property Method: “SRK” 202
7.5 Rplug Flowsheet for Methanol Production 203
7.6 Entering Input Parameters 203
7.7 Defining Methanol Production Reactions as LHHW Type 205
7.8 Sensitivity Analysis: Effect of Temperature and Pressure on Selectivity 216
References 219
Homework/Classwork 7.1 (Gas-Phase Oxidation of Chloroform) 220
Homework/Classwork 7.2 (Formation of Styrene from Ethylbenzene) 222
Homework/Classwork 7.3 (Combustion of Methane Over Steam-Aged Pt–Pd Catalyst) 225
8 Pressure Drop Friction Factor ANPSH and Cavitation 229
8.1 Problem Description 229
8.2 The Property Method: “STEAMNBS” 229
8.3 A Water Pumping Flowsheet 230
8.4 Entering Pipe, Pump, and Fittings Specifications 231
8.5 Results: Frictional Pressure Drop, the Pump Work, Valve Choking, and ANPSH Versus RNPSH 237
Exercise 8.1 238
8.6 Model Analysis Tools: Sensitivity for the Onset of Cavitation or Valve Choking Condition 242
References 247
Homework/Classwork 8.1 (Pentane Transport) 247
Homework/Classwork 8.2 (Glycerol Transport) 248
Homework/Classwork 8.3 (Air Compression) 249
9 The Optimization Tool 251
9.1 Problem Description: Defining the Objective Function 251
9.2 The Property Method: “STEAMNBS” 252
9.3 A Flowsheet for Water Transport 253
9.4 Entering Stream, Pump, and Pipe Specifications 253
9.5 Model Analysis Tools: The Optimization Tool 256
9.6 Model Analysis Tools: The Sensitivity Tool 260
9.7 Last Comments 263
References 264
Homework/Classwork 9.1 (Swamee–Jain Equation) 264
Homework/Classwork 9.2 (A Simplified Pipe Diameter Optimization) 264
Homework/Classwork 9.3 (The Optimum Diameter for a Viscous Flow) 265
Homework/Classwork 9.4 (The Selectivity of Parallel Reactions) 266
10 Heat Exchanger (H.E.) Design 269
10.1 Problem Description 269
10.2 Types of Heat Exchanger Models in Aspen Plus 270
10.3 The Simple Heat Exchanger Model (“Heater”) 272
10.4 The Rigorous Heat Exchanger Model (“HeatX”) 274
10.5 The Rigorous Exchanger Design and Rating (EDR) Procedure 279
10.5.1 The EDR Exchanger Feasibility Panel 279
10.5.2 The Rigorous Mode Within the “HeatX” Block 294
10.6 General Footnotes on EDR Exchanger 294
References 297
Homework/Classwork 10.1 (Heat Exchanger with Phase Change) 297
Homework/Classwork 10.2 (High Heat Duty Heat Exchanger) 298
Homework/Classwork 10.3 (Design Spec Heat Exchanger) 299
11 Electrolytes 301
11.1 Problem Description: Water De-Souring 301
11.2 What Is an Electrolyte? 301
11.3 The Property Method for Electrolytes 302
11.4 The Electrolyte Wizard 302
11.5 Water De-Souring Process Flowsheet 310
11.6 Entering the Specifications of Feed Streams and the Stripper 311
References 315
Homework/Classwork 11.1 (An Acidic Sludge Neutralization) 316
Homework/Classwork 11.2 (CO2 Removal from Natural Gas) 317
Homework/Classwork 11.3 (pH of Aqueous Solutions of Salts) 321
Appendix 11.A Development of “ELECNRTL” Model 324
12 Polymerization Processes 325
12.1 The Theoretical Background 325
12.1.1 Polymerization Reactions 325
12.1.2 Catalyst Types 326
12.1.3 Ethylene Process Types 327
12.1.4 Reaction Kinetic Scheme 327
12.1.5 Reaction Steps 327
12.1.6 Catalyst States 328
12.2 High-Density Polyethylene (HDPE) High-Temperature Solution Process 329
12.2.1 Problem Definition 330
12.2.2 Process Conditions 330
12.3 Creating Aspen Plus Flowsheet for HDPE 331
12.4 Improving Convergence 338
12.5 Presenting the Property Distribution of Polymer 339
References 343
Homework/Classwork 12.1 (Maximizing the Degree of HDPE Polymerization) 344
Homework/Classwork 12.2 (Styrene Acrylonitrile (SAN) Polymerization) 345
Appendix 12.A The Main Features and Assumptions of Aspen Plus Chain Polymerization Model 351
Appendix 12.A.1 Polymerization Mechanism 351
Appendix 12.A.2 Copolymerization Mechanism 351
Appendix 12.A.3 Rate Expressions 352
Appendix 12.A.4 Rate Constants 352
Appendix 12.A.5 Catalyst Preactivation 352
Appendix 12.A.6 Catalyst Site Activation 352
Appendix 12.A.7 Site Activation Reactions 353
Appendix 12.A.8 Chain Initiation 353
Appendix 12.A.9 Propagation 353
Appendix 12.A.10 Chain Transfer to Small Molecules 354
Appendix 12.A.11 Chain Transfer to Monomer 354
Appendix 12.A.12 Site Deactivation 354
Appendix 12.A.13 Site Inhibition 354
Appendix 12.A.14 Cocatalyst Poisoning 355
Appendix 12.A.15 Terminal Double Bond Polymerization 355
Appendix 12.A.16 Phase Equilibria 355
Appendix 12.A.17 Rate Calculations 355
Appendix 12.A.18 Calculated Polymer Properties 356
Appendix 12.B The Number Average Molecular Weight (MWN) and Weight Average Molecular Weight (MWW) 356
13 Characterization of Drug-Like Molecules Using Aspen Properties 361
13.1 Introduction 361
13.2 Problem Description 362
13.3 Creating Aspen Plus Pharmaceutical Template 363
13.3.1 Entering the User-Defined Benzamide (BNZMD-UD) as Conventional 363
13.3.2 Specifying Properties to Estimate 364
13.4 Defining Molecular Structure of BNZMD-UD 364
13.5 Entering Property Data 370
13.6 Contrasting Aspen Plus Databank (BNZMD-DB) Versus BNZMD-UD 373
References 375
Homework/Classwork 13.1 (Vanillin) 375
Homework/Classwork 13.2 (Ibuprofen) 376
14 Solids Handling 379
14.1 Introduction 379
14.2 Problem Description #1: The Crusher 379
14.3 Creating Aspen Plus Flowsheet 380
14.3.1 Entering Components Information 380
14.3.2 Adding the Flowsheet Objects 381
14.3.3 Defining the Particle Size Distribution (PSD) 382
14.3.4 Calculation of the Outlet PSD 385
Exercise 14.1 (Determine Crusher Outlet PSD from Comminution Power) 386
Exercise 14.2 (Specifying Crusher Outlet PSD) 386
14.4 Problem Description #2: The Fluidized Bed for Alumina Dehydration 387
14.5 Creating Aspen Plus Flowsheet 387
14.5.1 Entering Components Information 387
14.5.2 Adding the Flowsheet Objects 388
14.5.3 Entering Input Data 389
14.5.4 Results 391
Exercise 14.3 (Reconverging the Solution for an Input Change) 392
References 393
Homework/Classwork 14.1 (KCl Drying) 393
Homework/Classwork 14.2 (KCl Crystallization) 396
Appendix 14.A Solids Unit Operations 401
Appendix 14.A.1 Unit Operation Solids Models 401
Appendix 14.A.2 Solids Separators Models 401
Appendix 14.A.3 Solids Handling Models 402
Appendix 14.B Solids Classification 402
Appendix 14.C Predefined Stream Classification 403
Appendix 14.D Substream Classes 404
Appendix 14.E Particle Size Distribution (PSD) 405
Appendix 14.F Fluidized Beds 406
15 Aspen Plus® Dynamics 409
15.1 Introduction 409
15.2 Problem Description 410
15.3 Preparing Aspen Plus Simulation for Aspen Plus Dynamics (APD) 411
15.4 Conversion of Aspen Plus Steady-State into Dynamic Simulation 416
15.4.1 Modes of Dynamic CSTR Heat Transfer 417
15.4.2 Creating Pressure-Driven Dynamic Files for APD 422
15.5 Opening a Dynamic File Using APD 423
15.6 The “Simulation Messages” Window 424
15.7 The Running Mode: Initialization 425
15.8 Adding Temperature Control (TC) Unit 426
15.9 Snapshots Management for Captured Successful Old Runs 430
15.10 The Controller Faceplate 431
15.11 Communication Time for Updating/Presenting Results 434
15.12 The Closed-Loop Auto-Tune Variation (ATV) Test Versus Open-Loop Tune-Up Test 434
15.13 The Open-Loop (Manual Mode) Tune-Up for Liquid Level Controller 436
15.14 The Closed-Loop Dynamic Response for Liquid Level Load Disturbance 443
15.15 The Closed-Loop Dynamic Response for Liquid Level Set-Point Disturbance 448
15.16 Accounting for Dead/Lag Time in Process Dynamics 450
15.17 The Closed-Loop (Auto Mode) ATV Test for Temperature Controller (TC) 451
15.18 The Closed-Loop Dynamic Response: “TC” Response to Temperature Load Disturbance 459
15.19 Interactions Between “LC” and “TC” Control Unit 462
15.20 The Stability of a Process Without Control 464
15.21 The Cascade Control 466
15.22 Monitoring of Variables as Functions of Time 468
15.23 Final Notes on the Virtual (DRY) Process Control in APD 472
References 478
Homework/Classwork 15.1 (A Cascade Control of a Simple Water Heater) 478
Homework/Classwork 15.2 (A CSTR Control with “LMTD” Heat Transfer OPTION) 482
Homework/Classwork 15.3 (A PFR Control for Ethylbenzene Production) 483
16 Safety and Energy Aspects of Chemical Processes 487
16.1 Introduction 487
16.2 Problem Description 487
16.3 The “Safety Analysis” Environment 488
16.4 Adding a Pressure Safety Valve (PSV) 490
16.5 Adding a Rupture Disk (RD) 496
16.6 Presentation of Safety-Related Documents 500
16.7 Preparation of Flowsheet for “Energy Analysis” Environment 501
16.8 The “Energy Analysis” Activation 506
16.9 The “Energy Analysis” Environment 510
16.10 The Aspen Energy Analyzer 512
Homework/Classwork 16.1 (Adding a Storage Tank Protection) 513
Homework/Classwork 16.2 (Separation of C2/C3/C4 Hydrocarbon Mixture) 518
17 Aspen Process Economic Analyzer (APEA) 523
17.1 Optimized Process Flowsheet for Acetic Anhydride Production 523
17.2 Costing Options in Aspen Plus 525
17.2.1 Aspen Process Economic Analyzer (APEA) Estimation Template 525
17.2.2 Feed and Product Stream Prices 527
17.2.3 Utility Association with a Flowsheet Block 528
17.3 The First Route for Chemical Process Costing 531
17.4 The Second Round for Chemical Process Costing 532
17.4.1 Project Properties 533
17.4.2 Loading Simulator Data 535
17.4.3 Mapping and Sizing 537
17.4.4 Project Evaluation 544
17.4.5 Fixing Geometrical Design-Related Errors 546
17.4.6 Executive Summary 549
17.4.7 Capital Costs Report 550
17.4.8 Investment Analysis 551
Homework/Classwork 17.1 (Feed/Product Unit Price Effect on Process Profitability) 555
Homework/Classwork 17.2 (Using European Economic Template) 556
Homework/Classwork 17.3 (Process Profitability of Acetone Recovery from Spent Solvent) 556
Appendix 17.A 559
Appendix 17.A.1 Net Present Value (NPV) for a Chemical Process Plant 559
Appendix 17.A.2 Discounted Payout (PAYBACK) Period (DPP) 560
Example 17.1 (Uniform Cash Flow) 561
Example 17.2 (Non-Uniform Cash Flow) 561
Appendix 17.A.3 Profitability Index 561
Example 17.3 562
Appendix 17.A.4 Internal Rate of Return (IRR) 562
Appendix 17.A.5 Modified Internal Rate of Return (MIRR) 563
Example 17.4 563
18 Term Projects (TP) 565
18.1 TP #1: Production of Acetone via the Dehydration of Isopropanol 565
18.2 TP #2: Production of Formaldehyde from Methanol (Sensitivity Analysis) 569
18.3 TP #3: Production of Dimethyl Ether (Process Economics and Control) 570
18.3.1 Economic Analysis 570
18.3.2 Process Dynamics and Control 572
18.4 TP #4: Production of Acetic Acid via Partial Oxidation of Ethylene Gas 574
18.5 TP #5: Pyrolysis of Benzene 575
18.6 TP #6: Reuse of Spent Solvents 575
18.7 TP #7: Solids Handling: Production of Potassium Sulfate from Sodium Sulfate 576
18.8 TP #8: Solids Handling: Production of CaCO3-Based Agglomerate as a General Additive 577
18.9 TP #9: Solids Handling: Formulation of Di-Ammonium Phosphate and Potassium Nitrate Blend Fertilizer 577
18.10 TP #10: “Flowsheeting Options” | “Calculator”: Gas De-Souring and Sweetening Process 578
18.11 TP #11: Using More than One Property Method and Stream Class: Solid Catalyzed Direct Hydration of Propylene to Isopropyl Alcohol (IPA) 582
18.12 TP #12: Polymerization: Production of Polyvinyl Acetate (PVAC) 586
18.13 TP #13: Polymerization: Emulsion Copolymerization of Styrene and Butadiene to Produce SBR 588
18.14 TP #14: Polymerization: Free Radical Polymerization of Methyl Methacrylate to Produce Poly(Methyl Methacrylate) 590
18.15 TP #15: LHHW Kinetics: Production of Cyclohexanone-Oxime (CYCHXOXM) via Cyclohexanone Ammoximation Using Clay-Based Titanium Silicalite (TS) Catalyst 592
Index 595
About the Author :
Kamal Al-Malah, is professor of chemical engineering at Higher Colleges of Technology, United Arab Emirates and former chairman of the chemical engineering department at the University of Hail in Saudi Arabia. He holds B.S., M.S., and Ph.D. degrees in chemical/biochemical engineering. Dr. Al-Malah graduated from Oregon State University in 1993 and his area of specialty deals with mathematical modeling, optimization, simulation, and computer-aided design. Professor Al-Malah is Windows-based software developer and MATLAB® book author
