Aspen Plus

Kamal I. M. Al-Malah received his PhD degree from Oregon State University in 1993. He served as a Professor of Chemical Engineering in Jordan and other Gulf countries, as well as Former Chairman of the Chemical Engineering Department at the University of Hail in Saudi Arabia. Professor Al-Malah is an expert in both Aspen Plus® and MATLAB® applications. He has created a bundle of Windows-based software for engineering applications.

• Ch1. Introducing Aspen Plus1.1 What does ASPEN stand for?1.2 What is Aspen Plus Process Simulation Model?1.3 Launching Aspen Plus V12.01.4 Beginning a Simulation1.5 Entering Components1.6 Specifying the Property Method1.7 Improvement of the Property Method Accuracy1.8 File Saving1.9 Exercise 1.11.10 Good Flowsheeting Practice1.11 Aspen Plus Built-in Help1.12 For More Information1.13 Home/Class Work 1.1 (Pxy)1.14 Home/Class Work 1.2 (Gmix)1.15 Home/Class Work 1.3 (Likes Dissolve Likes) as Envisaged by NRTL Property Method1.16 Home/Class Work 1.4 (The Mixing Rule)Ch2. More on Aspen Plus Flowsheet Features (1)2.1 Problem Description2.2 Entering and Naming Compounds2.3 Binary Interactions2.4 The “Simulation” Environment: Activation Dashboard2.5 Placing a Block and Material Stream from Model Palette2.6 Block and Stream Manipulation2.7 Data Input, Project Title, & Report Options2.8 Running the Simulation2.9 The Difference among Recommended Property Methods2.10 NIST/TDE Experimental Data2.11 Home-/Class-Work 2.1 (Water-Alcohol System)2.12 Home-/Class-Work 2.2 (Water-Acetone-EIPK System with NIST/DTE Data)2.13 Home-/Class-Work 2.3 (Water-Acetone-EIPK System without NIST/DTE Data)Ch3. More on Aspen Plus Flowsheet Features (2)3.1 Problem Description: Continuation to Chapter Two Problem3.2 The Clean Parameters Step3.3 Simulation Results Convergence3.4 Adding Stream Table3.5 Property Sets3.6 Adding Stream Conditions3.7 Printing from Aspen Plus3.8 Viewing the Input Summary3.9 Report Generation3.10 Stream Properties3.11 Adding a Flash Separation Unit3.12 The Required Input for “Flash3”-Type Separator3.13 Running the Simulation and Checking the Results3.14 Home-/Class-Work 3.1 (Output of Input Data & Results)3.15 Home-/Class-Work 3.2 (Output of Input Data & Results)3.16 Home-/Class-Work 3.3 (Output of Input Data & Results)3.17 Home-/Class-Work 3.4 (The Partition Coefficient of a Solute)Ch4. Flash Separation & Distillation Columns4.1 Problem Description4.2 Adding a Second Mixer and Flash4.3 Design Specifications Study4.4 Exercise 4.1 (Design Spec)4.5 Aspen Plus Distillation Column Options4.6 “DSTWU” Distillation Column4.7 “Distl” Distillation column4.8 “RadFrac” Distillation Column4.9 Home/Class Work 4.1 (Water-Alcohol System)4.10 Home/Class Work 4.2 (Water-Acetone-EIPK System with NIST/DTE Data)4.11 Home/Class Work 4.2 (Water-Acetone-EIPK System without NIST/DTE Data)4.12 Home/Class Work 4.4 (Scrubber)Ch5. Liquid-Liquid Extraction Process5.1 Problem Description5.2 The Proper Selection for Property Method for Extraction Processes5.3 Defining New Property Sets5.4 Property Method Validation versus Experimental Data Using Sensitivity Analysis5.5 A Multi-Stage Extraction Column5.6 The Triangle Diagram5.7 References5.8 Home/Class Work 5.1 (Separation of MEK from Octanol)5.9 Home/Class Work 5.2 (Separation of MEK from Water Using Octane)5.10 Home/Class Work 5.3 (Separation of Acetic Acid from Water Using Iso-Propyl Butyl Ether)5.11 Home/Class Work 5.4 (Separation of Acetone from Water Using Tri-Chloro-Ethane)5.12 Home/Class Work 5.5 (Separation of Propionic Acid from Water Using MEK)Ch6. Reactors with Simple Reaction Kinetic Forms6.1 Problem Description6.2 Defining Reaction Rate Constant to Aspen Plus Environment6.3 Entering Components and Method of Property6.4 The Rigorous Plug Flow Reactor (RPLUG)6.5 Reactor and Reaction Specifications for RPLUG (PFR)6.6 Running the Simulation (PFR Only)6.7 Exercise 6.16.8 Compressor (CMPRSSR) and RadFrac Rectifying Column (RECTIF)6.9 Running the Simulation (PFR + CMPRSSR + RECTIF)6.10 Exercise 6.26.11 RadFrac Distillation Column (DSTL)6.12 Running the Simulation (PFR + CMPRSSR + RECTIF+DSTL)6.13 Reactor and Reaction Specifications for RCSTR6.14 Running the Simulation (PFR + CMPRSSR + RECTIF+DSTL+RCSTR)6.15 Exercise 6.36.16 Sensitivity Analysis: The Reactor’s Optimum Operating Conditions6.17 References6.18 Home/Class Work 6.1 (Hydrogen Peroxide Shelf-Life)6.19 Home/Class Work 6.2 (Esterification Process)6.20 Home/Class Work 6.3 (Liquid-Phase Isomerization of n-Butane)Ch7. Reactors with Complex (Non-Conventional) Reaction Kinetic Forms7.1 Problem Description7.2 Non-Conventional Kinetics: LHHW Type Reaction7.3 General Expressions for Specifying LHHW Type Reaction in Aspen Plus7.3.1 The “Driving Force” for the Non-Reversible (Irreversible) Case7.3.2 The “Driving Force” for the Reversible Case7.3.3 The “Adsorption Expression”7.4 The Property Method: “SRK”7.5 RPLUG Flowsheet for Methanol Production7.6 Entering Input Parameters7.7 Defining Methanol Production Reactions as LHHW Type7.8 Sensitivity Analysis: Effect of Temperature and Pressure on Selectivity7.9 References7.10 Home/Class Work 7.1 (Gas-Phase Oxidation of Chloroform)7.11 Home/Class Work 7.2 (Formation of Styrene from Ethyl-Benzene)7.12 Home/Class Work 7.3 (Combustion of Methane over Steam-Aged Pt-Pd Catalyst)Ch8. Pressure Drop, Friction Factor, NPSHA, and Cavitation8.1 Problem Description8.2 The Property Method: “STEAMNBS”8.3 A Water Pumping Flowsheet8.4 Entering Pipe, Pump, & Fittings Specifications8.5 Results: Frictional Pressure Drop, the Pump Work, Valve Choking, and ANPSH versus RNPSH8.6 Exercise 8.18.7 Model Analysis Tools: Sensitivity for the Onset of Cavitation or Valve Choking Condition8.8 References8.9 Home/Class Work 8.1 (Pentane Transport)8.10 Home/Class Work 8.2 (Glycerol Transport)8.11 Home/Class Work 8.3 (Air Compression)Ch9. The Optimization Tool9.1 Problem Description: Defining the Objective Function9.2 The Property Method: “STEAMNBS”9.3 A Flowsheet for Water Transport9.4 Entering Stream, Pump, and Pipe Specifications9.5 Model Analysis Tools: The Optimization Tool9.6 Model Analysis Tools: The Sensitivity Tool9.7 Last Comments9.8 References9.9 Home/Class Work 9.1 (Swamee-Jain Equation)9.10 Home/Class Work 9.2 (A Simplified Pipe Diameter Optimization)9.11 Home/Class Work 9.3 (The Optimum Diameter for a Viscous Flow)9.12 Home/Class Work 9.4 (The Selectivity of Parallel Reactions)Ch10. Heat Exchanger (H.E.) Design10.1 Problem Description10.2 Types of Heat Exchanger Models in Aspen Plus10.3 The Simple Heat Exchanger Model (“Heater”)10.4 The Rigorous Heat Exchanger Model (“HeatX”)10.5 The Rigorous Exchanger Design and Rating (EDR) Procedure10.5.1 The EDR Exchanger Feasibility Panel10.5.2 The Rigorous Mode within the “HeatX” Block10.6 General Footnotes on EDR Exchanger10.7 References10.8 Home/Class Work 10.1 (Heat Exchanger with Phase Change)10.9 Home/Class Work 10.2 (High Heat Duty Heat Exchanger)10.10 Home/Class Work 10.3 (Design Spec Heat Exchanger)Ch11. Electrolytes11.1 Problem Description: Water De-Souring11.2 What is an Electrolyte?11.3 The Property Method for Electrolytes11.4 The Electrolyte Wizard11.5 Water De-Souring Process Flowsheet11.6 Entering the Specifications of Feed Streams and the Stripper11.7 Appendix: Development of “ELECNRTL” Model11.8 References11.9 Home/Class Work 11.1 (An Acidic Sludge Neutralization)11.10 Home/Class Work 11.2 (CO2 Removal from Natural Gas)11.11 Home/Class Work 11.3 (pH of Aqueous Solutions of Salts)Ch12. Polymerization Processes12.1 The Theoretical Background12.1.1 Polymerization Reactions12.1.2 Catalyst Types12.1.3 Ethylene Process Types12.1.4 Reaction Kinetic Scheme12.1.5 Reaction Steps12.1.6 Catalyst States12.2 High-Density Poly-Ethylene (HDPE) High Temperature Solution Process12.2.1 Problem Definition12.2.2 Process Conditions12.3 Creating Aspen Plus Flowsheet for HDPE12.4 Improving Convergence12.5 Presenting the Property Distribution of Polymer12.6 Home/Class Work 12.1 (Maximizing the Degree of HDPE Polymerization)12.7 Home/Class Work 12.2 (Styrene Acrylo-Nitrile (SAN) Polymerization)12.8 References12.9 Appendix A: The Main Features & Assumptions of Aspen Plus Chain Polymerization Model12.9.1 Polymerization Mechanism12.9.2 Co-polymerization Mechanism12.9.3 Rate Expressions12.9.4 Rate Constants12.9.5 Catalyst Pre-Activation12.9.6 Catalyst Site Activation12.9.7 Site Activation Reactions12.9.8 Chain Initiation12.9.9 Propagation12.9.10 Chain Transfer to Small Molecules12.9.11 Chain Transfer to Monomer12.9.12 Site Deactivation12.9.13 Site Inhibition12.9.14 Co-Catalyst Poisoning12.9.15 Terminal Double Bond Polymerization12.9.16 Phase Equilibria12.9.17 Rate Calculations12.9.18 Calculated Polymer Properties12.10 Appendix B: The Number Average Molecular Weight (MWN) and Weight Average Molecular Weight (MWW)Ch13. Characterization of Drug-Like Molecules Using Aspen Properties13.1 Introduction13.2 Problem Description13.3 Creating Aspen Plus Pharmaceutical Template13.3.1 Entering the User-Defined Benzamide (BNZMD-UD) as Conventional13.3.2 Specifying Properties to Estimate13.4 Defining Molecular Structure of BNZMD-UD13.5 Entering Property Data13.6 Contrasting Aspen Plus Databank (BNZMD-DB) versus BNZMD-UD13.7 References13.8 Home/Class Work 13.1 (Vanillin)13.9 Home/Class Work 13.2 (Ibuprofen)Ch14. Solids Handling14.1 Introduction14.2 Problem Description #1: The Crusher14.3 Creating Aspen Plus Flowsheet14.3.1 Entering Components Information14.3.2 Adding the Flowsheet Objects14.3.3 Defining the Particle Size Distribution (PSD)14.3.4 Calculation of the Outlet PSD14.4 Exercise 14.1: (Determine Crusher Outlet PSD from Comminution Power)14.5 Exercise 14.2: (Specifying Crusher Outlet PSD)14.6 Problem Description #2: The Fluidized Bed for Alumina Dehydration14.7 Creating Aspen Plus Flowsheet14.7.1 Entering Components Information14.7.2 Adding the Flowsheet Objects14.7.3 Entering Input Data14.7.4 Results14.8 Exercise 14.3: (Re-Converging the Solution for an Input Change)14.9 References14.10 Home/Class Work 14.1 (KCl Drying)14.11 Home/Class Work 14.2 (KCl Crystallization)14.12 APPENDIX A: Solids Unit Operations14.12.1 Unit Operation Solids Models14.12.2 Solids Separators Models14.12.3 Solids Handling Models14.13 APPENDIX B: Solids Classification14.14 APPENDIX C: Predefined Stream Classification14.15 APPENDIX D: Substream Classes14.16 APPENDIX E: Particle Size Distribution (PSD)14.17 APPENDIX F: Fluidized BedsCh15. Aspen Plus Dynamics15.1 Introduction15.2 Problem Description15.3 Preparing Aspen Plus Simulation for Aspen Plus Dynamics (APD)15.4 Conversion of Aspen Plus Steady-State into Dynamic Simulation15.4.1 Modes of Dynamic CSTR Heat Transfer15.4.2 Creating Pressure-Driven Dynamic Files for APD15.5 Opening a Dynamic File Using APD15.6 The “Simulation Messages” Window15.7 The Running Mode: Initialization15.8 Adding Temperature Control (TC) Unit15.9 Snapshots Management for Captured Successful Old Runs15.10 The Controller Faceplate15.11 Communication Time for Updating/Presenting Results15.12 The Closed-Loop Auto-Tune Variation (ATV) Test versus Open-Loop Tune-Up Test15.13 The Open-Loop (Manual Mode) Tune-Up for Liquid Level Controller15.14 The Closed-Loop Dynamic Response for Liquid Level Load Disturbance15.15 The Closed-Loop Dynamic Response for Liquid Level Set-Point Disturbance15.16 Accounting for Dead/Lag Time in Process Dynamics15.17 The Closed-Loop (Auto Mode) ATV Test for Temperature Controller (TC)15.18 The Closed-Loop Dynamic Response: “TC” Response to Temperature Load Disturbance15.19 Interactions between “LC” and “TC” Control Unit15.20 The Stability of a Process without Control15.21 The Cascade Control15.22 Monitoring of Variables as Functions of Time15.23 Final Notes on the Virtual (Dry) Process Control in APD15.24 References15.25 Home/Class Work 15.1 (A Cascade Control of a Simple Water Heater)15.26 Home/Class Work 15.2 (A CSTR Control with “LMTD” Heat Transfer Option)15.27 Home/Class Work 15.3 (A PFR Control for Ethyl-Benzene Production)Ch16. Safety & Energy Aspects of Chemical Processes16.1 Introduction16.2 Problem Description16.3 The “Safety Analysis” Environment16.4 Adding a Pressure Safety Valve (PSV)16.5 Adding a Rupture Disk (RD)16.6 Presentation of Safety-Related Documents16.7 Preparation of Flowsheet for “Energy Analysis” Environment16.8 The “Energy Analysis” Activation16.9 The “Energy Analysis” Environment16.10 The Aspen Energy Analyzer16.11 Home/Class Work 16.1 (Adding a Storage Tank Protection)16.12 Home/Class Work 16.2 (Separation of C2/C3/C4 Hydrocarbon Mixture)Ch17. Aspen Process Economic Analyzer (APEA)17.1 Optimized Process Flowsheet for Acetic Anhydride Production17.2 Costing Options in Aspen Plus17.2.1 Aspen Process Economic Analyzer (APEA) Estimation Template17.2.2 Feed and Product Stream Prices17.2.3 Utility Association with a Flowsheet Block17.3 The First Route for Chemical Process Costing17.4 The Second Route for Chemical Process Costing17.4.1 Project Properties17.4.2 Loading Simulator Data17.4.3 Mapping and Sizing17.4.4 Project Evaluation17.4.5 Fixing Geometrical Design-Related Errors17.4.6 Executive Summary17.4.7 Capital Costs Report17.4.8 Investment Analysis17.5 Home/Class Work 17.1 (Feed/Product Unit Price Effect on Process Profitability)17.6 Home/Class Work 17.2 (Using European Economic Template)17.7 Home/Class Work 17.3 (Process Profitability of Acetone Recovery from Spent Solvent)17.8 Appendix17.8.1 Net Present Value (NPV) for a Chemical Process Plant17.8.2 Discounted Payout (Payback) Period (DPP)17.8.3 Profitability Index17.8.4 Internal Rate of Return (IRR)17.8.5 Modified Internal Rate of Return (MIRR)Ch18. Term Projects (TP) 18.1 What is Aspen Custom Modeler18.2 Main Feature of ACM18.3 Modeling and Simulation of a Simple Constant-Temperature Mixing Tank18.4 Modeling and Simulation of a non-Isothermal Mixing Tank18.5 Modeling and Simulation of a Flash Drum18.6 Modeling and Simulation of Heat Slab18.7 Modeling and Simulation of an Absorber18.8 Modeling and Simulation of a Jacketed Reactor18.9 Modeling and Simulation of a Heat Exchanger18.10 Merging of ACM models into AP Model PaletteCh19. Aspen Custom Modeler (ACM)19.1 TP #1: Production of Acetone via the Dehydration of Iso-Propanol19.2 TP #2: Production of Formaldehyde from Methanol (Sensitivity Analysis)19.3 TP #3: Production of Di-Methyl Ether (Process Economics & Control)18.3.1 Economic Analysis18.3.2 Process Dynamics & Control19.4 TP #4: Production of Acetic Acid via Partial Oxidation of Ethylene Gas19.5 TP #5: Pyrolysis of Benzene19.6 TP #6: Re-Use of Spent Solvents19.7 TP#7: Solids Handling: Production of Potassium Sulfate from Sodium Sulfate19.8 TP #8: Solids Handling: Production of CaCO3-Based Agglomerate as a General Additive19.9 TP #9: Solids Handling: Formulation of Di-Ammonium Phosphate and Potassium Nitrate Blend Fertilizer19.10 TP #10: “Flowsheeting Options” | “Calculator”: Gas De-Souring and Sweetening Process19.11 TP #11: Using More Than One Property Method and Stream Class: Solid Catalyzed Direct Hydration of Propylene to Iso-Propyl Alcohol (IPA)19.12 TP #12: Polymerization: Production of Poly-Vinyl Acetate (PVAC)19.13 TP #13: Polymerization: Emulsion Copolymerization of Styrene and Butadiene to Produce SBR19.14 TP #14: Polymerization: Free Radical Polymerization of Methyl-Methacrylate to Produce Poly (Methyl Methacrylate)19.15 TP #15: LHHW Kinetics: Production of Cyclo-Hexanone-Oxime (CYCHXOXM) via Cyclo-Hexanone Ammoximation Using Clay-Based Titanium Silicalite (TS) Catalyst