Distillation of Close Boiling Components with Aspen

HYSYS V8.0
1. Lesson Objectives

Use the Optimizer tool in HYSYS to optimize flowsheets

Use the Spreadsheet to perform calculations

A simple distillation column to separate Tetrahydrofuran (THF) from Toluene is simulated. The object of
the exercise is to select the product specifications such that profit is maximized. A special tool in HYSYS,
the Optimizer, will be used to find the optimum operating condition

Answer all red color requirements:

Create a Component List. In the Properties environment, select the Component Lists folder
in the navigation pane and click Add to add a new HYSYS component list. In Component
List 1 add Tetrahydrofuran and Toluene to the selected components list

Create a Fluid Package. Click on the Fluid Packages folder in the navigation pane and select
Add to add a new HYSYS fluid package. Select Wilson as the property package. On the Binary
Coeffs tab, check that the UNIFAC VLE estimation method is chosen, and press the Unknowns
Only button to estimate the missing Interaction Parameters.

Adding the Feed Stream

Add the Distillation Colum

Create two new Column Component Fraction specifications as shown below:

These two specifications should be Active. The DOF for the column should now be 0. The column should
now solve automatically. If it does not, press the Run button to start the solver. Save your case !

Changing the Column Tolerances

In order for the optimizer to work properly, we have to tighten the tolerances of the column solver.
There are two tolerances that the column must meet before it can be considered as solved.
The Equilibrium Error Tolerance
The Heat/Spec Error Tolerance
We want to set the value for both of these tolerances at 1e-6. Note that this will increase the
solving time of the column, but this column solves very fast anyway, so the tighter tolerances are
acceptable in this case. To change the tolerances, follow these steps:
1. Access the Solver page of the Parameters tab.
2. Enter 1e-6 for both the tolerance values. These cells are located in the Solving Options group
box.

This completes the changing of the tolerances. We are now ready to begin to optimize the column.

Adding the Optimizer

In todays highly competitive market place, with stringent plant emissions controls and increased
competition, a plants survivability is often determined by its ability to remain competitive.
Optimization methods are now available that give the process engineer the necessary tools to
perform on-going process improvement studies. Optimization studies lead directly to improved
plant performance, efficient plant operation and finally to increased profitability. Typically,
optimization studies involve an economic model composed of a Profit Function and operating
constraints. HYSYS contains a multi-variable Steady State Optimizer. Once your Flowsheet has
been built and a converged solution has been obtained, you can use the Optimizer to find the
operating conditions which minimize or maximize an Objective Function. The Optimizer owns its
own Spreadsheet for defining the Objective Functions as well as any constraint expressions to be
used. This allows you to construct Objective Functions which maximize profit, minimize utilities or
minimize exchanger UA.
Primary Variables - these are flowsheet variables whose values are manipulated in order to
minimize (or maximize) the objective function. You set the upper and lower bounds for the primary
variables, which are used to set the search range.
Objective Function - this is the function which is to be minimized or maximized. The function
has to be defined within the Spreadsheet. This allows the user a great deal of flexibility in defining
the function.
Constraint Functions - inequality and equality functions are defined in the Spreadsheet. In
solving the Objective Function, the Optimizer must also meet any constraints that are defined by
the user.
In our column example, the Profit Function/Cost Function (sometimes referred to as the Objective Function,
Performance Criterion or Performance Index) requires calculating a net profit for the column. The Profit
Function is a function of the revenue generated from desired products THF and Toluene, within the limit of
product purityconstraints. While increased profits is directly linked to increased production of the desired
product, plant profitability is generally offset by operating costs. In our column, operating costs are
associated with the column utility requirements for the reboiler and condenser. Ingeneral a profit function is
given by:
where:
PF = Profit Function/time
= Product Flows * Product Values
= Feedstock Flows * Feedstock Costs
OC = Operating Costs
Profit = (THF Product + Toluene Product) Heating Cost Cooling Cost
Feed Cost
Typically, the economic model includes operating constraints (equality or inequality constraints or
equations). The operating constraints comprise the model of the process or equipment. In this case, we
have no process constraints.

Which variable can we change to affect the Revenue?________

To invoke the Optimizer, select Optimizer under Simulation in the Menu Bar, or press <F5>.

Variables tab
When you invoke the Optimizer for the first time, you are placed on the Variables tab. On the Variables tab
you define the Adjusted (Primary) Variables to be used in the optimization. In this case, our Primary
Variables are the purity of our products, THF and Toluene.
1. Press the Add button to add the first variable, T-100, Spec Value, THF Purity Spec.

2. Set the Upper Bound at 0.99, and the Lower Bound at 0.90.
3. Add the second variable, T-100, Spec Value, Toluene Purity Spec, with the same bounds as above.

Defining the Spreadsheet

The Optimizer has its own Spreadsheet for defining the Objective and Constraint functions. Primary Variables may be imported and
functions defined within the Optimizer Spreadsheet, which possesses the same capabilities as the Main Flowsheet Spreadsheet
1. Press the Spreadsheet button on the Optimizer view to open the Spreadsheet.
2. Move to the Spreadsheet tab.

Importing and Exporting Variables

You may import virtually any variable in the simulation into the Spreadsheet and you can export a cells value to any specific field in
your simulation.

Object Inspection - object inspect (secondary mouse button) the cell which you want to Import into, or Export from. From
the Menu that appears, select Import Variable or Export Formula Result. Then, using the Variable Navigator, select the
variable you wish to import or export.
Connections page tab - select the Add Import or Add Export button. Then, using the Variable Navigator, select the
variable you wish to import or export.
Drag n Drop - using the secondary mouse button, click the variable value (from the WorkBook or Property View) you wish
to import, and drag it to the desired location in the Spreadsheet. If you are exporting the variable, drag it from the
Spreadsheet to the exported location.

Adding Formulas
Complex mathematical formulas can be created, using syntax that is similar to conventional Spreadsheets. Arithmetic, logarithmic
and trigonometric functions can be performed in the Spreadsheet. All common functions must be preceded by a + symbol. Special
Functions must be preceded by the @ symbol. Some of the functions available are:

Addition (+): +A1+A2

Subtraction (-): +A1-A2
Multiplication (*): +A1*A2
Division (/): +A1/A2
Power (^): +A1^3
Absolute Value (@ABS):@ABS(A1)
Square Root (@SQRT):@SQRT(A1)

 Natural Log (@ln):@ln(A1)

Exponential (@exp):@exp(A1)
The following variables need to be imported into the Spreadsheet. Text entries are added to the spreadsheet by typing them in the
appropriate cell.

The quickest way of importing variables is to right-click on the desired cell. Select Import Variable, and use the variable navigator
to locate the
desired variable. Use this method to import the variables above now.
Enter the following constants on the spreadsheet. The comments can be added, if desired.

Enter the following product prices:

Note: the prices of the products decrease as the impurities increase. The Objective Function is placed in Cell D8. The equation is:
+(b3*d4+b5*d6)-b7*d7-(b1*d1+b2*d2)/3600
Pay special attention to the units in this equation. If using field units, you may have to add an additional term to this equation to
convert between hours and days.

What is the value of cell D8, the Profit? __________

Functions tab
The Functions tab contains two groups, the Objective Function and the Constraint Functions. However, in this example we do not have
constraint functions.
1. In the Cell area of the Objective Function group, specify the Spreadsheet cell that defines the Objective Function. Use the drop down menu in
the Edit Bar to select the appropriate cell. The Current Value of the Objective Function will be provided.
2. Select the Maximize radio button.

Parameters tab
The Parameters tab is used for selecting the Optimization Scheme.

Box - Handles inequality constraints but not equality constraints. It generally requires a large number of iterations to
converge on the solution.
SQP - Sequential Quadratic Programming, handles inequality and equality constraints. Considered by many to be the most
efficient method for minimization.
Mixed - Handles inequality constraints only. It is a combination of the Box and SQP methods. It starts the minimization with
the Box method using a very loose convergence tolerance. After convergence, the SQP method is used to locate the final
solution.
Fletcher Reeves - Does not handle constraints. Efficient method for general minimization.
Quasi-Newton - Does not handle constraints. Similar method to Fletcher Reeves.
1. Select the Mixed method as the Scheme.
2. Use the defaults for Tolerance and Number of Iterations.

Monitor tab
The Monitor tab displays the values of the Objective Function and Primary Variables during the Optimizer calculations.
1. Move to the Monitor tab and press the Start button to begin the optimization.

Analyzing the Results

Once the Optimization is complete, examine the results and fill in the
following table:

Exercise 1
We are going to introduce a constraint on the liquid volume flow of the stream THF and examine how it affects the results, profit and
products
purities.

First, the case must be set back to its state before the optimization.
1. Go to the column subflowsheet.
2. On the Design tab, Monitor page, enter the initial value of 0.95 for the THF and Toluene purity specifications.
3. Re-run the column. The constraint on the liquid flow is that it must not exceed 1.85 m 3/h (65.5 ft3/hr). The THF
Liquid Flow must first be imported into the spreadsheet (use an empty cell), and the constraint value must be written in
the spreadsheet. Remember to write the comments next to the values so that they can be understood.
1. On the Functions tab of the Optimizer press the Add button.
2. Type in the reference of the cell where the variable constraint is located.
3. In the Cond column, use the scroll down arrow to find the less than sign. Type in the reference of the cell where the
value of the constraint is written.
4. Go to the Monitor tab and start the Optimizer.

What differences, if any, does the constraint make to the first optimized
solution? Fill in the following table:

Exercise 2
Here, we are going to model the reboiler with a steam-heated shell and tube heat exchanger. The heat exchanger will
be modelled with 115 psia steam and the maximum flow of steam available to the reboiler is limited to 840 kg/h (1850
lb/hr). (Note that there are a few approaches that can be taken with the heat exchanger modelling so two of the
possibilities are listed). The cost of the 115 psia steam is 0.682 $/kWh ($200/MMBtu).
1. Add Water as a component. This must be done in the Basis Environment.
2. Open the Columns Property viewer; on the Monitor page, reset the THF and Toluene purity specifications to 0.95.
3. Add a new internal stream (on the Flowsheet tab), ToReb with the following attributes:

4. Run the column.

5. Return to the Main Environment (notice that the "To Reb" stream is now shown on the PFD. Add a heat exchanger.
The stream ToReb is the shell side feed and steam is on the tube side.
6. Set the Shell and Tube side pressure drops to 0.
7. Specify the Steam inlet conditions at Vf = 1.0; P = 790 kPa (115 psia); Flow = 770 kg/h (1700 lb/hr). The outlet
steam is at its bubble point (Vf = 0.0).
8. Add a Duty Spec to the Heat Exchanger but do not specify a value (pass is Overall).

What is the Heat Exchanger Duty? __________

9. Add an Adjust operation. The Adjusted Variable is the Steam flowrate and the Target Variable is the Spec Calc
Value (Duty Spec).

10. Export the RebQ Heat Flow value (you will have to make this Exportable first) from the Optimizer spreadsheet into
the Target value for the Adjust operation. A cell on the spreadsheet can not be simultaneously imported and
exported. Copy the value of cell B2 to another empty cell by entering the formula "+B2". The value in this new cell can
then be exported to the Target Value of the Adjust operation.
11. Change the Heating Cost value to 0.682 $/kWh ($200/MMBtu) (Cell D2 on the spreadsheet) and Start the Adjust.

What is the Exchanger Duty and what is the Steam mass flow rate?
__________ & __________
12. Add the Steam Mass Flow (must be less than 840 kg/h (1850 lb/ hr)) constraint to the Optimizer.
13. Start the Optimizer.

Snapshot the result:

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