This intensive, hands-on course provides participants with the essential skills to effectively use Aspen HYSYS, the industry's leading process simulation software, for designing, modeling, and optimizing oil and gas processes. The training covers fundamental thermodynamic principles, proper fluid package selection, and the creation of accurate steady-state process flow diagrams (PFDs). Attendees will learn to model key equipment like separators, heat exchangers, compressors, and columns, enabling them to conduct sensitivity analyses, troubleshoot operating issues, and propose modifications with quantifiable results. This is a critical course for modern process engineers aiming to validate designs and improve plant performance through simulation.
Introduction
Objectives
Upon completion of this course, participants will be able to:
- Select the appropriate fluid property package (e.g., PR, SRK) based on the application.
- Build and customize a steady-state process flow sheet in Aspen HYSYS.
- Successfully model and size key equipment, including heat exchangers, pumps, and separators.
- Perform energy balances and conduct utility analysis for a process plant.
- Run sensitivity analysis and case studies to understand the impact of variable changes.
- Troubleshoot common convergence issues and simulation errors.
- Utilize the spreadsheet function and model environment for process calculations and reporting.
- Model basic reaction kinetics and separation units (e.g., distillation columns).
Target Audience
- Chemical and Process Engineers (Junior to Senior level).
- Design and Project Engineers in the oil and gas, refining, and petrochemical sectors.
- R&D Scientists and Technologists.
- Technical Sales and Support Personnel for process equipment.
- University Students and Academics requiring simulation skills.
- Operations Engineers involved in process optimization.
Methodology
- Hands-on Software Exercises: Building and troubleshooting a complex gas processing flow sheet.
- Case Studies: Analyzing a real-world separation process to identify optimization opportunities.
- Group Activities: Peer review and critique of simulation models for accuracy and completeness.
- Individual Exercises: Running sensitivity analysis to find the optimal operating temperature for a flash drum.
- Discussions on the limitations and appropriate application of different thermodynamic models.
Personal Impact
- Gain critical proficiency in the most widely used process simulation software.
- Enhance capability for design verification, optimization, and plant troubleshooting.
- Accelerate process design cycles and reduce the need for expensive pilot studies.
- Improve communication of complex process dynamics through clear visual models.
- Increase personal marketability in the competitive engineering job market.
- Develop the ability to confidently predict process response to changes.
Organizational Impact
- Reduced capital expenditure (CAPEX) through validated and optimized equipment sizing.
- Improved operational efficiency and reduced energy consumption via process optimization.
- Faster and safer plant troubleshooting by simulating 'what-if' scenarios offline.
- Enhanced design quality and reduced risk of costly construction or operational errors.
- Standardization of process modeling and documentation across the engineering department.
- Ability to accurately predict yields and product quality for commercial planning.
Course Outline
Unit 1: HYSYS Environment and Thermodynamics
Section 1.1: Program Fundamentals- Introduction to the Aspen HYSYS interface, workbook, and flow sheet environment.
- Review of fundamental thermodynamics and phase equilibrium concepts.
- Criteria for selecting the optimal fluid property package (EOS vs. Activity Models).
- Creating a component list and defining feed stream properties.
Unit 2: Modeling Process Utilities and Stream Handling
Section 2.1: Basic Equipment- Modeling and sizing of pumps, compressors, and turbines.
- Simulation of pipelines and valves, including pressure drop calculations.
- Introduction to unit operations: Mixers, splitters, and logic blocks.
- Using the HYSYS spreadsheet to perform custom calculations within the flow sheet.
Unit 3: Heat Transfer and Separation Equipment Modeling
Section 3.1: Core Units- Detailed modeling of heat exchangers (Heater, Cooler, Exchanger) and thermal rating.
- Simulation of two-phase and three-phase separators (Flash drums) for PFD generation.
- Modeling complex distillation columns (short-cut and rigorous methods).
- Troubleshooting model convergence failures and system warnings.
Unit 4: Process Analysis and Optimization Tools
Section 4.1: Advanced Analysis- Performing sensitivity analysis and defining case studies to explore operating windows.
- Utilizing the Adjust and Recycle blocks for complex flow sheet calculations.
- Analyzing energy consumption and performing basic pinch analysis concepts.
- Introduction to advanced modules (e.g., Acid Gas Cleaning, Electrolytes).
Unit 5: Dynamic Modeling Introduction and Reporting
Section 5.1: Simulation Extension- Introduction to the HYSYS Dynamics environment and its applications.
- Creating and exporting process flow diagrams (PFD) and equipment datasheets.
- Modeling basic reaction kinetics using reactor unit operations.
- Best practices for documentation, saving, and sharing simulation files.
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