S-138777-Activated Energy Analysis Jump Start Guide

Jump Start: Activated Energy Analysis in Aspen Plus and Aspen HYSYS
A Brief Tutorial (and supplement to training and online documentation)

Nicholas Brownrigg, Product Marketing, Aspen Technology, Inc. Jack Zhang, Product Management, Aspen Technology, Inc.
2013 Aspen Technology, Inc. AspenTech, aspenONE, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved. 11-4700-1113
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Setting Up an Energy Analysis Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Generating Process Revamp Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Performing Multiple Revamp Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Introducing Heat Exchanger Changes to Process Flowsheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Analyzing and Fine-Tuning Heat Integration Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Viewing Heat Exchanger Network Diagram and Composite Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Adding and Comparing Multiple Heat Integration Projects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Obtaining Heat Transfer Coefficients from Activated EDR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Filtering Streams by Pinch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Introduction
In todays business climate, profitability is of pinnacle importance. One of the challenges facing industrial plants in reaching profitability is the minimization of annual costs related to utility consumption. In order to achieve a reduction in utility costs, many plants choose to perform an integration of heat exchanger networks. The specific network of heat exchangers that make best use of the available in-house heating and cooling is constructed using pinch calculations. However, these calculations can be daunting for simple plant setups with little equipment, and only increase in difficulty with a higher sophistication of plant design. To respond to this challenge, Aspen Technology has introduced an innovative approach to reduce energy use and greenhouse gas outputs in its Activated Energy Analysis offering. Activated Energy Analysis works inside of Aspen HYSYS and Aspen Plus, with no need to operate another program concurrently. Using Activated Energy Analysis, a summary of annual process energy and greenhouse gas consumptions and expenditures, along with potential savings through process upgrades and redesign, are provided. Activated Energy Analysis generates extensive revamp scenarios that can be implemented to reduce fresh utility dependence and shows details relevant to the optimization including required capital cost, annual reduction in utility cost, and payback period for investment. The basic steps towards best utilizing Activated Energy Analysis will be described in this guide, as will advanced techniques. Some features denoted in this guide are only available in the V8.4 or later release of Activated Energy Analysis, but all basic workflow is included in Activated Energy Analysis V8.0 and higher. As a reminder, it is free for current AspenTech customers to upgrade to the latest version of the aspenONE Engineering suite. Simply contact AspenTech support via support.aspentech.com to do so. This document is not meant to be used as a stand-alone reference document. We recommend that a range of other resources be called upon to give the user a comprehensive view of how to use Activated Energy Analysis. These may include: AspenTech support website (support.aspentech.com) includes information on the use of AspenTech products and provides answers to frequently asked questions AspenTech courseware available in on-line and in-person versions AspenTech business consultants This guide will show how to utilize Activated Energy Analysis to analyze and optimize energy in Aspen Plus and Aspen HYSYS. It assumes that the user has Aspen HYSYS or Aspen Plus V8.0 or higher installed on her or his computer and a functional process design completed.
Setting Up an Energy Analysis Project

After completing a process design in Aspen HYSYS or Aspen Plus, Activated Energy Analysis can be initialized to perform a heat integration. Begin by clicking the Activated Analysis button from the ribbon and clicking the Activated Energy Analysis icon from the Activation panel that appears, as shown in Figure 1.
Figure 1. Activated Analysis Option and Activated Energy Analysis Icon
Once opened, an energy analysis project should be set up by clicking the Edit Options button from the dashboard and filling out the form that appears, as shown in Figure 2.
Figure 2. Setting Up Options for Energy Analysis Project
By default, the minimum approach temperature is set at 10C and all processes on the flowsheet are selected to be analyzed. To customize, in the Energy Analysis Options window, select the process type being analyzed, the desired approach temperature, and the portions of the flowsheet to be included in the energy analysis if the flowsheet has been hierarchied (the utility type fed to each heat exchanger shown in the form above is available in Aspen HYSYS only). Click OK and Activated Energy Analysis will evaluate the flowsheet sections chosen. When evaluation is complete, the dashboard will be updated. Activated Energy Analysis calculates the amounts of energy consumed and greenhouse gases emitted by the process, based on the current process flowsheet layout. The total saving potential is also determined through process revamp for both energy consumption and greenhouse gas emissions. Additionally, the user can toggle between viewing either the cost or energy present in the process. Toggling between these options and also a color-coded layout of the dashboard are shown in Figure 3.
Figure 3. Energy and GHG Cost and Output Forms
Clicking the Saving Potential button on the dashboard opens the Energy Analysis environment to the Saving Potential form, as shown in Figure 4.
Figure 4. Opening the Saving Potential Form
The Saving Potential form provides more details regarding the reduction of energy. Each utilitys current usage and the resulting greenhouse gas production are shown, as well as the target reduction for each. The yearly cost savings for each utility is also displayed, based on the reduced rate of utility required. If a utility specified during set up can be replaced with a cheaper option, Activated Energy Analysis will suggest this replacement on the Saving Potential form. This can be observed in two ways when the target amount for a utility is reduced to 0 MW in the utilities table, and when that amount is absorbed into another utility listing. For Aspen Plus users, only utilities defined in the Utilities Object Manager will be considered in the targeting process for utility switching. For Aspen HYSYS users, all utilities defined in the Process Utilities Manager will be considered. Undesired utilities need to be removed from the Process Utilities Manager in Aspen HYSYS if they are unavailable for selection. Also included on the Saving Potential form is a heat exchanger detail table. This table shows a listing of the heat exchangers included in the heat integration, each exchangers duty, temperatures, area, heat transfer coefficient, and hot and cold fluids. In version 8.4 or higher of Activated Energy Analysis, a column titled Ideas for Changes appears. In this column, if a light bulb appears, Activated Energy Analysis has detected a simple design change (i.e. changing the temperature of a heat exchanger inlet stream) that could lead to a more efficient energy usage in the process. Additionally, heat transfer coefficients obtained from rigorous Aspen Exchanger Design and Rating models can be used to improve the accuracy of the heat exchangers being used in the heat integration model. See the Obtaining Heat Transfer Coefficients from the Activated EDR section later in this guide to learn more.
Generating Process Revamp Solutions

To help achieve the saving potential given by Activated Energy Analysis, revamp solutions can be generated from the Activation dashboard. These solutions include the modification, addition, or relocation of heat exchangers in the process. Begin the creation of revamp solutions by clicking on the blue arrow of the Activated Energy Analysis dashboard, then click the Generate button. Activated Energy Analyzer can generate up to five solutions for both the addition and relocation of heat exchangers. The first solution for each revamp is displayed in the dropdown, shown in Figure 5.
Figure 5. Generating Process Revamp Solutions
Click on one of the solutions to view more in-depth details, or to view the other heat exchanger addition or relocation solutions. Shown in Figure 6 is the form for heat exchanger addition. Each form for the respective solutions has the same layout.
Figure 6. Revamp Solution Form for Exchanger Addition
The top table in the revamp solution form shows how the energy consumption and greenhouse gas emission of the revamp compares with the base simulation case and the targeted best case values calculated by Activated Energy Analysis. Also shown is the energy cost per year. The middle table displays all of the revamp solutions found for the particular solution type (i.e. heat exchanger addition). The capital cost for implementing the solutions, as well as the energy and yearly energy cost savings are provided, along with the corresponding payback period. The location of the solution in the process is also given so the user can modify, add, or relocate the heat exchanger revamp onto the flowsheet if desired for modeling purposes. The third table gives details on the heat exchangers in the network for the heat integration for the selected solution in the middle table. The New Load and New Area columns, as well as the Extra Capital Cost column, show what changes have been made to each heat exchanger. The Maximum Extra Area and Minimum Approach Temperature columns are defaulted to the values shown in Figure 6. If an area or approach temperature constraint exists for any heat exchanger in the network, enter that value in the appropriate column and click the Update button at the top left of the table. Figure 7 shows results of placing a constraint of 500m2 and 7C on E-114, as well as the location of the Update button. New results can be compared with those in Figure 6 to see how constraints affected the entire heat exchanger network.
Figure 7. Placing Constraints on Heat Exchanger Network
Performing Multiple Revamp Solutions

Multiple heat exchanger operations can be performed at once (i.e. a heat exchanger addition following previous heat exchanger relocation) by opening the first revamp solution and selecting the second revamp from the ribbon in the Energy Analysis environment. For example, if the heat exchanger relocation solution is opened, the Energy Analysis environment and form shown in Figure 8 will open. Clicking one of the retrofit options, highlighted in the ribbon, will add another second revamp solution to the previously existing solution.
Figure 8. Performing Multiple Revamp Solutions
After instituting the second revamp solution, the scenario form will update. Figure 9 shows a scenario in which the process has had a heat exchanger relocation followed by a heat exchanger addition.
Figure 9. Multiple Revamp Solutions Generated
The top table in Figure 9 now includes four rows that display the specs for the base case design, the initial revamp, the process after two revamps, and the target. This table can be used to track energy savings as more revamps are included.
Introducing Heat Exchanger Changes to Process Flowsheet

This section will demonstrate heat exchanger additions in Aspen HYSYS. The workflow shown is similar to the workflow in Aspen Plus. Since Activated Energy Analysis is included in Aspen HYSYS and Aspen Plus, heat exchanger modifications, additions, or relocations can be added to the process flowsheet immediately after being created using the specifications provided. Figure 10 shows a crude preheat train modeled in Aspen HYSYS.
Figure 10. Crude Preheat Train Flowsheet in Aspen HYSYS
After running Activated Energy Analysis to obtain a revamp solution, such as the heat exchanger addition case shown in Figure 11, use the Location of Heat Exchanger column in the design change table to determine where the new heat exchanger model should be placed on the flowsheet.
Figure 11. Heat Exchanger Solution Selection and Location
Then, using the Heat Exchanger Details table found on the same form, locate the new load for the heat exchangers in the process. Highlighted in Figure 12, Design Load represents the new heat exchanger duties after adding a revamp scenario, while the Base Load was the existing load for the initial simulation.
Figure 12. New Heat Exchanger Duty Specifications
Add a heat exchanger model to the flowsheet using the model palette in either Aspen HYSYS or Aspen Plus. Then, connect the appropriate streams as shown in Figure 11. Figure 13 shows the crude preheat train with the new heat exchanger addition. The shell side of the heat exchanger has been attached to the stream PA_3_1 which was previously a feed to E-113, and the tube side of the heat exchanger has been attached to the stream crude46, which was previously a feed to E-106.
Figure 13. Crude Preheat Train Flowsheet in Aspen HYSYS with Heat Exchanger Addition
The updated duties for the heat exchangers listed in the table in Figure 12 were then input to all the corresponding heat exchanger models. After converging the simulation with the new heat exchanger duties, the flowsheet is then indicative of the revamp solution. The Activated Energy Analysis dashboard will update with new saving potentials if opened after updating the flowsheet.
Analyzing and Fine-Tuning Heat Integration Results

When finished generating revamp solutions for the process, the scenarios can be compared on one form by selecting the Compare Scenarios option from the ribbon, as shown in Figure 14.
Figure 14. Comparing Scenarios within a Project
The Result Comparison form allows for a quick comparison of revamp solutions for a given heat integration project.
10
Viewing Heat Exchanger Network Diagram and Composite Curves

A copy of Aspen Energy Analyzer can be opened directly from within Activated Energy Analysis. This allows the user to see a detailed heat exchanger network (HEN) diagram and the composite curves used in generating the heat integration. The HEN diagram shows heat exchanger pairings and approach temperatures for the streams. To access this feature, click the Details button from the ribbon, shown in Figure 15.
Figure 15. Details Option to Open HEN Diagram and Composite Curves
Aspen Energy Analyzer then opens directly to the heat exchanger network diagram. An example HEN diagram is shown in Figure 16.
Figure 16. HEN Diagram from Aspen Energy Analyzer
At the bottom of the Aspen Energy Analyzer program, a tab labeled Performance is selected. To access the composite curves for the heat integration, select the Targets tab (Figure 17), adjacent to the Performance tab.
11
Figure 17. Accessing Composite Curves and Example Composite Curves Chart
Adding and Comparing Multiple Heat Integration Projects

In version 8.4 and higher of Activated Energy Analysis, if there are multiple sections of a flowsheet requiring separate analysis (for example hierarchies), multiple heat integration projects can be completed and compared. To do this, while in the Energy Analysis environment, click the Add Project option from the ribbon shown below in Figure 18 and then set up the new project using the same steps used for the initial project. (Note that in order to best use the multiple project feature to study the impact of process changes on energy saving opportunities, the energy dashboard should be deactivated and multiple project analysis then carried out directly inside the Energy Analysis environment.) After setting up multiple heat integration projects, they can be compared by clicking the Compare Projects button, also on the ribbon. This brings the user to a project comparison form (Figure 19) where energy, greenhouse gas savings, and reduction potentials can be viewed.
Figure 18. Adding a Heat Integration Project
12
Figure 19. Project Comparison Form
Obtaining Heat Transfer Coefficients from Activated EDR

In version 8.4 of Aspen HYSYS or Aspen Plus or higher, Activated EDR can be used to size rigorous heat exchangers. The heat exchanger parameters obtained from Activated EDR can be used to improve heat integration using Activated Energy Analysis, shown in Figure 20. Going back to the Saving Potential form, in the Heat Exchanger Details table, the value for the overall heat transfer coefficient can either be calculated in Aspen Energy Analyzer by default, be taken from simulation, or specified directly by the user.
Figure 20. Choosing Heat Exchanger Parameter Options
Simulation values and default values remain the same unless heat exchangers are sized using Activated EDR. To do this, return to the Simulation environment and click the Activated EDR icon from the Activation dashboard. A dropdown of heat exchangers showing their status as either rigorous or available to convert to rigorous will appear. Click a Convert button next to a heat exchanger to make it a rigorous model, as shown in Figure 21.
13
Figure 21. Initializing Activated EDR
After a heat exchanger has been sized, return to the Saving Potential form in the Energy Analysis environment, and choose Simulation on the dropdown. The heat transfer coefficient and heat exchanger area should change to the values obtained from rigorous sizing. For more information on using Activated EDR in Aspen HYSYS and Aspen Plus, including a separate Jump Start Guide, visit the Activated EDR webpage at www.aspentech.com/products/activated-edr/.
Filtering Streams by Pinch

In version 8.4 or higher of Activated Energy Analysis, the Heat Exchanger Details table on the Saving Potential form can be reduced to show streams that are either above, below, or across the pinch line. This enables visualization of process stream location relative to the pinch point and aids in development of process changes that maximize energy saving opportunities. To do this, click the Hot Side Fluid or Cold Side Fluid column in the table and choose an option, as shown in Figure 22.
Figure 22. Sorting Heat Exchanger Details Table by Pinch Location
Sorting this table to only show streams below the pinch reduces the table to that in Figure 23.
14
Figure 23. Reduced Heat Exchanger Details Table Sorted Below the Pinch
Conclusion
Activated Energy Analysis is a tool capable of calculating process energy reliance and greenhouse gas emissions, as well as reducing these values through more cost effective utility selections and process revamps. Located within Aspen HYSYS and Aspen Plus, Activated Energy Analysis allows users to generate changes and then implement them directly to simulation to view performance. Activated Energy Analysis, when used in conjunction with the other members of the Activated Analysis family, becomes an even more powerful process optimization tool. Activated Analysis can be implemented to new processes or existing ones to dramatically improve performance. As a reminder, it is free for current AspenTech customers to upgrade to the latest version of the aspenONE Engineering suite. Simply contact AspenTech support via support.aspentech.com to do so.
Additional Resources
Public Website:
http://www.aspentech.com/products/aspen-hysys.aspx http://www.aspentech.com/products/aspen-plus.aspx http://www.aspentech.com/Products/Activated-Energy-Analysis/ http://www.aspentech.com/products/aspen-hx-net.aspx
Supporting Documents:
Prepare a Flowsheet for Energy Analysis in Aspen Plus and Aspen HYSYS Activated Energy Analysis Demo File in Aspen HYSYS - Crude Preheat Train Activated Energy Analysis Demo File in Aspen Plus - Ethylene Separation Process
Online Training:
http://www.aspentech.com/products/aspen-online-training
AspenTech YouTube Channel:

http://www.youtube.com/user/aspentechnologyinc
15
About AspenTech
AspenTech is a leading supplier of software that optimizes process manufacturingfor energy, chemicals, engineering and construction, and other industries that manufacture and produce products from a chemical process. With integrated aspenONE solutions, process manufacturers can implement best practices for optimizing their engineering, manufacturing, and supply chain operations. As a result, AspenTech customers are better able to increase capacity, improve margins, reduce costs, and become more energy efficient. To see how the worlds leading process manufacturers rely on AspenTech to achieve their operational excellence goals, visit www.aspentech.com.
Worldwide Headquarters
Aspen Technology, Inc. 200 Wheeler Road Burlington, MA 01803 United States phone: +17812216400 fax: +17812216410 info@aspentech.com
Regional Headquarters
Houston, TX | USA phone: +12815841000 So Paulo | Brazil phone: +551134436261 Reading | United Kingdom phone: +44(0)1189226400 Singapore | Republic of Singapore phone: +6563953900 Manama | Bahrain phone: +97317503000
For a complete list of offices, please visit www.aspentech.com/locations

S-138777-Activated Energy Analysis Jump Start Guide

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

S-138777-Activated Energy Analysis Jump Start Guide

Uploaded by

Copyright:

Available Formats

Jump Start: Activated Energy Analysis in Aspen Plus and Aspen HYSYS

A Brief Tutorial (and supplement to training and online documentation)

Setting Up an Energy Analysis Project

Figure 1. Activated Analysis Option and Activated Energy Analysis Icon

Figure 2. Setting Up Options for Energy Analysis Project

Figure 3. Energy and GHG Cost and Output Forms

Figure 4. Opening the Saving Potential Form

Generating Process Revamp Solutions

Figure 5. Generating Process Revamp Solutions

Figure 6. Revamp Solution Form for Exchanger Addition

Figure 7. Placing Constraints on Heat Exchanger Network

Performing Multiple Revamp Solutions

Figure 8. Performing Multiple Revamp Solutions

Figure 9. Multiple Revamp Solutions Generated

Introducing Heat Exchanger Changes to Process Flowsheet

Figure 10. Crude Preheat Train Flowsheet in Aspen HYSYS

Figure 11. Heat Exchanger Solution Selection and Location

Figure 12. New Heat Exchanger Duty Specifications

Analyzing and Fine-Tuning Heat Integration Results

Figure 14. Comparing Scenarios within a Project

Viewing Heat Exchanger Network Diagram and Composite Curves

Figure 16. HEN Diagram from Aspen Energy Analyzer

Adding and Comparing Multiple Heat Integration Projects

Figure 18. Adding a Heat Integration Project

Figure 19. Project Comparison Form

Obtaining Heat Transfer Coefficients from Activated EDR

Figure 20. Choosing Heat Exchanger Parameter Options

Figure 21. Initializing Activated EDR

Filtering Streams by Pinch

Figure 22. Sorting Heat Exchanger Details Table by Pinch Location

AspenTech YouTube Channel:

For a complete list of offices, please visit www.aspentech.com/locations

You might also like