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Chemical Engineering Process Simulation PDF

498 Pages·2022·23.05 MB·English
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Chemical Engineering Process Simulation This page intentionally left blank Chemical Engineering Process Simulation Second Edition Edited by Dominic C. Y. Foo Department of Chemical and Environmental Engineering/Centre of Excellence for Green Technologies, University of Nottingham Malaysia, Semenyih, Selangor, Malaysia Elsevier Radarweg29,POBox211,1000AEAmsterdam,Netherlands TheBoulevard,LangfordLane,Kidlington,OxfordOX51GB,UnitedKingdom 50HampshireStreet,5thFloor,Cambridge,MA02139,UnitedStates Copyright(cid:1)2023ElsevierInc.Allrightsreserved. Nopartofthispublicationmaybereproducedortransmittedinanyformorbyanymeans, electronicormechanical,includingphotocopying,recording,oranyinformationstorage andretrievalsystem,withoutpermissioninwritingfromthepublisher.Detailsonhowto seekpermission,furtherinformationaboutthePublisher’spermissionspoliciesandour arrangementswithorganizationssuchastheCopyrightClearanceCenterandtheCopyright LicensingAgency,canbefoundatourwebsite:www.elsevier.com/permissions. Thisbookandtheindividualcontributionscontainedinitareprotectedundercopyrightby thePublisher(otherthanasmaybenotedherein). Notices Knowledgeandbestpracticeinthisfieldareconstantlychanging.Asnewresearchand experiencebroadenourunderstanding,changesinresearchmethods,professionalprac- tices,ormedicaltreatmentmaybecomenecessary. Practitionersandresearchersmustalwaysrelyontheirownexperienceandknowledgein evaluatingandusinganyinformation,methods,compounds,orexperimentsdescribed herein.Inusingsuchinformationormethodstheyshouldbemindfuloftheirownsafety andthesafetyofothers,includingpartiesforwhomtheyhaveaprofessionalresponsibility. Tothefullestextentofthelaw,neitherthePublishernortheauthors,contributors,or editors,assumeanyliabilityforanyinjuryand/ordamagetopersonsorpropertyasamatter ofproductsliability,negligenceorotherwise,orfromanyuseoroperationofanymethods, products,instructions,orideascontainedinthematerialherein. ISBN:978-0-323-90168-0 ForinformationonallElsevierpublicationsvisitourwebsiteat https://www.elsevier.com/books-and-journals Publisher:SusanDennis AcquisitionsEditor:AnitaKoch EditorialProjectManager:JudithClarissePunzalan ProductionProjectManager:PaulPrasadChandramohan CoverDesigner:VickyPearsonEsser TypesetbyTNQTechnologies Dedication The editor and author Dominic Foo would like to dedicate this book to his wife Cecilia and their kids Irene, Jessica, and Helena. He would also like to dedicate this book to his students who join his process simulation classes at the University of Nottingham Malaysia. This page intentionally left blank Contents Contributors xvii Acknowledgments xix Howtousethisbook xxi Part I Basics of process simulation 1. Introduction to process simulation DominicC.Y. FooandRafilElyas 1.1 Process designandsimulation 4 1.2 Historicalperspectiveforprocesssimulation 6 1.3 Basic architectures forcommercialsoftware 7 1.4 Basic algorithmsforprocesssimulation 9 1.4.1 Sequentialmodularapproach 9 1.4.2 Equation-orientedapproach 11 1.5 Degrees offreedom analysis 11 1.6 Incorporationofprocesssynthesis modelandsequential modular approach 15 1.6.1 Tengoodhabitsforprocesssimulation 20 Exercises 26 References 27 Furtherreading 28 2. Registration of new components DennyK.S.Ng,ChienHwaChongand Nishanth Chemmangattuvalappil 2.1 Registrationofhypotheticalcomponents 29 2.1.1 HypotheticalcomponentregistrationwithAspen HYSYS 30 2.1.2 HypotheticalcomponentregistrationwithPRO/II 30 2.2 Registrationofcrudeoil 32 Exercise 53 References 55 vii viii Contents 3. Physical property estimation and phase behavior for process simulation RafilElyas 3.1 Chemicalengineeringprocesses 58 3.1.1 Inletseparator 58 3.1.2 Heatexchanger 59 3.1.3 Gascompressor 59 3.2 Thermodynamicprocesses 60 3.2.1 Characteristicthermodynamicrelationships 61 3.2.2 Maxwellrelationships 62 3.3 Equationsofstate 63 3.3.1 Theidealgaslaw(c.1834) 63 3.3.2 Correctionstotheidealgaslaw (cubicequationsofstate) 63 3.4 Liquidvolumes 67 3.5 Viscosityandother properties 69 3.6 Phase equilibria 69 3.6.1 Vaporphasecorrection 71 3.6.2 Liquidphasecorrections 72 3.6.3 Bringingitalltogether 74 3.7 Flash calculations 75 3.7.1 “MESH” equations 76 3.7.2 Bubblepointflash 77 3.7.3 Dewpointflash 77 3.7.4 Two-phasepressureetemperatureflash 78 3.7.5 Otherflashroutines 78 3.8 Phase diagrams 79 3.8.1 Pressureetemperaturediagramsofpurecomponents andmixtures 79 3.8.2 Retrogradebehavior 83 3.9 Conclusions 84 Exercises 84 References 86 4. Simulation of recycle streams DominicC.Y.Foo,SiewhuiChong andNishanthChemmangattuvalappil 4.1 Typesofrecyclestreams 87 4.2 Tipsinhandling recyclestreams 88 4.2.1 Analyzetheflowsheet 88 4.2.2 Provideestimatesforrecyclestreams 90 4.2.3 Simplifytheflowsheet 90 4.2.4 Avoidoverspecifyingmassbalance 91 4.2.5 Checkfortrappedmaterial 92 4.2.6 Increasenumberofiterations 92 Contents ix 4.3 Recycleconvergenceandaccelerationtechniques 93 Exercises 99 References 100 Furtherreading 100 Part II UniSim design 5. Basics of process simulation with UniSim design DominicC.Y. Foo 5.1 Exampleonn-octaneproduction 103 5.2 Stage1:basic simulationsetup 104 5.3 Stage2:modeling ofreactor 108 5.4 Stage3:modeling ofseparationunit 112 5.5 Stage4:modeling ofrecyclesystem 113 5.5.1 Materialrecyclesystem 114 5.5.2 Energyrecyclesystem 117 5.6 Conclusions 121 Exercises 121 References 124 6. Design and simulation of distillation processes Nishanth ChemmangattuvalappilandJiaWenChong 6.1 Fundamentalsofdistillationcalculations 125 6.2 Distillationcolumn simulation 127 6.3 Debutanizerexample 128 6.3.1 Settinguptheproblem 128 6.3.2 Operating pressureselection 130 6.3.3 Effectofpressureonrelativevolatility 130 6.3.4 Effectofpressureonutilityselection 131 6.4 Preliminarydesignusingshortcutdistillation 132 6.5 Rigorous distillationcolumn design 133 6.6 Conclusions 137 Exercises 137 References 138 7. Modeling and optimization of separation and heating medium systems for offshore platform DominicC.Y. Foo,RaymondE.H.OoiandPitchaimuthuDiban 7.1 Oilandgasprocessing facilityforoffshoreplatform 139 7.2 Modelingofoilandgasprocessingfacilities 140 7.3 Process optimizationofheatingmediumsystems 145 7.4 Heatexchanger designconsideration 149 Exercises 152 References 154

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