Column Dynamics

Column Dynamics

Instructor: Eng. Ahmed Deyab Fares Mobile: 0127549943

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2004 Aspen Technology. - All Rights Reserved.

Column Dynamics

Learning Objectives
In this module you will learn to:

Configure a distillation column to meet purity specifications Prepare the distillation column for dynamic simulation analyses Develop a control strategy Test the model

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The Column Dynamics module introduces you to the process for setting up a distillation column with HYSYS Dynamics. Some of the concepts you have learned in the previous modules are applied here. However the distillation column is one of the most complex unit operations in HYSYS. As such, it deserves special attention. Starting with the Feed Heater Train, you will expand the Flowsheet by adding the DePropanizer column.

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Workshop

Process Overview

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Expanding the DePropanizer Simulation Flowsheet

Load the simulation case that you created and saved in the Transitioning from Steady State to Dynamics module (FHT-Dyn1.hsc). Click the Steady State Mode button to return to Steady State in order to add a column.
You may get a consistency error when you start the steady state solver. You need to resolve the error before you continue.

Add a Distillation Column

Distillation Column icon

Add a distillation column to the Flowsheet. Configure the distillation column with the following information:
In this cell... Connections Name Number of Stages Inlet Stream Inlet Stage Condenser Type Condenser Energy Stream Overhead Vapour Outlet DePropanizer 24 ColFeed 12 Full Reflux Q-Cond Propane Q-Reb C4+ 1925 kPa (280 psia) 2070 kPa (300 psia) 0 kPa (0 psi) 2 Enter...

HYSYS is equipped with a distillation column Input Expert option that allows you to have properly configured the column. The Use Input Expert option can be accessed from the Tools-PreferencesSimulation menu

Reboiler Energy Stream Bottoms Liquid Outlet Pressure Profile Condenser Pressure Reboiler Pressure Condenser Pressure Drop Specification Reflux Ratio

Column Dynamics

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On the Specs page of the Design tab add a new specification with the following information and make it Active:

Column Specification Types Name Stage Flow Basis Phase Spec Value Components

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Click the Run button to converge the column.

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The steady state model of the DePropanizer process is now complete. All unit operations, material and energy streams are solved. Save your case as Column_SS.hsc.

Save your case!

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Vapour 0.95

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Lights Condenser Mole Fraction Ethane, Propane

In this cell...

Enter...

Column Component Fraction

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Open the Column Property view to the Monitor page on the Design tab. Notice that two specifications are Active, Reflux Ratio and Overhead Vapour Rate. Make the Overhead Vapour Rate Inactive, and the Degrees of Freedom goes to 1.

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Adding Column Specifications

Column Dynamics

Preparing for Dynamic Simulation Analyses

Equipment Sizing
On the Rating tab of the Column Property View, you can input the sizing information for the Distillation Column. The information required to size a distillation column is the Condenser Volume, the Reboiler Volume and the Column Tray Section dimensions. Additionally, on the Rating tab there exists the facility to size other equipment that is in the column sub-flowsheet.

Vessels
Appropriate vessel sizing is important for dynamic simulation analyses. The vessel hold-up will affect the system's transient response during dynamic analyses as you move from one operating regime to the next. In addition, the vessel size affects the pressure calculations that are associated with the unit operation. 1. Input a Condenser Volume of 10 m3 (350 ft3) and Reboiler Volume of 20 m3 (700 ft3).

Sizing the Column Tray Section

If you do not know the dimensions of your process equipment, calculate the vessel size based on an appropriate residence time: 10 minutes is typically a suitable residence for liquid phase hold ups. 2 minutes is typically a suitable residence time for vapour phase hold ups.

In steady state mode you are free to specify the column pressure profile as you desire. In fact, we just specified a column pressure drop of 145 kPa (20 psi). In dynamics mode, the column pressure profile is calculated by the hydraulic calculations on each stage. Thus the calculated pressure drop on each tray section is a function of the tray geometry (diameter, weir height, weir length and tray spacing). The dynamic column pressure profile of each column in your Flowsheet can be estimated with the Tray Sizing utility. The Tray Sizing utility performs the hydraulic calculations on each stage of the column. If you do not know the actual dimensions of your column tray section the tray section geometry should be used to estimate the size of the tray section before running dynamically.
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Column Dynamics

Some columns may have multiple tray sections. In an effort to balance model rigour with ease of model development only 1 tray section geometry is provided on the Rating tab. Averaged tray section information should be specified on this tab.

Running the Tray Sizing Utility

To run the Tray Sizing utility, do the following:
The HYSYS Dynamics Assistant is capable of performing the Tray Sizing automatically. However, the process is given here because the Assistant is deactivated.

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Click the Add Section button. This adds the selected tray section to the utility, allowing the sizing calculations to be performed. Move to the Performance tab and then select the Results page. The hydraulic calculations based on the recommended tray geometry for the column are displayed. This page also displays the estimated Tray Section Pressure Drop. Notice the Tray Sizing utility estimates approximately a 10 kPa (1.4 psi) pressure drop through the 24 stages of the column.

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When we initially designed our column in Steady State mode, we inputted a pressure drop of 145 kPa (20 psi) through the column. The condenser pressure being specified as operating at 1925 kPa (280 psia) and the reboiler pressure being specified at 2070 kPa (300 psia). Additionally, the ColFeed pressure was calculated to be operating at 2000 kPa (290 psia).

Click the Select TS button and choose the tray section to size. In this case select the DePropanizer Flowsheet and Main TS as the object. Click the OK button.

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From the Tools menu, select Utilities and from the Available Utilities view select Tray Sizing and click the Add Utility button.

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If different tray sections are required for more accurate modelling, multiple tray sections can be configured and linked together.

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Column Dynamics

In dynamic mode, the pressure drop at each stage will be calculated based on the tray geometry. Moreover, the Condenser, Reboiler and ColFeed pressures will be based on this dynamic pressure profile. If the steady state pressure profile does not match the dynamic pressure profile the column tray pressures and flow rates will oscillate until an equilibrium pressure profile is established. As the column tries to adjust to an equilibrium pressure profile, the column can possibly go unstable. Thus a proper column pressure profile based on the hydraulic calculations should be entered for the column before moving to dynamic simulation analysis.

Size the Column Tray Section

1. From the Results page on the Performance tab of the Tray Sizing utility, fill in the appropriate tray dimensions in the table below.
Enter... In this cell... Rating - Tray Sections Section Diameter Weir Height Weir Length Tray Spacing Tray Volume (calculated)

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If the Tray Sizing utility determines more than one section in the Column, there are two options: 1. Use the weighted average dimensions for the dynamic tray dimensions. 2. Configure the column with multiple tray sections inside the column sub-flowsheet and supply the dimensions as appropriate.

Open the Column Property view (by double-clicking on the column). Enter the values shown in the table above into the appropriate fields on the Tray Sections page of the Rating tab. Click on the Parameters tab and select the Profiles page. Change the pressure of the Condenser and Reboiler as follows:
1925 kPa (280 psia) 1945 kPa (283 psia)

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Condenser Pressure Reboiler Pressure

Save your case as: ClmSize.hsc.

Save your case!

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Column Dynamics

Refer to the Rules to Remember Outlined in the Transitioning from Steady State to Dynamics module.

For your ease of reference, we have included the first seven rules here:
Dynamics Specifications Boundary Streams

Pressure Specifications

Distillation Columns

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Valves

K value

Pressure gradients

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Tray Sizing

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Dynamic specifications can only be modified when the integrator is stopped. Once the integrator is started the value of the dynamic specification can be changed (its value appears in blue), but the choice of dynamic specification can not be changed.

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Insert a valve on all boundary streams (feed/product streams) within the Flowsheet that are not connected to conductance devices (i.e., heat exchangers, coolers, heaters) Place a pressure specification on all boundary streams (feed/product streams) within the Flowsheet. Distillation columns with condensers require an extra specification around the condenser. Make a flow specification for the reflux flow. Use the pressure/flow relationship as the dynamic specification for a valve. Use the overall K value as the dynamic specification for coolers, heaters, and heat exchangers and LNG exchangers. Be sure to account for pressure gradients throughout the Flowsheet. Moreover, be sure to specify reasonable pressure drops/rises in the Flowsheet. Pressure differentials are the driving force for flow through the process Flowsheet. Use the tray sizing utility to estimate the column geometry and pressure profile.

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Making Pressure Flow and Dynamic Specifications

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Add Valves to the Boundary Feed and Product Streams

1. In the expanded Flowsheet, two boundary streams have been added and 1 boundary stream has been removed. The two new boundary streams are Propane and C4+. The boundary stream that has been removed is ColFeed. Remembering Rule one, add a valve to all boundary streams, so add a valve downstream of the Propane and C4+ streams in the Column Sub-flowsheet. Specify a pressure drop of 70 kPa (10 psi) and size the valves as you did in Module 2.
What Cv value does HYSYS calculate for the Propane valve? _____________ And for the C4+ valve? _______________________________________________

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Return to the Main Environment. Connect the boundary subflowsheet streams Propane Out and C4+ Out to the Main Flowsheet streams Propane and C4+, respectively. This is done on the Connections page of the Design tab of the Column Property view.

Make the Appropriate Pressure-Flow Specifications

6. On the Dynamics tab of streams Propane and C4+ select the Pressure Specification by checking the checkbox. Again, make sure only the Pressure Specification is Active. Propane and C4+ are boundary streams in the main Flowsheet. Remember to deactivate the Pressure Specification of the ColFeed stream.

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Column Dynamics

Figure 1

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On the Dynamics tab of the Reflux stream (Column Sub-flowsheet) make the Molar Flow specification Active.
Figure 2

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Column Dynamics

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Run the Dynamics Assistant to see if there is something else that needs to be changed.
What recommendations does the Dynamics Assistant make? ____________________________________________________________________

Dynamic specifications can only be modified when the integrator is stopped. Once the integrator is started the value of the dynamic specification can be changed (its value appears in blue), but the choice of dynamic specification can not be changed.

Save your case as: Clm-Specs.hsc.

Save your case!

Click the Dynamics Mode icon to enter dynamics, and start the integrator as the model is now ready to run in dynamics. Run the integrator for a few minutes of integrator time.
Integrator Start icon

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Column Dynamics

Add the following Controllers to your case for Column Control: 1.

Pressure Control Overhead Condenser In this cell... Control Valves should be sized with a maximum of twice the Steady-State value. Connections Name Process Variable Source Output Target Object Action PV Minimum PV Maximum Mode Kc TI Enter...

Parameters - Configuration

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SP

In this cell...

Connections Name

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Dont forget to size the control valve properly.

Process Variable Source Output Target Object Parameters - Configuration Action PV Minimum PV Maximum Mode Kc TI SP

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Direct Auto 2.0 Enter... Reflux Direct 0% 100% Auto 2.0 50%

Condenser Level Control

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Cond-PC C3 Valve 1725 kPa (250 psia) 2070 kPa (300 psia) 2.0 minutes 1925 kPa (280 psia) Cond-LC 10.0 minutes

Condenser, Vessel Pressure

Condenser, Liquid Percent Level

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Add the Column Controllers in the Column Environment. Installing the controllers in the Column Environment eliminates the need for the controllers to cross the Flowsheet boundary.

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Adding Strip Charts and Controllers

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Reboiler Duty Control In this cell... Connections Name Process Variable Source Output Target Object Parameters - Configuration Action PV Minimum PV Maximum Mode Kc TI SP Reverse 100C (200F) 200C (400F) Auto 2.0 10.0 minutes 140C (270F) Reboiler Level Control In this cell... Connections Name Process Variable Source Output Target Object Parameters - Configuration Action PV Minimum PV Maximum Mode Kc TI SP Direct 0% 100% Auto 2.0 10.0 minutes 50% Reb-LC Reboiler, Liq Percent Level C4+ Valve Enter... Tray23-TC Main TS, Stage Temp., Stage 23 Q-Reb Enter...

Save your case as: Clm-Control.hsc.

Save your case!

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Column Dynamics

Create a Strip Chart named Column and enter the following variables:

Does the simulation reach a steady state if given enough time? ____________________________________________________________________

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Change the Output Variable for the Condenser-LC to Cond-Q, from Reflux. Make sure that you choose reasonable values for the maximum and minimum cooling duty. Change the molar flow specification for the Reflux stream to 1620 kgmole/h (3560 lbmole/hr).
Does this control strategy provide better control over the De-Propanizer? ____________________________________________________________________ Can you think of another control strategy for the Condenser Liquid level? ____________________________________________________________________

Exercise 2

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Run the Integrator and watch the variables change over time.

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ColFeed Mass Flow Condenser Vessel Pressure C4+ Mass Flow Propane Mass Flow

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Exercise 1

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Exercise 3
Change the NGL-Feed composition as follows:
Component Ethane Propane i-Butane n-Butane i-Pentane n-Pentane Hexane Mole Fraction 0.01 0.25 0.08 0.15 0.07 0.07 0.37

How does this change affect the Propane concentration in the C4+ stream? ____________________________________________________________________ How long does it take for the change to occur? ____________________________________________________________________ Try changing the Tray23-TC set-point in order to return the Propane concentration back to its original level. Does the temperature have to be lowered or raised? ___________________________________________________

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Column Dynamics

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