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Chemical Engineering Guy
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1. Introduction
2. Study Cases (4x) – Chemical Processes
3. Study Cases (3x) – Process Analysis
4. Study Cases (3x) – Rigo...
 Chemical Processes
1. Hydrocarbon Systems
2. BTX Separation
3. Methanol from Syngas
4. Acetaldehyde Plant
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 Process Analysis
5. Dimethyl Ether Production (Design Spec.)
6. Ammonia in Cryogenics (Optimization & Constraint)
7. Cum...
 Rigorous Unit Operations
8. Heat-X Rigorous Model (Shell & Tube)
9. RadFrac for Absorption Operations
10. RadFrac in Dis...
 Plant Economy & Dynamic Control
11. Ammonia Economics
12. Plant Dynamics & Control
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 Learn about Aspen Plus and its use in the Industry
 Basics of the Physical Property Environment
 Flow sheeting techniq...
 Basic understanding of Plant Design & Operation
 Strong Chemical Engineering Fundamentals
 Aspen Plus V10 (at least 7....
 Engineers of the following areas:
 Chemical
 Process
 Plant Design
 Production
 Petrochemical Engineers
 Aspen Plu...
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 BOOTCAMP
 programs which enable students with little Process
Simulation proficiency to f...
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 BOOTCAMP
 INTENSIVE
 80-20 principle
 100% Practical
 Workshop based
 Hands-on
 Cas...
 Check out:
 Slideshows
 Simulations
 Spreadsheets
 & more… here:
 https://www.chemicalengineeringguy.com/courses/as...
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 Chemical Processes
1. Hydrocarbon Systems
2. BTX Separation
3. Methanol from Syngas
4. Acetaldehyde Plant
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 Case Study 1
 Open New, Saving & Opening Files
 Setup the Physical Property environment (component list + property met...
 Gas mixture is to be separated
 H2  Used in Syngas, must be purified
 C1  Used as Nat. Gas
 C2-C3  Sent to a NEW p...
 The Mix is to be flashed at P = 3 bar, T = 25°C
 The Vapor line is to be treated as follows:
 Membrane separation of H...
 (a) Verify purities
 (b) What is the mole rate for Plant 1
 (c) Volumetric Flow rate of H2
 (d) Mass flow rate of Pla...
 Try to get this:
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 Feed:
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Component (mol. Frac.)
H2 0.3
C1 0.2
C2 0.1
C3 0.12
C6 0.12
C7 0.09
C8 0.07
 Flash (FLASH2):
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 Cooler (HEATER):
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 Valve (VALVE):
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 Splitter (FSPLIT):
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 Membrane (SEP):
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 SEPX (SEP):
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 Run Results
 Get:
 (a) Verify purities
 (b) What is the mole rate for Plant 1
 (c) Volumetric Flow rate of H2
 (d) ...
 Case Study 2
 Physical Property  Analysis Tools
 Operations: Distillation, partial & total condensers
 Units: Distil...
 BTX (Benzene Toluene and p-Xylene) are to be separated from a mixture via
distillation
 Objectives:
 Get at least 94% ...
 Pressure of operations allowed:
 Distil 1 = 1.1-1.3 bar
 Distil 2 = 2.5-3.0 bar
 Final product specification:
 5.0 b...
 (A) Use Phys. Props to verify BP of each species at P = 1.2 bar
 (B) Use Flash to verify K values and volatilities (Lig...
 (A)
 Use Phys. Props to verify BP of species
at P = 1.0 bar
 Results should be similar to:
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 (A)
 Use Phys. Props to verify BP of species at P = 1.0 bar
 Results should be similar to:
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 (B) Use Flash2 to verify Data
 Components: B, T, p-X
 Feed
 350 kg/h, 500 kg/h, 150 kg/h
 T = 25C, P = 1.2bar
 Mode...
 Verify Volatilities
 B = 80°C, T = 111°C, X = 138°C
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 Verify Volatilities
 B = 80.1°C, T = 110.6°C, X = 138.4°C
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 Verify Volatilities
 B = 80.1°C, T = 110.6°C, X = 138.4°C
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 Calculate (manually)
 Min. Number of Stages
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...
 (C) Compare models
 Getting help in Aspen Plus V10
 Compare DSTWU vs. Distil
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 Compare DSTWU vs. Distil
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 (D) Separate light material with
 Model Theoretical “DISTIL”
 Use Min. Stages to verify:
 Min. Reflux Ratio
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 Model the “real” DSTWU with DISTIL
 N = 13
 F = 6
 RR = 1.313
 D:F = 0.402
 P = 1.07, P = 1.10
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 (A) Use Phys. Props to verify BP of each species at P = 1.2 bar
 (B) Use Flash to verify K values and volatilities (Lig...
 (F) Use Flash/DSTWU to verify K values and volatilities (Light and Heavy keys)
 P = 2.5/3.0
 Recovery 
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 Preliminary Results of DSTWU2
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DSTWU2
 (G) Use Flash/DSTWU to verify K values and volatilities (Light and Heavy keys)
 Add the pre-pumping
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 (G) Use Distil
 P = 2.5/3.0
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 Case Study 3
 Physical Property Env.  Binary Analysis (Methane : CO2)
 Adding Reactions, and Equilibrium Data
 Opera...
 Methanol is to be synthetized from Syngas
 Reactor is ISOTHERMAL
 Equilibrium Data (see in simulation)
 Feed:
 CO, C...
 Main goal is to:
 Pre-heat feed (to T = 270°C, P = 40 bar)
 Add Recycle + Feed to the Reactor Inlet
 Cool down (50°C,...
 (Ai) Verify Heat duty of Reactor (pre/after recycle)
 (Aii) For the CSTR, verify Calculated Keq vs. Given Built-in Expr...
 Try to aim this simulation:
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 Physical Property Environment
 Add Components
 Physical Property  PSRK
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 Simulation Environment
 FEED:
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 HEATER
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 R-CSTR
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 Reactions
 RXN – LHHW / Equilibium
 NOTE: Verify Enthalpy of Reactions
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 Reactions
 RXN –Equilibium
 NOTE: Verify Enthalpy of Reactions
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𝐶𝑂 + 2𝐻2 ↔ 𝐶𝐻3 𝑂𝐻 𝛥𝐻 = −...
 REACTOR:
 Compare “Compute Keq from Gibbs Free energy”
 Vs
 Compute Keq from Built-in Expression
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 Reactor:
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 Reactor (Based on Aspen Plus Calculation for Gibbs Free energy):
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 REACTOR:
 Compare “Compute Keq from Gibbs Free energy”
 Vs
 Compute Keq from Built-in Expression
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 Reactions
 RXN1, RXN2, RXN3
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 Reactions
 RXN1, RXN2, RXN3
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 Reactor (Based on Aspen Plus Calculation for Gibbs Free energy):
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 Reactor (Based on Aspen Plus Calculation for Gibbs Free energy):
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Auto Given
Expression
Au...
 Continue with flowsheeting
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 Use the INSERT option in Flowhseeting
 Select FEED  INSERT Compressor
 Compressor  Isentropic, Pdischarge = 40 bar
...
 Select Reactor OUTLET  INSERT Valve
 Valve  Pdrop = 40bar
 Chiller
 T = 50C, P = 10 bar / 0 bar
 Hydrogen Trap – M...
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 (B) Add Recycle & Purge
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 (B) Add Recycle & Purge
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 (B) Add Recycle & Purge
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 (C) Use Binary Analysis for Distillation
 Analysis base:
 TXY diagram
 Methanol – Water
 P = 10 bar
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 (D) DSWTU No. recommended Stages, given RR = 1.50
 Valve:
 Pdischarge = 1.5 bar
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 (D) DSWTU No. recommended Stages, given RR = 1.50
 Distillation
 Start with DSTWU
 RR = 1.5
 P(cond/reb) = 1.40/1.70...
 (D) DSWTU No. recommended Stages, given RR = 0.80
 Distillation
 Start with DSTWU
 RR = 1.5
 P(cond/reb) = 1.40/1.70...
 (E) DSWTU  DISTL  RadFrac
 Distillation
 Continue with DISTL
 N stages = 7
 Feed = 5
 RR = 1.5
 D:F = 0.50
 P(c...
 (E) DSWTU  DISTL  RadFrac
 Distillation
 Continue with DISTL
 N stages = 7
 Feed = 5
 RR = 1.5
 D:F = 0.50
 P(c...
 (E) DSWTU  DISTL  RadFrac
 Distillation
 Continue with DISTL
 N stages = 7
 Feed = 5
 RR = 1.5
 D:F = 0.50
 P(c...
 (E) DSWTU  DISTL  RadFrac
 Distillation
 Continue with RadFrac
 N stages = 7
 Feed = 5
 RR = 1.5
 D:F = 0.50
 P...
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 (G) Final Product Purity Specification
 Case Study 4
 Flowsheeting: “Views” Text/Figures
 Adding Reactions
 Operations: Isothermal Reactions, Purging, Recycl...
 Ethanol is to be converted to Acetaldehyde using a Plug flow reactor.
 The Reactor is to be isothermal, 274°C, Single-t...
 (A) Run the PFR with no recycle
 (B) Add separation scheme (Flashing, Degasser, Distillation Column)
 (C) Add recycle ...
 Try to make a flowsheet similar to this:
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 Physical Property Environment
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 Simulation Environment
 Feed + Pump + Mix
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En...
 Reactor (R-PLUG)
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 REACTIONS (RXN1)  Powerlaw
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 REACTIONS (RXN1)  Powerlaw
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 REACTIONS (RXN1)  Powerlaw
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 REACTIONS (RXN1)  Powerlaw
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 PFR Run:
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 (B) Add separation scheme (Flashing, Degasser, Distillation Column)
 Chiller
 dP = 0.25 atm
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 Degaser (Sep1)
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 Distillation Column (RADFRAC)
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 Distillation Column (RADFRAC)
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Stage Pressure
...
 Results of Distillation
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 (C) Add Recycle + Purge Streams
 90% Recycle Rate
 10% Purge Rage
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 (C) Add Recycle + Purge Streams
 90% Recycle Rate
 10% Purge Rage
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 (D) Het Exchanger Property Sets
 Size  HEAT1
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 (D) Het Exchanger Property Sets
 Setup Heat-X
 SHORTCUT
 Countercurrent
 Exchanger Duty
 2.54069e06 (cal/s)
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 (D) Het Exchanger Property Sets
 Convert to:
 Shell & Tube Exchanger
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 Accept design, run simulation, verify results
 Verify:
 Exchanger Area
 LMDT (Log mean. Difference in Temp)
 UA (Ove...
 (E) Verify Purity of Products, Specs of Exchanger (Heaters, Reboilers, Condensers)
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 Add “views” for simplicity
 PFR
 Heat-X
 Separation Scheme
 Purger
 Plant
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 Reactor (PFR) Conversion vs. Length
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 Distillation Column Pressure Profile
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 Process Analysis
5. Dimethyl Ether Production (Design Spec.)
6. Ammonia in Cryogenics (Optimization & Constraint)
7. Cum...
 Case Study 5
 Flowsheeting  Adding Figures & Timestamps, lines to the spreadsheet
 Physical Property  Binary Paramet...
 Dimethyl ether CH3-O-CH3, is to be produced from CO2 & H2. Initially there is
formation of CO + H2O, which is then conve...
 There is a special equipment which will recover most of non-polar substances in the
streams (DIM-Trap)
 The dimethyl wi...
 (A) Run CSTR1, verify results
 (B) Use Design Spec For Water flow rate
 (C) Verify Reactor 2 , ensure Dimethyl product...
 Try to get a simulation similar to this
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 Physical Property Environment
 First  Method RK-SOAVE / NRTL
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 Physical Property Environment
 First  Method RK-SOAVE / NRTL
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 Physical Property Environment
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 (A) Run CSTR
 Simulation Environment
 FEED
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 CSTR (Isothermal)
 T =400, P = 50bar, V = 10 m3
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 RXN1  Powerlaw
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 RUN 
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 (B) Use Design Spec For Water flow rate
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 (B) Use Design Spec For Water flow rate  We want to remove most of water…
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 Add Design Spec.
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 Add Design Spec.
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 Add Design Spec.
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 (C) Verify Reactor 2
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 (C) Verify Reactor 2
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 (C) Verify Reactor 2
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 Run Reactor 2
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 (D) Add Recycling & Purge  Design Spec for Degaser
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 (D) Add Recycling & Purge  Design Spec for Degaser
 Verify  No more than 0.10 kmol/h of Methanol is lost
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 (D) Add Recycling & Purge  Design Spec for Degaser
 Verify  No more than 0.10 kmol/h of Methanol is lost
 RESULT  T...
 (D) Add Recycling & Purge  Design Spec for Degaser
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 Results…
 Note that Methanol must be lost 0.23 kmol/h 
 OK since this is recycled..
 Purge loses 0.023 kmol/h
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 Verify Water content
 FLASH1  from 103 to
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 (E) Separate final products DIM-trap & Send to plant
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 (E) Separate final products DIM-trap & Send to plant
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 Add Table of Results to Flowsheet
 Physical Property: Ideal vs. Activity vs. EOS
 Tool Analysis  Optimization & Const...
 Ammonia gas is to be produced from a mixture of cryogenic gases, H2, N2,CH4, Ar
and some H2 (74.2, 24.7, 0.8, 0.3%)
 T ...
 (A) Run the reactor, verify the composition in the outlet given T-Reactor = 40°C
 (Ai) Verify for IDEAL
 (Aii) Verify ...
 Try getting a flowsheet similar to this one
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 (A) Run the reactor, verify the composition in the outlet given T-Reactor = 40°C
 (Ai) Verify for IDEAL
 (Aii) Verify ...
 Physical Property Environment  Methods (Peng-Robinson)
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 Ammonia is to be produced from Air
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 Ammonia is to be produced from Air
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 (Ai) IDEAL
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 (Aii) NRTL  (Aiii) PR
 (B) Cool down, then flash mixture  Verify Mole flow of Ammonia and purity
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 T-Cool  Approx to -10°C
 T-Flash  -30°C
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 (C) Recycle gases, recall that 90% of N2, H2 is recovered, all other is sent to stack &
Verify Composition of Reactor
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 (C) Recycle gases, recall that 90% of N2, H2 is recovered, all other is sent to stack &
Verify Composition of Reactor
ww...
 (C) Recycle gases, recall that 90% of N2, H2 is recovered, all other is sent to stack &
Verify Composition of Reactor
ww...
 (C) Recycle gases, recall that 90% of N2, H2 is recovered, all other is sent to stack &
Verify Composition of Reactor
ww...
 (D) Optimize temperature of Flash. Maximize NH3 flow rate with at least 99.5% purity
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 (D) Optimize temperature of Flash. Maximize NH3 flow rate with at least 99.5% purity
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 (E) Optimize temperature of Reactor. Maximize NH3 flow rate with at least 99.5 % purity
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 Finally, add table of results
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 Finally, add table of results
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 Export Table of Results to Spreadsheet/Excel
 Manipulators  Dupl / Mult
 Tool Analysis  Sensitivity Analysis
 Opera...
 Cumene (C9H12) is to be produced from the reaction of benzene and propane
 C6H6 propylene  Cumene
 The reactor is to ...
 The producto must be purified via Distillation(s)
 A 99.5%+ Cumene product is required, while maximizing yields
 A sin...
 (A) Run PFR, verify residence time & results
 (B) Use approx. Residence Time for CSTR
 (C) Continue with Reactor: (bes...
 Try to get a simulation similar to this:
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 Physical Property Environment
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 Simulation Environment
 FEED = 300 kmol/h
 0.75 Propylene
 0.25 n-Butane
 T = 25°C, P = 25bar
www.ChemicalEngineerin...
www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=yWbfzw04SvI
www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=yWbfzw04SvI
www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=yWbfzw04SvI
Enjoying so far?
This is a preview of the BOOTC...
 (A) Run PFR, verify residence time & results
www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=yWbfzw04SvI
...
 (B) Use approx. Residence Time for CSTR
www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=yWbfzw04SvI
 (C) Continue with PFR (best choice)
 Add separation scheme (Col1)
www.ChemicalEngineeringGuy.com https://www.youtube.co...
 (C) Continue with PFR (best choice)
 Add separation scheme (Col2)
www.ChemicalEngineeringGuy.com https://www.youtube.co...
 (D) Add Recycle (Benzene is fully recovered)
www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=yWbfzw04SvI
 (E) Use Sensitivity Analysis to verify best case scenario for Benzene Feed
 (initially 300 kmol/h)
www.ChemicalEngineer...
 (E) Use Sensitivity Analysis to verify best case
scenario for Benzene Feed
 (initially 300 kmol/h)
www.ChemicalEngineer...
 (E) Use Sensitivity Analysis to verify best case
scenario for Benzene Feed
www.ChemicalEngineeringGuy.com https://www.yo...
 (E) Use Sensitivity Analysis to verify best case
scenario for Benzene Feed
www.ChemicalEngineeringGuy.com https://www.yo...
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Aspen Plus - Bootcamp - 12 Case Studies (1 of 2) (Slideshare) Slide 1 Aspen Plus - Bootcamp - 12 Case Studies (1 of 2) (Slideshare) Slide 2 Aspen Plus - Bootcamp - 12 Case Studies (1 of 2) (Slideshare) Slide 3 Aspen Plus - Bootcamp - 12 Case Studies (1 of 2) (Slideshare) Slide 4 Aspen Plus - Bootcamp - 12 Case Studies (1 of 2) (Slideshare) Slide 5 Aspen Plus - Bootcamp - 12 Case Studies (1 of 2) (Slideshare) Slide 6 Aspen Plus - Bootcamp - 12 Case Studies (1 of 2) (Slideshare) Slide 7 Aspen Plus - Bootcamp - 12 Case Studies (1 of 2) (Slideshare) Slide 8 Aspen Plus - Bootcamp - 12 Case Studies (1 of 2) (Slideshare) Slide 9 Aspen Plus - Bootcamp - 12 Case Studies (1 of 2) (Slideshare) Slide 10 Aspen Plus - Bootcamp - 12 Case Studies (1 of 2) (Slideshare) Slide 11 Aspen Plus - Bootcamp - 12 Case Studies (1 of 2) (Slideshare) Slide 12 Aspen Plus - Bootcamp - 12 Case Studies (1 of 2) (Slideshare) Slide 13 Aspen Plus - Bootcamp - 12 Case Studies (1 of 2) (Slideshare) Slide 14 Aspen Plus - Bootcamp - 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Aspen Plus - Bootcamp - 12 Case Studies (1 of 2) (Slideshare)

This is a slideshow / resource / support material of the course.
Get full access (videlectures)

https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/

x-x-x
Requirements

Basic understanding of Plant Design & Operation
Strong Chemical Engineering Fundamentals
Aspen Plus V10 (at least 7.0)
Aspen Plus – Basic Process Modeling (Very Recommended)
Aspen Plus – Intermediate Process Modeling (Somewhat Recommended)
Description

This BOOTCAMP will show you how to model and simulate common industrial Chemical Processes.

It is focused on the “BOOTCAMP” idea, in which you will learn via workshops and case studies, minimizing theory to maximize learning.

You will learn about:

Better Flowsheet manipulation and techniques
Understand Property Method Selection and its effects on simulation results
More than 15 Unit Operations that can be used in any Industry
Model Analysis Tools required for process design
Reporting Relevant Results Plot relevant data
Analysis & Optimization of Chemical Plants
Economic Analysis
Dynamic Simulations
At the end of this Bootcamp, you will be able to model more industrial processes, feel confident when modeling new processes as well as applying what you have learnt to other industries.

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Aspen Plus - Bootcamp - 12 Case Studies (1 of 2) (Slideshare)

  1. 1. Chemical Engineering Guy www.ChemicalEngineeringGuy.com
  2. 2. www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  3. 3. 1. Introduction 2. Study Cases (4x) – Chemical Processes 3. Study Cases (3x) – Process Analysis 4. Study Cases (3x) – Rigorous Unit Operations 5. Study Cases (2x) – Plant Economy & Dynamic Control 6. Conclusion www.ChemicalEngineeringGuy.com
  4. 4.  Chemical Processes 1. Hydrocarbon Systems 2. BTX Separation 3. Methanol from Syngas 4. Acetaldehyde Plant www.ChemicalEngineeringGuy.com
  5. 5.  Process Analysis 5. Dimethyl Ether Production (Design Spec.) 6. Ammonia in Cryogenics (Optimization & Constraint) 7. Cumene Production (Sensitivity Analysis) www.ChemicalEngineeringGuy.com
  6. 6.  Rigorous Unit Operations 8. Heat-X Rigorous Model (Shell & Tube) 9. RadFrac for Absorption Operations 10. RadFrac in Distillation Operations www.ChemicalEngineeringGuy.com
  7. 7.  Plant Economy & Dynamic Control 11. Ammonia Economics 12. Plant Dynamics & Control www.ChemicalEngineeringGuy.com
  8. 8.  Learn about Aspen Plus and its use in the Industry  Basics of the Physical Property Environment  Flow sheeting techniques  Presenting Results: Plotting, Tables and Results  Model several Chemical Process  Use a variety of unit operations  Converge and debugging  Plant Utilities & Economics www.ChemicalEngineeringGuy.com
  9. 9.  Basic understanding of Plant Design & Operation  Strong Chemical Engineering Fundamentals  Aspen Plus V10 (at least 7.0) www.ChemicalEngineeringGuy.com
  10. 10.  Engineers of the following areas:  Chemical  Process  Plant Design  Production  Petrochemical Engineers  Aspen Plus Users  REFRESHERS  Students related to engineering fields, specially Process, Chemical and Biotech.  Instructor/Professors/Teachers willing to learn more about process simulation www.ChemicalEngineeringGuy.com
  11. 11. www.ChemicalEngineeringGuy.com  BOOTCAMP  programs which enable students with little Process Simulation proficiency to focus on the most important aspects of Simulation and immediately apply their new skills to solve real-world problems.  The goal of many bootcamps attendees is to transition into a career in Process Simulation development.  They do this by learning to simulate common processes  This provides the foundation they need to build production-ready applications and demonstrate they have the skills to add real value to the company.
  12. 12. www.ChemicalEngineeringGuy.com  BOOTCAMP  INTENSIVE  80-20 principle  100% Practical  Workshop based  Hands-on  Case Study based  Non theoretical!
  13. 13.  Check out:  Slideshows  Simulations  Spreadsheets  & more… here:  https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/ap-bootcamp-99512/  Get Tips & Help here:  https://www.facebook.com/groups/aspenplushysysforum/  Also check the “resources” on the course. www.ChemicalEngineeringGuy.com
  14. 14. www.ChemicalEngineeringGuy.com
  15. 15.  Chemical Processes 1. Hydrocarbon Systems 2. BTX Separation 3. Methanol from Syngas 4. Acetaldehyde Plant www.ChemicalEngineeringGuy.com
  16. 16.  Case Study 1  Open New, Saving & Opening Files  Setup the Physical Property environment (component list + property method)  Phys.Prop.Env  Binary Parameters, Equations & Models  Flowsheeting T/P/L labels; reconnecting source/distination  Add unit operations & streams to the flowsheet  Operations: Mixing, Splitting, Separation, Heating, Pressurizing  Units: Fsplit, Mix, Sep1, Sep2 Flash2, Heater, Valve  Understanding variable (input vs. outputs)  Running a Simulation & Viewing Results www.ChemicalEngineeringGuy.com
  17. 17.  Gas mixture is to be separated  H2  Used in Syngas, must be purified  C1  Used as Nat. Gas  C2-C3  Sent to a NEW plant for Ethane/Propane separation  C6-C8  Main Liquid Product… Must be divided to Plant 1, 70%, and Plant 2, 30%  Composition www.ChemicalEngineeringGuy.com Component Value H2 0.3 C1 0.2 C2 0.1 C3 0.12 C6 0.12 C7 0.09 C8 0.07
  18. 18.  The Mix is to be flashed at P = 3 bar, T = 25°C  The Vapor line is to be treated as follows:  Membrane separation of H2 (1.0) CH4 (98% recovery) and “C2-3” (95% recovery)  The “C2-3” line is to be treated in a Sep-X (Sep2) All C2-3 is separated.  The Liquid Line is to be treated as follows:  Cooled down 15°C  Pressure decrease to 1 bar  Split to Plant 1  70% and Plant 2  30% www.ChemicalEngineeringGuy.com
  19. 19.  (a) Verify purities  (b) What is the mole rate for Plant 1  (c) Volumetric Flow rate of H2  (d) Mass flow rate of Plant 2  (e) Heat Duty of the Chiller/Cooler  (f) Heat duty of the Flash Drum  (g) Composition of Product Lines www.ChemicalEngineeringGuy.com
  20. 20.  Try to get this: www.ChemicalEngineeringGuy.com
  21. 21.  Feed: www.ChemicalEngineeringGuy.com Component (mol. Frac.) H2 0.3 C1 0.2 C2 0.1 C3 0.12 C6 0.12 C7 0.09 C8 0.07
  22. 22.  Flash (FLASH2): www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  23. 23.  Cooler (HEATER): www.ChemicalEngineeringGuy.com
  24. 24.  Valve (VALVE): www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  25. 25.  Splitter (FSPLIT): www.ChemicalEngineeringGuy.com
  26. 26.  Membrane (SEP): www.ChemicalEngineeringGuy.com
  27. 27.  SEPX (SEP): www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  28. 28.  Run Results  Get:  (a) Verify purities  (b) What is the mole rate for Plant 1  (c) Volumetric Flow rate of H2  (d) Mass flow rate of Plant 2  (e) Heat Duty of the Chiller/Cooler  (f) Heat duty of the Flash Drum  (g) Composition of Product Lines www.ChemicalEngineeringGuy.com
  29. 29.  Case Study 2  Physical Property  Analysis Tools  Operations: Distillation, partial & total condensers  Units: Distil, DSTWU, Pump  Getting Help in Aspen Plus V10 www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=WZQl_y2ci2w
  30. 30.  BTX (Benzene Toluene and p-Xylene) are to be separated from a mixture via distillation  Objectives:  Get at least 94% of benzene (purity)  Get at least 96% of toluene (purity)  Get at least 96% of p-xylene (purity)  Optimize:  RR vs. Stages  Design:  Start by Flashing, then DSTWU model  Final Design must be DISTIL www.ChemicalEngineeringGuy.com
  31. 31.  Pressure of operations allowed:  Distil 1 = 1.1-1.3 bar  Distil 2 = 2.5-3.0 bar  Final product specification:  5.0 bar for benzene line  2.5 bar for benzene line  3.0 bar for p-xylene line www.ChemicalEngineeringGuy.com
  32. 32.  (A) Use Phys. Props to verify BP of each species at P = 1.2 bar  (B) Use Flash to verify K values and volatilities (Light and Heavy keys)  (C) Compare DSTWU vs. Distil Models  (D) Use DSWTU Model for min. conditions (Column 1)  (E) Use Distil, for real conditions (Column 1)  (F) Use Flash to verify K values and volatilities (Light and Heavy keys)  (G) Use Distil  (H) Verify Purity www.ChemicalEngineeringGuy.com
  33. 33.  (A)  Use Phys. Props to verify BP of species at P = 1.0 bar  Results should be similar to: www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=WZQl_y2ci2w TB°C 80.09 110.63 138.36
  34. 34.  (A)  Use Phys. Props to verify BP of species at P = 1.0 bar  Results should be similar to: www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=WZQl_y2ci2w TB°C 80.09 110.63 138.36
  35. 35.  (B) Use Flash2 to verify Data  Components: B, T, p-X  Feed  350 kg/h, 500 kg/h, 150 kg/h  T = 25C, P = 1.2bar  Model  NRTL-RK www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=WZQl_y2ci2w
  36. 36.  Verify Volatilities  B = 80°C, T = 111°C, X = 138°C www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=WZQl_y2ci2w
  37. 37.  Verify Volatilities  B = 80.1°C, T = 110.6°C, X = 138.4°C www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=WZQl_y2ci2w
  38. 38.  Verify Volatilities  B = 80.1°C, T = 110.6°C, X = 138.4°C www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=WZQl_y2ci2w 𝛼 = 𝐾𝐿𝑖𝑔ℎ𝑡−𝐾𝑒𝑦 𝐾 𝐻𝑒𝑎𝑣𝑦−𝐾𝑒𝑦 T LK HK a 80.1 0.8547 0.3356 2.547 110.6 1.9059 0.8461 2.253 138.4 3.428 1.6911 2.027 Average Arithmetic Geometric 2.28 2.27 Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  39. 39.  Calculate (manually)  Min. Number of Stages www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=WZQl_y2ci2w In this equation αave = (α1αB) 1/2 where α1 is the relative volatility of the overhead vapor and αB is the relative volatility of the bottoms liquid.
  40. 40.  (C) Compare models  Getting help in Aspen Plus V10  Compare DSTWU vs. Distil www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=WZQl_y2ci2w
  41. 41.  Compare DSTWU vs. Distil www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=WZQl_y2ci2w Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  42. 42.  (D) Separate light material with  Model Theoretical “DISTIL”  Use Min. Stages to verify:  Min. Reflux Ratio www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=WZQl_y2ci2w Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  43. 43.  Model the “real” DSTWU with DISTIL  N = 13  F = 6  RR = 1.313  D:F = 0.402  P = 1.07, P = 1.10 www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=WZQl_y2ci2w
  44. 44.  (A) Use Phys. Props to verify BP of each species at P = 1.2 bar  (B) Use Flash to verify K values and volatilities (Light and Heavy keys)  (C) Compare DSTWU vs. Distil Models  (D) Use DSWTU Model for min. conditions (Column 1)  (E) Use Distil, for real conditions (Column 1)  (F) Use Flash to verify K values and volatilities (Light and Heavy keys)  (G) Use Distil  (H) Verify Purity www.ChemicalEngineeringGuy.com
  45. 45.  (F) Use Flash/DSTWU to verify K values and volatilities (Light and Heavy keys)  P = 2.5/3.0  Recovery  www.ChemicalEngineeringGuy.com DSTWU2 Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  46. 46.  Preliminary Results of DSTWU2 www.ChemicalEngineeringGuy.com DSTWU2
  47. 47.  (G) Use Flash/DSTWU to verify K values and volatilities (Light and Heavy keys)  Add the pre-pumping www.ChemicalEngineeringGuy.com
  48. 48.  (G) Use Distil  P = 2.5/3.0 www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  49. 49.  Case Study 3  Physical Property Env.  Binary Analysis (Methane : CO2)  Adding Reactions, and Equilibrium Data  Operations: Isothermal Reactor, Purging, Recycling  Compare Claculated Keq vs Built-in Expressions for Keq  Units: R-CSTR, DSTWU, DISTL, RadFrac, Compressor  Personalizing Results (mass/vol/mol, etc…)  Results: Exporting to Spreadsheet, Plotting them www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=Dgwsgpohxmk
  50. 50.  Methanol is to be synthetized from Syngas  Reactor is ISOTHERMAL  Equilibrium Data (see in simulation)  Feed:  CO, CO2, H2  50,200, 600  T = 50°C, P = 1 bar www.ChemicalEngineeringGuy.com 𝐶𝑂 + 2𝐻2 ↔ 𝐶𝐻3 𝑂𝐻 𝛥𝐻 = −91𝑘 𝐽 𝑚 𝑜𝑙 𝐶𝑂2 + 3𝐻2 ↔ 𝐶𝐻3 𝑂𝐻 + 𝐻2 𝑂 𝛥𝐻 = −49.5𝑘 𝐽 𝑚 𝑜𝑙 𝐶𝑂2 + 𝐻2 ↔ 𝐶𝑂 + 𝐻2 𝑂 𝛥𝐻 = −41.2𝑘 𝐽 𝑚 𝑜𝑙 https://www.youtube.com/watch?v=Dgwsgpohxmk
  51. 51.  Main goal is to:  Pre-heat feed (to T = 270°C, P = 40 bar)  Add Recycle + Feed to the Reactor Inlet  Cool down (50°C, P = 10 bar)  Separate Vapors from products  Re-heat recycle (T = 270°C, P = 40 bar)  PURGE gas  Drop pressure of liquid product  Separate methanol/water www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=Dgwsgpohxmk
  52. 52.  (Ai) Verify Heat duty of Reactor (pre/after recycle)  (Aii) For the CSTR, verify Calculated Keq vs. Given Built-in Expressions  (B) Purge Ratio vs. Recycle  (C) Use Binary Analysis for Distillation  (D) DSWTU No. recommended Stages, given RR = 1.5  (E) DSWTU  DISTL  RadFrac  (F) Reboiler/Condenser Heating Duties of Column  (G) Final Product Purity Specification www.ChemicalEngineeringGuy.com
  53. 53.  Try to aim this simulation: www.ChemicalEngineeringGuy.com
  54. 54.  Physical Property Environment  Add Components  Physical Property  PSRK www.ChemicalEngineeringGuy.com
  55. 55.  Simulation Environment  FEED: www.ChemicalEngineeringGuy.com
  56. 56.  HEATER www.ChemicalEngineeringGuy.com  R-CSTR Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  57. 57.  Reactions  RXN – LHHW / Equilibium  NOTE: Verify Enthalpy of Reactions www.ChemicalEngineeringGuy.com
  58. 58.  Reactions  RXN –Equilibium  NOTE: Verify Enthalpy of Reactions www.ChemicalEngineeringGuy.com 𝐶𝑂 + 2𝐻2 ↔ 𝐶𝐻3 𝑂𝐻 𝛥𝐻 = −91𝑘 𝐽 𝑚 𝑜𝑙 𝐶𝑂2 + 3𝐻2 ↔ 𝐶𝐻3 𝑂𝐻 + 𝐻2 𝑂 𝛥𝐻 = −49.5𝑘 𝐽 𝑚 𝑜𝑙 𝐶𝑂2 + 𝐻2 ↔ 𝐶𝑂 + 𝐻2 𝑂 𝛥𝐻 = −41.2𝑘 𝐽 𝑚 𝑜𝑙 Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  59. 59.  REACTOR:  Compare “Compute Keq from Gibbs Free energy”  Vs  Compute Keq from Built-in Expression www.ChemicalEngineeringGuy.com
  60. 60.  Reactor: www.ChemicalEngineeringGuy.com
  61. 61.  Reactor (Based on Aspen Plus Calculation for Gibbs Free energy): www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  62. 62.  REACTOR:  Compare “Compute Keq from Gibbs Free energy”  Vs  Compute Keq from Built-in Expression www.ChemicalEngineeringGuy.com
  63. 63.  Reactions  RXN1, RXN2, RXN3 www.ChemicalEngineeringGuy.com
  64. 64.  Reactions  RXN1, RXN2, RXN3 www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  65. 65.  Reactor (Based on Aspen Plus Calculation for Gibbs Free energy): www.ChemicalEngineeringGuy.com
  66. 66.  Reactor (Based on Aspen Plus Calculation for Gibbs Free energy): www.ChemicalEngineeringGuy.com Auto Given Expression Auto Given Expression
  67. 67.  Continue with flowsheeting www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  68. 68.  Use the INSERT option in Flowhseeting  Select FEED  INSERT Compressor  Compressor  Isentropic, Pdischarge = 40 bar  Degaser (SEP1)  CO2, CO, H2 as gas  H2O, Methanol as liquid www.ChemicalEngineeringGuy.com
  69. 69.  Select Reactor OUTLET  INSERT Valve  Valve  Pdrop = 40bar  Chiller  T = 50C, P = 10 bar / 0 bar  Hydrogen Trap – Membrane (SEP1)  100% H2 recovery  CO2, CO go to purge/stack www.ChemicalEngineeringGuy.com
  70. 70. www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  71. 71.  (B) Add Recycle & Purge www.ChemicalEngineeringGuy.com
  72. 72.  (B) Add Recycle & Purge www.ChemicalEngineeringGuy.com
  73. 73.  (B) Add Recycle & Purge www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  74. 74.  (C) Use Binary Analysis for Distillation  Analysis base:  TXY diagram  Methanol – Water  P = 10 bar www.ChemicalEngineeringGuy.com
  75. 75. www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  76. 76.  (D) DSWTU No. recommended Stages, given RR = 1.50  Valve:  Pdischarge = 1.5 bar www.ChemicalEngineeringGuy.com
  77. 77.  (D) DSWTU No. recommended Stages, given RR = 1.50  Distillation  Start with DSTWU  RR = 1.5  P(cond/reb) = 1.40/1.70 bar  Light Key:  Comp = Methanol  Recovery = 0.95  Heavy Key = water  Comp = water  Recovery = 0.05 www.ChemicalEngineeringGuy.com
  78. 78.  (D) DSWTU No. recommended Stages, given RR = 0.80  Distillation  Start with DSTWU  RR = 1.5  P(cond/reb) = 1.40/1.70 bar  Light Key:  Comp = Methanol  Recovery = 0.95  Heavy Key = water  Comp = water  Recovery = 0.05 www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  79. 79.  (E) DSWTU  DISTL  RadFrac  Distillation  Continue with DISTL  N stages = 7  Feed = 5  RR = 1.5  D:F = 0.50  P(cond/reb) = 1.40/1.70 bar www.ChemicalEngineeringGuy.com
  80. 80.  (E) DSWTU  DISTL  RadFrac  Distillation  Continue with DISTL  N stages = 7  Feed = 5  RR = 1.5  D:F = 0.50  P(cond/reb) = 1.40/1.70 bar www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  81. 81.  (E) DSWTU  DISTL  RadFrac  Distillation  Continue with DISTL  N stages = 7  Feed = 5  RR = 1.5  D:F = 0.50  P(cond/reb) = 1.40/1.70 bar www.ChemicalEngineeringGuy.com
  82. 82.  (E) DSWTU  DISTL  RadFrac  Distillation  Continue with RadFrac  N stages = 7  Feed = 5  RR = 1.5  D:F = 0.50  P(cond/reb) = 1.40/1.70 bar www.ChemicalEngineeringGuy.com
  83. 83. www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  84. 84. www.ChemicalEngineeringGuy.com  (G) Final Product Purity Specification
  85. 85.  Case Study 4  Flowsheeting: “Views” Text/Figures  Adding Reactions  Operations: Isothermal Reactions, Purging, Recycling, Condensation / Boiling  Units: R-PFR, Heat-X (Shortcut / Tube & Shell)  Plotting Results of PFR www.ChemicalEngineeringGuy.com
  86. 86.  Ethanol is to be converted to Acetaldehyde using a Plug flow reactor.  The Reactor is to be isothermal, 274°C, Single-tube  L = 6m, D = 0.12 m  The reaction kinetics are known  Ethanol  H2 + Acetaldehyde (desired)  Ethanol + Acetaldehyde  Ethyl Acetate + H2 (undesired)  Separation of the gases (H2 ,mostly) is imperative  Final Product must be separated from the mix, at least 2/3  Purge can be added, recommended recycle ratio is 90% molar www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8
  87. 87.  (A) Run the PFR with no recycle  (B) Add separation scheme (Flashing, Degasser, Distillation Column)  (C) Add recycle + purge stream  (D) Change HEAT1 for Heat-X (Shell & Tube)  (E) Verify Purity f Products, Specs of Exchanger (Heaters, Reboilers, Condensers) www.ChemicalEngineeringGuy.com
  88. 88.  Try to make a flowsheet similar to this: www.ChemicalEngineeringGuy.com
  89. 89.  Physical Property Environment www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8
  90. 90.  Simulation Environment  Feed + Pump + Mix www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8 Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  91. 91.  Reactor (R-PLUG) www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8
  92. 92.  REACTIONS (RXN1)  Powerlaw www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8 Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  93. 93.  REACTIONS (RXN1)  Powerlaw www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8
  94. 94.  REACTIONS (RXN1)  Powerlaw www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8 Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  95. 95.  REACTIONS (RXN1)  Powerlaw www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8
  96. 96.  PFR Run: www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8
  97. 97.  (B) Add separation scheme (Flashing, Degasser, Distillation Column)  Chiller  dP = 0.25 atm www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8  Flash Drum (FLASH2)  Q = 0  P = 0
  98. 98.  Degaser (Sep1) www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8 Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  99. 99.  Distillation Column (RADFRAC) www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8
  100. 100.  Distillation Column (RADFRAC) www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8 Stage Pressure atm 1 6.8 2 6.92 3 6.95 4 6.93 5 6.97 6 7 7 7.08 8 7.11 9 7.15 10 7.18 11 7.22 12 7.25 13 7.23 14 7.27 15 7.3 16 7.38 17 7.42 18 7.45 19 7.47 20 7.5
  101. 101.  Results of Distillation www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8 Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  102. 102.  (C) Add Recycle + Purge Streams  90% Recycle Rate  10% Purge Rage www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8
  103. 103.  (C) Add Recycle + Purge Streams  90% Recycle Rate  10% Purge Rage www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8 Before recycle After recycle Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  104. 104.  (D) Het Exchanger Property Sets  Size  HEAT1 www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8
  105. 105.  (D) Het Exchanger Property Sets  Setup Heat-X  SHORTCUT  Countercurrent  Exchanger Duty  2.54069e06 (cal/s) www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8
  106. 106.  (D) Het Exchanger Property Sets  Convert to:  Shell & Tube Exchanger www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8
  107. 107. www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8
  108. 108. www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8
  109. 109.  Accept design, run simulation, verify results  Verify:  Exchanger Area  LMDT (Log mean. Difference in Temp)  UA (Overall Coefficient) www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8
  110. 110.  (E) Verify Purity of Products, Specs of Exchanger (Heaters, Reboilers, Condensers) www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8 Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  111. 111.  Add “views” for simplicity  PFR  Heat-X  Separation Scheme  Purger  Plant www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8
  112. 112.  Reactor (PFR) Conversion vs. Length www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8
  113. 113.  Distillation Column Pressure Profile www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=e2MZfVColH8 Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  114. 114.  Process Analysis 5. Dimethyl Ether Production (Design Spec.) 6. Ammonia in Cryogenics (Optimization & Constraint) 7. Cumene Production (Sensitivity Analysis) www.ChemicalEngineeringGuy.com
  115. 115.  Case Study 5  Flowsheeting  Adding Figures & Timestamps, lines to the spreadsheet  Physical Property  Binary Parameters  Design Specification Analysis  Operations: Multiple Reactions, Purging, Recycling, Flashing www.ChemicalEngineeringGuy.com
  116. 116.  Dimethyl ether CH3-O-CH3, is to be produced from CO2 & H2. Initially there is formation of CO + H2O, which is then converted to Methanol and simultaneously to dimethyl ether.  This is done in two reactors, stirred tank, at isothermal conditions. No pressure Drop  Feed is initially 1:3 ratio CO2:H2 at 25°C, P = 1 bar  The First reactor is operated at 50 bar, 400°C, since CO and H2O must be favored  The second reactor is operated at 50bar, 227°C, since methanol  dimethyl ether is required. Note that the second reactor must have a very low content of water, for which a Flash at very cold conditions must be used to separate liquid humidity.  No more than 0.20 kmol/h of Methanol must be lost in the purge/stack  The degasser must recover most of the liquid materials (water, methanol and dimethyl ether) www.ChemicalEngineeringGuy.com
  117. 117.  There is a special equipment which will recover most of non-polar substances in the streams (DIM-Trap)  The dimethyl will be recovered this way  Al other material, methanol-water mix must be sent to a distillation column  NOTE  Try using DSTWU at home  Reaction equilibrium (Ahrrenius) data is to be supplied later.  USE of Design Specification is REQURIED www.ChemicalEngineeringGuy.com
  118. 118.  (A) Run CSTR1, verify results  (B) Use Design Spec For Water flow rate  (C) Verify Reactor 2 , ensure Dimethyl production  (D) Add Recycling & Purge  Design Spec for Degaser  (E) Separate final products DIM-trap & Send to plant www.ChemicalEngineeringGuy.com
  119. 119.  Try to get a simulation similar to this www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=3vm91REoFxI
  120. 120.  Physical Property Environment  First  Method RK-SOAVE / NRTL www.ChemicalEngineeringGuy.com
  121. 121.  Physical Property Environment  First  Method RK-SOAVE / NRTL www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  122. 122.  Physical Property Environment www.ChemicalEngineeringGuy.com
  123. 123.  (A) Run CSTR  Simulation Environment  FEED www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  124. 124. www.ChemicalEngineeringGuy.com
  125. 125.  CSTR (Isothermal)  T =400, P = 50bar, V = 10 m3 www.ChemicalEngineeringGuy.com
  126. 126.  RXN1  Powerlaw www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  127. 127.  RUN  www.ChemicalEngineeringGuy.com
  128. 128.  (B) Use Design Spec For Water flow rate www.ChemicalEngineeringGuy.com
  129. 129.  (B) Use Design Spec For Water flow rate  We want to remove most of water… www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  130. 130.  Add Design Spec. www.ChemicalEngineeringGuy.com
  131. 131.  Add Design Spec. www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  132. 132.  Add Design Spec. www.ChemicalEngineeringGuy.com
  133. 133.  (C) Verify Reactor 2 www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  134. 134.  (C) Verify Reactor 2 www.ChemicalEngineeringGuy.com
  135. 135.  (C) Verify Reactor 2 www.ChemicalEngineeringGuy.com
  136. 136.  Run Reactor 2 www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  137. 137.  (D) Add Recycling & Purge  Design Spec for Degaser www.ChemicalEngineeringGuy.com
  138. 138.  (D) Add Recycling & Purge  Design Spec for Degaser  Verify  No more than 0.10 kmol/h of Methanol is lost www.ChemicalEngineeringGuy.com
  139. 139.  (D) Add Recycling & Purge  Design Spec for Degaser  Verify  No more than 0.10 kmol/h of Methanol is lost  RESULT  T = 0-1°C www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  140. 140.  (D) Add Recycling & Purge  Design Spec for Degaser www.ChemicalEngineeringGuy.com
  141. 141.  Results…  Note that Methanol must be lost 0.23 kmol/h   OK since this is recycled..  Purge loses 0.023 kmol/h www.ChemicalEngineeringGuy.com
  142. 142.  Verify Water content  FLASH1  from 103 to www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  143. 143.  (E) Separate final products DIM-trap & Send to plant www.ChemicalEngineeringGuy.com
  144. 144.  (E) Separate final products DIM-trap & Send to plant www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  145. 145.  Add Table of Results to Flowsheet  Physical Property: Ideal vs. Activity vs. EOS  Tool Analysis  Optimization & Constraint  Operations  Equilibrium Reactions, Purge  Unit Operations  R-Gibbs www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=vevVRwaZXEU
  146. 146.  Ammonia gas is to be produced from a mixture of cryogenic gases, H2, N2,CH4, Ar and some H2 (74.2, 24.7, 0.8, 0.3%)  T feed = 40°C, P = 100 bar, F = 5500 kmol/h  There is a reactor which converts Nitrogen gas and Hydrogen gas to Ammonia, as given in the Haber Process as: N2 + 3H2  2NH3  Use Gibbs Free Energy Reactor 40°C to verify the % composition of the outlet of the reactor  The mixture is then separated from Ammonia via flashing at low T… pre-specified T is -10°C, but the process engineer must verify/optimize the Temperature to maximize gains.  Min. Purity is to be 99.5% Molar in the product of NH3  Purge system has a 90% recovery of reactants, N2, H3 only. All other is purged www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=vevVRwaZXEU
  147. 147.  (A) Run the reactor, verify the composition in the outlet given T-Reactor = 40°C  (Ai) Verify for IDEAL  (Aii) Verify for NRTL  (Aiii) Verify for Peng Robinson (recommended)  (B) Cool down, then flash mixture  Verify Mole flow of Ammonia and purity  (C) Recycle gases, recall that 90% of N2, H2 is recovered, all other is sent to stack & Verify Composition of Reactor  (D) Optimize temperature of Flash. Maximize NH3 flow rate with at least 99.5% purity  (E) Optimize temperature of Reactor. Maximize NH3 flow rate with at least 99.5 % purity www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=vevVRwaZXEU
  148. 148.  Try getting a flowsheet similar to this one www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=vevVRwaZXEU
  149. 149.  (A) Run the reactor, verify the composition in the outlet given T-Reactor = 40°C  (Ai) Verify for IDEAL  (Aii) Verify for NRTL  (Aiii) Verify for Peng Robinson (recommended)  Physical Property Environment  Components www.ChemicalEngineeringGuy.com
  150. 150.  Physical Property Environment  Methods (Peng-Robinson) www.ChemicalEngineeringGuy.com Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  151. 151.  Ammonia is to be produced from Air www.ChemicalEngineeringGuy.com
  152. 152.  Ammonia is to be produced from Air www.ChemicalEngineeringGuy.com
  153. 153.  (Ai) IDEAL www.ChemicalEngineeringGuy.com  (Aii) NRTL  (Aiii) PR
  154. 154.  (B) Cool down, then flash mixture  Verify Mole flow of Ammonia and purity www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=vevVRwaZXEU Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  155. 155.  T-Cool  Approx to -10°C  T-Flash  -30°C www.ChemicalEngineeringGuy.com
  156. 156.  (C) Recycle gases, recall that 90% of N2, H2 is recovered, all other is sent to stack & Verify Composition of Reactor www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=vevVRwaZXEU
  157. 157.  (C) Recycle gases, recall that 90% of N2, H2 is recovered, all other is sent to stack & Verify Composition of Reactor www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=vevVRwaZXEU Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  158. 158.  (C) Recycle gases, recall that 90% of N2, H2 is recovered, all other is sent to stack & Verify Composition of Reactor www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=vevVRwaZXEU
  159. 159.  (C) Recycle gases, recall that 90% of N2, H2 is recovered, all other is sent to stack & Verify Composition of Reactor www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=vevVRwaZXEU
  160. 160.  (D) Optimize temperature of Flash. Maximize NH3 flow rate with at least 99.5% purity www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=vevVRwaZXEU
  161. 161.  (D) Optimize temperature of Flash. Maximize NH3 flow rate with at least 99.5% purity www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=vevVRwaZXEU Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  162. 162.  (E) Optimize temperature of Reactor. Maximize NH3 flow rate with at least 99.5 % purity www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=vevVRwaZXEU
  163. 163.  Finally, add table of results www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=vevVRwaZXEU
  164. 164.  Finally, add table of results www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=vevVRwaZXEU
  165. 165.  Export Table of Results to Spreadsheet/Excel  Manipulators  Dupl / Mult  Tool Analysis  Sensitivity Analysis  Operations  Equilibrium Reactions, Purge  Unit Operations  R-Gibbs  Sensitivity Analysis www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=yWbfzw04SvI
  166. 166.  Cumene (C9H12) is to be produced from the reaction of benzene and propane  C6H6 propylene  Cumene  The reactor is to be tested in: Multi-tubular PFR, CSTR with same residence time as the PFR  Conditions:  T = 25°C, 25 bar  pre-heated to 360°C  Initially, Benzene flow rate = 300 kmol/h,  Isopropylene source  75 kmol/h butane, 225 kmol/h isopropylene  The best reactor is to be selected as the one to operate www.ChemicalEngineeringGuy.com
  167. 167.  The producto must be purified via Distillation(s)  A 99.5%+ Cumene product is required, while maximizing yields  A single Purge & Recycle is allowed www.ChemicalEngineeringGuy.com
  168. 168.  (A) Run PFR, verify residence time & results  (B) Use approx. Residence Time for CSTR  (C) Continue with Reactor: (best choice)  (D) Add Recycle (Benzene is fully recovered)  (E) Use Sensitivity Analysis to verify best case scenario for Benzene Feed www.ChemicalEngineeringGuy.com
  169. 169.  Try to get a simulation similar to this: www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=yWbfzw04SvI
  170. 170.  Physical Property Environment www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=yWbfzw04SvI
  171. 171.  Simulation Environment  FEED = 300 kmol/h  0.75 Propylene  0.25 n-Butane  T = 25°C, P = 25bar www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=yWbfzw04SvI Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  172. 172. www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=yWbfzw04SvI
  173. 173. www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=yWbfzw04SvI
  174. 174. www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=yWbfzw04SvI Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  175. 175.  (A) Run PFR, verify residence time & results www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=yWbfzw04SvI Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  176. 176.  (B) Use approx. Residence Time for CSTR www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=yWbfzw04SvI
  177. 177.  (C) Continue with PFR (best choice)  Add separation scheme (Col1) www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=yWbfzw04SvI
  178. 178.  (C) Continue with PFR (best choice)  Add separation scheme (Col2) www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=yWbfzw04SvI Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  179. 179.  (D) Add Recycle (Benzene is fully recovered) www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=yWbfzw04SvI
  180. 180.  (E) Use Sensitivity Analysis to verify best case scenario for Benzene Feed  (initially 300 kmol/h) www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=yWbfzw04SvI
  181. 181.  (E) Use Sensitivity Analysis to verify best case scenario for Benzene Feed  (initially 300 kmol/h) www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=yWbfzw04SvI OK 261 0.995656 92.87585 OK 262 0.995772 94.59557 OK 263 0.990626 94.95583 Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
  182. 182.  (E) Use Sensitivity Analysis to verify best case scenario for Benzene Feed www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=yWbfzw04SvI
  183. 183.  (E) Use Sensitivity Analysis to verify best case scenario for Benzene Feed www.ChemicalEngineeringGuy.com https://www.youtube.com/watch?v=yWbfzw04SvI Enjoying so far? This is a preview of the BOOTCAMP. Join NOW here: https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/
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This is a slideshow / resource / support material of the course. Get full access (videlectures) https://www.chemicalengineeringguy.com/courses/aspen-plus-bootcamp-with-12-case-studies/ x-x-x Requirements Basic understanding of Plant Design & Operation Strong Chemical Engineering Fundamentals Aspen Plus V10 (at least 7.0) Aspen Plus – Basic Process Modeling (Very Recommended) Aspen Plus – Intermediate Process Modeling (Somewhat Recommended) Description This BOOTCAMP will show you how to model and simulate common industrial Chemical Processes. It is focused on the “BOOTCAMP” idea, in which you will learn via workshops and case studies, minimizing theory to maximize learning. You will learn about: Better Flowsheet manipulation and techniques Understand Property Method Selection and its effects on simulation results More than 15 Unit Operations that can be used in any Industry Model Analysis Tools required for process design Reporting Relevant Results Plot relevant data Analysis & Optimization of Chemical Plants Economic Analysis Dynamic Simulations At the end of this Bootcamp, you will be able to model more industrial processes, feel confident when modeling new processes as well as applying what you have learnt to other industries.

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