ASPEN HYSYS STUDIE KITE

1. (a) What are the four variables needed to be supplied to make a material stream in
HYSYS converge? (rep….3)

(b) A natural gas stream containing N2, C1, C2 and C3 is processed in a refrigeration
system to remove the heavier hydrocarbons. The lean, dry gas produced will meet a
pipeline hydrocarbon dew point specification.
The combined feed stream enters an inlet separator, which removes the free liquids.
Overhead gas from the separator is fed to the “gas/gas” heat exchanger, where it is pre-
cooled by already refrigerated gas. The cooled gas is then fed to the chiller, where further
cooling is accomplished through exchange with evaporating propane (represented by the
C3Duty stream). In the chiller, which is modeled simply as a Cooler, enough heavier
hydrocarbons condense such that the eventual sales gas meets a pipeline dew point
specification. The cold stream is then separated in a low-temperature separator (LTS).
The dry, cold gas is fed to the gas/gas exchanger and then to sales, while the condensed
liquid is mixed with free liquids from the inlet separator. The outlet will be feed to a de-
propaniser.

Feed 1 Feed 2 Chiller

Temp 60.00 F Temp 50.00 F
Pressure 600.00 psia Inlet Cool Gas
Pressure 600.00 psia
Molar Flow 800.00 lbmole/hr Outlet Cold Gas
Molar Flow 700.00 lbmole/hr
Composition (mole basis) Energy E-100
Composition (mole basis)
C1 C2 C3 Nitrogen Delta P 10.00 psia
C1 C2 C3 Nitrogen
0.2 0.3 0.4 0.1 Cold Gas 10.00oF
0.1 0.4 0.4 0.1
Temp
Heat Exchanger
Tube Side Shell Side
Inlet Inlet SepVap Inlet LTS Vap
Outlet Cool Gas Outlet Sales Gas
Delta P 10.00psi Delta P 10.00psi
Specification
Name: Hot Side Approach
Type: Delta Temp
Spec Value: 10.00oF

You are the process engineer for this facility, using HYSYS, show how you would:
I. Create your unit set.
II. Choose your property package (Peng-Robinson’s property package)
III. Select your components
IV. Create and specify feed streams
V. Install and define the unit operations prior to the de-propanizer
2. With the aid of a well labeled diagram, describe the Simulation Basis Environment in
HYSYS.(rep…2)
(a) What is the property package used for (i)Hydrocarbons (ii)Chemical systems (rep…1)
(b)The stream above is to be cooled from 200oC to saturated liquid at a constant pressure of
2bar, outline the steps you would take to;
I. Install the cooler and define its connections and parameter
II. Display the result of the entire result of the flowsheet in your PFD. (rep….3)
3. Outline the steps required to characterize oil in HYSYS, creating Hypo Components from
Laboratory Assay Data, using TBP Distillation Assay.(rep…2)
(a) Consider a gas stream containing 25% ammonia, the rest nitrogen and hydrogen in a 1:2
ratio, all in mole basis. The gas is at 270atm and 550K, with a mass flow rate of 6000lb/hr.
Outline the steps you would take in HYSYS to find the Heat Flow of this stream in Btu/hr,
using Peng Robinson’s property package. (rep..2)
(b)The stream above is to be prepared as a feed for a fractionating tower by separating it
into its vapour and liquid phases. The liquid phase is heated in a furnace to a condition of
900k and 300atm and then recombining with the vapor phase. Show how you will install
and define the streams and unit operations for this process.(rep..2)
4. With the aid of a well labeled diagram, describe the Simulation Basis Environment of a
Chemical Engineering Software.
(a) List the types of components that are used in the Chemical Engineering Software.
(b) Write on two types of components, describing how they are generated and installed in
the Simulation.
5.) A plant is to be designed for the production of 30,000kg per day of Urea by the reaction of
ammonia and carbon dioxide at elevated temperature and pressures, using a total recycle
process in which the mixture leaving the reactor is stripped by the carbon dioxide. The reaction
which produces urea from ammonia and carbon dioxide takes place in two stages; in the first,
ammonium carbonate is formed.

2NH3 + CO2 NH2COONH4

In the second, the ammonium carbonate is dehydrated to give urea.

NH2COONH4 CO(NH2)2 + H2O

Both reactions are reversible

 Ammonia and carbon dioxide are fed to the reactor at 125bar and 185 oC. The reactor
residence time is 45min at which 95% approach to equilibrium is achieved. The ammonia is
fed directly to the reactor, but the carbon dioxide is fed to the reactor upwards through a
stripper, down which flows the product stream from the reactor. The carbon dioxide
decomposes some of the carbonate in the product stream, take ammonia and water to a
high pressure condenser. The stripper is steam heated and operates at 180 oC, whilst the
high pressure condenser is at 170 oC. The heat released in it is used to raise the steam.
Additional recycled carbonate solution is added to the stream in the high pressure
condenser and the combined flow goes into the reactor.

The product stream leaving the stripper goes through an expansion valve to the low
pressure section, operating at 5bar.

6.) A two stage evaporative concentration under vacuum, produces a urea stream containing
0.5% water which is sprayed into a prilling tower.

i. List the components in this process

ii. How would you add these components into the simulation
iii. Describe how you would draw the PFD for the process and add some process stream
data.

7.) The interest in production of hydrogen from hydrocarbons has grown significantly in the last
decade. Efficient production of hydrogen is an enabling technology, directly related to the fuel
cell energy conversion device. The conversion of fuels to hydrogen can be carried out by partial
oxidation. The partial oxidation method relies on the reaction of the fuel for example, methane
with air in order to produce carbon oxides and hydrogen.

CH4 + 1/2O2 → CO +2H2

CH4 +O2 → CO2 + 2H2

Air Methane
Temp 25 Temp
O
C 25 O
C
Pressure 2 Pressure
Bar 2 Bar
Molar Flow 260 Molar
kgmole/hr 100
Flow kgmole/hr It’s your job to develop a model that represents
Composition N2 Composition
O2 C1 partial oxidation of methane to produce
(mole basis) 0.790 (mole
0.210basis) 1.000 hydrogen. Using HYSYS, Show how you would:
 VI. Create your Unit Set.
VII. Define the Simulation Basis. (Choosing property package and selecting component)
VIII. Add your Reactions and Reaction Set.
IX. Create and specify feed streams. Or Add the feed stream (Specifying compositions
and parameters
X. Install and define the Conversion Reactor and define its connections and parameters
XI. Determine if the reactor product has a vapor fraction using a separator.
XII. Display the entire result of the flowsheet on your PFD

8. (a) We have a stream containing 15% ethane, 20% propane, 60% i-butane and 5% n-butane
at 50oF and atmospheric pressure, and a flowrate of 100lbmole/hr. This stream is to be
compressed to 50psia, and then cooled to 32oF. The resulting vapour and liquid are to be
separated as the two product streams. Using Peng-Robinson equation of state as a fluid
package, show how you would:
I. Create your unit set
II. Define the simulation basis (choosing property package and selecting components)
III. Add the feed stream (specifying its composition and parameters)
IV. Install the compressor and define its connections and parameters
V. Install the cooler and define its connections and parameters
VI. Install the separator and define its connections
VII. Display the entire result of the flowsheet in your PFD (rep…3)
9.) It is desired to heat a water stream at 25 oC, 1 atm and 100kgmole/hr to 300 oC
under isobaric conditions.

Using Peng-Robinson’s Equation of State as the fluid Package, outline the

procedure for:

I. Selecting your components

II. Selecting your property package and Creating your unit set
III. Installing the inlet stream to the heater and defining its compositions
and parameters
IV. Install the heater and define its connections and parameters.
V. Display the entire result of the flowsheet in your PFD (rep….3)

10.) It is desired to find the duty in BTU/hr needed to heat an equimolar mixture of n-hexane
and n-octane from 20 oc to 200oC at a constant pressure of 2bar. The stream is flowing at
100lbmole/hr. Using Peng-Robinson’s property package in HYSYS, outline the procedures for:

VIII. Selecting your components

IX. Selecting your property package and Creating your unit set
X. Installing the inlet stream to the heater and defining its compositions
and parameters
 XI. Installing the heater and defining its connections and parameters.
XII. Displaying the result of the heating unit. (rep…3)

11. Simulate a series of three evaporators to concentrate a solution of sucrose/water

(saturated liquid) to 15% water (mass fraction basis). Each evaporator should be modeled
using a flash tank (separator). The condensates from the coolers (condensate, C2 and C3) are
saturated liquid. Heat Flow for Cooler 1 is 23870KJ/h. The temperature of C2 is 5.40F higher
than that of L2. The same goes for the temperatures of C3 and L3.

The figure below represents the PFD for the multiple effect evaporation, showing parameters
needed for the simulation. Use Wilson Activity Model as your property package.

One hundred and fifty kilogram per hour of an equimolar mixture of ethanol and water at 0 oC
are to be vaporized and heated to 350oC at 1atm. What is the rate at which heat must be
supplied to effect the vaporization?

12. In a crude oil processing facility, preheated crude is fed to the pre-flash drum, modeled
as a separator, where vapours are separated from the crude liquids. The liquids are then
heated to 650oF in the crude furnace; modeled as a Heater. The pre-flash vapours bypass the
furnace and are re-combined, using a Mixer, with the hot crude stream. The combined stream
is then fed to the atmospheric crude column for separation. You are one of the process
engineers in the facility and it’s your job to model the pre-crude column train along with the
utilities needed for the column using HYSYS. (Hint: Use the tables for the oil characterization
and the fig for your PFD units and parameters).
(a) Acrylonitrile is produced by the reaction of propylene, ammonia and oxygen:
2C3H6 + 2NH3 + 3O2 → 2C3H3N + 6H2O

Where 30 molar percent of the propylene is converted. A 45mole% propylene and 55mole%
ammonia stream at 25oC and 1 atm is fed to the reactor. The oxygen is fed to the reactor
through an air stream also at 25 oC and 1 atm. The feed stream is flowing at 22kgmol/her,
and the air stream is flowing at 78kgmol/hr. Assume adiabatic reactor with no pressure
drop. You are to find the temperature of the reactor product stream in oC. Also you are to
 find the dew-point temperature (Vf = 1) of the reactor product stream. (Hint: Air is 79mol%
N2 and 21mol% O2)
(b) For the process above, consider the same reaction and reactor inlet streams that were
used. Now the reactor is no longer adiabatic. Instead, it is an isothermal process, meaning
the product steam is at the temperature as the two inlet streams, 25 oC. What is the reactor
duty in kJ/h for this isothermal process? Is the chemical reaction endothermic or
exothermic? Must heat be added to or removed from the reactor.

In multiple effect evaporation, the volatile solvent recovered from the first evaporator is
condensed and used as a heat source for the next evaporator. This means that the second
evaporator must operate at a lower temperature and pressure than the first evaporator.
Simulate a series of three evaporators to concentrate a solution of sucrose/water
(saturated liquid) to 15% water (mass fraction basis). Each evaporator should be modeled
using a flash tank (separator). The condensates from the coolers (condensate, C2 and C3)
are saturated liquid. Heat Flow for Cooler 1 is 23870KJ/h
The temperature of C2 is 5.40F higher than that of L2. The same goes for the
temperatures of C3 and L3.

13. The figure below represents the PFD for the multiple effect evaporation, showing parameters
needed for the simulation.
Use Wilson Activity Model as your property package.
 GERMAN PART ONLY 4 TEST MOST TIMES

1. (a) The four variables needed to be supplied to make a material stream in HYSYS
converge are …………………., …………………….,……………………….. and ……………………

(b) HYSYS uses the concept of …………………………………. to contain all information

needed for performing physical and flash calculations.

(c) The property package in HYSYS suitable for modeling processes involving
Hydrocarbons is ………………………………………

(d) A heater is needed to heat water at 10psi to steam. It is to be modeled to

operate under isobaric conditions. The pressure and the vapour fraction of the
heater product are …………………. and ………………….

(e) For HYSYS to calculate the duty of the heater above, you need to
…………………………………….. of the product stream.

(f) For a HYSYS distillation column simulation, the feed, distillate, and bottoms
streams are to be ……………………………… liquids.

AUTOCAD
1. (a) With the aid of a well labeled diagram ONLY, describe the AUTOCAD Drawing
Environment.
(b) I) What are the four workspaces AUTOCAD offers?
II) Differentiate between the two types of workspaces in the 2D environment.
2. (a) Using the “Draw” Panel in AUTOCAD, outline the steps required to draw:
I. A line
II. A Polyline
III. An Arc
(b) Using the “Modify” Panel in AUTOCAD, outline the steps required to:
I. Move an object
II. Copy an object
III. Mirror an object
IV. Offset and object
V. Trim an object (rep..3)
3. (a) Outline the steps you would take to draw a window using AUTOCAD, consisting of
two concentric rectangles, having a line between the midpoints of the inner rectangle.
(b) Outline the steps required to:
I. Add dimensions to your drawing
II. Label your drawing.
III. Save and Print your drawing Environment.

4. The shape below is a mounting plate. Describe how it can be reproduced using AUTOCAD
outlining the procedures for drawing:

a) the construction lines (Using colored, broken lines)

b) the circles at the centre ( By Offsetting)
c) the circles at the extremes ( Using relative coordinate system)
note;(their midpoint are of equal distance from the centre of the mounting plate)
d) the arcs and the line for one quadrant of the entire border
e) the entire border (Using “Mirror” modification tool)
5. The figure attached is the PFD for question 13. Describe how it can be reproduced using
AUTOCAD outlining the procedures for drawing:
a) The material stream lines
b) The energy stream lines
c) The compressor
d) The cooler
e) The separator

6.Outline the steps you would take to draw a window using AUTOCAD, consist of two
concentric rectangles, having a line between the midpoints of the inner rectangle. (Making use
of the OFFSET command and Object snap) (rep…2)

3. Using AUTOCAD, reproduce the flowsheet for the crude oil processing facility for Question
12.
4. The figure below is the schematics for an air compressor, reproduce same using AUTOCAD.

The Figure above represents the schematic diagram of the vacuum distillation Unit in a petroleum
refinery.

(a) Outline the procedure you would adopt to quickly draw the process flowchart using AutoCAD.
(b) How will you text the flowchart?

GERMAN PART ONLY 4 TEST MOST TIMES

(c) In AUTOCAD…………………………….. mode prevents one from drawing lines in angles other
than 900.

(d) A line whose start point could be anywhere and whose endpoint is specified with the
relative point @2,0 is a …………………….. line …………….. units long.

(e) When you toogle on the ….................. it enables you determine the end point of a line.

(f) The OFFSET command creates lines or curves …………………. to one existing object.