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Comprehensive resource covering Aspen Plus V12.1 and demonstrating how to implement the program in versatile chemical process industries
Aspen Plus®: Chemical Engineering Applications facilitates the process of learning and later mastering Aspen Plus®, the market-leading chemical process modeling software, with step-by-step examples and succinct explanations. The text enables readers to identify solutions to various process engineering problems via screenshots of the Aspen Plus® platforms in parallel with the related text.
To aid in information retention, the text includes end-of-chapter problems and term project problems, online exam and quiz problems for instructors that are parametrized (i.e., adjustable) so that each student will have a standalone version, and extra online material for students, such as Aspen Plus®-related files, that are used in the working tutorials throughout the entire textbook.
The second edition of Aspen Plus®: Chemical Engineering Applications includes information on:
For chemical engineering students and industry professionals, the second edition of Aspen Plus®: Chemical Engineering Applications is a key resource for understanding Aspen Plus and the new features that were added in version 12.1 of the software. Many supplementary learning resources help aid the reader with information retention.
Kamal I. M. Al-Malah received his PhD degree from Oregon State University in 1993. He served as a Professor of Chemical Engineering in Jordan and other Gulf countries, as well as Former Chairman of the Chemical Engineering Department at the University of Hail in Saudi Arabia. Professor Al-Malah is an expert in both Aspen Plus® and MATLAB® applications. He has created a bundle of Windows-based software for engineering applications.
Ch1. Introducing Aspen Plus
1.1 What does ASPEN stand for?
1.2 What is Aspen Plus Process Simulation Model?
1.3 Launching Aspen Plus V12.0
1.4 Beginning a Simulation
1.5 Entering Components
1.6 Specifying the Property Method
1.7 Improvement of the Property Method Accuracy
1.8 File Saving
1.9 Exercise 1.1
1.10 Good Flowsheeting Practice
1.11 Aspen Plus Built-in Help
1.12 For More Information
1.13 Home/Class Work 1.1 (Pxy)
1.14 Home/Class Work 1.2 (Gmix)
1.15 Home/Class Work 1.3 (Likes Dissolve Likes) as Envisaged by NRTL Property Method
1.16 Home/Class Work 1.4 (The Mixing Rule)
Ch2. More on Aspen Plus Flowsheet Features (1)
2.1 Problem Description
2.2 Entering and Naming Compounds
2.3 Binary Interactions
2.4 The “Simulation” Environment: Activation Dashboard
2.5 Placing a Block and Material Stream from Model Palette
2.6 Block and Stream Manipulation
2.7 Data Input, Project Title, & Report Options
2.8 Running the Simulation
2.9 The Difference among Recommended Property Methods
2.10 NIST/TDE Experimental Data
2.11 Home-/Class-Work 2.1 (Water-Alcohol System)
2.12 Home-/Class-Work 2.2 (Water-Acetone-EIPK System with NIST/DTE Data)
2.13 Home-/Class-Work 2.3 (Water-Acetone-EIPK System without NIST/DTE Data)
Ch3. More on Aspen Plus Flowsheet Features (2)
3.1 Problem Description: Continuation to Chapter Two Problem
3.2 The Clean Parameters Step
3.3 Simulation Results Convergence
3.4 Adding Stream Table
3.5 Property Sets
3.6 Adding Stream Conditions
3.7 Printing from Aspen Plus
3.8 Viewing the Input Summary
3.9 Report Generation
3.10 Stream Properties
3.11 Adding a Flash Separation Unit
3.12 The Required Input for “Flash3”-Type Separator
3.13 Running the Simulation and Checking the Results
3.14 Home-/Class-Work 3.1 (Output of Input Data & Results)
3.15 Home-/Class-Work 3.2 (Output of Input Data & Results)
3.16 Home-/Class-Work 3.3 (Output of Input Data & Results)
3.17 Home-/Class-Work 3.4 (The Partition Coefficient of a Solute)
Ch4. Flash Separation & Distillation Columns
4.1 Problem Description
4.2 Adding a Second Mixer and Flash
4.3 Design Specifications Study
4.4 Exercise 4.1 (Design Spec)
4.5 Aspen Plus Distillation Column Options
4.6 “DSTWU” Distillation Column
4.7 “Distl” Distillation column
4.8 “RadFrac” Distillation Column
4.9 Home/Class Work 4.1 (Water-Alcohol System)
4.10 Home/Class Work 4.2 (Water-Acetone-EIPK System with NIST/DTE Data)
4.11 Home/Class Work 4.2 (Water-Acetone-EIPK System without NIST/DTE Data)
4.12 Home/Class Work 4.4 (Scrubber)
Ch5. Liquid-Liquid Extraction Process
5.1 Problem Description
5.2 The Proper Selection for Property Method for Extraction Processes
5.3 Defining New Property Sets
5.4 Property Method Validation versus Experimental Data Using Sensitivity Analysis
5.5 A Multi-Stage Extraction Column
5.6 The Triangle Diagram
5.7 References
5.8 Home/Class Work 5.1 (Separation of MEK from Octanol)
5.9 Home/Class Work 5.2 (Separation of MEK from Water Using Octane)
5.10 Home/Class Work 5.3 (Separation of Acetic Acid from Water Using Iso-Propyl Butyl Ether)
5.11 Home/Class Work 5.4 (Separation of Acetone from Water Using Tri-Chloro-Ethane)
5.12 Home/Class Work 5.5 (Separation of Propionic Acid from Water Using MEK)
Ch6. Reactors with Simple Reaction Kinetic Forms
6.1 Problem Description
6.2 Defining Reaction Rate Constant to Aspen Plus Environment
6.3 Entering Components and Method of Property
6.4 The Rigorous Plug Flow Reactor (RPLUG)
6.5 Reactor and Reaction Specifications for RPLUG (PFR)
6.6 Running the Simulation (PFR Only)
6.7 Exercise 6.1
6.8 Compressor (CMPRSSR) and RadFrac Rectifying Column (RECTIF)
6.9 Running the Simulation (PFR + CMPRSSR + RECTIF)
6.10 Exercise 6.2
6.11 RadFrac Distillation Column (DSTL)
6.12 Running the Simulation (PFR + CMPRSSR + RECTIF+DSTL)
6.13 Reactor and Reaction Specifications for RCSTR
6.14 Running the Simulation (PFR + CMPRSSR + RECTIF+DSTL+RCSTR)
6.15 Exercise 6.3
6.16 Sensitivity Analysis: The Reactor’s Optimum Operating Conditions
6.17 References
6.18 Home/Class Work 6.1 (Hydrogen Peroxide Shelf-Life)
6.19 Home/Class Work 6.2 (Esterification Process)
6.20 Home/Class Work 6.3 (Liquid-Phase Isomerization of n-Butane)
Ch7. Reactors with Complex (Non-Conventional) Reaction Kinetic Forms
7.1 Problem Description
7.2 Non-Conventional Kinetics: LHHW Type Reaction
7.3 General Expressions for Specifying LHHW Type Reaction in Aspen Plus
7.3.1 The “Driving Force” for the Non-Reversible (Irreversible) Case
7.3.2 The “Driving Force” for the Reversible Case
7.3.3 The “Adsorption Expression”
7.4 The Property Method: “SRK”
7.5 RPLUG Flowsheet for Methanol Production
7.6 Entering Input Parameters
7.7 Defining Methanol Production Reactions as LHHW Type
7.8 Sensitivity Analysis: Effect of Temperature and Pressure on Selectivity
7.9 References
7.10 Home/Class Work 7.1 (Gas-Phase Oxidation of Chloroform)
7.11 Home/Class Work 7.2 (Formation of Styrene from Ethyl-Benzene)
7.12 Home/Class Work 7.3 (Combustion of Methane over Steam-Aged Pt-Pd Catalyst)
Ch8. Pressure Drop, Friction Factor, NPSHA, and Cavitation
8.1 Problem Description
8.2 The Property Method: “STEAMNBS”
8.3 A Water Pumping Flowsheet
8.4 Entering Pipe, Pump, & Fittings Specifications
8.5 Results: Frictional Pressure Drop, the Pump Work, Valve Choking, and ANPSH versus RNPSH
8.6 Exercise 8.1
8.7 Model Analysis Tools: Sensitivity for the Onset of Cavitation or Valve Choking Condition
8.8 References
8.9 Home/Class Work 8.1 (Pentane Transport)
8.10 Home/Class Work 8.2 (Glycerol Transport)
8.11 Home/Class Work 8.3 (Air Compression)
Ch9. The Optimization Tool
9.1 Problem Description: Defining the Objective Function
9.2 The Property Method: “STEAMNBS”
9.3 A Flowsheet for Water Transport
9.4 Entering Stream, Pump, and Pipe Specifications
9.5 Model Analysis Tools: The Optimization Tool
9.6 Model Analysis Tools: The Sensitivity Tool
9.7 Last Comments
9.8 References
9.9 Home/Class Work 9.1 (Swamee-Jain Equation)
9.10 Home/Class Work 9.2 (A Simplified Pipe Diameter Optimization)
9.11 Home/Class Work 9.3 (The Optimum Diameter for a Viscous Flow)
9.12 Home/Class Work 9.4 (The Selectivity of Parallel Reactions)
Ch10. Heat Exchanger (H.E.) Design
10.1 Problem Description
10.2 Types of Heat Exchanger Models in Aspen Plus
10.3 The Simple Heat Exchanger Model (“Heater”)
10.4 The Rigorous Heat Exchanger Model (“HeatX”)
10.5 The Rigorous Exchanger Design and Rating (EDR) Procedure
10.5.1 The EDR Exchanger Feasibility Panel
10.5.2 The Rigorous Mode within the “HeatX” Block
10.6 General Footnotes on EDR Exchanger
10.7 References
10.8 Home/Class Work 10.1 (Heat Exchanger with Phase Change)
10.9 Home/Class Work 10.2 (High Heat Duty Heat Exchanger)
10.10 Home/Class Work 10.3 (Design Spec Heat Exchanger)
Ch11. Electrolytes
11.1 Problem Description: Water De-Souring
11.2 What is an Electrolyte?
11.3 The Property Method for Electrolytes
11.4 The Electrolyte Wizard
11.5 Water De-Souring Process Flowsheet
11.6 Entering the Specifications of Feed Streams and the Stripper
11.7 Appendix: Development of “ELECNRTL” Model
11.8 References
11.9 Home/Class Work 11.1 (An Acidic Sludge Neutralization)
11.10 Home/Class Work 11.2 (CO2 Removal from Natural Gas)
11.11 Home/Class Work 11.3 (pH of Aqueous Solutions of Salts)
Ch12. Polymerization Processes
12.1 The Theoretical Background
12.1.1 Polymerization Reactions
12.1.2 Catalyst Types
12.1.3 Ethylene Process Types
12.1.4 Reaction Kinetic Scheme
12.1.5 Reaction Steps
12.1.6 Catalyst States
12.2 High-Density Poly-Ethylene (HDPE) High Temperature Solution Process
12.2.1 Problem Definition
12.2.2 Process Conditions
12.3 Creating Aspen Plus Flowsheet for HDPE
12.4 Improving Convergence
12.5 Presenting the Property Distribution of Polymer
12.6 Home/Class Work 12.1 (Maximizing the Degree of HDPE Polymerization)
12.7 Home/Class Work 12.2 (Styrene Acrylo-Nitrile (SAN) Polymerization)
12.8 References
12.9 Appendix A: The Main Features & Assumptions of Aspen Plus Chain Polymerization Model
12.9.1 Polymerization Mechanism
12.9.2 Co-polymerization Mechanism
12.9.3 Rate Expressions
12.9.4 Rate Constants
12.9.5 Catalyst Pre-Activation
12.9.6 Catalyst Site Activation
12.9.7 Site Activation Reactions
12.9.8 Chain Initiation
12.9.9 Propagation
12.9.10 Chain Transfer to Small Molecules
12.9.11 Chain Transfer to Monomer
12.9.12 Site Deactivation
12.9.13 Site Inhibition
12.9.14 Co-Catalyst Poisoning
12.9.15 Terminal Double Bond Polymerization
12.9.16 Phase Equilibria
12.9.17 Rate Calculations
12.9.18 Calculated Polymer Properties
12.10 Appendix B: The Number Average Molecular Weight (MWN) and Weight Average Molecular Weight (MWW)
Ch13. Characterization of Drug-Like Molecules Using Aspen Properties
13.1 Introduction
13.2 Problem Description
13.3 Creating Aspen Plus Pharmaceutical Template
13.3.1 Entering the User-Defined Benzamide (BNZMD-UD) as Conventional
13.3.2 Specifying Properties to Estimate
13.4 Defining Molecular Structure of BNZMD-UD
13.5 Entering Property Data
13.6 Contrasting Aspen Plus Databank (BNZMD-DB) versus BNZMD-UD
13.7 References
13.8 Home/Class Work 13.1 (Vanillin)
13.9 Home/Class Work 13.2 (Ibuprofen)
Ch14. Solids Handling
14.1 Introduction
14.2 Problem Description #1: The Crusher
14.3 Creating Aspen Plus Flowsheet
14.3.1 Entering Components Information
14.3.2 Adding the Flowsheet Objects
14.3.3 Defining the Particle Size Distribution (PSD)
14.3.4 Calculation of the Outlet PSD
14.4 Exercise 14.1: (Determine Crusher Outlet PSD from Comminution Power)
14.5 Exercise 14.2: (Specifying Crusher Outlet PSD)
14.6 Problem Description #2: The Fluidized Bed for Alumina Dehydration
14.7 Creating Aspen Plus Flowsheet
14.7.1 Entering Components Information
14.7.2 Adding the Flowsheet Objects
14.7.3 Entering Input Data
14.7.4 Results
14.8 Exercise 14.3: (Re-Converging the Solution for an Input Change)
14.9 References
14.10 Home/Class Work 14.1 (KCl Drying)
14.11 Home/Class Work 14.2 (KCl Crystallization)
14.12 APPENDIX A: Solids Unit Operations
14.12.1 Unit Operation Solids Models
14.12.2 Solids Separators Models
14.12.3 Solids Handling Models
14.13 APPENDIX B: Solids Classification
14.14 APPENDIX C: Predefined Stream Classification
14.15 APPENDIX D: Substream Classes
14.16 APPENDIX E: Particle Size Distribution (PSD)
14.17 APPENDIX F: Fluidized Beds
Ch15. Aspen Plus Dynamics
15.1 Introduction
15.2 Problem Description
15.3 Preparing Aspen Plus Simulation for Aspen Plus Dynamics (APD)
15.4 Conversion of Aspen Plus Steady-State into Dynamic Simulation
15.4.1 Modes of Dynamic CSTR Heat Transfer
15.4.2 Creating Pressure-Driven Dynamic Files for APD
15.5 Opening a Dynamic File Using APD
15.6 The “Simulation Messages” Window
15.7 The Running Mode: Initialization
15.8 Adding Temperature Control (TC) Unit
15.9 Snapshots Management for Captured Successful Old Runs
15.10 The Controller Faceplate
15.11 Communication Time for Updating/Presenting Results
15.12 The Closed-Loop Auto-Tune Variation (ATV) Test versus Open-Loop Tune-Up Test
15.13 The Open-Loop (Manual Mode) Tune-Up for Liquid Level Controller
15.14 The Closed-Loop Dynamic Response for Liquid Level Load Disturbance
15.15 The Closed-Loop Dynamic Response for Liquid Level Set-Point Disturbance
15.16 Accounting for Dead/Lag Time in Process Dynamics
15.17 The Closed-Loop (Auto Mode) ATV Test for Temperature Controller (TC)
15.18 The Closed-Loop Dynamic Response: “TC” Response to Temperature Load Disturbance
15.19 Interactions between “LC” and “TC” Control Unit
15.20 The Stability of a Process without Control
15.21 The Cascade Control
15.22 Monitoring of Variables as Functions of Time
15.23 Final Notes on the Virtual (Dry) Process Control in APD
15.24 References
15.25 Home/Class Work 15.1 (A Cascade Control of a Simple Water Heater)
15.26 Home/Class Work 15.2 (A CSTR Control with “LMTD” Heat Transfer Option)
15.27 Home/Class Work 15.3 (A PFR Control for Ethyl-Benzene Production)
Ch16. Safety & Energy Aspects of Chemical Processes
16.1 Introduction
16.2 Problem Description
16.3 The “Safety Analysis” Environment
16.4 Adding a Pressure Safety Valve (PSV)
16.5 Adding a Rupture Disk (RD)
16.6 Presentation of Safety-Related Documents
16.7 Preparation of Flowsheet for “Energy Analysis” Environment
16.8 The “Energy Analysis” Activation
16.9 The “Energy Analysis” Environment
16.10 The Aspen Energy Analyzer
16.11 Home/Class Work 16.1 (Adding a Storage Tank Protection)
16.12 Home/Class Work 16.2 (Separation of C2/C3/C4 Hydrocarbon Mixture)
Ch17. Aspen Process Economic Analyzer (APEA)
17.1 Optimized Process Flowsheet for Acetic Anhydride Production
17.2 Costing Options in Aspen Plus
17.2.1 Aspen Process Economic Analyzer (APEA) Estimation Template
17.2.2 Feed and Product Stream Prices
17.2.3 Utility Association with a Flowsheet Block
17.3 The First Route for Chemical Process Costing
17.4 The Second Route for Chemical Process Costing
17.4.1 Project Properties
17.4.2 Loading Simulator Data
17.4.3 Mapping and Sizing
17.4.4 Project Evaluation
17.4.5 Fixing Geometrical Design-Related Errors
17.4.6 Executive Summary
17.4.7 Capital Costs Report
17.4.8 Investment Analysis
17.5 Home/Class Work 17.1 (Feed/Product Unit Price Effect on Process Profitability)
17.6 Home/Class Work 17.2 (Using European Economic Template)
17.7 Home/Class Work 17.3 (Process Profitability of Acetone Recovery from Spent Solvent)
17.8 Appendix
17.8.1 Net Present Value (NPV) for a Chemical Process Plant
17.8.2 Discounted Payout (Payback) Period (DPP)
17.8.3 Profitability Index
17.8.4 Internal Rate of Return (IRR)
17.8.5 Modified Internal Rate of Return (MIRR)
Ch18. Term Projects (TP)
18.1 What is Aspen Custom Modeler
18.2 Main Feature of ACM
18.3 Modeling and Simulation of a Simple Constant-Temperature Mixing Tank
18.4 Modeling and Simulation of a non-Isothermal Mixing Tank
18.5 Modeling and Simulation of a Flash Drum
18.6 Modeling and Simulation of Heat Slab
18.7 Modeling and Simulation of an Absorber
18.8 Modeling and Simulation of a Jacketed Reactor
18.9 Modeling and Simulation of a Heat Exchanger
18.10 Merging of ACM models into AP Model Palette
Ch19. Aspen Custom Modeler (ACM)
19.1 TP #1: Production of Acetone via the Dehydration of Iso-Propanol
19.2 TP #2: Production of Formaldehyde from Methanol (Sensitivity Analysis)
19.3 TP #3: Production of Di-Methyl Ether (Process Economics & Control)
18.3.1 Economic Analysis
18.3.2 Process Dynamics & Control
19.4 TP #4: Production of Acetic Acid via Partial Oxidation of Ethylene Gas
19.5 TP #5: Pyrolysis of Benzene
19.6 TP #6: Re-Use of Spent Solvents
19.7 TP#7: Solids Handling: Production of Potassium Sulfate from Sodium Sulfate
19.8 TP #8: Solids Handling: Production of CaCO3-Based Agglomerate as a General Additive
19.9 TP #9: Solids Handling: Formulation of Di-Ammonium Phosphate and Potassium Nitrate Blend Fertilizer
19.10 TP #10: “Flowsheeting Options” | “Calculator”: Gas De-Souring and Sweetening Process
19.11 TP #11: Using More Than One Property Method and Stream Class: Solid Catalyzed Direct Hydration of Propylene to Iso-Propyl Alcohol (IPA)
19.12 TP #12: Polymerization: Production of Poly-Vinyl Acetate (PVAC)
19.13 TP #13: Polymerization: Emulsion Copolymerization of Styrene and Butadiene to Produce SBR
19.14 TP #14: Polymerization: Free Radical Polymerization of Methyl-Methacrylate to Produce Poly (Methyl Methacrylate)
19.15 TP #15: LHHW Kinetics: Production of Cyclo-Hexanone-Oxime (CYCHXOXM) via Cyclo-Hexanone Ammoximation Using Clay-Based Titanium Silicalite (TS) Catalyst
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