AVEVA™ Process Simulation

Examples Guide

Version 2023.2
April 2023

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Version 2023.2
© 2023 AVEVA Group plc and its subsidiaries. All rights reserved. Page 2
Acknowledgements

CSPARSE
To analyze and report proper variable specification, AVEVA Process Simulation uses CSPARSE, a library of direct
methods for sparse linear systems by Timothy Davis. CSPARSE is free software and is distributed under the GNU
Lesser General Public License. We provide a copy of the GNU Lesser General Public License along with the AVEVA
Process Simulation installation files. You can also locate this license at http://www.gnu.org/licenses/
lgpl-3.0.txt. You can find more information about CSPARSE at http://www.suitesparse.com.
The source code used in AVEVA Process Simulation is available at http://github.com/DrTimothyAldenDavis/
SuiteSparse. We do not modify the original code.
© 2006 Timothy A. Davis
KLU
AVEVA Process Simulation uses KLU as its linear equation solver. KLU is an open-source solver package with a
focus on solving sparse linear systems of equations. KLU is free software and is distributed under the GNU Lesser
General Public License. We provide a copy of the GNU Lesser General Public License along with the AVEVA
Process Simulation installation files. You can also locate this license at http://www.gnu.org/licenses/
lgpl-3.0.txt. You can find more information about KLU at http://www.suitesparse.com.
The source code used in AVEVA Process Simulation is available at http://github.com/DrTimothyAldenDavis/
SuiteSparse. We do not modify the original code.
© 2004-2013 University of Florida
by Timothy A. Davis and Ekanathan Palamadai
Contents

Acknowledgements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

A3 - Azeo Splitter IPA Water with CH VLLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Libraries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

A6G - Ammonia Synthesis EQ. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Libraries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Reaction Submodels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

A7 - Reactive Distillation MTBE Plant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Reaction Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Version 2023.2
© 2023 AVEVA Group plc and its subsidiaries. All rights reserved. Page 4
 AVEVA™ Process Simulation Examples Guide
Contents

Methanol Recovery Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Libraries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Reaction Submodels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Scenarios. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

A8 - Air Separation Plant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Scenario. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Snapshot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

AA1 - Supercritical CO2 Brayton Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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 AVEVA™ Process Simulation Examples Guide
Contents

AA2 — Hydrogen Liquefaction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Reaction Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Scenarios. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Process and Fluid Flow Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

AA3 - Labscale PSA Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Scenarios. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Process and Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

AA4 - Fullsize PSA Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

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Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Scenarios. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Process and Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

BA1 - Water Methanol Batch Separation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Libraries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Scenarios. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

C1 - Water Methanol Separation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

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CC2 - Cumene Production. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
HXTR Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Custom Reactor Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Model Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

CC3 - Benzene Column Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Scenarios. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

CC25 - DME Process Optimization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

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Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Economics and Optimization Sets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

CC28 – H2 Production via Steam Methane Reforming. . . . . . . . . . . . . . . . . . . . . . . . . 161

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Libraries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Reaction Submodels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Economics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

F1 - Flare Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

F2 - Flare Relief Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

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Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Simulation Construction Workflow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

F3 - Flare Relief with Mixed Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Workflow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

F4 - Two Phase Flare Relief. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

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Contents

Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

G2 - Deethanizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Scenarios. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Process and Fluid Flow Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

GG1 - Dynamic Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Curves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Scenarios. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Process Mode and Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

GG5 - Cryogenic Depressuring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

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Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

H1 - Water Hammer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Process and Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

H2 - Heat Exchanger Tube Rupture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
UOM Slate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

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Contents

Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Process and Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

RR1 - Vacuum Transfer Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

SS1 - Renewable Energy Grid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

Review Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Libraries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Curves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Scenarios. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

U1 - Cooling Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

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Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Process Mode and Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

U2 - Steam Turbine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Process Mode and Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

U3 - Refinery Steam Distribution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Process Mode and Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

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U4 - Cooling Water Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Curves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Fluid Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

U5 - Fire Water Distribution Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Problem Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Process Mode and Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

U6 - Hot Oil Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Mode Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

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Contents

Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297

Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Fluid Flow Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Dynamics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

U7 - Refinery Steam Balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

Revision Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Process Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Simulation Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Library. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Process Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Snapshots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Microsoft Excel Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

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A3 - Azeo Splitter IPA Water with CH VLLE

Revision Log
Date By Comments

17 Mar 2022 SW Initial issue.

30 Mar 2023 RC Updated heat exchanger and decanter to use phase overrides instead of
FluidChange models.
Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
This example demonstrates the separation of a mixed isopropyl alcohol (IPA) and water stream by using
azeotropic distillation with a cyclohexane entrainer. The first tower isolates IPA in the bottom product. The
second tower isolates purified water in the bottom product while recycling a mixed distillate to the first tower.
We mix the recycle with fresh feed before we send it to the first tower. We mix the makeup cyclohexane with the
organic-phase recycle from the reflux drum of the first tower before we send it to the first tower as well.

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Figure 1: An IPA-Water Separation Process by Using Azeotropic Distillation in AVEVA Process

Simulation

Process Description
This simulation demonstrates the separation of a mixed IPA and water stream by using azeotropic distillation
with a cyclohexane entrainer. IPA-water systems exhibit azeotropic behavior at lower concentrations of water.
This hinders the separation in typical fractional distillation columns, since there's little difference between the
vapor and liquid compositions at low water concentrations. The Binary1 Binary Phase Diagram in the simulation
illustrates this behavior.

Figure 2: IPA-Water Azeotropic Behavior

To break the azeotrope, we add a cyclohexane (CH) entrainer to the system before we send it to a fractional
distillation column. The IPA-Water-CH mixture forms a lower-boiling azeotrope among two liquid phases. The
addition of the CH entrainer modifies the activity coefficients of the IPA and water in the mixtures and pushes
the IPA and water concentrations outside the binary azeotropic zone. This in turn provides better separation
between IPA and water. The Ternary1 Ternary Phase Diagram in the simulation illustrates this behavior.

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Figure 3: IPA-Water-CH Separation at 139 kPa

The process includes two fractional distillation towers (Columns) with a decanter (Separator) between the two
towers. The first tower (T1) isolates IPA in the bottom product. The decanter (V1) separates the organic liquid
phase from the aqueous liquid phase and recycles the organic phase to T1. The second tower (T2) isolates
purified water in the bottom product and recycles a mixed distillate to T1.
We mix the recycle from T2 with fresh IPA-water feed before we feed it to T1. We mix the organic reflux from V1
with fresh make-up cyclohexane (CH) before we feed it to T1.
Because vapor-liquid-liquid equilibrium (VLLE) calculations can be computationally expensive, we use VLLE
calculations only in the separation portion of the simulation. We know that CH breaks the azeotrope and no
second liquid layer forms in T1. The second liquid phase forms only at the condenser operating conditions.
Therefore, the liquid-liquid separation portion includes only the E1 heat exchanger and V1. We set the
E1.PhasesSS and V1.Phases parameters to VLLE to override the phases selection from the fluid (VLEFluid) and
perform VLLE calculations instead.
The following tables show the feed compositions, process conditions, and equipment configuration and sizes.
The tables show only those values that differ from the default values for each model.
Table 1: Feed Compositions

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Composition
Component
Feed Makeup_CH

WATER 0.35 0
IPA 0.65 0
CH 0 1
Table 2: Process Conditions

Variable Description Value UOM

Feed.T Temperature of the fresh IPA-water mixture that enters the 90 °C

process.
Feed.P Pressure of the fresh IPA-water mixture that enters the 175 kPa
process.
Feed.F* Molar flowrate of the fresh IPA-water mixture that enters the 100 kmol/h
process.
Makeup_CH.T Temperature of the fresh CH that enters the process. 50 °C
Makeup_CH.P Pressure of the fresh CH that enters the process. 200 kPa
E1.Tso Shell-side outlet temperature of the E1 heat exchanger. 60 °C
E1.Tti Tube-side inlet temperature of the E1 heat exchanger. 29.85 °C
E1.Tto Tube-side outlet temperature of the E1 heat exchanger. 50 °C
E1.DPs Shell-side pressure drop of the E1 heat exchanger. 1 kPa
E1.DPt Tube-side pressure drop of the E1 heat exchanger. 1 kPa
V1.T* Temperature of the decanter. 45 °C
T1.Ptop Pressure at the top stage of the first distillation tower. 140 kPa
T1.DPstage Pressure drop for each stage of the first distillation tower. 2 kPa
T1.DPreb Pressure drop for the reboiler of the first distillation tower. 2 kPa
T1.VFboilup Molar vapor fraction for the reboiler return of the first 1 mol frac
distillation tower.
P1.W* Mass flowrate of the P1 Pump. 12,270 kg/h
P1.DP Pressure drop of the P1 Pump. 100 kPa
P2.P2* Outlet pressure of the P2 Pump. 200 kPa
E2.VFto* Tube-side outlet vapor fraction of the E2 heat exchanger. 0.5 mol frac
E2.DPt Tube-side pressure drop of the E2 heat exchanger. 1 kPa

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Variable Description Value UOM

T2.Ptop Pressure at the top stage of the second distillation tower. 180 kPa
T2.DPstage Pressure drop for each stage of the second distillation tower. 1 kPa
T2.DPcond Pressure drop for the condenser of the second distillation 0 kPa
tower.
T2.DPreb Pressure drop for the reboiler of the second distillation 0 kPa
tower.
T2.Lreflux* Liquid molar reflux rate of the second distillation tower. 53.3 kmol/h
T2.VFcond Condenser vapor fraction of the second distillation tower. 0 mol frac
E3.Tto* Tube-side outlet temperature of the E3 heat exchanger. 88 °C
E3.DPt Tube-side pressure drop of the E3 heat exchanger. 1 kPa
Pure_IPA.z[IPA]* Molar composition of IPA in the final IPA product that exits 0.999 mol frac
the process.
SNK1.z[IPA]* Molar composition of IPA in the final water product that exits 0.001 mol frac
the process.
* You must switch specifications to set these values. See Process Mode for more information.

Table 3: Equipment Configuration and Sizes

Variable or Parameter Description Value UOM

T1.NStages Number of stages in the first distillation tower. 19 -

T1.FeedStage[S11] Stage at which the S11 stream enters the first distillation 3 -
tower.
T1.FeedStage[Rflx] Stage at which the Rflx stream enters the first distillation 1 -
tower.
T1.Condenser Configuration for the condenser of the first distillation None -
tower.
T1.Reboiler Configuration for the reboiler of the first distillation tower. Internal -
T1.Contact Overall contact efficiency factor of the first distillation 1 fraction
tower.
E1.PhasesSS Override for the phases selection in the fluid on the shell VLLE -
side of the heat exchanger.
V1.Phases Override for the phases selection in the fluid. VLLE -
V1.L Horizontal length of the decanter. 2 m
V1.D Diameter of the decanter. 1 m

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Variable or Parameter Description Value UOM

V1.Lboot Length of the boot of the decanter. 0.5 m

V1.Dboot Diameter of the boot of the decanter. 0.5 m
T2.NStages Number of stages in the first distillation tower. 18 -
T2.FeedStage[Rcy3] Stage at which the Rcy3 stream enters the second 9 -
distillation tower.
T2.Condenser Configuration for the condenser of the second distillation Internal -
tower.
T2.Reboiler Configuration for the reboiler of the second distillation Internal -
tower.
T2.Contact Overall contact efficiency factor of the second distillation 1 fraction
tower.

Simulation Model
Libraries
This simulation uses the default Process Library from AVEVA Process Simulation.

Fluids
This simulation uses two fluids from the simulation-specific Model Library, VLEFluid and VLLEFluid.
Both fluids use the NRTL method, which provides the best fit for this non-ideal system. They also use the same
thermodynamic data for calculations. However, VLEFluid includes vapor-liquid equilibrium (VLE) calculations
while VLLEFluid includes vapor-liquid-liquid equilibrium (VLLE) calculations. We use VLLEFluid only in:
• The Ternary1 Ternary Phase Diagram to visualize the three-phase separation in the decanter following the
first distillation tower.
• The Binary1 Binary Phase Diagram to visualize the behavior of the azeotrope between water and isopropyl
alcohol.

Mode Summary
This example uses Process mode to meet the design requirements and perform a heat and material balance on
the process. The objective of this mode is to provide a conceptual design that we can use to refine further
process development. We can then extend the process to a detailed engineering design within AVEVA Process
Simulation.

Process Mode
The objective of Process mode is to provide an overall mass and energy balance for the process and to estimate
the product flowrates and compositions. We switch the following process specifications to meet the design
requirements:

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• For the Feed Source, we switch the mass flow (W) and molar flow (F) specifications to set the fresh IPA-water
feed to 100 kmol/h.
• We calculate the boilup ratio of the first tower (T1.BoilupRatio) to set the feed flow of the cyclohexane feed
to the first tower (P1.W) to 12,270 kg/h.
• For the V1 Separator (decanter), we calculate the heat duty (Duty) to set the temperature (T) to 45°C.
• For the P2 Pump, we calculate the pressure drop (DP) to set the outlet pressure (P2) to 200 kPa.
• For the E2 heat exchanger, we calculate the heat duty (Duty) to set the tube-side outlet vapor fraction (VFto)
to 0.5.
• For the E3 heat exchanger, we calculate the heat duty (Duty) to set the tube-side outlet temperature (Tto) to
88°C.
• For the second tower (T2), we also calculate the reflux ratio (RefluxRatio) to set the molar reflux rate (Lreflux)
to 53.3 kmol/h.
• We calculate the boilup ratio of the second tower (T2.BoilupRatio) to set the molar composition of IPA in the
final water product (SNK1.z[IPA]) to 0.001.
• We calculate the mass flow rate of the fresh cyclohexane feed (Makeup_CH.W) to set the molar composition
of IPA in the final IPA product (Pure_IPA.z[IPA]) to 0.999.

Results
The following figures show the composition, phase flow, and temperature profiles throughout the first distillation
tower (T1).

Figure 4: Composition Profiles in the First Distillation Tower

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Figure 5: Vapor Flow, Liquid Flow, and Temperature Profiles in the First Distillation Tower
With the addition of cyclohexane (CH) to the isopropyl alcohol (IPA) and water mixture, we achieve a good
separation between the IPA and water. Water is concentrated at the top of the distillation tower while we
achieve effectively pure IPA at the bottom of the distillation tower.
The increase in water concentration after the first distillation tower and subsequent liquid-liquid phase
separation in the decanter provides us with an IPA-water stream that exceeds the azeotropic area of the vapor-
liquid equilibrium. We can then separate water and IPA in the second distillation tower without complications
from the azeotrope.
The following figures show the composition, phase flow, and temperature profiles throughout the second
distillation tower (T2).

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Figure 6: Composition Profiles in the Second Distillation Tower

Figure 7: Vapor Flow, Liquid Flow, and Temperature Profiles in the Second Distillation Tower
We find good separation between IPA and water within the second distillation tower. We achieve effectively pure
water at the bottom of the tower, as required by the process specifications. The top product of the second

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distillation tower is close enough to the fresh feed composition that we can recycle it back to the first distillation
tower as additional IPA-water feed.

Snapshots
This simulation includes the following snapshot:
• Pro 1: A solved steady-state, base-case solution in Process mode. If you make any changes to the simulation
that cause errors in Process mode, revert to this snapshot.

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A6G - Ammonia Synthesis EQ

Revision Log
Date By Comments

03 May 2022 SW Initial issue.

Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
This example demonstrates a simplified ammonia synthesis and purification process. Ammonia is produced from
a gaseous 3:1 hydrogen-nitrogen feed over an activated iron catalyst at elevated temperature and pressure to
achieve modest single-pass conversion (less than 30%). This modest conversion necessitates a large recycle flow
rate to return unreacted feed to the converter. Inert gases introduced from upstream natural gas reforming
processes can accumulate in the synthesis loop and unfavorably shift reaction equilibrium, necessitating a purge
stream.
Use this example simulation to explore the effect of inert concentrations on the synthesis and separation
processes for a simplified ammonia synthesis plant.

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A6G - Ammonia Synthesis EQ

Figure 1: An Ammonia Synthesis Plant Modeled in AVEVA Process Simulation

Process Description
This simulation includes one equilibrium reactor (RX7) and three flash drums (D6, D7, and D8).
The feed to the synthesis loop (SRC1) comes from reformed natural gas and is equivalent to a natural gas
consumption of six million square cubic feet per day (SCFD). We mix this fresh feed with a recycle stream from
the flash drum immediately downstream of RX7 (D6). We send this mixed feed to the D7 flash drum.
D7 chills the fluid to remove excess ammonia (introduced by the recycle) from the vapor and to produce
additional liquid ammonia. The resulting vapor product (S6) serves as the equilibrium reactor feed.
We want to study how the concentration of the inert components in the reactor feed affect the conversion to
ammonia and by extension the concentration of ammonia in the final ammonia product. Therefore, we add a
flowsheet variable (Rx_Feed_Inerts) to the simulation as well as a flowsheet equation (Eqn1) to determine this
value. We calculate the Rx_Feed_Inerts variable as the sum of the compositions of the two inert components
(argon and methane) in the reactor feed:

We use two heat exchangers to preheat the reactor feed. The first heat exchanger (X4) uses the feed to D7 as the
hot, tube-side fluid. The second heat exchanger (FDEF) uses the reactor product (S9) as the hot, tube-side fluid.
We feed the reactor product to D6, which chills the reactor product and provides the primary separation. We
split the vapor product of D6 between a purge stream (S18) and a recycle stream (S19). The purge stream helps
reduce the accumulation of inert components in the synthesis loop, which affects the ammonia conversion in
RX7. The recycle stream returns unreacted feed to the synthesis loop.

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We add a Compressor (CP4) to the recycle stream to maintain pressure in the synthesis loop. We also add Valves
(XV1, XV2, XV3, and XV4) on every feed stream to a flash drum to facilitate the pressure requirements for each
flash drum.
We combine the liquid products from D7 and D6 in a final flash drum (D8) to produce the final liquid ammonia
product (S16).
The following table shows the compositions and thermal condition of the feed to the synthesis loop.
Table 1: Feed Conditions

Variable Description Value UOM

SRC1.F* Molar flow rate 3256.54 lbmol/h

SCR1.P Pressure 4955 psig
SRC1.T Temperature 95 °F
SRC1.M[ARGON] Unnormalized molar feed composition of argon 9.58 lbmol
SRC1.M[H2] Unnormalized molar feed composition of hydrogen 2424.3 lbmol
SRC1.M[N2] Unnormalized molar feed composition of nitrogen 807.5 lbmol
SRC1.M[C1] Unnormalized molar feed composition of methane 15.16 lbmol
SRC1.M[NH3] Unnormalized molar feed composition of ammonia 0 lbmol
* You must switch specifications to set this value. See Process Mode for more information.

The following table shows the specified process conditions throughout the simulation. It shows only the values
that differ from the default value.
Table 2: Process Conditions

Variable Description Value UOM

D7.P* Pressure of the D7 flash drum 4840 psig

D7.T* Temperature of the D7 flash drum 40 °F
X4.Tso* Shell-side outlet temperature for the X4 heat exchanger 85 °F
X4.DPs Shell-side pressure drop for the X4 heat exchanger 50 psi
X4.DPt Tube-side pressure drop for the X4 heat exchanger 50 psi
FDEF.Tto* Tube-side outlet temperature for the FDEF heat exchanger 430 °F
FDEF.DPs Shell-side pressure drop for the FDEF heat exchanger 30 psi
FDEF.DPt Tube-side pressure drop for the FDEF heat exchanger 30 psi
RX7.DP Pressure drop for the RX7 equilibrium reactor 30 psi
RX7.DT Approach temperature for the RX7 equilibrium reactor 20 °F

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Variable Description Value UOM

D6.P* Pressure of the D6 flash drum 4660 psig

D6.T* Temperature of the D6 flash drum 85 °F
D8.P* Pressure of the D8 flash drum 350 psig
* You must switch specifications to set this value. See Process Mode for more information.

The following table shows the equipment sizes and configuration throughout the simulation. It shows only the
values that differ from the default value.
Table 3: Equipment Sizes and Configuration

Variable or Parameter Description Value UOM

XV1.ManPos Manual position of the XV1 valve 0.5 fraction

D7.InletPressures* Parameter to determine whether the flash drum Balanced -
allows any feed inlet pressure or sets all feed
inlet pressures equal to each other
D7.HeadRatio Ratio of the head length to the radius of the 0 -
cylinder for the D7 flash drum
X4.HotSide Parameter to determine which side of the X4 Tube -
heat exchanger is the hot side
X4.Feed Parameter to determine whether the X4 heat BothSide -
exchanger includes feed ports for the shell side,
the tube side, or both sides
FDEF.HotSide Parameter to determine which side of the FDEF Tube -
heat exchanger is the hot side
FDEF.Feed Parameter to determine whether the FDEF heat BothSide -
exchanger includes feed ports for the shell side,
the tube side, or both sides
RX7.RxnModelType Parameter to determine which reaction Models.EQAmmonia -
submodel the RX7 reactor uses
XV2.ManPos Manual position of the XV2 valve 0.5 fraction
D6.InletPressures* Parameter to determine whether the flash drum Balanced -
allows any feed inlet pressure or sets all feed
inlet pressures equal to each other
D6.HeadRatio Ratio of the head length to the radius of the 0 -
cylinder for the D6 flash drum
XV3.ManPos Manual position of the XV3 valve 0.5 fraction
XV4.ManPos Manual position of the XV4 valve 0.5 fraction

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Variable or Parameter Description Value UOM

D8.InletPressures* Parameter to determine whether the flash drum Balanced -

allows any feed inlet pressure or sets all feed
inlet pressures equal to each other
D8.HeadRatio Ratio of the head length to the radius of the 0 -
cylinder for the D8 flash drum
SP1.RatioSum** Summation of the outlet stream flow ratios for 1 -
the SP1 splitter
Purge.F** Molar flowrate for the Purge sink 70 lbmol/h
CP4.eta Isentropic efficiency for the CP4 compressor 0.95 fraction

MX1.InletPressures* Parameter to determine whether the mixer Balanced -

allows any feed inlet pressure or sets all feed
inlet pressures equal to each other
* You must switch specifications after you set this parameter value. See Process Mode for more information.
** You must switch specifications to set this value. See Process Mode for more information.

Simulation Model
Libraries
This simulation uses the default Process Library from AVEVA Process Simulation. It also uses a fluid and reaction
submodel from the simulation-specific Model Library. See Fluids and Reaction Submodels for more information.

Fluids
This simulation uses the A6GFluid fluid from the simulation-specific Model Library as the process fluid. This is a
Compositional fluid that uses the Soave-Redlich-Kwong Modified Panagiotopoulos-Reid (SRKM) method for
thermodynamic calculations combined with the Rackett method for liquid densities. The SRKM method contains
the necessary interaction parameters to predict the correct separation in the separators and generally yields
good results for ammonia plants. For the liquid densities, the Rackett method provides better predictions for
non-hydrocarbons such as nitrogen (N2) and hydrogen (H2) than the default API liquid density method.
The fluid also applies the high-pressure vapor-liquid equilibrium (VLE) adjustments to the k-value calculations to
improve the robustness of the phase calculations. This better suits the high pressures present in the process.
The fluid includes the following components:
• Argon (ARGON)
• Hydrogen (H2)
• Nitrogen (N2)
• Methane (C1)
• Ammonia (NH3)

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Reaction Submodels
This simulation uses the EQAmmonia reaction submodel from the simulation-specific Model Library.
The EQAmmonia reaction submodel includes only the ammonia synthesis reaction:

The reference condition for heat of reaction data is vapor at 800°F and the heat of reaction is -45.18×103 energy
units per mole of nitrogen converted. The equilibrium constant is a function of temperature according to the
Arrhenius equation:

where
A is the pre-exponential factor. In the reactor submodel, we enter this value as the EqnA parameter. For this
system, we use -32.975.
B is the combined activation energy constant calculated in terms of Rankine. In the reactor submodel, we enter
this value as the EqnB parameter. For this system, we use 22930.4.
Because AVEVA Process Simulation performs calculations in terms of the internal units of temperature (K), we
include the conversion factor for Rankine to Kelvin (9/5) to ensure that the temperature used in the equation
corresponds to the units of measure used to determine the B constant in the Arrhenius equation.
After we calculate the equilibrium constant, we then use the partial pressure expression for the equilibrium
constant to determine the equilibrium compositions of the reaction components and the corresponding reaction
rates:

where
pi is the partial pressure of component i in psig.
Because the partial pressures must be in terms of psig, the reaction includes an additional equation (Keq2) to
convert the partial pressure from internal units of pressure (kPa) to psig. You can open the reaction submodel in
the Model Editor and expand the Equations section to view the exact formulation of these equations in the
reaction submodel.

Mode Summary
This example uses Process mode to meet the design requirements and perform a heat and material balance on
the process. The objective of this mode is to provide a conceptual design that we can use to refine further
process development. We can then extend the process to a detailed engineering design within AVEVA Process
Simulation.

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We also use Process mode to perform case studies regarding the effects of inert concentrations on the synthesis
and separation processes.

Process Mode
The objective of Process mode is to provide an overall mass and energy balance for the process and to estimate
the product flowrates and compositions. We switch the following process specifications to meet the design
requirements:
• For the SRC1 Source, we calculate the mass flow (W) to set the molar flow (F) to 3256.54 lbmol/h.
• For the D7 Drum:
• We calculate the heat duty (Duty) to set the drum temperature (T) to 40°F.
• We set the InletPressures parameter to Balanced so that we can set the pressure (P) in Process mode to
4840 psig. Because the Balanced option forces all feeds to have the same pressure as the drum, we must
remove the specification on the XV1 pressure drop (XV1.DP) so that the valve pressure drop is calculated
based on the required inlet pressure to the drum (D7.P).
• For the X4 heat exchanger, we calculate the heat duty (Duty) to set the shell-side outlet temperature (Tso) to
85°F.
• For the FDEF heat exchanger, we calculate the heat duty (Duty) to set the tube-side outlet temperature (Tto)
to 430°F.
• For the D6 Drum:
• We calculate the heat duty (Duty) to set the drum temperature (T) to 85°F.
• We set the InletPressures parameter to Balanced so that we can set the pressure (P) in Process mode to
4660 psig. Because the Balanced option forces all feeds to have the same pressure as the drum, we must
remove the specification on the XV2 pressure drop (XV2.DP) so that the valve pressure drop is calculated
based on the required inlet pressure to the drum (D6.P).
• For the D8 Drum, we set the InletPressures parameter to Balanced so that we can set the pressure (P) in
Process mode to 350 psig. Because the Balanced option forces all feeds to have the same pressure as the
drum, we must remove the specifications on the XV3 and XV4 pressure drops (XV3.DP and XV4.DP) so that
the valve pressure drops are calculated based on the required inlet pressures to the drum (D8.P).
• For the SP1 splitter, we calculate the outlet flow ratios for the two product streams (OutRatio) to set the
RatioSum to 1 and the molar flowrate of the purge stream (Purge.F) to 70 lbmol/h.
• For the CP4 Compressor, we calculate the compressor pressure ratio (Pr) to set the InletPressures parameter
for the MX1 mixer (MX1.InletPressures) to Balanced. This allows CP4 to meet the pressure needs of the
synthesis loop.
The specification on the molar flowrate of the purge stream (Purge.F) allows us to meet the design requirements
defined in the AVEVA™ PRO/II Simulation example1 that we based this example simulation on. However,
specifying the molar flowrate may limit further detailed design and the transition into Fluid Flow and Dynamics
modes. A better specification setup is to set the purity constraints in the reactor instead. We do this for the two
case studies (Pro 2 and Pro 3 snapshots) included in this simulation. For the case studies, we switch the following
additional process specifications:

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• We calculate the molar flowrate of the purge stream (Purge.F) to set the combined argon and methane
impurity in the reactor feed (Rx_Feed_Inerts) to 0.12 for the first case study (Pro 2 snapshot) and then to
0.16 for the second case study (Pro 3 snapshot).

Results
The following figure shows the process conditions for the feed (S1), letdown gas (S15), ammonia product (S16),
and purge (S18) streams for the base case (Pro 1 snapshot).

When we switch the process specifications to calculate the flowrate of the purge stream (Purge.F) and set the
concentration of the inerts in the reactor feed (Rx_Feed_Inerts) to 0.12, we get the following results. You can
revert the simulation to the Pro 2 snapshot to see these results in the simulation.

This change represents a slight increase in the concentration of inerts in the reactor feed. We see an almost
negligible decrease in the purity of the overall ammonia product, but an increase in the flowrate of the ammonia
product.

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If we increase Rx_Feed_Inerts to 0.16, we get the following results. You can revert the simulation to the Pro 3
snapshot to see these results in the simulation.

The ammonia product purity decreases from 99.76% to 99.74%, but the flowrate of ammonia product increases
by 1.2%. A greater concentration of inerts in the reactor feed increases the reactor conversion. However, the
increased recycle flowrate due to the additional inerts also produces corresponding increases in the recycle
compressor work and in the separator (flash drum) duties.
We must compare the value of the increased ammonia product to the increased operating costs to determine if
the greater inert concentration in the reactor is the best operating strategy. Economic analysis is outside the
scope of this example, but you can extend this example simulation to include the economic data and then
identify the optimum operating conditions.

Snapshots
This simulation includes the following snapshots:
• Pro 1: A solved steady-state, base-case solution in Process mode. If you make any changes to the simulation
that cause errors in Process mode, revert to this snapshot.
• Pro 2: A case study in Process mode that calculates the flow rate of S18 to keep the bulk mole fraction of the
inerts (argon and methane) in the reactor feed (S6) at 0.12.
• Pro 3: A case study in Process mode that calculates the flow rate of S18 to keep the bulk mole fraction of the
inerts (argon and methane) in the reactor feed (S6) at 0.16.

References
1. AVEVA Group plc. Advanced: A6 - Ammonia Synthesis. AVEVA PRO/II Simulation Application Briefs; Version
10.5; 2022.

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Revision Log
Date By Comments

11 Oct 2021 MV Initial issue.

Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
This example demonstrates how you can use AVEVA Process Simulation to simulate the synthesis of methyl tert-
butyl ether (MTBE). It uses and highlights the following features in AVEVA Process Simulation:
• Petrochemical applications
• Local overrides for binary interaction parameters
• Stoichiometric reactor units
• Multi-tray reactive distillation columns
• Complex reaction kinetics submodels
• Liquid-liquid extractor columns that use vapor-liquid-liquid equilibrium (VLLE) thermodynamics
• Column diameter estimation by using simple tray calculations
Note: This example is based on the AVEVA PRO/II Simulation Casebook: Methyl Tertiary Butyl Ether. Small
differences between this example and the AVEVA PRO/II Simulation casebook are due to rounding during data
transfer, slightly different conditions, or different choices for the column specifications.
MTBE is an octane enhancing agent for unleaded motor gasoline. It has several desirable properties that make it
a suitable gasoline additive:
• It has a low boiling point and an RVP of 8–10 psi. This causes the gasoline enhanced with MTBE to have a
lower vapor pressure. The lower vapor pressure results in reduced emissions.
• It has an octane number of approximately 109. When MTBE is mixed with gasoline, it increases combustion
without reducing engine power.
• It increases the front-end octane number, which reduces engine knocking during acceleration.

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• The addition of MTBE to gasolines generally implies a reduced aromatic and butane content, which leads to
reduced carbon monoxide and hydrocarbon emissions.
Typically, MTBE is produced from the butylenes in the product streams of liquid-feed ethylene crackers and fluid
catalytic crackers (FCCs). Some plants use raffinates from butadiene extraction or catalytic butane
dehydrogenation to produce MTBE. MTBE synthesis also offers a method of selectively removing isobutylene
from mixed C4 streams. This enables the recovery of high purity 1-butene and 2-butene, which are superior
feedstocks for sulfuric acid alkylation.
There are numerous variations on MTBE plant designs. In general, an MTBE plant includes three sections: a
reactor section, an MTBE recovery section, and a methanol recovery section. For the Ethermax process, the
MTBE recovery section includes a second reaction zone in the distillation column. The following figure shows the
complete process flow diagram for the MTBE reactive distillation plant modeled in this example simulation.

Figure 1: An MTBE Plant Modeled in AVEVA Process Simulation

Process Description
The process plant includes a reactor along with an azeotropic distillation column for separation of the MTBE
product. We add a reactive distillation section to the azeotropic distillation column to increase the overall
conversion to MTBE.
The methanol recovery section follows the azeotropic distillation column (the MTBE recovery section) and
includes:
• A liquid-liquid extractor column
• A distillation column that provides the methanol recycle to the reactor and recycled feed water for the
liquid-liquid extractor
The SRKM equation of state with fitted binary interaction parameters provides a good simulation of the VLE
fractionators and the VLLE extractor. The thermodynamics successfully predict the azeotropic removal of
methanol from the MTBE product stream.
See Reaction Section and Methanol Recovery Section for details on the configuration and process requirements
for each section of the process plant.

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Reaction Section
Overview
MTBE is manufactured by catalytically reacting isobutylene and methanol in a fixed-bed reactor at a moderate
temperature and pressure. The reaction is exothermic and reversible and is carried out in the liquid phase over a
fixed bed of ion-exchange resin-type catalyst. It is highly selective since methanol reacts preferentially with the
tertiary olefin.
In the standard Hüls process, the reactor products are processed in the MTBE distillation column, where MTBE, t-
butanol, dimerized isobutylene, and a trace amount of methanol are removed as the bottom liquid product. In
the Ethermax process, further reaction of the isobutylene to MTBE takes place in a section of the distillation
column containing the catalyst resin in tower packing. The MTBE is removed as the bottom product in a manner
similar to the standard process. The MTBE product is greater than 99.5% pure and requires no further
purification.
The key to operating the MTBE distillation column is to have a sufficient amount of C4s in the column feed to
form azeotropes with the methanol in the feed. Conversely, if a proportionately large amount of methanol is
present in the column feed, it may result in breakthrough of methanol with the MTBE bottoms product.
Therefore, suitable azeotrope formation is possible only when a limited excess of methanol is used in the reactor
feed. In this manner, unreacted methanol, which has a higher boiling point than MTBE, is fractionated away from
the MTBE column bottoms. The overhead product containing non-reactive linear butenes, iso-butane, normal
butane, and unreacted methanol and isobutylene is sent to the methanol recovery section.
Process Specifics
In the Ethermax MTBE process, which we model in this example, we mix an isobutylene-rich mixed C4 stream, a
fresh methanol stream, and a recycled methanol stream. We then feed this mixture to the reactor section.
Table 1: Reactor Feed Stream Conditions

Name Olefins Feed MeOH Feed S20 (Methanol Recycle)*

Flowrate (kg/h) 55,000 8,982.72** 277.097

Temperature (°C) 16 16 30.48
Pressure (kPa) 1620 1620 1724
Component Mol %
n-Butane (NC4) 9.00 0.00 0.02
Isobutane (IC4) 41.00 0.00 0.04
1-Butene 7.00 0.00 0.00
Cis-2-butene (BTC2) 4.00 0.00 0.00
Trans-2-butene (BTT2) 6.00 0.00 0.00
Isobutylene (IBTE) 33.00 0.00 0.00
Methyl tert-butyl ether (MTBE) 0.00 0.00 0.00

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Name Olefins Feed MeOH Feed S20 (Methanol Recycle)*

Methanol (MeOH) 0.00 100.00 98.10

Tert-butanol (TBA, Tert-butyl 0.00 0.00 0.00
alcohol)
Water 0.00 0.00 1.84
Diisobutylene (DIB, 2,4,4- 0.00 0.00 0.00
Trimethyl-1-pentene)
* These values are calculated by the upstream unit. These values change when you make changes to the simulation.
** We calculate this value to specify the MEOH_IBTE_MOL_RATIO flowsheet variable instead. This value may change when
you make changes to the simulation.

We want to determine and set the ratio of methanol to isobutylene that we feed to the reactor. We add the
MEOH_IBTE_MOL_RATIO flowsheet variable to the simulation as well as a flowsheet equation (Eqn 3) to
calculate its value. Typically, the methanol-to-isobutylene ratio in the reactor feed is kept low (close to 1:1) to
minimize the costs of recovering unreacted methanol and to facilitate the operation of the MTBE column.
Therefore, we set the value of the MEOH_IBTE_MOL_RATIO flowsheet variable to 1.
We can easily achieve an isobutylene conversion to MTBE of 90% to 93% in the reactor. We can achieve overall
isobutylene conversions higher than those obtained in the standard process by either recycling a portion of the
overhead product from the MTBE reactive distillation column or by providing a second reactor unit and reactive
distillation column downstream of the first reactive distillation column. In this example, we use only one reactor
(R1) and one reactive distillation column (T1).
We use the HX1 heat exchanger to heat the reactor feed stream (the combined mixed olefins, fresh methanol,
and methanol recycle) to 43.5°C before it enters the R1 reactor.
Two side reactions can occur in the reactor to produce impurities in the product:
• Any water in the reactor feed (from the recycled methanol) instantly converts to t-butanol.
• Isobutylene can dimerize into di-isobutylene (2,4,4-Trimethyl-1-pentene).
While you should minimize the formation of di-isobutylene and t-butanol, their presence in small concentrations
in the MTBE product is acceptable since these byproducts also have very high octane numbers. The reactors are
cooled to under 200°F to prolong catalyst life and to minimize the undesirable side reactions.
The following table shows the three main reactions used in the stoichiometric reactor model as well as the base
component and conversion fraction for each reaction.
Table 2: Primary Reactions

Reaction Base Component Conversion %

2 IBTE = DIB IBTE 0.25

H2O + IBTE = TBA H2O 100.00
IBTE + MEOH = MTBE MEOH 93.00
The reactor uses the RxnConversion reaction submodel and the specified conversion levels in the preceding
table. See Reaction Submodels for details on the RxnConversion reaction submodel.

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Note: You can use the Reaction Generator to create the reaction submodel. You can open the Reaction
Generator from the Advanced tab.
We carry out the reaction at 55°C. There is a pressure drop of 69 kPa across the reactor.

Figure 2: Conversion Reactor Configuration

We use the HX2 heat exchanger to further heat the reactor product to 72°C before we send it to the reactive
distillation column (T1). We use the hot product coming from the T1 Column to reach the desired temperature in
the column feed before it enters the reactive distillation.
The T1 Column has a total of 28 stages, a top pressure of 621 kPa, and an overall pressure drop of 76.5 kPa. For
the reactive distillation process, the following figure shows the reaction zone (trays 7 through 12), the volume of
catalyst used, and the kinetic reaction submodel used in the reaction zone.

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Figure 3: Reactive Distillation Sections, Volume of Catalyst, and Kinetic Reaction Submodel
In AVEVA Process Simulation, you can carry out multiple reactions at different sections of the Column. Therefore,
you must specify the reaction submodel and the volume of catalyst for each tray in the Column.
The kinetic reaction submodel that we use for the reaction zone requires the density of the catalyst. This is not
an expected value on other reactive distillation columns, and you will not see this variable in the main Tray data
in the Mini Inspector. However, the Rxn submodel for each stage in the reaction zone includes the Rho_cat
variable that you can use to specify the catalyst density for each stage. You can access this variable in the
Simulation Manager or in the full Properties Inspector. The following figure shows this variable for Stage 7 in the
full Properties Inspector.

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Figure 4: Catalyst Density at Each Stage

A suitable catalyst for this operation is the Amberlyst 15 polymeric catalyst developed by Rohm and Haas. With
an apparent density of 770 g/L and a moisture content of 53%, the effective dry density is around 360 g/L, or 360
kg/m3.
There are a number of factors that affect the overall conversion rate of isobutylene. Some of these are:
• Methanol-to-isobutylene ratio
• Number of reaction trays
• Type of catalyst used
However, while the isobutylene conversion in the conversion reactor increases as you increase the methanol-to-
isobutylene ratio, the overall isobutylene conversion reaches a maximum and then decreases as you increase the
methanol-to-isobutylene ratio. This is due to the fact that more MTBE product is carried upward through the
column stripping section into the reaction trays. This promotes the reverse reaction of MTBE to methanol and
isobutylene, thus reducing the overall conversion of isobutylene.
The MTBE product (S7.z[MTBE]) is specified as 99.5% molar purity and is recovered at the bottom of the column.
A reflux ratio of 1.1 is typically sufficient. The product cools in the HX2 heat exchanger as it heats the feed to the
T1 Column.

Methanol Recovery Section

Overview
In the methanol recovery section, we wash the overhead product of the MTBE reactive distillation column with
water to extract methanol. We simulate this unit as a liquid-liquid extractor column. The raffinate, which

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contains less than 10 ppmw methanol, is suitable for use in other processes, such as recovering high purity C4
isomers or as a feed to an alkylation unit.
We warm and flash the extracted phase—which contains water, methanol, and small amounts of dissolved
hydrocarbons—to remove the hydrocarbons. We then fractionate the resultant methanol-water mixture in a
distillation column to recover methanol as the overhead product. We recycle the methanol (with a trace of
water) to the MTBE reactor. We return the wash water stream from the column bottoms, along with a small
amount of make-up water, to the liquid-liquid extractor column.
Process Specifics
The P1 pump delivers the methanol-C4s azeotrope (S6) to the HX3 heat exchanger, which cools it to 38°C against
cooling water. The HX3 heat exchanger also calculates the cooling water requirement given a cooling water
delivery temperature of 16°C and a return temperature of 32°C. We then feed the cooled process stream to the
bottom of the liquid-liquid extractor column (T2).
We simulate the T2 Extractor with 5 theoretical trays and a top pressure specification of 792 kPa. We feed
recirculating wash water to the top of the Extractor. The Extractor uses the P2FluidVLLE Fluid for the VLLE
calculations. We place Fluid Changers (FC1 and FC3) before the Extractor to switch to the P2FluidVLLE Fluid from
the P2Fluid Fluid, the main Fluid for the process. We calculate the fresh water feed to the Extractor (WMa.W) to
set the mass composition of methanol in the top product (C4s.zm[MeOH]) at 10 ppmw.
The raffinate leaves the top of the Extractor (S11_C4s) and contains the unreacted and non-reactive C4s. The
extracted liquid phase (S12) exits at the bottom of the Extractor and goes through another Fluid Changer (FC2) to
return the stream to the P2Fluid Fluid. The stream then enters the feed-bottoms heat exchanger (HX4), which
warms it to 99°C against the recycled wash water (S21).
The XV1 Valve drops the pressure of the heated methanol-water stream (S13) to 241 kPa. This generates a
mixed-phase stream (S14) which we adiabatically flash in the D1 Drum. We vent the vapor phase (S15)
containing the dissolved hydrocarbons there were released during the flash as a flare gas; we use the P2 Pump to
send the liquid phase (S16) to the methanol distillation column (T3) to recover the methanol.
We simulate the T3 Column with 20 theoretical trays, a top pressure of 138 kPa, and an overall pressure drop of
34.5 kPa. The feed (S17) enters on tray 9.
The column has a sub-cooled, fixed-temperature condenser that operates at 30°C and 103.5 kPa. The
performance specifications are 99.5% recovery of methanol in the overhead product and 99.95% recovery of
water in the bottom product. Because the Column does not calculate the recoveries, we add the MeOHRecovery
and WaterRecovery flowsheet variables to the simulation as well as the flowsheet equations to calculate their
values (Eqn2 and Eqn1). We calculate the RefluxRatio and BoilupRatio in the Column to specify the methanol
recovery (MeOHRecovery) and the water recovery (WaterRecovery) at the indicated performance specifications.
We also perform Simple Tray calculations for this Column for first-pass estimation of the diameter by specifying
the flooding factor at 80%.
We combine the recovered wash water from the column bottoms (S18_WaterRecycle) with additional make-up
water (MKUP). The P4 Pump sends the combined water stream (S21) to the HX4 heat exchanger.
A trim cooler (HX5) further cools the wash water (S22) to the desired temperature of 38°C before it (S10) goes
back to the liquid-liquid extractor column.
The P3 Pump recycles the overhead product (S19) from the top of the methanol distillation column (T3) to the
reactor section.

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Simulation Model
Libraries
This example uses the standard Process Library and the simulation-specific Model Library.
The simulation-specify Model Library include two Fluids and two replaceable reaction submodels. See Fluids and
Reaction Submodels for more information.

Fluids
This example uses two Fluids from the simulation-specific Model Library, P2Fluid and P2FluidVLLE.
Both Fluids use the same components and thermodynamic method and data. The only difference between them
is the Phases selection. We use the P2FluidVLLE Fluid in the portions of the simulation that require vapor-liquid-
liquid equilibrium (VLLE) calculations, such as in the liquid-liquid extractor column in the MTBE recovery section
of the plant. We use the P2Fluid in all other portions of the simulation for simpler, faster thermodynamic
calculations.

Figure 5: Method Selection for the P2Fluid Fluid

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Figure 6: Method Selection for the P2FluidVLLE Fluid

AVEVA Process Simulation's modified Soave-Redlich-Kwong (SRKM) equation of state (EOS) simulates well the
VLE and VLLE fractionators. For this EOS, AVEVA Process Simulation contains extensive, built-in databanks that
encompass binary interaction parameter data for many component pairs present in this simulation. However, in
this example, we directly supply the binary interaction data (kijs) for several component pairs to improve the
accuracy of the separations in the columns. The following figures shows the binary interaction parameters that
the P2Fluid and P2FluidVLLE Fluids use. Green badges indicate values that come from a databank, and blue
badges indicate values that we have locally overridden.

Figure 7: Availability for the SRKM Binary Interaction Parameters

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Figure 8: Locally Overridden Values for Selected Binary Interaction Parameters

Reaction Submodels
This example includes two reaction submodels in the simulation-specific Model Library:
• RxnConversion
• MTBEkinetics
RxnConversion
The RxnConversion submodel is a simple stoichiometric reaction submodel based on conversion rates. We use it
only in the conversion reactor (R1) in the reaction section of the process plant. It includes the following
reactions:

We model the equations such that the base components for each reaction are ITBE, water, and methanol,
respectively.

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Figure 9: MTBE Conversion Reaction Submodel

MTBEkinetics
The MTBEkinetics submodel is a rate-based reaction submodel. We use it only in the reactive distillation column
(T1) in the reaction section of the process plant. It includes only the following reaction:

We base the MTBE reaction rate expression on the rate expression described in a paper by Al-Jarallah et al.2. The
reaction rate equation described by Al-Jarallah et al. takes into account the forward and the reverse reaction. We
have modified the rate equation from Al- Jarallah et al. for this example to simulate the effect of catalyst loading
on the reaction rate. We achieved this by removing the catalyst terms from the concentration terms. The
following equations give the modified reaction rate:

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where
ks is the surface reaction rate constant in (gmol/g catalyst)^1.5/hr
KA is the equilibrium adsorption constant of IBTE in g catalyst/gmol
KC is the equilibrium adsorption constant of MTBE in g catalyst/gmol
Keq is the equilibrium constant
CA is the IBTE concentration in mol/L
CB is the MEOH concentration in mol/L
CC is the MTBE concentration in mol/L
The following figure shows the kinetic equations as modeled in AVEVA Process Simulation.

Figure 10: MTBE Kinetic Reaction Submodel

Mode Summary
This example uses Process mode to meet the design requirements. The objective of this mode is to provide a
conceptual design that we can use to further refine process development. In this example, we approach the
problem in its conceptual design phase and investigate the impact of various process changes on the overall
product rates and compositions.

Process Mode
The objective of this mode is to provide a conceptual design that we can use to further refine process
development. To meet the design requirements, we make the following specification changes in Process mode.

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Heat Exchangers
• For the HX1 heat exchanger, we calculate the heat duty (Duty) to specify the shell-side outlet temperature
(Tso) at 43.5°C
• For the HX2 heat exchanger, we calculate the heat duty (Duty) to specify the tube-side outlet temperature
(Tto) at 72°C.
• For the HX3 heat exchanger, we:
• Calculate the heat duty (Duty) to specify the shell-side outlet temperature (Tso) at 38°C.
• Calculate the cooling water feed rate (CWS1.W) to specify the tube-side outlet temperature (Tto) at 40°C.
• For the HX4 heat exchanger, we calculate the heat duty (Duty) to specify the tube-side outlet temperature
(Tto) at 99°C.
• For the HX5 heat exchanger, we:
• Calculate the heat duty (Duty) to specify the shell-side outlet temperature (Tso) at 38°C.
• Calculate the cooling water feed rate (CWS2.W) to specify the tube-side outlet temperature (Tto) at 40°C.
Pumps
• For the P1 Pump, we calculate the pressure drop across the Pump (DP) to specify the outlet pressure (P2) at
827 kPa.
• For the P2 Pump, we calculate the pressure drop across the Pump (DP) to specify the outlet pressure (P2) at
690 kPa.
• For the P3 Pump, we calculate the pressure drop across the Pump (DP) to specify the outlet pressure (P2) at
1,724 kPa.
• For the P4 Pump, we calculate the pressure drop across the Pump (DP) to specify the outlet pressure (P2) at
862 kPa.
Conversion Reactor
For the R1 reactor, we:
• Calculate the heat duty (Duty) to specify the outlet temperature (T2) at 55°C.
• Calculate the conversions of the base components in the second and third reactions (R1.Xrxn[2] and
R1.Xrxn[3]) to specify the total reaction conversion of methanol and water (R1.X[MeOH] and R1.X[H2O]) at
0.93 and 1.0, respectively.
• Calculate the methanol feed flow to the reactor (MeOHFeed.W) to specify the molar ratio of methanol to
isobutylene fed to the reactor (MEOH_ITBE_MOL_RATIO) at 1.
Columns
• For the T1 Column, we:
• Calculate the BoilupRatio to specify the MTBE composition of the bottom liquid product (S7.z[MTBE]) at
0.995.
• Calculate the condenser vapor fraction (VFcond) to specify the condenser outlet temperature (Tcond) at
43.5°C.

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• Calculate the pressure drop at each stage of the column (DPstage) to specify the total pressure drop
across the column stages (DPCol) at 76.5 kPa.
• For the T2 Extractor, we calculate the fresh water feed to the Extractor (WMa.W) to specify the mass
composition of the methanol in the top product (C4s.zm[MeOH]) at 10 ppmw.
• For the T3 Column, we:
• Calculate the condenser vapor fraction (VFcond) to specify the condenser outlet temperature (Tcond) at
30°C.
• Calculate the pressure drop at each stage of the column (DPstage) to specify the total pressure drop
across the column stages (DPCol) at 69 kPa.
• Calculate the condenser pressure drop (DPcond) to specify the condenser outlet pressure (Pcond) at
103.5 kPa.
• Calculate the column diameter (Dcol) to specify the overall stage flooding factor (FFcol) at 0.8. This
allows us to size the column to fit the desired flooding factor.
• Calculate the RefluxRatio and BoilupRatio to specify the methanol recovery (MeOHRecovery) and the
water recovery (WaterRecovery) at 0.995 and 0.9995, respectively.
Valve
For the XV1 Valve, we calculate the pressure drop (DP) to specify the outlet pressure (P2) at 241 kPa.

Scenarios
This example simulation includes the following Process mode scenarios:
• Reduce Olefins – Reduces the Olefins feed to 45,000 kg/h.

• Increase Olefins – Increases the Olefins feed to 65,000 kg/h.

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Results
Heat and Material Balance
The following figure shows a portion of the HMB Table, which includes data for selected streams and properties.
We generated a Microsoft Excel report from the Table to produce this figure. You can also view this data by
opening the Table directly in AVEVA Process Simulation.

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Figure 11: Heat and Material Balance

Column Profiles
The example simulation contains a variety of column profiles to help visualize the Columns.
The following figure shows the vapor flow, liquid flow, temperature, and net reaction rate throughout the T1
Column.

Figure 12: T1 Column Profile for the Base Case

The following figure shows the flow for each liquid phase and the temperature throughout the T2 Extractor.

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Figure 13: T2 Column Profile for the Base Case

The following figure shows the vapor flow, liquid flow, and temperature throughout the T3 Column.

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Figure 14: T3 Column Profile for the Base Case

Excel Report
The A7 - Rx Dist MTBE Equipment Report.xlsx file is a Microsoft Excel report for this example simulation. It
provides the results of the heat and material balance for the simulation and includes the following information:
• Equipment summaries
• Stream summaries
• Stage-wise column summaries for each Column in the simulation
You can find the A7 - Rx Dist MTBE Equipment Report.xlsx file in the %userprofile%\My Simulations\Examples
folder.

Snapshots
This example includes the following snapshots:
• Base – The base case that should match the descriptions in this document.
• PROII – The snapshot that matches the corrected AVEVA PRO/II Simulation casebook. The casebook example
in previous AVEVA PRO/II Simulation versions had an inconsistent use of the catalyst density. The values in

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this snapshot may not reflect the values in all AVEVA PRO/II Simulation versions but do reflect the corrected
version.

References
1. Hydrocarbon Process. 1982, 61 (9), 177.
2. Al-Jarallah, A. M.; Siddiqui, M. A. B.; Lee, A. K. K. Kinetics of Methyl Tertiary Butyl Ether Synthesis Catalyzed
by Ion Exchange Resin. Can. J. Chem. Eng. 1988, 66 (5), 802-807.
3. Bitar, L. S.; Hazbun, E. A.; Piel, W. J. MTBE Production and Economics. Hydrocarbon Processing 1984, 63 (10),
63-68.
4. Hutson, T.; et al. Chap. 1.12. In Handbook of Chemicals Production Processes, 1st ed.; Meyers, R. A., Ed.;
Chemical Process Technology Handbook Series; McGraw-Hill Book Company: New York, 1986.
5. Friedlander, R. H. Chap. 1.13. In Handbook of Chemicals Production Processes, 1st ed.; Meyers, R. A., Ed.;
Chemical Process Technology Handbook Series; McGraw-Hill Book Company: New York, 1986.
6. Jacobs, R.; Krishna, R. Multiple Solutions in Reactive Distillation for Methyl tert-Butyl Ether Synthesis. Ind.
Eng. Chem. Res. 1993, 32 (8), 1706–1709.
7. Hydrocarbon Process. 1990, 69 (10), 29,31,33,44.
8. Oil & Gas J. 1991, 89 (12), 26-29.
9. Shah, V.B.; Bluck, D.; Kovach, J. W., III; Parikh, R.; Yu, R. The Sensitivity of the Design and Operability of the
MTBE Process with Respect to Changes in Reaction Parameters and Process Configurations. Proceedings of
the LNG and Petrochemasia 94 Conference, Singapore, Dec 7-8, 1994.

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A8 - Air Separation Plant

Revision Log
Date By Comments

1 April 2020 RM Initial issue.

9 Sep 2021 DA Update feasibility of solution.
Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
This example shows how you can use AVEVA Process Simulation to model the cryogenic air separation plant
shown in Figure 1. Because the primary use of nitrogen is to exclude oxygen, the nitrogen product must contain
no more than 10 ppm of oxygen. Given this requirement, accurate thermodynamic calculations are crucial.
AVEVA Process Simulation offers a variety of thermodynamic methods to choose from and allows for method
customization to meet the requirements of even the most stringent processes. With the conceptual design
presented in this example, we explore various business cases to give direction for subsequent detailed
engineering. We investigate the impact of increasing the liquid oxygen throughput relative to the vapor oxygen
product. The objectives of this simulation are to:
• Design an air separation plant that separates nitrogen, oxygen, and argon from an air stream.
• Demonstrate how to switch specifications to meet different design requirements.
• Develop scenarios in Process mode to investigate a variety of process cases prior to detailed engineering.

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Figure 1: A Cryogenic Air Separation Plant Modeled in AVEVA Process Simulation

Process Description
The following table shows the specifications for the air feed to the process. For this simulation, we ignore all
other rare gases found in air. We also exclude any initial filtering and drying processes.
Table 1: Feed Stream Properties

Variable Description Value UOM

z[Nitrogen] Molar nitrogen composition 78.11 %

z[Argon] Molar argon composition 0.93 %
z[Oxygen] Molar oxygen composition 20.96 %
F Total molar flowrate 9,386 kmol/h
20,692 lbmol/h
T Temperature 278 K
40.73 °F

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Variable Description Value UOM

P Pressure 607.95 kPa

6 atm
The E1 heat exchanger cools the feed to its dew point before it enters a 44-stage high-pressure column, HP. The
feed stream enters the column at stage 44. The HP column includes a complete condenser and no reboiler. Both
the top and bottom products from the HP column enter the E2 heat exchanger, where the nitrogen product cools
the streams to their desired temperatures.
The low-pressure column, LP, consists of 69 stages and includes 4 feed stages, 2 vapor draws, and a reboiler. The
top product from the HP column, which is predominately nitrogen, enters at stage 1, while the bottom product
from the HP column enters at stage 28. A portion of the feed bypasses the HP column and enters at stage 32. A
recycle stream from the argon column, ARG, enters the LP column at stage 45. Stage 44 includes a vapor draw
which enters the ARG column for further separation of oxygen and argon. At Stage 69, an additional vapor draw
provides the vaporized oxygen product.
The ARG column consists of 55 stages and an external partial condenser (ARGCond) that cools the vapor from the
ARG column by using the bottom product from the HP column as the cooling utility. The V1 drum that follows the
ARGCond heat exchanger separates the product vapor from the reflux. The feed enters the ARG column at stage
55.

Simulation Model
Library
This simulation uses the default Process library from AVEVA Process Simulation.

Fluids
This example uses a custom fluid called A8Feed that resides in the simulation-specific Model Library. We use this
compositional-type fluid to model the feed stream, which has the starting composition found in the table in
Process Description. The Soave-Redlich-Kwong (SRK) equation of state is suitable for the thermodynamic
calculations required for the simulation. In general, equations of state do a poor job at predicting liquid densities.
AVEVA Process Simulation provides a separate method option for these estimations. Because the process does
not involve hydrocarbon components, we use library correlations to determine the liquid density estimations
instead of using the default API method.

Mode Summary
This example uses Process mode to meet the design requirements. The objective of this mode is to provide a
conceptual design that we can use to refine further process development. In this example, we approach the
problem in its conceptual design phase and investigate the impact of various process changes on the overall
product rates and compositions.
If desired, you can expand this process to a detailed engineering design within AVEVA Process Simulation. For a
discussion of this workflow, please see the C1 – Water Methanol Separation example.

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Process Mode
The objective of Process mode is to provide an overall mass and energy balance for the process and to estimate
product flowrates and compositions under a variety of conditions. We switch the following process specifications
during the conceptual design to meet process specifications:
• For the high-pressure column, we switch specifications for the reflux ratio and the molar composition of the
top product so that the reflux ratio is calculated. We specify the oxygen composition at 10 ppm in the top
product stream.
• In the low-pressure column, we calculate the boilup ratio and specify the overhead product composition.
Like the high-pressure column, the boilup ratio is calculated and we specify the oxygen composition at 10
ppm in the top product stream.
• We add an equation to the flowsheet to calculate the argon recovery (the total moles of argon leaving the
argon column divided by the moles entering). We specify the ArgonRec variable at 0.333 and the reflux ratio
of the argon column is calculated.
• We supply an additional flowsheet equation so that the heat duty of the low-pressure column reboiler
equals the heat duty of the high-pressure column condenser.

Scenario
This example simulation includes the Increase LiqO2 scenario, which increases the liquid oxygen throughput to 6
t/h in Process mode and then saves a snapshot of the results.

Results
Process Mode
The example simulation contains a variety of column profiles to help visualize the column and heat exchanger
interactions. The following figure shows the temperature and flowrate profile for the low-pressure column. You

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can find similar profiles for the high-pressure and argon columns on the Canvas near each column. Markers on
the figure show the location of each feed and vapor draw tray.

Figure 2: Low-pressure Column Temperature and Flow Profile

The following figure shows the composition profile for the low-pressure column. As expected, the top product is
nearly pure nitrogen while the bottom product is nearly pure oxygen.

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Figure 3: Low-pressure Column Composition Profile

The following figure shows the feed and product stream properties for the air separation plant. You can open the
Stream Table table on the Canvas to view these stream properties. As expected, the nitrogen product contains
only 10 ppm (1E-5 fraction) of oxygen and the oxygen streams are each more than 99.5% pure. Due to the
relative volatility of argon to oxygen, an additional catalytic deoxygenation step is required to increase the purity
of the argon stream. We do not include that process is in this example.

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Figure 4: Stream Properties

The following figure shows the temperature profile of the E2 heat exchanger. This plate-fin heat exchanger
(HXPF) models the simultaneous heat exchange between multiple hot and cold streams.

Figure 5: E2 Temperature Profile

As an extension of the base case design, we analyze the impact of increasing the liquid oxygen product relative
to the vapor product. The example simulation includes a scenario called Increase LiqO2 that increases the liquid
oxygen product flowrate to 6 t/h. To specify the liquid oxygen product flowrate, we calculate the vapor draw to
the argon column (we previously specified this value at 1875 kmol/h). The following table shows the results of
this scenario. You can also find these results in the A8 - Air Separation Plant.xlsx file in the %userprofile%
\MySimulations\Examples folder.
Table 2: Result of Increasing the Liquid Oxygen Product Flowrate

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Increasing the liquid oxygen product flowrate also increases the argon product flowrate and the purity of the
argon product. This scenario also increases the purity of both oxygen products. However, it may not be possible
to increase the liquid oxygen product flowrate much higher. A higher flowrate of the liquid oxygen product
causes the outlet temperature of the liquid nitrogen product to increase, which in turn pushes the temperature
profile in E2 close to a pinch point. This information may help inform decisions about how to approach the
detailed engineering of the plant.

Snapshot
This example includes the following snapshot.

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Excel Report
You can find the summarized results for this simulation in the A8 - Air Separation Plant.xlsx file in the
%userprofile%\MySimulations\Examples folder.

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AA1 - Supercritical CO2 Brayton Cycle

Revision Log
Date Who Change

28 Sep 2016 DK Initial release for SimCentral 1.5.

26 Jul 2019 SK Updated simulation to use ClosedLoop model in cyclic sCO2.
Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
Supercritical CO2 (sCO2) Brayton power cycles use CO2 at supercritical pressures as the working fluid. Compared
to conventional steam Rankine cycles, sCO2 cycles can achieve significantly higher cycle efficiencies, which is
defined as the ratio of net power gained (turbine power minus compression power) to the heat input. Higher
cycle efficiency leads to lower fuel cost, lower water usage, and lower greenhouse gas emissions. Additionally,
sCO2 cycles operate at high pressures throughout the cycle, which results in a working fluid with a high density.
This can minimize the plant footprint and therefore lower capital cost.
The objective of this simulation is to:
• Demonstrate the impact of varying bypass compressor flowrate on the overall efficiency of the system given
a constant heater duty.
• Demonstrate the impact of varying turbine outlet pressure on the overall cycle efficiency.
• Determine the optimum bypass flow that maximizes the cycle efficiency.
The following figure shows the schematic diagram of the Supercritical CO2 Brayton Cycle system, as modeled in
AVEVA Process Simulation.

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Process Description
Various arrangements for the Brayton power cycle, based on the idea of reducing the waste heat in the CO2
cooler, have been described in literature. These solutions aim at recuperating heat between the hot turbine and
the cold compressor products, and additionally at the bypass compressor, which recompresses the bypassed
CO2. We focus on this setup in this example and determine the optimum cycle and bypass rates that maximize
efficiency.
The design requirements are:
• Turbine inlet temperature is 700°C.
• Turbine outlet pressure is 8.96 MPa.
• The pressure drops for the individual recuperators and CO2 cooler are approximately 0.1 MPa.

Simulation Model
Library
This simulation uses the Process library.

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Fluids
This simulation uses a supercritical CO2 fluid (CO2_SW), which uses the Span and Wagner equation of state, and
a compositional burner gas fluid (BurnerGas).

Mode Summary
The following table provides a summary of the simulation operation in all three modes:

Process Fluid Flow Dynamics

Purpose Perform heat and material balance on the N/A N/A

system.
Furnace Provide the primary energy source such N/A N/A
that the feed is mostly methane.
Heater Apply heat to the high-pressure sCO2. N/A N/A
Specify the outlet pressure.
Cooler Cool the low-pressure CO2 before N/A N/A
compression.
Main Compressor Compress the cooled sCO2. Specify the N/A N/A
outlet pressure.
Bypass Compressor Recompress the bypassed sCO2. N/A N/A

Turbine Expand the high pressure sCO2 and gain N/A N/A
work.
Header H1 Split the flow between the main and bypass N/A N/A
compressors and determine the flow to the
CO2 cooler and low-temperature
recuperator.
High Temperature Recover the heat from the bypass N/A N/A
Recuperator (HTRecup) compressor. Specify the overall heat
transfer coefficient and area.
Low Temperature Recover the heat from the main N/A N/A
Recuperator (LTRecup) compressor. Specify the overall heat
transfer coefficient and area.
Header H2 Provide the recompressed CO2 streams N/A N/A
back to the high temperature recuperator.
ClosedLoop CO2 Set the Fluid Type and the molar flowrate N/A N/A
of the sCO2 cyclic loop.

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Process Mode
The purpose of Process mode is to properly design the closed loop cycle so that we can set up a sensitivity
analysis to determine the turbine outlet pressure and bypass rate that maximize the cycle efficiency. We can
conduct case studies on the overall efficiency of the cycle by imposing various constraints in the system. We
studied the following cases:
• Vary the turbine outlet pressure from 6 MPa to 15 MPa. Observe the impact on cycle efficiency and
determine the optimal turbine outlet pressure.
• Use the optimal turbine outlet pressure from the previous case and vary the bypass flow from 10 kg/s to 60
kg/s. Observe the impact on cycle efficiency and determine the optimal bypass flowrate.
We model these cases by using the Scenario feature and we save individual snapshots for each constraint within
the case. The following figure shows the list of Scenarios.

Fluid Flow Mode

While this simulation can solve in Fluid Flow mode, we did not conduct any Fluid Flow studies for this simulation.

Dynamics Mode
While this simulation can solve in Dynamics mode, we did not conduct any Dynamics studies for this simulation.

Results
Process Mode
We wish to see the overall impact on the cycle efficiency for the cases that we define in Process Mode. Based on
the results of the case studies, we can identify an optimum turbine outlet pressure that maximizes the cycle
efficiency. Then, we can use this pressure to determine the optimum flowrate through the bypass compressor.
We first begin by varying the turbine outlet pressure from 6 MPa to 15 MPa at a constant Heater outlet
temperature. The efficiency of the system reaches a local maximum before steadily dropping again. The following
figure displays the relationship between the cycle efficiency and the turbine outlet pressure.

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AA1 - Supercritical CO2 Brayton Cycle

Based on this relationship, the optimum value for the turbine outlet pressure is approximately 9 MPa. The critical
pressure of CO2 is known to be 7.38 MPa. Our optimum pressure is slightly beyond the critical pressure; if we
operate at the optimum pressure, we reduce the work needed to subsequently compress CO2.
We then fix the turbine outlet pressure at the optimum value and vary the bypass compressor flowrate to
determine the optimum flowrate. If the flowrate through the bypass compressor is too high, the main
compressor product cannot substantially cool the turbine product at the low temperature recuperator. Similarly,
if the flowrate through the bypass compressor is too low, the turbine product loses too much heat at the low
temperature recuperator, which the turbine then gains. The following figure displays the relationship between
the cycle efficiency and the bypass compressor flowrate.

We find that the optimum bypass compressor flowrate is approximately 30 kg/s.

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Snapshots
As mentioned in Process Mode, we use two Scenarios to automate the case studies in this simulation. If you
make a design change, you can run these Scenarios and identify the new optima. The Scenarios save each
constraint as an individual snapshot. The following figure shows the list of snapshots.

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Excel Report
You can find the system flows, pressures, and temperatures in the AA1 – Supercritical CO2 Brayton Cycle.xlsx file.

References
1. Bryant, J. C., Saari, H., and Zanganeh, K., "An Analysis and Comparison of the Simple and Recompression
Supercritical CO2 Cycles," Supercritical CO2 Power Cycle Symp., Boulder, CO, Mar. 2011.
2. Sarkar, J., "Second law analysis of supercritical CO2 recompression Brayton cycle," Energy, vol. 34, no. 9, pp.
1172-1178, Sept. 2009.

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AA2 — Hydrogen Liquefaction

Revision Log
Date By Comments

3 June 2020 RM Initial issue.

Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
This example shows how you can use AVEVA Process Simulation to design the hydrogen liquefaction process
shown in Figure 1. For many years, the aerospace industry has used liquid hydrogen as a rocket propellant.
Recently, researchers in fuel cell technologies have explored the use of liquid hydrogen as a fuel. Hydrogen also
plays an important role in semiconductor manufacturing processes. As hydrogen gas cools and liquefies, the ratio
of its ortho to para spin isomers decreases. AVEVA Process Simulation models this process by using a custom
equilibrium reaction model in the fluid. The objectives of this simulation are to:
• Design a hydrogen liquefaction process.
• Show how you can write a fluid reaction submodel by using existing experimental data.
• Demonstrate the Joule-Thomson effect in a control valve.

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Figure 1: A Hydrogen Liquefaction Process Modeled in AVEVA Process Simulation

Process Description
The process includes the following major flow paths:
• A gaseous hydrogen feed stream that we liquefy by using three plate-fin heat exchangers.
The following table shows the specifications of the feed stream.
Table 1: Feed Stream Properties

Variable Description Value UOM

z[OH2] Molar orthohydrogen composition 75 %

z[PH2] Molar parahydrogen composition 25 %
F Total molar flowrate 0.5 kmol/h
1.10 lbmol/h
T Temperature 298.15 K
77 °F
P Pressure 120 kPa
1.18 atm
• A closed refrigeration loop.
• A liquid nitrogen feed to provide additional cooling capacity to exchanger E1.

Simulation Model

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Library
This simulation uses the default Process library and the simulation-specific model library.

Fluids
This example uses three custom fluids that reside in the simulation-specific model library.

Fluid Description

Nitrogen This custom Compositional fluid uses the Soave-Redlich-Kwong (SRK) method to
model liquid nitrogen. The composition is 100% nitrogen with an initial pressure of
100 kPa (0.987 atm) and an initial temperature of 77.24 K (-320.6°F).
Cryo_H2 This custom IsomericHydrogen fluid has the initial composition and properties listed
in Table 1 in Process Description. It uses an equilibrium reaction model (EQOPH2)
from the simulation-specific model library to calculate the ratio of hydrogen spin
isomers at various temperatures. See Reaction Model for more information.
Refr_Cryo_H2 This custom IsomericHydrogen fluid is identical to Cryo_H2 but does not use the
EQOPH2 equilibrium reaction model.
An IsomericHydrogen fluid implements the rigorous hydrogen thermodynamic properties for orthohydrogen and
parahydrogen published in Leachman et al.1. The software calculates mixture properties by using the ideal
mixing rules according to the GERG-2004 equation of state2. It determines the vapor-liquid equilibrium by
assuming a pseudo-pure component vapor pressure that uses a mole-fraction weighted average of the ortho and
para component vapor pressures. We assume that the vapor and liquid phases have the same composition at
equilibrium conditions. The enthalpy model, which we have developed by using available published data,
calculates the heat of conversion from orthohydrogen to parahydrogen.

Reaction Model
The EQOPH2 equilibrium reaction model from the simulation-specific model library calculates the ratio of
hydrogen spin isomers at various temperatures. This reaction model uses experimental data from NBS Report
88123 to define the equilibrium composition. The ParaConversion curve in the simulation-specific library
contains this experimental data. We use the Curve Editor in AVEVA Process Simulation to trace the equilibrium
composition curve based on the graphical equilibrium data from NBS Report 8812, as shown in the following
figure. The EQOPH2 reaction model uses a Submodels.CurveState submodel to access the data in the
ParaConversion curve.

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Figure 2: Ortho-Para Hydrogen Conversion Modeled with AVEVA Process Simulation

Mode Summary
Process Mode
The objective of Process mode is to provide an overall mass and energy balance for the process and to estimate
product temperatures and compositions. In Process mode, we take the following steps to meet the process
specifications:
• For the plate-fin heat exchangers (E1, E2, and E3), we specify the surface area, pressure drop, outlet
temperature, and heat transfer coefficient for each hot and cold path.
• We specify the pressure change and efficiency of the EX1 expander and the K1 compressor.
• We specify the molar flowrate of LN2 and calculate E1.Tco[1].
Fluid Flow Mode
Fluid Flow mode serves as an intermediate calculation before dynamic simulation. Process mode performs flow-
driven, steady-state calculations that are a good basis for subsequent process design. When you switch to Fluid
Flow mode, the simulation converts from a flow-driven model to a pressure-driven model. Typically, you do not

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specify flowrates in this mode. Instead, you calculate the flowrates by balancing pressures on each piece of
equipment.
Dynamics Mode
Dynamics mode allows you to observe process behavior during and after a process disruption or change. For this
example, we examine the impact of throttling the XV1 valve on the refrigeration loop temperature.

Scenarios
This example includes the Throttle XV1 scenario, which changes the manual position of XV1 from 100% to 80%
and records the inlet and outlet temperatures of the valve over the next 20 minutes. You can use this scenario to
examine the Joule-Thomson effect.

Figure 3: Throttle XV1 Scenario

Results
Process and Fluid Flow Modes
The following table summarizes the properties for the boundary streams of the solved steady-state solution. This
information also appears in the Stream Report Table in the simulation. You can open this Table to quickly view
and generate a Microsoft Excel report for these results.
Table 2: Selected Stream Properties for the Steady-State Solution

Variable Description Units H2Feed H2Prod LN2 LN2Ret

F Molar flow kmol/h 0.5 0.5 46.15 46.15

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Variable Description Units H2Feed H2Prod LN2 LN2Ret

P Pressure kPa 120 112 100 96

T Temperature K 298.15 16.96 77.24 87.99
VF Vapor fraction fraction 1 0 -0.013 1.66
z[OH2] Orthohydrogen composition fraction 0.75 0.0037 - -
z[PH2] Parahydrogen composition fraction 0.25 0.99 - -
The simulation also includes temperature profiles for each of the plate-fin heat exchangers. The following figure
shows the temperature of each hot and cold stream across the E1 heat exchanger.

Figure 4: Temperature Profile of the E1 Heat Exchanger

Dynamics Mode
In Dynamics mode, we study the impact of the Joule-Thomson effect on the refrigeration loop temperature by
manually throttling XV1. The Joule-Thomson effect describes the temperature change of a gas resulting from a
sudden change in pressure (for example, by throttling a valve). As the pressure drop across the valve increases,
so does the temperature difference. The following figure shows the system response to suddenly changing the
manual position of XV1 from 100% to 80%.

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Figure 5: Joule-Thomson Effect

Snapshots
The simulation includes the following snapshots:
• Pro 1: A solved steady-state solution in Process mode. If you make any changes to the simulation that cause
errors in Process mode, revert to this snapshot.
• FF 1: A solved steady-state solution in Fluid Flow mode. If you make any changes to the simulation that cause
errors in Fluid Flow mode, revert to this snapshot.
• Dyn 1: The initial Dynamics solution after switching from Fluid Flow mode. You should revert the simulation
to this snapshot before you run any custom scenarios in Dynamics mode.

Excel Report
You can find summaries for the hydrogen feed and product streams and for each inlet and outlet stream for the
plate-fin heat exchangers in the AA2 - Hydrogen Liquefaction.xlsx file.

References
1. Leachman, J. W.; Jacobsen, R. T.; Penoncello, S. G.; Lemmon, E. W. Fundamental Equations of State for
Parahydrogen, Normal Hydrogen, and Orthohydrogen. J. Phys.Chem. Ref. Data 2009, 38 (3), 721–748.
2. Kunz, O.; Klimeck, R.; Wagner, W.; Jaeschke, M. The GERG-2004 Wide-Range Equation of State for Natural
Gases and other Mixtures; GERG TM 15; Groupe Européen de Recherches Gazières: Düsseldorf, Germany,
2007.

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3. Hust, J. G.; Stewart, R. B. A Compilation of the Property Differences of Ortho and Para Hydrogen or Mixtures
of Other and Para Hydrogen; NBS-8812; U.S. Department of Commerce, National Bureau of Standards:
Gaithersburg, MD, May, 1965.

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Revision Log
Date Who Change

26 Jan 2020 YY Initial release for AVEVA Process Simulation 4.3.

Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
This example demonstrates how you can use AVEVA Process Simulation to simulate a two-bed pressure swing
adsorption (PSA) process that separates oxygen from air. The two-bed PSA process runs two adsorption beds in
repetitive counter-parallel action; while Bed 1 pressurizes and produces high-purity product, bed 2 vents and
regenerates, and vice versa. Combined, these actions form a repetitive cycle of short duration. The beds
regenerate by depressurizing and venting through a vacuum blower. During operation, after an initial set of
cycles, the process reaches a steady state of repetitive bed cycles for which the initial and end conditions
between cycles become identical.
We base this example on the paper by Farooq and Ruthven1. The objective of this simulation is to:
• Design a PSA column that separates nitrogen from air to produce high-purity oxygen.
• Analyze the concentration profiles and the cycle durations of the adsorption beds during operation.
• Quantify the time to reach semi steady-state behavior.

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Figure 1: The Laboratory Two-bed Pressure Swing Adsorption (PSA) System

Process Description
The two-bed pressure swing adsorption (PSA) process has the following characteristics:
• We feed compressed, cooled ambient air to the two adsorber beds.
• While one bed adsorbs nitrogen to produce high-purity oxygen, the other bed regenerates, depressurizes,
and vents through the vacuum blower.
• For the initial condition, all holdups consist of 100% helium.
The following table shows the feed conditions.
Table 1: Feed Conditions

Variable Description Value UOM

P Pressure 200 kPa

T Temperature 25 °C
z[O2] Molar composition of oxygen 21 %
z[N2] Molar composition of nitrogen 78 %
z[Ar] Molar composition of argon 1 %
z[He] Molar composition of helium 0 %

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The following table shows the specifications for the adsorption beds. The beds consist of one adsorbent layer
filled with alumina desiccant-grade adsorbent.
Table 2: Adsorption Bed Specifications

Variable Description Value UOM

L Adsorber total length 35 cm

Di Adsorber inner diameter 3.5 cm
thk Adsorber wall thickness 0.35 cm
The following table shows the cycle times for each step of the two-bed PSA process:
Table 3: Cycle Time

Step Time UOM

Pressurization 30 s
Production 20 s
Blowdown 30 s
Purge 20 s
Total 100 s

Simulation Model
The two adsorption beds are identical. We model the adsorption beds according to the following specifications:
• We use one (NLayers = 1) BedLayer submodel with 40 segments (Layer[1].Ne = 40) of alternating bed and
wall elements.
• We calculate the pressure drop according to Ergun3 (PressureDrop = Ergun).
• We create copies of the RatesLocal, RatesLDF, IsothermInert, and IsothermExLangmuir submodels from the
Adsorption library in the simulation-specific library. Then, we update the rate expressions, saturation
concentration calculations, and equilibrium loading calculations to match the empirical data that we have for
our alumina adsorbent.
• We use the RatesLDF submodel from the simulation-specific library to calculate the adsorption rates of N2
and O2. These linear driving force (LDF) rate expressions are based on the paper by Farooq and Ruthven1.
• We use the IsothermExLangmuir submodel from the simulation-specific library to calculate the saturation
concentrations and equilibrium loading. We calculate the equilibrium loading by using the Extended
Langmuir equation.
• We model the outlet valve by using a first-order time constant (Tc) of 0.02 seconds.

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Library
This simulation uses the Adsorption library, which is designed for pressure swing adsorption (PSA) studies for O2-
N2 separation. Before you use the simulation, you must import the Adsorption library. You can find the
Adsorption library in the %userprofile%\My Libraries\Examples folder.

Fluids
This simulation uses a custom VLE compositional fluid named Air, which we model by using the AirIGState
submodel. This submodel applies ideal gas correlations for density and energy terms.

Mode Summary
Process Fluid Flow Dynamics

Objective Provide an initial estimate to Create an initial steady-state Observe the dynamic
Fluid Flow mode. condition from which to start composition changes by using
the dynamic run. the scenarios.

Fluid Flow Mode

We use Fluid Flow mode to design the adsorber based on the space velocity and to create the initial starting
condition for dynamic runs.

Figure 2: The Space Velocity of the Bed Layer

Dynamics Mode
We use Dynamics mode to study the compositional profile during the adsorption cycles.
Each pressure swing adsorption (PSA) cycle involves the following four steps:
1. Pressurization: Pressurize Bed 1 and vent Bed 2.
2. Production: Produce high-purity oxygen from Bed 1 and continue to vent Bed 2.

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3. Blowdown: Pressurize Bed 2 and vent Bed 1.

4. Purge: Produce high-purity oxygen from Bed 2 and continue to vent Bed 1.
We provide respective scenarios for each step. The following images illustrate the valve settings specific to each
step, where green indicates a fully opened valve, red indicates a fully closed valve, and yellow indicates a 50%
opening position for the valve.

Figure 3: Valve Setup for Each PSA Step

We also provide a scenario that runs a full cycle (that is, all four steps), a scenario that runs five cycles, and a
scenario that runs ten cycles. See the following section for more information.

Scenarios
Step 1 - Pressurize Bed 1 and Vent Bed 2
This scenario pressurizes Bed 1. At the same time, it vents Bed 2 through the RV3 valve by opening the SV2_2
supply valve. It routes the unit feed entirely to Bed 1 as the SV1_1 supply valve opens and the SV1_2 supply valve
closes. The duration is 30 seconds.

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Step 2 - Bed 1 Produces and Vent 2 Keeps Venting

This scenario draws product from Bed 1 by opening the SV5 and RV2 valves in the upper-left product line. The
top RV2 valve on the exit line also opens, although the final exit valve, EX1, remains fully closed. Bed 2 continues
to vent through the lower-right vent line during this scenario. The duration is 20 seconds.

Step 3 - Pressurize Bed 2 and Vent Bed 1

This scenario is the inverse of the initial pressurization step for Bed 1. It depressurizes Bed 1 and pressurizes Bed
2. That is, while Bed 2 pressurizes, Bed 1 vents through the RV3 valve by opening the SV2_1 valve. This scenario
routes the unit feed entirely to Bed 2 as the SV1_2 supply valve opens and the SV1_1 supply valve closes. The
duration is 30 seconds.

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Step 4 - Bed 2 Produces and Vent 1 Keeps Venting

This scenario is the inverse of the initial production step for Bed 1. It draws product from Bed 2 by opening the
SV3 and RV2 valves in the upper-right product line. The RV1 valve on the exit line also opens, although the final
exit valve, EX1, remains fully closed. Bed 1 continues to vent through the lower-left vent line during this scenario.
The duration is 20 seconds.

All Steps - The Full Cycle

This scenario combines the four steps into a single scenario that represents a full pressure swing adsorption
(PSA) cycle. Initially, we pressurize Bed 1 and then set it into production while Bed 2 vents in parallel. Then, we

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reverse the actions to pressurize Bed 2 and then set it into production while Bed 1 vents in parallel. The duration
of the full cycle is 110 seconds.

Run 5 Cycles
This scenario runs five full PSA cycles so that you can observe how the cycles slowly approach identical,
repetitive behavior.

Run 10 Cycles
This scenario runs ten full PSA cycles. The conditions at the initial and final moments of each cycle will slowly
converge to the same numbers, indicating a cyclic behavior.

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Results
Process and Fluid Flow Mode
Since the pressure swing adsorption (PSA) process is dynamic in nature, we do not discuss any results for Process
and Fluid Flow modes for this example.

Dynamics Mode
To view the results:
1. Open the Product Purity Trend.
2. Open the Compositions Profile.
3. Run the Run 10 Cycles scenario.
The following figure shows the results in the Product Purity Trend.

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Figure 4: Trend of the Product Purity

The following figure shows the results in the Compositions Profile. During the scenario, you can see how the
compositions change.

Figure 5: Composition Profile during the Scenario

The composition after 10 cycles run shows a close match to the theoretically and experimentally validated
response proposed by Farooq and Ruthven1.
The Canvas includes variable references to the number of segments in the adsorption columns (Bed1.Layer[1].Ne
and Bed2.Layer[1].Ne). You can directly change these values to observe the effects of increasing or decreasing
the number of segments.

Snapshots
This simulation includes the following snapshots:

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• FF 1 loads the steady-state condition. The valve setup matches the Production step for the PSA process.
• FF 2 loads the initial condition for Dynamics mode. The beds are full of helium.
• Dyn 1 loads the initial condition.
• Dyn 2 shows the final conditions after running the All Steps - the full Cycle scenario.
• Dyn 3 shows the final conditions after running the Run 5 Cycles scenario.
• Dyn 4 shows the final conditions after running the Run 10 Cycles scenario.
To load the initial steady-state conditions:
1. Switch to Fluid Flow mode.
2. Revert the simulation to the FF 2 snapshot.
3. Switch back to Dynamics mode.
4. Change the source composition from 100% helium to the air condition (21% O2, 78% N2, and 1% Ar).

Excel Report
You can open the AA3 - Labscale PSA Process.xlsx file to view the adsorber summary and the exact dynamic
response values. You can find this Microsoft Excel Report in the %userprofile%\My Simulations\Examples folder.
It includes the following worksheets:
• Equipment Summary: A summary of the process units.
• Composition Profile: A composition profile of the inlet and outlet of Bed 1 and Bed 2.

References
1. Farooq, S.; Ruthven, D.M. Numerical simulation of a kinetically controlled pressure swing adsorption bulk
separation process based on a diffusion model. Chem. Eng. Sci. 1991, 46, 2213–2224.
2. Hassan, M.M; Ruthven, D.M; Raghavan, N.S. Air separation by pressure swing adsorption on a carbon
molecular sieve. Chem. Eng. Sci. 1986, 41, 1333–1343.
3. Ergun, S. Fluid flow through packed columns. Chem. Eng. Prog. 1952, 48 (2), 89–94.

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Revision Log
Date Who Change

4 Mar 2020 YY Initial release for AVEVA Process Simulation 4.3.

Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
This example demonstrates how you can use AVEVA Process Simulation to simulate a two-bed pressure swing
adsorption (PSA) process that separates oxygen from air. The two-bed PSA process runs two adsorption beds in
repetitive counter-parallel action; while Bed 1 pressurizes and produces high-purity product, Bed 2 vents and
regenerates, and vice versa. Combined, these actions form a repetitive cycle of short duration. The beds
regenerate by depressurizing and venting through a vacuum blower. During operation, after an initial set of
cycles, the process reaches a steady state of repetitive bed cycles for which the initial and end conditions
between cycles become identical.
The objective of this simulation is to:
• Design a PSA column that separates nitrogen from air to produce high-purity oxygen.
• Analyze the concentration profiles and the cycle durations of the adsorption beds during operation.
• Quantify the time to reach semi steady-state behavior.

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Figure 1: The Two-bed Pressure Swing Adsorption System

Process Description
The two-bed pressure swing adsorption (PSA) process has the following characteristics:
• We feed compressed, cooled ambient air to the two adsorber beds.
• While one bed adsorbs nitrogen to produce high-purity oxygen, the other bed regenerates, depressurizes,
and vents through the vacuum blower.
• For the initial condition, all holdups consist of 100% oxygen.
• The total cycle time for one PSA cycle is 110 seconds.
The following table shows the feed conditions.
Table 1: Feed Conditions

Variable Description Value UOM

P Pressure 101.325 kPa

T Temperature 25 °C
z[O2] Molar composition of oxygen 22 %
z[N2] Molar composition of nitrogen 78 %

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The following table shows the specifications for the adsorption beds.
Table 2: Adsorption Bed Specifications

Variable Description Value UOM

L Adsorber total length 304 cm

Di Adsorber inner diameter 437 cm
thk Adsorber wall thickness 1.5 cm
The adsorption beds consist of three adsorbent layers filled with the following adsorbents:
• Layer 1: Alumina desiccant-grade adsorbent
• Layer 2: UOP13X molecular sieve adsorbent
• Layer 3: VSA6 molecular sieve adsorbent
The following table shows the specifications for each layer.
Table 3: Adsorbent Layer Specifications

Variable Description UOM Layer 1 – Layer 2 – Layer 3 –

Alumina UOP13X VSA6

Layer[].Ne Number of segments - 10 20 40

Layer[].rhos Density of Adsorbent kg/m3 1433.6 1338.6 1290.3

Layer[].eps Bulk void fraction fraction 0.614 0.634 0.643

Layer[].Tot_eps Total void fraction fraction 0.65 0.694 0.69
Layer[].d Particle diameter m 0.0025 0.0025 0.0025
Layer[].Cs Heat capacity cal/g-K 0.22 0.22 0.22
Layer[].asf Surface area of beads m2/m3 770 770 770

Simulation Model
The two adsorption beds are identical. We model the adsorption beds according to the following specifications:
• We use three BedLayer submodels (NLayers = 3), one for each type of adsorbent that we use in the
adsorption bed.

Figure 2: Diagram of the Bed Layers

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• We calculate the pressure drop according to Ergun3 (PressureDrop = Ergun).

• We create three copies of the RatesLDF submodel from the Adsorption library in the simulation-specific
library, one copy for each adsorbent type that we use in the adsorption beds. Then, we update the rate
expressions in each submodel to match the empirical data that we have for our alumina adsorbent
(Alumina_LDF), UOP13X adsorbent (UOP13X_LDF), and VSA6 (VSA6_LDF) adsorbent.

Figure 3: The Adsorption Rate Submodels in the Simulation-specific Library

These submodels calculate the adsorption rates of N2 and O2. These linear driving force (LDF) rate
expressions are based on the paper by Farooq and Ruthven1. We use the Layer[].RateType parameters to
specify the submodel for each layer.

Figure 4: The Adsorption Rate Submodel for Each Bed Layer

• We create three copies of the RatesLDF submodel from the Adsorption library in the simulation-specific
library, one copy for each adsorbent type that we use in the adsorption beds. Then, we update the rate
expressions to match the empirical data that we have for our alumina adsorbent (Alumina_LDF), UOP13X
adsorbent (UOP13X_LDF), and VSA6 (VSA6_LDF) adsorbent.

Figure 5: The Equilibrium Loading Submodels in the Simulation-specific Library

These submodels calculate the saturation concentrations. They use the Extended Langmuir equation to
calculate the equilibrium loading. We use the Layer[].IsoType parameters to specify the submodel for each
layer.

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Figure 6: The Equilibrium Loading Submodel for Each Layer

Library
This simulation uses the Adsorption library, which is designed for pressure swing adsorption (PSA) studies for O2-
N2 separation. Before you use the simulation, you must import the Adsorption library. You can find the
Adsorption library in the %userprofile%\My Libraries\Examples folder.

Fluids
This simulation uses a custom VLE compositional fluid named Air_IG, which we model by using the AirIGState
submodel. This submodel applies ideal gas correlations for density and energy terms.

Mode Summary
Process Fluid Flow Dynamics

Objective Provide an initial estimate to Create an initial steady-state Observe the dynamic
Fluid Flow mode. condition from which to start composition changes by using
the dynamic run. the scenarios.

Fluid Flow Mode

We use Fluid Flow mode to design the adsorber based on the space velocity and to create the initial starting
condition for dynamic runs.

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Figure 7: Maximum Space Velocity of Each Bed Layer

Dynamics Mode
We use Dynamics mode to study the compositional profile during the adsorption cycles.
Each pressure swing adsorption (PSA) cycle involves the following steps:
1. Bed 1 produces while Bed 2 purges
2. Bed 1 pressurizes into Bed 2
3. Bed 1 vents while Bed 2 regenerates
4. Bed 1 vents while Bed 2 produces
5. Bed 1 purges while Bed 2 produces
6. Bed 2 pressurizes into Bed 1
7. Bed 2 vents while Bed 1 regenerates
8. Bed 2 vents while Bed 1 produces
We provide respective scenarios for each step. The following images illustrate the valve settings specific to each
step, where green indicates a fully opened valve, red indicates a fully closed valve, and yellow indicates a 30%
(PV1 and PV2) or 50% (PCV) opening position for the valve.

Figure 8: Valve Setup for Steps 1 to 8

We also provide a scenario that runs a full cycle (that is, all eight steps) and a scenario that runs ten cycles. See
the following section for more information.

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Scenarios
Step 1 - Bed 1 Produces and Bed 2 Regeneration
This scenario draws product from Bed 1 through the PV1 valve and regenerates Bed 2 at the same time by using
the flow through the PCV valve and venting through the BDV2 vent valve. We route the entire unit feed to Bed 1
as the FV1 supply valve opens and FV2 supply valve closes. The duration is 8 seconds.

Step 2 - Bed 1 Pressurizes into Bed 2

This scenario pressurizes Bed 2 by using the dry gas from Bed 1 to reduce the energy consumption of the
pressurization for the Bed 2 regeneration. After 4 seconds of pressurization in Bed 2, Bed 1 vents through the
BDV1 valve for 3 seconds.

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Step 3 - Bed 1 Depressurizes and Bed 2 Pressure Equalization

This scenario pressurizes Bed 2 before production and depressurizes Bed 1 through the BDV1 vent valve. The
duration is 2 seconds.

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Step 4 - Bed 1 Regeneration and Bed 2 Produces

This scenario draws product from Bed 2 while Bed 1 depressurizes at the same time through the BDV1 vent
valve. We route the entire unit feed to Bed 2 as the FV2 supply valve opens and the FV1 supply valve closes. The
duration is 38 seconds.

Step 5 - Bed 2 Produces and Bed 1 Regeneration

This scenario is the inverse of step 1.

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Step 6 - Bed 2 Pressurizes into Bed 1

This scenario is the inverse of step 2.

Step 7 - Bed 2 Depressurize and Bed 1 Pressure Equalization

This scenario is the inverse of step 3.

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Step 8 - Bed 2 Regeneration and Bed 1 Produces

This scenario is the inverse of step 4.

All Steps – The Full Cycle

This scenario combines the eight steps of the pressure swing adsorption (PSA) process into a single scenario that
represents a full PSA cycle. Summarized, we initially set Bed 1 into production while Bed 2 regenerates in
parallel. Then, actions reverse to pressurize Bed 2 before we set it into production while Bed 1 regenerates in
parallel. The duration of the full cycle is 110 seconds.

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Run 5 Cycles
This scenario runs five full PSA cycles so that you can observe how the cycles slowly approach identical,
repetitive behavior.

Run 10 Cycles
This scenario runs ten full PSA cycles. The conditions at the initial and final moments of each cycle slowly
converge to the same numbers, indicating a cyclic behavior.

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Results
Process and Fluid Flow Mode
Since the pressure swing adsorption (PSA) process is dynamic in nature, we do not discuss any results for Process
and Fluid Flow modes for this example.

Dynamics Mode
To view the results:
1. Open the Product Compositions Trend.
2. Open the Compositions Profile.
3. Run the Run 10 Cycles scenario.
The following figure shows the results in the Product Compositions Trend.

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Figure 9: Trend of the Concentration of Oxygen

The following figure shows the results in the Compositions Profile. During the scenario, you can see how the
profile changes.

Figure 10: Composition Profile during the Production and Regeneration of the Adsorber
The oxygen concentration of the product is more than 99.9% after 10 cycles.

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The Canvas includes variable references to the simulation’s time step (dt) and the number of segments in the
adsorber bed layers (Bed1.Layer[x].Ne and Bed2.Layer[x].Ne). You can directly change these values to observe
the effects of increasing or decreasing the number of segments.

Snapshots
This simulation includes the following snapshots:

FF 1 loads the steady-state condition. The valve setup matches the first step in the PSA process, where Bed 1
produces and Bed 2 vents.
FF 2 loads the initial condition for Dynamics mode. Both beds are full of oxygen.
Dyn 1 loads the initial condition.
Dyn 2 shows the final conditions after running the All Steps - the full Cycle scenario.
Dyn 3 shows the final conditions after running the Run 5 Cycles scenario.
Dyn 4 shows the final conditions after running the Run 10 Cycles scenario.
To load the initial steady-state conditions:
1. Switch to Fluid Flow mode.
2. Revert the simulation to the FF 2 snapshot.
3. Switch back to Dynamics mode.

Excel Report
You can open the AA4 - Fullsize PSA Process.xlsx file to view the adsorber summary and the exact dynamic
response values. You can find this Microsoft Excel Report in the %userprofile%\My Simulations\Examples folder.
It includes the following worksheets:
• Equipment Summary: A summary of the process units.
• Composition Profile: A composition profile of the inlet and outlet conditions of all three layers in Bed 1 and
Bed 2.

References
1. Farooq, S.; Ruthven, D.M. Numerical simulation of a kinetically controlled pressure swing adsorption bulk
separation process based on a diffusion model. Chem. Eng. Sci. 1991, 46, 2213–2224.

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2. Hassan, M.M; Ruthven, D.M; Raghavan, N.S. Air separation by pressure swing adsorption on a carbon
molecular sieve. Chem. Eng. Sci. 1986, 41, 1333–1343.
3. Ergun, S. Fluid flow through packed columns. Chem. Eng. Prog. 1952, 48 (2), 89–94.

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Revision Log
Date By Comments

13 Sep 2022 SW Initial issue.

Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
This example demonstrates the separation of methanol from water in a batch distillation column. You must
model a batch separation as dynamic, because there is no steady-state solution for batch operations. This
example contains a scenario in Dynamics mode to observe how the system behaves during operation. To
accomplish this, the simulation uses specialized models to simulate both a batch source and batch distillation
unit.
Use this example to observe how the batch system behaves during operation to produce a high-purity methanol
product. We achieve a high-purity methanol product by stopping the product collection when the column
distillate drops to 70% methanol.

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Figure 1: A Methanol-Water Batch Separation Modeled in AVEVA Process Simulation

Process Description
This simulation includes a single feed to the system (SRC1) and a single batch distillation column (C1).
We first add material to the pot of the batch distillation column (the initial "charge" for the distillation column).
We then heat the material to produce a specified molar boilup rate (C1.Fpot). The vapor from the pot enters the
tray section of the batch distillation column. In Process mode, the condenser at the top of the batch distillation
column operates at total reflux. In Dynamics mode, the condenser operates at total reflux and then switches to
include a product draw to an internal tank.
The following table shows the composition and thermal condition of the feed.
Table 1: Feed Conditions

Variable Description Value UOM

SRC1.F Molar flow rate 172.602 kmol/h

SRC1.P Pressure 101.325 kPa
SRC1.T Temperature 46.85 °C
SRC1.M[MEOH] Unnormalized molar feed composition of methanol 1 kmol
SRC1.M[H2O] Unnormalized molar feed composition of water 1 kmol
The following table shows the equipment sizes and configuration throughout the simulation. It shows only the
values that differ from the default value.
Table 2: Equipment Sizes and Configuration

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Variable or Parameter Description Value UOM

C1.NStages Number of stages in the distillation column 10 -

C1.CompBasis Parameter to determine whether the distillation column Mass -
reports values on a molar or mass basis

C1.Contact Contact efficiency factor for the stages in the distillation 1 fraction
column
C1.TankVol Parameter to determine whether the tank volume is Specify -
specified or calculated
C1.VT1 Internal tank volume 0.1 m3

C1.Vpot Volume of the pot 0.111 m3

C1.Levelpot Level of the pot 0.9 fraction

C1.VFpot Vapor fraction in the pot 0 mol frac

C1.Fpot Molar boilup rate in the pot 3.6 kmol/h

C1.Vohd Molar vapor product rate of the distillation column 0 kmol/h

C1.Int1.T1.TankType Parameter to determine whether the tank is a simplified Tank -

model with no required geometry or a rigorous model
that accounts for tank geometry and displays the tank
level on the Canvas
C1.Int1.T1.CompBasis Parameter to determine whether the tank reports values Mass -
on a molar or mass basis

Simulation Model
Libraries
This simulation uses the custom Batch Library from AVEVA Process Simulation. You may need to import the latest
version of the Batch Library from the %userprofile%/My Libraries/Examples folder before you import this
simulation.
This simulation also uses a fluid from the simulation-specific Model Library. See Fluids for more information.

Fluids
This simulation uses the DefFluid fluid from the simulation-specific Model Library as the process fluid. This is a
Compositional fluid that uses the Non-Random Two-Liquid (NRTL) method for the thermodynamic calculations.
The fluid includes the following components:

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• Methanol (MEOH)
• Water (H2O)

Mode Summary
This example uses Process mode to provide a conceptual design that serves as a good initial starting point for
dynamic simulation.
Due to the specialized nature of batch models and the exclusion of column hydraulic options, we do not need to
transition to Fluid Flow mode before we switch to Dynamics mode. Therefore, we do not include descriptions or
results for Fluid Flow mode for this simulation.
Note: If we had included hydraulic options in the batch distillation column, we would have transitioned to Fluid
Flow mode before moving on to Dynamics mode.
This example uses Dynamics mode to observe the transient behavior during batch operation. We can use the
results of the dynamic simulation to adjust the process to better meet our design requirements.

Process Mode
The objective of Process mode is to provide an overall steady-state mass and energy balance for the process and
to estimate the product flowrates and compositions. However, batch processes are inherently transient, and a
batch distillation column achieves a steady-state solution only when its condenser is at total reflux. Therefore,
the total reflux configuration is the default option in Process mode for sizing and initializing the batch distillation
column for dynamics. In the total reflux configuration, the batch distillation column has no products, so Process
mode provides only a conceptual design that serves as a good initial starting point for dynamic simulation. (That
is, we don't produce meaningful results for analyzing the system until we run the simulation in Dynamics mode.)
The default set of specified variables includes all the variables that we need to meet the design requirements.
Therefore, we do not switch any process specifications in Process mode.

Dynamics Mode
The objective of Dynamics mode is to observe the transient behavior of the system during batch operations.
The default set of specified variables includes all the variables that we need to meet the design requirements.
Therefore, we do not switch any process specifications in Dynamics mode.

Scenarios
This simulation includes the following scenarios:
• Scenario RR3 – Switches the simulation from Process mode to Dynamics mode to produce high-purity
methanol. It changes the configuration of the condenser to include a product draw and sets the reflux ratio
to 3. It stops the dynamic run when the methanol purity of the column distillate drops to 70%.

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• BackToProcess – Returns the simulation to Process mode and resets the configuration of the column, tank,
and source for the initial setup.

Results
Process Mode
Process mode requires steady-state conditions to correctly solve a simulation. Because batch processes are
inherently transient and a batch distillation column achieves a steady-state solution only when its condenser is at
total reflux, the Process mode results serve only as an initial starting point for the dynamic simulation.

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The following figure shows the vapor and liquid compositions at each stage of the batch distillation column at
total reflux. We achieve purified methanol at the top of the batch distillation column.

The following figure shows the vapor flow rates, liquid flow rates, and temperature at each stage of the batch
distillation column at total reflux.

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Dynamics Mode
In Process mode, the condenser operates at total reflux. The Scenario RR3 scenario switches the simulation to
Dynamics mode and then runs a dynamic simulation. At the start of the dynamic simulation, the scenario
switches the condenser operation to include a product draw. It sets the reflux ratio (C1.RefluxRatio) to 3, and we
see methanol product accumulate in the internal tank (T1). When the purity of the distillate from the batch
distillation column reaches less than 70%, the dynamic simulation stops, and the batch is complete.
The following figure shows the liquid compositions of methanol and water in both the pot and the distillate as
the dynamic simulation progresses. We see that water does not reach the top of the batch distillation column
until about 95 minutes have passed, at which point we see a relatively steep drop in methanol purity in the
distillate.

The following figure shows the compositions of methanol and water in T1 as the methanol product accumulates.
We maintain pure methanol until water reaches the top of the batch distillation column at about 95 minutes.
Because we shut off the product draw when the methanol purity in the distillate drops below 70% and the drop
in purity is relatively swift once water reaches the top of the batch distillation column, we see a very limited drop
in the purity of the accumulated methanol product in T1.

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Overall, we produce 1.57 kmol of methanol (C1.IntT.T1.MI) at 99.4% purity (C1.IntT.T1.x[MEOH]). Therefore, our
process requirement (stopping the product draw once the column distillate drops to 70% methanol) meets our
high-purity objective.

Snapshots
This simulation includes the following snapshots.
• Pro 1: A solved steady-state, base-case solution in Process mode. If you make any changes to the simulation
that cause errors in Process mode, revert to this snapshot.
This snapshot also provides the initial setup for the batch simulation and the starting point for the dynamic
simulation. You can revert the simulation to this starting point and then run multiple scenarios in Dynamics
mode to analyze the behavior of this system during batch operations.
• Dyn 1: The results of the Scenario RR3 scenario.

Excel Report
The BA1 - Water Methanol Batch Separation.xlsx file is a Microsoft Excel report for this example simulation. It
provides the results of the latest Dynamics run stored in the Dyn 1 snapshot and a graph of the product purity v.
time.
You can find the BA1 - Water Methanol Batch Separation.xlsx file in the %userprofile%\My
Simulations\Examples folder.

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Revision Log
Date Who Change

14 Jul 2017 DK Initial draft for first release.

Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
This example demonstrates how you can use AVEVA Process Simulation to design a distillation column to
separate methanol from a water-methanol mixture. We provide two individual simulations, C1 - Water Methanol
Separation and C1 - Water Methanol Separation Detailed Engineering, which illustrate how to approach the
separation. The C1 - Water Methanol Separation simulation illustrates the conceptual engineering in Process
mode. The C1 - Water Methanol Separation Detailed Engineering simulation illustrates the detailed engineering.
It is a continuation of the first simulation and provides for both the detailed steady-state equipment design in
Process mode and the process strategy validation in Dynamics mode. We provide these simulations with the
following objectives in mind:
• Design a distillation column that separates methanol and water into products with required purity.
• Demonstrate how to trade specifications for different design requirements.
• Demonstrate how to migrate a conceptual design simulation to a detailed design simulation.
• Demonstrate how to model external condenser and reboiler circuits for detailed engineering.
• Validate the process control strategy.
The following figures illustrate the two different water-methanol separation simulations. Figure 1 shows the C1 -
Water Methanol Separation simulation as a conceptual design model. Figure 2 shows the C1 - Water Methanol
Separation Detailed Engineering simulation as a detailed engineering model.

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Figure 1: Conceptual Design Model

Figure 2: Detailed Engineering Model and Dynamic Simulation

The Column model addresses both conceptual and detailed engineering. For conceptual engineering, we model
the water-methanol separation process with a single column model representing both condenser and reboiler
duties on the top and bottom stage. We then use built-in Column features to migrate this model to an extended,
detailed simulation that models the condenser and reboiler externally. The extended model enables more
detailed equipment design, reports utility requirements, and allows for pipe sizing. We also perform flow

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analysis in Fluid Flow mode and dynamic simulation in Dynamics mode for the extended model. Both simulations
report identical results in Process mode regarding the separation and the internal column profiles.

Process Description
A water-methanol feed enters the column at 1430 kmol/h with 29% methanol. The column includes 13 stages, a
water-cooled total condenser and a steam-heated thermosiphon reboiler. The feed location is at stage 7. The
target purity is 96% methanol in the distillate.
The overhead condenser completely condenses the column overhead by using cooling water on the tube side of
a shell and tube heat exchanger. A vent valve on the reflux drum removes any non-condensables. A pump
returns the reflux drum liquid as reflux and as produced liquid distillate.
The column includes a sump, which supplies the bottoms product and feeds a thermosiphon reboiler that uses
condensable steam supplied to the shell side of a shell and tube heat exchanger. Natural circulation pushes the
product flow through the thermosiphon reboiler, which partially vaporizes the product flow before it returns to
the column.
The following table provides a summary of the design criteria for the simulation model.
Table 1: Design Criteria

Variable SI US Refining

Feed flowrate 1430 kmol/h 3152 kmol/h

Required distillate methanol purity 0.96 fraction 0.96 fraction
Cooling water supply pressure 150 kPa 7.1 psig
Cooling water supply temperature 25 °C 77 °F
Cooling water return temperature 50 °C 122 °F
Steam supply pressure 475 kPa 54.2 psig
Steam supply temperature 150 °C 302 °F
Steam return temperature 120 °C 248 °F
Column flooding factor 0.78 fraction 0.78 fraction
Tray pressure drop 2 kPa 0.29 psi
Column top pressure 101.325 kPa 0 psig
Target reboiler vaporization 0.3 fraction 0.3 fraction
Condenser heat transfer coefficient 0.137 kW/m2-K 24.13 BTU/h-ft-F
Reboiler heat transfer coefficient 0.068 kW/m2-K 12.03 BTU/h-ft-F
We design the control scheme according to the recommendations provided in Distillation Operation by Henry
Kister1. We apply the following process control strategy:
• A flow controller controls the column feed flow.

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• We control the pressure on the top tray of the column by manipulating the cooling water supply to the
overhead condenser.
• We control the reflux drum level by manipulating the distillate product.
• We control the column sump level by manipulating the bottoms product.
• We control the temperature on stage 9 of the column by manipulating steam supply to the shell side of the
reboiler.

Simulation Model
The following section provides a high-level view of both simulation models. See Process Mode for a detailed
workflow description.
Conceptual Engineering
The conceptual design model (Figure 1) consists of a Source, a Column, and two Sinks that represent the
destinations for the distillate and bottoms products. We model the condenser and reboiler as additional top and
bottom stage duties that are internal to the column by setting the Condenser and Reboiler parameters to
Internal. We set the Internals parameter to Trays so that the column includes basic hydraulic tray sizing and
rating calculations according to Fair’s entrainment flooding correlation for 24-inch tray spacing. We initially size
the stages by assuming 78% tray flooding and setting the Hydraulics parameter to Sizing. The Dcol variable then
reports the maximum stage diameter.
Detailed Engineering
The extended simulation for detailed engineering (Figure 2) utilizes additional features, including hydraulic
calculations. We construct it by using external condenser and reboiler circuits. We now supply reflux and reboiler
return flow externally by setting the Condenser and Reboiler parameters to External. We make similar
declarations for the column sump. To ensure that the internal vapor traffic is identical to that of the conceptual
model, we quantify the sump’s reboiler draw by using the RoutFrac variable and base it on a 30% vaporized
reboiler return.
We also rate the column by setting the Hydraulics parameter to Rating, which uniformly sets the calculated Dcol
variable for all stages. The FF array variable reports the individual flooding factors for the trays.
The overhead condenser circuit consists of a heat exchanger model with cooling water on the tube side. We
calculate the required flowrate needed to completely condense the overhead product by specifying the process-
side vapor fraction as zero and the cooling water return temperature at the design condition of 50°C. AVEVA
Process Simulation calculates the required cooling water flow and exchanger duty.
The following table illustrates the specified variables by default and the modified arrangement to meet design
conditions.
Table 2: Specifications for Overhead Condenser and Cooling Water Supply

Default Specifications Modified Specifications

Variable
Status* Value Status* Value

COND.Duty 0 kW 10,723 kW

COND.Tto 25°C 50°C

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Default Specifications Modified Specifications

Variable
Status* Value Status* Value

COND.VFso 0.1 fraction 0 fraction

CW.W 3,600 kg/h 369,506 kg/h

*A indicates that the variable is calculated and a indicates that the variable is specified

The fully condensed overhead condensate flows to the reflux drum where vapor can flow through a vent valve
(XV6) and we pump and split the remaining liquid product into reflux and distillate streams. Since the feed into
the reflux drum is all liquid and our feed does not include any non-condensable components, the vent valve flow
is zero and we cannot size the control valve Cv. Therefore, we use an arbitrary valve Cv of 10. We specify the
valve Cv and calculate the valve position, ManPos.
The following table illustrates the variable specification configuration for valve XV6 in order to achieve this.
Table 3: Specifications for Valve XV6

Default Specifications Modified Specifications

Variable
Status* Value Status* Value

DP 5 kPa 5 kPa

Cv 0 10

ManPos 1 fraction 0 fraction

*A indicates that the variable is calculated and a indicates that the variable is specified

In Process mode, we calculate that the position of the valve is closed based on zero flow. However, it is good
engineering practice to keep the valve open. After you transition to Fluid Flow mode, you should specify the
valve position as slightly opened by setting the ManPos variable to 0.5.
We calculate the thermosiphon reboiler flow to achieve the required reboiler duty. We assume the typical
thermosiphon reboiler return is 30% mole fraction vapor and the steam is supplied at 475 kPa and 150°C. To
ensure complete condensation of the steam supplied to the thermosiphon reboiler, we specify the steam outlet
temperature to be sub-cooled at a design temperature of 120°C instead of specifying the vapor fraction of the
exiting steam, which would calculate the dew point temperature.
The following table illustrates the default specifications in the reboiler and the steam supply as well as the
modified specifications to meet the design conditions.
Table 4: Specifications for Thermosiphon Reboiler and Steam Supply

Default Specifications Modified Specifications

Variable
Status* Value Status* Value

REB.Duty 0 kW 11,165 kW

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Default Specifications Modified Specifications

Variable
Status* Value Status* Value

REB.VFso 0 fraction 0 fraction

REB.VFto 0 fraction 0.3 fraction

HotSteam.W 3,600 kg/h 18,935 kg/h

*A indicates that the variable is calculated and a indicates that the variable is specified

Library
This simulation uses the Process, Controls, and Fluids libraries.
Many of the features and aspects specific to the Column model are also introduced in the Column’s Help section,
which you can access by right-clicking the Column icon on Process library, and then clicking Help.

Fluids
This simulation uses a custom VLE compositional fluid named C1Feed, which we model by using the Non-
Random Two-Liquid (NRTL) method.
We simulate the condenser cooling water with the Cooling Water fluid in the Fluids Library.
We simulate the reboiler steam with the IF97 steam fluid in the Fluids Library.

Mode Summary
The following table includes the mode summary for both the conceptual and extended simulation to illustrate
their differences. We use Fluid Flow mode only as an intermediate step for moving the extended simulation from
Process mode to Dynamics mode. Therefore, we do not include it in the mode summary.

Process (Conceptual) Process (Extended) Dynamics (Extended)

Purpose Create a heat and Create a heat and material Validate the process control
material balance. balance and design the strategy.
column, reboiler, and
condenser equipment.
Column Calculate and check Determine the column Perform stage-wise dynamic
the number of stages diameter. mass and energy balances to
and reflux ratio. calculate the pressure and
stage compositions.
Source (Feed) Set the feed Set the feed conditions. Introduce the change in feed
conditions. conditions.

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Process (Conceptual) Process (Extended) Dynamics (Extended)

Source (CW) N/A Set the pressure and Set the pressure and
temperature of the cooling temperature of the cooling
water. water.
Source (Hot Steam) N/A Set the pressure and Set the pressure and
temperature of the steam. temperature of the steam.
Condenser N/A Set the water-side outlet Calculate the duty from the
temperature and the process flow, water flow, and
process-side outlet quality surface area.
to calculate the required
heat duty, area, and cooling
water.
Reflux Drum N/A Separate the vapor and Calculate the drum pressure
liquid. and liquid level.
Reboiler N/A Set the shell-side and tube- Calculate the duty from the
side qualities to calculate steam flow and heat transfer
the pressure and reboiler surface.
steam supply.
Supply the boilup return
into column.
Sink Specify the desired Specify the desired product Set the boundary pressure
product composition. composition. and report the product
composition.

Process Mode
The purpose of Process mode for the conceptual model is to determine the number of stages and reflux
requirements. The purpose of Process mode for the extended model is to design the condenser and reboiler
circuits, and to define a simulation that can be taken to dynamics.
While we do not include any procedures for designing the condenser and reboiler circuits in this guide, you can
refer to the PRO-8: Detailed Column Condenser and Reboiler Design training exercise for details on this process.
All training exercises are available upon request. Please contact us at the AVEVA Knowledge and Support center
(https://softwaresupport.aveva.com) to learn more.

Fluid Flow Mode

The purpose of Fluid Flow mode is to serve as an intermediate calculation before running dynamic cases.

Dynamics Mode
The purpose of Dynamics mode is to study and validate the controls strategies designed in Process mode for a
case when we increase the feed methanol concentration.

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Results
Process Mode
The following table summarizes the stream properties for both the conceptual design simulation as well as the
extended simulation by displaying properties of the input and output streams for the Column.
Table 7: Stream Summary

DIST

HotSteam
BOTTOMS
MeOH_Water

Reflux

Reboiler Return

CW
Variable Description UOM

Mass Flow (W) kg/h 31,653 14,877 59,617 13,747 17,906 15,096 308,928
Mole Flow (F) kmol/h 1,430 473 3,309 437 993 837 17,148
Pressure (P) kPa 150 101 127 100 115 475 150
Temperature (T) °C 78 65 106 64.8 103 150 25
Vapor Fraction (VF) fraction 0.00 0.00 0.30 0.00 0.00 1.00 0.00

Methanol fraction 0.29 0.96 0.002 0.96 0.00

Composition
(z[METHANOL])
Water Composition fraction 0.71 0.04 0.998 0.04 1.00
(z[WATER])
The columns for the Reflux, Reboiler Return, HotSteam, and CW streams apply only to the extended simulation
model. The conceptual design simulation calculates the reflux and reboiler return internally and does not use
utility streams.
The VLT Profile plot shows the column vapor flow, liquid flow, and temperature across the column stages.

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Figure 3: Column Profile Plot

Dynamics Mode
The extended simulation model generates the dynamic mode results. We set up the Increase Methanol
Concentration scenario for dynamic analysis. This scenario increases the feed methanol concentration from 29%
to 33% by mole.
When the methanol concentration increases, the change in density causes the feed flow rate to initially drop
before stabilizing back at the setpoint set by the feed flow controller (FC1). The temperature across the column
drops and the temperature controller at stage 9 (TC1) increases the hot steam supply, as shown in the following
figure.

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Figure 4: Stage 9 Temperature and Steam Supply

The column pressure increases due to the increased reboiler duty. More overheads are condensed and the reflux
drum level increases. The level controller at the drum (LC1) increases the distillate rate after an initial oscillation,
as shown in the following figure.

Figure 5: Distillate Rate and Reflux Drum Level

At the same time, the level controller at the sump (LC2) lowers the bottom product rate after an initial oscillation
because the increased boilup reduces the amount of liquid reaching the sump, as shown in the following figure.

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Figure 6: Bottoms Rate and Sump Level

The changes in feed quality do not have a significant impact on the product purity. The system maintains the
quality of methanol in the distillate at 95.8% instead of the design requirement of 96%, as shown in the following
figure. Note that we have significantly adjusted the scales to show the disturbance in the product quality.

Figure 7: Product Compositions

In addition to the Increase Methanol Concentration scenario, we set up another scenario that runs dynamics for
20 minutes to study any further changes. The following figure shows the list of scenarios in this simulation.

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Snapshots
This example includes different snapshots for the conceptual design simulation and the extended simulation.
The conceptual design simulation includes two snapshots:
• The Pro 1 snapshot keeps the column specified according to default specifications.
• The Pro 2 snapshot applies purity specifications on the distillate sink, and thus calculates the required reflux
ratio.

The extended model simulation includes an initial snapshot in Process mode:

• The Pro 1 snapshot retains the key design conditions from the conceptual model.

Excel Report
The results for this simulation are summarized in the C1 – Water Methanol Separation.xlsx file. The conceptual
design results are displayed in one worksheet while the extended model results are shown in another.

References
1. Kister, H.Z., Distillation Operation, McGraw-Hill, 1990, pp. 690-740.

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CC2 - Cumene Production

Revision Log
Date Who Change

15 Nov 2017 RC Initial draft for first release.

03 Dec 2018 DHJ CC2 uses standard PFR in Process Library.

22 Aug 2019 YY CC2 uses HXTR in Process Library.

Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
This example demonstrates how you can use AVEVA Process Simulation to model the cumene production
process. It represents a comprehensive model for steady-state and dynamic studies that combines custom
models for chemical reactions in a tubular reactor, two distillation columns with 40 equilibrium stages in total,
and material recycles.
The model is based on the detailed process description by Turton et al.1 and uses the same specifications as the
Turton publication for the feeds, the reaction kinetics for main- and side-reaction, the reactor design, and the
two distillation towers. The steady-state model is complemented by the control scheme suggested by Luyben2
for this process. The steady-state results reported by Turton are matched and the control behavior discussed by
Luyben is confirmed.
The objective of this simulation is to:
• Model the cumene production process, which converts pure benzene and propylene to cumene.
• Illustrate how you can formulate user-defined models for reaction kinetics in a plug flow reactor.
• Generate a heat and material balance for the process that covers the feed section, the reactor section, and
the separation section.
• Validate the process control strategy and prove its robustness against process disturbances.
• Compare its steady-state results and the dynamic performance against the numbers and performance
reported in the referenced sources.

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The following figure illustrates AVEVA Process Simulation’s cumene production process.

Figure 1: The Cumene Process Model

Process Description
The Cumene production process, described by Turton1 for a capacity of 100,000 tons per year, consists of the
feed section, a cooled tubular reactor at elevated pressure, and two distillation columns at atmospheric
pressure. We combine fresh liquid feeds of propylene (FeedC3) and benzene (FeedBenzene) with recycled,
unreacted benzene (RecycleBenz). The combined feed is then vaporized (V800), preheated (FE801 and H801),
and fed into the gas-phase reactor (R802). We remove the exothermic reaction heat (HSR802) on the reactor’s
shell side to generate high-pressure steam (V804). We cool the hot reactor effluent against the reactor feed
(FE801) and then feed it to the first column (T801), which produces a distillate stream of benzene (S12) that we
recycle back into the feed section (RecycleBenz). The second column (T802) separates the desired cumene
product from p-diisopropylbenzene, the product of the undesired side reaction.
We apply the following control strategy, suggested by Luyben for this process:
Feed Section
• Control the flow of the fresh propylene feed.
• Regulate the fresh benzene feed by controlling the ratio of the mass rates of fresh propylene and total
benzene (fresh and recycled benzene rates).
• Control the level in the vaporizer by manipulating the heat input.
Reactor Section
• Control the reactor section’s pressure by manipulating the letdown valve opening.
• Control the reactor inlet temperature by manipulating the hot-side utility valve in the feed heater.
• Control the reactor temperature by manipulating the high-pressure steam valve on the shell side. We model
the shell side by using a Drum that represents a boiler.
• Controller the level in the boiler by manipulating the inlet value for the boiler feed water.

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Purge
• Control the pressure in the flash tank by manipulating the vent valve, thus regulating the purge gas outlet.
Separation Section
The two distillation columns have almost identical controls:
• Control the Stage 1 temperature of the benzene column by manipulating the reflux valve.
• Control the ratio of the feed to the reflux rates of the cumene column by manipulating the reflux valve.
• Control the condenser levels by manipulating the distillate valves, thus regulating the distillate draws.
• Control the condenser pressures by manipulating the cooling water valves.
• Control a stage temperature in each column by manipulating the steam supply for the reboilers. For the
benzene column, control the temperature for Stage 11. For the cumene column, control the temperature for
Stage 16.
• Control the sump levels by manipulating the outlet valves for the bottom products, thus regulating the
bottom product draws.

Simulation Model
The simulation model is based on Turton’s1 design except that it also incorporates a feed effluent heat
exchanger, as suggested by Luyben2. The control scheme is based on Luyben’s control design except that we
manipulate the reflux of the benzene column to control the top stage temperature instead of manipulating the
feed-to-reflux ratio. Similar to Turton’s work, the simulation model also uses SRK thermodynamics with VLE.
We use the same rate expressions for the surface kinetics reported by Turton.
Reaction 1

where
r1 is the rate of reaction 1 in mol/(g catalyst)-sec
k1 is the reaction constant for reaction 1
cp is the concentration of propylene in mol/L
cb is the concentration of benzene in mol/L
T is the temperature in Kelvin

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Reaction 2

where
r2 is the rate of reaction 2 in mol/(g catalyst)-sec
k2 is the reaction constant for reaction 2
cp is the concentration of propylene in mol/L
cc is the concentration of cumene in mol/L
T is the temperature in Kelvin
Catalyst
Both reaction rates are specific to the catalyst reference conditions:
• Catalyst mass density (rcat)= 1600 kg/m3
• Catalyst void fraction (e) = 0.5
To derive the reaction rates for the individual reactants, we must multiply the preceding rate expressions by the
catalyst mass, which relates to the reactor volume, V, the catalyst void fraction, e, and catalyst density, rcat, as
follows:

where
Gi1 is the production or consumption rate in kmol/s for component i in reaction 1
Gi2 is the production or consumption rate in kmol/s for component i in reaction 2

V is the reactor volume in m3

e is the catalyst void fraction
rcat is the density of the catalyst in kg/m3
r1 is the rate of reaction 1 in kmol/(kg catalyst)-sec
r2 is the rate of reaction 2 in kmol/(kg catalyst)-sec
Additional Features
The simulation also includes the following specific elements of AVEVA Process Simulation.

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• AVEVA Process Simulation’s Column model.

• AVEVA Process Simulation’s model writing environment, which we use to formulate the following:
• The kinetics of the chemical reactions.
• The plug flow reactor modeled as an array of reactor elements.
• AVEVA Process Simulation’s Stream model, which reports component molar rates that are important in the
context of reaction models.
• AVEVA Process Simulation’s Recycle model, which allows you to break recycles for open loop calculations to
initialize recycles in a sequential modular manner. We insert Recycle models into the following:
• The benzene recycle.
• The thermosiphon circulations for both columns.
• AVEVA Process Simulation’s Heat Exchanger (HXTR) model.

HXTR Model
We use the HXTR model from the Process Library to model the thermosyphon reboiler on the benzene column
and the cumene column.

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The two HXTRs are named E804 and E806, respectively, and they have the following characteristics:
• The heat transfer coefficient is given as the overall heat transfer coefficient.
• The friction loss is proportional to the square root of the flowrate.
The following figure shows the specifications for the two HXTRs, their inlet and outlet pipes, and the column
sumps that they are connected to.

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Custom Reactor Model

We provide the CumeneRates submodel to formulate the reaction. You can view and edit this custom model in
the simulation-specific library for the example simulation.

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We use this custom submodel in the Plug Flow Reactor (PFR) to include the reaction rates, in kmol/(kg-catalyst)-
sec, for the cumene reactor. It includes rates for the following reactions:
• Propylene + Benzene à Cumene
• Propylene + Cumene à p-Diisopropylbenzene

Library
This simulation uses the Process and Controls libraries. It also uses its simulation-specific library for the custom
model described in Custom Reactor Models.

Fluids
This simulation uses the custom fluid named CC2Feed, which is a VLE compositional fluid modeled with the
Soave-Redlich-Kwong (SRK) equation of state. It also uses the custom fluid named DowthermA, which is an
incompressible liquid.

Model Summary
See Process Mode and Dynamics Mode for a summary of the design case in Process mode and the dynamic
performance in Dynamics mode, respectively.

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Process Mode
The purpose of Process mode is to construct the simulation according to the process conditions provided by
Turton1 and provide mass and energy balances for the simulation.

Fluid Flow Mode

The purpose of Fluid Flow mode is to serve as an intermediate calculation before we run the Dynamics cases.

Dynamics Mode
The purpose of Dynamics mode is to study and validate the controls strategies according to the case studies
reported by Luyben2.

Results
Process Mode
The following table summarizes the steady-state results for the simulation (in green) in comparison to the design
reported by Turton1 in the C.14 table in his publication. We achieve good agreements, especially for the highly
temperature-dependent and pressure-dependent reactor product, the resulting benzene recycle, and the T802
distillate, that is, the cumene product. The observed deviations result from eventual differences in the
interaction parameters and the pure component properties.

These results are saved in the Pro 1 snapshot.

The following figures and tables summarize the composition and temperature profiles for the reactor, R802:

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Figure 2: Composition Profiles for R802

Figure 3: Temperature Profiles for R802

The following figures summarize the temperature and composition profiles for the benzene column, T801:

Figure 4: Temperature, Vapor Flow Rate, and Liquid Flow Rate Profiles for T801

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Figure 5: Composition Profiles for T801

The following figures summarize the temperature and composition profiles for the cumene column, T802:

Figure 6: Temperature, Vapor Flow Rate, and Liquid Flow Rate Profiles for T802

Figure 7: Composition Profiles for T802

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Fluid Flow Mode

The purpose of Fluid Flow mode is to serve as an intermediate calculation before we run the Dynamics cases. As
such, we do not report any significant results for this mode.

Dynamics Mode
We developed a set of six scenarios in line with the publication by Luyben2 to test the control scheme against the
following disturbances:
• Increase the C3 fresh feed from 4600 kg/h to 5200 kg/h.
• Decrease the C3 fresh feed from 4600 kg/h to 4200 kg/h.
• Increase the setpoint of the reactor outlet temperature controller from 350°C to 355°C.
• Decrease the setpoint of the reactor outlet temperature controller from 350°C to 345°C.
• Increase the propylene composition in the C3 fresh feed to 97%.
• Decrease the propylene composition in the C3 fresh feed to 93%.
We composed an additional scenario to run all of the preceding scenarios sequentially and save each scenario’s
history to an individual snapshot for review.
We have arranged a series of trend charts with an overview on the following aspects:
• Reactor outlet temperature
• Fresh feed rates, recycle rate, and cumene rate in the reactor outlet
• All liquid levels in the process
• All pressures in the process
• All heat duties in the process
• Benzene column performance
• Cumene column performance
We recommend that you:
• Click the Solve to Steady State button either at the end of a scenario or after stopping it prematurely, and
then run the simulation for another 10 minutes to observe where the process stabilizes.
• Run at higher time steps, for example, 1 sec or greater, and compare performance.
Overall, the process stabilizes for each of the preceding 6 scenarios, as shown by the following trend charts for
the reactor outlet temperature, the feed rate, and the recycle rate:

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Figure 8: Results for the Scenarios to Increase and Decrease C3 Feed from 4600 kg/h to
5200 kg/h and 4200 kg/h, Respectively

Figure 9: Results for the Scenarios to Increase and Decrease SP of Reactor Outlet TC from
350°C to 355°C and 345°C, Respectively

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Figure 10: Results for the Scenarios to Increase and Decrease Propylene Composition in C3
Fresh Feed to 97% and 93%, Respectively

Notes
Luyben2 reports the steady-state results in Figure 9.2 in his publication. These results form the basis for his
dynamic studies. We can replicate these results only with fundamental model changes. Compared to Turton’s1
original design (in the 4th edition), Luyben’s results are based on different numbers for the process conditions
and the reactor design:
• The recycle pump’s outlet pressure is 25 bar instead of 30 bar.
• The reactor geometry counts 342 tubes instead of 234.
• The reactor inlet temperature is 360°C instead of 350°C.
• The reactor cold-side temperature is 360°C instead of 250°C.
• The reactor outlet temperature is 427°C instead of 350°C.
If we adjust the flowsheet in Process mode according to the preceding design changes, we can match Luyben's
reported cumene production and the reactor outlet temperature (the most prominent numbers to look at) only
if we apply a different catalyst mass density of 640 kg/m3 instead of the intended 2000 kg/m3 (Turton specified
1600 kg/m3). We can reverse engineer this number by applying the factor 0.5*1600/2000 = 0.4 to the catalyst
density (resulting in 1600 kg/m3*0.4 = 640 kg/m3, with e = 0.5).
Luyben’s control scheme is based on the assumption of a reactor cold-side temperature that is directly
manipulated through a temperature controller. Our simulation models the reactor cold side as a high-pressure
steam boiler powered by the reaction heat. This affects the dynamics.
Another key variable is the reactor’s overall heat transfer coefficient for the hot reactor gases on the hot side and
the convective boiling on the cold side. Both Turton and Luyben suggest U = 65 W/m2-K. This confirms the cold-

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side temperature of 250°C that the simulation calculates for this U value, which agrees with the cold-side
temperature reported by Turton.
If we use U = 65 W/m2-K, the simulation reports a pronounced temperature spike of ±10°C for scenarios 1 and 2.
This contrasts Luyben’s results, which suggest an almost unnoticeable spike of ±0.1°C. If we make a 10-fold
change to the U value such that U = 650 W/m2-K and we reduce the HPS valve (PV101) pressure drop to be DP =
2 bar, the temperature response to scenario 1 reduces to a maximum increase of 0.6°C. This indicates that the
entire process model is very sensitive to the assumptions made for the reactor cooling mechanism. This aspect
deserves attention.

Snapshots
The simulation includes the following snapshot:
• Pro 1: Design case Turton
This snapshot represents Turton’s design case in Process mode.

Excel Report
The results for this simulation are summarized in the CC2 – Cumene Production.xlsx file. It includes the following
worksheets:
• Equipment Summary: A summary of the process units.
• Stream Summary: A summary of the main process streams.
• Stream Comparison to Turton: A comparison table for the 14 streams reported in Table C.14 in Turton1.
• R802: The temperature and composition profiles for reactor R802.
• T801: The temperature, vapor flow rate, liquid flow rate, and composition profiles for column T801.
• T802: The temperature, vapor flow rate, liquid flow rate, and composition profiles for column T802.
• FeedRateChange: The trends for increasing and decreasing the C3 fresh feed from 4600 kg/h to 5200 kg/h
and 4200 kg/h, respectively
• FeedCompositionChange: The trends for increasing and decreasing the setpoint of the controller for the
reactor outlet temperature from 350°C to 355°C and 345°C, respectively
• ReactorTemp: The trends for increasing and decreasing the propylene composition in the C3 fresh feed to
97% and 93%, respectively

References
1. Turton, R., Bailie, R. C., Whiting, W. B., Shaelwitz, J. A. Analysis, Synthesis and Design of Chemical Processes,
4th ed.; Prentice Hall: Upper Saddle River, NJ, 2012
2. W. Luyben, Design and Control of the Cumene Process, Ind. Eng. Chem. Res. 2010, 49, 719–734.

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Revision Log
Date Who Change

5 Jan 2018 SK Initial draft.

26 Mar 2018 AL Added VLT profile information for the column stages.
30 Jan 2020 RC Renamed C3 prefix to CC3.
Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
Conventional methods (like the unbalanced heat method) that calculate column relief loads are generally
conservative. This leads to overly-sized relief devices and flare networks. Alternatively, we can use dynamic
simulation to accurately predict the transient pressure increase. According to API 5211, section 4.3.3, dynamic
simulation is an accepted way to calculate column relief loads.
This example demonstrates how you can use AVEVA Process Simulation to quickly build dynamic simulations for
column relief. We use AVEVA Process Simulation's modeling capabilities to make customizations that reflect the
API 521 guidelines for relief estimation.
The objectives of this example are to:
• Build a column simulation that reflects the pressure relief guidelines in API 521.
• Identify the peak relief flow for the following scenarios:
• Partial power failure
• Total power failure
The following figure illustrates the benzene column simulation that we use for the relief study in AVEVA Process
Simulation.

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Figure 1: Benzene Column Simulation

Process Description
The feed consists of 29% benzene and 70% toluene. It enters the Benzene column with a flow of 103 kmol/h.
Heat exchanger E2 preheats the feed to a temperature of 182.5°C. The column operates at a pressure of 720 KPa.
We obtain the benzene product as vapor product from the receiver.
The column consists of 56 sieve trays, an air-cooled condenser with total reflux, and a steam-heated
thermosiphon reboiler. Electric motors drive the feed, reflux, and bottoms toluene pumps.

Simulation Model
The following table describes the typical relief scenario assumptions and how we set up the AVEVA Process
Simulation simulation to implement these assumptions.

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Assumption Simulation Setup

The power failure scenarios are Since the feed or reflux flow is either at its normal flow or at zero
based on whether the motors that flow depending on the relief scenario, we do not need to
drive the pumps will lose electrical rigorously model the pump with its performance curve and flow
supply. control valve.
We model the pump, its driving motor, and its flow control valve
as a single Valve with the FlowType parameter set to FlowRange.
With this configuration, you can simulate a pump trip by setting
the valve position to zero. In this case, the flow goes from normal
flow to the minimum flow of zero.
As API 521 stipulates, we take no While a column pressurizes, the temperature in the column also
allowances for automatic control rises. With rising temperatures, the TIC controllers on the reboiler
action unless it tends to increase may reduce the steam flow to maintain the bottom temperature.
relief loads. However, this controller action may reduce the relief load and we
should therefore ignore the controller action. To do this, we
assume that the steam condensate out of the reboiler is constant
by using the FlowRange approach in the Valve.
Sieve trays weep at low vapor rates, We model weeping in the sieve trays by setting the WeepVapFrac
such as when the column is (vapor flow fraction at which liquid weeping begins) and
pressurizing. Tray weeping provides DumpVapFrac (vapor flow fraction at which liquid dumping
benzene to the column, which begins) variables in the Stage[i].TrayWeep submodel. See Figure 2
increases the reboiler temperature, for the relationship between the weep vapor fraction, the dump
driving force, and heat duty. vapor fraction, and the liquid weeping fraction.
If the column trays have valve trays, we can turn off weeping by
updating the Stage[i].TrayWeep.WeepAreaFrac variable to 0%.
The relief valves are typical gas or Typical gas or vapor service relief valves pop open either
vapor service reliefs valves. completely or to some initial fraction. However, since our goal is
to find the design relief load, we use a modulating relief valve.
Modulating relief valves keep a constant process pressure to
provide the required relief load for actual relief valve sizing.
Power failure trips the air cooler We can configure natural convection heat transfer by updating
fans, but natural convection heat the A1.AirSide.NatConv parameter with the minimum fractional
transfer remains. air flow that we expect due to natural convection.
A fully-filled overhead receiver will We model the flooded condenser by adding the Flood flowsheet
flood the condenser. equation to the simulation. This equation calculates the heat
transfer area fraction for the condenser as follows:
Flood: A1.Af = max(0.01, min(1, (1-V1.Level)/
(1-0.95) ) )

The liquid tray holdup depends on We model the column with 56 actual trays as 40 theoretical
the actual number of trays. stages (70% efficiency) with the holdup adjusted to a value of 1.4.

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Figure 2: Tray Weeping Diagram

The following table shows the important relief scenario settings.

Parameter/Variable Description Value

PSV1.SP The set pressure difference between the 800 kPa

inlet pressure and the back pressure at
which the pressure relief valve opens.
A1.Tai The air-side inlet temperature in the air 24.85°C
cooler.

A1.AirSide.NatConv1 The air-side natural convection fraction. 5%

T1.Stage[i].TrayWeep.WeepVapFrac2 The vapor flow fraction at which liquid 60%

weeping begins.

T1.Stage[i].TrayWeep.DumpVapFrac2 The vapor flow fraction at which liquid 20%

dumping (100% weeping) begins.
1 NatConv is a non-favorite parameter. You can view and change its value by opening the full Properties Inspector for A1.
2 WeepVapFrac and DumpVapFrac are non-favorite variables. You can view and change their values by opening the full
Properties Inspector for T1.

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Library
This simulation uses the Process library.

Fluids
This simulation uses a VLE compositional fluid named BenTol, which we model by using the Soave Redlich Kwong
(SRK) method.
We use the Air_IG fluid in the Fluids Library to model the condenser air.
We use the IF97 steam fluid in the Fluids Library to model the reboiler steam.

Mode Summary
We use Fluid Flow mode only as an intermediate step for moving the simulation from Process mode to Dynamics
mode. Therefore, we do not include it in the mode summary.
The following table describes how the process models operate in each simulation mode.

Process Dynamics

Purpose Build a column simulation from heat Identify the peak relief flow rate for the
and material balances. partial power failure and total power
failure scenarios.

Source (FEED) Set the feed flow, temperature, Set the feed temperature, pressure, and
pressure, and composition. composition.

Feed Heat Exchanger Set the column inlet temperature. Set the column inlet temperature.
(E3)

Column (T1) Perform heat and material balances Perform stage-wise dynamic mass and
that meet the design requirements and energy balances to calculate the
reflect normal process operations. pressure and stage compositions.
The column sump models the inventory
of benzene accumulated by sieve tray
weeping to provide the correct dynamic
composition to the reboiler.
Air Condenser (A1) Calculate the air flowrate and the heat Calculate the duty from the process
transfer surface area. flow, air flow, and heat transfer surface
area.

Reflux Drum (V1) Separate the flashed condenser vapor Calculate the drum pressure and liquid
product. level.

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Process Dynamics

Reboiler (E2) Calculate the steam flowrate and the Calculate the duty from the steam flow
heat transfer surface area. and heat transfer surface area based on
the composition from the column sump.
Sink Specify the desired product Set the boundary pressure
composition.

Process Mode
The purpose of Process mode is to match the heat and material balances with a state that reflects normal
process operations. This initial state serves as a basis for the power failure scenarios in Dynamics mode.
The VLT Profile plot shows the column vapor flow, liquid flow, and temperature across the column stages and
provides a quick overview of the column's heat and material balances.

Fluid Flow Mode

The purpose of Fluid Flow mode is to serve as an intermediate calculation before running dynamic cases.
Because we do not include level controls for the reflux drum or the column sump, we need to swap the
specifications in the following table to obtain appropriate solutions for the drum and sump levels in Fluid Flow
mode.

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Default Specifications Modified Specifications

Variable
Status* Value Status* Value

V1.Level - 50%

FV2.ManPos 50% -

T1.LevelSmp - 50%

LV1.ManPos 50% -

*A indicates that the variable is calculated and a indicates that the variable is specified

Dynamics Mode
The purpose of Dynamics mode is to identify the peak relief flows for the partial power failure and total power
failure scenarios.
While you run these Dynamics scenarios, you can open the VTL Profile plot to watch the conditions in the
column change in real time.

Scenarios
Scenario 1: Partial Power Failure
The partial power failure scenario assumes that the following motors trip:
• Reflux pump FV2
• Bottoms pump LV1
• Half of the fan motors in air cooler A1. (Set A1.AirSide.Wf to 40%, which is half of the design value of 80%).

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Scenario 2: Total Power Failure

The total power failure scenario assumes that the following motors trip:
• Reflux pump FV2
• Bottoms pump LV1
• Feed pump FV1
• All the fan motors in air cooler A1. (Set A1.AirSide.Wf to 0.)

Results
Dynamics Mode
Partial Power Failure Results
With the trip of both reflux pumps and the continued availability of 50% of the air condenser fans, the reflux
drum fills completely and floods the air cooler. The air cooler duty then drops to zero. In the following figure, the
condenser duty is not available after 11 minutes and the column pressure begins to rise more steeply as a result.

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Figure 3: Condenser Duty and Reflux Drum Level for Partial Power Failure
Column relief begins at around 14 minutes and a peak of 12,500 kg/h occurs after 16 minutes, as shown in the
following figure.

Figure 4: Column Relief Load for Partial Power Failure

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Total Power Failure Results

The total power failure trips all pumps and all the condenser fan motors. With reduced natural convection
airflow, we observe a lower condenser duty of 387 kW (around 31% of the design duty), as shown in the
following figure.

Figure 5: Condenser Duty and Reflux Drum Level for Total Power Failure
As the sump level decreases, the reboiler duties go to zero after 10 minutes, as shown in the following figure.

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Figure 6: Reboiler Duty and Reflux Drum Level for Total Power Failure
While we still see a condenser duty, the column starts relieving at around 7 minutes with a peak of 8,500 kg/h
after 10 minutes, as shown in the following figure.

Figure 7: Column Relief Load for Total Power Failure

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Analysis
The partial power failure scenario has a higher relief load than the total power failure scenario because feed
continues to flow to the column and provides low-boiling-point benzene to the reboiler.
The relief in the partial power failure scenario continues until an operator manually stops the feed or steam.
There is only a momentary relief in the total power failure scenario because the initial benzene inventory in the
column is consumed and there is no feed to replenish it.

Snapshots
This simulation includes the following snapshots:

Excel Report
The results for this simulation are summarized in the CC3 - Benzene Column Relief.xlsx file.

References
1. API Standard 521, Sixth Edition, January 2014
2. Depew, C.; Dessing, J. Dynamic simulation improves column relief-load estimates. Hydrocarbon Process.
1999, 78(12), 81-86.

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CC25 - DME Process Optimization

Revision Log
Date By Comments

13 Aug 2020 RM Initial issue.

26 Oct 2021 RM Add greenhouse gas emission calculations to optimization set.
Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
This example shows how you can use AVEVA Process Simulation to design and optimize the dimethyl ether
(DME) production process shown in Figure 1. The focus of this exercise is to minimize the overall operating cost
associated with the process by adjusting a variety of specifications. Operating cost optimization is critical for
existing plants that plan to reduce overall expenses and maximize their profits. While capital expenses are an
important consideration in the initial plant design, operating costs present an opportunity for continuous
optimization long after plant startup and commissioning. The objectives of this simulation are to:
• Design a process to produce 10 t/h of DME through the dehydration of methanol
• Demonstrate how you can extend parent equipment models to use default operating cost submodels
• Demonstrate how you can use AVEVA Process Simulation for simultaneous optimization of multiple process
specifications
• Minimize the operating cost associated with the process

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Figure 1: A DME Production Process Modeled in AVEVA Process Simulation

Process Description
The following table shows the specifications for the methanol feed to the process.
Table 1: Feed Stream Properties

Variable Description Value UOM

W Total mass flowrate 13.97 t/h

30800 lb/h
P Pressure 1.30 bar
1.28 atm
T Temperature 30 °C
86 °F
z[Methanol] Molar methanol composition 99 %
z[DME] Molar DME composition 0 %
z[H2O] Molar water composition 1 %
We combine the fresh methanol feed with a recycled methanol stream from the end of the process and then
vaporize the combined feed by using the E1 heat exchanger. We then use the effluent stream from the R1
reactor to pre-heat the feed stream prior to entering the reactor. The E3 heat exchanger condenses the reactor
effluent stream as we feed it to the separation section of the process. The T1 Column separates the DME product

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from water and methanol. The T2 Column then dries the wet methanol stream and we pump the recovered
methanol back to the beginning of the process. We send the recovered water, which contains less than 250 ppm
of methanol, for treatment.
You can find a detailed description of the process in Turton et. al1. We use the kinetic data from Berćić and
Levec2 for the dehydration reaction.

Simulation Model
Library
This simulation uses the default Process and Economics Libraries from AVEVA Process Simulation.

Fluids
This example uses the custom MeOH_Feed fluid in the simulation-specific Model Library. We use this
compositional-type fluid to model the feed stream, which has the starting composition from the table in Process
Description. The fluid uses the standard Non-Random Two-Liquid (NRTL) thermodynamic method.

Mode Summary
This example uses Process mode to meet the design requirements and perform the operating cost optimization.
The objective of this mode is to provide a conceptual design that we can use to refine further process
development. After optimization, we can extend the process to a detailed engineering design within AVEVA
Process Simulation.

Process Mode
The objective of Process mode is to provide an overall mass and energy balance for the process and to estimate
the product flowrates and compositions. We switch the following process specifications to meet the design
requirements:
• For each heat exchanger, we switch the duty and utility flowrate specifications with the outlet stream
temperature (Tto or Tso) or vapor fraction (VFto or VFso) specifications. This allows us to calculate the
required utility flowrates.
• In the DME column (T1), we switch the specifications for the reflux ratio (OutRatio[T1Reflux] in SP1) and the
molar composition of the DME product. We specify the DME concentration in the overhead product as
99.5 wt%.
• In the methanol dryer column (T2), we switch specifications for the reflux ratio (OutRatio[T2Reflux] in SP2)
and the molar composition of the methanol recycle stream. We specify the methanol concentration in the
recycle stream as 99 mol%.
• In T2, we also switch the specifications for RoutFrac and the molar composition of the bottoms product. We
specify the concentration of methanol in the wastewater stream at 250 ppmw.

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Economics and Optimization Sets

After you have designed the base-case process, AVEVA Process Simulation can simultaneously optimize multiple
process specifications to maximize or minimize an objective function. For this example, our objective is to
minimize the overall operating cost for the process.
We use the model extension feature in AVEVA Process Simulation to add economic and greenhouse gas emission
calculations to the Source and Pump models. To do this:
1. Press and hold Shift and then drag the Economics.Utility submodel onto each Source and Pump model
instance in the simulation.
2. Select the utility type and view the utility cost associated with that model instance.
3. Press and hold Shift and then drag the Economics.SteamGHG submodel onto each steam Source instance in
the simulation (LPS1, MPS1, and MPS2).
4. Select the calculation method and emission factor submodel. If you use the Boiler Efficiency method, also set
the boiler efficiency (eta).
Alternatively, you can add the Economics.Utility submodel to multiple model instances at the same time. To do
this:
1. Select all the desired model instances.
2. Right-click the selection, and then on the Submodels submenu, on the Add submenu, on the Economics
submenu, select Utility.
In the Economics Library, the Summary model provides a central location to adjust global utility prices and view
the overall economics of the process. By adding this model to the simulation, we can edit global utility prices and
use the total calculated costs to perform an economic optimization. The following figure shows the utility prices
that we use in this example. See the model help for the Summary model for an explanation of how we have
estimated the default utility prices.

Figure 2: Economic Summary Model and Global Utility Prices

The SummaryGHG model in the Economics Library provides a central location to view the total greenhouse gas
(GHG) emissions of the process. We can also edit the Global Warming Potential (GWP) factors for methane (CH4)

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and nitrous oxide (N2O), which impact the final calculation of the CO2 equivalent (CO2e) emissions. For this
simulation, we use the default GWP factors for CH4 and N2O.

Figure 3: GHG Emission Summary Model and Global GWP Factors

In this example, we do not consider the raw material cost, product value, or cost associated with treatment of
the wastewater stream. We have specified the simulation such that the feed and product flow rates remain
effectively the same. Therefore, we assume that these costs are fixed and do not impact the overall optimization.
A detailed analysis might consider the wastewater treatment cost with respect to the methanol concentration in
the waste stream, but this is beyond the intended scope of this simulation.
We provide the Minimize operating cost optimization set to specify the objective function and constraints of the
optimization. We used the following considerations when we selected the optimization variables and constraints:
• Based on the reaction kinetics, increasing the temperature of the reactor feed stream (E2.Tto) increases the
overall methanol conversion, decreases the required methanol recycle rate, and decreases the duty of the E3
exchanger. We set the upper bound of the reactor outlet temperature to 400°C to meet the maximum
temperature constraints of the material of construction.
• The reboil ratio of T1 impacts the condenser duty, reboiler duty, and reflux ratio of the column. To meet the
product specifications, we specify the weight percentage of DME in the overhead product stream to
≥99.5wt%.

Figure 4: Optimization Set to Minimize Total Utility Cost

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Results
In the following figure, the Economic Summary model shows the utility costs for the process before and after
optimization.

Figure 5: Economic Summary Before (Left) and After (Right) Optimization

AVEVA Process Simulation simultaneously optimizes over multiple process specifications to find an ideal
operating point that offers the greatest cost savings. After optimization, we decrease the operating cost of the
process from $1320/h to $920/h (a savings of over $3MM per year) while still maintaining product flowrates and
specifications.

Snapshots
The simulation includes the following snapshots:
• Pro 1: A solved steady-state, base-case solution in Process mode. If you make any changes to the simulation
that cause errors in Process mode, revert to this snapshot.

References
1. Turton, R. A.; Shaeiwitz, J. A.; Bhattacharyya, D.; and Whiting, W. B. Analysis, Synthesis, and Design of
Chemical Processes, 5th ed.; Prentice Hall International Series in the Physical and Chemical Engineering
Sciences; Pearson: 2018.

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2. Berćić, G.; Levec, J. Catalytic Dehydration of Methanol to Dimethyl Ether, Kinetic Investigation and Reactor
Simulation. Ind. Eng. Chem. Res. 1993, 32 (11), 2478-2484.

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CC28 – H2 Production via Steam Methane
Reforming

Revision Log
Date By Comments

11 Aug 2021 SW, RM Initial issue.

Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
This example demonstrates a typical process to produce hydrogen by using steam methane reforming (SMR). We
react natural gas and high-pressure steam over a Ni/MgAl2O4 catalyst to produce H2, CO, and CO2. We then
further refine the CO and H2O in the outlet stream by using two sequential water-gas shift reactors, one at high-
temperature and one at low-temperature. These reactors convert much of the remaining CO and H2O into H2
and CO2.
The final step of the SMR process separates H2 from the remaining components by using pressure swing
adsorption (PSA). For simplicity, we do not rigorously model this step in this example. Instead, we use a
component splitter to define the separation.
Note: The AA4 - Fullsize PSA Process example demonstrates how to rigorously model a PSA process. You can use
the AA4 - Fullsize PSA Process example for ideas on how to expand this example to include a rigorously modeled
PSA process.

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Figure 1: An H2 Production Process by Using Steam Methane Reforming in AVEVA Process

Simulation

Process Description
The process includes three plug flow reactors (PFRs) that model the steam methane reforming (SMR), the high-
temperature water-gas shift (HTS), and the low-temperature water-gas shift (LTS) reactions.
We feed natural gas to the process and split it between burner gas and process feed streams.
Since the SMR reaction is endothermic, we must provide heat by using a fired furnace. In this example, we use a
single burner (B1) and four independent HX models (HXSMR, HX2A, HX2B, and HX2C) to model the furnace. We
use a compressor (K1) to compress the natural gas feed stream before it enters the furnace. Upon entering the
furnace, we mix the natural gas feed with high pressure steam and heat it to the target temperature of 850°C by
using the flue gas from B1. The natural gas and high-temperature steam react to form H2 in the SMR reactor. We
use a flowsheet equation to connect the duty of the SMR reactor to HXSMR to model the required heat input for
the reaction.
The shift reactors then convert unreacted CO and H2O in the SMR product stream (Syngas) into CO2 and H2. We
use HX3 to cool the syngas to 450°C before it enters the high-temperature shift reactor (HTS). The water-gas shift
reaction is exothermic, so we must cool the product stream from the HTS reactor to 200°C before it enters the
LTS reactor. The LTS reactor converts most of the remaining CO and H2O in the syngas stream.
We then cool and compress the product stream to separate the remaining water from the hydrocarbons. Since
the product stream consists primarily of light hydrocarbons, a knockout drum (V1) is sufficient for this
separation. The gas stream from the knockout drum enters the PSA units which we model here with a simple
component splitter. The hydrogen product stream leaves the process and the off gas is recycled back to the front
of the process as fuel for the burners.
The process also includes extensive heat integration. A feed water header provides cooling water to exchangers
HX3B, HX4, HX5, and HX6. HX3A acts as a superheater for the steam fed to the SMR reactor and therefore does
not require cooling water. The hot water outlet stream from the utility side of HX5 mixes with enough feed water
to produce a saturated steam product on the utility side of HX4. Saturated steam from HX3B, HX4, and HX6 mix
in the steam header. We feed much of the steam in this header to HX3A where the effluent stream from the
furnace superheats it. We calculate the flowrate of this stream to achieve the desired steam-to-carbon ratio in
the SMR (SC_Ratio). We export the remaining steam in the common header from the process, which we can
then use in another portion of the process or sell to another unit.
We base the feed rate and composition of the natural gas stream on typical operating conditions for an industrial
SMR[1],[2]. We adjust the flowrate of steam to achieve a typical steam-to-carbon ratio in the reactor inlet of
2.75[2]. Higher steam-to-carbon ratios increase the conversion in the SMR but require larger reactors and process
piping. Low steam-to-carbon ratios reduce the overall mass flow in the process but result in a higher methane
slippage from the SMR. You can reduce this effect by operating the SMR at higher temperatures.
The following tables show the gas source conditions, process conditions, and equipment sizes.
Table 1: Natural Gas Feed Composition

Component Composition

Hydrogen (H2) 0.0002

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Component Composition

Nitrogen (N2) 0.005

Oxygen (O2) 0.0
Carbon Monoxide (CO) 0.0
Carbon Dioxide (CO2) 0.003
Methane (CH4) 0.9472
Ethane (C2H6) 0.042
Propane (C3H8) 0.002
n-Butane (C4H10) 0.0004
n-Pentane (C5H12) 0.0002
Water (H2O) 0.0
Table 2: Process Conditions

Variable Description Value UOM

NatGas.T Temperature of the natural gas that enters the process. 25 °C

NatGas.P Pressure of the natural gas that enters the process. 2 bar
Air.T Temperature of the air that we feed to the burner. 24.85 °C
FeedWater.T Temperature of the fresh feed water that enters the 25 °C
process.
FeedWater.P Temperature of the fresh feed water that enters the 30 bar
process.
SC_Ratio The steam-to-carbon ratio of the feed stream that enters 2.75 -
the SMR reactor.
B1.xO2 The excess oxygen for the combustion reaction in the 21 %
burner.
HXSMR.Tso The temperature of the shell-side product stream of the 1100 °C
HXSMR heat exchanger.
HX2A.Tto The temperature of the tube-side product stream of the 850 °C
HX2A heat exchanger. This ensures that the feed stream to
the SMR reactor is sufficiently heated.
NatGasFeed.F The flowrate of the natural gas that we mix with steam 65,000 Nm3/h
and then feed to the SMR reactor.
NatGasFeed.P The pressure of the natural gas that we mix with steam 29 bar
and then feed to the SMR reactor.

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Variable Description Value UOM

HX3A.Tto The temperature of the tube-side product stream of the 840 °C

HX3A heat exchanger. This product stream serves as the
steam feed stream to the SMR reactor.
HX3B.Tso The temperature of the shell-side product stream of the 450 °C
HX3B heat exchanger. This ensures that the feed stream to
the HTS reactor is sufficiently cooled.
HX3B.VFto The vapor fraction of the tube-side product stream of the 1 fraction
HX3B heat exchanger. The ensures that the cooling water
in the tubes exits the heat exchanger as steam.
HX4.Tso The temperature of the shell-side product stream of the 200 °C
HX4 heat exchanger. This ensures that the feed stream to
the LTS reactor is sufficiently cooled.
HX4.VFto The vapor fraction of the tube-side product stream of the 1 fraction
HX4 heat exchanger. The ensures that the cooling water in
the tubes exits the heat exchanger as steam.
HX5.Tso The temperature of the shell-side product stream of the 180 °C
HX5 heat exchanger.
HX5.VFto The vapor fraction of the tube-side product stream of the 1 fraction
HX5 heat exchanger. The ensures that the cooling water in
the tubes exits the heat exchanger as steam.
HX6.VFto The vapor fraction of the tube-side product stream of the 1 fraction
HX6 heat exchanger. The ensures that the cooling water in
the tubes exits the heat exchanger as steam.
K2.Pr The pressure ratio of the K2 compressor. 1.35 fraction
V1Out.z[H2O] The water composition of the V1Out stream, which is the 0.025 fraction
product stream of the V1 knockout drum.
H2.z[H2] The hydrogen composition of the H2 Sink. 0.9998 fraction
Table 3: Equipment Sizes

Variable Description Value UOM

SMR.Nt The number of tubes in the SMR reactor. 200 -

SMR.L The length of the tubes in the SMR reactor. 12 m
SMR.D The internal diameter of the tubes in the SMR reactor. 0.1016 m

SMR.Ne The number of elements in the SMR reactor 13 -

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Variable Description Value UOM

SMR.eps The catalyst void fraction for the catalyst in the SMR 0.528 fraction
reactor.
HTS.Nt The number of tubes in the HTS reactor. 1 -
HTS.L The length of the tubes in the HTS reactor. 2.5 m
HTS.D The internal diameter of the tubes in the HTS reactor. 1.25 m
HTS.Ne The number of elements in the HTS reactor 8 -
HTS.eps The catalyst void fraction for the catalyst in the HTS 0.5 fraction
reactor.
LTS.Nt The number of tubes in the LTS reactor. 1 -
LTS.L The length of the tubes in the LTS reactor. 1.5 m
LTS.D The internal diameter of the tubes in the LTS reactor. 0.75 m
LTS.Ne The number of elements in the LTS reactor 8 -
LTS.eps The catalyst void fraction for the catalyst in the LTS 0.5 fraction
reactor.
V1.L The height of the V1 knockout drum. 2 m
V1.D The diameter of the V1 knockout drum. 1 m

Simulation Model
Libraries
This simulation uses the default Process and Economics Libraries from AVEVA Process Simulation.

Fluids
This simulation uses the Feed fluid from the simulation-specific model library. This Fluid uses the Soave-Redlich-
Kwong (SRK) method and includes vapor-liquid equilibrium (VLE) calculations.

Reaction Submodels
This simulation uses the following reaction submodels from the simulation-specific model library:
• SMR — Provides all necessary reaction kinetics for the steam methane reforming (SMR) reaction. We use
this reaction submodel in the SMR plug flow reactor.
• HTS — Provides the reaction kinetics for the high-temperature water-gas shift (HTS) reaction. We use this
reaction submodel in the HTS plug flow reactor.
• LTS — Provides the reaction kinetics for the low-temperature water-gas shift (LTS) reaction. We use this
reaction submodel in the LTS plug flow reactor.

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• Burner — Provides the reaction kinetics for the combustion reaction in the furnace. We use this reaction
submodel in the B1 burner.
The following sections provide details on the reactions and associated reaction kinetics.
Steam Methane Reforming (SMR)
We use the kinetic rate expressions from Xu and Froment[1] for the SMR reaction. While there are many
proposed mechanisms, we chose these rate expressions because they are the most generally accepted kinetic
models in industry[2]. The overall rate expressions include kinetic reaction rate constants, equilibrium constants,
and adsorption constants for each component. The SMR reaction submodel includes three reactions:

The corresponding reaction rate equations are:

where
ki is the reaction rate coefficient for each reaction
Ki is the equilibrium constant for each reaction

Kj is the adsorption constant for component j, in bar-1

pj is the partial of component j, in bar

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ri is the reaction rate, in kmol/kgcat-h

Xu and Froment[1] give the pre-exponential factors, activation energies, and enthalpy changes for the final
model. We use the equilibrium constants published by Hou and Hughes[3].
High-Temperature Water-Gas Shift (HTS)
We use the kinetic rate expressions in Hla et al.[4] for the HTS reaction. Hla et al. describes the kinetics for the
HTS reaction over two commercial Fe2O3/Cr2O3/CuO catalysts. We selected Catalyst 2 (HTC2) for this simulation.
The HTS reaction submodel includes the following reaction:

The corresponding reaction rate expression is:

where
T is the temperature, in K
R is the universal gas constant, in kJ/kmol-K
b is the reversibility factor
Keq is the equilibrium constant
pj is the partial of component j, in kPa
ri is the reaction rate, in kmol/kgcat-s

We use the generally accepted empirical model[5] for the equilibrium constant (Keq):

Low-Temperature Water-Gas Shift (LTS)

We use the kinetic rate expressions in Moe[5] for the LTS reaction. Moe describes the kinetics for the LTS reaction
over a Cu/ZnO/Al2O3 catalyst. The LTS reaction submodel includes the following reaction:

The corresponding reaction rate equation is:

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where
T is the temperature, in K
b is the reversibility factor
Keq is the equilibrium constant
pj is the partial of component j, in bar
ri is the reaction rate, in kmol/kgcat-min

We use the generally accepted empirical model[5] for the equilibrium constant (Keq):

Burner
We use a set of conversion reactions to model the combustion of natural gas with no side reactions.

Mode Summary
This example uses Process mode to meet the design requirements and perform a heat and material balance on
the process. The objective of this mode is to provide a conceptual design that we can use to refine further
process development. We can then extend the process to a detailed engineering design within AVEVA Process
Simulation.

Process Mode
The objective of Process mode is to provide an overall mass and energy balance for the process and to estimate
the product flowrates and compositions. We switch the following process specifications to meet the design
requirements:
• For each heat exchanger, we switch the duty and utility flowrate specifications with the outlet stream
temperature (Tto or Tso) or vapor fraction (VFto or VFso) specifications. This allows us to calculate the
required utility flowrates.
• We calculate the CO2 recovery(R[CO2]) in the PSA units to specify the composition of H2 in the H2 Sink
(H2.z[H2]). This allows us to meet product specifications.
• We calculate the flowrate from the natural gas Source (NatGas.W) to specify the flowrate of the natural gas
fed to the SMR process (S44.F). This allows us to specify the amount of natural gas that we want to send to
the SMR reactor.
• We calculate the flowrate of the air Source (Air.W) to specify the excess oxygen in the B1 burner (B1.xO2).
This allows us to completely combust the natural gas fed to the burner.
• We calculate the duty of HX6 (HX6.Duty) to specify the composition of water in the vapor that we send to
the PSA unit (V1Out.z[H2O]). This allows us to separate most of the water from the hydrocarbons as liquid
water that we then reuse in the process.

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• We calculate all the outlet ratios of the steam header (STMHDR.OutRatio) to specify the steam-to-carbon
ratio (SC_Ratio).

Economics
We add the WasteGHG submodel to the FlueGas Sink to calculate our greenhouse gas emissions from the
furnace. We also add the SummaryGHG model to our main flowsheet to quickly view the total amount of
greenhouse gas emissions for the process.

Results
The following figure shows the composition and temperature profiles in the SMR reactor:

The following figure shows the composition profiles in the HTS and LTS reactors:

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CC28 – H2 Production via Steam Methane Reforming

The process produces 191,530 Nm3/h of hydrogen gas at 99.98% purity.

The total greenhouse gas (GHG) emissions for the simulation are 134.675 t/h of CO2 equivalent emissions.

Snapshots
The simulation includes the following snapshots:
• Pro 1: A solved steady-state, base-case solution in Process mode. If you make any changes to the simulation
that cause errors in Process mode, revert to this snapshot.

References
1. Xu, J.; Froment, G. F. Methane Steam Reforming, Methanation and Water-Gas Shift: I. Intrinsic Kinetics. AIChE
Journal 1989, 35 (1), 88-96.
2. Severinsen, I.; Herritsch, A.; Watson, M. Modeling Kinetic, Thermodynamic, and Operational Effects in a
Steam Methane Reformer. Part A: Reformer Output. Ind. Eng. Chem. Res. 2021, 60 (5), 2041-2049.
3. Hou, K.; Hughes, R. The kinetics of methane steam reforming over a Ni/a-Al2O catalyst. Chem. Eng. J. 2001,
82, 311-328.
4. Hla, S. S.; Park, D.; Duffy, G. J.; Edwards, J. H.; Roberts, D. G.; Ilyushechkin, A.; Morpeth, L. D.; Nguyen, T.
Kinetics of high-temperature water-gas shift reaction over two iron-based commercial catalysts using
simulated coal-derived syngases. Chem. Eng. J. 2009, 146, 148-154.
5. Moe, J. M. Design of water-gas shift reactors. Chem. Eng. Prog. 1962, 58, 33-36.

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CC28 – H2 Production via Steam Methane Reforming

6. Smith, B.; Loganathan, M.; Shantha, M. S. A Review of the Water Gas Shift Reaction. Int. J. Chem. React. Eng.
2010, 8 (1).
7. Seo, Y.-S.; Seo, D.-J.; Seo, Y.-T.; Yoon, W.-L. Investigation of the characteristics of a compact steam reformer
integrated with a water-gas shift reactor. J. Power Sources 2006, 161 (2), 1208-1216.

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F1 - Flare Relief

Revision Log
Date Who Change

15 Feb 2016 DK Initial release for SimCentral 1.4.

17 Nov 2016 DK Updated for SimCentral 1.6
19 Oct 2018 DHJ Updated for SimCentral Simulation Platform 3.1
Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
The flare relief system is a set of relief valves, collection piping, and a flare stack used to discard flammable
gasses during unplanned over-pressuring of plant equipment.
The objective of this simulation is to:
• Size the pressure relief valves, relief valve inlet pipes, and collection piping network.
• Calculate back pressure for the relief valves to check that high back pressure does not reduce the relieving
capacity of the relief valve.
The following figure illustrates a flare relief network as modeled in AVEVA Process Simulation.

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Process Description
The process consists of the following:
• Four sources of flare gas at different pressures that propagate through a set of four relief valves, a piping
collection system, and a flare stack, which burns the gas.
• Inlet pipes that we size such that the pressure drop is less than 3% of the specified pressure in the respective
relief valves to prevent relief valve chatter.
• Tail pipes and downstream flare header piping that we size to have less than 10% superimposed back
pressure (for conventional valves) so that high back pressure does not reduce relieving capacity.
• A pipe enlarger to calculate pressure recovery due to gas acceleration.
• A small diameter tail pipe after relief valve RV1, which exhibits choked flow.

Simulation Model
Library
This simulation uses the FlareLib library.

Fluids
This simulation uses the CompGas fluid from the simulation-specific library, a typical refinery flare gas modeled
as a compositional fluid.

Mode Summary

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Mode Process Fluid Flow

Objective Size relief valves based on required Calculate relief valve back pressures.
flow.
Size pipe diameters.
Sources Specify required flow. Specify required flow.
Relief Valves Size relief valve by selecting a relief Report the back pressure that AVEVA
valve orifice letter designation. Process Simulation calculates by using
the downstream piping.
Calculate the required fraction of relief
valve capacity.
Pipes Calculate approximate diameter. Set inside diameter based on nominal
pipe size.
Calculate downstream pressure.
Calculate upstream pressure from flow.
Check for choked flow.
Mixers Set pressure to the minimum inlet Set all outlet pressures to be the same
pressures. as the inlet pressures.
Stack Calculate pressure from upstream Set pressure to atmospheric pressure.
piping.

Process Mode
The purpose of Process mode is to size the relief valves and provide initial pipe sizes at the required flow rates. If
this is an existing system and you already know the sizes, enter the known sizes. For new systems:
• Size relief valves based on the required flow rate by selecting an orifice letter so that the required area is less
than the calculated area.
• Size the relief valve inlet pipes such that the pressure drop is less than 3% of the set pressure (SP) of the
relief valve at the rated flow to prevent relief valve chatter (3% rule). Confirm this by setting the Service
parameter to InletPipe. For sizing, set the inlet pipes to use the rated capacity flow for the relief valve by
selecting RatedCapacity for the Design Basis parameter.
• Estimate the relief valve tail pipe sizes assuming that they have 10% back pressure (for conventional valves)
at rated flow. For sizing, set the tail pipe to use the rated capacity flow for the relief valve by selecting
RatedCapacity for the Design Basis parameter and select TailPipe for the Service parameter. Since back
pressure depends on the pressure drop in the common headers from other relief valves, this calculation is
only an estimate and you must confirm the sizing in Fluid Flow mode.
• Estimate the collection laterals pipe sizes at the required flow rate and on a velocity or pressure drop sizing
criteria. Since back pressure depends on the pressure drop in the common headers from other relief valves,
this calculation is only an estimate and you must confirm the sizing in Fluid Flow mode.
• Model inlet pipes with the Incompressible flow equation. Model all other pipes with the Isothermal flow
equation according to the API 520 recommended practice.

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• Specify the flare gas flow and pressures at each source to determine the initial pressure profile for Fluid Flow
mode.

Fluid Flow Mode

The purpose of Fluid Flow mode is to determine PSV back pressures at relieving conditions. In Fluid Flow mode,
all of the mixers provide a pressure balance and pipes use their nominal pipe inside diameter. We make the
following assumptions:
• As in Process mode, we specify the flow at each source.
• We calculate the relief valve back pressure based on the flare stack pressure at atmospheric pressure.
• We model several relief events as different combinations of relieving relief valves, which we save as the
following snapshots to show the resulting imposed back pressure on the different relief valves.
• FF1 - All valves are open.
• FF2 - Total power failure occurs.
• FF3 - Cooling water failure occurs.

Dynamics Mode
While the simulation will solve in Dynamics mode, this simulation does not support dynamic simulation.

Results
Fluid Flow Mode
The following table shows the relief valve back pressures for the case in which total power failure occurs (FF2) at
the required flow conditions.

Variable Name UOM RV1 RV2 RV3 RV4

Mass flow W kg/h 10000 0 30000 40000

Set pressure SP kPa 1726.07 1271.52 816.98 362.43
Area A mm2 1840 4116 10322 20644

Capacity Capacity % 62 0 63 80
Inlet pressure P1 kPa 2000 1400 1000 500
Back pressure Pb kPa 685 178 204.5 188
Back pressure BPf % 33.8 6.2 12.6 23.85
fraction
Relief valve RV1 has a high back pressure. We analyze the inlet and tail pipes at RV1 and find that tail pipe PT1 is
undersized. The following table shows the tail pipe sizing in which relief valve RV1 is at rated flow conditions.
Values in the Original column represent the current simulation data which do not meet design criteria. Values in

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the Recommended column represent enlarged inlet and tail pipes to satisfy the 3% rule and 10% superimposed
backpressure.

Variable Name UOM Original Recommended

Mass flow W kg/h 16224 16224

Diameter D NPS 4 in 8 in
Length L m 20 20
Outlet velocity Vel2 m/s 508 203
Outlet Mach Ma2 1.0 0.40
Pressure drop DP kPa 406 22.5
Back pressure fraction BPf % 33.8 15.7

Dynamics Mode
Not supported.

Snapshots
The simulation includes the following snapshots:

Excel Report
You can find the system flows, pressures, and relief valve sizing in the F1 – Flare Relief.xlsx file.

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F2 - Flare Relief Network

Revision Log
Date Who Change

26 Apr 2016 DK Initial release for SimCentral 1.4.

22 Feb 2021 SR Updates for flowsheet additions.
Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
A flare relief network is a set of relief valves, collection piping, and flare stacks that are used to discard
flammable gasses during unplanned over-pressuring of plant equipment. This example provides a flare relief
network for a typical refinery with relief flow coming from multiple process units.
The objective of this simulation is to:
• Size the pressure relief valves, relief valve inlet pipes, tail pipes, and collection piping network.
• Calculate relief valve back pressures to check that high back pressure does not reduce relief valve relieving
capacity.
The following figures illustrate the flare relief network as modeled in AVEVA Process Simulation.

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Main Flowsheet

Coker Flowsheet

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FCCU Flowsheet

Hydrotreater Flowsheet

Alky Flowsheet

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Crude Flowsheet

Sulfur Flowsheet

Oxidation Flowsheet

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Reformer Flowsheet

Process Description
The process consists of the following:
• Seven separate refinery flare systems interconnected by jumper lines and valves. The different process units
include:
• Coker
• FCC
• Hydrotreater
• Alkylation
• Crude
• Sulfur
• Oxidation
• Reformer
• Several sources with relief fluids at various pressures, temperatures, and molecular weights that propagate
through the relief valves, a piping collection system, and multiple flare stacks where the gas is burned.
• Inlet pipes that we size such that the pressure drop is less than 3% of the set pressure (SP) in the respective
relief valves to prevent relief valve chatter. We size the inlet pipes for the rated capacity of the relief valves.
• Tail pipes and downstream flare header piping that we size to have less than 10% superimposed back
pressure (for conventional valves) so that high back pressure does not reduce relieving capacity. We size the
tail pipes for the rated capacity of the relief valves while we size the collection headers for required flow
according to API 521.
• Multiple relief contingencies that represent single events that can cause multiple relief valves to relieve.

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Simulation Model
Library
This simulation uses the FlareLib library.

Fluids
This simulation uses a custom fluid that includes C1 – C7 alkanes and Hydrogen. We model it as a compositional
fluid.

Mode Summary
Mode Process Fluid Flow

Objective Size the relief valves based on the Calculate the relief valve back
required flow. pressures.
Size all the pipes.
Source Specify the required flow. Specify the required flow.

Relief Valves Calculate the required orifice area so Report the back pressure calculated by
that you can select the appropriate the downstream piping.
orifice letter designation.
Calculate the required fraction of relief
valve capacity.
Pipes Calculate the approximate diameter Set the inside diameter based on the
so that you can set the nominal pipe nominal pipe size.
size.
Calculate the upstream pressure from
Calculate the downstream pressure. the flow.
Check for choked flow.
Mixers Calculate the pressure from the Set all outlet pressures to be the same
minimum inlet pressures. as the inlet pressures.

Stack Calculate the pressure from the Set the pressure to atmospheric
upstream piping. pressure.

Process Mode
The purpose of Process mode is to size the relief valves and provide initial pipe sizes. If this is an existing system
and you already know the sizes, enter the known pipe sizes. For new systems:

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• Size the relief valves based on a required flow by selecting an orifice letter so that the required area is less
than the calculated area.
• Size the relief valve inlet pipes such that the pressure drop is less than 3% of the set pressure (SP) of the
relief valve at the rated flow to prevent relief valve chatter (3% rule). For sizing, set the inlet pipes to use the
rated capacity flow for the relief valve by selecting RatedCapacity for the Design Basis parameter.
• Estimate the relief valve tail pipe sizes assuming that they have 10% back pressure (for conventional valves)
at rated flow. For sizing, set the tail pipe to use the rated capacity flow for the relief valve by selecting
RatedCapacity for the Design Basis parameter. Since back pressure depends on the pressure drop in the
common headers from other relief valves, this calculation is only an estimate and you much confirm the
sizing in Fluid Flow mode.
• Estimate the common collection header pipe sizes at the required flow rate and on a velocity or pressure
drop sizing criteria. Since back pressure depends on the pressure drop in the common headers from other
relief valves, this calculation is only an estimate and you must confirm the sizing in Fluid Flow mode.
• Set the FlowModel parameter for the inlet pipes to the Incompressible flow equation. Set the FlowModel
parameter for all other pipes to the Isothermal flow equation according to the API 521 recommended
practice.
• Specify the flare gas flow, pressures, and temperatures at each source to determine the initial pressure
profile for Fluid Flow mode.

Fluid Flow Mode

The purpose of Fluid Flow mode is to calculate the relief valve back pressures by using rated flow rates for tail
pipes and the summation of required flows for common headers. In Fluid Flow mode, all of the Mixers provide a
pressure balance and pipes use their nominal pipe inside diameter.
As in Process mode, we specify the flow at each source. The pipes calculate the relief valve back pressure based
on the flare stack pressure at atmospheric pressure.
We model several relief contingencies for each section with different combinations of relieving relief valves. We
save the relief contingencies as Snapshots to show the resulting superimposed back pressure on the different
relief valves. Additionally, we model global plant-wide contingencies for which the results are shown in this
document. We save these contingencies as the following Snapshots:
• GLOB 1 – Global Cooling Water Failure
• GLOB 2 – Global Power Failure

Dynamics Mode
While this simulation will solve in Dynamics mode, it does not include dynamic simulation.

Simulation Construction Workflow

We constructed this simulation in a piecewise manner. We built the individual process units mentioned in
Process Description separately and then combined them to represent the large network. The following table
shows one possible procedure to add a new process unit to an existing network.

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Step Mode Models Action

1 Process Begin in Process mode. Revert to the A1 snapshot,

which contains a nominal flow through the system.
2 Process Import the simulation of the new process unit and
copy and paste it into this simulation. Merge the
piping to make one integrated network.
3 Process Overwrite the A1 snapshot.
4 Process Sources Set the source flows according to the most severe
contingencies associated with the new process
unit.
5 Process Inlet Pipes Set the Design Basis parameter to RatedCapacity
and Service parameter to Inlet and estimate the
pipe sizes appropriately.
6 Process Relief Valves Estimate the relief valve sizes appropriately.
7 Process Tail Pipes Set the Design Basis parameter to RatedCapacity
and estimate the pipe sizes appropriately.
8 Process Common Headers Estimate the pipe sizes appropriately.
9 Fluid Flow Switch to Fluid Flow mode and revert to the zero
flow snapshot (B2) so that no other relief valves are
relieving.
10 Fluid Flow Inlet Pipes, Tail Confirm the sizes for the inlet pipes, tail pipes,
Pipes, Relief Valves, relief valves, and common headers to make sure
Common Headers that the 3% and 10% rules are obeyed. Confirm the
Relief Valve set pressures.
11 Fluid Flow Save a snapshot for the new contingency.

Results
Fluid Flow Mode
The following table shows the Relief Valve back pressures for the Global Cooling Water Failure case (GLOB 1).

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Inlet Pressure

Back Pressure
Name Size Type

Required Flow
Back Pressure
Set Pressure
Capacity
Area

Fraction
in2 fraction psi psia psia % lb/h

RV59 N Balanced 4.340 0.914 175 207.196 16.754 1.2 82,500

RV102 L Conventional 2.852 0.583 130 157.696 15.546 0.7 26,700
RV49 K Balanced 1.837 0.034 435 493.196 15.988 0.3 1,283
RV11 RR Conventional 52.000 0.918 75 97.196 16.958 3.0 410,000
RV14 R Pilot 15.999 0.682 150 179.696 16.456 1.2 250,000
RV44 K Pilot 1.837 0.859 110 135.696 15.730 0.9 17,000
RV39 M Conventional 3.601 0.512 655 735.196 16.852 0.3 124,000
RV32 K Conventional 1.837 0.823 100 124.696 26.173 12.7 7,000
Relief valve RV32 has a high back pressure and a high inlet pipe pressure drop. Check the inlet pipe and tail pipe
for this relief valve for proper sizing to obey the 3% rule and 10% superimposed back pressure rule, respectively.
The following table shows the original sizing based on the initial sizes provided in Process mode and also the
recommended sizing for the inlet and tail pipes for RV32, respectively, at rated flow.
DP Percent of RV Set

RV32 Back Pressure

RV32 Back Pressure

Required Flow
Outlet Mach

Rated Flow
Diameter

Length

Name
Pressure

Fraction

NPS ft % psia % lb/h lb/h

PI32 2 in 20 15.4 7,000 15,224

(inlet)
Original
PT32 4 in 25 13.0 0.378 26.173 12.7 7,000 15,224
(tail)

PI32 3 in 20 2.0 7,000 15,224

(inlet)
Recommended
PT32 6 in 25 1.1 0.167 24.229 9.5 7,000 15,224
(tail)

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We can take the same approach to analyze results during the Global Power Failure case (GLOB 2), as shown in
the following table. Since none of the relief valves show a high back pressure fraction, we can conclude that we
have adequately sized all the inlet pipes and tail pipes at the relief valves.

Required Flow
Back Pressure

Back Pressure
Set Pressure
Capacity
Area

Fraction
Name Size Type

in2 fraction psi psia % lb/h

RV43 K Balanced 1.837 0.819 100 15.617 0.92 15,000

RV67 Q Conventional 11.050 0.599 145 16.266 1.08 73,389
RV49 K Balanced 1.837 0.036 435 16.326 0.37 1,328
RV60 Q Balanced 11.050 0.970 150 17.341 1.76 175,000
RV88 M Balanced 3.601 0.376 170 17.121 1.43 25,000
RV86 L Balanced 2.852 0.579 305 17.620 0.96 39,700
RV89 J Conventional 1.287 0.095 725 17.106 0.33 16,500
RV108 N Balanced 4.340 0.112 240 16.781 0.87 10,000
RV17 TT Conventional 52.000 0.488 125 24.502 7.84 390,312
RV11 TT Conventional 52.000 0.898 50 16.658 3.92 285,000
The following table summarizes the inlet pipes and tail pipes for the relief valves shown in the preceding table.
Tail Pipe: RV Back
Percent of RV Set

Pressure Fraction

Required Flow
Pressure Drop

Outlet Mach

Rated Flow
Inlet Pipe: DP
Diameter
Length

Pressure

Name Type

ft NPS psi % % lb/h lb/h

PI43 Inlet 24 3in 2.293 0.023 15,000 18,304

PT41 Tail 4 6in 0.104 0.92 0.316 15,000 18,304

PI45 Inlet 5 6in 0.726 0.005 73,389 122,522

PT67 Tail 5 16in 0.088 1.08 0.420 73,389 122,522

PI50 Inlet 1 3in 0.456 0.001 1,328 37,309

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Tail Pipe: RV Back

Percent of RV Set

Pressure Fraction

Required Flow
Pressure Drop

Outlet Mach

Rated Flow
Inlet Pipe: DP
Diameter
Length

Pressure
Name Type

ft NPS psi % % lb/h lb/h

PT49 Tail 75 18in 0.160 0.37 0.165 1,328 37,309

PI62 Inlet 20 6in 2.816 0.019 175,000 180,473

PT61 Tail 60 16in 1.127 1.76 0.441 175,000 180,473

PI87 Inlet 4 3in 2.353 0.014 25,000 66,450

PT87 Tail 25 10in 0.479 1.43 0.354 25,000 66,450

PI88 Inlet 20 4in 3.122 0.010 39,700 68,543

PT86 Tail 75 12in 0.994 0.96 0.330 39,700 68,543

PI90 Inlet 26 3in 7.036 0.010 16,500 173,101

PT89 Tail 20 10in 1.639 0.33 0.655 16,500 173,101

PI108 Inlet 20 4in 5.617 0.023 10,000 89,192

PT108 Tail 75 12in 1.676 0.87 0.439 10,000 89,192

PI17 Inlet 3 8in 1.832 0.015 390,312 799,263

PT16 Tail 6 20in 0.712 7.84 0.762 390,312 799,263

PI11 Inlet 20 24in 0.027 0.001 285,000 317,468

PT10 Tail 75 24in 0.500 3.92 0.345 285,000 317,468

Dynamics Mode
This simulation does not include dynamic simulation.

Snapshots
The simulation includes the following snapshots:

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Excel Report
You can find an Excel report with the system flows, pressures, and relief valve sizing in the F2 – Flare Relief
Network.xlsx file. The file includes worksheets based on the individual process units and their contingencies as
well as a main worksheet that contains all the process units and a list of the snapshots that you can use to load
specific contingencies.

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F3 - Flare Relief with Mixed Fluids

Revision Log
Date Who Change

10 Aug 2016 DK Initial release for SimCentral 1.5.

Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
The flare relief system is a set of relief valves, collection piping, and a flare stack that is used to discard
flammable gasses during unplanned over-pressuring of plant equipment. In many plants, the only available data
is the fluid temperature, molecular weight, and specific heat ratio, which is known as a Flare Gas component in
AVEVA Process Simulation. This example demonstrates a simulation that contains fluids based on these three
values rather than individual components. It also demonstrates how you can create hybrid flare networks that
use both Flare Gas and compositional fluids.
The objective of this simulation is to:
• Size the pressure relief valves, relief valve inlet pipes, and collection piping network.
• Calculate back pressure for the relief valves to check that high back pressure does not reduce the relieving
capacity of the relief valve.
• Use a Flare Gas fluid based on Temperature, MW, and Cp/Cv ratio.
• Use a converter model to take properties such as molecular weight and specific heat ratio from a
compositional fluid and create a Flare Gas fluid.
• Demonstrate the ability to use both compositional fluids and Flare Gas in the same simulation.
The following figure illustrates the flare network with Flare Gas and a compositional fluid.

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Process Description
The process consists of the following:
• Three sources that contain Flare Gas (SRC1, SRC2, SRC3), which we define by molecular weight and Cp/Cv
ratio, and three sources that contain a compositional fluid (SRC4, SRC5, SRC6) at different pressures and
temperatures that propagate through a corresponding set of relief valves, a piping collection system, and a
flare stack, which burns the gas.
• Inlet pipes that we size such that the pressure drop is less than 3% of the specified pressure in the respective
relief valves to prevent relief valve chatter.
• Tail pipes and downstream flare header piping that we size to have less than 10% superimposed back
pressure (for conventional valves) so that high back pressure does not reduce relieving capacity.
• A fluid converter model that converts the compositional flare gas fluid to a molecular weight-based flare gas.
The converter takes the molecular weight from a compositional source and the specific heat ratio calculated
internally so that it can mix with a source that contains the Flare Gas fluid defined by those same properties.

Simulation Model
Library
This simulation uses the FlareLib library.

Fluids
This simulation uses the FlareGas fluid from the FlareLib library, a flare gas modeled by its molecular weight and
Cp/Cv ratio, along with the compositional CompGas fluid from the simulation-specific library.

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Mode Summary
Mode Process Fluid Flow

Objective Size the relief valves based on Calculate the relief valve back
required flow. pressures.
Size the inlet and tail pipe diameters
based on rated flow.
Sources Specify the required flow. Specify the required flow.
Relief Valves Size the relief valve by selecting a Calculate the back pressure based on
relief valve orifice letter designation. the downstream piping.
Calculate the required fraction of relief
valve capacity.
Pipes Calculate the required nominal pipe Set the inside diameter based on the
size. nominal pipe size.
Calculate the downstream pressure. Calculate the upstream pressure from
the flow.
Check for choked flow.
Mixers Set the outlet pressure to the Set all inlet and outlet pressures to be
minimum inlet pressures. the same pressure.
Converter Convert the Compositional fluid to a Convert the Compositional fluid to a
FlareGas fluid based on the FlareGas fluid based on the
temperature, molecular weight, and temperature, molecular weight, and
Cp/Cv ratio. Cp/Cv ratio.
Stack Calculate the pressure from Set the pressure to atmospheric
upstream piping. pressure.

Process Mode
The purpose of Process mode is to size the relief valves and provide initial pipe sizes at the required or rated flow
rates. Use the following sizing criteria for new systems:
• Size relief valves based on the required flow rate by selecting an orifice letter so that the required area is less
than the calculated area.
• Estimate the inlet pipe size for the relief valve such that the pressure drop is less than 3% of the specified
pressure of the relief valve at the rated flow to prevent relief valve chatter (3% rule).
• Estimate the tail pipes and collection laterals pipe sizes at the required flow rate and on a velocity or
pressure drop sizing criteria. You must confirm the Lateral and Header sizing in Fluid Flow mode and the
individual tail pipes sizes at rated flow.
• Model inlet pipes with the Incompressible flow equation. Model all other pipes with the Isothermal flow
equation according to the API 520 recommended practice.

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• Specify the flare gas flow and pressures at each source to determine the initial pressure profile for Fluid Flow
mode.

Fluid Flow Mode

The purpose of Fluid Flow mode is to determine PSV back pressures at relieving conditions. In Fluid Flow mode,
all of the mixers provide a pressure balance and pipes use their nominal pipe inside diameter. We make the
following assumptions:
• As in Process mode, we specify the flow at each source.
• We calculate the relief valve back pressure based on the flare stack pressure at atmospheric pressure.

Dynamics Mode
While the simulation will solve in Dynamics mode, this simulation does not support dynamic simulation.

Workflow
In addition to the features mentioned above and also in examples F1 and F2, a key component of this simulation
is the use of the fluid converter to allow the use of hybrid fluids in the same simulation. The converter uses an
input from a compositional-based fluid and extracts the calculated molecular weight from the source and
calculates the specific heat ratio using the molar heat capacity and the ideal gas constant.
Consider the basic example that has a Source model connected to a Converter, shown in the following figure. We
enter a compositional fluid in the source and AVEVA Process Simulation calculates the molecular weight based
on the mole fraction of the specified components. Along with the specific heat ratio that AVEVA Process
Simulation calculates internally, AVEVA Process Simulation can combine these values with a different part of the
simulation that uses a fluid where only the molecular weight and specific heat capacity are known.

Results
Fluid Flow Mode
The following table shows the relief valve back pressures after all the equipment has been properly rated in Fluid
Flow mode. The Type is Conventional for all the relief valves.

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Variable Name UOM RV1 RV2 RV3 RV4 RV5 RV6

Size Size L L J J K L
Area A mm2 1840.00 1840.00 830.00 830.00 1185.00 1840.00

Capacity Capacity % 0.67 0.70 0.63 0.91 0.87 0.66

Rated mass W kg/h 11339.81 22679.62 34019.43 4535.92 9071.85 13607.77
flow
Set pressure SP kPa 1005.79 1205.36 2768.87 614.62 1255.85 1688.08
Inlet pressure P1 kPa 1207.69 1427.22 3147.08 777.40 1482.76 1958.21
Back pressure Pb kPa 134.68 131.41 118.19 122.75 125.18 118.40
Back pressure BPf % 3.32 2.50 0.61 3.49 1.90 1.01
fraction
The following table shows the relief valve inlet pipes properly sized for rated capacity. The Flow Model is
Incompressible and the Design Basis is RatedCapacity for all the inlet pipes.

Variable UOM PI1 PI2 PI3 PI4 PI5 PI6

Size 4in 4in 3in 3in 3in 4in

Mass Flow kg/h 16091.59 28606.14 38044.81 4481.85 10292.56 21060.19
Diameter mm 102.26 102.26 77.93 77.93 77.93 102.26
Diameter Margin mm 37.56 42.35 43.10 34.11 18.95 27.87
Length m 9.14 9.14 9.14 9.14 9.14 9.14
Moody Friction 0.02 0.02 0.02 0.02 0.02 0.02
Inlet Pressure kPa 1172.37 1302.09 2689.10 711.19 1505.77 2015.89
Outlet Pressure kPa 1156.62 1278.35 2679.92 702.77 1471.35 1988.59
Inlet Velocity m/s 39.46 33.60 4.07 31.29 55.99 52.20
Outlet Velocity m/s 40.03 34.32 19.98 31.67 57.30 52.92
Pressure Drop kPa 15.75 23.74 9.18 8.42 34.42 27.30
DP Percent % 1.64 2.22 0.39 1.54 2.76 1.59
The following table shows the relief valve tail pipes properly sized for rated capacity. The Flow Model is
Isothermal and the Design Basis is RatedCapacity for all the tail pipes.

Variable UOM PT1 PT2 PT3 PT4 PT5 PT6

Size 8in 10in 12in 6in 8in 12in

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Variable UOM PT1 PT2 PT3 PT4 PT5 PT6

Mass Flow kg/h 16091.59 28606.14 38044.81 4481.85 10292.56 21060.19

Diameter mm 202.72 254.51 303.23 154.05 202.72 303.23
Diameter Margin mm 7.51 55.82 151.76 51.13 19.66 11.53
Length m 15.24 15.24 15.24 15.24 15.24 15.24
Moody Friction 0.00 0.00 0.00 0.00 0.00 0.00
Inlet Pressure kPa 122.50 118.31 110.85 146.66 149.01 139.81
Outlet Pressure kPa 113.45 113.45 108.16 144.57 144.57 137.25
Inlet Velocity m/s 101.54 67.45 51.01 39.44 83.83 85.72
Outlet Velocity m/s 109.69 70.36 52.29 40.02 86.41 87.32
Inlet Mach Ma1 0.34 0.30 0.26 0.13 0.22 0.22
Outlet Mach Ma2 0.37 0.31 0.27 0.14 0.23 0.23
Pressure Drop kPa 9.05 4.86 2.69 2.10 4.45 2.56
DP Percent % 7.39 4.11 2.43 1.43 2.98 1.83

Dynamics Mode
Not supported.

Snapshots
This simulation includes the following snapshots:

Excel Report
You can find the system flows, pressures, and relief valve sizing in the F3 – Flare Relief with Mixed Fluids.xlsx file.

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F4 - Two Phase Flare Relief

Revision Log
Date Who Change

17 Nov 2016 DK Initial release for SimCentral 1.6.

27 Sep 2017 SK Updates for SimCentral 2.0.
Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
The flare relief system is a set of relief valves, collection piping, a knockout drum, and a flare stack used to
discard flammable gasses during unplanned over-pressuring of plant equipment.
The objective of this simulation is to:
• Size the pressure relief valves, relief valve inlet pipes, and collection piping network.
• Use the knockout drum to separate the fluid into its vapor and liquid phase.
• Demonstrate the heat loss in pipes.
• Calculate back pressure for the relief valves to check that high back pressure does not reduce the relieving
capacity of the relief valve.
The following figure illustrates a flare relief network as modeled in AVEVA Process Simulation.

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Process Description
The process consists of the following:
• Four sources of a multiphase flare fluid at different pressures that propagate through a set of four relief
valves, a piping collection system, a knockout drum that separates the vapor and liquid, and a flare stack,
which burns the gas.
• Inlet pipes are sized such that the pressure drop is less than 3% of the specified pressure in the respective
relief valves to prevent relief valve chatter.
• Tail pipes and downstream flare header piping are sized to have less than 10% superimposed back pressure
(for conventional valves) so that high back pressure does not reduce relieving capacity.
• A knockout drum that we connect to a level controller to regulate the flow through the drum. We also use
the level controller to conduct independent dynamic studies as necessary.

Simulation Model
Library
This simulation uses the FlareLib library.

Fluids
This simulation uses a custom Multiphase fluid in the simulation-specific library, which we model as a
compositional fluid.

Mode Summary

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Mode Process Fluid Flow

Objective Size the relief valves based on Calculate the relief valve back
required flow. pressures.
Size the pipe diameters.
Sources Specify the required flow. Specify the required flow.
Relief Valves Size the relief valve by selecting a Report the back pressure that AVEVA
letter designation for the relief valve Process Simulation calculates by using
orifice. the downstream piping.
Calculate the required fraction of relief
valve capacity.
Pipes Calculate the approximate diameter. Set the inside diameter based on
nominal pipe size.
Calculate the downstream pressure.
Calculate the upstream pressure from
the flow.
Mixers Set the pressure to the minimum Set all outlet pressures to be the same
inlet pressures. as their respective inlet pressures.
Drum Specify a liquid level fraction. Calculate the liquid level fraction based
on the accumulated holdup volume.
Calculate the vapor and liquid outlet
flow. Calculate the pressure from the
differential mass and energy balances.
Valves Specify the DP to size Cv. Set the Cv to calculate the flow.
Stack Calculate the pressure from the Set the pressure to atmospheric
upstream piping. pressure.

Process Mode
The purpose of Process mode is to size the relief valves and provide initial pipe sizes at the required flow rates. If
this is an existing system and you already know the sizes, enter the known sizes. For new systems:
• Specify the flare gas flow and pressures at each source to determine the initial pressure profile for Fluid Flow
mode.
• Size relief valves based on the required flow rate by selecting an orifice letter that has a larger area than the
calculated area.
• Model simple inlet pipes with the simple pipe using the Incompressible flow option.
• For multiphase flow, use rigorous pipes. Model them using the Beggs, Brill & Moody High Velocity (BBMHV)
correlations. To do so, select BBMHV for the PressureDropMethod. Designate the number of segments by
setting an integer value for N so that temperature, flow and pressure profiles can be viewed.
• Size the relief valve inlet pipes such that the pressure drop is less than 3% of the set pressure (SP) of the
relief valve at the rated flow to prevent relief valve chatter (3% rule). Confirm this by setting the Service

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parameter to InletPipe. For sizing, set the inlet pipes to use the rated capacity flow for the relief valve by
selecting RatedCapacity for the Design Basis parameter.
• Estimate the relief valve tail pipe sizes assuming that they have 10% back pressure (for conventional valves)
at rated flow. For sizing, set the tail pipe to use the rated capacity flow for the relief valve by selecting
RatedCapacity for the Design Basis parameter and select TailPipe for the Service parameter. Since back
pressure depends on the pressure drop in the common headers from other relief valves, this calculation is
only an estimate and you must confirm the sizing in Fluid Flow mode.
• Estimate the collection laterals pipe sizes at the required flow rate and on a velocity or pressure drop sizing
criteria. Since back pressure depends on the pressure drop in the common headers from other relief valves,
this calculation is only an estimate and you must confirm the sizing in Fluid Flow mode.
• Set the HeatModel parameter to PipeInAir for all pipes to show heat loss due to ambient conditions.

Fluid Flow Mode

The purpose of Fluid Flow mode is to determine PSV back pressures at relieving conditions. In Fluid Flow mode,
all of the mixers provide a pressure balance and pipes use their nominal pipe inside diameter. We make the
following assumptions:
• As in Process mode, we specify the flow at each source.
• We calculate the relief valve back pressure based on the flare stack pressure at atmospheric pressure, and
pressure drop through the piping system.
• We model several relief events as different combinations of relieving relief valves, which we save as the
following snapshots to show the resulting imposed back pressure on the different relief valves.
• FF 1 - All valves are open.
• FF 2 – Total power failure occurs.
• FF 3 – Cooling water failure occurs.

Dynamics Mode
While the simulation will solve in Dynamics mode, this simulation does not demonstrate dynamic cases.

Results
Fluid Flow Mode
The following table shows the relief valve back pressures for the case in which all valves are relieving (FF 1) at the
rated flow conditions. We can see that all the downstream piping has been adequately sized since the back
pressure is low for all relief valves.

Name Variable UOM RV1 RV2 RV3 RV4

Model PSV PRV PRV PRV

Relief Valve Type Conventional Conventional Conventional Conventional
Type

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Name Variable UOM RV1 RV2 RV3 RV4

Orifice Letter Size N J G D

Mass flow W kg/h 18,000 6,000 10,000 2,000
Set pressure SP kPa 844 1,726 1,272 3,544
Area A mm2 2,800 830 324 71

Capacity Capacity % 82 51 37 16
Molar Vapor OutState.VF % 100 100 17 0
Fraction
Inlet pressure P1 kPa 1,030 2,000 1,499 4,000
Back pressure Pb kPa 154 152 195 136
Back pressure BPf % 6 3 7 1
fraction
The following table shows the relief valve back pressures for the case in which total power failure (FF2) occurs at
the rated flow conditions. We see that during a total power failure, the relief valves are still appropriately sized,
with all back pressure fractions being less than 10%.

Name Variable UOM RV1 RV2 RV3 RV4

Model PSV PRV PRV PRV

Relief Valve Type Conventional Conventional Conventional Conventional
Type
Orifice Letter Size N J G D
Mass flow W kg/h 18,000 6,000 10,000 0
Set pressure SP kPa 844 1,726 1,272 3,544
Area A mm2 2,800 830 324 71

Capacity Capacity % 82 51 37 81
Vapor Fraction OutState.VF % 100 100 17 0
Inlet pressure P1 kPa 1,030 2,000 1,499 4,000
Back pressure Pb kPa 153 151 194 132
Back pressure BPf % 6 3 7 1
fraction
The following table shows the relief valve back pressures for the case in which cooling water failure (FF3) occurs.
In this case as well, no back pressure fraction exceeds 6% and the relief valves are still appropriately sized.

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Name Variable UOM RV1 RV2 RV3 RV4

Model PSV PRV PRV PRV

Relief Valve Type Conventional Conventional Conventional Conventional
Type
Orifice Letter Size N J G D
Mass flow W kg/h 18,000 6,000 0 0
Set pressure SP kPa 844 1,726 1,272 3,544
Area A mm2 2,800 830 324 71

Capacity Capacity % 82 51 59 81
Vapor Fraction OutState.VF % 100 100 4 0
Inlet pressure P1 kPa 1,030 2,000 1,499 4,000
Back pressure Pb kPa 138 133 129 123
Back pressure BPf % 4 2 2 1
fraction
Additionally, we can observe the heat loss across specified inlet and tail pipes only looking at the temperature
difference (DT). The heat transfer across each pipe, including the heat loss method is shown in the below table
for the case where all valves are relieving.

Case – All Valves Relieving

Model Pipe Service Heat Loss Method Temperature Difference (°C)

PI1 Inlet PipeInAir 0.4

PIR1 Tail PipeInAir 6.2
PIR2 Inlet PipeInAir 0.0
PIR3 Tail PipeInAir 2.2
PIR4 Inlet PipeInAir 0.0
PIR5 Tail PipeInAir 8.2
PIR6 Inlet PipeInAir 0.8
PIR7 Tail PipeInAir 4.1
PIR8 Other PipeInAir 1.5
PIR9 Other PipeInAir 2.7
PIR10 Other PipeInAir 6.6

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After all the fluid has been collected by the common headers, the fluid is sent to the knockout drum where the
phases are separated. For each case, the amount of fluid fed to the drum changes, which results in differing
vapor and liquid product that is sent to the stack and downstream pump, respectively. The table below shows
the mass balance around the drum for each case.

Variable Model Variable UOM Case – All Valves Case – Total Case – Cooling
Relieving Power Failure Water Failure

Drum Feed S28 W kg/h 36,000.00 36,000.00 36,000.00

Vapor Product S17 W kg/h 26,824.46 26,824.46 26,824.46
to Stack
Liquid Product S19 W kg/h 9,175.54 9,175.54 9,175.54
to Pump

Dynamics Mode
Not supported.

Snapshots
The simulation includes the following snapshots:

Excel Report
You can find the system flows, pressures, pipe sizing, and relief valve sizing in the F4 – Two Phase Flare Relief.xlsx
file.

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G2 - Deethanizer

Revision Log
Date Who Change

24 Jan 2020 RM Initial release for AVEVA Simulation 4.2 Beta.

30 Mar 2023 RC Improved TC1 control loop in the detailed engineering simulation.
Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
This example demonstrates how you can use AVEVA Process Simulation to design a deethanizer that separates
ethane from a mixture of light hydrocarbons. We provide two simulations for this example. These simulations
illustrate how to approach the separation at different stages of the design process.
• G2 - Deethanizer
A conceptual design that uses only Process mode within AVEVA Process Simulation.
• G2 - Deethanizer Detailed Engineering
A continuation of the conceptual design that includes additional process details. This simulation provides
both the detailed steady-state equipment design in Process mode and a validation of the process control
strategy in Dynamics mode.
These simulations meet the following objectives:
• Design a deethanizer that separates ethane from a light hydrocarbon mixture into products with required
purity.
• Switch specifications to meet different design requirements.
• Migrate a conceptual design to a detailed design simulation by using AVEVA Process Simulation.
• Validate the process control strategy for the separation.
The following figures show the two different simulations. Figure 1 shows the deethanizer process as a conceptual
design model (G2 - Deethanizer). Figure 2 shows the detailed process design model (G2 - Deethanizer Detailed
Engineering).

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Figure 1: Conceptual Design Model

Figure 2: Detailed Engineering Model and Dynamic Simulation

Within AVEVA Process Simulation, we use the Column model from the Process library to address both the
conceptual and detailed engineering shown in these examples. For conceptual engineering, the Column model
integrates both a condenser and reboiler for a simplified engineering approach. We then use the built-in column

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features to extend the conceptual design to a detailed engineering design with external condenser and reboiler
models. Both simulations provide the same output in Process mode, but the detailed engineering simulation
provides additional details in Fluid Flow and Dynamics modes.

Process Description
A mixed light hydrocarbon feed stream enters the Column (P = 3,135 kPa, VF = 0.3) with the composition shown
in the following table. The total molar flow rate of the feed stream is 408 kmol/h.
Table 1: Feed Stream Composition

Component Mole % Component Mole %

Nitrogen 0.03 n-Butane 4.60

Methane 44.59 Isopentane 1.68
Ethane 19.83 n-Pentane 1.16
Propane 19.09 n-Hexane 2.96
Isobutane 4.16 n-Heptane 1.90
The feed stream enters the Column for separation of the components. The deethanizer Column includes 18
stages, a cryogenic condenser, and a steam-heated thermosiphon reboiler. The feed stream enters the Column at
stage 9.
The simulation uses the following process control strategy:
• A flow controller regulates the feed flowrate into the Column.
• A level controller maintains the column sump level by manipulating the bottom product flowrate.
• A temperature controller regulates the temperature (and vapor fraction) of the boilup by adjusting the flow
of steam into the thermosiphon reboiler.
• A level controller maintains the reboiler shell-side drum level by manipulating the condensate flowrate.
• A pressure control loop regulates the overhead product flowrate and maintains the pressure at the top of
the deethanizer.
• A level controller on the reflux drum maintains the reflux flowrate.
• A temperature controller regulates the temperature of the reflux stream by manipulating the refrigerant
flowrate to the overhead condenser.

Simulation Model
Library
These simulations use the Process, Controls, and Fluids libraries.

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Fluids
These simulations use a custom VLE compositional fluid named G2Feed, which uses the Soave-Redlich-Kwong
(SRK) method. You can find this fluid in the simulation-specific library. The default composition for this fluid is the
same as the feed stream composition given in Process Description. The refrigerant in the overhead condenser
also uses this fluid, but the refrigerant composition is 90 mol% ethane and 10 mol% propane.
These simulations also use the Steam fluid from the Fluids library for the thermosyphon reboiler.

Mode Summary
The following table includes the mode summary for both the conceptual and detailed engineering simulations to
illustrate their differences. We use Fluid Flow mode only as an intermediate step for moving the detailed solution
from Process mode to Dynamics mode. Therefore, we do not include it in the mode summary. You can find
additional details about each mode in the following sections.

Process Mode Process Mode (Detailed) Dynamics mode

(Conceptual) (Detailed)

Purpose Create a mass and energy Create a mass and energy Validate the process
balance of the overall balance of the overall control strategy.
process. process and design the
column, reboiler, and
condenser.
Column Calculate and verify the Determine the Column Perform a stage-wise
number of stages, diameter. dynamic mass and energy
location of the feed stage, balance to calculate the
and the reflux and boilup pressure and stage
ratios. compositions.
Source (Feed) Set the feed flowrate and Set the feed flowrate and Observe the process
composition. composition. response to a change in
feed flowrate.
Source (Refrigerant) N/A Set the flowrate and feed Set the flowrate and feed
properties of the properties of the
refrigerant. refrigerant.
Source (Steam) N/A Set the flowrate and feed Set the flowrate and feed
properties of the steam. properties of the steam.
Condenser N/A Set the shell-side and Calculate the duty from
tube-side outlet vapor the process conditions.
fractions to calculate the
required heat duty, area,
and refrigerant flowrate.

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Process Mode Process Mode (Detailed) Dynamics mode

(Conceptual) (Detailed)

Reflux Drum N/A Separate the overhead Calculate the drum

vapor product from the pressure and liquid level.
liquid reflux stream and
specify the top pressure
of the Column.
Reboiler N/A Specify the shell-side and Calculate duty from the
tube-side vapor fractions stream flow rate and heat
to calculate the required transfer surface.
steam supply and supply
boilup return to the
Column.

Process Mode
The purpose of Process mode in both simulations is to provide a basis for subsequent pressure-driven and
dynamic calculations. Some important aspects of this mode include:
• Calculating an overall mass and energy balance for the process.
• Determining the number of required stages and the feed stage location.
Note: For detailed workflows on how to transition between a conceptual and a detailed column design, see the
model help for the Column. To open the model help for the Column, right-click the Column in the Model Library,
and then click Help.

Fluid Flow Mode

Fluid Flow mode serves as an intermediate calculation before the dynamic simulation. Process mode performs
flow-driven, steady-state calculations that are a good basis for subsequent process design. When you switch to
Fluid Flow mode, the simulation changes from a flow-driven model to a pressure-driven model. Instead of
specifying the flowrates in this mode, you typically calculate the flowrates by balancing the pressures on each
piece of equipment.

Dynamics Mode
You use Dynamics mode to observe process behavior during and after a process disruption or change. For this
example, we use the scenario named Increase Feed to 15000 kgh to examine the process control response to an
increase in the feed flowrate. After one minute, the scenario increases the feed to 15,000 kg/h and records the
control response over the next 20 minutes.

Scenarios
The conceptual design simulation does not incorporate any control systems or use Dynamics mode. Therefore, it
does not include any scenarios.
The detailed engineering simulation includes the following scenarios.

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Scenario 1: Increase Feed to 15000 kgh

This scenario increases the feed flowrate to 15,000 kg/h and records the control response over the next 20
minutes. You can use this scenario to examine the process control response to an increase in the feed flowrate.

Scenario 2: Increase Reboiler TC to 120 C

This scenario increases the setpoint of the reboiler temperature to 120°C and records the process response. You
can use this scenario to investigate the process response to unplanned changes.

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Scenario 3: Run for 1 min

This scenario runs the simulation for an additional minute. After you run any other scenario, you can run this
scenario to study any further process changes.

Results
Process and Fluid Flow Modes
The following table summarizes the properties for select column input and output streams for the detailed
engineering simulation.
Table 2: Selected Stream Properties for the Steady-state Solution

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Variable
Units (SI) Feed Overhead Bottoms Refrigerant Steam
Description

Molar Flow (F) kmol/h 408.23 256.03 152.20 101.57 143.92

Pressure (P) kPa 3,135 3,026.28 2,835.08 140.81 476.10
Temperature (T) °C -36.25 -40.64 102.62 -80 150
Vapor Fraction (VF) fraction 0.3 1 0.097 0 1
Ethane Composition fraction 0.198 0.288 0.047 0.9 -
(z[Ethane])
Note: This information also appears in Table named Stream Table in the detailed engineering simulation. You can
open this Table to quickly view and generate a Microsoft Excel report for these results.
The VLT Profile plot (Figure 3) shows the vapor flow, liquid flow, and temperature across the Column stages at
steady-state. The Comp Profile plot (Figure 4) shows the steady-state stage compositions across the deethanizer
column.

Figure 3: Column Profile

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Figure 4: Deethanizer Stage Composition Profile

Dynamics Mode
The detailed engineering simulation provides the Dynamics mode results. The objective of the dynamic
simulation is to study the behavior of the process control system for upset conditions in the feed stream. This
scenario increases the feed stream flowrate from 13,500 kg/h to 15,000 kg/h by adjusting the setpoint of the
feed flowrate controller (FC1) to 15,000 kg/h. The control loop responds by modulating XV1 to increase the
flowrate. The following figure shows the resulting flowrate (FC1.PV) in comparison to the setpoint (FC1.SP).

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Figure 5: Step Response of the Change in Flow Controller Setpoint

The flowrate significantly oscillates around the setpoint rather than converging. For this scenario, the default
controller values do not give the desired response.
As a result of the poor feed control, the reboiler duty and bottom product composition also oscillate rather than
converging to a single value, as shown in the following figure. We observe a similar trend for the overhead
condenser and product.

Figure 6: Response of the Final Products

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Here we have an opportunity to modify the control scheme to yield a better response. There are a variety of
ways to accomplish this, but the logical starting point is FC1. The default control range for FC1 is from 0 to 36,000
kg/h. With these default values, an increase of 1,500 kg/h represents less than 5% of the control range. To
improve control performance for such a small change, you can adjust the gain (Kp) of the controller. Given the
number of existing resources related to PID tuning, we do not include the controller tuning in this example.
Note: The detailed engineering simulation also includes Trends for additional process specifications and
parameters. You can use these Trends to further investigate the process control responses, if desired.

Snapshots
The conceptual design simulation includes the following snapshot:
• Pro 1: A solved steady-state solution in Process mode. If you make any changes to the simulation that cause
errors in Process mode, revert to this snapshot.
The detailed engineering simulation includes the following snapshots:
• Pro 1: A solved steady-state solution in Process mode. If you make any changes to the simulation that cause
errors in Process mode, revert to this snapshot.
• FF 1: A solved steady-state solution in Fluid Flow mode. If you make any changes to the simulation that cause
errors in Fluid Flow mode, revert to this snapshot.

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GG1 - Dynamic Compressor

Revision Log
Date Who Change

22 Aug 2016 SK Initial release for SimCentral 1.5.

02 Dec 2016 SK Updates for SimCentral 1.6.
10 Oct 2017 SK Updates for improved ASC model for SimCentral 2.1.
16 May 2018 SK Updates for improved anti-surge setup.
23 Jul 2018 SK Dynamics snapshots removed.
4 Sep 2020 AL Compressor updated with multiple curves.
Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
Centrifugal compressors that are employed in gas processing plants and in gas pipeline transmission systems
provide a vital function to the overall plant operation, and therefore must ensure a high level of operational
reliability. It is essential to design these compressor systems in a manner that eliminates or minimizes potential
for surge, which is a dynamic instability that is detrimental to the integrity of the unit.
The objective of this simulation is to:
• Determine the appropriate valve and pipe sizing required for anti-surge protection.
• Validate the anti-surge control strategy for upsets like motor trip or blocked outlet scenarios.
• Determine the maximum compressor outlet temperature during upset situations.
The following figure shows the Dynamic Compressor system modeled in AVEVA Process Simulation.

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Process Description
The compressor system consists of the following:
• A Source model that contains the fluid that must be pressurized to send to the downstream unit.
• An inlet valve XV1, which acts as a check valve to avoid back flow to the upstream unit.
• A knockout drum V1, which ensures that compressor inlet is completely vapor.
• An after cooler E1, which cools the compressed gas to the required temperature at the downstream unit.
• A cold recycle anti-surge valve FV1 that is downstream of E1.
• A hot recycle anti-surge valve FV2 that is upstream of E1.

Simulation Model
Library
This simulation uses the Process library.

Curves
This simulation uses the Performance curve in the simulation-specific library for the compressor K1.
The Performance curve contains the following curves:
• Adiabatic head vs. compressor actual volumetric flow at the following speeds:
• 3600 rpm

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• 3000 rpm
• 2400 rpm
• 1800 rpm
• 1200 rpm
• Adiabatic efficiency vs. compressor actual volumetric flow
• Surge head vs. compressor actual volumetric flow

Fluids
This simulation uses the C1C8 fluid in the simulation-specific library. This fluid has a hydrocarbon mixture of
alkanes and carbon dioxide.

Mode Summary
The following table provides a summary of the simulation operation in all three modes:

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Process Dynamic

Purpose Size the control valves for the required Validate control valve size and piping
pressure drop. size for anti-surge line.
Set the compressor speed and calculate Validate anti-surge control strategy for
the compressor outlet temperature. upsets like motor trip and blocked
outlet scenarios.
Initially set control valve Cv and piping
size for anti-surge line.
Source Specify the flow, temperature, and Specify the pressure and temperature.
pressure.
Calculate the flow.
Compressor Specify the outlet pressure. Calculate the flow from performance
curves.
Calculate the efficiency from
performance curves. Calculate the efficiency based on the
calculated flow.
Drum Calculate the vapor and liquid outlet Calculate the pressure from the
flow. differential mass and energy balances.
Heat Exchangers Specify the outlet temperature. Specify the outlet temperature.
Valves For the inlet and outlet control valves, For the inlet and outlet control valves,
specify DP to size Cv. set Cv to calculate the flow.
For XV1, XV2: Specify the CheckValve For XV1, XV2: Specify the CheckValve
parameter as Check to avoid reverse flow parameter as Check to avoid reverse
to the upstream unit. flow to the upstream unit.
For the anti-surge valves, set the initial For the anti-surge valves, adjust the Cv
Cv value. You should validate this Cv values based on the required dynamic
value based on the dynamic surge surge control response.
control scenarios.
Pipes For pipes in anti-surge lines, specify Calculate pressure drop.
D_margin = 0 (instead of DP).
Set initial pipe size. You should validate
this pipe size based on maximum
velocities during dynamic surge control
scenarios (observe Trend “Pipe
Velocities”).
Headers Set the the outlet flow ratio (OutRatio) Calculate the outlet flow ratio
for the anti-surge recycle streams to (OutRatio).
zero.

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Process Dynamic

Anti-surge Control Calculate the output to the anti-surge Specify the maximum compressor
control valve (OP). AVEVA Process design flow expected for the stonewall
Simulation initially calculates this value condition.
as zero based on the zero flow through
the anti-surge valve.
Specify the maximum capacity (MaxCap)
over the design for the stonewall
condition.
Specify the margin over the surge flow at
which to trigger a control response
(MarginSCL).
Specify the margin over the surge flow at
which to trigger a larger recycle trip
response (MarginRTL).
Switch To study the response with the cold Same in all modes.
recycle anti-surge valve, set the Switch
parameter to “One” in model SW1. This
setting ensures that the AS1.Output
signal is sent to FV1.Control.
To study the response with hot recycle
anti-surge valve, set the Switch
parameter to “Two” in model SW1. This
setting ensures that the AS1.Output
signal is sent to FV2.Control.

Process Mode
The purpose of Process mode is to design the compressor at steady-state operation. Some important aspects
include:
• Size the control valves for the required steady-state pressure drops with 50% open position.
• Set the anti-surge valve for zero flow during normal steady-state operations by using the following setup:
• Set the header outlet ratio (OutRatio) for the anti-surge recycle streams to zero.
• Set the anti-surge Cv to an initial value that you should validate in Dynamics mode.
• Calculate the output variable (OP) for the anti-surge controller. Because you set the OutRatio for the
anti-surge recycle streams to zero, the anti-surge flow is zero and AVEVA Process Simulation initially
calculates OP as zero.
• Set the exchanger outlet temperature as required.

Dynamics Mode
To protect the compressor adequately from surge, the discharged flow must be restored very quickly.

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For this reason, we keep the anti-surge controller (AS1) connected to the anti-surge control valve for the hot
recycle (FV2), which is closest to the compressor (on HDR1).
However, we also consider connecting the anti-surge controller to the anti-surge control valve for the cold
recycle (FV1), which is downstream of cooler E1, to determine if this control setup can suitably control the
suction temperature and thereby prevent the compressor outlet temperature from rising too high.
The purpose of Dynamics mode is to accomplish the following:
• Validate the surge control response for the upset scenarios.
• Validate the size of the control valves and pipes by confirming they are adequate for the motor trip upset
scenario.
• Compare the maximum outlet temperature for the compressor for the hot recycle anti-surge valve to the
maximum outlet temperature for the compressor for the cold recycle anti-surge valve.

Scenarios
Scenario 1: Motor Trip with Cold Recycle Anti-surge Valve
Run the Motor Trip with Cold Recycle Scenario. This Scenario trips motor M1 after 5 seconds.

Scenario 2: Blocked Outlet with Cold Recycle Anti-surge Valve

Run the Blocked Outlet with Cold Recycle Scenario. This Scenario closes outlet valve XV2 after 5 seconds.

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Scenario 3: Motor Trip with Hot Recycle Anti-surge Valve

Run the Motor Trip with Hot Recycle Scenario. This Scenario trips motor M1 after 5 seconds.

Scenario 4: Blocked Outlet with Hot Recycle Anti-surge Valve

Run the Blocked Outlet with Hot Recycle Scenario. This Scenario closes outlet valve XV2 after 5 seconds.

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Results
Process Mode and Fluid Flow Mode
While the simulation solves in both these modes, there are no significant results to present from these modes.

Dynamics Mode
Scenario 1: Motor Trip with Cold Recycle Anti-surge Valve
Run the Motor Trip with Cold Recycle Scenario and observe the following results:

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Scenario 2: Blocked Outlet with Cold Recycle Anti-surge Valve

Run the Blocked Outlet with Cold Recycle Scenario observe the following results:

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Scenario 3: Motor Trip with Hot Recycle Anti-surge Valve

Run the Motor Trip with Hot Recycle Scenario and observe the following results:

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Scenario 4: Blocked Outlet with Hot Recycle Anti-surge Valve

Run the Blocked Outlet with Hot Recycle Scenario and observe the following results:

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Comparison of Maximum Outlet Temperatures

The following figures show the comparison of the maximum compressor outlet temperature for the blocked
outlet scenarios for the hot and cold recycle anti-surge valves:

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The maximum temperature for the blocked outlet The maximum temperature for the blocked outlet
Scenario for the cold recycle anti-surge valve is Scenario for the hot recycle anti-surge valve is
122.6°C (395.7 K). 123.4°C (396.6 K).

Snapshots
The simulation includes the following snapshots.

Snapshot Name Description Simulation Mode

Pro 1 Initial Compressor and Anti-surge design with cold Process

recycle
FF 1 Pressure Balanced Solution Fluid Flow

Excel Report
You can find the surge control dynamics response in the GG1 - Dynamic Compressor.xlsx file.

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GG5 - Cryogenic Depressuring

Revision Log
Date Who Change

8 May 2017 DK Initial draft for first release.

11 Sep 2017 DK Modified for SimCentral 2.0.
31 May 2019 AL Modified for SimCentral 3.3 Beta.
15 July 2021 SR Remodeled to use the Process Library for AVEVA Process Simulation 2022.
Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
This example demonstrates how we can use AVEVA Process Simulation for the thermal analysis of flare relief
lines to realistically calculate the mean metal temperatures for pipe walls during relief and avoid unnecessary
metallurgy costs.
According to ASME code, the design of vessels and piping should be based on the mean metal temperature, not
on the temperature of the fluid contacting the metal. The use of very cold or very hot fluid temperatures can
lead to expensive metallurgy choices and unrealistic mechanical design requirements for equipment and can
complicate the piping stress design. In many cases, such as this cryogenic depressuring simulation, the mean
metal temperature is substantially less severe than the fluid temperature and we can avoid expensive metallurgy
and design choices.
The following figure illustrates the refinery steam balance as constructed in AVEVA Process Simulation.

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The objective of this simulation is to calculate the temperature profile along the length of the pipe as a function
of time to facilitate the metallurgy selection for a long cryogenic flare relief pipe.

Process Description
In this system, the process, which we represent by two drums (V1 and V2), is depressurized through a valve, XV5,
in an emergency situation. Due to the high initial pressure, the fluid temperature becomes very cold while
depressurizing and is further reduced due to a Joule-Thomson expansion across XV5. As a result, the metal
temperature of the pipe wall cools due to heat transfer with the cold fluid. Since there is a finite holdup in the
drums, the pipe does not reach a steady-state solution and the flow diminishes as the inventory in the drums
depletes. We must determine which sections of the pipe require stainless steel and which sections can use
carbon steel, with the use of carbon steel resulting in a significant cost savings.
The following tables show the gas source conditions, process conditions and equipment sizes.
Stream Composition

Component Mole %

Methane 43.2

Ethane 43.2

Propane 13.1

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Component Mole %

Butane 5
Process Conditions

Type Name Condition Value UOM

Source SRC1 Flow 95,627 kg/h

Source SRC1 Temperature 25.85 °C

Source SRC1 Pressure 6,500 kPa

Drum V1 Pressure 6,458 kPa

Drum V2 Pressure 6,034 kPa

Equipment Sizes

Type Name Size Value UOM

Drum V1 Volume 96 m3
Drum V2 Volume 96 m3
Valve XV1 Cv 500

Valve XV4 Cv 500

Valve XV5 Cv 100

Pipe PIR1 Total Length 625 m

Pipe PIR1 Diameter 20 in

Simulation Model
Library
This simulation uses the Process Library.

Fluids
This simulation uses a custom fluid named GG5fluid, which we designed as a VLE compositional fluid and
modeled with the Soave-Redlich-Kwong (SRK) equation of state.

Mode Summary
The following table summarizes the different simulation modes.

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Mode Process Fluid Flow Dynamics

Purpose Perform a heat and Not applicable. Dynamically calculate the

material balance to drum pressures, the drum
initialize the dynamic temperatures, and the
simulation. wall temperatures of the
metal pipes.

Drums Calculate the vapor-liquid Not applicable. Isentropically

separation if any. depressurize the drums
to calculate the pressure
and temperatures.

Valve XV5 Has no impact. The valve Not applicable. Calculate the flow
is closed. assuming choked flow
from the valve Cv.

PipeRig Calculate the initial wall Not applicable. Calculate the dynamic
temperature based on wall temperature of the
heat transfer to the air. metal pipe from the heat
transfer from the fluid
and to the air.

Header SP1 Has no impact. Not applicable. Calculate the pressure

due to the fluid
accumulation.

Process Mode
The purpose of Process mode is to initialize the system at normal operating conditions prior to the
depressurization. The feed valve, XV1, and product valve, XV4, are open. The depressurizing valve, XV5, is closed.
There is no flow in the relief pipe, so the wall temperature of the metal pipe equilibrates with the ambient air
temperature.

Dynamics Mode
During Dynamics mode, the inlet and outlet valves, XV1 and XV4, close and the drums are isentropically
depressurized through valve XV5 to calculate the fluid temperature. To accurately calculate the metal
temperatures across the length of the pipe, we use a rigorous pipe with the PipeInAir heat transfer method that
calculates the heat transfer from the fluid to the pipe wall and from the pipe wall to the ambient air.
The rigorous pipe calculates the temperature along the length of the pipe. This 20-inch pipe has 5 segments of
equal length. We model the pressure drop through the entire pipe by using the length of each pipe segment to
calculate the correct fluid pressure.
We set the following conditions for the rigorous pipe:
• It calculates the heat transfer from the fluid to the pipe wall.
• It uses the PipeInAir setting to calculate the heat transfer from the pipe metal to the ambient air.

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• It uses the Beggs and Brill Moody High Velocity (BBMHV) calculations.
• It uses average conditions of pressure and temperature for each segment.
• The total length of the pipe is 625 m.
We automate the depressurization of the drums by using a Scenario, as shown in the following figure. In this
Scenario, after one minute, we isolate the two drums by closing the feed valve XV1 and the product valve XV4
while opening the vent valve XV5 to the relief pipe. The simulation then runs until it reaches 20 minutes.

Results
Dynamics Mode
The following figure shows the depressurized drums after the vent valve opens. The drums are depressurized
from 6,500 kPa to 850 kPa in 20 minutes. The maximum relief flow is approximately 120,000 kg/h.

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The following figure shows the temperature profile in the pipe during the depressurization process.

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The fluid enters the pipe at less than 50°C but then rises again as backpressure builds in the pipe. Note that the
fluid is below -50°C at time 0, before the valve opens. We calculate this temperature from the adiabatic
expansion of the fluid through the valve XV5, which is upstream of the pipe. At time 0, there is no flow, but we
still get a calculated temperature from the pressure difference. The metal wall is at ambient temperature, as
expected.
Each pipe segment gradually cools down. The pipe metal wall and the fluid inside it are initially at ambient
temperature. The segment closest to valve XV5 cools down first, as shown by the darkest blue line. The
temperature of the last segment (the lightest blue line) slightly increases at first because of the compression of
the gas inside the pipe. As we establish flow, the temperature of the metal starts to decrease.
We can see that only the first and second pipe segments cool down to less than -29°C, the temperature at which
stainless steel piping may be required. However, all other pipe segments remain above -29°C, meaning that we
can make a substantial portion of the pipe (~400 m) by using carbon steel for a significant cost savings.

Snapshots
The simulation includes the following snapshots.

Excel Report
The results for this simulation are summarized in the GG5 - Cryogenic Depressuring.xlsx file.

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H1 - Water Hammer

Revision Log
Date Who Change

2 Feb 2016 DK Initial release for SimCentral 1.4.

26 Mar 2018 AL Added profile information for the pipe segments to the Dynamics results.
Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
Water hammer, also known as pressure surge, occurs when a fluid in motion suddenly changes velocity. Typically,
it occurs when a valve closes suddenly at the end of a pipeline. The pressure spikes at the valve and a pressure
wave propagates down the pipe. Sudden pressure surge can cause major problems, including causing a pipe to
fall off of its supports or even pipe damage. The objective of this simulation is to:
• Reproduce water hammer physics by using AVEVA Process Simulation with the Transient Flow library
• Demonstrate how to determine pressure surge due to water hammer after a valve closure.
The following figure illustrates the water hammer system as modeled in AVEVA Process Simulation.

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Process Description
The process consists of the following:
• Water is flowing through a forty-foot, half-inch pipe at steady state conditions, as described in the reference
paper1.
• A valve at the end of the pipe that can suddenly close. The valve has a linear trim.

Simulation Model
We make the following assumptions while constructing the simulation:
• The integration time step (dt) is 1E-5 seconds for the very fast dynamics of this system. You can set the time
step on the Simulation Manager while in the Model Writing role.

• We use the segmented pipe model with 40 alternating pipe and wall elements.
• We model the outlet valve with a first order time constant (Tc) of 0.001 seconds.

Library
This simulation uses the Transient Flow library, which is specifically designed for transient fluid case studies. You
may need to import the Transient Flow library before you import this simulation.

Fluids
The Transient Flow library does not use Fluid Types like the other libraries. Instead, we enter the density,
viscosity, and fluid modules for water in the Source model.

Mode Summary
Process Mode Dynamics Mode

Objective Create an initial steady-state condition Observe the dynamic pressure response
from which to start the dynamic run. upon valve closure.
Source Specify the required flow and pressure. Specify the boundary pressure.
Pipe Calculate the discharge pressure in The flow elements calculate the flow from
each segment from its upstream the pressures in the surrounding wall
pressure and flow. elements. The wall elements calculate the
pressure from the dynamic flow balance,
fluid modulus, and pipe elasticity.

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Process Mode Dynamics Mode

Valve Calculate the outlet pressure. Calculate the flow from the final pipe
segment pressure and valve position.
Sink Calculate the pressure. Specify the pressure boundary.

Process Mode
The purpose of Process mode is to create the initial starting condition. We set the number of Pipe segments to
40.

Fluid Flow Mode

Fluid Flow mode does not provide any additional purpose in this simulation.

Dynamics Mode
The purpose of Dynamics mode is to study the pressure response in the Pipe after we suddenly shut the outlet
valve.
The Close Outlet Valve Scenario programs the outlet valve to shut after 0.005 seconds.

To generate the results

1. Open the Pressure trend.
2. Run the Close Outlet Valve Scenario.

Results

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Process and Fluid Flow Mode

While the simulation solves in both these modes, there are no significant results to be presented from these
modes.

Dynamics Mode
To view the results
1. Open the Pressure trend.
2. Open the Pressure Profile plot.
3. Run the Close Outlet Valve Scenario.
The following figure shows the results in the Pressure trend.

These results show that the pressure response after AVEVA Process Simulation closes the outlet valve very
closely resembles the theoretical and experimentally validated response proposed by Contractor1.
The simulation time step (dt) and the number of segments in the pipe (PIP1.N) are important in the calculation
of the water hammer. These values appear on the flowsheet above the pipe and you change them by directly
modifying the values on the flowsheet.
The following figure shows the results in the Pressure Profile plot. The plot shows the pressure wave as it travels
through the pipe segments. Note that the wave is visible only while the Close Outlet Valve Scenario is running.

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Snapshots
This simulation includes the following snapshots:

Dyn 1 loads the conditions before AVEVA Process Simulation closes the outlet valve. Dyn 2 shows the final
conditions after you run the Close Outlet Valve Scenario. If you want to load the initial steady-state conditions,
switch to Process mode and revert the simulation to Pro 1.

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Excel Report
You can find the pipe summary and exact dynamic response values with respect to time in the H1 – Water
Hammer.xlsx file.

References
1. Contractor, D.N. "The Reflection of Waterhammer Pressure Waves from Minor Losses." 08 August 1964.
Journal of Basic Engineering, Vol 87.

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H2 - Heat Exchanger Tube Rupture

Revision Log
Date Who Change

1 June 2016 SK Initial release for SimCentral 1.5.

Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
Shell and tube heat exchangers often have a wide pressure difference between their fluids. If the MAWP
(maximum allowable working pressure) of the low-pressure side is less than 10/13th of the high-pressure side,
the low-pressure side may exceed its test pressure after a tube rupture.
API Standard 5211 section 4.4.14 recommends transient analysis for heat exchanger tube rupture even if
protected by a relief valve. This type of analysis is recommended in cases where the low-pressure side is liquid-
filled and the high-pressure side contains a gas or a fluid that flashes across the rupture. The pressure spike may
occur very fast, in the order of milliseconds, after the rupture.
Similarly, a tube rupture may over-pressurize adjacent piping as well.
The objectives of this simulation are:
• Estimate pressure spike in the low-pressure side of the exchanger.
• Estimate the pressure spike in the adjacent piping.
• Determine the effectiveness of a relief valve which must open in response to the pressure spike.
The following figure illustrates the tube rupture simulation as modeled in AVEVA Process Simulation.

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Process Description
This example reproduces the published case of the reference case by Sumaria2. The process consists of the
following:
• Cooling water on the tube side cools the methanator effluent gas on the shell side.
• The low-pressure side of the heat exchanger has two passes with half-circle shaped inlet channels and a full
circle shaped return channel.
• The relief valve is on the inlet channel. The relief valve size has an area of 7135 mm2 (11.06 in2) and the
mass of its moving parts is 50.8 kg (112 lb).
• We assume a 298.5 mm ID (11.75 in) cooling water header supplies the cooling water. It connects to the heat
exchanger through 154 mm ID (6.065 in) laterals. The cooling water returns to a return header in a similar
way through 154 mm ID (6.065 in) lateral and back into the 298.5 mm ID (11.75 in) cooling water return
header.
• A single tube ruptures at the heat exchanger tubesheet, thus immediately introducing gas to the front
channel.

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Simulation Model
We make the following assumptions while constructing the simulation:
• The integration time step (dt) is 1E-4 seconds for the very fast dynamics of this system. You can set the time
step on the Simulation Manager while in the Model Writing role.

• Heat transfer is negligible for the short duration of the transients of interest.
• The tube ruptures instantly as a conservative assumption.
• The high-pressure fluid only flows into the outlet channel. High-pressure fluid would also flow into the
opposite return channel. However, since the reference paper2 assumes that this does not occur, we do not
introduce a second flow of rupture material into the return channel.
• The entire low-pressure section (cooling water side) splits into control volumes in the following sequence:
a. Supply header
b. Inlet piping
c. Inlet channel
d. First tube pass bundle
e. Middle channel
f. Second tube pass bundle
g. Outlet channel
h. Outlet piping
i. Return header
• Each individual control volume is a combination of a PipeFlow and PipeWall model. The PipeFlow helps to
calculate the inertia of the low-pressure fluid and the PipeWall model helps to calculate the pressure based
on flow, fluid bulk modulus, and elasticity.
• We assume pressure is uniform throughout each pipe wall, which includes the pipe wall where the tube
high-pressure fluid enters.
• The equivalent length of each tube bundle pass is based on the total cross sectional area of all of the tubes,
and the pressure drop provided from the exchanger data sheet.

Library
This simulation uses the Transient Flow library, which is specifically designed for transient fluid case studies. You
need to import the Transient Flow library before you import this simulation.

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Fluids
This simulation uses two fluids:
• HPFluid is a compositional fluid that we use for the methanator effluent gas. It contains methane and
hydrogen.
• The low-pressure side does not use Fluid Types like the other libraries. Instead, we enter the density,
viscosity, and fluid bulk modulus for water in the Supply model.

UOM Slate
This simulation uses a simulation-specific UOM slate, UOM from Reference Paper. This ensures uniformity of
data input and results with the reference paper2.

Mode Summary
Process Mode Dynamics Mode

Objective Create an initial steady-state condition Observe the dynamic pressure response
from which to start the dynamic run. upon tube rupture.
Calculate the equivalent lengths of all
of the piping sections based on a
known steady-state pressure profile.
Source Specify the flow and pressure. Specify the boundary pressure.
PipeFlow Specify the flow and pressure drop of Calculate the flow acceleration from the
each pipe. Calculate the equivalent pressures in the surrounding wall elements
length. and the inertia of the low-pressure fluid.
PipeFlows also represent the tube
bundle pass.
PipeWall Mix or split the low-pressure fluid Calculate the pressure from the dynamic
flows. flow balance, fluid modulus, and pipe
elasticity.
Channel No action. Same as a pipe wall. The channel which
receives the high-pressure fluids calculates
the pressure based on a volume balance of
the low-pressure and high-pressure fluids.
Tube No action. Calculate the flow of high-pressure fluid
based on critical flow conditions.
Relief Valve Update the set pressure and mass of Calculate the acceleration of the disk based
the moving parts. on a force balance.
Calculate the flow based on the inlet
pressure and position of the relief valve
disk.

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Process Mode Dynamics Mode

Sink Calculate the pressure. Specify the pressure boundary.

Process Mode
The purpose of Process mode is to specify the initial pressure profile of the system. You can do this in two ways:
• Calculate the equivalent length of each section of pipe and enter the data. We entered equivalent lengths
from the reference paper2.
• If the pressure profile is known from another source, specify the pressure profile throughout the system and
allow the PipeFlow models to calculate the equivalent length. This approach is very useful for the tube
bundle.
In this example, we use the first approach for the pipes, because the reference paper provided equivalent
lengths. We use the second approach for the tube bundle, because the reference paper provided the heat
exchanger pressure drop.

Fluid Flow Mode

Fluid Flow mode does not provide any additional purpose in this simulation.

Dynamics Mode
The purpose of Dynamics mode is to study the pressure response in the entire low-pressure section after we
suddenly introduce tube rupture in Tube1.
The Rupture Scenario programs the Tube1 to rupture after 0.05 seconds.

To generate the results

1. Open the Figure 5, Figure 6, Figure 7, and Figure 8 trends.
2. Run the Rupture Scenario.

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Results
Process and Fluid Flow Mode
There are no significant results to present.

Dynamics Mode
To view the results, open the Figure 5, Figure 6, Figure 7, and Figure 8 trends. Note that the figures have the
same figure numbers as the reference paper2 for easy comparison. The following figures show the results.

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These results show that the pressure response shown in AVEVA Process Simulation very closely resembles the
theoretical response proposed in the reference paper2.

Snapshots
This simulation includes the following snapshots:

Time Zero loads the conditions before the Rupture scenario. If you want to load the initial steady-state
conditions, switch to Process mode and revert the simulation to Pro 1.

Excel Report
You can find the pipe summary and dynamic response values with respect to time in the H2 – Heat Exchanger
Tube Rupture.xlsx file.

References
1. American Petroleum Institute, API Recommended Practice 521, "Pressure-relieving and Depressuring
Systems", 6th Edition, 2014.

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2. Sumaria, V.H, J.A. Rovnak, I. Heitner and R.J. Herbert, "Model to predict transient consequences of a heat
exchanger tube rupture," Proceedings – Refining Department, Vol. 55, American Petroleum Institute,
Washington, D.C., 1976, p. 631.

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RR1 - Vacuum Transfer Line

Revision Log
Date Who Change

18 Feb 2016 DK Initial release for SimCentral 1.4.

26 Mar 2018 AL Added profile information for the pipe segments to the Fluid Flow results.
Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
Vacuum transfer lines (VTL) route atmospheric column bottoms from the vacuum charge heater to the vacuum
column. VTLs are generally very large in diameter, have a low pressure drop, and are constructed of costly
materials to withstand severe operating conditions of high temperature, erosion from high velocity, and
experience a large thermal expansion load. Hydraulic calculations for VTLs are generally very tedious and involve
critical flashing flow. Hence, the use of conventional two-phase flow software is limited due to the continuous
change in vapor-liquid ratios and the fluid properties through the length of the line.
SimSci has developed a specialized simulation in AVEVA Process Simulation to simulate a vacuum transfer line to
avoid tedious iterative calculation techniques. AVEVA Process Simulation uses its VLE thermodynamics to
generate vapor and liquid ratios and fluid properties. It calculates the two-phase pressure drop using the Beggs
and Brill two-phase flow pressure drop method with SimSci’s modification for high velocity flow (BBMHV).
The objective of this simulation is to:
• Design a vacuum transfer line from the vacuum charge heater discharge to the vacuum column flash zone
that meets process engineering design requirements.
• Generate pressure and velocity profiles by using the AVEVA Process Simulation Excel add-in.
The simulation includes:
• Segmented pipes (TPPipe) that calculate the two-phase pressure drop in each pipe segment. Each pipe
segment:
• Calculates a two-phase friction factor based on the Beggs and Brill Moody High Velocity algorithm
(BBMHV), which applies an acceleration pressure drop term.

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• Calculates the two-phase critical velocity by using the method from Hewit and Semeria. If the flow is
critical, AVEVA Process Simulation calculates the critical pressure discontinuity in the final pipe segment.
• Pipe enlargers that calculate the pressure recovery due to fluid acceleration.
The following figure illustrates the VTL system as modeled in AVEVA Process Simulation.

Process Description
The process consists of the following:
• Piping from each pass outlet in the vacuum charge heater to the vacuum transfer line.
• The vacuum transfer line that feeds into the vacuum column flash zone.
• Pipe enlargers that periodically increase the diameter of the vacuum transfer line to limit the approach to
critical flow.
The following table outlines the design requirements for the vacuum transfer line:

Specification Variable Value (SI) Value (US Comments

Refining)

Total Flow W 97500 kg/hr 214,950 lb/hr

Flash Zone 35 mmHg 35 mmHg
Operating
pressure

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Specification Variable Value (SI) Value (US Comments

Refining)

Maximum 85% 85% Avoid critical velocity at any

approach to location in the vacuum transfer
critical velocity line. High velocity results in liquid
entrainment.
Distance from 152.4 m 500 ft
fired heater to
vacuum column.
Charge heater 404°C 760°F Avoid high temperature to prevent
maximum outlet cracking and coke formation.
temperature
Vacuum column 395°C 735°F
inlet
temperature

Simulation Model
Library
This simulation uses the Process library.

Fluids
This simulation uses the Vacuum Feed fluid from the simulation-specific library. This fluid contains several petro
components.

Mode Summary
The following table provides a summary of how the equipment models behave in Process and Fluid Flow mode.

Process Fluid Flow

Purpose Initially size the vacuum transfer line by Rate the vacuum transfer line for a given
determining the required diameter for piping design with a specified size and
each pipe as you construct the simulation length and modify the design as needed.
in the direction of flow.
Source Specify required flow. Specify required flow.
Specify pressure. Calculate pressure.
Pipe Calculate pipe diameter given a specified Set inside diameter based on nominal
pressure drop. pipe size.
Sets the Size parameter accordingly. Calculate pressure drop and velocity.

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Process Fluid Flow

Mix Set pressure to the minimum inlet Set all inlet and outlet pressures to be the
pressure. same.
Enlarger Calculate pressure drop recovery based Calculate pressure drop recovery based
on inlet and outlet diameter. on inlet and outlet diameter.
Sink Calculate pressure in the vacuum column Specify pressure in the vacuum column
flash zone from upstream pipes. flash zone.

Process Mode
The purpose of Process Mode is to set an initial transfer line configuration and provide an initial set of solution
values for the transition to Fluid Flow mode. We configure the pipe sizes in Process mode in the direction of flow.
We build the simulation by doing the following:
1. Specify the flow and estimate the starting pressure in the source models.
2. Add a pipe model, starting with HP1. Set an appropriate number of pipe segments (for example, 10). Specify
the pipe length. Specify the pipe pressure drop so that the outlet approach to critical velocity (Mach) in the
last pipe segment is around 80%. Set the pipe Size parameter such that D_margin is positive.
3. Repeat step 2 until you reach the vacuum column while adding mixers and pipe enlargers as necessary. Add a
sink to represent the vacuum tower.
4. If the pressure at the vacuum column is not close to the design requirement (35 mmHg), modify the source
pressure and the DP in each pipe until the pressure profile is close to the design requirements.
5. Take a Snapshot
It is not necessary to obtain a perfect solution in Process mode. The Process mode solution only needs to be
close enough to the design requirements so that simulation successfully solves when you transition to Fluid Flow
mode.
After going to Fluid Flow mode, you may find that you need to add more pipe enlargers to avoid critical flow. If
this is the case, return to Process mode to add the enlargers and provide a new initial estimate.

Fluid Flow Mode

The purpose of Fluid Flow mode is to rate the system as configured in Process mode. You can adjust the pipe
sizes and lengths as required to satisfy the design requirements in the table in Process Description. Specifically,
make sure that the velocity in any of the pipes does not exceed the critical velocity. We configure the pipe sizes
in Fluid Flow mode in the backwards direction, opposite of flow. We configure the pipe sizes by doing the
following:
1. Specify the pressure in the Sink, which represents the pressure in the vacuum column flash zone.
2. Set the Size of VTL3 to achieve the required velocity. If the diameter is too small, the velocity will be too high
entering the column. If the diameter is too big, you will have high velocity in the upstream pipe VLT2.
3. Set the Size of VTL2 to achieve the required velocity in the last segment. You can also redistribute the length
of VLT3 (by changing the location of the Enlarger) to change the back pressure, which will change its velocity.
4. Repeat step 3 until all of the pipes are close to the target velocity.

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We have sized the pipes to ensure that the velocity in the pipes does not approach the critical velocity. If it is not
possible to achieve the desired velocity profile, then you may need to return to Process mode to add another
enlarger and redistribute the pipe lengths for each section of constant diameter pipe.

Dynamics Mode
This simulation can solve in Dynamics mode. However, we currently do not include any dynamic studies in this
document.

Results
Process Mode
The purpose of Process mode is to develop preliminary equipment sizing and to provide an initial estimate for
Fluid Flow mode. Since we do not intend to use the results from Process mode to validate the final vacuum
transfer line design, we do not present any results.

Fluid Flow Mode

The following table shows the final design of the vacuum transfer line.

Inside Diameter Length Elevation Change

Number of
Pipe
Segments
mm in m ft m ft

HP1 5 428.65 16.876 3.048 10 0 0

HP2 5 381.00 15.000 3.048 10 0 0
VP1 5 428.65 16.876 9.144 30 9.144 30
VTL1 10 742.95 29.250 30.48 100 0 0
VTL2 10 844.55 33.250 53.34 175 0 0
VTL3 10 996.95 39.250 54.86 180 0 0
The following table displays the pressure and velocity profile from FF 1 snapshot when you set the column
pressure to 35 mmHg. Observe that because all three pipes are incrementally getting larger, we do not achieve
critical velocity in any section of pipe.

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Segment Length

Outlet Pressure
Inlet Pressure

Fluid Velocity

Critical Flow
DP (mmHg)
Cumulative
Length (m)

Approach
(faction)
Pipe Segment

(mmHg)

(mmHg)

(m/s)
(m)
1 3.98 3.98 94.61 92.36 2.26 59.28 0.55
2 3.78 7.75 92.36 90.10 2.26 60.90 0.56
3 3.57 11.32 90.10 87.85 2.26 62.60 0.58
4 3.36 14.69 87.85 85.59 2.26 64.40 0.59
5 3.16 17.85 85.59 83.33 2.26 66.29 0.61
VTL1
6 2.95 20.80 83.33 81.08 2.26 68.30 0.63

7 2.74 23.54 81.08 78.82 2.26 70.42 0.64

8 2.53 26.06 78.82 76.57 2.26 72.66 0.66
9 2.32 28.38 76.57 74.31 2.26 75.05 0.69
10 2.10 30.48 74.31 72.06 2.26 77.59 0.71
1 8.41 38.89 54.13 78.42 75.41 3.01 57.26
2 7.75 46.64 61.88 75.41 72.40 3.01 59.83
3 7.08 53.72 68.96 72.40 69.39 3.01 62.63
4 6.40 60.12 75.36 69.39 66.39 3.01 65.68
5 5.72 65.84 81.08 66.39 63.38 3.01 69.04
VTL2
6 5.03 70.86 86.10 63.38 60.37 3.01 72.73
7 4.33 75.19 90.43 60.37 57.36 3.01 76.82
8 3.61 78.80 94.04 57.36 54.35 3.01 81.37
9 2.88 81.68 96.92 54.35 51.34 3.01 86.46
10 2.14 83.82 99.06 51.34 48.34 3.01 92.20

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Segment Length

Outlet Pressure
Inlet Pressure

Fluid Velocity

Critical Flow
DP (mmHg)
Cumulative
Length (m)

Approach
(faction)
Pipe Segment

(mmHg)

(mmHg)

(m/s)
(m)
1 8.55 92.37 107.61 55.11 53.10 2.01 60.01
2 7.89 100.26 115.50 53.10 51.09 2.01 62.53
3 7.22 107.48 122.72 51.09 49.08 2.01 65.26
4 6.55 114.03 129.27 49.08 47.07 2.01 68.23
5 5.87 119.90 135.14 47.07 45.06 2.01 71.46
VTL3
6 5.18 125.08 140.32 45.06 43.04 2.01 75.00
7 4.48 129.57 144.81 43.04 41.03 2.01 78.90
8 3.77 133.34 148.58 41.03 39.02 2.01 83.20
9 3.04 136.38 151.62 39.02 37.01 2.01 87.97
10 2.30 138.68 153.92 37.01 35.00 2.01 93.31
The following figure displays the pressure profile through the VTL pipe to the vacuum column. Since there are
enlargers between the three VTL pipes, you can see pressure recovery between each pipe.

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The following figure displays the fluid velocity as a function of approach to critical flow (Mach number) through
the VTL pipes.

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To demonstrate the impact of proper pipe sizing, the following table displays the pressure profile when VTL3 is
undersized from 40 in to 36 in. Observe that we achieve critical velocity at the end of VTL3 and you can observer
a pressure discontinuity at the entrance to the vacuum column flash zone.

Segment Length

Outlet Pressure
Inlet Pressure

Fluid Velocity

Critical Flow
DP (mmHg)
Cumulative
Length (m)

Approach
(faction)
Pipe Segment

(mmHg)

(mmHg)

(m/s)
(m)
1 10.62 94.44 78.71 74.87 3.85 57.65 0.53
2 9.53 103.96 74.87 71.02 3.85 61.02 0.56
3 8.42 112.38 71.02 67.17 3.85 64.79 0.59
4 7.31 119.69 67.17 63.33 3.85 69.03 0.63
5 6.18 125.87 63.33 59.48 3.85 73.82 0.67
VTL3
6 5.02 130.89 59.48 55.64 3.85 79.29 0.72
7 3.84 134.73 55.64 51.79 3.85 85.59 0.77
8 2.61 137.34 51.79 47.95 3.85 92.91 0.84
9 1.34 138.68 47.95 44.10 3.85 101.53 0.91
10 0.01 138.68 44.10 40.26 3.85 111.82 1.00
The Pressure and Velocity Profile plot shows the outlet pressure and velocity by segment for all three pipes.
Because we define different lengths and equal pressure drops for the pipe segments, the segment-wise plot is
different than the length-wise plots presented in the preceding figures.

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Snapshots
The following snapshots are available.

Snapshot Description

Pro 1 Stores the initial sizing of the pipes that we estimated based on the design
requirements.
FF 1 Sets the pressure in the vacuum column and sizes pipes accordingly

Excel Report
You can find an Excel report with the Process and Fluid Flow mode results from the different snapshots in the
RR1 – Vacuum Transfer Line.xlsx file.

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SS1 - Renewable Energy Grid

Review Log
Date By Comments

14 Sep 2021 SW Initial issue.

Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
This example simulation demonstrates a small renewable energy grid. Two wind farms and three solar farms
supply power to the grid. The Process mode simulation represents the power output at average conditions. The
simulation includes an additional scenario that uses 15-minute wind and solar resource data to calculate the
total power output throughout the day. For simplification, we assume that the Production facility requires a
constant 0.8 MW of power. We sell the remaining power to other local facilities (LocalGrid).
The following figure shows the renewable energy grid modeled in AVEVA Process Simulation.

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Figure 1: A Small Renewable Energy Grid in AVEVA Process Simulation

Process Description
The process includes two wind farms (WF1 and WF2) and three solar farms (SF1, SF2, and SF3).
We include Breakers on each output electrical stream for safety and the ability to isolate any part of the
renewable energy grid.
We use an Inverter for each solar farm to convert the direct current (DC) to alternating current (AC). We then
combine the power output from each solar farm by using a Busbar (B2).
We add a Transformer and Cable to the output electrical streams for each wind farm and for the B2 Busbar.
These Transformers allow us to step up the voltage in the lines to 33 kV. The Cables allow us to account for
transmission losses through the electrical streams.
We then use the B3 Busbar to combine the power outputs from the wind and solar farms, which we then send
across a long-distance transmission line to the B4 Busbar for distribution between the Production consumer and
the LocalGrid consumer. We model the long-distance connection with a Transformer to step up the voltage to
220 kV, a Cable to account for the transmission losses, and another Transformer to step down the voltage back to
33 kV.
The Production consumer requires 0.8 MW of power. We add a Transformer just before the Production consumer
to step down the voltage to 480 V, a more manageable voltage for the process equipment.
The following tables summarize the equipment sizes and process conditions. The tables show only the values
that differ from default values in the equipment configuration.
Table 1: Equipment Sizes

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Variable Description Value UOM

Wind Farms
WF1.Nturbines The number of wind turbines in the first wind farm. 2 -
WF1.Prat The rated power of each wind turbine in the first wind farm. 2.5 MW
WF1.Vel_rat The wind velocity at the rated power for the wind turbines in 13 m/s
the first wind farm.
WF1.Lblade The blade length for each wind turbine in the first wind farm. 50 m
WF2.Nturbines The number of wind turbines in the second wind farm. 3 -
WF2.Prat The rated power of each wind turbine in the second wind 1.5 MW
farm.
WF2.Lblade The blade length for each wind turbine in the second wind 38.5 m
farm.
Solar Farms
SF1.NPanels The number of solar panels in the first solar farm. 8000 -
SF1.A The surface area of each solar panel in the first solar farm. 2.83 m2
SF1.eta The panel module efficiency from the manufacturer for the 0.212 fraction
solar panels in the first solar farm.
SF1.V The output voltage for the first solar farm. 32 V
SF1.Lshade The losses due to shading of the solar panels. 0.01 fraction
SF2.NPanels The number of solar panels in the second solar farm. 5500 -
SF2.A The surface area of each solar panel in the second solar farm. 2.83 m2
SF2.eta The panel module efficiency from the manufacturer for the 0.212 fraction
solar panels in the second solar farm.
SF2.V The output voltage for the second solar farm. 32 V
SF2.Lsoil The losses due to dirt and dust on the solar panels. 0.01 fraction
SF2.Lshade The losses due to shading of the solar panels. 0.04 fraction
SF3.NPanels The number of solar panels in the third solar farm. 2400 -
SF3.A The surface area of each solar panel in the third solar farm. 2.83 m2
SF3.eta The panel module efficiency from the manufacturer for the 0.19 fraction
solar panels in the third solar farm.
SF3.V The output voltage for the third solar farm. 32 V
Busbars

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Variable Description Value UOM

B2.Ltotal The total loss fraction of the B2 Busbar. 0.005 fraction

B3.Ltotal The total loss fraction of the B3 Busbar. 0.01 fraction
B4.Ltotal The total loss fraction of the B4 Busbar. 0.01 fraction
Transformers
T1.Vout The output voltage of the T1 Transformer. 33 kV
T2.Vout The output voltage of the T2 Transformer. 33 kV
T3.Vout The output voltage of the T3 Transformer. 33 kV
T4.Vout The output voltage of the T4 Transformer. 220 kV
T5.Vout The output voltage of the T5 Transformer. 33 kV
T6.Vout The output voltage of the T6 Transformer. 480 V
Cables
C1.Ltotal The transmission losses of the C1 Cable. 0.01 fraction
C2.Ltotal The transmission losses of the C2 Cable. 0.01 fraction
C3.Ltotal The transmission losses of the C3 Cable. 0.01 fraction
LongRngTrans.Ltotal The transmission losses of the LongRngTrans Cable. 0.02 fraction
C4.Ltotal The transmission losses of the C4 Cable. 0.01 fraction

Table 2: Process Conditions

Variable Description Value UOM

WF1.Vel* The wind velocity for the first wind farm. 12 m/s
WF2.Vel* The wind velocity for the second wind farm. 6 m/s
SF1.H* The solar irradiance per unit area for the first solar farm. 900 W/m2
SF1.Tc The temperature of the photovoltaic cells in the first solar farm. 301 K
SF2.H* The solar irradiance per unit area for the second solar farm. 900 W/m2
SF2.Tc The temperature of the photovoltaic cells in the first solar farm. 300 K
SF3.H* The solar irradiance per unit area for the third solar farm. 900 W/m2
SF3.Tc The temperature of the photovoltaic cells in the first solar farm. 302 K
* In Dynamics mode, these values come from the Curves in the simulation-specific Model Library.

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Simulation Model
Libraries
This simulation uses models from the custom Renewables Library. You can import this Model Library from the
%userprofile%\My Libraries\Examples folder.

Fluids
This simulation uses no Fluids. The connectors on the Canvas transport electricity instead of fluid material.

Curves
This simulation includes the following curves:
• WF1Trend – Provides wind velocity data for WF1 over a 24-hour period at 15-minute intervals.
• WF2Trend – Provides wind velocity data for WF2 over a 24-hour period at 15-minute intervals.
• SolarTrend – Provides solar irradiance data for SF1, SF2, and SF3 over a 24-hour period at 15-minute
intervals.
The simulation uses these trends to simulate wind velocity and solar irradiance data to determine the total
power generated daily by the wind and solar farms.
We obtained the wind resource data and solar radiation data from the Wind Integration National Dataset (WIND)
and the National Solar Radiation Database (NSRD) published by the National Renewable Energy Laboratory
(NREL).

Mode Summary
This example uses Process mode to meet the design requirements. The objective of this mode is to provide a
conceptual design that we can use to refine further process development.
This example then uses Dynamics mode to determine how much power generation we can reasonably expect
per day from the renewable energy grid we have designed.

Process Mode
The objective of Process mode is to estimate the power output for the process. We switch the following process
specifications to meet the design requirements:
• We specify the output voltage for all the transformers by calculating the transformer turns ratio.
• We specify the power consumption of the Production consumer by calculating the output split ratio of the
B4 Busbar.

Dynamics Mode
The purpose of Dynamics mode is to determine the typical daily power generation of the renewable energy grid.
In Dynamics mode, we return the N value and the Vout value in each Transformer to their default specification
status and set the N value to the value we calculated in Process mode. Therefore, we switch only the following
process specification to meet the design requirements:

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• We specify the power consumption of the Production consumer by calculating the output split ratio of the
the B4 Busbar.

Scenarios
This simulation includes only the Daily Renewable Trends scenario. This scenario runs the renewable energy grid
for 24 hours, but disconnects the SF2 solar farm from the grid for five hours. Make sure you are in Dynamics
mode before you run this scenario.

Results
The following figures show the hourly power output from the wind farms and the solar farms over a 24-hour
period. They match what we expect to see from the wind velocity data and solar irradiance data that we
provided in the WF1Trend, WF2Trend, and SolarTrend Curves from the simulation-specific Model Library.

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Figure 2: The Hourly Power Output from the Wind Farms

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Figure 3: The Hourly Power Output from the Solar Farms

The following figure shows the hourly power input to the LocalGrid consumer. The power input never
approaches zero. Therefore, we can assume that the typical daily power output from our renewable energy grid
will always produce enough power to keep our production process running. In addition, it produces an excess
utility power that we can sell to increase the profitability of our production process and mitigate the costs we
incurred when we installed our renewable energy grid.

Figure 4: The Hourly Power Input to the Local Grid from the Renewable Energy Gird

Snapshots
This simulation includes the following snapshots:

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U1 - Cooling Water

Revision Log
Date Who Change

23 Feb 2016 DHJ Initial release for SimCentral 1.4.

21 Dec 2016 CAD Updated for next larger pipe size.
Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
Cooling water networks supply cooling water to heat exchangers in a plant. In this example, we use a small
simulation to demonstrate key features of a cooling water network.
The objective of this simulation is to:
• Size pipes for a desired cooling water flow requirement.
• Calculate the actual flow distribution for actual pipe diameters.
Please refer to the AVEVA Process Simulation Getting Started Guide for detailed instructions on how to build this
simulation.
The following figure shows the schematic diagram of the cooling water system, as modeled in AVEVA Process
Simulation.

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Process Description
The following table summarizes the design assumptions and information for the simulation:

Model Variable Description Value (SI) Value (US

Refining)

All pipes Vel Pipe sizing velocity 4 m/s 12 ft/s

All pipes L Pipe actual length 10 m 50 ft
HX1 W Mass flow 100,000 kg/hr 210,000 lb/hr
HX1 DP Pressure drop at reference flow 110 kPa 17.4 psi
HX2 W Mass flow 50,000 kg/hr 120,000 lb/hr
HX2 W Pressure drop at reference flow 100 kPa 14.5 psi

Simulation Model
Library
This simulation uses the CWLib library.

Fluids
This simulation uses the CoolingWater fluid as a simple incompressible fluid.

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Mode Summary
The following table provides a summary of the simulation operation in all three modes:

Process Fluid Flow Dynamic

Purpose Size pipes for required Determine the actual Not used.
flow rates. Check flow rate distribution
exchanger outlet though the network.
temperatures.
Pump Operates at estimated Operates on its
pressure rise. performance curve.
Pipes Calculate diameters to Set inside diameters
check nominal pipe size based on nominal pipe
requirements. size.
Mixer Set pressure to the Operate at a pressure
minimum of inlet balanced state. All inlet
pressures. and outlet pressures are
the same.
Heat Exchangers Specify the required Calculate actual flow
flow. Check the outlet based on reference
temperature. conditions.

Process Mode
The purpose of Process mode is to size the pipes and set the heat exchanger design flow requirement.
• For the each pipe, select the Size parameter so that the diameter margin (D_margin) is positive for each pipe
while maintaining cooling water velocities at 4 m/s (12ft/s).
Alternatively, set the Size parameter to Next Larger NPS so that when you change to Fluid Flow mode, the
selected size will be the next larger size compared to the calculated diameter (D).
• For each heat exchanger, specify the required flow rates. As a result, AVEVA Process Simulation calculates the
overall flow and the split fraction between the two flow paths.

Fluid Flow Mode

The purpose of Fluid Flow mode for this simulation is to show the actual flow distribution based on the selected
pipe diameters and to maintain a pressure balance between the two flow paths. In Fluid Flow mode, the mixer
model provides a pressure balance. The pipe sets the diameter margin to zero and uses the next larger pipe
diameter from the pipe schedule table. AVEVA Process Simulation calculates actual flow through the two paths.

Results

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Process Mode and Fluid Flow Mode

You can use the Snapshot Manager to display the results saved for the different modes. Revert the simulation to
the Pro 1 snapshot to display the results for Process mode. Revert the simulation to the FF 1 snapshot to display
the results for Fluid Flow mode.
The following table provides a comparison of the Process mode target flows and the actual flow distribution in
Fluid Flow mode.

Mode Process Fluid Flow

Snapshot Pro 1 FF 1

UOM kg/h lb/h kg/h lb/h

HX1.W 100,000 220,462 107,373 236,711

HX2.W 50,000 110,231 55,708 122,815

Snapshots
The simulation includes the following snapshots.

Excel Report
You can find a pipe summary table and a heat exchanger summary table in the U1 – Cooling Water.xlsx file.

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U2 - Steam Turbine

Revision Log
Date Who Change

29 Feb 2016 DHJ Initial release for SimCentral 1.4.

Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
The objectives of the steam turbine simulation are to:
• Perform a basic steam balance to calculate steam turbine power at a steam flow rate.
• Design the equipment, which includes determining the Cv of the valves.
• Determine the turbine turndown performance for different feed valve positions.
• Calculate the dynamic response of the simulation after a change in the set point for the pressure controller;
improve the controller tuning constants.

Process Description
The following figure shows the steam turbine power plant. Two feed valves provide steam to a steam header,
which supplies steam to a back pressure steam turbine. A pressure controller on the header operates the steam
turbine governor to maintain a constant header pressure.

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The following table summarizes the design parameters of the plant.

Model Variable Value (SI) Value (US

Refining)

Feed1 T 550 K 990 R

Feed2 T 560 K 1008 R
Feed1 and Feed2 P 5000 kPa 725.2 psi
Feed1 and Feed2 W 30 kg/s 66.1 lb/s
H1 P 4500 kPa 652.7 psi
H1 ResidenceTime 20 s 20 s
XV2 and XV2 ManPos 90% 90%
T1 eta (efficiency) 75% 75%
PC1 OP (PID output) 90% 90%
Product P 2000 kPa 290.1 psi

Simulation Model
Library
This simulation uses the SteamLib and Controls libraries.

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Fluids
This simulation uses the Steam fluid from the SteamLib library based on the IF97 formulation.

Mode Summary
The following table provides a summary of the simulation operation in all three modes:

Process Fluid Flow Dynamic

Purpose Calculate turbine power Calculate turbine power View dynamic responses
production at a given flow production at alternate after the setpoint for the
and inlet pressure. conditions, such as header pressure changes.
partially closed feed valves
Size the control valves. Tune pressure controls for
and different source and
faster response.
sink pressures.
Source Specify flow. Calculate flow. Same as Fluid Flow.
Specify pressure. Specify pressure.
Valves Specify the manual Specify the manual Same as Fluid Flow.
position. position.
Calculate the Cv. Specify the Cv.
Header Specify the operating Calculate the pressure Same as Fluid Flow.
pressure. from the pressure
balance.
Calculate the header
volume.
Turbine Specify the efficiency. Specify the efficiency and Same as Fluid Flow.
expander flow area.
Calculate the flow.
Pressure Specify the pressure Specify the setpoint. Change the setpoint to
Controller controller output to set simulate the dynamic
Calculate the controller
the turbine governor response of the simulation.
output, which sets the
position.
turbine governor position.

Process Mode
The purpose of Process mode is to perform a steam balance to calculate steam turbine power. Process mode
also sizes the Cv for the valves and flow area for the turbine.
Process mode has a residence time to provide an initial estimate for volume, which you must provide in
Dynamics mode.

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Fluid Flow Mode

Fluid Flow mode simulates the performance of the equipment based on the design variables calculated in
Process mode. The simulation contains two snapshots that show performance in a 100% case and in a turndown
case where the feed valves are partially closed.

Dynamics Mode
In Dynamics mode, you can simulate the dynamic response of the turbine when the setpoint for the pressure
controller changes.

Results
Process Mode and Fluid Flow Mode
The following table summarizing the different results for the two Fluid Flow snapshots: the 100% flow case and
the turndown case. You can also find these results in the U2 – Steam Turbine.xlsx file distributed with this
simulation.

Snapshot
Model Variable Units
FF 1 FF 2

Feed1 P kPa 5000 5000

Feed1 W kg/h 108000 73124
Feed2 P kPa 5000 5000
Feed2 W kg/h 108000 71749
XV1 ManPos fraction 0.9 0.6
XV2 ManPos fraction 0.9 0.6
XV1 DP kPa 500 500
XV2 DP kPa 500 500
PC1 SP kPa 4500 4500
PC1 OP fraction 0.90 0.60
H1 P kPa 4500 4500
T1 Power MW 7.257 4.867
T1 DP kPa 2500 2500
Product P kPa 2000 2000
Product W kg/h 216000 144873

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Dynamics Mode
Changing the setpoint pressure (PC1.SP) from 4500 kPa to 4750 kPa and running dynamics demonstrates the
dynamic response of the turbine. Different PID controller tuning parameters can improve the response. The
following figure trends the header pressure change due to a change in set point with the controller (PC1) tuning
parameters from the following table.

Description Var/Par Value Units

Control range high valve PVHi 5000 kPa

Control range low valve PVLo 1000 kPa
Proportional Gain Kp 10
Integral time Ti 20 s
Derivative time Td 0 s

Snapshots
The simulation includes the following snapshots.

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Excel Report
You can find a table that summarizes the different results for the two Fluid Flow snapshots, the 100% flow case
and the turn down case, in the U2 – Steam Turbine.xlsx file.

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U3 - Refinery Steam Distribution

Revision Log
Date Who Change

24 Jan 2016 CAD Initial release for SimCentral 1.4.

Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
Steam distribution systems found in refineries and large petrochemical complexes are complex and highly
integrated systems with multiple pressure levels. The objective of this simulation is to:
• Provide a steam balance to show the steam generation required to satisfy the electrical power demand and
the process steam consumption.
• Size piping to meet steam delivery pressures at the steam consumers.
• Validate the process control strategy by showing how the controls respond in the event of an upset, such as
a trip of a steam turbine.
The following figure illustrates the refinery steam distribution system as modeled in AVEVA Process Simulation.

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Process Description
The process consists of the following:
• Two external, parallel steam generation facilities provide high pressure steam. The steam generation facilities
are not simulated.
• There are three steam levels: high pressure at 4240 kPa (600 psig), medium pressure at 2170 kPa (300 psig),
and low pressure at 1135 kPa (150 psig).
• There are two steam turbines, a back-pressure turbine from high pressure to medium pressure and a
medium pressure condensing turbine.
• The simulation provides steam to consumers at two locations in the refinery, one at the north end and one
at the south end. It provides steam at all three pressure levels in both locations.

Simulation Model
Library
This simulation uses the SteamLib library.

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Fluids
This simulation uses the Steam fluid from the SteamLib library based on the IF97 formulation..

Mode Summary
Mode Supported Purpose

Process Supported Perform steam balances.

Size steam turbines, letdown valves, and piping.
Fluid Flow Supported Determine steam delivery pressures.
Dynamic Supported Study process control behavior.

Process Mode
The purpose of Process mode is to perform a steam balance. Some important aspects include:
• We specify the steam flow at each steam consumer, which we model as Sinks in the simulation. To make this
specification, we calculate the outlet flow ratios (OutRatio) of the Junction models and the total steam
generation.
• We combine the mechanical power for both steam turbines into a single shaft so that you can specify a total
power from both turbines by using the Power_net variable in the shaft if desired.
• We use a desuperheater model (that is, a Desup model) to calculate the boiler feed water required to
maintain 18°C (10°F) of superheat after the high pressure to medium pressure letdown.
• We size the high pressure pipes to provide the required pressure drop. Select a pipe size so that the diameter
margin (D_margin) is positive for each pipe while maintaining steam velocities less than 70 m/s (200 ft/s).
You should perform this step in Process mode before transitioning the simulation to Fluid Flow mode.

Fluid Flow Mode

The purpose of Fluid Flow mode is to show the steam delivery pressure at a required steam flow rate. In Fluid
Flow mode, all of the junctions provide a pressure balance. The pipe models set the margin to zero and use the
actual pipe diameter from the pipe schedule table. We make the following assumptions:
• As in Process mode, we specify the flow at each steam consumer. We calculate the Sink pressure to
determine the steam delivery pressure.

Dynamics Mode
The purpose of Dynamics mode is to study the behavior of the simulation after a steam turbine trip.
• We add pressure controllers to each steam level. These pressure controllers remain in the other modes as
well, but we specify them such that they have no impact on the solution of those modes.
• The STGA Trip Scenario programs a steam turbine trip to occur after 10 seconds.

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Results
Process Mode and Fluid Flow Mode
You can find the system flows, pressures, and temperatures in the U3 – Refinery Steam Distribution.xlsx file
distributed with this simulation.

Dynamics Mode
The objective of Dynamic mode for this simulation is to study the process control system behavior for upset
conditions. To view the results, perform the following steps.
1. Open the HeaderPressures trend.
2. Run the STGA Trip Scenario.

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The Dynamics worksheet in the U3 – Refinery Steam Distribution.xlsx file provides the same results.

These results show that the pressure control system returned the pressure back to the required set points.
However, there was a very high peak in the header pressure for the high pressure line and a low peak in the

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header pressure for the medium pressure line, which may require additional improvements to the control
strategy.

Snapshots
The simulation includes the following snapshots:

Excel Report
You can also find the results of the STGA Trip Scenario in the U3 – Refinery Steam Distribution.xlsx file, on the
Dynamics worksheet.

References
1. SimSci™ DYNSIM® 5.3 Application Briefs. "Refinery Steam System." Schneider Electric Software, LLC:
September 2015.

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U4 - Cooling Water Network

Revision Log
Date Who Change

2 Feb 2016 SK Initial release for SimCentral 1.4.

Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
An existing cooling water network supplies cooling water to sixteen heat exchangers in a chemical plant. After
the heat exchangers, the cooling water network returns the cooling water to a cooling tower at 15 psia.
The objective of this simulation is to:
• Confirm that pipe sizes maintain water velocities between minimum and maximum requirements.
• Determine the required pressure for cooling water pump selection.
• Determine the actual flow rates distribution compared to process requirements
• Determine the total water flow if only one of two available pumps is operating.
The following figure shows the schematic diagram of the Cooling Water Network system, as modeled in AVEVA
Process Simulation.

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Process Description
The cooling tower provides cooling water at 20.5°C (69°F) based on a wet-bulb temperature (WBT) of 23.3°C
(74°F) and a cooling tower approach of 2.8°C (5°F).
The design requirements are:
• The minimum pipe velocity is1m/s (3 ft/s) to avoid deposition of sediments
• The maximum pipe velocity is 3.7 m/s (12 ft/s) to avoid erosion
• The maximum outlet temperature of the heat exchanger cooling water is 45°C (113°F).
• The cooling water pump has not been selected. That is, both pumps are operating.
• The pipe roughness is 0.0046 mm (0.0018 in).
The following table provides a summary of the existing heat exchanger design, which includes the required heat
duty and the pressure drop information. We obtain the reference pressure drop and reference flow from the
heat exchanger data sheets so that we can calculate the actual pressure drops by relating the pressure drop
changes to the square of the flow rate.

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Pressure Drop at
Heat Exchanger Required Duty Reference Flow
Reference Flow

(kW) (MMBtu/hr) (kg/hr) (lb/hr) (kPa) (psi)

E11 927.5 3.165 80430 177318 68.6 9.95

E12 538.5 1.837 46715 102989 68.6 9.95
E14 744.2 2.539 64562 142335 68.6 9.95
E15 462.6 1.578 40135 88482 68.6 9.95
E20 1779.9 6.073 63170 139266 68.6 9.95
E20A 1116.7 3.810 39636 87382 68.6 9.95
E22 1780.7 6.076 63198 139328 68.6 9.95
E22A 1117 3.811 39645 87402 68.6 9.95
E27 3567.6 12.173 126618 279145 68.6 9.95
E28 1930.7 6.588 68525 151072 68.6 9.95
E30 2944.4 10.047 104503 230389 68.6 9.95
E31 1626.1 5.548 57715 127240 68.6 9.95
E4 649.2 2.215 39182 86381 68.6 9.95
E4A 649.2 2.215 39179 86375 68.6 9.95
E6 910.3 3.106 54933 121106 68.6 9.95
E7A 1633.1 5.572 98548 217261 68.6 9.95
Heat exchangers E11, E12, E14, and E15 are in series to E7A, E6, E4, and E4A. Heat exchangers E7A, E6, E4, and
E4A do not need as cold of cooling water. This series configuration reduces the required cooling water compared
to a completely parallel network.

Simulation Model
Library
This simulation uses the CWLib library.

Curves
This simulation uses the default curve for the cooling water pump (CWPumpDefault) since the pump is not
selected yet.

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Fluids
This simulation uses the CoolingWater fluid as an incompressible fluid.

Mode Summary
The following table provides a summary of the simulation operation in all three modes:

Process Fluid Flow Dynamic

Purpose Size pipes for required Determine the actual Not applicable.
flow rates. Check heat flow rate distribution
exchanger outlet though the network.
temperatures.
Pumps Estimate pressure rise. Operate on a
performance curve
Pipes Calculate diameter to Set the Inside diameter
check nominal pipe size based on nominal pipe
requirements. size.
Mixers Use the minimum of Set all inlet and outlet
inlet pressures. pressures the same.
Heat Exchangers Specify required flow for Calculate actual flow
flow balance. Check based on reference
outlet temperature. conditions.

Process Mode
The purpose of Process mode is to estimate the water flows required for the cooling duty in the individual heat
exchangers and to check the pipe sizes. This helps determine an initial solution for the transition to Fluid Flow
mode.
You can model Heat Exchangers by specifying three of the following four variables: heat duty, flow rate, pressure
drop, or outlet temperature. We specify the heat duty, pressure drop, and outlet temperature. AVEVA Process
Simulation calculates the required cooling water flow.
By specifying the heat exchanger duty, pressure drop, and outlet temperature, we develop a flow and heat
balance that we can use to size the pipes. AVEVA Process Simulation automatically assumes that the Process
mode flow rate and pressure drop is the reference flow and pressure drop unless you modify these values.
When we size the pipes, we can specify the maximum velocity as 3 m/s to determine the required diameter.
Engineers need to pay attention to pipe sizes. The D_margin value should be positive in Process mode.
Otherwise, the selected size may be too small.

Fluid Flow Mode

The purpose of Fluid Flow mode for this simulation is to show that the network that we designed in Process
mode meets the cooling water flow requirements. In Fluid Flow mode, AVEVA Process Simulation moves the
entire network to a pressure-balanced solution. We make the following assumptions:

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• The Pumps operate on their performance curves.

• All of the Mixers provide a pressure-balanced solution.
• The Pipes use the actual pipe diameter from the pipe schedule table.
• Pipe flows are not based on process requirements like they were in Process mode. AVEVA Process Simulation
calculates the Pipe flows based on system hydraulics.
To obtain the correct pressure drop through the Heat Exchangers, it is important that the Wref and DPref values
for each Heat Exchanger are correct based on a reference condition for that Heat Exchanger. Usually you obtain
this data from the heat exchanger data sheet.
The change to Fluid Flow mode moves Heat Exchanger flows based on the network pressure balance. The Wref
and DPref variables in Fluid Flow mode take values from the W and DP values in Process mode. Therefore, AVEVA
Process Simulation recalculates the DP value for each individual Heat Exchanger by using the updated pressure-
driven flows according to the following equation:

The Trip One Pump Scenario shows how much flow is possible when only one of the two pumps is operating.

Results
Process Mode
The following table compares the existing actual pipe sizes with the calculated diameter required for a 3 m/s
flow rate. Only 10 pipes are shown for brevity. See the Excel document for a complete report. We size all pipes
such that no pipes are grossly oversized and the velocity is lower than the minimum velocity.

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Calculated
Size
Required Flow Velocity Diameter
Pipe Action
(kg/hr) (m/s)
NPS (in) DN (mm) (in) (mm)

P001 16 DN400 794852 3 12 306 No Change

P1 14 DN300 794852 3 12 306 No Change
P10 6 DN150 151413 3 5 134 No Change
P11 4 DN100 80430 3 4 97 No Change
P12 4 DN100 46715 3 3 74 No Change
P13 6 DN150 104698 3 4 111 No Change
P14 4 DN100 64562 3 3 87 No Change
P15 4 DN100 40135 3 3 69 No Change
P15A 6 DN150 127145 3 5 122 No Change
P15B 6 DN150 104698 3 4. 111 No Change

Fluid Flow
The following table compares the actual flow to the required flow for each heat exchanger and provides the
outlet temperature based on the required duty in the table in Process Description.

Cooling Water
Required Flow
Exchanger Required Duty (kW) Actual Flow (kg/hr) Outlet Temperature
(kg/hr)
(°C)

E11 927.5 80430 78392 45.5

E12 538.5 46715 46211 45.4
E14 744.2 64562 62144 45.6
E15 462.6 40135 39651 45.4
E20 1779.9 63170 65341 44.2
E20A 1116.7 39636 42040 43.6
E22 1780.7 63198 67799 43.3
E22A 1117 39645 42000 43.6
E27 3567.6 126618 194156 36.5
E28 1930.7 68525 106573 36.3
E30 2944.4 104503 155226 37.0

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Cooling Water
Required Flow
Exchanger Required Duty (kW) Actual Flow (kg/hr) Outlet Temperature
(kg/hr)
(°C)

E31 1626.1 57715 83911 37.4

E4 649.2 39182 29075 39.9
E4A 649.2 39179 29073 39.9
E6 910.3 54933 59439 33.9
E7A 1633.1 98548 108812 33.6
The following table provides the pump requirements and pump performance with one of two pumps operating.

Pump Pump A (m3/hr) Pump B (m3/h) Total Flow (m3/h) DP (kPa)

Required Flow 397.4 397.4 794.9 1241

(Process Mode)
Two Pumps 491.7 491.7 983.4 897.4
Operating
One Pump 536.6 0 536.6 642
Operating

Snapshots
The simulation includes the following snapshots.

Snapshot Name Description Simulation Mode

Pro 1 Basic Engineering Design - for CW Utility network Process

FF 1 Pressure Balanced Network Fluid Flow
FF 2 Pressure Balanced Network - one pump tripped Fluid Flow

Excel Report
You can find the system flows, pressures, and temperatures in the U4 - Cooling Water Network.xlsx file.

References
1. SimSci INPLANT® 4.4 Application Briefs. "Application Brief 7 Cooling Water Network." Invensys Systems, Inc.:
May 2014.

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U5 - Fire Water Distribution Network

Revision Log
Date Who Change

11 Feb 2016 SK Initial release for SimCentral 1.4.

Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Problem Description
A chemical plant is expanding its fire water network (see the figure in Summary) to cover new process facilities.
The total flow capacity in the water network needs to be increased from 0.126 m3/s (2000 gpm) to 0.158 m3/s
(2500 gpm).

Summary
Fire water distribution networks are an essential part of the plant safety system. The optimal design of the pipe
network will deliver water to all delivery points at minimum flow and minimum pressure as needed for
firefighting. Due to the critical nature of the fire water system, a robust and efficiently designed fire water
distribution network is a must to aid in fire-related emergencies.
Fire water distribution networks are often designed with a ring network to ensure fire water availability if a part
of the network is isolated for maintenance.
It is a common scenario to expand existing networks to accommodate expansion requirements.
The objective of this simulation is to validate that the new modifications will provide fire water of minimum flow
and pressure.
The following figure illustrates the revamped fire water distribution network as modeled in AVEVA Process
Simulation. As shown in the legend, the color green symbolizes the new equipment that is needed for the
expansion. Blue colored models show the existing network.

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Process Description
The fire water supply temperature is 25.5°C (78°F) and pressure is 2170 kPa (300 psig).
In the revamped network, all fire water delivery points will have a minimum flow requirement of 0.0158 m3/s
(250 gpm) and a minimum pressure requirement of 1032 kPa (135 psig).
Details of the fire water delivery points are as follows:

Existing Delivery Points SNK1, SNK2, SNK3, SNK4, SNK7, SNK8, SNK9, SNK10
New Expansion Delivery Points SNK5, SNK6
The fire water pumping station will take care of additional fire water flow requirements.
Details of existing pipe network are as follows:

Pipe Size NPS (in.) Schedule L (m) DE (m)

PIPE1 6 40 30 0
PIPE2 6 40 30 0
PIPE3 6 40 91 0

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Pipe Size NPS (in.) Schedule L (m) DE (m)

PIPE4 6 40 305 0
PIPE5 4 40 152 0
PIPE9 4 40 152 0
PIPE10 6 40 305 0
PIPE11 4 40 152 0
PIPE12 6 40 914 0
PIPE13 3 40 91 0
PIPE14 3 40 91 0
PIPE15 3 40 91 0
PIPE16 3 40 91 0
PIPE19 3 40 91 0
PIPE20 3 40 91 0
PIPE21 3 40 91 0
PIPE22 3 40 91 0

Simulation Model
Library
The U5 - Fire Water Network simulation uses the CWLib library.

Fluids
The fire water network uses the CoolingWater fluid as an incompressible fluid.

Modes
The following table provides a summary of the simulation operation in all three modes:

Process Fluid Flow Dynamic

Purpose Size pipes for required Determine the actual Not applicable.
flow rates pressure at delivery point
Pipes Diameter is calculated to Inside diameter is set
check nominal pipe size based on nominal pipe
requirements. size.

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Process Fluid Flow Dynamic

Mixers Uses the minimum of Sets all inlet and outlet

inlet pressures. pressures the same.

Process Mode
The purpose of Process mode is to determine minimum new pipe size requirements at increased network flow
requirements. For existing systems such as this, we also use Process mode to generate an initial solved solution
in preparation for switching to Fluid Flow mode.
We specify the fire water supply (SRC1) temperature and pressure and the delivery flows (SNK models) with
values as mentioned in Process Description.
AVEVA Process Simulation uses a summation of the individual hydrant flows to calculate the split ratios for all
network splitter models except SP1. We assume that the SP1 splitter model has a 50% flow split for the ring
network. This creates a pressure imbalance, which shows in the Pslack variable in the MX1 model. AVEVA
Process Simulation calculates the pressure in mixer MX1 as the minimum of inlet stream pressures.
For new designs, we specify the pipes with their equivalent length and elevation change based on planned plant
layout and assumed pipe velocities of 3 m/s. We select the pipe diameter by ensuring that D_margin is greater
than 0 mm. For existing designs, we can still use Process mode with existing pipe sizes to generate an initial
solved solution, even if some pipes are undersized for an assumed 3 m/s pipe velocity.
The following table provides the details of the newly added pipes required to provide fire water to the new
delivery points, SNK5 and SNK6.

Pipe Size NPS (in.) Schedule L (m) DE (m)

PIPE6 6 40 61 0
PIPE7 4 40 152 0
PIPE8 6 40 305 0
PIPE17 6 40 91 0
PIPE18 6 40 91 0

Fluid Flow Mode

Fluid Flow mode determines the actual flow distribution by imposing a pressure balanced flow calculation.
Case FF 1
We specify the fire water supply temperature and pressure and the fire hydrant flows with values as mentioned
in the tables in Process Description. We achieve the network pressure balance by removing MX1.Pslack and
calculating the flow split for SP1. The FF 1 snapshot reflects this pressure and material balance solution.
Case FF 2
When the fire water supply pressure drops, all sinks must meet their minimum pressure. We model such a
scenario by calculating the fire water supply pressure (SRC1.P) and specifying the pressure in SNK8 with the
minimum pressure.

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Results
Process Mode and Fluid Flow Mode
The fire water station supply pressure of 2170 kPa (300 psig) is adequate for the increased fire water flow
requirements of 0.158 m3/s (2500 gpm) as shown in the following table in the following section.
Case FF 1
The following table shows the pressure profile for the fire water delivery:

Pressure Flows
Fire Water Delivery
kPa psig m3/s gpm

SRC1 2170 300 0.1577 2500

SNK1 1874 257 0.0158 250
SNK2 1874 257 0.0158 250
SNK3 1427 192 0.0158 250
SNK4 1427 192 0.0158 250
SNK5 1524 206 0.0158 250
SNK6 1524 206 0.0158 250
SNK7 1397 188 0.0158 250
SNK8 1397 188 0.0158 250
SNK9 1413 190 0.0158 250
SNK10 1413 190 0.0158 250
The SNK7 and SNK8 fire water hydrants have the lowest pressure (1397 kPa) in the network, but still satisfy the
minimum pressure requirements.
Case FF 2
We must maintain a minimum supply pressure of 1804 kPa (247 psig) so that the SNK7 and SNK8 fire water
hydrants meet the minimum pressure. In such a scenario, the fire water hydrants can obtain individual minimum
flow requirements with a pressure profile as shown in the following table.

Pressure Flows
Fire Water Flows
kPa psig m3/s gpm

SRC1 1804 247 0.1577 2500

SNK1 1508 204 0.0158 250
SNK2 1508 204 0.0158 250

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Pressure Flows
Fire Water Flows
kPa psig m3/s gpm

SNK3 1062 139 0.0158 250

SNK4 1062 139 0.0158 250
SNK5 1159 153 0.0158 250
SNK6 1159 153 0.0158 250
SNK7 1032 135 0.0158 250
SNK8 1032 135 0.0158 250
SNK9 1048 137 0.0158 250
SNK10 1048 137 0.0158 250

Reverse flow occurs in PIPE8 when each fire water hydrant produces 0.0158 m3/s (250 gpm) of fire water.

Snapshots
The simulation includes the following snapshots.

Snapshot Name Description Simulation Mode

Pro 1 Fire Water Distribution Expansion Plan Process

FF 1 Pressure balanced simulation solution to supply minimum Fluid Flow
flow to all fire water hydrants with the SRC1 pressure
specified at 2170 kPa (300 psig)
FF 2 Pressure balanced simulation solution to supply minimum Fluid Flow
flow to all fire water hydrants with the SNK7 and SNK8
pressure specified at a minimum pressure of 1032 kPa (135
psig)

Excel Report
You can find the system flows, pressures, and temperatures in the U5 - Fire Water Network Report.xlsx file.

References
1. SimSci INPLANT® 4.4 Application Briefs. "Application Brief 6 Fire Water Distribution Network." Invensys
Systems, Inc.: May 2014.

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U6 - Hot Oil Network

Revision Log
Date Who Change

11 Aug 2016 DK Initial release for SimCentral 1.5.

9 Dec 2016 SK Updates for SimCentral 1.6.

30 Dec 2016 SK Updates for SimCentral 1.7.

3 May 2017 DK Updates for SimCentral 2.0.

Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
Hot oil networks are used in process industries to transfer thermal energy by using a non-boiling heat transfer
fluid. Hot oil networks use a liquid heat transfer fluid that does not boil at high temperatures where water boils.
They may be preferable over steam where steam is not readily available.
The objective of this simulation is to:
• Design a hot oil network for the specified duty and outlet temperatures of the process-side heat exchangers.
• Determine the load on the bypass valve if you shut down one of the process consumers for maintenance.
• Determine the load on the process consumers if the temperature of the hot oil increases or decreases.
• Determine the total hot oil flow if only one of two available pumps is operating.
• Validate the temperature control strategy by using dynamic simulation.
The following figure shows the schematic diagram of the Hot Oil Network system, as modeled in AVEVA Process
Simulation.

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Process Description
The hot oil system is a closed-loop heating system that uses a fired heater as the primary heat source. A makeup
line from a storage tank supplies hot oil to the system. Circulator pumps then feed the hot oil to the fired heater,
which heats the hot oil to a temperature of 400°C and supplies it to all process consumers. After the heat
exchange, hot oil returns to the main line through the expansion tank, which creates a closed loop.
The design requirements are:
• The temperature of the process consumer is 220°C.
• The temperature of the hot oil that returns to the circulator pumps is 100°C.
• The heat transfer fluid is based on DowTherm™ A.

Simulation Model
Library
This simulation uses the CWLib library.

Fluids
This simulation uses the DowTherm™ A fluid as an incompressible fluid with a density of 994 kg/m3 and a
specific heat of 1.8 kJ/kg-K.

Mode Summary
The following table provides a summary of the simulation operation in all three modes:

Process Fluid Flow Dynamics

Purpose Size the pipes for Determine the actual Perform dynamic
required flow rates. flow distribution studies.
Check the heat through the network.
exchanger outlet
temperatures.

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Process Fluid Flow Dynamics

Pumps Estimate the pressure Operate based on Operate based on

rise. performance curve. performance curve.
Pipes Calculate the diameter Set the inside diameter Set the inside diameter
to check nominal pipe based on nominal pipe based on nominal pipe
size requirements. size. size.
Mixers Use the minimum of Set all inlet and outlet Set all inlet and outlet
inlet pressures. pressures the same. pressures the same.
Splitters Set the split fraction to Calculate the split Calculate the split
the required flow rate. fraction based on the fraction based on the
flow from the system flow from the system
hydraulics. hydraulics.
Heat Exchangers Specify the required Calculate the actual Calculate the actual
flow for the required flow based on reference flow based on
heat transfer. Check the conditions. reference conditions.
outlet temperature.
Flow Controller Calculate the set point Calculate the process Adjust the controller
and process variable variable based on output position with
based on specified specified conditions. time.
conditions.

Temperature Controller Calculate the set point Calculate the process Adjust the valve
based on specified variable based on the position with time.
conditions. desired set point.

Process Mode
The purpose of Process mode is to:
• Check the pipe sizes.
• Specify a pressure drop for valves.
• Check the outlet temperatures of the process-side heat exchangers.
• Determine an initial solution for the transition to Fluid Flow mode.
You can model the heat exchangers by specifying the pressure drop and outlet temperature.

Fluid Flow Mode

The purpose of Fluid Flow mode for this simulation is to show that the network that we designed in Process
mode meets the hot oil network requirements. In Fluid Flow mode, AVEVA Process Simulation moves the entire
network to a pressure-balanced solution and therefore calculates the actual flow available to maintain the
process conditions.
We can begin analyzing the available flow through the system should one of the pumps trip. We make the
following assumptions:

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• The Pumps operate on their performance curves.

• All of the Mixers provide a pressure-balanced solution.
• The Pipes use the actual pipe diameter from nominal pipe size.
The change to Fluid Flow mode moves the Heat Exchanger flows based on the network pressure balance. The
Wref and DPref variables in Fluid Flow mode take values from the W and DP values in Process mode. Therefore,
AVEVA Process Simulation recalculates the DP value for each individual Heat Exchanger by using the updated
pressure-driven flows according to the following equation:

Dynamics Mode
The purpose of Dynamics mode is to observe the response in the system when a particular change is made.
Specifically, we study the following cases, which we represent as Scenarios:

Results
Process Mode
The following table compares the pipe sizes with the calculated diameter required for a velocity of 3 m/s.

Velocity Calculated
Pipe NPS (in) Flowrate (kg/hr)
(m/s) Diameter (in)

PIPE1 4in 50000 3.0 3

PIPE2 4in 25000 3.0 2
PIPE3 4in 25000 3.0 4
PIPE4 4in 50000 3.0 3
PIPE5 4in 50000 3.0 3
PIPE6 3in 25000 3.0 2
PIPE9 3in 25000 3.0 2
PIPE10 4in 50000 3.0 3

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Velocity Calculated
Pipe NPS (in) Flowrate (kg/hr)
(m/s) Diameter (in)

PIPE11 3in 45000 3.0 3

PIPE12 2in 5000 3.0 2

Fluid Flow Mode

The following table compares the actual flow to the required flow for each heat exchanger and provides the
outlet temperature based on the required duty specified in Process Description.

Required Flow Actual Flow Required Outlet

Exchanger Duty (kW)
(kg/hr) (kg/hr) Temperature (°C)

E1 1280 16000 18207 80

E2 1280 26176 29334 80
FHTR 2698 20141 21427 400
The following table provides the pump requirements and pump performance with one of two pumps operating.
You can find the results for when Pump 2 trips in the Snapshot FF 2.

Pump Pump 1 (kg/hr) Pump 2 (kg/h) Total Flow (kg/h) DP (kPa)

Required Flow 25000 25000 50000 370

(Process Mode)
Two Pumps 25000 25000 50000 370
Operating

One Pump 35883 0 35883 130

Operating

Dynamics Mode
The following curves are representative of the different cases mentioned in Dynamics Mode.
Scenario 1: Hot Oil at 285C
Details: Change the TC.SP value to 285°C at time 30 seconds.
You can view the results for this Scenario by reverting to the Dyn 2 snapshot.

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Scenario 2: Hot Oil at 200C

Details: Change the TC.SP value to 200°C at time 30 seconds.
You can view the results for this Scenario by reverting to the Dyn 3 snapshot.

Scenario 3: E1 Shutdown
Details: Close the E1 inlet valve, XV3, at time 30 seconds.
You can view the results for this Scenario by reverting to the Dyn 4 snapshot.
In this event, XV3 is closed to carry out maintenance of heat exchanger E1. The duties for the Fired Heater and
heat exchanger E2 are affected, as shown by their duty profiles and their corresponding flow profiles in the

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following figures. In this case, E2 picks up some of the loss of heat exchange performed by E1, thus indicating a
more negative value.

Snapshots
This simulation includes the following snapshots.

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Excel Report
You can find the system flows, pressures, and temperatures in the U6 – Hot Oil Network.xlsx file.

References
1. Mitra, S. "A technical report on design of hot oil system." University of Newcastle. June 2015. Research Gate.
2. Ataei, A., Tahouni, N., Yoo C., and M.H. Panjeshahi. "A novel approach to hot oil system design for energy
conservation. Applied Thermal Engineering. May 2014. Research Gate.

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U7 - Refinery Steam Balance

Revision Log
Date Who Change

26 Jan 2017 CAD Initial draft for SimCentral 1.7.

11 Jun 2018 DHJ Update for SimCentral 2.3 Beta.
01 Feb 2019 CAD Update for optimization for SimCentral Simulation Platform 3.3 Beta.
Note that we occasionally make changes to AVEVA Process Simulation and the example simulations. These
changes may not be reflected in this document for every AVEVA Process Simulation software release. There may
be modeling details that are different, screenshots that do not match, and numerical answers that are different.
We will update the examples in a future version of AVEVA Process Simulation.

Summary
Refinery steam systems require steam balances.
The objective of this simulation is to:
• Create an initial steam balance for a typical refinery steam system that contains steam at three different
pressure levels:
• High pressure (HP)
• Middle pressure (MP)
• Low pressure (LP)
• Demonstrate how to model the deaerator and close the condensate and boiler feedwater loop.
• Create sequence logic that sets the priority of letdown valves, steam turbines, and turbine extraction valves
to meet a wider range of process steam demand.
• Create alternative cases where the steam sequence logic automatically changes the letdown valve and steam
turbine operation to satisfy the steam balance.
• Demonstrate how to use optimization to minimize boiler feed water and venting steam.
The following figure illustrates the refinery steam balance as constructed in AVEVA Process Simulation.

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Process Description
The following table summarizes the design assumptions and information for the boilers in the base case
snapshot (Pro 1) for the simulation. The refinery has three boilers. We do not flash the blowdown and do not
recover the resulting steam.

Superheated
Boilers Generation (lb/hr) Blowdown (percent) Drum Pressure (psig)
Temperature (°F)

B1SH 476,642 2 620 675

B2SH 100,000 2 620 675
B3SH 190,000 2 620 600
The following table summarizes the design assumptions and information for the pressure headers in the base
case snapshot (Pro 1).The refinery has three pressure headers. We import steam from several process units. We

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recover steam for process heating as condensate. We do not condense or recover other steam used by the
process, which is called live steam.

Pressure Import Flow Import Live Steam to Heating Steam to

Headers
(psig) (lb/hr) Temperature (°F) Process (lb/hr) Condensate (lb/hr)

HP 600 - - 200,000 200,000

MP 150 100,000 450 100,000 100,000
LP 40 100,000 330 150,000 75,000
The refinery has five steam turbines:
• T1 is an extraction turbine that produces power. T1 uses HP steam, produces MP extraction, and exhausts to
LP.
• T2 is an extraction turbine that produces power. T2 uses HP steam, produces LP extraction, and produces an
additional steam product that we condense.
• T3 is an HP-to-MP backpressure turbine that produces power.
• T4 is an MP-to-LP backpressure turbine that produces power.
• T5 is an LP condensing turbine that drives a compressor.
The following table summarizes the design assumptions and information for the steam turbines in the base case
snapshot (Pro 1). Values without parentheses indicate feeds and values within parentheses indicate products.

MP Steam Condensate Efficiency

Turbines HP Steam (lb/hr) LP Steam (lb/hr)
(lb/hr) (lb/hr) (fraction)

T1 138,000 (94,000) (44,000) - 0.7

T2 134,000 - (39,000) (95,000) 0.7
T3 60,000 (60,000) - - 0.7
T4 - 42,000 (42,000) - 0.7
T5 - 13,000 - (13,000) 0.7

Simulation Model
Library
This simulation uses the Steam library.

Fluids
This simulation uses the Steam fluid from the Steam library.

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Process Mode
We use only Process mode, because this model exclusively performs steam balances. We make the following
assumptions and design requirements for process simulation:
• Set all headers to use balanced inlet pressures. Balancing the inlet pressures works much better than setting
the minimum inlet pressure because there are many flows into and out of each header.
• Model the condensers as heat exchangers and set the vapor fraction of the shell side (VFso) to zero.
• Specify at least one OutRatio element for each Header. This must be a flow that will never be zero. If you
specify the OutRatio corresponding to the letdown valve at any positive values, then when the flowdown
valve is closed, all outer OutRatio values will be infinite and the system will not solve.
Sequence Logic Approach
To accommodate alternative refinery operating conditions, we use sequence logic for the material balance to
control the letdown valves, turbine extractions, and some of the steam turbines. For example, if the LP steam
demand decreased by more than the excess MP steam in the MP-to-LP letdown, the model would not solve.
However, in this situation, you could reduce the turbine extraction to the LP header when the letdown valve is
fully closed. The sequence logic allows you to define these relationships.
The HP header does not need sequence logic, since one of the boilers can have a calculated (floating) flow rate
and can move up and down accordingly.
The sequence logic that controls the material balance for the MP header (MPSQ) has the following priority
sequence as you increase MP steam demand.

Priority Device Description Min Flow (lb/hr) Max Flow (lb/hr)

1 PV7 Open the T3 governor valve (HP-to-MP) 0 60,000

2 PV4 Open the valve for T1 MP Extraction 0 94,000
3 PV1 Open the HP-to-MP letdown valve 0 400,000
For example, if PV1 is open, PV7 and PV4 are completely open, as they are in the base case operation. However,
if the LP demand falls and HP-to-MP steam is not required, then the MP extraction decreases to balance the MP
header.
The sequence logic that controls the material balance for the LP header (LPSQ) has the following priority
sequence as you move from high LP import to high LP demand.

Priority Device Description Min Flow (lb/hr) Max Flow (lb/hr)

1 PV3 Close LP atmospheric vent to LP letdown 0 100,000

valve
2 PV8 Close the valve for the LP bypass condenser 0 47,619
3 PV5 Open the valve for T2 LP Extraction 0 39,000
4 PV2 Open the MP-to-LP letdown valve 0 400,000

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Optimization Approach
Alternatively, you can use optimization instead of sequence logic to find the appropriate steam balance
conditions. We use the Optimization Set in the following figure. The objective function minimizes the boiler feed
water in stream S60 by adjusting the letdown valves, PV1 and PV2, and the steam turbine extraction valves, PV4
and PV5. The optimizer opens the extraction valves and closes the letdown valves as much as possible to prevent
steam from venting through valve PV3 while still meeting the live steam and heat steam demands from the HP,
MP, and LP headers. You can open the U7 - Refinery Steam Balance with Optimization.simx file in the Examples
folder to explore this optimization approach.

Results

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Process Mode
The following table provides a comparison of the Process mode target flows for the various snapshots in the
simulation.

Snapshot

Service Device Pro 4 —

Pro 1 — Base Pro 2 — Min Pro 3 — Max
Compressor Trip
Case (lb/hr) Demand (lb/hr) Demand (lb/hr)
(lb/hr)

HP Live Steam HPUsers 200,000 100,000 300,000 200,000

HP Heating Steam HPCond 200,000 100,000 300,000 200,000
MP Live Steam MPUsers 100,000 50,000 150,000 100,000
MP Heating Steam MPCond 100,000 50,000 150,000 100,000
LP Live Steam LPUsers 150,000 75,000 300,000 150,000
LP Heating Steam LPCond 75,000 37,500 150,000 75,000
Compressor T5 13,000 13,000 13,000 0

Snapshots
The simulation includes the following snapshots.

Microsoft Excel Report

The Microsoft Excel report contains two worksheets, Schematic and Master. The Schematic worksheet provides
the following schematic that summarizes the results of the material balances and power generation. The Master
worksheet shows the detailed properties of each unit in the refinery steam system along with a summary of the
simulation name, the currently selected snapshot, the units slate, the simulation mode, and the solution status
of the simulation.

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