Aspen HYSYS

Aspen HYSYS is powerful process simulation software used in oil, gas, and chemical engineering to model plant designs. Training outlines typically progress from Basic (steady-state modeling and stream definition) to Advanced (dynamic modeling, crude characterization, and column optimization) to prepare users for the Aspen HYSYS Certification Exam.

Module 1: HYSYS Basics and User Interface

  • Introduction to Process Modeling: Understand what chemical process simulation is and how HYSYS computes mass and energy balances.
  • Workspace Navigation: Learn to use the menu, toolbar, and the Process Flow Diagram (PFD) window.
  • Unit Sets: Create and modify custom measurement units (e.g., SI or Field units).

Module 2: Setting up the Simulation Basis

  • Component List: Add chemical components using formulas or HYSYS databanks.
  • Fluid Packages: Define the thermodynamic methods and equations of state (e.g., Peng-Robinson for oil and gas).
  • Hypothetical Components: Create pseudo-components to model undefined mixtures.

Module 3: Defining Material and Energy Streams

  • Stream Specifications: Input temperature, pressure, composition, and flow rates to achieve converged streams.
  • Flash Calculations: Understand how HYSYS automatically calculates phase states (vapor fraction, dew point, bubble point).
  • Stream Utilities: Attach analysis tools like the Phase Envelope and the Property Table.

Module 4: Basic Unit Operations

  • Separators: Simulate two-phase and three-phase separators (flash drums).
  • Rotating Equipment: Model pumps, compressors, and expanders, including adiabatic efficiencies and duty.
  • Heat Transfer: Add coolers, heaters, and simple heat exchangers (shell-and-tube models).
  • Logical Operations: Utilize Adjust and Balance blocks to solve design targets.

Module 5: Columns (Distillation and Absorption)

  • Column Input Expert: Use wizards to configure columns (Reboiled Absorbers, Distillation columns, etc.).
  • Specifications: Tailor column operations to product constraints (e.g., reflux ratio, bottom composition).
  • Column Sizing: Estimate internal column sizing and tray rating requirements.

Module 6: Oil Characterization (Petroleum Refining)

  • Petroleum Assays: Input laboratory data (e.g., TBP or ASTM distillation curves).
  • Oil Manager: Blend multiple assays and generate hypothetical cuts (heavy/light naphtha, diesel).
  • Atmospheric Crude Columns: Model refinery distillation units based on characterized crude.

 

Module 7: Advanced Modules & Utilities

  • Reactions: Simulate chemical reactors (Conversion, Equilibrium, CSTR, and Plug Flow).
  • Recycle Loops: Build complex flowsheets with recycling operations.
  • Heat Exchanger Rating: Integrate rigorous equipment design tools.

Module 8: HYSYS Dynamic Simulation

  • Steady to Dynamic Transition: Learn to convert steady-state models into dynamic systems.
  • Control Strategies: Install valves, PID controllers, and level indicators.
  • Plant Troubleshooting: Check equipment performance and operator responses under varying operating conditions.