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Copyright (c) 1981-2008 by Aspen Technology, Inc. All rights reserved. 
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ThTechnical Supportv
  Online Technical Support Center ........................................................ vi
  Phone and E-mail .............................................................................. vii
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ThOnline Technical Support 
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ThPhone and E-mail
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Table of ContentsTechnical Support..................................................... v
Online Technical Support Center ............................vi
Phone and E-mail................................................ vii
A  Aspen HYSYS Tutorials .........................................A-1
1  Gas Processing Tutorial ........................................1-1
1.1 Introduction .................................................... 1-2
1.2 Steady State Simulation.................................... 1-3
1.3 Dynamic Simulation.......................................1-114
2  Refining Tutorial...................................................2-1
2.1 Introduction .................................................... 2-2
2.2 Steady State Simulation.................................... 2-4
2.3 Dynamic Simulation.......................................2-130
3  Chemicals Tutorial................................................3-1
3.1 Introduction .................................................... 3-2
3.2 Steady State Simulation.................................... 3-3
3.3 Dynamic Simulation.........................................3-86
B  Aspen HYSYS Applications....................................B-1
G1  Acid Gas Sweetening with DEA ...........................G1-1
G1.1 Process Description ........................................ G1-2
G1.2 Setup ........................................................... G1-4
G1.3 Steady State Simulation.................................. G1-4
G1.4 Simulation Analysis ...................................... G1-15
G1.5 Calculating Lean & Rich Loadings.................... G1-15
G1.6 Dynamic Simulation...................................... G1-17
G1.7 References .................................................. G1-34
R1  Atmospheric Crude Tower ..................................R1-1iii
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R1.1 Process Description ........................................ R1-2
R1.2 Setup ........................................................... R1-5
R1.3 Steady State Simulation.................................. R1-8
R1.4 Results ........................................................R1-16
R2  Sour Water Stripper ...........................................R2-1
R2.1 Process Description ........................................ R2-2
R2.2 Setup ........................................................... R2-4
R2.3 Steady State Simulation.................................. R2-4
R2.4 Results ......................................................... R2-7
R2.5 Case Study.................................................... R2-9
P1  Propylene/Propane Splitter................................P1-1
P1.1 Process Description .........................................P1-2
P1.2 Setup ............................................................P1-4
P1.3 Steady State Simulation...................................P1-4
P1.4 Results ..........................................................P1-9
C1  Ethanol Plant......................................................C1-1
C1.1 Process Description ........................................ C1-2
C1.2 Setup ........................................................... C1-5
C1.3 Steady State Simulation.................................. C1-5
C1.4 Results ........................................................C1-13
C2  Synthesis Gas Production ...................................C2-1
C2.1 Process Description ........................................ C2-2
C2.2 Setup ........................................................... C2-4
C2.3 Steady State Simulation.................................. C2-7
C2.4 Results ........................................................C2-14
X1  Case Linking .......................................................X1-1
X1.1 Process Description ........................................ X1-2
X1.2 Building Flowsheet 1....................................... X1-4
X1.3 Building Flowsheet 2....................................... X1-7
X1.4 Creating a User Unit Operation........................X1-10iv
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Aspen HYSYS Tutorials A-1
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ThA  Aspen HYSYS 
Tutorials
The Tutorials section of this guide presents you with 
independent tutorial sessions. Each tutorial guides you step-by-
step through the complete construction of a Aspen HYSYS 
simulation. The tutorial(s) you choose to work through will likely 
depend on the simulation topic that is most closely related to 
your work, your familiarity with Aspen HYSYS, and the types of 
simulation cases you anticipate on creating in the future.
Regardless of which tutorial you work through first, you will gain 
the same basic understanding of the steps and tools used to 
build a Aspen HYSYS simulation. After building one of these 
tutorial cases, you might choose to build one or several more, or 
begin creating your own simulations.
The three tutorials are grouped in three general areas of 
interest:
• Gas Processing
• Refining
All completed Tutorial cases are included with your Aspen 
HYSYS package, and are available on Aspen HYSYS\Samples 
folder.
If you are new to Aspen HYSYS, it is recommended that you 
begin with the steady state tutorials. These tutorials 
explicitly detail each step required to complete the 
simulation. In steps where more than one method is 
available to complete a particular action, all methods are 
outlined. The dynamic tutorials (which are continued after 
the steady state section) are also presented in a step-by-
step manner, but are less detailed in their explanations. 
They assume a rudimentary knowledge of the Aspen HYSYS 
interface and methods.A-1
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Th• Chemicals
Each area has an associated steady state and dynamic tutorial. 
The dynamic tutorials use the steady state cases and add 
control schemes and dynamic specifications required to run the 
case in Dynamic mode. If you are interested only in steady state 
simulation, go through the steady state tutorial(s) that most 
interest you and stop at the dynamics section. If you are 
interested only in learning to apply dynamic simulation 
methods, use the pre-built steady state base case, included with 
Aspen HYSYS, as the starting point for your dynamic tutorial 
case.
Introduction
In the chapters that follow, example problems are used to 
illustrate some of the basic concepts of building a simulation in 
Aspen HYSYS. 
Three complete tutorials are presented:
1. Gas Processing
• Steady State. Models a sweet gas refrigeration plant 
consisting of an inlet separator, gas/gas heat exchanger, 
chiller, low-temperature separator and de-propanizer 
column.
• Dynamics. Models the Gas Processing tutorial case in 
Dynamic mode. This tutorial makes use of the 
recommendations of the Dynamic Assistant when 
building the case.
2. Refining 
• Steady State. Models a crude oil processing facility 
consisting of a pre-flash drum, crude furnace and an 
atmospheric crude column.
• Dynamics. Models the Refining example problem in 
Dynamic mode.
3. Chemicals 
There are also several Aspen HYSYS training courses 
available. 
Contact your Hyprotech agent for more information, or visit 
the training page of our web site www.AspenTech.com.A-2
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Aspen HYSYS Tutorials A-3
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Th• Steady State. Models a propylene glycol production 
process consisting of a continuously-stirred-tank reactor 
and a distillation tower.
• Dynamics. Models the Chemicals example problem in 
Dynamic mode. This tutorial make use of the 
recommendations of the Dynamic Assistant when 
building the case.
Each example contains detailed instructions for choosing a 
property package and components, installing and defining 
streams, unit operations and columns, and using various 
aspects of the Aspen HYSYS interface to examine the results 
while you are creating the simulation.
Often in Aspen HYSYS, more than one method exists for 
performing a task or executing a command. Many times you can 
use the keyboard, the mouse, or a combination of both to 
achieve the same result. The steady state tutorials attempt to 
illustrate Aspen HYSYS' flexibility by showing you as many of 
these alternative methods as possible. You can then choose 
which approach is most appropriate for you.
The dynamics tutorials use the steady state solution as a basis 
for building the dynamic case. If you like, you can build the 
steady state case and then proceed with the dynamic solution, 
or you can simply call up the steady state case from disk and 
begin the dynamic modeling.
The solved steady state cases are saved in the Aspen 
HYSYS\Samples folder as TUTOR1.hsc, TUTOR2.hsc, and 
TUTOR3.hsc files.
For the dynamics tutorials, you can use the pre-built steady 
state cases as your starting point. The solved dynamics 
cases are also included as dyntut1.hsc, dyntut2.hsc, and 
dyntut3.hsc.A-3
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ThStarting Aspen HYSYS
The installation process creates the following shortcut to Aspen 
HYSYS:
1. Click on the Start menu.
2. Select Programs | AspenTech | Process Modeling V.x | 
Aspen HYSYS | Aspen HYSYS.
The Aspen HYSYS Desktop appears:
 Figure A.1
To learn more about the 
basics of the Aspen HYSYS 
interface, refer to 
Chapter 1 - Interface in 
the Aspen HYSYS User 
Guide. Toolbar Menu Bar Maximize icon
Status Bar Object Status 
Window
Trace Window Performance 
SliderA-4
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Aspen HYSYS Tutorials A-5
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ThGetting Started
You are now ready to begin building a Aspen HYSYS simulation, 
so proceed to the Tutorial of your choice. 
Once you have completed one or more tutorials, you may want 
to examine the Applications section for other examples that may 
be of interest.
Tutorial Chapter
Samples Case Name
(Steady State/Dynamic)
Gas Processing Chapter 1 TUTOR1.HSC
dyntut1.hsc
Refining Chapter 2 TUTOR2.HSC
dyntut2.hsc
Chemicals Chapter 3 TUTOR3.HSC
dyntut3.hsc
The tutorials start in Steady State mode, and end in Dynamic 
mode.A-5
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ThA-6
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Gas Processing Tutorial 1-1
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The1  Gas Processing 
Tutorial1-1
1.1  Introduction................................................................................... 2
1.2  Steady State Simulation................................................................. 3
1.2.1  Process Description .................................................................. 3
1.2.2  Setting Your Session Preferences................................................ 5
1.2.3  Building the Simulation ............................................................. 9
1.2.4  Entering the Simulation Environment ........................................ 19
1.2.5  Using the Workbook................................................................ 21
1.2.6  Installing Unit Operations ........................................................ 36
1.2.7  Using Workbook Features ........................................................ 49
1.2.8  Using the PFD........................................................................ 54
1.2.9  Viewing and Analyzing Results ................................................. 87
1.2.10  Optional Study ....................................................................102
1.3  Dynamic Simulation ................................................................... 113
1.3.1  Modifying the Steady State Flowsheet ......................................114
1.3.2  Column Sizing.......................................................................124
1.3.3  Using the Dynamics Assistant .................................................131
1.3.4  Adding Controller Operations ..................................................138
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1-2 Introduction
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The1.1 Introduction
The gas processing simulation will be built using the following 
basic steps:
1. Create a unit set. 
2. Choose a property package.
3. Select the components.
4. Create and specify the feed streams.
5. Install and define the unit operations prior to the column.
6. Install and define the column.
In this Tutorial, a natural gas stream containing N2, CO2, and 
C1 through n-C4 is processed in a refrigeration system to 
remove the heavier hydrocarbons. The lean, dry gas produced 
will meet a pipeline hydrocarbon dew point specification. The 
liquids removed from the rich gas are processed in a 
depropanizer column, yielding a liquid product with a specified 
propane content.
The following pages will guide you through building a HYSYS 
case to illustrate the complete construction of the simulation, 
from selecting a property package and components to 
examining the final results. The tools available in the HYSYS 
interface will be utilized to illustrate the flexibility available to 
you. 
A solved case is located in the file TUTOR1.HSC in your 
HYSYS\Samples directory.
Before proceeding, you should have read the introductory 
chapter which precedes the Tutorials in this guide.1-2
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The1.2 Steady State 
Simulation
1.2.1 Process Description
This tutorial will model a natural gas processing facility that uses 
propane refrigeration to condense liquids from the feed and a 
distillation tower to process the liquids. The flowsheet for this 
process appears below. 
The combined feed stream enters an inlet separator, which 
removes the free liquids. Overhead gas from the Separator is 
fed to the gas/gas exchanger, where it is pre-cooled by already 
refrigerated gas. The cooled gas is then fed to the chiller, where 
further cooling is accomplished through exchange with 
evaporating propane (represented by the C3Duty stream). In 
the chiller, which will be modeled simply as a Cooler, enough 
heavier hydrocarbons condense such that the eventual sales gas 
meets a pipeline dew point specification. The cold stream is then 
separated in a low-temperature separator (LTS). The dry, cold 
gas is fed to the gas/gas exchanger and then to sales, while the 
condensed liquids are mixed with free liquids from the inlet 
separator. These liquids are processed in a depropanizer column 
to produce a low-propane-content bottoms product.
 Figure 1.11-3
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1-4 Steady State Simulation
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TheOnce the results for the simulation have been obtained, you will 
have a good understanding of the basic tools used to build a 
HYSYS simulation case. At that point, you can either proceed 
with the Optional Study presented at the end of the tutorial or 
begin building your own simulations.
In this tutorial, three logical operations will be installed in order 
to perform certain functions that cannot be handled by standard 
physical unit operations:
The Balance operation will be installed in the main example. In 
the Optional Study section, the Adjust and Spreadsheet 
operations will be installed to investigate the effect of the LTS 
temperature on the sales gas heating value.
The two primary building tools, the Workbook and the PFD, will 
be used to install the streams and operations and to examine 
the results while progressing through the simulation. Both of 
these tools provide you with a lot of flexibility in building your 
simulation and in quickly accessing the information you need.
The Workbook will be used to build the first part of the 
flowsheet, starting with the feed streams and building up to and 
including the gas/gas heat exchanger. The PFD will be used to 
install the remaining operations, from the chiller through to the 
column.
Logical Flowsheet Function
Balance To duplicate the composition of the SalesGas 
stream in order to calculate its dew point 
temperature at pipeline specification pressure.
Adjust To determine the required LTS temperature which 
gives a specified SalesGas dew point.
HYSYS Spreadsheet To calculate the SalesGas net heating value.1-4
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Gas Processing Tutorial 1-5
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The1.2.2 Setting Your Session 
Preferences
1. To start a new simulation case, do one of the following:
• From the File menu, select New and then Case.
• Click the New Case icon in the toolbar.
The Simulation Basis Manager appears: 
The Simulation Basis Manager property view allows you to 
create, modify, and manipulate fluid packages in your 
simulation case. Most of the time, as with this example, you 
will require only one fluid package for your entire simulation.
Next, you will set your Session Preferences before building a 
case.
All commands on the toolbar are also available as menu 
items.
 Figure 1.21-5
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1-6 Steady State Simulation
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The2. From the Tools menu, select Preferences. The Session 
Preferences property view appears.You should be on the 
Options page of the Simulation tab. 
The HYSYS default session settings are stored in a 
Preference file called HYSYS.prf. When you modify any of 
the preferences, you can save the changes in a new 
Preference file by clicking the Save Preference Set button. 
HYSYS prompts you to provide a name for the new 
Preference file, which you can later load into any simulation 
case by clicking the Load Preference Set button.
3. In the General Options group, ensure the Use Modal 
Property Views checkbox is unchecked.
 Figure 1.31-6
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Gas Processing Tutorial 1-7
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TheCreating a New Unit Set
The first step in building the simulation case is choosing a unit 
set. Since HYSYS does not allow you to change any of the three 
default unit sets listed, you will create a new unit set by cloning 
an existing one. For this example, a new unit set will be made 
based on the HYSYS Field set, which you will then customize.
To create a new unit set, do the following:
1. In the Session Preferences property view, click the 
Variables tab.
2. Select the Units page if it is not already selected.
3. In the Available Unit Sets group, select Field to make it the 
active set. 
4. Click the Clone button. A new unit set named NewUser 
appears. This unit set becomes the currently Available Unit 
Set.
5. In the Unit Set Name field, enter a name for the new unit 
set.
You can now change the units for any variable associated 
with this new unit set.
 Figure 1.41-7
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1-8 Steady State Simulation
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The6. In the Display Units group, scroll down until you find the unit 
for Flow. The default setting is lbmole/hr. 
A more appropriate unit for the Flow is MMSCFD.
7. To view the available units for Flow, open the drop-down list 
in the cell beside the Flow cell.  
8. Scroll through the list using either the scroll bar or the arrow 
keys, and select MMSCFD.
Your new unit set is now defined. 
9. Click the Close icon  (in the top right corner) to close the 
Session Preferences property view. 
Next, you will start building the simulation case.
 Figure 1.51-8
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Gas Processing Tutorial 1-9
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The1.2.3 Building the Simulation
In building a simulation case HYSYS split the configuration 
options into two different environment: 
• Basis environment enables you to specify the basic 
information like components, property package, 
reactions and so forth associated to the simulation.
• Case environment enables you to specify the streams 
and operation equipment associated to the simulation, 
and view the calculated results from the simulation.
Creating a Fluid Package
The next step is to add a Fluid Package. As a minimum, a Fluid 
Package contains the components and property method (for 
example, an Equation of State) HYSYS will use in its calculations 
for a particular flowsheet. Depending on what is required in a 
specific flowsheet, a Fluid Package may also contain other 
information such as reactions and interaction parameters.
1. On the Simulation Basis Manager property view, click the 
Fluid Pkgs tab.
2. Click the Add button, and the property view for your new 
Fluid Package appears.    
 Figure 1.61-9
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1-10 Steady State Simulation
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TheThe property view is divided into a number of tabs. Each tab 
contains the options that enables you to completely define 
the Fluid Package.
The first step in configuring a Fluid Package is to choose a 
Property Package on the Set Up tab. The current selection is 
. 
For this tutorial, you will select the Peng Robinson property 
package. 
3. Do one of the following:
• Select  in the Property Package Selection list 
and type Peng Robinson. HYSYS automatically finds the 
match to your input.
• Select  in the Property Package Selection list 
and the up and down keys to scroll through the Property 
Package Selection list until Peng Robinson is selected.
• Use the vertical scroll bar to move up and down the list 
until Peng Robinson becomes visible, then select it. 
The Property Pkg indicator at the bottom of the Fluid 
Package property view now indicates that Peng Robinson is 
the current property package for this Fluid Package. HYSYS 
has also automatically created an empty component list to 
be associated with the Fluid Package.
HYSYS has created a Fluid Package with the default name 
Basis-1. You can change the name of this fluid package by 
typing a new name in the Name field at the bottom of the 
property view.
 Figure 1.71-10
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Gas Processing Tutorial 1-11
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The    
Alternatively, you could have selected the EOSs radio button 
in the Property Package Filter group, which filters the list to 
display only property packages that are Equations of State. 
The filter option helps narrow down your search for the Peng 
Robinson property package, as shown in the figure below.  
Creating a Component List
Now that you have selected a property package to be used in 
the simulation, the next step is to select the components. You 
can create a list of components using the options on the 
Components tab of the Simulation Basis Manager property view 
or from the Set Up tab of the Fluid Package property view.
In this tutorial, we will create the component list using the 
option in the Fluid Package property view:
1. In the Set Up tab, select Component List-1 from the 
Component List Selection drop-down list.
2. Click the View button. 
 Figure 1.8
 Figure 1.91-11
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1-12 Steady State Simulation
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TheThe Component List property view appears.
There are a number of ways to select components for your 
simulation. One method is to use the matching feature. Each 
component is listed in three ways on the Selected tab:
At the top of each of these three columns is a corresponding 
radio button. Based on the selected radio button, HYSYS 
locates the component(s) that best matches the input you 
type in the Match cell.
For this tutorial, you will add the following components: N2, 
CO2, C1, C2, C3, i-C4 and n-C4.
First, you will add nitrogen using the match feature.
3. Ensure the Full Name/Synonym radio button is selected, 
and the Show Synonyms checkbox is checked.
 Figure 1.10
Matching Method Description
Sim Name The name appearing within the simulation.
Full Name/
Synonym
IUPAC name (or similar), and synonyms for many 
components.
Formula The chemical formula of the component. This is useful 
when you are unsure of the library name of a 
component, but know its formula.1-12
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Gas Processing Tutorial 1-13
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The4. Move to the Match field by clicking on the field, or by 
pressing Alt M.
5. Type Nitrogen. HYSYS filters as you type and displays only 
components that match your input. 
6. With Nitrogen selected, add it to the current composition 
list by doing one of the following:
• Press the ENTER key.
• Click the Add Pure button.
• Double-click on Nitrogen.
In addition to the three match criteria radio buttons, you can 
also use the Filters property view to display only those 
components belonging to certain families.
Next you will add CO2 to the component list using the filter 
feature.
7. Ensure the Match field is empty by pressing ALT M and 
DELETE.
 Figure 1.111-13
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1-14 Steady State Simulation
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The8. Click the View Filters button. The Filters property view 
appears as shown in the figure below.  
9. Select the Use Filter checkbox. 
10.CO2 does not fit into any of the standard families, so select 
the Miscellaneous checkbox.
11.Scroll down the filtered list until CO2 becomes visible.
12.Add the CO2 component to the component list. 
The Match feature remains active when you use a filter, so 
you could also type CO2 in the Match field to find the 
component.
13. To add the remaining components C1 through n-C4 using 
the filter, clear the Miscellaneous checkbox, and check the 
Hydrocarbons checkbox.
 Figure 1.121-14
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Gas Processing Tutorial 1-15
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TheThe following shows you a quick way to add components that 
appear consecutively in the library list:
14.Click on the first component in the list (in this case, C1).
15.Do one of the following:
• Hold the SHIFT key and click on the last component 
required, in this case n-C4. All components C1 through 
n-C4 will now be selected. Release the SHIFT key.
• Click and hold on C1, drag down to n-C4, and release 
the mouse button. C1 through n-C4 will be selected.
16.Click the Add Pure button. The highlighted components are 
transferred to the Selected Components list. 
The completed component list appears below. 
A component can be removed from the current components 
list by selecting it in the Selected Components list and 
clicking the Remove button or pressing the DELETE key. 
To select multiple non-consecutive components, use the 
CTRL key.
 Figure 1.131-15
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TheViewing Component Properties
To view the properties of one or more components, select the 
component(s) and click the View Component button. HYSYS 
opens the property view(s) for the component(s) you selected. 
For example:
1. Click on CO2 in the Selected Components list.
2. Press and hold the CTRL key.
3. Click on n-Butane. The two components should now be 
selected.
4. Release the CTRL key.
 Figure 1.141-16
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The5. Click the View Component button. The property views for 
the two components appear.    
The Component property view only allows you to view the 
pure component information. You cannot modify any 
parameters for a library component, however, HYSYS allows 
you to clone a library component as a Hypothetical 
component, which you can then modify as required. 
6. Close both of the component property views and the 
Component List property view to return to the Fluid Package 
property view. 
If your project required it, you could continue to add 
information such as interaction parameters and reactions to 
the Fluid Package. For the purposes of this tutorial, however, 
the Fluid Package is now completely defined. 
 Figure 1.15
If the Simulation Basis Manager is not visible, click the Home 
View icon from the toolbar.
See Chapter 3 - 
Hypotheticals in the 
HYSYS Simulation 
Basis guide for more 
information about cloning 
library components.
View icon1-17
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The7. Close the Fluid Package property view to return to the 
Simulation Basis Manager property view. 
The list of Current Fluid Packages now displays the new Fluid 
Package, Basis-1, and shows the number of components 
(NC) and property package (PP). The new Fluid Package is 
assigned by default to the main flowsheet, as shown in the 
Flowsheet-Fluid Pkg Associations group. Now that the Basis 
is defined, you can install streams and operations in the 
Main Simulation environment.
8. To leave the Basis environment and enter the Simulation 
environment, do one of the following:
• Click the Enter Simulation Environment button on the 
Simulation Basis Manager property view.
• Click the Enter Simulation Environment icon on the 
tool bar.
 Figure 1.16
Enter Simulation 
Environment icon1-18
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The1.2.4 Entering the Simulation 
Environment
When you enter the Simulation environment, the initial property 
view that appears depends on your current Session Preferences 
setting for the Initial Build Home property view. Three initial 
property views are available: 
• PFD
• Workbook
• Summary
Any or all of these can be displayed at any time; however, when 
you first enter the Simulation environment, only one appears. In 
this example, the initial home property view is the PFD (HYSYS 
default setting).
 Figure 1.171-19
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TheThere are several things to note about the Main Simulation 
environment. In the upper right corner, the Environment has 
changed from Basis to Case (Main). A number of new items 
are now available in the menu bar and tool bar, and the PFD and 
Object Palette are open on the Desktop. These latter two objects 
are described below.
1. Before proceeding any further, save your case by doing one 
of the following:
• From the File menu, select Save.
• Press CTRL S.
• Click the Save icon on the toolbar.
If this is the first time you have saved your case, the Save 
Simulation Case As property view appears. 
Objects  Description
PFD The PFD is a graphical representation of the flowsheet topology for a 
simulation case. The PFD property view shows operations and streams and 
the connections between the objects. You can also attach information tables 
or annotations to the PFD. By default, the property view has a single tab. If 
required, you can add additional PFD pages to the property view to focus in 
on the different areas of interest.
Object 
Palette 
A floating palette of buttons that can be used to add streams and unit 
operations.
You can toggle the palette open or closed by pressing F4, or by selecting the 
Open/Close Object Palette command from the Flowsheet menu.
 Figure 1.18
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TheBy default, the File Path is the Cases sub-directory in your 
HYSYS directory.
2. In the File Name cell, type a name for the case, for example 
GASPLANT. You do not have to enter the *.hsc extension; 
HYSYS automatically adds it for you.
3. Once you have entered a file name, press the ENTER key or 
click the Save button. 
HYSYS saves the case under the name you have given it 
when you save in the future. The Save As property view will 
not appear again unless you choose to give it a new name 
using the Save As command. 
If you enter a name that already exists in the current 
directory, HYSYS will ask you for confirmation before over-
writing the existing file.
1.2.5 Using the Workbook
The Workbook displays information about streams and unit 
operations in a tabular format, while the PFD is a graphical 
representation of the flowsheet. 
1. Click the Workbook icon on the toolbar to access the 
Workbook property view.
When you choose to open an existing case by clicking the 
Open Case icon, or by selecting Open Case from the File 
menu, a property view similar to the one shown in Figure 
1.18 appears. 
The File Filter drop-down list will then allow you to retrieve 
backup (*.bk*) and HYSIM (*.sim) files in addition to 
standard HYSYS (*.hsc) files.
Open Case icon
Workbook icon1-21
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TheInstalling the Feed Streams
In general, the first action you perform when you enter the 
Simulation environment is installing one or more feed streams. 
The following procedure explains how to create a new stream.
1. On the Material Streams tab of the Workbook, type the 
stream name Feed 1 in the cell labelled **New**, and 
press ENTER.
HYSYS will automatically create the new stream with the 
name defined above. 
Your Workbook should appear as shown below.  
When you pressed ENTER after typing in the stream name, 
HYSYS automatically advanced the active cell down one to 
Vapour Fraction.
Next you will define the feed conditions.
2. Move to the Temperature cell for Feed 1 by clicking it, or by 
pressing the DOWN arrow key.
3. Type 60 in the Temperature cell. In the Unit drop-down 
list, HYSYS displays the default units for temperature, in this 
case F. This is the correct unit for this exercise.
4. Press the ENTER key.
HYSYS accepts blank spaces within a stream or operation 
name.
 Figure 1.191-22
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TheYour active location should now be the Pressure cell for Feed 
1. If you know the stream pressure in another unit besides 
the default unit of psia, HYSYS will accept your input in any 
one of the available different units and automatically convert 
the supplied value to the default unit for you. For this 
example, the pressure of Feed 1 is 41.37 bar.
5. In the Pressure cell, type 41.37.
6. Click the  icon in the Unit drop-down list to open the list of 
units, or press the SPACE BAR to move to the Units drop-
down list. 
7. Either scroll through the list to find bar, or begin typing it. 
HYSYS will match your input to locate the required unit.
8. Once bar is selected, press the ENTER key. 
HYSYS will automatically convert the pressure to the default 
unit, psia, and the active selection moves to the Molar Flow 
cell for Feed 1.
9. In the Molar Flow cell, type 6 and press ENTER. The 
default Molar Flow unit is already MMSCFD, so you do not 
have to modify the units.
 Figure 1.201-23
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TheProviding Compositional Input
In the previous section you specified the stream conditions in 
the Workbook property view. Next you will input the composition 
information in the Stream property view.
1. Close the Workbook property view.
The PFD becomes visible and displays a light blue arrow on 
it, labeled Feed 1. That arrow is the stream Feed 1 that you 
just created.
2. Double-click the blue arrow. The Feed 1 view appears.
 Figure 1.21
 Figure 1.221-24
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The3. Click on the Composition page. By default, the components 
are listed by Mole Fractions.
4. Click on the Mole Fractions cell for the first component, 
Nitrogen.
5. Type 0.01 and press ENTER. 
The Input Composition for Stream property view appears.
This property view enables you to access certain features 
designed to streamline the specification of a stream 
composition and complete the stream’s compositional input.
 Figure 1.23
 Figure 1.241-25
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TheThe following table lists and describes the features available 
on the Input Composition for Stream property view: 
6. Click on the Mole Fraction cell for CO2, type 0.01, then 
press ENTER.
Composition Input Feature Description
Composition Basis 
Radio Buttons 
Allows you to input the stream composition in 
some fractional basis other than Mole Fraction, or 
by component flows, by selecting the appropriate 
radio button before providing your input.
Normalizing The Normalizing feature allows you to enter the 
relative ratios of components; for example, 2 parts 
N2, 2 parts CO2, 120 parts C1, etc. Rather than 
manually converting these ratios to fractions 
summing to one, enter the individual numbers of 
parts and click the Normalize button. HYSYS will 
compute the individual fractions to total 1.0.
Normalizing is also useful when you have a stream 
consisting of only a few components. Instead of 
specifying zero fractions (or flows) for the other 
components, enter the fractions (or the actual 
flows) for the non-zero components, leaving the 
others . Click the Normalize button, and 
HYSYS will force the other component fractions to 
zero.
Calculation status/
colour
As you input the composition, the component 
fractions (or flows) initially appear in red, 
indicating the final composition is unknown. These 
values will become blue when the composition has 
been calculated. Three scenarios will result in the 
stream composition being calculated:
• Input the fractions of all components, 
including any zero components, such that 
their total is exactly 1.0000. Then click the 
OK button.
• Input the fractions (totalling 1.000), flows or 
relative number of parts of all non-zero 
components. Click the Normalize button, 
then the OK button.
• Input the flows or relative number of parts of 
all components, including any zero 
components, then click the OK button.
The red and blue text are the default colours; 
yours may appear different depending on your 
settings on the Colours page of the Session 
Preferences property view.1-26
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The7. Enter the remaining fractions as shown in the figure below.
When you have entered the fraction of each component the 
total at the bottom of the property view will equal 1.0000.
8. Click the OK button, and HYSYS accepts the composition. 
The stream is now completely defined, so HYSYS flashes it at 
the conditions given to determine its remaining properties.
9. Close the Feed 1 property view and access the Workbook 
property view by clicking on the Workbook icon.
10.Ensure that the Material Streams tab is active. 
 Figure 1.25
 Figure 1.26
Workbook icon1-27
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TheThe properties of Feed 1 appear below. The values you 
specified are blue and the calculated values are black. 
Alternative Methods for Defining Streams
In addition to the method you just learned, there are several 
alternative ways to define streams.
1. Access the Object Palette by pressing F4. 
2. Do any one of the following:
• Press F11.
• From the Flowsheet menu, select Add Stream.
• Double-click the Material Stream icon on the Object 
Palette.
• Click the Material Stream icon on the Object Palette, 
then click on the Add Object icon.
Each of the above four methods creates a new stream and 
access the property view of the new stream.
 Figure 1.27
If you want to delete a stream, click on it in the PFD, then 
press the DELETE key. HYSYS will ask for confirmation 
before deleting.
You can also delete the stream using the Delete button on 
that stream’s property view.
Material 
Stream icon
Add Object 
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TheThe new stream is named according to the Automatic 
Naming of Flowsheet Objects setting defined in the Session 
Preferences (Simulation tab, Naming page). HYSYS names 
any new material streams with numbers starting at 1 and 
any new energy streams starting at 100.
When you initially access the stream property view, the 
Conditions page on the Worksheet tab is the active page, 
and 1 appears in the Stream Name cell.
3. In the Stream Name cell, replace the name by typing Feed 
2, then press ENTER.
4. Enter the following values:
• Temperature: 60
• Pressure: 600
• Molar Flow: 4  
5. Select the Composition page and click the Edit button.
The above variable values are in the default units. 
 Figure 1.281-29
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TheThe Input Composition for Stream property view appears.  
6. Change the Composition Basis to Mass Fractions by 
selecting the appropriate radio button, or by pressing ALT 
N.
7. Click on the compositional cell for Nitrogen, type 6 for the 
number of parts of this component, then press ENTER.
8. Press the DOWN arrow key to move to the input cell for 
Methane. Feed 2 does not contain CO2.
 Figure 1.29
The current Composition Basis setting is the Preferences 
default. You must enter the stream composition on a mass 
basis.1-30
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The9. Input the number of mass parts for the remaining 
components as shown in the following figure. 
10.Click the Normalize button once you have entered the 
parts, and HYSYS will convert your input to component mass 
fractions.  
11.Click the OK button to close the property view and return to 
the stream property view.
HYSYS performed a flash calculation to determine the 
unknown properties of Feed 2, as indicated by the green OK 
status in the status bar.
 Figure 1.30
For CO2 (the component you left ), the Mass 
Fraction was automatically forced to zero.
 Figure 1.311-31
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The 
For streams with multiple phases, you can view the 
properties of each phase using the horizontal scroll bar in 
the table on the property view, or drag and expand the 
stream property view to see all the phase columns.
To expand the property view, move your cursor over the 
right border of the property view. The cursor becomes a 
sizing arrow. With the arrow visible, click and drag to the 
right until the horizontal scroll bar disappears, leaving the 
entire table visible. 
The compositions currently appear in Mass Fraction. To 
change this, click the Basis button, then select the 
appropriate radio button in the Composition Basis group of 
the property view that appears.
 Figure 1.32
 Figure 1.33
Sizing Arrow cursor1-32
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TheTo view the calculated stream properties, click the 
Conditions page. New or updated information is 
automatically and instantly transferred among all locations 
in HYSYS.  
Viewing a Phase Diagram
You can view a phase diagram for any material stream using the 
HYSYS Envelope Utility.
1. On the property view for stream Feed 2, click the 
Attachments tab, then select the Utilities page.
2. Click the Create button to create a phase envelope for the 
stream. The Available Utilities property view appears, 
displaying a list of HYSYS utilities.
3. Do one of the following:
• Select Envelope and click the Add Utility button.
• Double-click on Envelope. 
 Figure 1.341-33
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TheThe Envelope Utility property view appears. 
HYSYS creates and displays a phase envelope for the 
stream. Just as with a stream, a Utility has its own property 
view containing all the information needed to define the 
utility.
Initially, the Connections page of the Design tab appears.
 Figure 1.35
A Utility is a separate entity from the stream to which it is 
attached; if you delete it, the stream will not be affected.
Likewise, if you delete the stream, the Utility will remain but 
will not display any information until you attach another 
stream using the Select Stream button.
 Figure 1.361-34
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TheThe Design tab allows you to change the name of the Utility 
and the stream that it is attached to, and view Critical Values 
and Maxima.
4. Click the Performance tab, then select the Plots page.
The default Envelope Type is PT.
To view another envelope type, select the appropriate radio 
button in the Envelope Type group. Depending on the type of 
envelope selected, you can specify and display Quality 
curves, Hydrate curves, Isotherms, and Isobars. 
To view the data in a tabular format, select the Table page. 
5. Close the Utility property view.
6. Close the Feed 2 property view.
 Figure 1.37
To make the envelope property view more readable, 
maximize or re-size the property view.
For more information 
about defining utilities, 
refer to Section 7.26 - 
Utilities in the HYSYS 
User Guide.1-35
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The1.2.6 Installing Unit 
Operations
In the last section you defined the feed streams. Now you will 
install the necessary unit operations for processing the gas.
Installing the Mixer
The first operation that you will install is a Mixer, used to 
combine the two feed streams. As with most commands in 
HYSYS, installing an operation can be accomplished in a number 
of ways. One method is through the Unit Ops tab of the 
Workbook.
1. Click the Workbook icon to access the Workbook property 
view.
2. Click the Unit Ops tab of the Workbook.
3. Click the Add UnitOp button. 
 Figure 1.38
Workbook icon1-36
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TheThe UnitOps property view appears, listing all available unit 
operations. 
4. Select Mixer by doing one of the following:
• Click on an operation in the Available Unit Operations list 
and type mixer.
• Click on an operation in the Available Unit Operations list 
an press the DOWN arrow key to scroll down the list of 
available operations to Mixer.
• Scroll down the list using the vertical scroll bar and click 
on Mixer.
5. With Mixer selected, click the Add button or press the 
ENTER key.
You can also use the filters to find and add an operation. For 
example, select the Piping Equipment radio button under 
Categories. A filtered list containing just piping operations 
appears in the Available Unit Operations group.
 Figure 1.39
You can also double-click an operation name to install it.1-37
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TheThe Mixer property view appears. 
As with a stream, a unit operation’s property view contains 
all the information defining the operation, organized in tabs 
and pages. The four tabs shown for the Mixer, namely 
Design, Rating, Worksheet, and Dynamics, appear in the 
property view for most operations. More complex operations 
have more tabs. HYSYS provides the default name MIX-100 
for the Mixer. 
As with streams, the default naming scheme for unit 
operations can be changed on the Session Preferences 
property view.
Many operations, such as the Mixer, accept multiple feed 
streams. Whenever you see a table like the one in the Inlets 
group, the operation will accept multiple stream connections at 
that location. When the Inlets table has focus, you can access a 
drop-down list of available streams.
6. Click the <> cell.
The status bar at the bottom of the property view shows that 
the operation requires a feed stream.
 Figure 1.40
See Section 12.2.4 - 
Naming Page in the 
HYSYS User Guide for 
detailed information on 
setting your Session 
Preferences.1-38
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The7. Open the <> drop-down list of feeds by clicking 
on  or by pressing the F2 key and then the DOWN arrow 
key.  
8. Select Feed 1 from the list. The stream is added to the list 
of Inlets, and <> automatically moves down to a 
new empty cell.
9. Repeat steps 6-8 to connect the other stream, Feed 2.
The status indicator now displays Requires a product 
stream. 
10.Click in the Outlet field.
11. Type MixerOut in the cell and press ENTER. 
HYSYS recognizes that there is no existing stream named 
MixerOut, so it will create the new stream with this name.
 Figure 1.41
Alternatively, you can make the connections by typing the 
exact stream name in the cell, then pressing ENTER.1-39
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TheThe status indicator now displays a green OK, indicating that 
the operation and attached streams are completely 
calculated. 
12.Click the Parameters page. 
13. In the Automatic Pressure Assignment group, leave the 
default setting at Set Outlet to Lowest Inlet.    
HYSYS has calculated the outlet stream by combining the 
two inlets and flashing the mixture at the lowest pressure of 
the inlet streams. In this case, both inlets have the same 
pressure (600 psia), so the outlet stream is set to 600 psia.
 Figure 1.42
 Figure 1.431-40
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The14.To view the calculated outlet stream, click the Worksheet 
tab and select the Conditions page.  
15.Now that the Mixer is completely known, close the property 
view to return to the Workbook. The new operation appears 
in the table on the Unit Ops tab of the Workbook.  
The table shows the operation Name, its Object Type, the 
attached streams (Feeds and Products), whether it is 
Ignored, and its Calculation Level. 
 Figure 1.44
The Worksheet tab is a condensed Workbook property view, 
displaying only those streams attached to the selected 
operation.
 Figure 1.451-41
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TheWhen you select an operation in the table and click the View 
UnitOp button, the property view for the selected operation 
appears. Alternatively, double-clicking on any cell (except 
Inlet, Outlet, and Ignored) associated with the operation 
also opens the operation property view.
When any of the Name, Object Type, Ignored, or Calc. Level 
cells are active, the box at the bottom of the Workbook 
displays all streams attached to the current operation. 
Currently, the Name cell for MIX-100 has focus, and the box 
displays the three streams attached to this operation.
You can also open the property view for a stream directly 
from the Unit Ops tab. To open the property view for one of 
the streams attached to an operation, do one of the 
following:
• Select the operation in the Unit Ops tab and double-click 
on the stream you want to access in the list at the 
bottom of the Workbook property view.
• Double-click on the Inlet or Outlet cell of the operation. 
The property view for the first listed feed or product 
stream appears.
Installing the Inlet Separator
Next you will install and define the inlet separator, which splits 
the two-phase MixerOut stream into its vapour and liquid 
phases. 
1. In the Workbook property view, click the Unit Ops tab.
2. Click the Add UnitOp button. The UnitOps property view 
appears. You can also access the Unit Ops property view by 
pressing F12.
3. In the Categories group, select the Vessels radio button.
4. In the list of Available Unit Operations, select Separator.
5. Click the Add button. The Separator property view appears, 
displaying the Connections page on the Design tab. 
6. In the Name cell, change the name to InletSep and press 
ENTER.
7. Move to the Inlets list by clicking on the << Stream>> cell, 
or by pressing ALT L.
8. Open the drop-down list of available feed streams.1-42
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The9. Select the stream MixerOut by doing one of the following:
• Click on the stream name in the drop-down list.
• Press the DOWN arrow key to highlight the stream name 
and press ENTER.
10.Move to the Vapour Outlet cell by pressing ALT V.
11.Create the vapour outlet stream by typing SepVap and 
pressing ENTER.
12.Click on the Liquid Outlet cell, type the name SepLiq, and 
press ENTER. The completed Connections page appears as 
shown in the following figure. 
 Figure 1.46
An Energy stream could be attached to heat or cool the 
vessel contents. For this tutorial, however, the energy 
stream is not required.1-43
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The13.Select the Parameters page. The current default values for 
Delta P, Volume, Liquid Volume, and Liquid Level are 
acceptable.  
14. To view the calculated outlet stream data, click the 
Worksheet tab, then select the Conditions page. The table 
appearing on this page is shown below.  
15.When finished, click the Close icon  to close the 
separator property view. 
 Figure 1.47
The Volume, Liquid Volume, and Liquid Level default values 
generally apply only to vessels operating in dynamic mode or 
with reactions attached.
 Figure 1.481-44
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TheInstalling the Heat Exchanger
Next, you will install the gas/gas exchanger.
1. Access the Object Palette by pressing F4.
2. On the Object Palette, double-click the Heat Exchanger 
icon.
The Heat Exchanger property view appears. 
The Connections page on the Design tab is active.
3. In the Name field, change the operation name from its 
default E-100 to Gas/Gas.
 Figure 1.49
Heat Exchanger icon1-45
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The4. Attach the Inlet and Outlet streams as shown below, using 
the methods learned in the previous sections.  
You will have to create all streams except SepVap, which is 
an existing stream that can be selected from the Tube Side 
Inlet drop-down list.
Create the new streams by selecting the appropriate input 
field, typing the name, then pressing ENTER.
5. Click the Parameters page.
The Exchanger Design (End Point) is the acceptable 
default setting for the Heat Exchanger Model for this tutorial.
 Figure 1.501-46
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The6. Enter a pressure drop of 10 psi for both the Tube Side 
Delta P and Shell Side Delta P.  
7. Click the Rating tab, then select the Sizing page.
8. In the Configuration group, click in the Tube Passes per 
Shell cell and change the value to 1, to model Counter 
Current Flow.  
 Figure 1.51
 Figure 1.521-47
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The9. A warning appears to remind you that the number of tube 
passes must be an even multiple of the shell passes. Click 
the OK button. 
10.Close the Heat Exchanger property view to return to the 
Workbook property view.
11.Click the Material Streams tab of the Workbook.
Stream CoolGas has not yet been flashed, as its temperature 
is unknown. The CoolGas stream is flashed later when a 
temperature approach is specified for the Gas/Gas heat 
exchanger. 
 Figure 1.53
Notice how partial information is passed (for stream 
CoolGas) throughout the flowsheet. HYSYS always calculates 
as many properties as possible for the streams based on the 
available information.1-48
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The1.2.7 Using Workbook 
Features
Before installing the remaining operations, you will examine a 
number of Workbook features that allow you to access 
information quickly and change how information is displayed.
Accessing Unit Operations from the 
Workbook
There are several ways to open the property view for an 
operation directly from the Workbook. In addition to using the 
Unit Ops tab, you can use the following method:
1. Click one of the Workbook stream tabs (Material Streams, 
Compositions, or Energy Streams). 
The list at the bottom of the Workbook property view 
displays the operations to which the selected stream is 
attached.
2. Click on any cell associated with the stream SepVap. 
The list at the bottom displays the names of the two 
operations, InletSep and Gas/Gas, to which this stream is 
attached.
Any utilities attached to the stream with the Workbook 
active also appears in (and are accessible through) this list.1-49
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The3. To access the property view for either of these operations, 
double-click on the operation name.
Adding a Tab to the Workbook 
When the Workbook has focus, the Workbook item appears in 
the HYSYS menu bar. This allows you to customize the 
Workbook to display specific information.
In this section you will create a new Workbook tab that displays 
only stream pressure, temperature, and flow.
1.  Do one of the following:
• From the Workbook menu, select Setup.
• Right-click the Material Streams tab in the Workbook, 
then select Setup from the object inspect menu that 
appears.
 Figure 1.54
The operations to which SepVap is attached 
are displayed in this list. You can access the 
property view by double-clicking on the 
corresponding operation name.
Stream SepVap is the current 
Workbook location.1-50
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TheThe Workbook Setup property view appears.     
The four existing tabs are listed in the Workbook Pages 
group. When you add a new tab, it will be inserted before 
the highlighted tab (currently Material Streams).
2. In the Workbook Tabs group list, select the Compositions 
tab.
3. In the Workbook Tabs group, click the Add button. The New 
Object Type property view appears. 
 Figure 1.55
 Figure 1.56
Currently, all variables are displayed with four 
significant figures. You can change the display format or 
precision of any Workbook variables by clicking the 1-51
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The4. Click the + icon beside Stream to expand the tree branch 
into Material Stream and Energy Streams.
5. Select the Material Stream and click the OK button. You 
will return to the Setup property view, and the new tab 
appears in the list after the existing Material Streams tab.
6. In the Object group, click in the Name cell and change the 
name for the new tab from the default Material Streams 1 to 
P,T,Flow to better describe the tab contents.
Next you will customize the tab by removing the irrelevant 
variables.
7. In the Variables group, select the first variable, Vapour 
Fraction.   
 Figure 1.57
 Figure 1.581-52
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The8. Press and hold the CTRL key.
9. Click on the following variables: Mass Flow, Heat Flow, 
and Molar Enthalpy. Four variables are now selected.
10.Release the CTRL key.
11.Click the Delete button. The variables are removed from the 
list. The finished Setup appears below. 
Deleting variables removes them from the current Workbook 
tab only. If you want to remove variables from another tab, 
you must edit each tab individually.
12.Close the Setup property view to return to the Workbook 
property view and check the new tab. 
 Figure 1.59
 Figure 1.60
The new tab 
displays only 
these four 
Variables.
The new tab 
now appears in 
the list of 
Workbook Tabs 
in the same 
order as it 
appears in the 
Workbook.1-53
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The13.At this point, save your case by doing one of the following:
• Click the Save icon on the toolbar.
• Select Save from the File menu.
• Press CTRL S.
1.2.8 Using the PFD
The PFD is the other home property view used in the Simulation 
environment. To open the PFD:
1. Do one of the following:
• Click the PFD icon on the toolbar.
• Press CTRL P or from the Tools menu select PFDs. The 
Select PFD property view appears. Select the PFD you 
want to access from the list and click the View button.
The current tutorial PFD property view appears as shown in 
the figure below, with all streams and unit operations visible.
If the streams or operations are not all visible, select Auto 
Position All from the PFD menu. HYSYS now displays all 
streams and operations, arranging them in a logical manner.
The PFD menu option appears in the HYSYS menu bar 
whenever the PFD is active. 
 Figure 1.61
Save icon
PFD icon
PFD toolbar
Stream/
Operation 
labels
Unit Operation icon for 
a Separator
Material 
Stream arrow1-54
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TheAs a graphic representation of your flowsheet, the PFD shows 
the connections among all streams and operations, also known 
as ‘objects’. Each object is represented by a symbol or ‘icon’. A 
stream icon is an arrow pointing in the direction of flow, while an 
operation icon is a graphic representation of the actual physical 
operation. The object name or ‘label’ appears near each icon.
Like any other non-modal property view, the PFD property view 
can be re-sized by clicking and dragging anywhere on the 
outside border. Other functions you can perform while the PFD is 
active include the following:
• Access commands and features from the PFD tool bar.
• Open the property view for an object by double-clicking 
on its icon.
• Move an object by clicking and dragging it to the new 
location.
• Access ‘fly-by’ summary information for an object by 
placing the cursor over it.
• Change an icon's size by clicking the Size Mode icon, 
clicking on the icon you want to resize, then clicking and 
dragging the sizing “handles” that appear.
• Accessing the Object Inspection menu for an object by 
placing the cursor over it and right-clicking. This menu 
provides access to a number of commands associated 
with that particular object.
• Zoom in and out or display the entire flowsheet in the 
PFD window by clicking the zoom buttons at the bottom 
left corner of the PFD property view.
Some of these functions will be illustrated in this tutorial. For 
more information, refer to the HYSYS User Guide.
 Figure 1.62
Fly-by information example:
Icon Name Icon Name
Zoom Out 25% Zoom In 25%
Display Entire PFD
Size Mode icon1-55
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TheCalculation Status
Before proceeding, you will examine a feature of the PFD which 
allows you to trace the calculation status of the objects in your 
flowsheet. If you recall, the status indicator at the bottom of the 
property view for a stream or operation displayed three different 
states for the object:
When you are working in the PFD, the streams and operations 
are also colour-coded to indicate their calculation status. The 
mixer and inlet separator are completely calculated, so they 
have a black outline. For the heat exchanger Gas/Gas, however, 
the conditions of the tube side outlet and both shell side streams 
are unknown, so the exchanger has a yellow outline indicating 
its unsolved status.
A similar colour scheme is used to indicate the status of 
streams. For material streams, a dark blue icon indicates the 
stream has been flashed and is entirely known. A light blue icon 
indicates the stream cannot be flashed until some additional 
information is supplied. Similarly, a dark red icon indicates an 
energy stream with a known duty, while a purple icon indicates 
an unknown duty.
Indicator Status Description
Red Status A major piece of defining information is missing from 
the object. 
For example, a feed or product stream is not attached 
to a Separator. The status indicator is red, and an 
appropriate warning message appears.
Yellow Status All major defining information is present, but the 
stream or operation has not been solved because one 
or more degrees of freedom is present.
For example, a Cooler where the outlet stream 
temperature is unknown. The status indicator is yellow, 
and an appropriate warning message appears.
Green Status The stream or operation is completely defined and 
solved. The status indicator is green, and an OK 
message appears.
Keep in mind that the above colours are the HYSYS default 
colours. You can change/customize the colours in the 
Session Preferences.1-56
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TheInstalling the Chiller
In the next step you will install a chiller, which will be modeled 
as a Cooler. The operation is installed using the Object Palette 
the PFD.
Adding the Chiller to the PFD
1. Press F4 to access the Object Palette
The Chiller will be added to the right of the LTS, so make 
some empty space available in the PFD by scrolling to the 
right using the horizontal scroll bar.
2. Click the Cooler icon on the Object Palette. 
If you click the wrong button, click the Cancel icon.
3. Position the cursor over the PFD. 
The cursor changes to a special cursor with a + symbol 
attached to it. A frame attached to the cursor is used to 
indicate the location of the operation icon. 
4. Click on the PFD where you want to drop the Cooler. 
HYSYS creates a new Cooler with a default name, E-100. 
The Cooler has a red status (and colour), indicating that it 
requires feed and product streams.
The icons for all streams installed to this point are dark blue 
except for the Heat Exchanger shell-side streams LTSVap 
and SalesGas, and tube-side outlet CoolGas.
 Figure 1.63
Cooler icon
Cancel icon1-57
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TheConnecting the Chiller
1. Click the Attach Mode icon on the PFD toolbar to enter 
Attach mode.
When you are in Attach mode, you will not be able to move 
objects in the PFD. To return to Move mode, click the Attach 
icon again.
You can temporarily toggle between Attach and Move mode 
by holding down the CTRL key.
2. Position the cursor over the right end of the CoolGas stream 
icon. 
A small transparent box appears at the cursor tip. Through 
the transparent box, you can see a square connection point, 
and a pop-up description attached to the cursor tail. The 
pop-up Out indicates which part of the stream is available 
for connection, in this case the stream outlet.
3. With the pop-up Out visible, click and hold. 
The transparent box becomes solid black, indicating that you 
are beginning a connection.
4. Move the cursor toward the left (inlet) side of the Cooler. 
A trailing line appears between the CoolGas stream icon and 
the cursor, and a connection point appears at the Cooler 
inlet.
5. Place the cursor near the connection point, and the trailing 
line snaps to that point. 
 Figure 1.64
.
Attach Mode icon1-58
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TheAlso, a solid white box appears at the cursor tip, indicating 
an acceptable end point for the connection. 
6. Release the left mouse button, and the connection is made 
to the connection point at the Cooler inlet.
Adding Outlet and Energy Streams
1. Position the cursor over the right end of the Cooler icon. 
The connection point and pop-up Product appears.
2. With the pop-up visible, left-click and hold. 
The transparent box again becomes solid black.
3. Move the cursor to the right of the Cooler. 
A white stream icon appears with a trailing line attached to 
the Cooler outlet.
The stream icon indicates that a new stream will be created 
after the next step is completed.
4. With the white stream icon visible, release the left mouse 
button. 
HYSYS creates a new stream with the default name 1.
5. Repeat steps 1-4 to create the Cooler energy stream, 
originating the connection from the arrowhead on the Cooler 
icon. 
 Figure 1.65
 Figure 1.661-59
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TheThe new stream is automatically named Q-100. The Cooler 
has yellow (warning) status, indicating that all necessary 
connections have been made but the attached streams are 
not entirely known. 
6. Click the Attach Mode icon again to return to Move mode.
If you make an incorrect connection:
1. Click the Break Connection icon on the PFD toolbar.
2. Move the cursor over the stream line connecting the two 
icons. A checkmark attached to the cursor appears, 
indicating an available connection to break.
3. Click once to break the connection.
Defining the Material and Energy Streams
The Cooler material streams and the energy stream are 
unknown at this point, so they are light blue and purple, 
respectively.
1. Double-click the Cooler icon to open its property view. 
On the Connections page, the names of the Inlet, Outlet, 
and Energy streams that you recently attached appear in the 
appropriate cells. 
 Figure 1.67
Break Connection icon1-60
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The2. In the Name field, change the operation name to Chiller.    
3. Select the Parameters page.
4. In the Delta P field, specify a pressure drop of 10 psi. 
5. Close the cooler property view.
At this point, the Chiller has two degrees of freedom; one of 
these will be exhausted when HYSYS flashes the CoolGas 
stream after the exchanger temperature approach is 
specified.
To use the remaining degree of freedom, either the Chiller 
outlet temperature or the amount of duty in the Chiller 
energy stream must be specified. The amount of chilling 
duty which is available is unknown, so you will provide an 
 Figure 1.68
 Figure 1.691-61
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Theinitial guess of 0oF for the Chiller outlet temperature. Later, 
this temperature can be adjusted to provide the desired 
sales gas dew point temperature.
6. Double-click on the outlet stream icon (1) to open its 
property view.
7. In the Name field, change the name to ColdGas.
8. In the Temperature field, specify a temperature of 0oF.
The remaining degree of freedom for this stream has now 
been used, so HYSYS flashes ColdGas to determine its 
remaining properties.  
9. Close the ColdGas property view and return to the PFD 
property view.
The Chiller still has yellow status, because the temperature 
of the CoolGas stream is unknown.
10.Double-click the energy stream icon (Q-100) to open its 
property view. 
The required chilling duty (in the Heat Flow cell) is calculated 
by HYSYS when the Heat Exchanger temperature approach 
is specified in a later section.
 Figure 1.701-62
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The11.Rename the energy stream C3Duty and close the property 
view.    
Installing the LTS
Now that the chiller has been installed, the next step is to install 
the low-temperature separator (LTS) to separate the gas and 
condensed liquids in the ColdGas stream.
Adding and Connecting the LTS
1. Make some empty space available to the right of the Chiller 
using the horizontal scroll bar.
2. Position the cursor over the Separator icon on the Object 
Palette.
3. Right-click, hold, and drag the cursor over the PFD to the 
right of the Chiller. 
The cursor changes to a special “bulls-eye” cursor. A frame 
attached to the bulls-eye cursor indicates the location of the 
operation icon.
4. Release the right mouse button to drop the Separator onto 
the PFD. 
A new Separator appears with the default name V-100.
5. Click the Attach Mode icon on the PFD tool bar.
6. Position the cursor over the right end of the ColdGas stream 
icon. The connection point and pop-up Out appears.
 Figure 1.71
Separator icon
Attach Mode icon1-63
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The7. With the pop-up visible, left-click, hold, and drag the cursor 
toward the left (inlet) side of the Separator.
Multiple connection points appear at the Separator inlet.
8. Place the cursor near the inlet area of the Separator. A solid 
white box appears at the cursor tip.
9. Release the mouse button and the connection is made.
Adding Connections
The Separator has two outlet streams, liquid and vapour. The 
vapour outlet stream LTSVap, which is the shell side inlet stream 
for Gas/Gas, has already been created. The liquid outlet will be 
a new stream.
1. In the PFD, position the cursor over the top of the Separator 
icon. 
The connection point and pop-up Vapour Product appears.
2. With the pop-up visible, left-click and hold.
3. Drag the cursor to the LTSVap stream icon. 
A solid white box appears when you move over the 
connection point.
Multiple connection points appear because the Separator 
accepts multiple feed streams.
 Figure 1.72
 Figure 1.731-64
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The4. Release the mouse button, and the connection is made. 
5. Position the cursor over the bottom of the Separator icon. 
The connection point and pop-up Liquid Product appears.
6. With the pop-up visible, left-click and hold.
7. Move the cursor to the right of the Separator. 
A white arrow stream icon appears with a trailing line 
attached to the Separator liquid outlet. 
8. With the stream icon visible, release the mouse button. 
HYSYS creates a new stream with the default name 1.
9. Click the Attach Mode icon to leave Attach mode.
10.Double-click on the stream icon 1 to open its property view.
11. In the Stream Name cell, type LTSLiq, then press ENTER.
12.Close the LTSLiq stream property view.
13.Select Auto Position All from the PFD menu. 
Your PFD should appear similar to the one shown below.  
14.Double-click the icon for the new Separator (V-100) to open 
its property view.
15. In the Name field, change the name to LTS.
 Figure 1.74
Streams LTSVap and LTSLiq are now known, as shown by the 
change in their PFD colour from light blue to dark blue.
Attach Mode icon1-65
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The16.Close the LTS property view. 
At this point, the outlet streams from heat exchanger Gas/
Gas are still unknown. 
17.Double-click on the Gas/Gas icon to open the exchanger 
property view.
18.Click the Design tab and select the Specs page.    
The Specs page allows you to input specifications for the 
Heat Exchanger and view its calculation status. The Solver 
group on this page shows that there are two Unknown 
Variables and the Number of Constraints is 1, so the 
remaining Degrees of Freedom is 1. HYSYS provides two 
default constraints in the Specifications group, although only 
one has a value:
 Figure 1.75
Specification Description
Heat 
Balance 
The tube side and shell side duties must be equal, so the 
heat balance must be zero (0).
UA This is the product of the overall heat transfer coefficient 
(U) and the area available for heat exchange (A). HYSYS 
does not provide a default UA value, so it is unknown at this 
point. It will be calculated by HYSYS when another 
constraint is provided.1-66
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TheAdding a Heat Exchanger 
Specification
To exhaust the remaining degree of freedom, a 10oF minimum 
temperature approach to the hot side inlet of the exchanger will 
be specified.
1. In the Specifications group, click the Add button. 
The ExchSpec (Exchanger Specification) view appears.
2. In the Name cell, change the name to Hot Side Approach.
The default specification in the Type cell is Delta Temp, 
which allows you to specify a temperature difference 
between two streams. The Stream (+) and Stream (-) 
cells correspond to the warmer and cooler streams, 
respectively.
3. In the Stream (+) cell, select SepVap from the drop-down 
list.
4. In the Stream (-) cell, select SalesGas from the drop-down 
list.
5. In the Spec Value cell, enter 10oF. 
The property view should appear as shown in the following 
figure.
HYSYS will converge on both specifications and the unknown 
streams will be flashed.
6. Close the specification property view to return to the Gas/
Gas property view. 
 Figure 1.761-67
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TheThe new specification appears in the Specifications group on 
the Specs page.
7. Click the Worksheet tab, then select the Conditions page 
to view the calculated stream properties.  
Using the 10oF approach, HYSYS calculates the temperature 
of CoolGas as 42.9oF. All streams in the flowsheet are now 
completely known.
 Figure 1.77
 Figure 1.781-68
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The8. Click the Performance tab, then select the Details page, 
where HYSYS displays the Overall Performance and Detailed 
Performance.   
Two parameters of interest are the UA and LMTD 
(logarithmic mean temperature difference), which HYSYS 
has calculated as 2.08e4 Btu/F-hr and 22.6oF, 
respectively. 
9. When you are finished reviewing the results, click the Close 
icon  to leave the Gas/Gas property view.
 Figure 1.791-69
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TheChecking the Sales Gas Dew Point
The next step is to check the SalesGas stream to see if it meets 
a dew point temperature specification. This is to ensure no 
liquids form in the transmission line. A typical pipeline dew point 
specification is 15oF at 800 psia, which will be used for this 
example.
You can test the current dew point by creating a stream with a 
composition identical to SalesGas, specifying the dew point 
pressure, and having HYSYS flash the new stream to calculate 
its dew point temperature. To do this you will install a Balance 
operation.
1. Double-click the Balance icon on the Object Palette. 
The property view for the new operation appears.
2. In the Name field, type DewPoint, then press ENTER.
3. Click in the <> cell in the Inlet Streams table. 
 Figure 1.80Balance icon1-70
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The4. Open the drop-down list of available streams and select 
SalesGas.   
5. Click in the <> cell in the Outlet Streams table.
6. Create the outlet stream by typing SalesDP, then press 
ENTER. 
7. Click the Parameters tab.
Changes made to the vapour fraction, temperature or 
pressure of stream SalesDP will not affect the rest of the 
flowsheet. However, changes which affect SalesGas will 
cause SalesDP to be re-calculated because of the molar 
balance between these two streams.
8. In the Balance Type group, select the Mole radio button.
 Figure 1.81
 Figure 1.821-71
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The9. Click the Worksheet tab. 
The vapour fraction and pressure of SalesDP can now be 
specified, and HYSYS will perform a flash calculation to 
determine the unknown temperature.
10. In the SalesDP column, Vapour cell, enter 1.0.
11. In the Pressure cell, enter 800 psia.
HYSYS flashes the stream at these conditions, returning a 
dew point Temperature of 5.27oF, which is well within the 
pipeline of 15oF. 
12.Close the DewPoint property view to return to the PFD.
When HYSYS created the Balance and new stream, their 
icons were probably placed in the far right of the PFD. If you 
like, you can click and drag the Balance and SalesDP icons to 
a more appropriate location, such as immediately to the 
right of the SalesGas stream.
Installing the Second Mixer 
In this section you will install a second mixer, which is used to 
combine the two liquid streams, SepLiq and LTSLiq, into a single 
feed for the Distillation Column.
1. In the PFD, make some empty space available to the right of 
the LTS using the horizontal scroll bar.
2. Click the Mixer button on the Object Palette.
 Figure 1.83
Mixer icon1-72
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The3. In the PFD, position the cursor to the right of the LTSLiq 
stream icon.
4. Click to drop the Mixer onto the PFD. 
A new Mixer named MIX-101 appears.
5. Press and hold the CTRL key to temporarily enable Attach 
mode while you make the Mixer connections.
6. Position the cursor over the right end of the LTSLiq stream 
icon. 
The connection point and pop-up Out appears.
7. With the pop-up visible, click and drag the cursor toward the 
left (inlet) side of the Mixer, and multiple connection points 
appear at the Mixer inlet.
Multiple connection points appear because the Mixer accepts 
multiple feed streams.
8. Place the cursor near the inlet area of the Mixer. 
When the solid white box appears at the cursor tip, release 
the left mouse button to make the connection.
9. Repeat steps 5-8 to connect SepLiq to the Mixer.
10.Move the cursor over the right end of the Mixer icon. 
The connection point and pop-up Product appears.
11.With the pop-up visible, click and drag the cursor to the right 
of the Mixer. 
A white arrow stream icon appears.
12.With the stream icon visible, release the mouse button. 
HYSYS will create a new stream with the default name 1.   
13.Release the CTRL key to leave Attach mode.
14.Double-click on the outlet stream icon 1 to access its 
property view.
When you created the Mixer outlet stream, HYSYS 
automatically combined the two inlet streams and flashed 
the mixture to determine the outlet conditions. 
 Figure 1.841-73
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The15. In the Stream Name cell, rename the stream to 
TowerFeed, then click the Close icon .
Installing the Column
HYSYS has a number of pre-built column templates that you can 
install and customize by changing attached stream names, 
number of stages, and default specifications.
In this section, you will install a Distillation Column.
1. From the Tools menu, select Preferences.
2. On the Simulation tab, Options page, ensure that the Use 
Input Experts checkbox is selected (checked), then close 
the property view.
3. Press F4 to access the Object Palette.
4. Double-click on the Distillation Column icon on the Object 
Palette. 
The first page of the Input Expert property view appears. 
 Figure 1.85
The Input Expert property view is a logical sequence of input 
property views that guide you through the initial installation 
of a Column. Completion of the steps will ensure that you 
have provided the minimum amount of information required 
to define the column.
Distillation Column icon1-74
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TheWhen you install a column using a pre-built template, HYSYS 
supplies certain default information, such as the number of 
stages. The current active cell is # Stages (Number of 
Stages), indicated by the thick border around this cell and 
the presence of 10 (default number of stages). 
Some points worth noting:
• These are theoretical stages, as the HYSYS default stage 
efficiency is one. If you want to specify real stages, you 
can change the efficiency of any or all stages later.
• The Condenser and Reboiler are considered separate 
from the other stages, and are not included in the Numb 
Stages field.
For this example, 10 theoretical stages will be used, so leave 
the Number of Stages at its default value.
5. Click on the <> cell in the Inlet Streams table.
6. Open the drop-down list for the available feed streams by 
clicking the  icon or pressing F2 then the DOWN or UP 
arrow key.
7. Select TowerFeed as the inlet feed stream to the column.
HYSYS will supply a default feed location in the middle of the 
Tray Section (TS), in this case stage 5 (indicated by 5_Main 
TS). This default location is used, so there is no need to 
change the Feed Stage.
This column has Overhead Vapour and Bottoms Liquid 
products, but no Overhead Liquid (distillate) product.
8. In the Condenser group, select the Full Rflx radio button.
The distillate stream disappears. This is the same as leaving 
the Condenser as Partial and later specifying a zero distillate 
rate.1-75
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The9. Enter the stream and Column names as shown in the figure 
below. 
When you are finished, the Next button becomes active, 
indicating sufficient information has been supplied to 
advance to the next page of the Input Expert. 
10.Click the Next button to advance to the Pressure Profile 
page.
11. In the Condenser Pressure field, enter 200 psia.
12. In the Reboiler Pressure field, enter 205 psia.
 Figure 1.861-76
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TheThe Condenser Pressure Drop can be left at its default value 
of zero.    
13.Click the Next button to advance to the Optional 
Estimates page. 
14.Specify a Condenser temperature of 40°F and a Reboiler 
Temperature Estimates of 200°F.    
 Figure 1.87
Although HYSYS does not require estimates to produce a 
converged column, good estimates will usually result in a 
faster solution.
 Figure 1.881-77
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The15.Click the Next button to advance to the fourth and final 
page of the Input Expert. 
The Specifications page allows you to supply values for the 
default column specifications that HYSYS has created.
16.Enter a Vapour Rate of 2.0 MMSCFD and a Reflux Ratio 
of 1.0. 
The Flow Basis applies to the Vapour Rate, so leave it at the 
default of Molar.  
In general, a Distillation Column has three default 
specifications, however, by specifying zero overhead liquid 
flow (Full Reflux Condenser) one degree of freedom was 
eliminated. For the two remaining default specifications, 
overhead Vapour Rate is an estimate only, and Reflux Ratio 
is an active specification.
17.Click the Done button.
 Figure 1.891-78
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TheThe Distillation Column property view appears.
18.Select the Monitor page.
The Monitor page displays the status of your column as it is 
being calculated, updating information with each iteration. 
You can also change specification values and activate or de-
activate specifications used by the Column solver directly 
from this page.
 Figure 1.90
 Figure 1.911-79
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TheAdding a Column Specification
The current Degrees of Freedom is zero, indicating the column is 
ready to be run. The Vapour Rate you specified in the Input 
Expert, however, is currently an Active specification, and you 
want to use this only as an initial estimate for the solver for this 
exercise. 
1. In the Vent Rate row, click the Active checkbox to clear it, 
leaving the Estimate checkbox checked.
The Degrees of Freedom will increase to 1, indicating that 
another active specification is required. For this example, a 
2% propane mole fraction in the bottoms liquid will be 
specified.
2. Select the Specs page. 
This page lists all the Active and non-Active specifications 
which are required to solve the column.  
3. In the Column Specifications group, click the Add button. 
The Add Specs property view appears.
4. From the Column Specification Types list, select Column 
Component Fraction. 
5. Click the Add Spec(s) button.
 Figure 1.921-80
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TheThe Comp Frac Spec property view appears.
6. In the Name cell, change the specification name to 
Propane Fraction.
7. In the Stage cell, select Reboiler from the drop-down list of 
available stages. 
8. In the Spec Value cell, enter 0.02 as the liquid mole 
fraction specification value.
 Figure 1.93
 Figure 1.941-81
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The9. Click in the first cell <> in the Components 
table, and select Propane from the drop-down list of 
available components. 
10.Close this property view to return to the Column property 
view.
The new specification appears in the Column Specifications 
list on the Specs page.
11.Return to the Monitor page. 
The new specification may not be visible unless you scroll 
down the table because it has been placed at the bottom of 
the Specifications list.
 Figure 1.95
HYSYS automatically made the new specification active 
when you created it.1-82
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The12.Click the Group Active button to bring the new specification 
to the top of the list, directly under the other Active 
specification.
The Degrees of Freedom has returned to zero, so the column 
is ready to be calculated.
 Figure 1.961-83
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TheRunning the Column
1. Click the Run button to begin calculations. 
The information displayed on the Monitor page is updated 
with each iteration. The column converges quickly, in three 
iterations. 
The table in the Optional Checks group displays the Iteration 
number, Step size, and Equilibrium error and Heat/Spec 
error.
The column temperature profile appears in the Profile 
group.You can view the pressure or flow profiles by selecting 
the appropriate radio button
The status indictor has changed from Unconverged to 
Converged.
 Figure 1.971-84
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The2. Click the Performance tab, then select the Column 
Profiles page to access a more detailed stage summary. 
Accessing the Column Sub-flowsheet
When considering the column, you might want to focus only on 
the column sub-flowsheet. You can do this by entering the 
column environment.
1. Click the Column Environment button at the bottom of the 
column property view.
HYSYS desktop now displays the Column Sub-flowsheet 
environment. 
 Figure 1.98
 Figure 1.99
The Environment label displays DePropanizer (Col1).1-85
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The2. In this environment you can do the following:
• Click the PFD icon to view the column sub-flowsheet 
PFD. 
• Click the Workbook icon to view a Workbook for the 
column sub-flowsheet objects.
 Figure 1.100
 Figure 1.101
PFD icon
Workbook icon1-86
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The• Click the Column Runner icon to access the inside 
column property view. 
This property view is essentially the same as the outside, 
or main flowsheet, property view. 
3. When you are finished in the column environment, return to 
the main flowsheet by clicking the Enter Parent 
Simulation Environment icon in the tool bar or the Parent 
Environment button on the column Worksheet property 
view.
1.2.9 Viewing and Analyzing 
Results
1. Open the Workbook for the main case to access the 
calculated results for all streams and operations.
2. Click the Material Streams tab. 
Column Runner icon
Enter Parent Simulation 
Environment icon
 Figure 1.1021-87
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The3. Click the Compositions tab.  
Using the Object Navigator
In this section, you will use the Object Navigator to view 
properties for a particular stream or operation. The Object 
Navigator allows you to quickly access the property view for any 
stream or unit operation at any time during the simulation.
1. To open the Navigator, do one of the following:
• Press F3.
• From the Flowsheet menu, select Find Object.
• Click the Object Navigator icon.
The Object Navigator property view appears:   
 Figure 1.103
 Figure 1.104
Object Navigator icon1-88
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TheThe UnitOps radio button in the Filter group is currently 
selected, so only the Unit Operations appear in the list of 
available objects.
2. To open a property view, select the operation in the list and 
click the View button, or double-click on the operation.
• To change which objects appear, select a different radio 
button in the Filter group. 
• To list all streams and unit operations, select the All 
button.
3. You can also search for an object by clicking the Find 
button. 
When the Find Object property view appears, enter the 
Object Name, then click the OK button. HYSYS opens the 
property view for the object.
Using the Databook
The HYSYS Databook provides you with a convenient way to 
examine your flowsheet in more detail. You can use the 
Databook to monitor key variables under a variety of process 
scenarios, and view the results in a tabular or graphical format.
For this example, the effects of LTS temperature on the Sales 
Gas dew point and flow rate, and the Liquid Product flow rate 
will be examined.
You can start or end the search string with an asterisk (*), 
which acts as a wildcard character. This lets you find 
multiple objects with one search. 
For example, searching for VLV* will open the property view 
for all objects with VLV at the beginning of their name.1-89
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TheDefining the Key Variables
Before opening the Databook, close the Object Navigator or any 
property view you might have opened using the Navigator.
1. To open the Databook, do one of the following:
• Press CTRL D.
• Open the Tools menu and select Databook.
The Databook appears as shown below.   
2. Click the Variables tab. 
Here you will add the key variables to the Databook.
3. Click the Insert button. 
 Figure 1.1051-90
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TheThe Variable Navigator property view appears.
The Variable Navigator is used extensively in HYSYS for 
locating and selecting variables.
The Navigator operates in a left-to-right manner. The 
selected Flowsheet determines the Object list; the chosen 
Object dictates the Variable list; the selected Variable 
determines whether any Variable Specifics are available. 
4. In the Object Filter group, select the UnitOps radio button. 
The Object list will be filtered to show unit operations only.
5. In the Object list, select LTS. 
The Variable list available for the LTS appears to the right of 
the Object list.
6. In the Variable list, select Vessel Temperature.
HYSYS displays this variable name in the Variable 
Description field.
 Figure 1.1061-91
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The 
7. Click the OK button to add this variable to the Databook.
The new variable Vessel Temperature appears in the 
Databook.     
Continue adding variables to the Databook.
8. Click the Insert button, and the Variable Navigator 
reappears.
9. In the Object Filter group, select the Streams radio button. 
The Object list is filtered to show streams only.
10. In the Object list, select SalesDP. 
The Variables list available for material streams appears to 
the right of the Object list.
 Figure 1.107
 Figure 1.1081-92
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The11. In the Variable list, select Temperature.
12. In the Variable Description field, change description to 
Dew Point, then click the Add button. 
The variable now appears in the Databook, and the Variable 
Navigator property view remains open.   
13.Repeat the previous steps to add the following variables to 
the Databook:
• SalesGas stream; Molar Flow variable; change the 
Variable Description to Sales Gas Production
• LiquidProd stream; Liq Vol Flow@Std Cond variable; 
change the Variable Description to Liquid Production
14.Click the Close button to close the Variable Navigator 
property view.
 Figure 1.1091-93
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TheThe completed Variables tab of the Databook appears as 
shown below.
Creating the Data Table
In this section you will create a data table to display the 
variables.
1. Click the Process Data Tables tab.
2. In the Available Process Data Tables group, click the Add 
button. 
HYSYS creates a new table with the default name ProcData1.     
 Figure 1.110
 Figure 1.1111-94
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TheThe four variables that were added to the Databook appear 
in the table on this tab.
3. In the Process Data Table field, change the name to Key 
Variables.
4. Activate each variable by clicking on the corresponding 
Show checkbox. 
5. Click the View button to view the Key Variables Data table, 
which appears below.     
You will access this table again later to demonstrate how its 
results are updated whenever a flowsheet change is made.
6. For now, click the Minimize icon  in the upper right 
corner of the Key Variables Data property view. 
HYSYS reduces the property view to an icon and places it at 
the bottom of the Desktop.
 Figure 1.112
 Figure 1.1131-95
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TheUsing the Data Recorder
In this section you will use the Data Recorder to automatically 
record the current values of the key variables before making any 
changes to the flowsheet.
1. On the DataBook property view, click the Data Recorder 
tab. 
When using the Data Recorder, you first must create a 
Scenario containing one or more of the key variables, then 
record the variables in their current state.
2. In the Available Scenarios group, click the Add button. 
HYSYS creates a new scenario with the default name 
Scenario 1. 
 Figure 1.1141-96
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The3. In the table, activate each variable by clicking on the 
corresponding Include checkbox.
4. Click the Record button to record the variables in their 
current state. 
The New Solved State property view appears, prompting you 
for the name of the new state.
5. Enter the new name Base Case, then click OK. 
The New Solved State property view close and you return to 
the Databook property view.
6. In the Available Display group, select the Table radio 
button.
7. Click the View button. 
 Figure 1.1151-97
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TheThe Data Recorder appears, displaying the values of the key 
variables in their current state.    
Now you can make the necessary flowsheet changes and 
these current values remain as a permanent record in the 
Data Recorder unless you choose to erase them. 
8. Click the Minimize button  to reduce the Data Recorder 
to an icon.
9. Click the Restore Up icon  on the Key Variables Data 
property view to restore the property view to its original 
size. 
Modifying the ColdGas Stream
In this section, you will change the temperature of stream 
ColdGas (which determines the LTS temperature) and view the 
changes in the process data table.
1. Click the Object Navigator icon on the toolbar. The Object 
Navigator property view appears
2. In the Filter group, select the Streams radio button.
3. In the Streams list, select ColdGas, then click the View 
button. 
 Figure 1.116
Object Navigator icon1-98
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TheThe ColdGas property view appears.
4. Ensure that you are on the Worksheet tab, Conditions 
page of the property view.
5. Arrange the two property views, as shown below, by clicking 
and dragging on their title bars.   
 Figure 1.117
 Figure 1.1181-99
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TheCurrently, the LTS temperature is 0oF. The key variables will 
be checked at 10oF.
6. In the ColdGas Temperature cell, type 10oF. 
HYSYS automatically recalculates the flowsheet. The new 
results are shown below.    
The change in Temperature generates the following results:
• The Sales Gas flow rate has increased.
• The Liquid Product flow rate has decreased.
• The sales gas dew point has increased to 15.9oF. This 
temperature no longer satisfies the dew point 
specification of 15oF.
7. Click the Close icon  on the ColdGas stream property 
view and return to the Databook.
 Figure 1.1191-100
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TheRecording the New Variables in the 
Databook
In this section you will record the key variables in their new 
state.
1. Click the Data Recorder tab in the Databook.
2. Click the Record button, and the New Solved State property 
view appears. 
HYSYS provides you with the default name State 2 for the 
new state.
3. Change the name to 10F in LTS, then click the OK button to 
accept the new name.
4. Click the View button and the Data Recorder appears, 
displaying the new values of the variables.
5. Click the Close icon  on the Data Recorder, then on the 
Databook, and finally on the Key Variables Table.
6. Save the case.
The basic simulation for this example has now been completed. 
You can continue with this example by proceeding to the 
Optional Study sections, or you can begin building your own 
simulation case. In the Optional Study, you will use some of the 
other tools available in HYSYS to examine the process in more 
detail.
 Figure 1.1201-101
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The1.2.10 Optional Study
In the following sections, the effects of the LTS temperature on 
the SalesGas dew point and heating value are determined. 
Before proceeding, re-specify the temperature of ColdGas back 
to its original value of 0oF:
1. Click the Workbook icon on the toolbar.
2. On the Material Streams tab of the Workbook, click in the 
Temperature cell for the ColdGas stream.
3. Type 0, then press ENTER.
Using the Spreadsheet
HYSYS has a Spreadsheet operation that allows you to import 
stream or operation variables, perform calculations, and export 
calculated results.
To install a Spreadsheet and display its property view:
1. Access the Object Palette.
2. Double-click the Spreadsheet icon in the Object Palette.
The Spreadsheet property view appears.
3. On the Connections tab, change the spreadsheet name to 
Heating Value.
 Figure 1.121
Workbook icon
Spreadsheet icon1-102
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TheThe heating value of the sales gas is calculated by importing 
the stream composition into the Spreadsheet then 
multiplying the mole fraction of each component by its 
individual heating value.
Importing Variables - First Method
In this section you will import variables on the Connections tab.
1. Click the Add Import button, and the Select Import for cell 
property view appears.
2. Choose the SalesGas Object, Comp Mole Frac Variable, 
and Methane Variable Specific as shown.  
NO2 and CO2 are not included in the calculation as their 
individual heating values are negligible.
3. Click the OK button.
4. Click the Add Import button again, then select the 
SalesGas Object, Comp Mole Frac Variable, and Ethane 
Variable Specific. 
5. Click the OK button.
6. Repeat steps 4 and 5 to add the Propane Variable Specific.
For illustration purposes, the two remaining components will 
be added later using an alternative import method. HYSYS 
assigned the imported variables to Spreadsheet cells A1 
through A3, by default.
 Figure 1.1221-103
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The7. Change the cell locations to B3 through B5 as shown in the 
following figure; the reason for doing so will become 
apparent on the Spreadsheet tab. 
8. No information is required on the Parameters and Formulas 
tabs, so click the Spreadsheet tab.
9. Enter the column headings as shown in the table below.
You can move to a cell by clicking it, or by pressing the 
arrow keys.
10.Enter the components in the Component column as shown 
as shown in the table below.
 Figure 1.123
Column/Row Heading
A1 Component
B1 Mole Fraction
C1 Comp Heat Value
D1 Total Heat Value
The HYSYS Spreadsheet behaves similarly to commercial 
spreadsheet packages; you enter data and formulas in the 
cells, and calculated results are returned.
Row Component
3 C1
4 C2
5 C3
6 iC4
7 nC41-104
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The11.Enter the component net heating values in the Comp Heat 
Value column as shown in the figure below.
Importing Variables - Second Method
The next task is to import the remaining two variables’ mole 
fractions in the Sales Gas.
1. Select the Spreadsheet cell B6, which is reserved for the i-
C4 mole fraction.
2. Right-click and select Import Variable from the Object 
Inspect menu.
The Select Import for cell property view appears.
3. Select the SalesGas Object, Comp Mole Frac Variable, and 
i-Butane Variable Specific.
4. Click the OK button to accept the input and close the 
property view.
5. Follow steps 1 to 4 to import the mole fraction for n-C4 into 
cell B7.
• Position the cursor over cell B7.
• Right-click once, and select Import Variable.
• Select the SalesGas Object, Comp Mole Frac Variable, 
and n-Butane Variable Specific.
 Figure 1.124
Object Inspect menu1-105
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The• Click the OK button.
Entering Formulas
The next task is entering the formulas for calculating the 
component and total sales gas heating values.
1. Click in cell D3.
2. Type +b3*c3, then press ENTER. 
This multiplies the Methane mole fraction by its Net Heating 
Value.
3. Enter the following formulas in cells D4 through D7.
4.  The table should appear as shown in the figure below.
5. Click in cell C9, and type Sales Gas NHV.
6. Click in cell D9.
All formulas must be preceded by a +.
Cell Formula
D4 +b4*c4
D5 +b5*c5
D6 +b6*c6
D7 +b7*c7
 Figure 1.1251-106
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The7. Enter +d3+d4+d5+d6+d7 in cell D9 to sum the individual 
heating values. 
The result is the NHV of SalesGas in Btu/scf.    
The current heating value of the sales gas is 1080 Btu/scf. 
Whenever flowsheet changes are made that result in the re-
calculation of the stream SalesGas, the compositional 
changes will be automatically transferred to the 
Spreadsheet, and the heating value updated accordingly.
8. Close the Heating Value property view.
Optional, you can add the value of Sales Gas NHV to the 
Databook by:
1. Click the Parameters tab of the Heating Value property 
view.
2. In the Exportable Cells table, enter a Variable Name for cell 
D9 (for example NHV).
3. Open the Databook by pressing CTRL D.
4. On the Variables tab, insert the variable, selecting the 
Heating Value operation as the Object and NHV as the 
variable.
 Figure 1.1261-107
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TheInstalling an Adjust for Calculating 
the LTS Temperature
Suppose the market price of your liquid product is currently 
unfavourable and you want to raise the LTS temperature to 
leave more of the heavier components in the gas phase. This 
will increase the sales gas heating value, resulting in a bonus 
from the transmission company. The sales gas must, however, 
still comply with the dew point specification.
An Adjust operation can be used to adjust the temperature of 
the LTS (ColdGas stream) until the sales gas dew point is within 
a few degrees of the pipeline specification. In effect, this 
increases the gas heating value while still satisfying the dew 
point criteria.
Installing, Connecting, and Defining the 
Adjust
1. Click the PFD icon to display the PFD and access the Object 
Palette by pressing F4.
2. Click the Adjust icon on the Object Palette.
3. Position the cursor on the PFD to the right of the SalesDP 
stream icon.
4. Click to drop the Adjust icon onto the PFD. 
A new Adjust object appears with the default name ADJ-1.
5. Click the Attach Mode icon on the PFD toolbar to enter 
Attach mode.
6. Position the cursor over the left end of the ADJ-1 icon. 
The connection point and pop-up Adjusted Object appears.
7. With the pop-up visible, left-click and drag toward the 
ColdGas stream icon.
The Adjust operation performs automatic trial-and-error 
calculations until a target value is reached.
PFD icon
Adjust icon
Attach Mode icon1-108
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The8. When the solid white box appears on the ColdGas stream, 
release the mouse button. 
The Select Adjusted Variable property view appears.     
At this point, HYSYS knows that the ColdGas should be 
adjusted in some way to meet the required target. An 
adjustable variable for the ColdGas must now be selected 
from the Select Adjusted Variable property view.
9. From the Variable list, select Temperature.
10.Click the OK button.
11. Position the cursor over the right corner of the ADJ-1 icon. 
The connection point and pop-up Target Object appears.
12.With the pop-up visible, left-click and drag toward the 
SalesDP stream icon.
13.When the solid white box appears at the cursor tip, release 
the mouse button. 
The Select Target Variable property view appears.
14. From the Variable list, select Temperature.
15.Click the OK button.
 Figure 1.127
 Figure 1.1281-109
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The16.Click the Attach Mode icon to leave Attach mode.
17.Double-click the ADJ-1 icon to open its property view. 
The connections made in the PFD have been transferred to 
the appropriate cells in the property view.
Adjusting the Target Variable
The next task is to provide a value for the target variable, in this 
case the dew point temperature. A 5°F safety margin will be 
used on the pipeline specification of 15°F, so the desired dew 
point is 10°F.
1. In the Connections page, enter 10°F in the Specified 
Target Value field.
2. Click the Parameters tab.
3. In the Parameters page, enter 0.1°F in the Tolerance cell.
4. In the Step Size cell, enter 5°F. 
 Figure 1.1291-110
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TheNo values will be entered in the Minimum and Maximum 
field, as these are optional parameters.      
5. Click the Monitor tab. 
This tab enables you to view the calculations.
6. Click the Start button. 
The Adjust converges on the target value within the 
specified tolerance in five iterations. An LTS temperature 
(adjusted variable) of 4.4°F gives a sales gas dew point 
(target variable) of 10°F. 
 Figure 1.130
 Figure 1.1311-111
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TheThe Adjust has changed the LTS temperature from the 
original value of 0°F to 4.4°F. The new sales gas heating 
value can now be compared to the previous value to see the 
effect of this change.
7. Click the Close icon  on the Adjust property view. 
Results of the Study
1. Open the Workbook to access the calculated results for the 
entire flowsheet. 
The Material Streams and Compositions tabs of the 
Workbook appear below. 
 Figure 1.1321-112
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The1.3 Dynamic Simulation
In this tutorial section, the dynamic capabilities of HYSYS will be 
incorporated into a basic steady state gas plant model. 
The plant takes two different natural gas streams containing 
carbon dioxide and methane through n-butane and combines 
and processes them in a simple refrigeration system. A series of 
separators and coolers removes the heavier hydrocarbon 
components from the natural gas stream, allowing it to meet a 
pipeline dew point specification. The heavier liquid component of 
the gas stream is processed in a depropanizer column, yielding 
a liquid product with a specified propane content.    
The Dynamics Assistant will be used to make pressure-flow 
specifications and size pieces of equipment in the simulation 
flowsheet. It is also possible to set your own pressure-flow 
specifications and size the equipment without the aid of the 
Dynamics Assistant.
You can continue to this dynamic section with the case you 
built during the steady state section, or you can open the 
completed steady state version (which is the starting point 
for this dynamic section) called TUTOR1.hsc in the 
HYSYS\Samples directory.
 Figure 1.1331-113
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TheThis tutorial will comprehensively guide you through the steps 
required to add dynamic functionality to a steady state gas plant 
simulation. 
To help you navigate these detailed procedures, the following 
milestones have been established for this tutorial:
1. Modify the steady state model so that a pressure-flow 
relation exists between each unit operation.
2. Implement a tray sizing utility for sizing the Depropanizer 
column.
3. Use the Dynamics Assistant to set pressure flow 
specifications and size the equipment in the simulation case.
4. Install and define the appropriate controllers.
In this tutorial section, you will follow this basic procedure in 
building the dynamic model.
5. Set up the Databook. Make changes to key variables in the 
process and observe the dynamic behaviour of the model.
1.3.1 Modifying the Steady 
State Flowsheet
It is necessary to add unit operations such as valves, heat 
exchangers, or pumps, to define pressure flow relations 
between unit operations that have no pressure flow relation. In 
this tutorial, valve operations will be added between Separator, 
Mixer, and Column operations.
This is only one method of preparing a steady state case for 
Dynamic mode. 
A completed dynamic case has been pre-built and is called 
dyntut1.hsc in the HYSYS\Samples directory.1-114
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TheA Heater operation will also be added between the Mixer and 
Column operation for dynamic simulation purposes. Installing a 
heater allows you to vary the temperature of the feed entering 
the column.
Valves will be added to the following material streams:
• SepLiq
• LTSLiq
• TowerFeed
• LiquidProd
Set Session Preferences
The first task is to set the session preferences.
1. Open the pre-built case file TUTOR1.hsc. 
The steady state Gas Processing simulation file TUTOR1.hsc 
is located in your HYSYS\Samples directory.
2. From the Tools menu, select Preferences. 
The Session Preferences property view appears.
3. Click the Variables tab, then select the Units page.
4. In the Available Unit Sets group list, select Field.
5. Click the Simulation tab, then select the Dynamics page.
In the Dynamic simulation part of this tutorial you will work 
with the default Field units.1-115
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The6. In the Assistant group, uncheck both the Set dynamic 
stream specifications in the background and the 
Perform checks when switching to dynamics or 
starting the integrator checkboxes. 
7. Close the Session Preferences property view along with all 
the open property views on the HYSYS desktop (except for 
the PFD property view) by clicking the Close icon  in the 
top right corner of each property view.
Remove Specified Pressures
In the PFD, the stream pressure for Feed 2 will be deleted so 
that it will be calculated by the MIX-100 in dynamic mode.
1. Double-click the Feed 2 stream icon to open its property 
view.
2. On the Conditions page of the Worksheet tab, click in the 
Pressure cell, then press DELETE to remove the stream 
pressure.
3. Close the stream property view.
Next you will change the pressure setting for the MIX-100 so 
that the whole PFD can be simulated.
4. Double-click the MIX-100 icon to open its property view.
5. On the Design tab, select the Parameters page.
 Figure 1.1341-116
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The6. In the Automatic Pressure Assignment group, click the 
Equalize All radio button.
7. Close the MIX-100 property view.
Insert Sep Valve
Next you will insert a valve operation between the SepLiq 
stream and the MIX-101 unit operation.
1. Click the Break Connection icon in the PFD toolbar.
2. Break the SepLiq stream connection by doing the following:
• Position the mouse pointer over the connection line 
between the SepLiq stream icon and the MIX-101 icon.
• When the mouse pointer has a checkmark beside it, left-
click and the SepLiq stream will disconnect from the MIX-
101.
3. Open the Object Palette by pressing F4.
4. On the Object Palette, right-click and hold on the Valve icon.
5. Drag the cursor over the PFD. 
The mouse pointer becomes a bullseye.
6. Position the bullseye pointer beside the SepLiq stream and 
release the mouse button.
7. A Valve icon named VLV-100 appears.
8. Double-click the VLV-100 icon on the PFD to open its 
property view.
9. In the valve property view, specify the following 
connections:      
10.Click the Close icon  to close the valve property view.
11.Connect the SepExit stream to the inlet of the MIX-101 unit 
operation by doing the following:
• Click the PFD Attach Mode icon.
Tab [Page] In this cell... Enter...
Design 
[Connections]
Name Sep Valve
Inlet SepLiq
Outlet SepExit
Design [Parameters] Delta P 25 psi
Break Connection icon
Valve icon
Attach Mode icon1-117
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The• Position the mouse pointer at the tip of the SepExit 
stream arrow. A white box appears.
• Click and drag the pointer to the left side of MIX-101. A 
white box appears, indicating a connection point.
• Release the mouse button to complete the connection.
• Click the Attach Mode icon again to exit from the attach 
mode.
Insert LTS Valve
Next you will insert a valve operation between the LTSLiq stream 
and the MIX-101 unit operation.
1. Break the line between the LTSLiq stream and the MIX-101 
unit operation.
• Click the Break Connection icon in the tool bar.
• Click to the right of the arrow on the LTSLiq stream.
2. Install a second valve operation.
• On the Object Palette, right-click the Valve icon.
• Drag the cursor to the right of the LTSLiq stream.
• Release the mouse button.
3. Double-click the valve icon to open its property view.
4. Specify the following connections:
5. Close the valve property view.
6. Attach the LTSExit stream to the MIX-101 unit operation.
• Click the Attach Mode icon
• Move the cursor over the LTSExit stream icon. A white 
box appears.
• Click and drag the cursor to the inlet side of the MIX-101 
icon. A white box appears, indicating a connection point.
• Release the mouse button to complete the connection.
• Click the Attach Mode icon again to exit the attach 
mode.
Tab [Page] In this cell... Enter...
Design 
[Connections]
Name LTS Valve
Inlet LTSLiq
Outlet LTSExit
Design [Parameters] Delta P 5 psi1-118
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TheInsert Tower Valve
Next you will add a valve operation between the MIX-101 unit 
operation and the TowerFeed stream.
1. Break the line between the TowerFeed stream and the MIX-
101 unit operation. Be sure to break the line to the left of the 
TowerFeed stream arrow.
2. Install a third valve operation with the following connections:
3. Close the valve property view.
4. Click the Attach Mode icon, then connect the TowerIn 
stream to the exit of the MIX-101 unit operation. 
5. Exit the attach mode.
6. Install a Heater operation and position it near the Tower 
Valve and the DePropanizer.
• In the Object Palette, click once on the Heater icon.
• In the PFD, click where you want to insert the heater.
7. Open the heater property view and specify the following 
connections:
Tab [Page] In this cell... Enter...
Design 
[Connections]
Name Tower Valve
Inlet TowerIn
Outlet TowerInlet
Design [Parameters] Delta P 363 psi
You can use the scroll bars to navigate around the PFD. 
You can also use the PAGE UP and PAGE DOWN keys to zoom 
in and out of the PFD, respectively.
Tab [Page] In this cell... Enter...
Design 
[Connections]
Name Heater
Inlet TowerInlet
Outlet TowerFeed
Energy Heater Q
Design [Parameters] Delta P 9 psi1-119
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The8. In the heater property view, click the Worksheet tab, then 
select the Conditions page.
9. In the Temperature cell of the TowerFeed stream, enter 
24.73°F.   
10.Close the Heater property view.
Insert Reboil Valve
Next you will add a valve to the LiquidProd stream in the Column 
subflowsheet. The valve operation will be inserted between the 
LiquidProd stream and the Reboiler unit operation in the Column 
subflowsheet.
 Figure 1.135
When considering pieces of equipment associated with a 
column, it may be necessary to enter the Column sub-
flowsheet environment.1-120
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The1. Double-click the DePropanizer column to open its property 
view.  
2. Click the Column Environment button to enter the Column 
Sub-flowsheet environment.
3. In the PFD of the column sub-flowsheet, break the 
connection between the LiquidProd stream and the 
Reboiler unit operation.
4. Press F4 to open the Object Palette.
5. Install a valve operation between the Reboiler and the 
LiquidProd stream icon. Move the LiquidProd stream to make 
room if required.
 Figure 1.136
The Object Palette in the Column Environment contains 
fewer available unit operations than the Object Palette in the 
Parent Environment.1-121
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The6. Open the valve property view and specify the following 
connections:
7. Close the valve property view.
8. Press CTRL to connect the LiquidExit stream to the liquid 
exit connection point of the Reboiler.
9. Click the Run Column Solver icon in the tool bar. 
The column will solve with the existing column specifications 
and the added valve unit operations.  
Tab [Page] In this cell... Enter...
Design 
[Connections]
Name Reboil Valve
Inlet LiquidExit
Outlet LiquidProd
Design [Parameters] Delta P 25 psi
 Figure 1.137
Run Column Solver icon1-122
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TheRemove Non-Applicable Operations
Next you will delete unit operations that have no impact on the 
Dynamic solver.
1. Return to the Main Flowsheet environment by clicking the 
Enter Parent Simulation Environment icon in the toolbar.
2. Close the DePropanizer column property view. 
The ADJ-1 and DewPoint logical operations have calculated 
the ColdGas stream temperature required to achieve a 10°F 
dewpoint in the SalesGas stream.
3. In the PFD, double-click the ColdGas icon to open the 
stream property view.   
4. Record the temperature of the ColdGas material stream so 
that it may be controlled in Dynamic mode:
5. Close the ColdGas property view.
6. On the PFD, click on the ADJ-1 logical operation icon, then 
press the DELETE key. 
 Figure 1.138
Variable Value
Cold Gas Stream Temperature 4.444°F
Enter Parent Simulation 
Environment icon1-123
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The7. HYSYS prompts you to confirm that you want to delete the 
object. Click the Yes button.
8. Delete the DewPoint logical operation and the SalesDP 
material stream from the PFD.
9. Ensure that the Standard Windows file picker radio 
button is selected on the File tab in the Session Preferences 
property view.
10. From the File menu, select Save As. Save the file as 
DynTUT1-1.hsc.
1.3.2 Column Sizing
In preparation for Dynamic operation, the column and 
surrounding equipment must be sized. In the steady state 
environment, column pressure drop is user-specified. In 
dynamics, it is calculated using dynamic hydraulic calculations. 
Complications will arise in the transition from steady state to 
dynamics if the steady state pressure profile across the column 
is very different from that calculated by the dynamics pressure-
flow solver.
Column Tray Sizing
1. To access the Available Utilities property view, do one of the 
following:
• Press CTRL U.
• From the Tools menu, select Utilities.
When you delete a stream, unit or logical operation from the 
flowsheet, HYSYS will ask you to confirm the deletion.
For more information on 
Session Preferences refer 
to Section 12.5 - Files 
Tab in the HYSYS User 
Guide.1-124
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The2. Scroll down the list of available utilities and select the Tray 
Sizing utility.
3. Click the Add Utility button. 
The Tray Sizing property view appears.      
4. In the Name field, change the name to DEPROP TS.
5. Click the Select TS button. 
The Select Tray Section property view appears.
 Figure 1.139
 Figure 1.1401-125
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The6. In the Flowsheet group, select DePropanizer. In the Object 
group, select Main TS. Click the OK button. 
7. In the Setup Sections group, click the Auto Section button.
The Auto Section Information property view appears. The 
default tray internal types appear as follows:    
8. Select the Valve radio button and click Next. 
 Figure 1.141
 Figure 1.1421-126
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TheThe Tray Section Information property view displays the 
specific dimensions of the valve-type trays.
9. Keep the default values. Click the Complete AutoSection 
button.
HYSYS calculates the Main TS tray sizing parameters based 
on the steady state flow conditions of the column and the 
desired tray types. HYSYS labels the DePropanizer tray 
section as Section_1.
10. To confirm the dimensions and configuration of the trays for 
Section_1, click the Performance tab, then select the 
Results page.
 Figure 1.1431-127
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TheConfirm the following tray section parameters for Section_1, 
which will be used for the Main TS tray sections.  
11.Click Design tab, then select the Setup page. 
12.Select the Active checkbox.
13.On the Results page of the Performance tab, click the 
Export Pressures button. 
For now, ignore any warnings by clicking the OK button.
14.Close the Tray Sizing property view and the Available Utilities 
property view.
 Figure 1.144
Variable Value
Section Diameter 2.5 ft
Weir Height 2 in
Tray Spacing 24 in
Total Weir Length 25.38 in
Remember the Max DP/Tray value on the Results page.
You can view column profile information on the Table and 
Plot pages.1-128
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The15.Double-click the DePropanizer icon to open the Column 
property view. 
16.Click the Column Environment button to enter the Column 
sub-flowsheet.
17. In the column PFD, double-click the Main TS Column object 
to open the Main TS property view.
18.Click the Rating tab, then select the Sizing page.
19.Enter the tray section parameters as follows:     
20. In the Internal Type group, select the Valve radio button.
Variable Value
Diameter 2.5 ft
Weir Height 2 in
Tray Space 24 in
Weir Length 25.38 in
Be aware that the units for each tray section parameter may 
not be consistent with the units appearing in the tray sizing 
utility. Use the drop-down list to select the units you want to 
input. HYSYS automatically converts the value to the default 
unit.
 Figure 1.145
Open this drop-down list to select the proper units.1-129
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TheThe complete Main TS tray section property view appears 
below:  
21.Close the Main TS property view.
22.Access the Column property view by clicking the Column 
Runner icon.
23. In the Profiles page of the Parameters tab, note the 
steady state pressure profile across the column. 
The theoretical top and bottom stage pressure should be 
calculated so that the pressure on stage 5_Main TS (the 
Tower Feed stage) is about 203 psia, while the total 
pressure drop across the column is about 0.7 psi. 
24. In the Profiles group, Pressure column, click in the Pressure 
cell for the Condenser and press DELETE.
25.Click in the Reboiler pressure cell and press DELETE.
26.Click in the Pressure cell for the top stage (1_Main TS) and 
input a value of 202.6 psia.
27.Specify the bottom stage pressure (10_Main TS) as 203.3 
psia.
28.Click the Run button at the bottom of the column property 
view to start the Column Solver.
29.Return to the Parent (Main) Simulation environment.
30.Save the case as DynTUT1-2.hsc.
 Figure 1.146
Column Runner icon1-130
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The1.3.3 Using the Dynamics 
Assistant
Before you can run the simulation case in Dynamic mode, the 
degrees of freedom for the flowsheet must be reduced to zero 
by setting the pressure-flow specifications. It is also necessary 
to size the existing valves, vessels, coolers, and heat 
exchangers in the Main Flowsheet and the Column Sub-
flowsheet. The following sizing parameters must be specified for 
these unit operations:
The Dynamics Assistant makes recommendations as to how the 
flowsheet topology should change and what pressure-flow 
specifications are required in order to run a case in Dynamic 
mode. In addition, it automatically sets the sizing parameters of 
the equipment in the simulation flowsheet. Not all the 
suggestions that the Dynamics Assistant offers need to be 
followed.
The Dynamics Assistant will be used to do the following:
• Add Pressure-Flow specifications to the simulation case.
• Size the Valve, Vessel, and Heat Exchanger operations.
Unit Operation Sizing Parameter
Valves Cv value
Vessels Volume
Coolers/Heat Exchangers k-values1-131
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The1. Click the Dynamics Assistant icon in the toolbar. 
Green checkmarks appear in the Make Changes column 
beside all recommendations by default. You can choose 
which recommendations will be executed by the Assistant by 
activating or deactivating the checkboxes beside each 
recommendation.
Browse through each tab in the Dynamics Assistant property 
view to inspect the recommendations.
2. Click the Streams tab. 
 Figure 1.147
 Figure 1.148
Dynamics Assistant icon1-132
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TheThe Streams tab contains a list of recommendations 
regarding the setting or removing of pressure-flow 
specifications in the flowsheet.
3. For each page in the Streams tab, set the following 
recommendations as active or inactive according to the table 
shown below:   
Tab [Page] Recommendation Stream OK Checkbox
Streams 
[Pressure Specs]
Remove Pressure 
Specifications
Feed 1 Active
Set Pressure 
Specifications
LiquidProd Active
SalesGas Active
Streams [Flow 
Specs]
Remove Flow 
Specifications
Feed 1 Inactive
Feed 2 Inactive
Streams [Insert 
Valves]
Insert Valves Feed 1 Inactive
Feed 2 Inactive
Ovhd Inactive
Streams [Int. 
Flow Spec]
Set Internal Flow 
Specification
Reflux Active
Checkbox Description
An active recommendation will be implemented by the 
Dynamics Assistant.
An inactive recommendation will be ignored by the 
Dynamics Assistant.
If some of the columns or rows on the pages are not visible, 
use the scroll bars beside or under the information area to 
bring the columns or rows into view.1-133
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The4. Click the Pressure Flow Specs tab.  
This tab contains a list of unit operations which can use a 
Pressure Flow or Pressure Drop (DeltaP) specification. 
Typically, all unit operations in Dynamic mode should use the 
Pressure Flow specification.
5. Ensure that all the recommendations in this page are active:
 Figure 1.149
Tab [Page] Recommendation Unit Operation OK Checkbox
Pressure Flow Specs        
[PF versus DP]
Pressure Flow Spec 
instead of Delta P
Chiller Active
Gas/Gas Active
Heater Active1-134
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The6. Click the Unknown Sizes tab and select the Volumes 
page.    
You can modify any of the default sizing parameters in the 
Unknown Sizes tab. Once you modify a sizing parameter, the 
piece of equipment is automatically sized and the volume, 
Cv, or k-value displayed.
7. For each page in the Unknown Sizes tab, ensure that all 
the recommendations are active:
 Figure 1.150
The Unknown Sizes tab contains a list of the unit operations 
in the flowsheet that require sizing.
• The Valve operations are sized based on the 
current flow rate and pressure drop across the 
valve. The valves are sized with a 50% valve 
opening.
• The Vessel operation volumes are determined 
based on the liquid exit volumetric flow rate and 
a 10-second residence time.
• The Heat Exchanger operations are sized based 
on the current flow rate and pressure drop 
across the equipment.
Tab [Page] Recommendation Unit Operation OK Checkbox
Unknown 
Sizes 
[Volumes]
Vessel Sizing Chiller Active
Gas/Gas (Tube) 1 Active
Gas/Gas (Shell) 2 Active1-135
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The8. Click the Tray sections tab.
The Tray sections tab identifies tray sections and streams 
whose total steady state pressure drops are inconsistent 
with the total pressure drop calculated according to the 
dynamics rating model.
For the purpose of this tutorial, recommendations on this tab 
will be ignored.
9. Click the Other tab.  
10.Activate the following recommendations:
The Other tab contains a list of miscellaneous changes that 
should to be made in order for the Dynamic simulation case 
to run effectively.
11.Click the Make Changes button once. 
All the active suggestions in the Dynamics Assistant are 
implemented.
12.Close the Dynamics Assistant property view.
Unknown 
Sizes           
[k values]
Heat Exchanger 
Sizing
Chiller Active
Gas/Gas (Tube) Active
Gas/Gas (Shell) Active
 Figure 1.151
Tab [Page] Recommendation Unit Operation OK Checkbox
Other [Misc 
Specs]
Set Equalize 
Option Mixers
Mixer-101 Active
Tab [Page] Recommendation Unit Operation OK Checkbox1-136
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The13.Switch to Dynamic mode by clicking the Dynamic mode 
icon. When asked “Are you sure you want to switch to 
dynamics?”, click the Yes button.
Since you deactivated the suggestion to insert a valve on the 
Ovhd stream, you must set a pressure-flow specification on 
this stream.
14. In the PFD, double-click the Ovhd stream icon to open 
stream property view.
15.Click the Dynamics tab, then select the Specs page. 
16.Activate the Pressure specification by selecting the 
appropriate checkbox. 
The Pressure specification should be the only specification 
active. 
Ensure that the Ovhd Molar Flow specification is inactive.
17.Close the Ovhd property view.
18. In the PFD, double-click the Heater icon to access the 
property view.
You can enter the Ovhd stream pressure specification in 
either the Main Flowsheet environment or the Column Sub-
Flowsheet.
 Figure 1.152
Dynamic Mode icon1-137
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TheYou can specify the exit temperature of the Heater operation 
in Dynamic mode. The duty of the heater is back-calculated 
to make the temperature specification.
19.Click the Dynamics tab, then select the Specs page. 
20. In the Model Details group, select the Product Temp Spec 
radio button.    
21.Close the property view.
22.Save the case as DynTUT1-3.hsc.
1.3.4 Adding Controller 
Operations
In this section you will identify and implement key control loops 
using PID Controller logical operations. Although these 
controllers are not required to run in Dynamic mode, they will 
increase the realism of the model and provide more stability.
 Figure 1.1531-138
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ThePFD of the main flowsheet environment after all controllers are 
added: 
PFD of the Column sub-flowsheet after controllers are added:
 Figure 1.154
 Figure 1.1551-139
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TheLevel Control
In this section you will add level controllers to both the Main 
flowsheet and Column sub-flowsheet to control the liquid levels 
of each vessel operation.
1. In the Main flowsheet, access the Object Palette by pressing 
F4.
2. In the Object Palette, click the Control Ops icon. 
A sub-palette appears.
3. In the sub-palette, right-click and drag the PID Controller 
icon to the PFD between InletSep and Sep Valve. 
The controller icon IC-100 appears in the PFD.
4. Double-click the controller icon to open its property view. 
5. Click the Connections tab. In the Name field, change the 
name of the PID Controller operation to Sep LC.
6. In the Process Variable Source group, click the Select PV 
button. 
The Select Input PV property view appears.
 Figure 1.156
PID Controller icon1-140
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The7. In the Flowsheet list, select Case (Main). In the Object list, 
select InletSep. In the Variable list, select Liquid Percent 
Level. Click the OK button.   
8. In the Output Target Object group, click the Select OP 
button. The Select OP Object property view appears.
The Select OP Object property view is exactly the same as 
the Select Input PV property view.
9. In the Flowsheet list, select Case (Main). In the Object list, 
select Sep Valve. In Variable list, select Percentage open. 
Click the OK button.
10.Click the Parameters tab, then select the Configuration 
page.
11.Enter the information specified in the following table:
12.Click the Face Plate button at the bottom of the property 
view.
13.Change the controller mode to Auto on the face plate by 
opening the drop-down list and selecting Auto. Close the 
face plate property view when you are finished. 
 Figure 1.157
In this cell... Enter...
Action Select the Direct radio button
Kc 2
PV Minimum 0%
PV Maximum 100%1-141
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The14.Using the same procedures, add another PID Controller 
operation that will serve as the LTS level controller. Specify 
the following details:
15.Click the Face Plate button. Change the controller mode to 
Auto on the face plate property view.
Next you will enter the Column sub-flowsheet environment.
16. Instead of entering through the Column property view, click 
the Object Navigator icon in the toolbar.
17.Double-click on DePropanizer in the Flowsheets group to 
enter the Column sub-flowsheet environment.
18. Ensure the PFD for the column is visible.
19. In the Column sub-flowsheet, add a PID Controller operation 
that will serve as the Condenser level controller. Specify the 
following details: 
Tab [Page] In this cell... Enter...
Connections Name LTS LC
Process Variable Source LTS object, Liquid Percent 
Level variable
Output Target Object LTS Valve, Percentage open
Parameters 
[Configuration]
Action Direct
Kc 2
PV Minimum 0%
PV Maximum 100%
Tab [Page] In this cell... Enter...
Connections Name Cond LC
Process Variable Source Condenser, Liquid Percent 
Level
Output Target Object Reflux, Control Valve
Parameters 
[Configuration]
Action Direct
Kc 1
Ti 5 minutes
PV Minimum 0%
PV Maximum 100%
Object Navigator icon1-142
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The20.Click the Control Valve button. 
The FCV for Reflux property view appears.
21. Enter the following details in the Valve Sizing group:  
22.Close the FCV for Reflux property view.
23.Click the Face Plate button. Change the controller mode to 
Auto on the face plate property view, then close the 
property view.
24.Close the Cond LC controller property view.
The Column sub-flowsheet uses a simplified Object Palette.
To add a PID Controller operation in the sub-flowsheet, 
right-click the PID Controller icon in the Object Palette and 
drag the cursor to the PFD.
In this cell... Enter...
Flow Type Molar Flow
Minimum Flow 0 lbmole/h
Maximum Flow 500 lbmole/h
The Flow values shown above do not use the default units. 
Enter the values, then select the correct units from the drop-
down list. HYSYS automatically converts the values to the 
default units.
 Figure 1.1581-143
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1-144 Dynamic Simulation
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The25.Add another PID Controller operation that will serve as the 
Reboiler level controller. Specify the following details:
26.Click the Control Valve button. 
The FVC for RebDuty view appears.
27. In the Duty Source group, select the Direct Q radio button if 
it is not already selected.
28. In the Direct Q group, enter the following values: 
The values shown above do not use the default units. 
Enter the values, then select the correct units from the drop-
down list. HYSYS automatically converts the values to the 
default units.
Tab [Page] In this cell... Enter...
Connections Name Reb LC
Process Variable Source Reboiler, Liq Percent Level
Output Target Object RebDuty, Control Valve
Parameters 
[Configuration]
Action Direct
Kc 0.1
Ti 3 minutes
PV Minimum 0%
PV Maximum 100%
In this cell... Enter...
Min Available 0 Btu/h
Max Available 6e6 Btu/h
 Figure 1.1591-144
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The29.Close the FCV for RebDuty view.
30.Click the Face Plate button. Change the controller mode to 
Auto on the face plate. Close the face plate property view.
31.Close the Reb LC property view.
Temperature Control
Temperature control is important in this dynamic simulation 
case. A temperature controller will be placed on the ColdGas 
stream to ensure that the SalesGas stream makes the 10°F 
dewpoint specification. Temperature control will be placed on 
the top and bottom stages of the depropanizer to ensure 
product quality and stable column operation.
1. Enter the Main Flowsheet environment by clicking the Enter 
Parent Simulation Environment button.
Next you will add a PID Controller operation that will serve 
as the ColdGas temperature controller.
2. On the Object Palette, click the Control Ops icon. 
A sub-palette appears.
3. Right-click the PID Controller icon, and drag the cursor to 
the PFD.
4. Double-click the controller icon to open its property view. 
Specify the following details: 
Tab [Page] In this cell... Enter...
Connections Name Cold TC
Process Variable Source ColdGas, Temperature
Output Target Object C3Duty, Control Valve
Parameters 
[Configuration]
Action Direct
Kc 1
Ti 10 minutes
PV Minimum -20 oF
PV Maximum 20 oF
The temperature values shown above do not use the default 
units. Enter the values, then select the correct units from the 
drop-down list. HYSYS automatically converts the values to 
the default units.
Enter Parent Simulation 
Environment icon
PID Controller icon1-145
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The5. Click the Control Valve button. 
The FCV for C3Duty appears.
6. In the Duty Source group, select the Direct Q radio button.
7. In the Direct Q group, enter the following details:
8. Close the FCV for C3Duty view.
9. Click the Face Plate button. Change the controller mode to 
Auto on the face plate property view, then close the 
property view.
10.Enter the Depropanizer Column sub-flowsheet environment.
11.Add a PID Controller operation that will serve as the 
Depropanizer Top Stage temperature controller.
12. In the controller property view, specify the following details: 
13.Click the Control Valve button. 
The FCV for CondDuty view appears.
In this cell... Enter...
Min Available 0 Btu/h
Max Available 2e6 Btu/h
The values shown here do not use the default units. Enter 
the values, then select the correct units from the drop-down 
list. HYSYS automatically converts the values to the default 
units.
Tab [Page] In this cell... Enter...
Connections Name Top Stage TC
Process Variable Source Main TS, Top Stage 
Temperature
Output Target Object CondDuty, Control Valve
Parameters 
[Configuration]
Action Direct
Kc 1
Ti 5 minutes
PV Minimum 50oF
PV Maximum 130oF
Ensure that you select the correct temperature units from 
the units drop-down list.1-146
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The14. In the Duty Source group, select the Direct Q radio button.
15.  in the Direct Q group, enter the following details: 
16.Close the FCV for CondDuty view.
17.Click the Face Plate button. 
The Top Stage TC face plate property view appears.
18.Change the controller mode to Auto. In the PV field, enter a 
set point of 86oF. 
19.Close the Top Stage TC face plate property view.
20.Close the Top Stage TC property view.
21.Add another PID Controller operation that will serve as the 
Depropanizer 9th stage temperature controller.
22. In the controller property view, specify the following details:
23.Click the Face Plate button. 
The Stage 9 TC face plate property view appears.
In this cell... Enter...
Min Available 0 Btu/h
Max Available 3e6 Btu/hr
Ensure that you select the correct units from the units drop-
down list.
Tab [Page] In this cell... Enter...
Connections Name Stage9 TC
Process Variable Source Main TS, Stage 
Temperature, 9_Main TS
Output Target Object Reboil Valve, Percentage 
open
Parameters 
[Configuration]
Action Direct
Kc 2
Ti 5 minutes
PV Minimum 110oF
PV Maximum 260oF1-147
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The24.Change the controller mode to Auto. In the PV field, input a 
set point of 184oF.
You should be able to run the integrator at this point without 
any problems, however, you will probably want to monitor 
important variables in the dynamic simulation using strip 
charts. 
25.Return to the Parent Environment.
26.Save the case as DynTUT1-4.hsc.
Monitoring in Dynamics
Now that the model is ready to run in Dynamic mode, you will 
create a strip chart to monitor the general trends of key 
variables. The following is a general procedure for installing strip 
charts in HYSYS.
1. Open the Databook by using the hot key combination CTRL 
D.   
In the next set of steps, you will add all of the variables that 
you would like to manipulate or model.
Ensure that you select the correct temperature units from 
the units drop-down list.
 Figure 1.160
For more information, 
refer to section Using 
the Databook.1-148
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The• Include feed and energy streams that you want to modify 
in the dynamic simulation.
• Include unit operation temperature, levels, and pressures 
that you want to monitor and record.
2. On the Variables tab, click the Insert button. The Variable 
Navigator appears.  
Select Case (Main) in the Flowsheet group to ensure you can 
find all streams and operations.
3. Select the Object and Variable groups for any of the 
following suggested variables.
4. Click the Add button to add the selected variable to the 
Variables page.
 Figure 1.161
Object Variable
Tower Feed Molar Flow
Heater Q Utility outlet Temp
Feed 1 Molar Flow
Feed 2 Molar Flow
Ovhd Molar Flow
InletSep Liquid Percent Level
LTS Liquid Percent Level1-149
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The5. Repeat steps #3 and #4 to add any remaining variables to 
the Databook.
6. Click the Strip Charts tab.
7. In the Available Strip Charts group, click the Add button.
HYSYS will create a new strip chart with the default name 
DataLogger1. You may change the default name by editing 
the Logger Name cell.
8. In the table, check the Active checkbox for each of the 
variables that you would like to monitor on this particular 
strip chart.  
9. If required, add more strip charts by repeating steps #7 and 
#8.
The purpose of selecting manipulated and monitored objects 
is to see how the monitored objects will respond to the 
changes you make to the manipulated variable.
 Figure 1.162
To make the strip chart easier to read, do not activate more 
than six variables per strip chart.
To change the configuration of each strip chart, click the 
Setup button. 1-150
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The10.To access a strip chart property view, select the strip chart 
name, then click the Strip Chart button.
11.Minimize the Databook property view.
12.Before starting the integrator, open the property view for the 
Ovhd stream.
13.Click the Dynamics tab, then select the Specs page.
14. In the Dynamic Specifications group, ensure that the 
Pressure specification checkbox is Active and the Molar Flow 
specification checkbox is Inactive.
15.Close the Ovhd stream property view.
16.Arrange both strip chart property views so you can see 
them.
17.Start the Integrator by clicking the Start Integrator icon in 
the tool bar and observe as the variables line out on the strip 
charts.
18.Click the Stop Integrator icon to stop the process.
To use the Databook feature for analysis, manipulate the 
stream and operation variables via their property views, click 
the Start Integrator icon again, and view the results in the 
monitored variables in the strip charts.1-151
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The1-152
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Refining Tutorial 2-1
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Th2  Refining Tutorial2-1
2.1  Introduction................................................................................... 2
2.2  Steady State Simulation................................................................. 4
2.2.1  Process Description .................................................................. 4
2.2.2  Setting Your Session Preferences................................................ 6
2.2.3  Building the Simulation ............................................................. 9
2.2.4  Entering the Simulation Environment ........................................ 39
2.2.5  Using the Workbook................................................................ 42
2.2.6  Installing Unit Operations ........................................................ 52
2.2.7  Using Workbook Features ........................................................ 58
2.2.8  Using the PFD........................................................................ 64
2.2.9  Viewing and Analyzing Results ................................................112
2.2.10  Installing a Boiling Point Curves Utility....................................114
2.2.11  Using the Databook .............................................................120
2.3  Dynamic Simulation ................................................................... 130
2.3.1  Simplifying the Steady State Flowsheet ....................................131
2.3.2  Adding Equipment & Sizing Columns ........................................136
2.3.3  Adding Controller Operations ..................................................149
2.3.4  Adding Pressure-Flow Specifications.........................................155
2.3.5  Monitoring in Dynamics..........................................................161
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Th2.1 Introduction
You will build the Refining simulation using the following basic 
steps:
1. Create a unit set.
2. Choose a property package.
3. Select the non-oil components.
4. Characterize the Oil.
5. Create and specify the preheated crude and utility steam 
streams.
6. Install and define the unit operations in the pre-fractionation 
train.
7. Install and define the crude fractionation column.
In this tutorial, crude oil is processed in a fractionation facility to 
produce naphtha, kerosene, diesel, atmospheric gas oil, and 
atmospheric residue products. Preheated crude (from an 
upstream preheat train) is fed to a pre-flash drum where 
vapours are separated from the liquids, which are heated in a 
furnace. The pre-flash vapours bypass the furnace and are 
recombined with the hot crude from the furnace. The combined 
stream is then fed to the atmospheric crude column for 
fractionation. 
This complete case has also been pre-built and is located in 
the file TUTOR2.HSC in your Aspen HYSYS\Samples 
directory.2-2
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ThThe main flowsheet for this process appears in the figure below.     
The crude column consists of a refluxed absorber with three side 
strippers and three cooled pump around circuits. The column 
sub-flowsheet appears below.  
The following pages guide you through building a Aspen HYSYS 
case for modeling this process. This tutorial illustrates the 
complete construction of the simulation, from selecting a 
property package and components, characterizing the crude oil, 
to installing streams and unit operations, through to examining 
 Figure 2.1
 Figure 2.22-3
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2-4 Steady State Simulation
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Ththe final results. The tools available in Aspen HYSYS are utilized 
to illustrate the flexibility available to you. 
2.2 Steady State 
Simulation
2.2.1 Process Description
This example models a crude oil processing facility consisting of 
a pre-fractionation train used to heat the crude liquids, and an 
atmospheric crude column to fractionate the crude into its 
straight run products. The Main Flowsheet for this process 
appears in the following figure. 
Preheated crude (from a preheat train) is fed to the pre-flash 
drum, modeled as a Separator, where vapours are separated 
from the crude liquids. The liquids are then heated to 650°F in 
the crude furnace, modeled as a Heater. The pre-flash vapours 
bypass the furnace and are re-combined, using a Mixer, with the 
hot crude stream. The combined stream is then fed to the 
atmospheric crude column for separation.
Before proceeding, you should have read Chapter A - HYSYS 
Tutorials which precedes the Tutorials in this guide.
 Figure 2.32-4
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ThThe crude column is modeled as a Refluxed Absorber, equipped 
with three pump-around and three side stripper operations. The 
Column sub-flowsheet appears in the figure below.  
The main column consists of 29 trays plus a partial condenser. 
The TowerFeed enters on stage 28, while superheated steam is 
fed to the bottom stage. In addition, the trim duty is 
represented by an energy stream feeding onto stage 28. The 
Naphtha product, as well as the water stream WasteH2O, are 
produced from the three-phase condenser. Crude atmospheric 
Residue is yielded from the bottom of the tower.
Each of the three-stage side strippers yields a straight run 
product. Kerosene is produced from the reboiled KeroSS side 
stripper, while Diesel and AGO (atmospheric gas oil) are 
produced from the steam-stripped DieselSS and AGOSS side 
strippers, respectively.
The two primary building tools, Workbook and PFD, are used to 
install the streams and operations and to examine the results 
while progressing through the simulation. Both of these tools 
provide you with a large amount of flexibility in building your 
simulation, and in quickly accessing the information you need.
 Figure 2.42-5
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2-6 Steady State Simulation
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ThThe Workbook is used to build the first part of the flowsheet, 
from specifying the feed conditions through to installing the pre-
flash separator. The PFD is then used to install the remaining 
operations, from the crude furnace through to the column.
2.2.2 Setting Your Session 
Preferences
1. Start Aspen HYSYS and create a new case. The Simulation 
Basis Manager property view appears. 
Your first task is to set your Session Preferences.
2. From the Tools menu, select Preferences. 
The Session Preferences property view appears.
The Workbook displays information about streams and unit 
operations in a tabular format, while the PFD is a graphical 
representation of the flowsheet.
 Figure 2.52-6
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Refining Tutorial 2-7
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ThThe most important preference you will set is the unit set. 
Aspen HYSYS does not allow you to change any of the 
default unit sets listed, however, you can create a new unit 
set by cloning an existing one. In this tutorial you will create 
a new unit set based on the Aspen HYSYS Field set and 
customize it.
3. Click the Variables tab, then select the Units page.
4. In the Available Unit Sets group, select Field.
5. Click the Clone button. 
A new unit set named NewUser appears and is automatically 
selected as the current unit set.
6. In the Unit Set Name field, rename the new unit set to 
Field-density. 
You can now change the units for any variable associated 
with this new unit set.
The default Preference file is named Aspen HYSYS.prf. When 
you modify any of the preferences, you can save the changes 
in a new Preference file by clicking the Save Preference Set 
button. Aspen HYSYS prompts you to provide a name for the 
new Preference file, which you can later use in any 
simulation case by clicking the Load Preference Set button.
 Figure 2.62-7
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2-8 Steady State Simulation
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Th7. In the Display Units group, use the vertical scroll bar to find 
the Standard Density cell. 
The current default unit for Standard Density is lb/ft3. A 
more appropriate unit for this example is API_60.
8. Click in the Standard Density cell on lb/ft3.
9. Press the SPACEBAR or the DOWN arrow to open the drop-
down list of available units.
10. In the unit list, select API_60.  
11.Repeat steps #8-#10 to change the Mass Density units to 
API.
 Figure 2.7
 Figure 2.82-8
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Refining Tutorial 2-9
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Th12.Your new unit set is now defined. Close the Session 
Preferences property view to return to the Simulation Basis 
Manager property view. 
2.2.3 Building the Simulation
Selecting Components
Before defining a fluid package in Aspen HYSYS, you will create 
a component list for the fluid package. In this example, the 
component list contains non-oil components, Light Ends, and 
hypocomponents. You must first add the non-oil components 
and Light Ends from Aspen HYSYS pure component library into 
the component list.
1. Click the Components tab, then click the Add button. The 
Component List property view appears. 
All commands accessed via the toolbar are also available as 
Menu items.
 Figure 2.92-9
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2-10 Steady State Simulation
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ThThere are a number of ways to select components for your 
simulation. One method is to use the matching feature. 
Notice that each component is listed in three ways on the 
Selected tab:
At the top of each of these three columns is a corresponding 
radio button. Based on the selected radio button, Aspen 
HYSYS will locate the component(s) that best matches the 
input you type in the Match cell.
2. Optional: To rename the component list, click in the Name 
field at the bottom of the property view and type a new 
name.
For this tutorial example, you will add the following non-oil 
components: H2O, C3, i-C4, n-C4, i-C5 and n-C5.
First, you will add H2O using the match feature.
3. Ensure the Sim Name radio button is selected, and the 
Show Synonyms checkbox is selected. 
4. Click in the Match field.
You can also move to the Match field by pressing ALT M.
Matching Method Description
SimName The name appearing within the simulation.
FullName/
Synonym
IUPAC name (or similar), and synonyms for many 
components.
Formula The chemical formula of the component. This is useful 
when you are unsure of the library name of a 
component, but know its formula.
The Component List property view contains two tabs. In this 
example, the Selected tab is the only tab used, because it 
contains all the functions you need to add components to the 
list.2-10
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Refining Tutorial 2-11
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Th5. Begin typing ‘water’. Aspen HYSYS filters through its library 
as you type, displaying only those components that match 
your input.
6. With Water selected, add it to the Current Component List by 
doing one of the following:
• Press the ENTER key.
• Click the Add Pure button.
• Double-click on Water.
You can also use the Family Filter to display only those 
components belonging to certain families. Next, you will add 
Propane to the component list using a Family Filter: 
7. Ensure the Match field is empty, and click the View Filter 
button. The Filters property view appears as shown on the 
left.
8. On the Filters property view, select the Use Filter checkbox 
to activate the Family Filter. 
 Figure 2.10
Filters property view2-11
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2-12 Steady State Simulation
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Th9. Select the Hydrocarbons checkbox. The remaining 
components are known to be hydrocarbons. 
10.Double-click Propane to add it to the component list. 
Next you will add the remaining Light Ends components i-C4 
through n-C5. The following procedure shows you quick way 
to add components that appear consecutively in the library 
list.
11.Click on the first component to be added (in this case, i-C4).
12.Do one of the following: 
• Hold down the SHIFT key and click on the last 
component, in this case n-C5. All components i-C4 
through n-C5 are now selected. Release the SHIFT key.
 Figure 2.11
The Match feature remains active when you are using a 
family filter, so you could have also typed C3 in the Match 
field and then added it to the component list.
To select consecutive components, use the SHIFT key. 
To select non-consecutive components, use the CTRL key.
On the 
Component 
property 
view, 
Propane 
appears 
near the top 
of the 
filtered list.2-12
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Refining Tutorial 2-13
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Th• Click and drag from i-C4 to n-C5. Components i-C4 
through to n-C5 are selected.
13.Click the Add Pure button. The selected components are 
transferred to the Selected Component group.  
The complete list of non-oil components appears in the 
figure above.
14.Close the Component List property view and Filters property 
views to return to the Simulation Basis Manager property 
view. 
On the Components tab, the Component Lists group now 
contains the name of the new component list that you 
created.
Defining a Fluid Package
In the Simulation Basis Manager property view, your next task is 
to define a fluid package.
A fluid package contains the components and property methods 
that Aspen HYSYS will use in its calculations for a particular 
 Figure 2.12
Aspen HYSYS displays the current Environment and Mode in 
the upper right corner of the property view. Whenever you 
begin a new case, you are automatically placed in the Basis 
environment, where you can choose the property package 
and non-oil components.
To remove a 
component from the 
Current Components 
List, select it and 
click the Remove 
button or press the 
DELETE key. 2-13
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2-14 Steady State Simulation
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Thflowsheet. Depending on what is required, a fluid package can 
also contain other information, such as a petroleum fluid 
characterization.
The fluid package for this example will contain the property 
package (Peng Robinson), the pure components H2O, C3, i-C4, 
n-C4, i-C5, n-C5, and the hypothetical components which are 
generated in the Oil characterization.
1. Click the Fluid Pkgs tab, then click the Add button. The 
Fluid Package: Basis-1 view appears.  
This property view is divided into a number of tabs that allow 
you to supply all the information necessary to completely 
define the fluid package. For this tutorial, however, only the 
Set Up tab is used.
On the Set Up tab, the currently selected Property Package 
The Simulation Basis Manager allows you to create, modify, 
and otherwise manipulate fluid packages in your simulation 
case. Most of the time, as with this example, you require only 
one fluid package for your entire simulation.
Aspen HYSYS has created a fluid package with the default 
name Basis-1. You can change the name of this fluid package 
by typing a new name in the Name field at the bottom of the 
property view.
 Figure 2.132-14
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Refining Tutorial 2-15
ww
This . Before you begin characterizing your petroleum 
fluid, you must choose a property package that can handle 
hypothetical components. 
2. Select the Peng Robinson property package by doing one of 
the following:
• Type Peng Robinson. Aspen HYSYS finds the match to 
your input.
• Use the up and down arrow keys to scroll through the list 
of available property packages until Peng Robinson is 
selected.
• Use the vertical scroll bar to scroll through the list until 
Peng Robinson becomes visible, then click on it.
The Fluid Package: Basis - 1 view appears as shown below.
Alternatively, you could have selected the EOSs radio button 
in the Property Pkg Filter group. The list would then display 
only those property packages that are Equations of State. 
Peng Robinson would appear in this filtered list.
In the Component List Selection group, you could use the 
drop-down list to find the name of any component lists you 
 Figure 2.14
The Property Pkg indicator now indicates Peng Robinson 
is the current property package for this fluid package.2-15
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2-16 Steady State Simulation
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Thhad created (currently empty). 
The View button opens the Component List property view of 
the selected component list.
3. Close the Fluid Package: Basis - 1 view to return to the 
Simulation Basis Manager property view.
The list in the Current Fluid Packages group displays the new 
fluid package, Basis-1, showing the number of components 
(NC) and property package (PP). The new fluid package is 
assigned by default to the main flowsheet, as shown in the 
Flowsheet-Fluid Pkg Associations group.
If you have multiple fluid packages and components lists in a 
case, you can use the drop-down list in the Component List 
Selection group to attache a component list to a particular 
property package.
If the selected component list contains components not 
appropriate for the selected property package, Aspen HYSYS 
opens the Components Incompatible with Property Package 
property view. On this property view, you have the options 
of Aspen HYSYS removing the incompatible components 
from the component list or changing to a different property 
package using the drop-down list or the Cancel button. 
 Figure 2.152-16
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Refining Tutorial 2-17
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ThCreating Hypocomponents
Your next task is to create and add the hypocomponents to the 
component list. In this example, you will characterize the oil 
(Petroleum Fluid) using the given Assay data to create the 
hypocomponents.
Characterizing the Oil
In this section, you will use the following laboratory Assay data:     
Bulk Crude Properties 
MW 300.00
API Gravity 48.75
Light Ends Liquid Volume Percent
i-Butane 0.19
n-Butane 0.11
i-Pentane 0.37
n-Pentane 0.46
TBP Distillation Assay
Liquid Volume 
Percent Distilled
Temperature (°F) Molecular Weight
0.0 80.0 68.0
10.0 255.0 119.0
20.0 349.0 150.0
30.0 430.0 182.0
40.0 527.0 225.0
50.0 635.0 282.0
60.0 751.0 350.0
70.0 915.0 456.0
80.0 1095.0 585.0
90.0 1277.0 713.0
98.0 1410.0 838.0
API Gravity Assay
Liq Vol% Distilled API Gravity
13.0 63.282-17
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2-18 Steady State Simulation
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ThAccessing the Oil Environment
The Aspen HYSYS Oil Characterization procedure is used to 
convert the laboratory data into petroleum hypocomponents. 
1. On the Simulation Basis Manager property view, click the Oil 
Manager tab. 
The text on the right side of the property view indicates that 
before entering the Oil Environment, two criteria must be 
33.0 54.86
57.0 45.91
74.0 38.21
91.0 26.01
Viscosity Assay
Liquid Volume 
Percent Distilled
Viscosity (cP) 100°F Viscosity (cP) 210°F
10.0 0.20 0.10
30.0 0.75 0.30
50.0 4.20 0.80
70.0 39.00 7.50
90.0 600.00 122.30
 Figure 2.16
API Gravity Assay2-18
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Refining Tutorial 2-19
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Thmet:
• at least one fluid package must be present. In this case, 
only one fluid package, Basis-1, is selected. 
• the property package must be able to handle 
Hypothetical Components. In our case, the property 
package is Peng Robinson, which is capable of handling 
Hypothetical components.
Since both criteria are satisfied, the oil is characterized in 
the Oil Environment.
2. To enter the Oil Characterization environment, do one of the 
following:
• click the Enter Oil Environment button on the Oil 
Manager tab.
• click the Oil Environment icon on the toolbar.
The Oil Characterization property view appears. 
The Oil Characterization property view allows you to create, 
modify, and otherwise manipulate the Assays and Blends in 
your simulation case. For this example, the oil is 
characterized using a single Assay.
The Associated Fluid Package drop-down list indicates which 
fluid package is used for the oil characterization. Since there 
is only one fluid package, Aspen HYSYS has made Basis-1 the 
Associated Fluid Package. 
 Figure 2.17
Oil Environment icon2-19
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2-20 Steady State Simulation
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ThIn general, three steps must be completed when you are 
characterizing a petroleum fluid:
1. Supply data to define the Assay.
2. Cut the Assay into hypothetical components by creating a 
Blend.
3. Install the hypothetical components into the fluid package.
Defining the Assay
1. On the Assay tab, click the Add button to create and view a 
new Assay. The Assay property view appears. 
When the property view for a new Assay is opened for the 
first time, the property view contains minimal information. 
Depending on the Assay Data Type you choose, the property 
view is modified appropriately. For this example, the Assay is 
defined based on TBP data. 
Aspen HYSYS has given the new Assay the default name of 
Assay-1. You can change this by typing a new name in the 
Name field.
 Figure 2.182-20
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Refining Tutorial 2-21
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Th2. From the Assay Data Type drop-down list, select TBP. The 
property view is customized for TBP data. 
The next task is to enter the composition of the Light Ends in 
the Assay. 
3. From the Light Ends drop-down list, select Input 
Composition.
4. In the Input Data group, select the Light Ends radio button.
5. Ensure that Liquid Volume% is selected in the Light Ends 
Basis drop-down list.
6. Click in the Composition cell for i-Butane.
7. Type 0.19, then press the ENTER key. You are automatically 
advanced down one cell to n-Butane.
 Figure 2.192-21
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2-22 Steady State Simulation
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Th8. Type the remaining compositions as shown. The total 
Percent of Light Ends in Assay is calculated and displayed at 
the bottom of the table.
Before entering any of the assay data, you must activate the 
molecular weight, density, and viscosity curves by choosing 
appropriate curve types in the Assay Definition group. 
Currently, these three curves are not used.
9. From the Bulk Properties drop-down list, select Used. A new 
radio button labeled Bulk Props appears in the Input Data 
group.
10. From Molecular Wt. Curve drop-down list, select Dependent. 
A new radio button labeled Molecular Wt appears in the 
Input Data group.
11. From the Density Curve and Viscosity Curves drop-down 
lists, select Independent as the curve type. For Viscosity, two 
radio buttons appear as Aspen HYSYS allows you to input 
viscosity assay data at two temperatures.
Your property view now contains a total of seven radio 
buttons in the Input Data group. The laboratory data are 
input in the same order as the radio buttons appear. 
 Figure 2.202-22
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Refining Tutorial 2-23
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ThIn the next few sections, you will enter the following laboratory 
assay data:
• bulk molecular weight and density
• TBP Distillation assay data
• dependent molecular weight assay data
• independent density assay data
• independent viscosity assay data (at two temperatures)
Entering Bulk Property Data
1. Select the Bulk Props radio button, and the bulk property 
table appears to the right of the radio buttons.
2. Click in the Molecular Weight cell in the table. Type 300 
and press ENTER. You are automatically advanced down one 
cell to the Standard Density cell.
3. In the Standard Density cell, enter 48.75 and press 
SPACE BAR. To the right of the cell, a field containing the 
current default unit associated with the cell appears. When 
you defined the new unit set, you specified the default unit 
for standard density as API_60, which appears in the field. 
4. Since this is the correct unit, press ENTER, and Aspen 
HYSYS accepts the density value. 
 Figure 2.212-23
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2-24 Steady State Simulation
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ThNo bulk Watson UOPK or Viscosity data is available for this 
assay. Aspen HYSYS provides two default temperatures 
(100°F and 210°F) for entering bulk viscosity, but these 
temperature values are ignored unless corresponding 
viscosities are provided. Since the value for bulk viscosity is 
not supplied, there is no need to delete or change the 
temperature values.
Entering Boiling Temperature (TBP) Data
The next task is to enter the TBP distillation data.
1. Click the Calculation Defaults tab.
2. In the Extrapolation Methods group, select Lagrange for each 
method using the drop-down lists.
3. Return to the Input Data tab.
4. Select the Distillation radio button. 
The corresponding TBP data matrix appears. Aspen HYSYS 
displays a message under the matrix, stating that ‘At least 5 
points are required’ before the assay can be calculated.
5. From the Assay Basis drop-down list, select Liquid Volume.
6. Click the Edit Assay button. The Assay Input Table property 
view appears.
7. Click in the top cell of the Assay Percent column.
8. Type 0 then press ENTER. You are automatically advanced 
to the corresponding empty Temperature cell.
9. Type 80 then press ENTER. You are automatically advanced 
down to the next empty Assay Percent cell.2-24
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Refining Tutorial 2-25
ww
Th10.Repeat steps #8 and #9 to enter the remaining Assay 
Percent and Temperature values as shown.
11.Click the OK button to return to the Assay property view.
Entering Molecular Weight Data 
1. Select the Molecular Wt radio button. 
The corresponding assay matrix appears. Since the 
Molecular Weight assay is Dependent, the Assay Percent 
column displays the same values as those you entered for 
the Boiling Temperature assay. Therefore, you need only 
enter the Molecular Weight value for each assay percent.
2. Click the Edit Assay button and the Assay Input Table 
property view appears.
3. Click on the first empty cell in the Mole Wt column.
4. Type 68, then press the down arrow key.
 Figure 2.222-25
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2-26 Steady State Simulation
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Th5. Type the remaining Molecular Weight values as shown.
6. Click the OK button when you are finished.
Entering Density Data
1. Select the Density radio button. 
The corresponding assay matrix appears. Since the Density 
assay is Independent, you must input values in both the 
Assay Percent and Density cells.
 Figure 2.232-26
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Refining Tutorial 2-27
ww
Th2. Using the same method as for the previous assays, enter the 
API gravity curve data as shown here.
Entering Viscosity Data
1. Select the Viscosity 1 radio button. The corresponding 
assay matrix appears.
2. In the Viscosity Type drop-down list above the assay matrix, 
ensure Dynamic is selected.
3. In the Viscosity Curves group, select the Use Both radio 
button. The Temperature field is for each of the two viscosity 
curves. 
Click the Edit Assay button to access the Assay Input Table.
 Figure 2.242-27
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2-28 Steady State Simulation
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Th4. Input the Viscosity 1 assay data as shown here. This 
viscosity curve corresponds to Temperature 1, 100°F. 
5. Select the Viscosity 2 radio button.
6. Enter the assay data corresponding to Temperature 2, 210°F, 
as shown.
The Assay is now completely defined based on our available 
data.
7. Click the Calculate button at the bottom of the Assay 
property view. Aspen HYSYS calculates the Assay, and the 
status message at the bottom of the property view changes 
to Assay Was Calculated. 
 Figure 2.25
 Figure 2.262-28
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Refining Tutorial 2-29
ww
Th8. Click the Working Curves tab of the Assay property view to 
view the calculated results. 
Aspen HYSYS has calculated 50 points for each of the Assay 
Working Curves. 
9. To view the Assay data you input in a graphical format, click 
the Plots tab. By default, Aspen HYSYS plots the Distillation 
(TBP) data. This plot appears below.  
 Figure 2.27
 Figure 2.282-29
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2-30 Steady State Simulation
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ThThe independent (x-axis) variable is the Assay percent, while 
the dependent variable is the TBP in °F. You can view any of 
the other input curves by selecting the appropriate variable 
in the Property drop-down list.
The plot property view can be re-sized to make the plot 
more readable. To re-size the property view, do one of the 
following:
• Click and drag the outside border to the new size.
• Click the Maximize icon .
The remaining tabs in the Assay property view provide access to 
information which is not required for this tutorial.
10.Close the Assay property view to return to the Oil 
Characterization property view. 
Cutting the Assay (Creating the Blend)
Now that the assay has been calculated, the next task is to cut 
the assay into individual petroleum hypocomponents.
1. Click the Cut/Blend tab of the Oil Characterization property 
view.
The input curve that appears is dependent on the current 
variable in the Property drop-down list.2-30
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Refining Tutorial 2-31
ww
Th2. Click the Add button. Aspen HYSYS creates a new Blend and 
displays its property view. 
3. In the list of Available Assays, select Assay-1. 
4. Click the Add button. There are two results:
• The Assay is transferred to the Oil Flow Information 
table. (When you have only one Assay, there is no need 
to enter a Flow Rate in this table.)
• A Blend (Cut) is automatically calculated based on the 
current Cut Option.
In this case, the Blend was calculated based on Auto Cut, 
the default Cut Option. Aspen HYSYS calculated the Blend 
based on the following default values for the boiling point 
ranges and number of cuts per range:
• IBP to 800°F: 25°F per cut, generating [(800-IBP)/25] 
hypocomponents
• 800 to 1200°F: 50°F per cut, generating 8 
hypocomponents
• 1200 to 1400°F: 100°F per cut, generating 2 
hypocomponents
The IBP, or initial boiling point, is the starting point for the 
first temperature range. The IBP is the normal boiling point 
(NBP) of the heaviest component in the Light Ends, in this 
case n-Pentane at 96.9°F. The first range results in the 
generation of (800-96.9)/25 = 28 hypocomponents. All the 
cut ranges together result in a total of 28+8+2 = 38 
hypocomponents. 
 Figure 2.292-31
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2-32 Steady State Simulation
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Th5. Click the Tables tab to view the calculated properties of 
these hypocomponents.
These components could be used in the simulation. 
Suppose, however, that you do not want to use the IBP as 
the starting point for the first temperature range. You could 
specify another starting point by changing the Cut Option to 
User Ranges. For illustration purposes, 100°F is used as 
the initial cut point.
6. Return to the Data tab.
7. From the Cut Option Selection drop-down list, select User 
Ranges. The Ranges Selection group appears.
8. In the Starting Cut Point field, enter 100°F. This is the 
starting point for the first range. The same values as the 
Aspen HYSYS defaults are used for the other temperature 
ranges.
 Figure 2.30
Since the NBP of the heaviest Light Ends component is the 
starting point for the cut ranges, these hypocomponents 
were generated on a “light-ends-free” basis. That is, the 
Light Ends are calculated separately and are not included in 
these hypocomponents.2-32
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Refining Tutorial 2-33
ww
Th9. In the Cut End point T column in the table, click on the top 
cell labeled . The value you will enter in this cell is 
the upper cut point temperature for the first range (and the 
lower cut point for the second range).
10. Type 800 then press ENTER.
11. Enter the remaining cut point temperatures and the number 
of cuts values as shown in the figure below.
12.Once you have entered the data, click the Submit button to 
calculate the Blend based on the current initial cut point and 
range values. The message Blend Was Calculated appears in 
the status bar.
13.  Click the Tables tab to view the properties of the petroleum 
hypocomponents. 
 Figure 2.31
 Figure 2.322-33
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2-34 Steady State Simulation
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ThUse the vertical scroll bar to view the components which are 
not currently visible in the Component Physical 
Properties table.
 
Viewing the Oil Distributions
1. To view the distribution data, select Oil Distributions from 
the Table Type drop-down list. 
The Tables tab is modified as shown below. 
At the bottom of the Cut Input Information group, the 
Straight Run radio button is selected, and Aspen HYSYS 
provides default TBP cut point temperatures for each 
Straight Run product. The Cut Distributions table shows the 
Fraction of each product in the Blend. Since Liquid Vol is the 
current Basis in the Table Control group, the products are 
listed according to liquid volume fraction.
These fractions can be used to estimate the product flow 
rates for the fractionation column. For example, the 
Aspen HYSYS has provided the Initial Boiling Point (IBP) and 
Final Boiling Point (FBP). The IBP is the normal boiling point 
(NBP) of the heaviest component in the Light Ends (in this 
case, n-Pentane). The FBP is calculated by extrapolating the 
TBP Assay data to 100% distilled.
 Figure 2.332-34
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Refining Tutorial 2-35
ww
ThKerosene liquid volume fraction is 0.129. With 100,000 bbl/
day of crude feeding the tower, the Kerosene production is 
expected at 100,000 * 0.129=12,900 or roughly 13,000 
bbl/day.
If you want, you can investigate other reporting and plotting 
options by selecting another Table Type or by viewing 
information on the other tabs in the Blend property view. 
2. When you are finished, close the Blend property view to 
return to the Oil Characterization property view. Now that 
the Blend has been calculated, the next task is to install the 
oil.
Installing the Oil
The last step in the oil characterization procedure is to install the 
oil, which accomplishes the following:
• The petroleum hypocomponents are added to the fluid 
package.
• The calculated Light Ends and Oil composition are 
transferred to a material stream for use in the 
simulation.
1. On the Oil Characterization property view, click the Install 
Oil tab.
2. In the Stream Name column, click in the top blank cell.2-35
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2-36 Steady State Simulation
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Th3. Type the name Preheat Crude, then press the ENTER key. 
Aspen HYSYS creates a new stream named Preheat Crude in 
the flowsheet associated with the fluid package associated 
with this oil.
In this case, there is only one fluid package (Basis-1) and 
one flowsheet (the main flowsheet), so the stream is created 
in the main flowsheet. Aspen HYSYS assigns the composition 
of the calculated oil and light ends to stream Preheat Crude. 
The properties of the new stream can be viewed from the 
Simulation environment. 
The characterization procedure is now complete. 
4. Return to the Basis environment by clicking the Leave Oil 
Environment icon. 
5. Click the Components tab of the Simulation Basis Manager 
property view.
6. Select Component List - 1 from the list in the Component 
Lists group. Click the View button to open the component 
list property view.
 Figure 2.34
Leave Oil Environment 
icon2-36
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Refining Tutorial 2-37
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Th7. The hypocomponents generated during the oil 
characterization procedure now appear in the Selected 
Components group. 
Viewing Component Properties
To view the properties of one or more components, select the 
component(s) and click the View Component button. Aspen 
HYSYS opens the property view(s) for the component(s) you 
selected.
1. In the Selected Components list, select H2O and 
NBP[0]113*.
Press and hold the CTRL key to select more than one 
component.
 Figure 2.35
Hypothetical 
components 
are indicated 
by a * after 
the component 
name.2-37
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2-38 Steady State Simulation
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Th2. Click the View Component button. The property views for 
these two components appear. 
The Component property view provides you with complete 
access to the component information. For pure components 
like H2O, the information is provided for viewing only. You 
cannot modify any parameters for a library (pure) 
component, however, Aspen HYSYS allows you to clone a 
library component into a Hypothetical component, which you 
can then modify as required.
The petroleum hypocomponent shown here is an example of 
a hypothetical component. You can modify any of the 
parameters listed for this component. For this example, the 
properties of the hypothetical components generated during 
the oil characterization are not changed.
3. Close each of these two component property views.
4. The fluid package is now completely defined, so close the 
Component List property view. The Simulation Basis 
Manager property view should again be visible; if not, click 
the Basis Manager icon to access it.
 Figure 2.36
See Chapter 3 - 
Hypotheticals in the 
Aspen HYSYS 
Simulation Basis guide 
for more information on 
cloning library 
components.
Basis Manager icon2-38
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Th5. Click the Fluid Pkgs tab to view a summary of the new fluid 
package. 
The list of Current Fluid Packages displays the new fluid 
package, Basis-1, showing the number of components (NC) 
and property package (PP). The fluid package contains a 
total of 44 components:
• 6 library (pure) components (H2O plus five Light Ends 
components)
• 38 petroleum hypocomponents
The new fluid package is assigned by default to the Main 
Flowsheet, as shown in the Flowsheet-Fluid Pkg 
Associations group. Next you will install streams and 
operations in the Main Simulation environment. 
 Figure 2.372-39
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Th2.2.4 Entering the Simulation 
Environment
1. To leave the Basis environment and enter the Simulation 
environment, do one of the following: 
• Click the Enter Simulation Environment button on the 
Simulation Basis Manager property view.
• Click the Enter Simulation Environment icon.
When you enter the Simulation Environment, the initial 
property view that appears depends on your current 
preference setting for the Initial Build Home property view. 
Three initial property views are available: PFD, Workbook, 
and Summary. Any or all of these can be displayed at any 
time, however, when you first enter the Simulation 
Environment, only one appears. For this example, open the 
Workbook under the Tools menu or by pressing CTRL W. 
 Figure 2.38
Enter Simulation 
Environment icon2-40
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ThThere are several things to note about the Main Simulation 
Environment. In the upper right corner, the Environment 
has changed from Basis to Case (Main). A number of new 
items are now available on the menu and toolbar, and the 
Workbook and Object Palette are open on the Desktop. 
These latter two objects are described below.
Also notice that the name of the stream (Preheat Crude) you 
created during the Oil characterization procedure appears in 
the Workbook, and the white Object Status window at the 
very bottom of the environment property view shows that 
the stream has an unknown pressure. As you specify the 
conditions of Preheat Crude, the message displayed in the 
Object Status window is updated appropriately. Before 
specifying the feed conditions, you can view the stream 
composition, which was calculated by the Oil 
characterization.
Objects Description
Workbook A multiple-tab property view containing information 
regarding the objects (streams and unit operations) in the 
simulation case. By default, the Workbook has four tabs, 
namely Material Streams, Compositions, Energy Streams 
and Unit Ops. You can edit the Workbook by adding or 
deleting tabs, and changing the information displayed on 
any tab.
Object 
Palette 
A floating palette of buttons which can be used to add 
streams and unit operations.
You can toggle the palette open or closed by pressing F4, 
or by selecting Open/Close Object Palette from the 
Flowsheet menu.2-41
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ThViewing the Feed Composition
1. In the Workbook, click the Compositions tab to view the 
composition of the streams.  
The Light Ends and petroleum hypocomponents are listed by 
Mole Fraction. To view the components which are not 
currently visible, use the up and down arrow keys or the 
vertical scroll bar to advance down the component list.
Before proceeding any further to install streams or unit 
operations, save your case.
2. Do one of the following:
• Click the Save icon on the toolbar.
• Select Save from the File menu.
• Press CTRL S.
If this is the first time you have saved your case, the Save 
Simulation Case As property view appears. By default, the 
File Path is the cases sub-directory in your Aspen HYSYS 
directory.
 Figure 2.39
Save icon2-42
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Th3. In the File Name field, type a name for the case, for 
example REFINING. You do not have to enter the *.hsc 
extension; Aspen HYSYS adds it automatically.
4. Once you have entered a file name, press the ENTER key 
and Aspen HYSYS saves the case under the name you gave 
it. The Save As property view does not appear again unless 
you choose to give it a new name using the Save As 
command.
2.2.5 Using the Workbook
Click the Workbook icon on the toolbar to ensure the Workbook 
property view is active.
Specifying the Feed Conditions
In general, the first task in the Simulation environment is to 
install one or more feed streams, however, the stream Preheat 
Crude was already installed during the oil characterization 
procedure. At this point, your current location should be the 
Compositions tab of the Workbook property view.
1. Click the Material Streams tab. The preheated crude 
enters the pre-fractionation train at 450°F and 75 psia.
2. In the Preheat Crude stream, click in the Temperature cell 
and type 450. Aspen HYSYS displays the default units for 
temperature, in this case °F.
If you enter a name that already exists in the current 
directory, Aspen HYSYS ask you for confirmation before 
over-writing the existing file.
 Figure 2.40
Workbook icon2-43
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2-44 Steady State Simulation
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Th3. Since this is the correct unit, press the ENTER key. Aspen 
HYSYS accepts the temperature. Aspen HYSYS advances to 
the Pressure cell.
If you know the stream pressure in another unit besides the 
default of psia, Aspen HYSYS will accept your input in any 
one of a number of different units and automatically convert 
the value to the default. For example, the pressure of 
Preheat Crude is 5.171 bar, but the default units are psia.
4. In the Pressure cell, type 5.171.
5. Press SPACE BAR. The field containing the active cell units 
becomes active.
6. Begin typing ‘bar’. The field opens a drop-down list and 
scrolls to the unit(s) most closely matching your input.
7. Once bar is selected, press the ENTER key. Aspen HYSYS 
accepts the pressure and automatically converts to the 
default unit, psia. 
Alternately, you can specify the unit simply by selecting the 
unit in the drop-down list.
8. Click in the Liquid Volume Flow cell, then type 1e5. The 
stream flow is entered on a volumetric basis, in this case 
100,000 barrel/day.
9. Press the ENTER key.
When you press ENTER after entering a stream property, you 
are advanced down one cell in the Workbook only if the cell 
below is . Otherwise, the active cell remains in its 
current location.
 Figure 2.41
 
2-44
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ThThe stream is now completely defined, so Aspen HYSYS 
flashes it at the conditions given to determine the remaining 
properties.
The properties of Preheat Crude are shown below. 
The values you specified are a different colour (blue) than 
the calculated values (black).
The next task is to install and define the utility steam streams 
that will be attached to the fractionation tower later.
Installing the Utility Steam Streams
1. On the Material Streams tab, click in the header cell 
labeled **New**.
2. Type the new stream name Bottom Steam, then press 
ENTER. Aspen HYSYS creates the new stream.
3. In the Temperature cell, enter 375°F.
If Aspen HYSYS does not flash the stream, ensure that the 
Solver Active icon in the toolbar is selected.
 Figure 2.42
Aspen HYSYS accepts blank spaces within a stream or 
operation name.
Solver Active icon2-45
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2-46 Steady State Simulation
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Th4. In the Pressure cell, enter 150 psia. 
5. In the Mass Flow cell, enter 7500 lb/hr.
6. Create a new utility stream called Diesel Steam.
7. Define the conditions of this stream as follows:
• Temperature 300°F
• Pressure 50 psia
• Mass Flow 3000 lb/hr.
The Workbook property view appears as shown below.
 Figure 2.43
 Figure 2.442-46
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Refining Tutorial 2-47
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ThProviding Compositional Input
Now that the utility stream conditions have been specified, the 
next task is to input the compositions.
1. Click the Compositions tab in the Workbook. The 
components are listed by Mole Fraction by default.
2. In the Bottom Steam column, click in the input cell for the 
first component, H2O.
3. Since the stream is all water, type 1 for the H2O mole 
fraction, then press ENTER. 
The Input Composition for Stream property view appears, 
allowing you to complete the compositional input.
The Input Composition for Stream property view is Modal, 
indicated by the absence of the Minimize/Maximize icons in 
the upper right corner.
When a Modal property view is visible, you are unable to 
move outside the property view until you are finish with it, 
by clicking either the Cancel or OK button.
 Figure 2.452-47
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2-48 Steady State Simulation
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ThThe Input Composition for Stream property view allows you 
to specify a stream composition quickly and easily. The 
following table lists and describes the features available on 
this property view:
This stream is pure water, therefore, there is no need to 
enter fractions for any other components.
4. Click the Normalize button and all other component 
fractions are forced to zero.
5. Click the OK button. Aspen HYSYS accepts the composition 
and you are returned to the Workbook property view.
Features  Description
Compositional 
Basis Radio 
Buttons 
You can input the stream composition in some 
fractional basis other than Mole Fraction, or by 
component flows, by selecting the appropriate radio 
button before providing your input.
Normalizing The Normalizing feature is useful when you know the 
relative ratios of components (2 parts N2, 2 parts CO2, 
etc.) Rather than manually converting these ratios to 
fractions summing to one, enter the numbers of parts 
for each component and click the Normalize button. 
Aspen HYSYS computes the individual fractions to total 
1.0.
Normalizing is also useful when you have a stream 
consisting of only a few components. Instead of 
specifying zero fractions (or flows) for the other 
components, enter the fractions (or the actual flows) 
for the non-zero components, leaving the others 
. Click the Normalize button, and Aspen 
HYSYS forces the other component fractions to zero.
Calculation 
status/colour 
As you input the composition, the component fractions 
(or flows) initially appear in red, indicating the final 
composition is unknown. These values become blue 
when the composition has been calculated. Three 
scenarios result in the stream composition being 
calculated:
• Input the fractions of all components, including 
any zero components, such that their total is 
exactly 1.0000, then click the OK button.
• Input the fractions (totalling 1.000), flows or 
relative number of parts of all non-zero 
components, then click the Normalize button then 
the OK button.
• Input the flows or relative number of parts of all 
components, including any zero components, 
then click the OK button.
The above colours are the Aspen HYSYS default 
colours; yours can appear differently depending on 
your settings on the Colours page of the Session 
Preferences property view.2-48
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ThThe stream is now completely defined, so Aspen HYSYS 
flashes it at the conditions given to determine the remaining 
properties.
6. Repeat steps #2 to #5 for the other utility stream, Diesel 
Steam.
7. Click the Material Streams tab. The calculated properties 
of the two utility streams appear here.
If you want to delete a stream, move to the Name cell for 
the stream, then press DELETE. Aspen HYSYS ask for 
confirmation of your action.
Next, you will learn alternative methods for creating a new 
stream.
8. To add the third utility stream, do any one of the following: 
• Press F11.
• From the Flowsheet menu, select Add Stream.
• Double-click the Material Stream icon on the Object 
Palette.
• Click the Material Stream icon on the Object Palette, 
then click on the Palette's Add Object icon.
Each of these four methods displays the property view for 
the new stream, which is named according to the Auto 
Naming setting in your Preferences. The default setting 
names new material streams with numbers, starting at 1, 
and energy streams starting at Q-100.
 Figure 2.46
Material Stream icon
Add Object icon2-49
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Th9. In the stream property view, click in the Stream Name cell 
and rename the stream AGO Steam.
10. Press enter.
11. In the Temperature cell, enter 300.
12. In the Pressure cell, enter 50. 
Both of the temperature and pressure parameters are in the 
default units, so you do not need to change the unit with the 
values. 
Do not enter a flow, it is entered through the Composition 
page.
 Figure 2.472-50
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Th13.Select the Composition page to begin the compositional 
input for the new stream.
14.Click the Edit button. The Input Composition for Stream 
property view appears.
15. In the Composition Basis group, select the Mass Flows 
radio button.
16.Click in the compositional cell for H2O.
17. Type 2500 for the steam mass flow, then press ENTER. As 
there are no other components in this stream, the 
compositional input is complete.
 Figure 2.48
The current Composition Basis setting is set to the 
Preferences Default of Mole Fractions. The stream 
composition is entered on a mass basis.2-51
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Th18.Click the OK button to close the property view and return to 
the stream property view.  
Aspen HYSYS performs a flash calculation to determine the 
unknown properties of AGO Steam, as shown by the status 
indicator displaying ‘OK’. You can view the properties of each 
phase using the horizontal scroll bar in the matrix or by re-
sizing the property view. In this case, the stream is 
superheated vapour, so no Liquid phase exists and the 
Vapour phase is identical to the overall phase. To view the 
vapour compositions for AGO Steam, scroll to the right by 
clicking the right scroll arrow, or by click and dragging the 
scroll button. 
19.Close the AGO Steam property view.
 Figure 2.49
Since only H2O contain any significant value, Aspen HYSYS 
automatically forces all other components’ value to be zero.
The compositions are currently displayed by Mass Flows. You 
can change this by clicking the Basis button and choosing 
another Composition Basis radio button.2-52
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Refining Tutorial 2-53
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Th2.2.6 Installing Unit 
Operations
Now that the feed and utility streams are known, the next task 
is to install the necessary unit operations for processing the 
crude oil.
Installing the Separator
The first operation is a Separator, used to split the feed stream 
into its liquid and vapour phases. As with most commands in 
Aspen HYSYS, installing an operation can be accomplished in a 
number of ways. One method is through the Unit Ops tab of the 
Workbook.
1. Click the Workbook icon to ensure the Workbook is the 
active property view.
2. Move to the Unit Ops tab.
3. Click the Add UnitOp button. The UnitOps property view 
appears, listing all available unit operations. 
4. In the Categories group, select the Vessels radio button. 
Aspen HYSYS produces a filtered list of unit operations, 
showing only those in the current category.
 Figure 2.50
Workbook icon2-53
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Th5. Add the separator by doing one of the following:
• Select Separator in the list of Available Unit Operations, 
and click the Add button or the ENTER key.
• Double-click on Separator.
The property view for the separator appears in the figure 
below. 
A unit operation property view contains all the information 
defining the operation, organized into tabs and pages. The 
Design, Rating, and Worksheet tabs appear for most 
operations. Property views for more complex operations 
contain more tabs. 
Many operations, like the separator, accept multiple feed 
streams. Whenever you see a matrix like the one in the 
Inlets group, the operation accepts multiple stream 
connections at that location. When the matrix is active, you 
can access a drop-down list of available streams.
6. Click in the Name field, type PreFlash, then press enter. 
The status indicator at the bottom of the property view 
shows that the operation requires a feed stream.
 Figure 2.51
Aspen HYSYS provides the default name V-100 for the 
separator. The default naming scheme for unit operations 
can be changed in your Session Preferences.2-54
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Refining Tutorial 2-55
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Th7. In the Inlets matrix, click in the <> cell.
8. Click the down arrow  to open the drop-down list of 
available streams.
9. Select Preheat Crude from the list. Preheat Crude appears 
in the Inlets matrix, and the <> label is 
automatically moved down to a new empty cell. The status 
indicator now displays Requires a product stream. 
Alternatively, you could have made the connection by typing 
the exact stream name in the cell, and pressing ENTER.
10.Click in the Vapour Outlet field, or press tab to move to the 
field.
11. Type PreFlashVap in the field, then press enter. This 
stream does not yet exist, so Aspen HYSYS creates this new 
stream.
 Figure 2.522-55
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2-56 Steady State Simulation
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Th12.Click in the Liquid Outlet field and type PreFlashLiq. 
Aspen HYSYS creates another new stream.
The status indicator displays a green OK message, showing 
that the operation and attached streams are completely 
calculated.
 Figure 2.53
An Energy stream could be attached to heat or cool the 
vessel contents, however, for the purposes of this example, 
the energy stream is not required.2-56
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Th13.Select the Parameters page. The default Delta P (pressure 
drop) of zero is acceptable for this example. The Liquid 
Level is also acceptable at its default value.  
 Figure 2.54
Since there is no energy stream attached to the separator, 
no Optional Heat Transfer information is required.2-57
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2-58 Steady State Simulation
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Th14.To view the calculated outlet streams, click the Worksheet 
tab. This is a condensed Workbook displaying only those 
streams attached to the operation.
15.Now that the separator is completely known, close the 
PreFlash property view and the UnitOps property view, and 
return to the Workbook property view. The new separator 
appears on the Unit Ops tab. 
The matrix shows the operation Name, its Object Type, the 
attached streams (Inlet and Outlet), whether it is 
Ignored, and its Calculation Level. 
 Figure 2.55
 Figure 2.562-58
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Refining Tutorial 2-59
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ThOptional Methods for Accessing Property Views
When you click the View UnitOp button, the property view for 
the operation occupying the active row in the matrix opens. 
Alternatively, by double-clicking on any cell (except Inlet and 
Outlet) associated with the operation, you also open its 
property view. 
You can also open the property view for a stream directly from 
the Unit Ops tab of the Workbook. When any of the Name, 
Object Type, Ignored or Calc. Level cells are active, the 
display field at the bottom of the property view displays all 
streams attached to the current operation. Currently, the Name 
cell for PreFlash is active, and the display field displays the 
three streams attached to this operation. To open the property 
view for one of the streams attached to the separator (such as 
Preheat Crude), do one of the following:
• Double-click on Preheat Crude in the display field at the 
bottom of the property view.
• Double-click on the Inlet cell for PreFlash. The property 
view for the first listed feed stream opens. In this case, 
Preheat Crude is the only feed stream, so its property 
view also opens.
2.2.7 Using Workbook 
Features
Before you install the remaining operations, you will examine a 
number of Workbook features that allow you to access 
information quickly and change how information appears.2-59
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ThAccessing Unit Operations from the 
Workbook
There are a number of ways to open the property view for an 
operation directly from the Workbook besides using the Unit 
Ops tab.
1. Return to the Material Streams tab of the Workbook 
property view.
When your current location is a Workbook streams tab 
(Material Streams, Compositions, and Energy Streams tabs), 
the field at the bottom of the Workbook property view 
displays the operations to which the current stream is 
attached. 
2. In the display field, you can double-click on any unit 
operation associated with the stream to open the unit 
operation.
For example, if you click in any cell for Preheat Crude, the field 
displays the name of the operation, PreFlash, to which this 
stream is attached.
Any utilities attached to the stream with the Workbook 
active are also displayed in (and are accessible through) this 
display field.2-60
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ThThe display field also displays FeederBlock_Preheat Crude, 
because the Preheat Crude stream is a boundary stream. 
To access the property view for the PreFlash operation, double-
click on PreFlash. 
The operation property view appears.
Adding a Tab to the Workbook 
When the Workbook is active, the Workbook item appears in the 
Aspen HYSYS menu bar. This item allows you to customize the 
Workbook.
In this section, you will create a new Workbook tab that displays 
only stream pressure, temperature, and flow.
1. Do one of the following:
• From the Workbook menu, select Setup.
• Object inspect (right-click) the Material Streams tab in 
the Workbook, then select Setup from the menu that 
appears.
 Figure 2.57
The operation to which Preheat Crude is attached appears in this 
display field. Double-click the operation name to access its 
property view.
Stream Preheat Crude is the current 
Workbook location.2-61
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ThThe Workbook Setup property view appears.
The four existing tabs are listed in the Workbook Tabs 
area. When you add a new tab, it is inserted before the 
selected tab (currently Material Streams). You will insert 
the new tab before the Compositions tab.
2. In the Workbook Tabs group list, select Compositions.
3. Click the Add button. The New Object Type property view 
appears.
 Figure 2.58
 Figure 2.59
Currently, all 
variables appear 
with four 
significant 
figures. You can 
change the 
display format or 
precision of any 
Workbook 
variables by 
clicking the 
Format button.2-62
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Refining Tutorial 2-63
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Th4. Click the Plus icon  beside Stream, select Material 
Stream from the branch, then click the OK button. You 
return to the Setup property view, and the new tab appears 
after the existing Material Streams tab.
5. In the Tab Contents Object group, click in the Name field.
6. Change the name of the new tab to P,T,Flow to better 
describe the tab contents.
The next task is to customize the tab by removing the 
variables that are not required.
7. In the Variables group, click on the first variable, Vapour 
Fraction.
8. Press and hold the CTRL key.
9. Click on the other variables, Molar Flow, Mass Flow, Heat 
Flow, and Molar Enthalpy. These four variables are now 
highlighted.
10.Release the CTRL key.
 Figure 2.602-63
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2-64 Steady State Simulation
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Th11.Click the Delete button to remove them from this 
Workbook tab. The finished Setup property view appears 
below. 
If you want to remove variables from another tab, you must 
edit each tab individually.
12.Click the Close icon  to return to the Workbook property 
view and see the new tab.
13.Save your case by doing one of the following:
• Click the Save icon on the toolbar.
• Select Save from the File menu.
• Press CTRL S.
 Figure 2.61
 Figure 2.62
The new tab 
displays only 
these three 
Variables.
The new tab 
now appears 
in the list of 
Workbook 
Tabs in the 
same order as 
it appears in 
the Workbook.
Save icon2-64
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Th2.2.8 Using the PFD
The PFD is the other main property view used in Aspen HYSYS. 
The PFD item appears in the Aspen HYSYS menu bar whenever 
the PFD is active.
1. To open the PFD, click the PFD icon on the toolbar. The PFD 
property view should appear similar to the one shown below, 
except some stream icons may overlap each other.
As a graphical representation of your flowsheet, the PFD shows 
the connections among all streams and operations, also known 
as ‘objects’. Each object is represented by a symbol, also known 
as an ‘icon’. A stream icon is an arrow pointing in the direction 
of the flow, while an operation icon is a graphic representing the 
actual physical operation. The object name, also known as a 
‘label’, appears near each icon.
The PFD shown above has been rearranged by moving the three 
utility stream icons below and to the left of the Separator. To 
move an icon, click and drag it to the new location. 
 Figure 2.63
You can click and drag either the icon (arrow) itself, or the 
label (stream name), as these two items are grouped 
together.
PFD icon
PFD toolbar Stream/Operation labels
Unit Operation 
icon for a 
Separator
Material 
Stream icon2-65
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ThLike any other non-modal property view, the PFD property view 
can be re-sized by clicking and dragging anywhere on the 
outside border.
Other things you can do while the PFD is active include the 
following:
• Access commands and features through the PFD toolbar.
• Open the property view for an object by double-clicking 
on its icon.
• Move an object by click and dragging it to the new 
location.
• Access “pop-up” summary information for an object 
simply by placing the cursor over it.
• Change an icon's size by clicking the Size Mode icon, 
clicking on the icon, and click and dragging the sizing 
handles that appear around the icon.
• Display the Object Inspection menu for an object by 
placing the cursor over it, and right-clicking. This menu 
provides access to a number of commands associated 
with the particular object.
• Zoom in and out, or display the entire flowsheet in the 
PFD window by clicking the zoom buttons at the bottom 
left corner of the PFD property view.
Some of these functions are illustrated here.
Icon Name Icon Name
Zoom Out 25% Zoom In 25%
Display Entire PFD
Size Mode icon
For more information, 
see Section 7.24 - PFD 
in the Aspen HYSYS 
User Guide.2-66
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ThCalculation Status
Before proceeding, you will examine a feature of the PFD that 
allows you to trace the calculation status of the objects in your 
flowsheet. If you recall, the status indicator at the bottom of the 
property view for a stream or operation displays one of three 
possible states for the object: 
When you are in the PFD, the streams and operations are 
colour-coded to indicate their calculation status. The inlet 
separator is completely calculated, so its normal colours appear. 
While installing the remaining operations through the PFD, their 
colours (and status) changes appropriately as information is 
supplied.
A similar colour scheme is used to indicate the status of 
streams. For material streams, a dark blue icon indicates the 
stream has been flashed and is entirely known. A light blue icon 
indicates the stream cannot be flashed until some additional 
information is supplied. Similarly, a dark red icon is for an 
energy stream with a known duty, while a purple icon indicates 
an unknown duty.
Status  Description
Red Status A major piece of defining information is missing from 
the object. For example, a feed or product stream is 
not attached to a separator. The status indicator is red, 
and an appropriate warning message appears.
Yellow Status All major defining information is present, but the 
stream or operation has not been solved because one 
or more degrees of freedom is present, for example, a 
cooler where the outlet stream temperature is 
unknown. The status indicator is yellow, and an 
appropriate warning message appears.
Green Status The stream or operation is completely defined and 
solved. The status indicator is green, and an OK 
message appears.
These status colours are the Aspen HYSYS default colours. 
You can change the colours in the Session Preferences.
The icons for all streams installed to this point are dark blue, 
indicating they have been flashed.2-67
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2-68 Steady State Simulation
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ThInstalling the Crude Furnace 
In this section, you will install a crude furnace. The furnace is 
modeled as a Heater.
1. Ensure the Object Palette is visible (if it is not, press F4).
You will add the furnace to the right of the PreFlash 
Separator, so make some empty space available by scrolling 
to the right using the horizontal scroll bar.
2. In the Object Palette, click the Heater icon. The cursor 
changes to a special cursor, with a black frame and plus (+) 
symbol attached to it. The frame indicates the size and 
location of the operation icon.
3. Position the cursor over the PFD to the right of the 
separator.
4. Click to ‘drop’ the heater onto the PFD. Aspen HYSYS 
creates a new heater with a default name, E-100.
Next you will change the heater icon from its default to one 
more closely resembling a furnace.
5. Right-click the heater icon. The Object Inspect menu 
appears.
 Figure 2.64
Notice the heater has red status (colour), indicating that it 
requires feed and product streams. 
Heater icon (Red)
Cooler icon (Blue)2-68
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Th6. Select Change Icon command from the Object Inspect 
menu. The Select Icon property view appears.
7. Click the WireFrameHeater5 icon (scroll to the right), then 
click the OK button. The new icon appears in the PFD.
Attaching Streams to the Furnace
1. Click the Attach icon on the PFD toolbar to enter Attach 
mode. 
2. Position the cursor over the right end of the PreFlashLiq 
stream icon. A small box appears at the cursor tip. 
3. With the pop-up ‘Out’ visible, click and hold the mouse 
button. The white box becomes black, indicating that you 
are beginning a connection. 
 Figure 2.65
When you are in Attach mode, you are not able to move 
objects in the PFD. 
To return to Move mode, click the Attach button again. 
You can temporarily toggle between Attach and Move mode 
by holding down the CTRL key.
 Figure 2.66
Furnace icon
Attach Mode icon
At the square connection 
point, a pop-up description 
appears attached to the 
cursor. The pop-up “Out” 
indicates which part of the 
stream is available for 
connection, in this case, the 
stream outlet.2-69
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2-70 Steady State Simulation
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Th4. Drag the cursor toward the left (inlet) side of the heater. A 
trailing line appears between the PreFlashLiq stream icon 
and the cursor, and a connection point appears at the 
Heater inlet. 
5. Place the cursor near the connection point of the heater, and 
the trailing line snaps to that point. As well, a white box 
appears at the cursor tip, indicating an acceptable end point 
for the connection.
6. Release the mouse button, and the connection is made to 
the heater inlet.
7. Position the cursor over the right end of the heater icon. 
The connection point and pop-up ‘Product’ appears.
8. With the pop-up visible, click and hold the mouse button. 
The white box again becomes black.
9. Move the cursor to the right of the heater. A stream icon 
appears with a trailing line attached to the heater outlet. 
The stream icon indicates that a new stream is being 
created.
10.With the stream icon visible, release the mouse button. 
Aspen HYSYS creates a new stream with the default name 1.
 Figure 2.67
If you make an incorrect connection:
1. Click the Break Connection icon on the PFD toolbar.
2. Move the cursor over the stream line connecting the two icons. 
A checkmark attached to the cursor appears, indicating an acceptable 
connection to break.
3. Click once to break the connection.
 Figure 2.68
Break Connection icon2-70
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Th11.Create the Heater energy stream, starting the connection 
from the bottom left connection point on the Heater icon 
labeled ‘Energy Stream’. The new stream is automatically 
named Q-100, and the heater now has yellow (warning) 
status. This status indicates that all necessary connections 
have been made, but the attached streams are not entirely 
known.
12.Click the Attach icon again to return to Move mode.
The heater outlet and energy streams are unknown at this 
point, so they appear light blue and purple, respectively. 
Modifying Furnace Properties
1. Double-click the Heater icon to open its property view.
2. Click the Design tab, then select the Connections page. 
The names of the Inlet, Outlet, and Energy streams appear 
in the appropriate fields.
3. In the Name field, change the operation name to Furnace.
4. Select the Parameters page.
 Figure 2.69
 Figure 2.702-71
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2-72 Steady State Simulation
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Th5. In the Delta P field, enter 10 psi, then close the property 
view. 
The Furnace has one available degree of freedom. Either 
the outlet stream temperature or the amount of duty in the 
energy stream can be specified. In this case, you will specify 
the outlet temperature.
6. Double-click the outlet stream icon (1) to open its property 
view.
7. In the Stream Name field, change the name to Hot Crude.
 Figure 2.712-72
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Refining Tutorial 2-73
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Th8. In the Temperature field, specify a temperature of 650°F. 
The remaining degree of freedom in the Furnace has now 
been used, so Aspen HYSYS can flash Hot Crude and 
determine its remaining properties. 
9. Close the property view to return to the PFD property view. 
The Furnace now has green status, and all attached 
streams are known.
10.Double-click on the energy stream icon (Q-100) to open its 
property view. The required heating duty calculated by 
Aspen HYSYS appears in the Heat Flow cell. 
 Figure 2.722-73
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2-74 Steady State Simulation
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Th11. In the Stream Name cell, rename this energy stream 
Crude Duty, then close the property view.
Installing the Mixer 
In this section, you will install a Mixer operation. The Mixer is 
used to combine the hot crude stream with the vapours 
bypassing the furnace. The resulting stream is the feed for the 
crude column.
1. Make some empty space available to the right of the 
Furnace using the horizontal scroll bar. Move other objects 
if necessary.
2. Click the Mixer icon on the Object Palette.
3. Position the cursor over the PFD to the right of the Hot 
Crude stream icon.
4. Click to ‘drop’ the mixer onto the PFD. Aspen HYSYS 
creates a new mixer with the default name MIX-100.
5. Press and hold the CTRL key to temporarily enable the 
Attach mode while you make the mixer connections (you 
will not release it until step #13).
6. Position the cursor over the right end of the PreFlashVap 
stream icon. The connection point and pop-up ‘Out’ appears.
7. With the pop-up visible, click and hold the mouse button, 
then drag the cursor toward the left (inlet) side of the 
mixer. Multiple connection points appear at the mixer inlet.
Multiple connection points appear because the Mixer 
accepts multiple feed streams.
 Figure 2.73
Mixer icon2-74
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Th8. Place the cursor near the inlet area of the mixer, and when 
the white box appears at the cursor tip, release the mouse 
button to make the connection.
9. Repeat steps #6 to #8 to connect the Hot Crude stream to 
the Mixer.
10. Position the cursor over the right end of the mixer icon. The 
connection point and pop-up ‘Product’ appears.
11.With the pop-up visible, click and drag to the right of the 
mixer. A white stream icon appears, with a trailing line 
attached to the mixer outlet. 
12.With the white stream icon visible, release the mouse 
button. Aspen HYSYS creates a new stream with the default 
name 1.
13.Release the CTRL key to leave Attach mode.
14.Double-click on the outlet stream icon 1 to access its 
property view. When you created the mixer outlet stream, 
Aspen HYSYS automatically combined the two inlet streams 
and flashed the mixture to determine the outlet conditions. 
15. In the Stream Name cell, rename the stream Tower Feed, 
then close the property view.
16.Double-click the mixer icon, MIX-100. Change the name to 
Mixer, then close the property view.
 Figure 2.742-75
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2-76 Steady State Simulation
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ThResizing Icons in the PFD
Resize icons in the PFD to make it easier to read.
1. Resize the PFD property view by clicking and dragging the 
outside border. 
2. Click the Zoom All icon  to fill the PFD window, including 
any objects that were not visible previously. 
A possible property view of the resized PFD appears in the 
figure below.
3. Click the Size Mode icon on the PFD toolbar.
4. Click the Furnace icon in the PFD. A frame with sizing 
handles appears around the icon.
5. Place the cursor over one of the sizing handles. The cursor 
changes to a double-ended sizing arrow.
 Figure 2.75
 Figure 2.76
Size Mode icon
Double-
ended sizing 
arrow2-76
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Th6. With the sizing arrow visible, click and drag to resize the 
icon.
7. Click the Size Mode icon again to return to Move mode.
Adding an Energy Stream
In this section, you will add an energy stream. Prior to installing 
the column, an energy stream must be created to represent the 
trim duty on stage 28 of the main tower.
1. Double-click on the Energy Stream icon on the Object 
Palette. Aspen HYSYS creates a new energy stream with 
the default name Q-100 and display its property view.
2. In the Stream Name field, change the name to Trim Duty.
3. Close the property view.
4. Save your case by doing one of the following:
• press CTRL S.
• from the File menu, select Save.
• click the Save icon.
Installing the Column
Aspen HYSYS has a number of pre-built column templates that 
you can install and customize by changing attached stream 
names, number of stages and default specifications, and adding 
side equipment. 
One of these templates is going to be used for this example (a 
crude column with three side strippers), however, a basic 
Refluxed Absorber column with a total condenser is installed 
If you choose to use the pre-built crude column template you 
still have to customize the column by modifying the various 
draw and return stages and default specifications. Although 
using the template eliminates the majority of the work over 
the next few pages, it is recommended that you work 
through these pages the first time you build a crude column 
in Aspen HYSYS. Once you are comfortable working with the 
side equipment, try using the template. Instructions on 
using the crude column template are given in an annotation 
on the next page.
Energy Stream icon
Save icon2-77
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2-78 Steady State Simulation
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Thand customized in order to illustrate the installation of the 
necessary side equipment.
1. Before installing the column, select Preferences from the 
Aspen HYSYS Tools menu. Click the Simulation tab. 
2. On the Options page, ensure the Use Input Experts 
checkbox is selected, then close the property view.
3. Double-click the Refluxed Absorber icon on the Object 
Palette. The first page of the Input Expert appears.  
The Input Expert is a Modal property view, indicated by the 
absence of the Maximize/Minimize icons. You cannot exit 
or move outside the Expert property view until you supply 
the necessary information or click the Cancel button.
When you install a column using a pre-built template, Aspen 
HYSYS supplies certain default information, such as the number 
 Figure 2.77
To install this column using the pre-built crude column template:
1. Double-click on the Custom Column icon on the Object Palette.
2. On the property view that appears, click the Read an Existing Column 
Template button. 
The Available Column Templates property view appears, listing the 
template files *.col that are provided in your Aspen HYSYS\template 
directory. Both 3- and 4-side stripper crude column templates are 
provided.
3. Select 3sscrude.col and click the OK button. The property view for the 
new column appears. You can now customize the new column.
Refluxed Absorber icon2-78
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Refining Tutorial 2-79
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Thof stages. The current active field is # Stages (Number of 
Stages), indicated by the thick border inside this field.
Entering Inlet Streams and Number of Trays
For this example, the main column has 29 theoretical stages.
1. Enter 29 in the # Stages field.
2. Advance to the Optional Inlet Streams table by clicking on 
the <> cell, or by pressing tab.
3. Click the down arrow  to open the drop-down list of 
available feeds.
4. Select Tower Feed as the feed stream to the column. Aspen 
HYSYS supplies a default feed location in the middle of the 
Tray Section (TS), in this case stage 15 (indicated by 
15_Main TS). However, the feed stream needs to enter 
stage 28.
These are theoretical stages, as the Aspen HYSYS default 
stage efficiency is one.
If present, the Condenser and Reboiler are considered 
separate from the other stages, and are not included in the # 
Stages field.
 Figure 2.782-79
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2-80 Steady State Simulation
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Th5. In the Optional Inlet Streams group, click in the Inlet Stage 
cell for TowerFeed.
6. Type 28 and press enter, or select 28_Main TS from the 
drop-down list of stages.
7. Click on <> in the same table, which was 
automatically advanced down one cell when you attached 
the Tower Feed stream.
8. From the Stream drop-down list, select the Trim Duty 
stream, which is also fed to stage 28.
9. Advance to the Bottom Stage Inlet field by clicking on it or 
by pressing tab.
10. In the Bottom Stage Inlet field, click the down arrow  to 
open the drop-down list of available feeds.
11. From the list, select Bottom Steam as the bottom feed for 
the column. 
Entering Outlet Streams
In the Condenser group of the Input Expert property view, the 
default condenser type is Partial. To the right of this group, 
there are two Overhead Outlets, vapour and liquid. In this 
case, the overhead vapour stream has no flow, and two liquid 
phases (hydrocarbon and water) are present in the condenser. 
The hydrocarbon liquid product is attached in the liquid 
Overhead Outlets field, while the water draw is attached using 
the Optional Side Draws table.
 Figure 2.792-80
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Th 
Although the overhead vapour product has zero flow, do not 
change the condenser to Total. At this time, only the Partial 
radio button allows you to specify a three-phase condenser.
1. Click in the top Ovhd Outlets field.
2. Enter Off Gas as the name of the overhead vapour product 
stream. Aspen HYSYS creates and attaches a new stream 
with this name. 
3. Press tab again to move to the bottom Ovhd Outlets field, 
and enter the new stream name Naphtha. 
The next task is to attach the water draw stream to the 
condenser. 
4. In the Optional Side Draws table, click in the 
<> cell.
5. Enter the name of the draw stream, WasteH2O. Aspen 
HYSYS automatically places a hydrocarbon liquid (indicated 
by the L in the Type column) draw on stage 15. You will 
change this to a condenser water draw.
6. Click on the Type cell (the L) for the WasteH2O stream.
7. Specify a water draw by typing W then pressing enter, or by 
selecting W from the drop-down list.
8. Click on the Draw Stage cell (15_Main TS) for the 
WasteH2O stream.
 Figure 2.80
Overhead 
vapour 
product field.
Overhead 
liquid 
product field.
The water 
draw is 
attached 
using this 
table.2-81
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2-82 Steady State Simulation
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Th9. Select Condenser from the drop-down list. The condenser is 
now three-phase.
10. In the Column Name field, enter Atmos Tower.
11. In the Bottoms Liquid Outlet field, type Residue to create 
a new stream.
12. In the Condenser Energy Stream field, type Cond Duty to 
define a new stream. Press ENTER.
The first page of the Input Expert should appear as shown 
below.  
 Figure 2.81
 Figure 2.822-82
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ThThe Next button now becomes available, indicating sufficient 
information has been supplied to advance to the next page 
of the Input Expert.
13.Click the Next button to advance to the Pressure Profile 
page.
Entering the Initial Estimate Values
1. On the Pressure Profile page, specify the following:
• Condenser Pressure 19.7 psia
• Condenser Pressure Drop 9 psi
• Bottom Stage Pressure 32.7 psia 
2. Click the Next button to advance to the Optional 
Estimates page. Although Aspen HYSYS does not usually 
require estimates to produce a converged column, good 
estimates result in a faster solution.
All stream attachments made on this page result in the 
creation of Column sub-flowsheet streams with the same 
names. For example, when the Main Flowsheet stream 
BottomSteam was attached as a feed, Aspen HYSYS 
automatically created an identical stream named 
BottomSteam to be used in the Column sub-flowsheet.
 Figure 2.832-83
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2-84 Steady State Simulation
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Th3. Specify the following:
• Condenser 100°F
• Top Stage 250°F
• Bottom Stage 700°F
4. Click the Next button to advance to the fourth and final 
page of the Input Expert. This page allows you to supply 
values for the default column specifications that Aspen 
HYSYS has created.
In general, a refluxed absorber with a partial condenser has 
two degrees of freedom for which Aspen HYSYS provides two 
default specifications. For the two specifications given, 
overhead Vapour Rate is used as an active specification, and 
Reflux Ratio as an estimate only.
5. From the Flow Basis drop-down list, select Volume. All flow 
specifications are provided in barrels per day.
6. Specify the following:
• Vapour Rate = 0
• Reflux Ratio = 1.0
 Figure 2.842-84
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Th 
7. Click the Done button. The Column property view appears. 
 Figure 2.85
 Figure 2.862-85
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2-86 Steady State Simulation
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ThAdding Specification Values
1. On the Design tab, select the Monitor page.
The main feature of this page is that it displays the status of 
your column as it is being calculated, updating information 
with each iteration. You can also change specification values, 
and activate or deactivate specifications used by the Column 
solver, directly from this page.
The current Degrees of Freedom is one, indicating that 
only two specifications are active. 
As noted earlier, a Refluxed Absorber with a partial 
condenser has two degrees of freedom and, therefore, 
requires two active specifications. In this case, however, a 
third degree of freedom was created when the Trim Duty 
stream was attached as a feed, for which the heat flow is 
unknown. Aspen HYSYS has not made a specification for the 
third degree of freedom, therefore you need to add a water 
draw spec called WasteH2O Rate to be the third active 
specification.
2. Select the Specs page. Here you will remove two 
specifications and add one new specification.
3. In the Column Specifications group, select Reflux Rate and 
then click the Delete button.
4. Delete the Btms Prod Rate specification also.
5. Next you will add the WasteH2O Rate specification. Click the 
Add button. The Add Specs property view appears.
6. Select Column Draw Rate and click the Add Spec(s) button. 
The Draw Spec property view appears. 
The basic column has three available degrees of freedom. 
Currently, two Specifications are Active, so the overall 
Degrees of Freedom is one. The number of available degrees 
of freedom increases with the addition of side equipment.2-86
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Th7. In the Name cell, type WasteH2O Rate. No further 
information is required as this specification is deactivated 
and only estimated when you run the column.
The Draw Spec is entered so that the degrees of freedom is 
kept at zero throughout this tutorial. It is good practice to 
keep the degrees of freedom at zero as you modify your 
column so that you can solve the column after every 
modification. 
8. Close the property view. The new specification appears in 
the Column Specifications group. The Degrees of Freedom is 
now zero.
9. Select the Connections page. See Figure 2.86.
The Connections page is similar to the first page of the 
Input Expert. Currently, the column is a standard type, so 
this page shows a column schematic with the names of the 
attached streams. When the side equipment is added to the 
column, the page becomes non-standard. There are a large 
number of possible non-standard columns based on the 
types and numbers of side operations that are added. 
Therefore, Aspen HYSYS modifies the Connections page 
into a tabular format, rather than a schematic format, 
whenever a column becomes non-standard. 
In the next section you will add the side equipment and 
observe how the Connections page is modified.
 Figure 2.872-87
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2-88 Steady State Simulation
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ThInstalling the Side Strippers
1. Click the Side Ops tab of the Column property view.
On this tab, you can Install, View, Edit, or Delete all types of 
Side Equipment. The table displays summary information for 
a given type of side operation, depending on the page you 
are currently on.
When you install side equipment, it resides in the Column 
sub-flowsheet. You can build a complex column in the sub-
flowsheet while in the Main Flowsheet, the column appears 
as a single operation. You can then transfer any needed 
stream information from the sub-flowsheet by simply 
attaching the stream to the Main Flowsheet.
2. Ensure that you are on the Side Strippers page.
 Figure 2.882-88
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Th3. Click the Add button. The Side Stripper property view 
appears.
4. In the Name field, change the name to KeroSS.
This is a reboiled 3-stage stripper with a 0.75 boil up ratio, 
so leave the Configuration radio button at Reboiled, and 
the k = and Boil Up Ratio fields at their defaults.
5. In the Return Stage drop-down list, select stage 8 (8_Main 
TS).
6. In the Draw Stage drop-down list, select stage 9 (9_Main 
TS).
7. In the Flow Basis group, select the Std Ideal Vol radio 
button.
8. In the Product Stream field, enter Kerosene.
 Figure 2.892-89
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2-90 Steady State Simulation
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ThThe straight run product distribution data calculated during 
the Oil Characterization appears in the figure below. 
The Kerosene liquid volume fraction is 0.129. For 100,000 
bbl/day of crude fed to the tower, Kerosene production can 
be expected at 100,000 * 0.129 = 12,900 or 
approximately 13,000 bbl/day.
9. In the Draw Spec field, enter 13000. The completed Side 
Stripper property view appears below. 
10.Click the Install button, and a property view summarizing 
your input appears.
 Figure 2.90
 Figure 2.91
Kerosene 
Liquid 
Volume 
Fraction2-90
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Th11.Click the Close icon  to return to the Column property 
view. Summary information for the new side operation 
appears in the table on the Side Ops tab.
12.Use the previous steps to install the two remaining side 
strippers DieselSS and AGOSS. These are both Steam 
Stripped, so choose the appropriate Configuration radio 
button and create the Steam Feed and Product streams 
as shown in the following figures. The @COL1 suffix is added 
automatically. 
The completed DieselSS and AGOSS side stripper property 
views appear in the following figure. 
 Figure 2.92
 Figure 2.93
Although not a requirement, the names of the Steam Feed 
streams created for these side strippers are identical to the 
names of the utility steam streams that were created 
previously in the Main Flowsheet. The conditions of these 
Steam Feed streams, which reside in the Column sub-
flowsheet, are unknown at this point. The conditions of the 
Main Flowsheet streams are duplicated into these sub-
flowsheet streams when the stream attachments are 
performed.2-91
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2-92 Steady State Simulation
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ThThe completed Side Stripper Summary table appears 
below.
13.Click the Design tab and select the Monitor page. 
The Specifications table on this page has a vertical scroll 
bar, indicating that new specifications have been created 
below the default ones. Resize the property view to examine 
the entire table. 
14.Click and drag the bottom border of the property view down 
until the scroll bar disappears, making the entire matrix 
visible.
The installation of the side strippers created four additional 
degrees of freedom, so Aspen HYSYS created a Prod Flow 
(product flow) specification for each side stripper, plus a 
BoilUp Ratio specification for the Kerosene side stripper. 
The new specifications were automatically made Active to 
exhaust the four degrees of freedom, returning the overall 
Degrees of Freedom to 0.
The addition of the side strippers has created four more 
degrees of freedom above the basic column, resulting in a 
total of seven available degrees of freedom. Currently, 
however, seven Specifications are Active, so the overall 
Degrees of Freedom is zero.
 Figure 2.94
 Figure 2.952-92
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ThInstalling the Pump Arounds
1. Click the Side Ops tab and select the Pump Arounds page. 
2. Click the Add button. The initial Pump Around property view 
appears.
3. In the Return Stage drop-down list, select stage 1 (1_Main 
TS).
4. In the Draw Stage drop-down list, select stage 2 (2_Main 
TS).
5. Click the Install button, and a more detailed Pump Around 
property view appears.
Each cooled pump around circuit has two specifications 
associated with it. The default Pump Around 
Specifications are circulation rate and temperature drop 
(Dt) between the liquid draw and liquid return. For this 
example, the Dt specification is changed to a Duty 
specification for the pump around cooler. The pump around 
rate is 50,000 bbl/day.
6. In the empty cell under the PA_1_Rate(Pa) specification, 
enter 5e4.
 Figure 2.96
 Figure 2.972-93
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Th7. Double-click in the blank space under the PA_1_Dt(Pa) 
specification, and the Spec property view appears.
8. In the Spec Type drop-down list, select Duty. 
9. in the Spec Value cell, enter -55e6.  
10.Click the Close icon  to return to the Pump Around 
property view.
The remainder of the information on the above property 
view is calculated by the Column solver.
11.Click the Close icon  on the main Pump Around property 
view to return to the Column property view.
12.Repeat the previous steps to install the two remaining pump 
arounds.
 Figure 2.98
 Figure 2.99
Notice the 
negative sign 
convention 
indicates 
cooling.2-94
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ThSummary of previous steps in table below:
Enter Rate specifications of 3e4 barrel/day and Duty 
specifications of -3.5e7 Btu/hr for both of these pump 
arounds. 
The completed Pump Around property views and Liquid 
Pump Around Summary table appear in the following 
figures.   
Step summary
1. Click the Add button.
2. Specify the Return Stage and 
Draw Stage.
3. Click the Install button. The 
second property view appears.
4. Specify the 1st Active spec.
5. Double-click the empty cell in the 
2nd Active spec.
6. Select Duty from the Spec Type 
drop-down list.
7. Enter the Spec Value.
8. Close the property view.
 Figure 2.100
 Figure 2.1012-95
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Th13.Click the Design tab and select the Monitor page. Re-size 
the property view again so the entire Specifications table is 
visible.
The addition of each pump around created two additional 
degrees of freedom. As with the side strippers, the 
specifications for the pump arounds have been added to the 
list and were automatically activated.
Overall the addition of the pump arounds has created six 
more degrees of freedom, resulting in a total of 13 available 
degrees of freedom. Currently, 13 Specifications are active, 
so the overall Degrees of Freedom is zero.
 Figure 2.1022-96
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Th14.Select the Connections page.
The Connections page of a standard refluxed absorber 
property view is essentially identical to the first page of the 
refluxed absorber Input Expert, with a column schematic 
showing the feed and product streams. Side equipment have 
been added to the standard refluxed absorber, however, 
making the column non-standard. The Connections page 
has therefore been modified to show tabular summaries of 
the Column Flowsheet Topology (i.e., all equipment), 
Feed Streams, and Product Streams.
The column has 40 Total Theoretical Stages:
• 29 in the main tray section
• 1 condenser for the main column
• 9 in the side strippers (3 side strippers with 3 stages 
each)
• 1 reboiler for the Kerosene side stripper
This topology results in 4 Total Tray Sections—one for the 
main column and one for each of the three side strippers.
 Figure 2.1032-97
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ThCompleting the Column Connections
When the stream attachments were made on the initial page of 
the Input Expert, Aspen HYSYS automatically created Column 
sub-flowsheet streams with the same names. For example, 
when Bottom Steam was attached as a column feed stream, 
Aspen HYSYS created an identical sub-flowsheet stream named 
Bottom Steam. In the Inlet Streams table on the 
Connections page, the Main Flowsheet stream is the External 
Stream, while the sub-flowsheet stream is the Internal 
Stream.
If you scroll down the list of Inlet Streams, notice that the two 
side stripper steam streams, DieselSteam and AGOSteam, 
are Internal and External, meaning that these streams are 
attached to the Main Flowsheet streams that were created 
earlier. 
For the purposes of this tutorial, it is not required to export the 
pump around duty streams PA_1_Q, PA_2_Q, and PA_3_Q to 
the Main Flowsheet, so their External Stream cells remain 
undefined.
Adding Column Specifications
Select the Monitor page of the Column property view. 
The current Degrees of Freedom is zero, indicating the column 
is ready to be solved. Before you run the column, however, you 
will have to replace two of the active specifications, Waste H2O 
Rate and KeroSS BoilUp Ratio, with the following new ones:
• Overflash specification for the feed stage (Tray Net 
Liquid Flow specification)
 Figure 2.1042-98
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Th• Kerosene side stripper reboiler duty specification
Adding the Overflash Specification
1. On the Design tab, move to the Specs page.   
2. In the Column Specifications group, click the Add button. 
The Add Specs property view appears. 
3. Select Column Liquid Flow as the Column Specification 
Type.
4. Click the Add Spec(s) button, and the Liq Flow Spec 
property view appears.
5. Change the name from its default to Overflash.
6. In the Stage cell, select 27_Main TS from the drop-down 
list of available stages.
A typical range for the Overflash rate is 3-5% of the total 
feed to the column. In this case, the total feed rate is 
100,000 barrels/day. For the Overflash specification 3.5%, 
or 3,500 barrels/day is used.
 Figure 2.1052-99
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Th7. In the Spec Value cell, enter 3500.   
8. Close the property view to return to the Column property 
view. The new specification appears in the list of Column 
Specifications group on the Specs page.
Adding the Duty Specification
1. Click the Add button again to add the second new 
specification.
2. Select Column Duty as the Column Specification Type, 
then click the Add Spec(s) button. The Duty Spec property 
view appears.
3. In the Name cell, change the name to Kero Reb Duty.
4. In the Energy Stream cell, select KeroSS_Energy @COL1 
from the drop-down list.
5. In the Spec Value cell, enter 7.5e6 (Btu/hr). 
 Figure 2.106
 Figure 2.1072-100
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Th6. Close the property view to return to the Specs page of the 
Column property view. The completed list of Column 
Specifications is shown in the figure below 
Running the Column
1. Select the Monitor page to view the Specifications matrix.
The Degrees of Freedom is again zero, so the column is 
ready to be calculated, however, a value for the distillate 
(Naphtha) rate specification must be supplied initially. In 
addition, there are some specifications which are currently 
Active that you want to use as Estimates only, and vice 
versa.
Make the following final changes to the specifications:
2. In the Specified Value cell for the Distillate Rate 
specification, enter 2e4 (barrel/day).
3. Activate the Overflash specification by selecting its Active 
checkbox.
4. Activate the Kero Reb Duty specification.
5. Activate the Vap Prod Rate specification.
 Figure 2.108
If the column begins to run on its own before you click the 
Run button, click the Stop button and continue activating or 
deactivating specifications.2-101
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Th6. Deactivate the Reflux Ratio specification.
7. Deactivate the Waste H2O Rate specification.
8. Deactivate the KeroSS BoilUp Ratio specification.
Aspen HYSYS begins calculations and the information 
displayed on the page is updated with each iteration. The 
column converges as shown in the figure below. 
The converged temperature profile is currently displayed in 
the upper right corner of the property view. To view the 
pressure or flow profiles, select the appropriate radio button. 
9. Click on the Performance tab, then select the Column 
Profiles or Feed/Products page to see a more detailed 
stage summary.
 Figure 2.109
This matrix displays the 
Iteration number, Step size, 
Equilibrium error and Heat/
Spec error.
The column temperature profile is shown 
here. You can view the pressure or flow 
profiles by picking the appropriate radio 
button.
The status indicator has changed from Unconverged to Converged.2-102
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ThThe Column Profiles page appears below. 
In the Basis group near the top of the property view, select 
the Liq Vol radio button to examine the tray vapour and 
liquid flows on a volumetric basis.
 Figure 2.1102-103
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ThViewing Boiling Point Profiles for the 
Product Stream
You can view boiling point curves for all the product streams on 
a single graph:
1. On the Performance tab, click on the Plots page. 
2. In the Assay Curves group, select Boiling Point Assay.
3. Click the View Graph button, and the Boiling Point 
Properties property view appears.
 Figure 2.111
 Figure 2.112
No data is plotted 
on the graph, 
since there is 
currently No Tray 
Attached, as 
shown in the title 
bar.2-104
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Th4. Click the Profile Data Control button, and the Data Control 
property view appears as shown below.
5. Select the Multi Tray radio button in the Style group. The 
Data Control property view is modified, showing a matrix of 
column stages with a checkbox for each stage.
You can view boiling point properties of a single tray or 
multiple trays. The boiling point properties of all stages, 
from which products are drawn, are important for this 
Tutorial.
6. Activate the following stages by selecting on the 
corresponding checkboxes:
• Condenser (Naphtha product stage)
• 29_Main TS (Residue)
• KeroSS_Reb (Kerosene)
• 3_DieselSS (Diesel)
• 3_AGOSS (AGO)
The TBP profile for the light liquid phase on each stage can 
be viewed, on a liquid volume basis.
7. Select TBP in the drop-down list under the tray matrix in the 
Style group.
8. In the Basis group, select the Liquid Vol radio button.
9. Select the Light Liquid checkbox in the Phase group to 
activate it.
10. Leave the Visible Points at its default setting of 15 Points. 
You can display more data points for the curves by selecting 
the 31 Points radio button. 
 Figure 2.1132-105
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ThThe completed Data Control property view is shown below. 
11.Click on the Close icon  to close the Data Control property 
view. You return to the Boiling Point Properties property 
view, which now displays the TBP curves.
12.Make the Boiling Point Properties property view more 
readable by clicking the Maximize icon  in the upper right 
corner of the property view, or by clicking and dragging its 
border to a new property view size.
 Figure 2.114
The independent (x-axis) variable is the Assay Volume 
Percent, while the dependent (y-axis) variable is the TBP in 
°C.2-106
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ThThe Boiling Point Properties property view is shown below. 
Move the graph legend by double-clicking inside the plot 
area, then click and drag the legend to its new location.
13.When you are finished viewing the profiles, click the Close 
icon .
Moving to the Column Sub-
Flowsheet
When considering the column, you might want to focus only on 
the column sub-flowsheet. You can do this by entering the 
column environment.
1. Click the Column Environment button at the bottom of the 
column property view. 
2. While inside the column environment, you might want to:
• view the Column sub-flowsheet PFD by clicking the PFD 
icon.
• view a Workbook of the Column sub-flowsheet objects by 
clicking the Workbook icon.
• access the “inside” column property view by clicking the 
Column Runner icon. This property view is essentially 
the same as the “outside”, or Main Flowsheet, property 
view of the column.
 Figure 2.115
PFD icon
Workbook icon
Column Runner icon2-107
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ThThe Column sub-flowsheet PFD is shown below. 
Customizing the Column PFD
You can customize the PFD shown above by re-sizing the 
column and “hiding” some of the column trays to improve the 
overall readability of the PFD. To hide some of the trays in the 
main column:
1. Click the PFD icon to ensure the column PFD is active. 
2. Click the Maximize icon  in the upper right corner of the 
PFD property view to make it full-screen.
3. Click the Zoom All icon  at the bottom left of the PFD 
property view to fill the re-sized PFD property view.
4. Object inspect (right-click) the main column tray section and 
the object inspection menu appears.
5. Select Show Trays from the object inspection menu. The 
Stage Visibility view appears.
6. Select the Selected Expansion radio button.
7. Click the Check All button.
 Figure 2.116
Object Inspect menu2-108
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Th8. Hide stages 4, 5, 6, 11, 12, 13, 14, 24, 25, and 26 by 
clearing their Shown checkboxes.
9. Click the Close icon  on the Stage Visibility view to return 
to the PFD. The routing of some streams in the PFD can be 
undesirable. You can improve the stream routing by 
completing the next step.
10. From the PFD menu item, select Auto Position All, and 
Aspen HYSYS rearranges the PFD in a logical manner.
Enlarge Icon
The next task in customizing the PFD is to enlarge the icon for 
the main column:
1. Click on the icon for the main tray section (Main TS).
2. Click the Size icon on the PFD button bar, and a frame with 
eight sizing handles appears around the tray section icon.
3. Place the cursor over the handle at the middle right of the 
icon, and the cursor changes to a double-ended sizing arrow.
4. With the sizing cursor visible, click and drag to the right. An 
outline appears, showing what the new icon size is when you 
complete the next step.
5. When the outline indicates a new icon size of about 1.5 to 2 
times the width of the original size, release the button. The 
tray section icon is now re-sized.
6. Click the Size icon again to return to Move mode.
 Figure 2.117
Size icon2-109
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ThThe final task is to customize the PFD by moving some of 
the streams and operation labels (names) so they do not 
overlap. To move a label:
7. Click on the label you want to move.
8. Right-click and select Move/Size Label.
9. Move the label to its new position by clicking and dragging it, 
or by pressing the arrow keys.
You can also move the icon on its own simply by clicking and 
dragging it to the new location.
10.When you are finished working with the maximized Column 
PFD, click the Restore icon  for the PFD (not for the 
Aspen HYSYS Application property view) in the upper right 
corner of the property view of the PFD. The PFD returns to 
its previous size. 
11. You can manually resize the property view, and expand the 
PFD to fill the new size by again clicking the Zoom All icon 
 in the lower left corner of the PFD property view.
The customized PFD appears below. 
 Figure 2.118
For more information on 
customizing the PFD, 
refer to Section 7.24 - 
PFD in the Aspen 
HYSYS User Guide. 2-110
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Th12.To view the workbook for the column, click the Workbook 
icon.
13.When you are finished working in the Column environment, 
return to the Main Flowsheet by clicking the Enter Parent 
Simulation Environment icon. 
 Figure 2.119
Enter Parent Simulation 
Environment icon2-111
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Th14.Open the PFD for the Main Flowsheet, then select Auto 
Position All from the PFD menu item. Aspen HYSYS 
arranges the Main Flowsheet PFD in a logical manner 
according to the layout of the flowsheet. 
The PFD shown in the Figure 2.120 has been manually 
rearranged by moving some of the stream icons, and by 
enlarging the furnace icon.
 Figure 2.1202-112
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Th2.2.9 Viewing and Analyzing 
Results
1. Open the Workbook to access the calculated results for the 
Main Flowsheet. The Material Streams tab of the 
Workbook appears below. 
Using the Object Navigator
Now that results have been obtained, you can view the 
calculated properties of a particular stream or operation. The 
Object Navigator allows you to quickly access the property 
view for any stream or unit operation at any time during the 
simulation. 
1. Open the Navigator by doing one of the following:
• Press F3.
• From the Flowsheet menu, select Find Object.
• Double-click on any blank space on the Aspen HYSYS 
Desktop.
• Click the Object Navigator icon.
 Figure 2.121
Object Navigator icon2-113
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ThThe Object Navigator property view appears:
The UnitOps radio button in the Filter group is currently 
selected, so only Unit Operations appear in the list of objects. 
To open a property view, select the operation in the list and click 
the View button, or double-click on the operation. You can 
change which objects appear by selecting a different Filter radio 
button. For example, to list all the streams and unit operations, 
select the All radio button.
You can also search for an object by clicking the Find button. 
When the Find Object property view appears, enter the Object 
Name and click the OK button. Aspen HYSYS opens the 
property view for the object whose name you entered.
 Figure 2.122
You can start or end the search string with an asterisk (*), 
which acts as a wildcard character. This lets you find 
multiple objects with one search. For example, searching for 
VLV* will open the property view for all objects with VLV at 
the beginning of their name.2-114
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Th2.2.10 Installing a Boiling 
Point Curves Utility
Previously, the boiling point profiles for the product streams was 
viewed using the Plots page in the column property view. You 
can also view boiling point curves for a product stream using 
Aspen HYSYS' BP Curves Utility. 
To create a Boiling Point Curves utility for the Kerosene product:
1. Open the Navigator using one of the methods described 
above.
2. Select the Streams radio button.
3. Scroll down the list of Streams and select Kerosene.
4. Click the View button, and the property view for stream 
Kerosene appears.
5. On the Attachments tab, move to the Utilities page of the 
stream property view.
6. Click the Create button. The Available Utilities property view 
appears, presenting you with a list of Aspen HYSYS utilities.
7. Find BP Curves and do one of the following:
• Select BP Curves, then click the Add Utility button.
• Double-click on BP Curves.
8. Aspen HYSYS creates the utility and opens the Boiling Point 
Curves property view. 
9. On the Design tab, go to the Connections page. Change the 
name of the utility from the default Boiling Point Curves-1 to 
Kerosene BP Curves.
 Figure 2.1232-115
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Th10.Change the curve basis to Liquid Volume by selecting it 
from the Basis drop-down list.
A Utility is a separate entity from the stream it is attached 
to; if you delete it, the stream is not affected. Likewise, if 
you delete the stream, the Utility remains but cannot display 
any information until you attach another stream using the 
Select Object button.
 Figure 2.1242-116
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Th11.You can scroll through the matrix of data to see that the TBP 
ranges from 267°F to 502°F by going to the Performance 
tab and selecting the Results page. 
This boiling range predicted by the utility is slightly wider 
than the ideal range calculated during the Oil 
characterization procedure for Kerosene, 356°F to 464°F.  
 Figure 2.125
 Figure 2.126
Ideal boiling 
range calculated 
during Oil 
Characterization.2-117
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Th12.Select the Plots page on the Parameters tab of the utility 
property view to view the data in graphical format.  
13.When you move to the Plots property view, the graph legend 
can overlap the plotted data. To move the legend, double-
click anywhere in the plot area then click and drag the 
legend to its new location. 
To make the envelope more readable, maximize or resize 
the property view.
14.When you are finished viewing the Boiling Point Curves, 
click the Close icon .
Installing a Second Boiling Point 
Curves Utility
Alternative to using the Utilities page of a stream property 
view, you can also install a utility using the Available Utilities 
property view. Another BP Curves utility is installed for stream 
Residue. This utility is used for the case study in the next 
section. 
 Figure 2.1272-118
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ThTo install the utility:
1. Do one of the following:
• press CTRL U.
• from the Tools menu, select Utilities.
The Available Utilities property view appears.
2. Select Boiling Point Curves and click the Add Utility button. 
The Boiling Point Curves property view appears, opened to 
the Design tab. 
3. Change the name from its default Boiling Point Curves-1 to 
Residue BP Curves.
4. Change the Basis to Liquid Volume by selecting it in the 
drop-down list. The next task is to attach the utility to a 
material stream.
 Figure 2.128
 Figure 2.129
Notice the name of the 
utility created previously, 
Kerosene BP Curves, 
appears in the Available 
Utilities property view.2-119
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Th5. Click the Select Object button, and the Select Process 
Stream property view appears.
6. Select Residue in the Object list, then click the OK button. 
Aspen HYSYS calculates the boiling point curves. The 
completed Performance tab appears below. 
 Figure 2.130
 Figure 2.131
Notice that the stream name Residue now appears in the 
Stream cell.2-120
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Th7. Click the Close icon  on the Residue BP Curves property 
view, and then on the Available Utilities property view.
2.2.11 Using the Databook
The Aspen HYSYS Databook provides you with a convenient 
way to examine your flowsheet in more detail. You can use the 
Databook to monitor key variables under a variety of process 
scenarios, and view the results in a tabular or graphical format.
1. To open the Databook, do one of the following:
• press CTRL D.
• from the Tools menu, select Databook.
The Databook appears below.
Adding Variables to Databook
The first step is to add the key variables to the Databook using 
the Variables tab. For this example, the Overflash specification 
is varied and examined to investigate its effect on the following 
variables:
• D1160 Boiling Temperature for 5% volume cut point of 
stream Residue
• heat flow of energy stream Trim Duty
• column reflux ratio
 Figure 2.1322-121
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Th1. Click the Insert button and the Variable Navigator property 
view appears.
2. Select the UnitOps radio button in the Object Filter group. 
The Object list is filtered to show unit operations only.
3. Select Atmos Tower in the Object list, and the Variable list 
available for the column appears to the right of the Object 
list.
4. Select Reflux Ratio in the Variable list.
The Variable Navigator is used extensively in Aspen HYSYS 
for locating and selecting variables. The Navigator operates 
in a left-to-right manner—the selected Flowsheet determines 
the Object list, the chosen Object dictates the Variable list, 
and the selected Variable determines whether any Variable 
Specifics are available.
5. Click the Add button. The variable appears in the Databook 
and the Variable Navigator property view remains open.
6. To add the next variable, select the Streams radio button in 
the Object Filter group. The Object list is filtered to show 
streams only.
7. Scroll down and click on Trim Duty in the Object list, and 
the Variable list available for energy streams appears to the 
right of the Object list.
8. Select Heat Flow in the Variable list.
The variable name is duplicated in the Variable Description 
field. 
 Figure 2.1332-122
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ThIf you want, you can edit the default description. To edit the 
default description:
9. Click inside the Variable Description field and delete the 
default name. 
10. Type a new description, such as Trim Duty, and click the 
Add button. The variable now appears in the Databook.
11. To add the third variable, the ASTM D1160 cut point from 
the Residue BP Curves utility, select the Utility radio 
button in the Navigator Scope group.
12.Select Residue BP Curves in the Object list.
13.Select ASTM D1160 - Vac in the Variable list.
14.Select Cut PT-5.00% in the Variable Specifics column. This 
corresponds to the 5% volume cut point.
 Figure 2.1342-123
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Th15. In the Variable Description field, change the variable 
name to ASTM 1160 - Vac 5% Residue, and click the 
Close button. 
16. The completed Variables tab of the Databook appears 
below.
 Figure 2.135
 Figure 2.1362-124
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ThCreate a Data Table
Now that the key variables to the Databook have been added, 
the next task is to create a data table to display those variables:
1. Click on the Process Data Tables tab.
2. Click the Add button in the Available Process Data Tables 
group. Aspen HYSYS creates a new table with the default 
name ProcData1.
3. Change the default name from ProcData1 to Key 
Variables by editing the Process Data Table field.
Notice that the three variables added to the Databook 
appear in the matrix on this tab.
4. Activate each variable by selecting on the corresponding 
Show checkbox.
 Figure 2.137
 Figure 2.1382-125
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Th5. Click the View button to view the new data table, which is 
shown below. 
This table is accessed later to demonstrate how its results 
are updated whenever a flowsheet change is made. 
6. For now, click the Minimize icon in the upper right corner of 
the Key Variables Data property view. Aspen HYSYS reduces 
the property view to an icon and place it at the bottom of the 
Desktop.
Recording Data
Suppose you now want to make changes to the flowsheet, but 
you would like to record the current values of the key variables 
before making any changes. Instead of manually recording the 
variables, you can use the Data Recorder to automatically 
record them for you. 
 Figure 2.1392-126
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ThTo record the current values:
1. Click on the Data Recorder tab. 
When using the Data Recorder, you first create a Scenario 
containing one or more of the key variables, then record the 
variables in their current state.
2. Click the Add button in the Available Scenarios group, and 
Aspen HYSYS creates a new scenario with the default name 
Scenario 1. It is required to include all three key variables 
in this scenario.
3. Activate each variable by selecting on the corresponding 
Include checkbox.
4. Click the Record button to record the variables in their 
current state. The New Solved State property view appears, 
prompting you for the name of the new state.
 Figure 2.140
 Figure 2.1412-127
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Th5. Change the Name for New State from the default State 1 
to 3500 O.F. (denoting 3500 bbl/day Overflash). Click the 
OK button and you return to the Databook.
6. In the Available Display group, select the Table radio 
button.
7. Click the View button and the Data Recorder appears 
showing the values of the key variables in their current 
state. 
Now you can make the necessary flowsheet changes and 
these current values remain as a permanent record in the 
Data Recorder unless you choose to erase them. 
8. Click the Minimize icon to reduce the Data Recorder to an 
icon.
Changing the Overflash Specification
The value of the Overflash specification is going to be changed 
in the column and the changes is viewed in the process data 
table:
1. Click the Object Navigator icon on the toolbar.
2. Select the UnitOps radio button in the Filter group.
3. Select Atmos Tower and click the View button. The Atmos 
Tower property view appears.
4. Go to the Design tab and select the Monitor page.
 Figure 2.142
Object Navigator icon2-128
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Th5. Scroll down to the bottom of the Specifications table so the 
Overflash specification is visible.
A typical range for the Overflash rate is 3-5% of the tower 
feed. A slightly wider range is examined: 1.5-7.5%, which 
translates to 1500-7500 bbl/d.
6. Change the Specified Value for the Overflash specification 
from its current value of 3500 barrel/day to 1500 barrel/
day. Aspen HYSYS automatically recalculates the flowsheet.
7. Double-click on the Key Variables Data icon to restore the 
property view to its full size. The updated key variables are 
shown below. 
As a result of the change:
• the Trim Duty has decreased
• the Residue D1160 Vacuum Temperature 5% cut point 
has decreased
• the column reflux ratio has decreased
8. Press CTRL D to make the Databook active again. You can 
now record the key variables in their new state.
9. Move to the Data Recorder tab in the Databook.
10.Click the Record button, and Aspen HYSYS provides you 
with the default name State 2 for the new state.
11.Change the name to 1500 O.F. and click the OK button to 
accept the new name.
 Figure 2.1432-129
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Th12.Click the View button and the Data Recorder appears, 
displaying the new values of the variables. 
13.Record the process variables for Overflash rates of 5500 
and 7500 barrels/day. Enter names for these variable states 
of 5500 O.F. and 7500 O.F., respectively. The final Data 
Recorder appears below. 
14.Save your case by doing one of the following:
• press CTRL S.
• from the File menu, select Save.
• click the Save icon.
 Figure 2.144
 Figure 2.145
Save icon2-130
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Th2.3 Dynamic Simulation
In this tutorial, the dynamic capabilities of Aspen HYSYS are 
incorporated into a basic steady state oil refining model. 
A simple fractionation facility produces naphtha, kerosene, 
diesel, atmospheric gas oil, and atmospheric residue products 
from a heavy crude feed. In the steady state refining tutorial, 
preheated crude was fed into a pre-flash drum which separated 
the liquid crude from the vapour. The liquid crude was heated in 
a furnace and recombined with the vapour. The combined 
stream was then fed to the atmospheric crude column for 
fractionation. The dynamic refining tutorial only considers the 
crude column. That is, the crude preheat train is deleted from 
the flowsheet and only the crude column in the steady state 
refining tutorial is converted to dynamics.
The main purpose of this tutorial is to provide you with adequate 
knowledge in converting an existing steady state column to a 
This complete dynamic case has been pre-built and is located 
in the file DynTUT2.hsc in your Aspen HYSYS\Samples 
directory.
 Figure 2.1462-131
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Thdynamics column. The tutorial provides a single way of 
preparing a steady state case for dynamics mode, however, you 
can also choose to use the Dynamic Assistant to set pressure 
specifications, size the equipment in the plant, and/or add 
additional equipment to the simulation flowsheet.
This tutorial comprehensively guides you through the steps 
required to add dynamic functionality to a steady state oil 
refinery simulation. To help navigate these detailed procedures, 
the following milestones have been established for this tutorial.
1. Obtain a simplified steady state model to be converted to 
dynamics.
2. Implement a tray sizing utility for sizing the column and the 
side stripper tray sections.
3. Install and define the appropriate controllers.
In this tutorial, you follow this basic procedure in building 
the dynamic model.
4. Add the appropriate pressure-flow specifications.
5. Set up the Databook. Make changes to key variables in the 
process and observe the dynamic behaviour of the model.
2.3.1 Simplifying the Steady 
State Flowsheet
In this section, you will delete the preflash train in the steady 
state simulation case R-1.hsc:
1. Open the pre-built case file R-1.hsc. The crude column 
simulation file R-1.hsc is located in your Aspen 
HYSYS\Samples directory.
2. Press F4 to make the Object Palette visible.
For the purpose of this example, the Session Preferences are 
set so that the Dynamic Assistant will not manipulate the 
dynamic specifications.
3. From the Tools menu, select Preferences. The Session 
Preferences property view appears.
4. On the Simulation tab, select the Dynamics page. 2-132
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Th5. Clear the Set dynamic stream specifications in the 
background checkbox. 
6. Click the Variables tab, then select the Units page.
In this tutorial, you are working with SI units. The units are 
changed by entering the Preferences property view in the 
Tools menu bar. In the Units tab, specify SI in the Current 
Unit Set group.
7. In the Available Unit Sets group, select SI.
8. Click the Close icon  to close the Session Preferences 
property view. Close all other property views except for the 
PFD property view.
9. Add a material stream to the PFD by doing one of the 
following:
• From the Flowsheet menu, select Add Stream.
• Double-click the Material Stream icon on the Object 
Palette.
10. In the Stream Name cell, type Store. This stream will be 
used to store information from the Atm Feed stream.
 Figure 2.147
 Figure 2.1482-133
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Th11. In the Store stream property view, click the Define from 
Other Stream button. The Spec Stream As property view 
appears.
12. In the Available Streams group, select Atm Feed.
13.Click on the OK button to copy the Atm Feed stream 
information to the Store stream.
 Figure 2.149
 Figure 2.1502-134
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Th14.Close the Store stream property view.
15.Delete all material streams and unit operations upstream of 
the Atm Feed stream. The following eight items should be 
deleted: 
After you delete the above items, stream Atm Feed is not 
fully specified.
16.Double-click the Atm Feed stream icon to open its property 
view.
17.Click the Define from Other Stream button. The Spec 
Stream As property view appears.
18. In the Available Streams group, select Store, then click OK.
Items to be deleted
Material Streams Energy Streams Unit Operations
• Hot Crude
• PreFlsh Liq
• PreFlsh Vap
• Raw Crude
Crude Duty • PreFlash 
Separator
• Crude Heater
• Mixer
When you delete a stream, unit operation, or logical 
operation from the flowsheet, Aspen HYSYS asks you to 
confirm the deletion. If you want to delete the object, click 
the Yes button. If not, click the No button.
 Figure 2.1512-135
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Th19.Close the Atm Feed stream property view, then delete the 
stream Store.
This steady state case now contains the crude column 
without the preflash train. Since the identical stream 
information was copied to stream Atm Feed, the crude 
column operates the same as before the deletion of the 
preflash train.
20.Save the case as DynTUT2-1.hsc.
Make sure that the Standard Windows file picker radio 
button is selected on the File page in the Session 
Preferences property view. 
For more information on 
Session Preferences 
please refer to Section 
12.5 - Files Tab in the 
Aspen HYSYS User 
Guide.2-136
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Th2.3.2 Adding Equipment & 
Sizing Columns
In preparation for dynamic operation, the column and side 
stripper tray sections and surrounding equipment must be sized. 
In the steady state scenario, column pressure drop is user 
specified. In dynamics, it is calculated using dynamic hydraulic 
calculations. Complications arise in the transition from steady 
state to dynamics if the steady state pressure profile across the 
column is very different from that calculated by the Dynamic 
Pressure-Flow solver.
The Cooler operations in the pump arounds are not specified 
with the Pressure Flow or Delta P option, however, each cooler 
must be specified with a volume in order to run properly in 
dynamic mode.
Column Tray Sizing
1. Open the Utilities property view by pressing CTRL U. 
The Available Utilities property view appears.
2. Scroll down the list of available utilities until the Tray Sizing 
utility is visible.
 Figure 2.1522-137
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Th3. Select Tray Sizing, then click the Add Utility button. The 
Tray Sizing property view appears. 
4. In the Name field, change the name to Main TS.
5. Click the Select TS button. The Select Tray Section property 
view appears.
6. In the Flowsheet list, select T-100, then select Main TS in 
the Object list. Click the OK button.
 Figure 2.153
 Figure 2.1542-138
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Th7. In the Use Tray Vapour to Size drop-down list, select 
Always Yes.
8. Click the Auto Section button. The Auto Section 
Information property view appears. The default tray internal 
types appear with the Valve type selected.
9. Keep the default values and click Next. The next property 
view displays the specific dimensions of the valve-type trays.
The Valve tray type is selected as the default option. This 
option is entered into the Main TS property view.
 Figure 2.1552-139
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Th10.Keep the default values and click the Complete 
AutoSection button.
Aspen HYSYS calculates the Main TS tray sizing parameters 
based on the steady state flow conditions of the column and 
the desired tray types.
Two tray section sizes, Section_1 and Section_2, appear in 
the Setup page of the Design tab. Section_1 includes trays 1 
to 27; Section_2 includes trays 28 and 29. Since there are 
different volumetric flow conditions at each of these 
sections, two different tray section types are necessary.
11.Click the Design tab, then select the Specs page.
 Figure 2.156
 Figure 2.1572-140
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Th12.  In the Number of Flow Paths cell, enter 3 for both 
Section_1 and Section_2.
13.Click the Performance tab, then select the Results page to 
see the dimensions and configuration of the trays for 
Section_1 and Section_2. Since Section_1 is sized as having 
the largest tray diameter, its tray section parameters should 
be recorded.
14.Confirm the following tray section parameters for Section_1. 
The number of flow paths for the vapour is 3. The Actual 
Weir length is therefore the Total Weir Length recorded/3.
15.Calculate the Actual Weir length:
16.Confirm the Maximum Pressure Drop/Tray and check the 
number of trays in the Main TS column. The Total Section 
Pressure drop is calculated by multiplying the number of 
trays by the Maximum Pressure Drop/Tray.
17.Close the Tray Sizing: Main TS and Available Utilities 
property views.
18.Double-click on the Column T-100 icon in the PFD, then click 
the Column Environment button to enter the Column 
subflowsheet.
19.On the column PFD, double-click the Main TS Column icon to 
enter the Main TS property view.
20.Click the Rating tab, then select the Sizing page.
Variable Value
Section Diameter 5.639 m
Weir Height 0.0508 m
Tray Spacing 0.6096 m
Total Weir Length 13.31 m
Variable Value
Actual Weir Length (Total Weir Length/3) 4.44 m
Variable Value
Maximum Pressure Drop/Tray 0.86 kPa
Number of Trays 29
Total Section DeltaP 24.94 kPa2-141
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Th21.Enter the previous calculated values into the following tray 
section parameters:
• Diameter 5.639m
• Tray Spacing 0.6096m
• Weir Height 0.0508m
• Weir Length (Actual Weir Length) 4.44m
22. In the Internal Type group, select the Valve radio button.
23.Close the Main TS property view.
24.Access the Column property view by clicking the Column 
Runner icon in the toolbar.
Be aware that the default units for each tray section 
parameter may not be consistent with the units provided in 
the tray sizing utility. You can select the units you want from 
the drop-down list that appears beside each input cell.
 Figure 2.158
Column Runner icon2-142
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Th25.Click the Parameters tab, then select the Profiles page. 
Observe the steady state pressure profile across the column. 
26.Record the top stage pressure (1_Main TS). Calculate the 
theoretical bottom stage pressure as follows:
27. In the Pressure column of the Profiles group, specify a 
bottom stage pressure (29_Main TS) of 222.84 kPa.
28.Converge the Column sub-flowsheet by clicking the Run 
Column Solver icon in the toolbar.
29.Close the Column property view.
 Figure 2.159
Bottom Stage Pressure = Top Stage Pressure + Total 
Section Pressure Drop
(2.1)
Variable Value
Top Stage Pressure 197.9 kPa
Total Section Pressure Drop 24.94 kPa
Bottom Stage Pressure 222.84 kPa
Run Column Solver icon2-143
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ThSide Stripper Tray Sizing
In this section, you will size the following side stripper 
operations using the tray sizing utility as described in the 
Column Tray Sizing section.
• Kero_SS
• Diesel_SS
• AGO_SS
1. From the Tools menu, select Utilities. The Utilities property 
view appears.
2. Double-click on the Tray Sizing utility. The Tray Sizing 
property view appears.
3. In the Name field, change the name to Kero_SS TS. 
4. Click the Select TS button. The Select Tray Section property 
view appears.
5. From the Flowsheet list, select T-100, then select Kero_SS 
from the Object list. Click the OK button.
6. Click the Auto Section button. The Auto Section 
Information property view appears.
7. Select the Valve radio button and click the Next button. 
8. Click the Complete AutoSection button to calculate the 
Kero_SS TS tray sizing parameters.
9. Record the following tray section parameters available on 
the Performance tab in the Results page:
10.Close the Kero_SS TS tray sizing utility.
11.Repeat steps #2-#8 to size the Diesel_SS and AGO_SS 
side strippers.
Variable Kero_SS
Section Diameter 1.676 m
Weir Height 0.0508 m
Tray Spacing 0.6096 m
Total Weir Length 1.362 m
Number of Flow Paths 1
Actual Weir Length (calc) 1.362 m2-144
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Th12.Click the Performance tab, select the Results page, then 
confirm that the following tray section parameters match the 
table below: 
The pressure drop rating information found in the side 
stripper tray sizing utilities is not used to specify the 
pressure profile of the Side Stripper unit operations. Since 
there are only three trays in each side stripper, the pressure 
drop across the respective tray sections is small. Keeping 
the pressure profile across the side strippers constant does 
not greatly impact the transition from steady state mode to 
dynamics.
13.Close the Available Utilities property view.
You should still be in the Column sub-flowsheet 
environment. If not, double-click the Column T-100 and then 
click the Column Environment button on the bottom of the 
Column property view.
14. In the PFD, double-click the Kero_SS side stripper icon to 
open its property view.
15.Click the Rating tab, then select the Sizing page.
16.Specify the following tray section parameters that were 
calculated in the previous table:
• Section Diameter
• Tray Spacing
• Weir Height
• Actual Weir Length
Variable Diesel_SS AGO_SS 1 AGO_SS 2
Section Diameter 1.676 m 1.067 m 0.6096 m
Weir Height 0.0508 m 0.0508 m 0.0508 m
Tray Spacing 0.6096 m 0.6096 m 0.6096 m
Total Weir Length 3.029 m 0.7038 m 0.5542 m
Number of Flow Paths 2 1 1
Actual Weir Length (calc) 1.515 m 0.7038 m 0.5542 m2-145
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Th17.Close the Kero_SS property view.
18.Double-click the Diesel_SS icon, then specify the tray rating 
information using the table on the previous page. Close the 
property view when you are done.
19.Repeat the same procedure to specify the tray rating 
information for AGO_SS.
20.After the column has been specified with the tray rating 
information, converge the column by clicking the Run 
Column Solver icon in the toolbar.
21.Save the case as DynTUT2-2.hsc.
 Figure 2.160
Run Column Solver icon2-146
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ThVessel Sizing
The Condenser and Kero_SS_Reb operations require proper 
sizing before they can operate effectively in dynamic mode. The 
volumes of these vessel operations are determined based on a 
10 minute liquid residence time.
1. Double-click the Condenser icon on the PFD to open its 
property view.
2. Click the Worksheet tab, then select the Conditions page.
3. On the Conditions page, confirm the following Liquid 
Volumetric Flow (Std Ideal Liq Vol Flow) of the following 
streams:
 Figure 2.161
Liquid Volumetric Flow Rate (m3/h) Value
Reflux 106.7
Naphtha 152.4
Waste Water 5.736
To Condenser 264.82-147
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Th4. Calculate the vessel volume as follows, assuming a 50% 
liquid level residence volume and a 10 min. residence time:
The vessel volume calculated for the Condenser is 88.3 m3.
5. Click the Dynamics tab, then select the Specs page.
6. In the Model Details group, specify the vessel Volume as 
88.3 m3 and the Level Calculator as a Vertical Cylinder.
7. Close the Condenser property view.
8. In the PFD, double-click the Kero_SS_Reb icon to open its 
property view.
9. Click the Worksheet tab, then select the Conditions page.
(2.2)
 Figure 2.162
 Figure 2.163
Vessel Volume Total Liquid Exit Flow Residence Time×
0.5
---------------------------------------------------------------------------------------------------------------=2-148
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Th10. In the Conditions page, confirm that the Liquid Volumetric 
Flow (Std Ideal Liq Vol Flow) for Kerosene is 61.61 m3/h.
Assume a 10 minute of residence time and a 50% liquid 
level residence volume. The vessel volume calculated for the 
Kero_SS_Reb is 20.5 m3.
11.Click the Dynamics tab, then select the Specs page.
12. In the Volume cell, enter 20.5 m3. In the Level Calculator 
cell, select Horizontal Cylinder from the drop-down list.
13.Close the Kero_SS_Reb property view.
Cooler Volume Sizing
Aspen HYSYS assigns a default volume to each Cooler unit 
operation in the Column sub-flowsheet. In this section you will 
modify each pump around cooler to initialize with a default 
vessel volume.
1. Double-click the PA_1_Cooler operation in the PFD to open 
the property view.
2. Click the Dynamics tab, then select the Specs page.
3. In the Model Details group, click in the Volume cell, then 
press DELETE. The default volume of 0.10 m3 appears.
4. In the Dynamic Specifications group, ensure that all the 
specification checkboxes are clear. No dynamic specifications 
should be set for the pump around coolers. 
 Figure 2.164
 Figure 2.1652-149
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Th5. Close the PA_1_Cooler property view.
6. Repeat this process for the PA_2_Cooler and the 
PA_3_Cooler operations.
7. Save the case as DynTUT2-3.hsc.
2.3.3 Adding Controller 
Operations
Controller operations can be added before or after the transition 
to dynamic mode. Key control loops are identified and controlled 
using PID Controller logical operations. Although these 
controllers are not required to run the design in dynamic mode, 
they increase the realism of the model and provide more 
stability.
Adding a Level Controller
In this section you will add level controllers to the simulation 
flowsheet to control the levels of the condenser and reboiler.
First you will install the Condenser controller.
1. If the Object Palette is not visible, press F4.
2. In the Object Palette, click the PID Controller icon.
3. In the PFD, click near the Condenser operation. The 
controller icon, named IC-100, appears in the PFD. 
4. Double-click the IC-100 icon to open the controller property 
view. 
5. On the Connections tab, click in the Name field and change 
the name of the Controller to Cond LC.
PID Controller icon
For more information 
regarding PID 
Controller, see Section 
5.4.4 - PID Controller 
of the Aspen HYSYS 
Operations Guide.2-150
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Th6. In the Process Variable Source group, click the Select PV 
button, then select the information as shown in the figure 
below. Click the OK button when you are done.  
7. In the Output Target Object group, click the Select OP 
button, then select the information as shown in the figure 
below. Click the OK button when you are finished.  
8. Click the Parameters tab, then select the Configuration 
page.
9. Supply the following for the Configuration page: 
 Figure 2.166
 Figure 2.167
In this cell... Enter...
Action Direct
Kc 42-151
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Th10.Click the Control Valve button. The FCV for Reflux property 
view appears.
11. In the Max Flow cell of the Valve Sizing group, enter 2000 
kgmole/h. 
12.Close the FCV for Reflux property view.
13.Click the Face Plate button. The face plate for Cond LC 
appears. 
14.Change the controller mode to Auto on the face plate by 
opening the drop-down list and selecting Auto. 
15.Double-click the PV cell, then input the set point at 50%. 
16.Close the Cond LC property view, but leave the face plate 
property view open.
Ti 5 minutes
PV Minimum 0%
PV Maximum 100%
 Figure 2.168
 Figure 2.169
 Figure 2.170
In this cell... Enter...
For more information 
regarding Face Plates, 
see Section 5.13.2 - 
Controller Face Plate 
in the Aspen HYSYS 
Operations Guide.2-152
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Refining Tutorial 2-153
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Th17.Repeat the procedures you just learned to add a PID 
Controller operation which serves as the Kero_SS_Reb level 
controller. Specify the following: 
If you cannot locate a stream or operation in the Select 
Input for PV property view, select the All radio button in the 
Object Filter group and look again.
18.Click the Control Valve button. The FCV for Kero_SS_Draw 
property view appears.
19. In the Valve Sizing group, enter the following
20.Close the FCV for Kero_SS_Draw property view.
21.Click the Face Plate button. Change the controller mode to 
Auto on the face plate, then input a set point of 50%. Leave 
the face plate property view open.
22.Close the Reb LC property view.
Tab [Page] In this cell... Enter...
Connections Name Reb LC
Process Variable Source Kero_SS_Reb, Liq Percent 
Level
Output Target Object Kero_SS_Draw
Parameters 
[Configuration]
Action Reverse
Kc 1
Ti 5 minutes
PV Minimum 0%
PV Maximum 100%
In this cell... Enter...
Flow Type MolarFlow
Minimum Flow 0 kgmole/h
Maximum Flow 1000 kgmole/h2-153
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ThAdding a Flow Controller
In this section you will add flow controllers to the product 
streams of the column. These controllers ensure that sufficient 
material is leaving the column.
1. Click the PID Controller icon in the Object Palette, then click 
in the PFD near the Off Gas stream. The controller icon 
appears.
2. Double-click the controller icon to access the property view. 
Specify the following details: 
3. Click the Control Valve button. The FCV for Atmos Cond 
property view appears.
4. In the Duty Source group, ensure that the Direct Q radio 
button is selected.
5.  In the Direct Q group, enter the following details:
6. Close the FCV for Atmos Cond property view.
7. Click the Face Plate button. The Off Gas FC face plate 
property view appears. Change the controller mode to Auto, 
then input a set point of 5 kgmole/h.
8. Close the Off Gas FC property view, but leave the face plate 
property view open.
9. In the Object Palette, click the PID Controller icon, then 
click in the PFD near the Diesel stream. The controller icon 
appears in the PFD.
Tab [Page] In this cell... Enter...
Connections Name Off Gas FC
Process Variable Source Off Gas, Molar Flow
Output Target Object Atmos Cond
Parameters 
[Configuration]3
Action Direct
Kc 0.01
Ti 5 minutes
PV Minimum 0 kgmole/h
PV Maximum 100 kgmole/h
In this cell... Enter...
Minimum Available 0 kJ/h
Maximum Available 2 x 108 kJ/h2-154
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Refining Tutorial 2-155
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Th10.  Double-click the controller icon to access the property view. 
then specify the following details: 
11.Click the Control Valve button. The FCV for 
Diesel_SS_Draw property view appears.
12. In the Valve Sizing group, enter the following details:
13.Close the FCV for Diesel_SS_Draw property view.
14.Click the Face Plate button. The Diesel FC face plate 
property view appears. Change the controller mode to Auto 
and input a set point of 127.5 m3/h.
15.Close the property view, but leave the face plate property 
view open.
16.Click the PID Controller icon in the Object Palette, then 
click near the AGO stream on the PFD. The controller icon 
appears.
17.Double-click the controller icon, then specify the following 
details:   
Tab [Page] In this cell... Enter...
Connections Name Diesel FC
Process Variable Source Diesel, Liq Vol Flow@Std 
Cond
Output Target Object Diesel_SS_Draw
Parameters 
[Configuration]
Action Reverse
Kc 1
Ti 5 minutes
PV Minimum 0 m3/h
PV Maximum 250 m3/h
In this cell... Enter...
Flow Type MolarFlow
Minimum Flow 0 kgmole/h
Maximum Flow 1200 kgmole/h
Tab [Page] In this cell... Enter...
Connections Name AGO FC
Process Variable Source AGO, Liq Vol Flow@Std 
Cond
Output Target Object AGO_SS_Draw2-155
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Th18.Click the Control Valve button. The FCV for AGO_SS_Draw 
property view appears.
19. In the Valve Sizing group, enter the following details:
20.Close the FCV for AGO_SS_Draw property view.
21.Click the Face Plate button. The AGO FC face plate property 
view appears. Change the controller mode to Auto and input 
a set point of 29.8 m3/h.
22.Close the property view, but leave the face plate property 
view open.
23.Save the case as DynTUT2-4.hsc.
2.3.4 Adding Pressure-Flow 
Specifications
Before integration can begin in Aspen HYSYS, the degrees of 
freedom for the flowsheet must be reduced to zero by setting 
the pressure-flow specifications. 
Normally, you make one pressure-flow specification per 
flowsheet boundary stream, however, there are exceptions to 
the rule. One extra pressure flow specification is required for 
every condenser or side stripper unit operation attached to the 
main column. This rule applies only if there are no pieces of 
equipment attached to the reflux stream of the condenser or the 
draw stream of the side strippers. Without other pieces of 
equipment (i.e., pumps, coolers, valves) to define the pressure 
Parameters 
[Configuration]
Action Reverse
Kc 0.7
Ti 3 minutes
PV Minimum 0 m3/h
PV Maximum 60 m3/h
In this cell... Enter...
Flow Type MolarFlow
Minimum Flow 0 kgmole/h
Maximum Flow 250 kgmole/h
Tab [Page] In this cell... Enter...2-156
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Refining Tutorial 2-157
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Thflow relation of these streams, they must be specified with a 
flow specification.
Pressure-flow specifications for this case will be added to the 
following boundary streams:
• Atm Feed
• Main Steam
• AGO Steam
• Diesel Steam
• Off Gas
• Waste Water
• Naphtha
• Kerosene
• Diesel
• AGO
• Residue
This simplified column has all the feed streams specified with a 
flow specification. The Off Gas stream has a pressure 
specification which defines the pressure of the condenser and 
consequently the entire column. The liquid exit streams of the 
column and the side stripper operations require pressure 
specifications since there are no attached pieces of equipment in 
these streams. All the other exit streams associated with the 
column require flow specifications.
The following pump around streams require flow specifications 
since both the Pressure Flow and the Delta P specifications are 
not set for the pump around coolers.
• PA_1_Draw
• PA_2_Draw
• PA_3_Draw
The following streams have their flow specifications defined by 
PID Controller operations.
• Reflux
• Kero_SS_Draw
• Diesel_SS_Draw
• AGO_SS_Draw
For more information 
regarding Pressure Flow 
specifications in Column 
unit operations see 
Chapter 2 - Column 
Operations in Aspen 
HYSYS Operations 
Guide.2-157
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Th1. Enter the Main Flowsheet environment. Close the column 
property view if it is still open.
2. Switch to dynamic mode by clicking the Dynamic Mode 
icon. When asked if you want to allow dynamics assistant to 
identify items which are needed to be addressed before 
proceeding into dynamics, click the No button.
Every material stream in the Main Flowsheet requires either 
a pressure or flow specification.
3. Double-click the Diesel Steam icon to enter its property 
view.
4. Click the Dynamics tab, then select the Specs page.
5. In the Pressure Specification group, clear the Active 
checkbox.
6. In the Flow Specification group, select the Molar radio 
button, then select the Active checkbox.
7. In the Molar Flow cell, enter 75.54 kgmole/h if required.
Once a pressure or flow specification has been made active, 
the stream value turns blue and can be modified.
 Figure 2.171
Enter Parent Simulation 
Environment icon
Dynamic Mode icon2-158
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ThSet the following pressure or flow specifications for the 
following streams in the Main Flowsheet.
8. Use the Object Navigator to enter the Column subflowsheet 
environment. Click the Object Navigator icon in the 
toolbar. The Object Navigator property view appears. In the 
Flowsheets group, double-click T-100.
Every material stream in the column environment also 
requires either a pressure or flow specification. Use the 
following procedure to set a pressure-flow specification for 
the PA_1_Draw stream.
9. In the PFD, double-click the PA_1_Draw stream icon to open 
the property view.
10.Click the Dynamics tab, then select the Specs page.
Material Stream Pressure Specification Flow Specification Value
Atm Feed Inactive Molar Flow, Active 2826 kgmole/h
Main Steam Inactive Molar Flow, Active 188.8 kgmole/h
AGO Steam Inactive Molar Flow, Active 62.95 kgmole/h
Off Gas Active Inactive 135.8 kPa
Waste Water Inactive Molar Flow, Active 317.8 kgmole/h
Naphtha Inactive Ideal LiqVol, Active 152.4 m3/h
Kerosene Inactive Ideal LiqVol, Active 61.61 m3/h
Diesel Active Inactive 211.4 kPa
AGO Active Inactive 215.6 kPa
Residue Active Inactive 221.6 kPa2-159
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2-160 Dynamic Simulation
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Th11. In the Flow Specification group, select the Molar radio 
button, then select the Active checkbox.
12.Close the PA_1_Draw property view.
13.Activate the following flow specifications for the following 
streams in the Column sub-flowsheet.
14.Save the case as DynTUT2-5.hsc.
15.Close all the property views except the face plates.
16. To arrange the face plates, select the Arrange Desktop 
command from the Windows menu.
17. The integrator can be run at this point. Click the Start 
Integrator icon. When you are given the option to run 
dynamic assistant, select No.
 Figure 2.172
Material Stream Pressure-Flow Specification Value
PA_2_Draw Molar Flow 830.2 kgmole/h
PA_3_Draw Molar Flow 648.0 kgmole/h
Reflux Molar Flow 879.7 kgmole/h
Kero_SS_Draw Molar Flow 426.6 kgmole/h
Diesel_SS_Draw Molar Flow 616.8 kgmole/h
AGO_SS_Draw Molar Flow 124.8 kgmole/h
Start Integrator icon2-160
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ThWhen the integrator initially runs, Aspen HYSYS detects that 
no vapour phase exists in the Condenser at the specified 
process conditions. It displays the following message:
Aspen HYSYS recommends that you increase the 
temperature setting to create a vapour phase. You can also 
create a non-equilibrium vapour phase or set the liquid level 
to be 100%. For the sake of this example, select the default 
recommendation.
18.Click the Increase Temperature button.
19. Let the integrator run for few minutes so all the values can 
propagate through the column. Observe the value changes 
on the face plate property view. 
20. To stop the integrator, click the Stop Integrator icon.
 Figure 2.1732-161
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Th2.3.5 Monitoring in Dynamics
Now that the model is ready to run in dynamic mode, the next 
step is to install a strip chart to monitor the general trends of 
key variables. The following is a general procedure for installing 
strip charts in Aspen HYSYS.
1. Open the Databook by using the hot key combination CTRL 
D.
2. On the Variables tab, click the Insert button. The Variable 
Navigator property view appears. 
The Variable Navigator is used extensively in Aspen HYSYS 
for locating and selecting variables. The Navigator operates 
in a left-to-right manner-the selected Flowsheet determines 
the Object list, the chosen Object dictates the Variable list, 
and the selected variable determines whether any Variable 
Specifics are available.
3. In the Flowsheet list, select the Column T-100.
4. In the Object Filter group, select the UnitOps radio button. 
The Object list is filtered to show unit operations only.
5. In the Object list, select the Condenser. The Variable list 
available for the column appears to the right of the Object 
list.
 Figure 2.1742-162
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Th6. In the Variable list, select Liquid Percent Level.
7. Click the OK button. The variable now appears in the 
Databook.
8. Add the following variables to the Databook.
If you select the top variable in the list of Available Data 
Entries before inserting a new variable, the new variable will 
always be added to the top of the list. 
The next task is to create a Strip Chart to monitor the 
dynamics behaviour of the selected variables.
9. Click the Strip Charts tab in the Databook property view.
10.Click the Add button. Aspen HYSYS creates a new Strip 
Chart with the name DataLogger1.
 Figure 2.175
Object Variable
Kero_SS_Reb Liquid Percent Level
Off Gas Molar Flow
Condenser Vessel Temperature
If you can’t find an Object in the Variable Navigator property 
view, select the All radio button in the Object Filter group, 
then select Case (Main) in the Flowsheet group. All 
operations and streams for the design will appear in the 
Object list.2-163
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Th11.Click in the blank Active checkbox beside the Condenser/
Liquid Percent Level variable.2-164
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Chemicals Tutorial 3-1
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Th3  Chemicals Tutorial3-1
3.1  Introduction................................................................................... 2
3.2  Steady State Simulation................................................................. 3
3.2.1  Process Description .................................................................. 3
3.2.2  Setting Your Session Preferences................................................ 4
3.2.3  Building the Simulation ............................................................. 7
3.2.4  Defining the Reaction.............................................................. 18
3.2.5  Entering the Simulation Environment ........................................ 28
3.2.6  Using the Workbook................................................................ 31
3.2.7  Installing Equipment on the PFD............................................... 52
3.2.8  Viewing Results...................................................................... 76
3.3  Dynamic Simulation ..................................................................... 88
3.3.1  Simplifying the Steady State Flowsheet ..................................... 89
3.3.2  Using the Dynamics Assistant .................................................. 91
3.3.3  Modeling a CSTR Open to the Atmosphere ................................. 95
3.3.4  Adding Controller Operations ................................................... 99
3.3.5  Monitoring in Dynamics..........................................................105
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3-2 Introduction
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Th3.1 Introduction
In this tutorial, a flowsheet for the production of propylene 
glycol is presented. Propylene oxide is combined with water to 
produce propylene glycol in a continuously-stirred-tank reactor 
(CSTR). The reactor outlet stream is then fed to a distillation 
tower, where essentially all the glycol is recovered in the tower 
bottoms. A flowsheet for this process appears below. 
The following pages will guide you through building a Aspen 
HYSYS case for modeling this process. This example will 
illustrate the complete construction of the simulation, including 
selecting a property package and components, defining the 
reaction, installing streams and unit operations, and examining 
the final results. The tools available in Aspen HYSYS interface 
will be utilized to illustrate the flexibility available to you. 
 Figure 3.1
The complete case for this tutorial has been pre-built and is 
located in the file TUTOR3.HSC in your Aspen 
HYSYS\Samples directory.
Before proceeding, you should have read Chapter A - Aspen 
HYSYS Tutorials which precedes the tutorials in this guide.3-2
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Th3.2 Steady State 
Simulation
3.2.1 Process Description
The process being modeled in this example is the conversion of 
propylene oxide and water to propylene glycol in a CSTR 
Reactor. The reaction products are then separated in a 
distillation tower. A flowsheet for this process appears below. 
The propylene oxide and water feed streams are combined in a 
Mixer. The combined stream is fed to a Reactor, operating at 
atmospheric pressure, in which propylene glycol is produced. 
The Reactor product stream is fed to a distillation tower, where 
essentially all the glycol is recovered in the bottoms product. 
The two primary building tools, Workbook and PFD, are used to 
install the streams and operations, and to examine the results 
while progressing through the simulation. Both of these tools 
provide you with a large amount of flexibility in building your 
simulation and in quickly accessing the information you need.
 Figure 3.2
The simulation will be built using these basic steps:
1. Create a unit set.
2. Choose a property package.
3. Select the components.
4. Define the reaction.
5. Create and specify the feed streams.
6. Install and define the Mixer and 
Reactor.
7. Install and define the Distillation 
Column.3-3
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3-4 Steady State Simulation
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ThThe Workbook is used to build the first part of the flowsheet, 
including the feed streams and the mixer. The PFD is then used 
to install the reactor, and a special sequence of property views 
called the Input Expert will be used to install the distillation 
column.
3.2.2 Setting Your Session 
Preferences
Start Aspen HYSYS and create a new case. Your first task is to 
set your Session Preferences.
1. From the Tools menu, select Preferences. The Session 
Preferences property view appears.     
2. The Simulation tab, Options page should be visible. 
Ensure that the Use Modal Property Views checkbox is 
clear.
The Workbook displays information about streams and unit 
operations in a tabular format, while the PFD is a graphical 
representation of the flowsheet.
 Figure 3.33-4
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Chemicals Tutorial 3-5
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Th3. Click the Variables tab, then select the Units page.
Creating a New Unit Set
The first task you perform when building the simulation case is 
choosing a unit set. Aspen HYSYS does not allow you to change 
any of the three default unit sets listed, however, you can create 
a new unit set by cloning an existing one. For this tutorial, you 
will create a new unit set based on the Aspen HYSYS Field set, 
then customize it
1. In the Available Units Sets list, select Field.
The default unit for Liq. Vol. Flow is barrel/day; next you 
will change the Liq. Vol. Flow units to USGPM.  
The default Preference file is named Aspen HYSYS.prf. 
When you modify any of the preferences, you can save the 
changes in a new Preference file by clicking the Save 
Preference Set button. Aspen HYSYS prompts you to 
provide a name for the new Preference file, which you can 
later recall into any simulation case by clicking the Load 
Preference Set button.
2. Click the Clone button. A new unit set named NewUser 
appears in the Available Unit Sets list.
 Figure 3.43-5
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3-6 Steady State Simulation
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Th3. In the Unit Set Name field, change the name to Field-
USGPM. You can now change the units for any variable 
associated with this new unit set.
4. Find the Liq. Vol. Flow cell. Click in the barrel/day cell 
beside it.
5. To open the list of available units, click the down arrow , or 
press the F2 key then the Down arrow key. 
6. From the list, select USGPM. 
7. The new unit set is now defined. Close the Session 
Preferences property view.
 Figure 3.53-6
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Th3.2.3 Building the Simulation
1. Click the New Case icon.
The Simulation Basis Manager appears. 
2. The next task is to create a Fluid Package. 
A Fluid Package, at minimum, contains the components and 
property method that Aspen HYSYS will use in its 
calculations for a particular flowsheet. Depending on what a 
specific flowsheet requires, a Fluid Package may also contain 
other information such as reactions and interaction 
parameters.
All commands accessed via the toolbar are also available as 
menu items.
 Figure 3.6
Aspen HYSYS displays the current Environment and Mode in 
the upper right corner of the property view. Whenever you 
begin a new case, you are automatically placed in the Basis 
Environment, where you can define your property package 
and components.
New Case Icon3-7
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3-8 Steady State Simulation
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ThSelecting Components
Now that you have chosen the property package to be used in 
the simulation, your next task is to select the components. 
1. On the Components tab of the Simulation Basis Manager 
property view, click the Add button in the Component Lists 
group. The Component List property view appears.   
Each component can appear in three forms, corresponding 
to the three radio buttons that appear above the component 
list.
Based on the selected radio button, Aspen HYSYS locates 
the component(s) that best matches the information you 
type in the Match field.
 Figure 3.7
Feature Description
Sim Name The name appearing within the simulation.
Full Name/Synonym IUPAC name (or similar), and synonyms for many 
components.
Formula The chemical formula of the component. This is 
useful when you are unsure of the library name of 
a component, but know its formula.3-8
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Chemicals Tutorial 3-9
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ThIn this tutorial you will use propylene oxide, propylene 
glycol, and H2O. First, you will add propylene oxide to 
the component list.
2. Ensure the Sim Name radio button is selected and the 
Show Synonyms checkbox is selected.
3. In the Match field, start typing propyleneoxide, as one 
word. Aspen HYSYS filters the list as you type, displaying 
only those components that match your input. 
4. When propylene oxide is selected in the list, add it to the 
Selected Components List by doing one of the following:
• Press the ENTER key.
• Click the Add Pure button.
• Double-click on PropyleneOxide.
 Figure 3.83-9
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3-10 Steady State Simulation
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ThThe component now appears in the Selected Components 
list.     
Another method for finding components is to use the View 
Filters to display only those components belonging to 
certain families.
Next, you will add Propylene Glycol to the component list 
using the filter. 
5. Ensure the Match field is empty by pressing ALT M and then 
the DELETE key.
6. Click the View Filters button. The Filters property view 
appears.
7. Select the Use Filter checkbox to activate the filter 
checkboxes.
8. Since Propylene Glycol is an alcohol, click the Alcohols 
checkbox.
 Figure 3.93-10
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Chemicals Tutorial 3-11
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Th9. In the Match field, begin typing propyleneglycol, as one 
word. Aspen HYSYS filters as you type, displaying only the 
alcohols that match your input.   
10.When Propylene Glycol is selected in the list, press the 
ENTER key to add it to the Selected Components list.
Finally, you will add the component H2O.
11. In the Filter property view, clear the Alcohols checkbox by 
clicking on it.
12. Ensure the Match field is empty by pressing ALT M and then 
the DELETE key
13.H2O does not fit into any of the standard families, so click 
on the Miscellaneous checkbox.
14.Scroll down the filtered list until H2O is visible, then double-
click on H2O to add it to the Selected Components list.
 Figure 3.103-11
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3-12 Steady State Simulation
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Th15.The final component list appears below. 
Viewing Component Properties
To view the properties of one or more components, select the 
component(s) and click the View Component button. Aspen 
HYSYS opens the property view(s) for the component(s) you 
select.
 Figure 3.11
A component 
can be removed 
from the 
Selected 
Components 
list by selecting 
the component 
and clicking the 
Remove 
button or the 
DELETE key.3-12
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Chemicals Tutorial 3-13
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Th1. Click on 12-C3diol in the Selected Components list.
2. Click the View Component button. The property view for 
the component appears.  
The Component property view provides you with complete 
access to the pure component information for viewing only. 
You cannot modify any parameters for a library component, 
however, Aspen HYSYS allows you to clone a library 
component into a Hypothetical component, which can then 
be modified as desired. 
3. Close the individual component property view, then close the 
Component List property view to return to the Simulation 
Basis Manager.
Creating a Fluid Package
1. Click the Fluid Pkgs tab of the Simulation Basis Manager.
The Simulation Basis Manager allows you to create, 
modify, and otherwise manipulate Fluid Packages in your 
simulation case. Most of the time, as with this example, you 
will require only one Fluid Package for your entire 
simulation.
 Figure 3.12
Refer to Chapter 3 - 
Hypotheticals in the 
Aspen HYSYS 
Simulation Basis guide 
for more information on 
cloning library 
components.3-13
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3-14 Steady State Simulation
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Th2. Click the Add button. The Fluid Package property view 
appears. 
The Fluid Package property view allows you to supply all the 
information required to completely define the Fluid Package. 
In this tutorial you will use the following tabs: Set Up, 
Binary Coeffs (Binary Coefficients), and Rxns (Reactions).
You will select the Property Package on the Set Up tab. The 
currently selected property package is . There are a 
number of ways to select the desired base property package, 
in this case UNIQUAC.
3. Do one of the following:
• Begin typing UNIQUAC, and Aspen HYSYS finds the 
match to your input.
 Figure 3.13
Aspen HYSYS has created a Fluid Package with the default 
name Basis-1. You can change the name of this fluid package 
by typing a new name in the Name cell at the bottom of the 
property view.3-14
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Chemicals Tutorial 3-15
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Th• Use the vertical scroll bar to move down the list until 
UNIQUAC becomes visible, then click on it.    
The Property Pkg indicator bar at the bottom of the 
property view now indicates UNIQUAC is the current 
property package for this Fluid Package.    
Alternatively, you can select the Activity Models radio 
button in the Property Package Filter group, producing a 
list of only those property packages which are Activity 
Models. 
 Figure 3.14
 Figure 3.153-15
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3-16 Steady State Simulation
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ThUNIQUAC appears in the filtered list, as shown in the figure 
below. 
In the Component List Selection drop-down list, Aspen 
HYSYS filters to the library components to include only those 
appropriate for the selected Property Package. In this case, 
Component List - 1 is selected as it is the only list you have 
created.
Providing Binary Coefficients
The next task in defining the Fluid Package is providing the 
binary interaction parameters.
1. Click the Binary Coeffs tab of the Fluid Package property 
view.
 Figure 3.16
 Figure 3.173-16
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Chemicals Tutorial 3-17
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ThIn the Activity Model Interaction Parameters group, the Aij 
interaction table appears by default. Aspen HYSYS 
automatically inserts the coefficients for any component 
pairs for which library data is available. You can change any 
of the values provided by Aspen HYSYS if you have data of 
your own.
In this case, the only unknown coefficients in the table are 
for the 12C3Oxide/12-C3diol pair. You can enter these 
values if you have available data, however, for this example, 
you will use one of Aspen HYSYS' built-in estimation 
methods instead. 
Next, you will use the UNIFAC VLE estimation method to 
estimate the unknown pair.
2. In the Coeff Estimation group, ensure the UNIFAC VLE 
radio button is selected.
3. Click the Unknowns Only button. Aspen HYSYS provides 
values for the unknown pair. The final Activity Model 
Interaction Parameters table for the Aij coefficients appears 
below.    
4. To view the Bij coefficient table, select the Bij radio button. 
For this example, all the Bij coefficients will be left at the 
default value of zero.
 Figure 3.183-17
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3-18 Steady State Simulation
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Th3.2.4 Defining the Reaction
1. Return to the Simulation Basis Manager property view by 
clicking on its title bar, or by clicking the Home View icon.
2. Click the Reactions tab. This tab allows you to define all the 
reactions for the flowsheet.    
The reaction between water and propylene oxide to produce 
propylene glycol is as follows: 
Selecting the Reaction Components
The first task in defining the reaction is choosing the 
components that will be participating in the reaction. In this 
tutorial, all the components that were selected in the Fluid 
Package are participating in the reaction, so you do not have to 
 Figure 3.19
                
(3.1)
These steps will be followed in defining our reaction:
1. Create and define a Kinetic 
Reaction.
2. Create a Reaction Set containing 
the reaction.
3. Activate the Reaction set to make 
it available for use in the 
flowsheet.
Home View Icon
H2O C3H6O+ C3H8O2→3-18
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Thmodify this list. For a more complicated system, however, you 
would add or remove components from the list.
To add or remove a component, click the Add Comps button. 
The Component List property view appears.
Creating the Reaction
Once the reaction components have been chosen, the next task 
is to create the reaction.
1. In the Reactions group, click the Add Rxn button. 
The Reactions property view appears. 
2. In the list, select the Kinetic reaction type, then click the 
Add Reaction button. 
The Kinetic Reaction property view appears, opened to the 
Stoichiometry tab. 
 Figure 3.20
 Figure 3.21
Refer to the Providing 
Binary Coefficients 
section in Section 3.2.3 
- Building the 
Simulation for more 
information.3-19
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3-20 Steady State Simulation
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ThOn the Stoichiometry tab, you can specify which of the Rxn 
Components are involved in the particular reaction as well as 
the stoichiometry and the reaction order.
3. In the Component column, click in the cell labeled **Add 
Comp**.
4. Select Water as a reaction component by doing one of the 
following:
• Open the drop-down list and select H2O from the list of 
available reaction components.
• Type H2O. Aspen HYSYS filters as you type, searching for 
the component which matches your input. When H2O is 
selected, press the ENTER key to add it to the 
Component list.
5. Repeat this procedure to add 12C3Oxide and 12-C3diol to 
the reaction table.
The next task is to enter the stoichiometric information. A 
negative stoichiometric coefficient indicates that the 
component is consumed in the reaction, while a positive 
coefficient indicates the component is produced.
6. In the Stoich Coeff column, click in the  cell 
corresponding to H2O.
7. Type -1 and press the enter key.
Often you will have more than one reaction occurring in your 
simulation case. On the Stoichiometry tab of each reaction, 
select only the Rxn Components participating in that 
reaction.3-20
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Th8. Enter the coefficients for the remaining components as 
shown in the property view below:  
Once the stoichiometric coefficients are supplied, the 
Balance Error cell will show 0 (zero), indicating that the 
reaction is mass balanced. Aspen HYSYS will also calculate 
and display the heat of reaction in the Reaction Heat cell. 
In this case, the Reaction Heat is negative, indicating that 
the reaction produces heat (exothermic).
Aspen HYSYS provides default values for the Forward 
Order and Reverse Order based on the reaction 
stoichiometry. The kinetic data for this Tutorial is based on 
an excess of water, so the kinetics are first order in 
Propylene Oxide only. 
 Figure 3.223-21
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3-22 Steady State Simulation
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Th9. In the Fwd Order cell for H2O, change the value to 0 to 
reflect the excess of water. The Stoichiometry tab is now 
completely defined and appears as shown below.  
The next task is to define the reaction basis.
10. In the Kinetic Reaction property view, click the Basis tab.
11. In the Basis cell, accept the default value of Molar Concn.
12.Click in the Base Component cell. By default, Aspen HYSYS 
has chosen the first component listed on the Stoichiometry 
tab, in this case H2O, as the base component. 
13.Change the base component to Propylene Oxide by doing 
one of the following:
• Open the drop-down list of components and select 
12C3Oxide.
• Begin typing 12C3Oxide, and Aspen HYSYS filters as you 
type. When 12C3Oxide is selected, press the ENTER 
key.
 Figure 3.23
Notice that the default 
values for the Forward 
Order and Reverse 
Order appear in red, 
indicating that they are 
suggested by Aspen 
HYSYS. When you enter 
the new value for H2O, 
it will be blue, indicating 
that you have specified 
it.3-22
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Th14. In the Rxn Phase cell, select CombinedLiquid from the 
drop-down list. The completed Basis tab appears below. 
The Min. Temperature, Max. Temperature, Basis Units, 
and Rate Units are acceptable at their default values.
15.Click the Parameters tab. On this tab you provide the 
Arrhenius parameters for the kinetic reaction. In this case, 
there is no Reverse Reaction occurring, so you only need 
to supply the Forward Reaction parameters.
16. In the Forward Reaction A cell, enter 1.7e13.
17. In the Forward Reaction E cell (activation energy), enter 
3.24e4 (Btu/lbmole).
The status indicator at the bottom of the Kinetic Reaction 
property view changes from Not Ready to Ready, 
indicating that the reaction is completely defined. The final 
 Figure 3.24
You can have the same reaction occurring in different phases 
with different kinetics and have both calculated in the same 
REACTOR.3-23
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3-24 Steady State Simulation
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ThParameters tab appears below. 
18.Close both the Kinetic Reaction property view and the 
Reactions property view.
19.Click the Home View icon to ensure the Simulation Basis 
Manager property view is active. On the Reactions tab, the 
new reaction, Rxn-1, now appears in the Reactions group. 
The next task is to create a reaction set that will contain the 
new reaction. In the Reaction Sets list, Aspen HYSYS 
provides the Global Rxn Set (Global Reaction Set) which 
contains all of the reactions you have defined. In this 
tutorial, since there is only one REACTOR, the default Global 
Rxn Set could be attached to it, however, for illustration 
 Figure 3.25
 Figure 3.26
Home View Icon3-24
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Thpurposes, a new reaction set will be created.
Creating a Reaction Set
Reaction Sets provide a convenient way of grouping related 
reactions. For example, consider a flowsheet in which a total of 
five reactions are taking place. In one REACTOR operation, only 
three of the reactions are occurring (one main reaction and two 
side reactions). You can group the three reactions into a 
Reaction Set, then attach the set to the appropriate REACTOR 
unit operation.
1. In the Reaction Sets group, click the Add Set button. The 
Reaction Set property view appears with the default name 
Set-1. 
2. In the Active List, click in the cell labeled .
3. Open the drop-down list and select Rxn-1. 
The drop-down list contains all reactions in the Global 
Reaction Set. Currently, Rxn-1 is the only reaction defined, 
so it is the only available selection.
A checkbox labeled OK automatically appears next to the 
reaction in the Active List.
The reaction set status bar changes from Not Ready to 
The same reaction(s) can be in multiple Reaction Sets.
 Figure 3.273-25
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3-26 Steady State Simulation
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ThReady, indicating that the new reaction set is complete. 
4. Close the Reaction Set property view to return to the 
Simulation Basis Manager. The new reaction set named 
Set-1 now appears in the Reaction Sets group.  
Making the Reaction Set Available to 
the Fluid Package
The final task is to make the set available to the Fluid Package, 
which also makes it available in the flowsheet.
1. Click on Set-1 in the Reaction Sets group on the Reactions 
tab.
2. Click the Add to FP button. 
 Figure 3.283-26
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Chemicals Tutorial 3-27
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ThThe Add 'Set-1' view appears.
3. Select Basis-1, then click the Add Set to Fluid Package 
button. 
 Figure 3.29
 Figure 3.30
This property view prompts you to 
select the Fluid Package to which you 
would like to add the reaction set. In 
this example, there is only one Fluid 
Package, Basis-1.3-27
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3-28 Steady State Simulation
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Th4. Click the Fluid Pkgs tab to view a summary of the 
completed Fluid Package.
The list of Current Fluid Packages displays the new Fluid 
Package, Basis-1, showing the number of components (NC) 
and property package (PP). The new Fluid Package is 
assigned by default to the Main Simulation, as shown in the 
Flowsheet - Fluid Pkg Associations group. Now that the 
Basis is defined, you can install streams and operations in 
the Simulation environment (also referred to as the Parent 
Simulation environment or Main Simulation environment). 
3.2.5 Entering the Simulation 
Environment
To leave the Basis environment and enter the Simulation 
environment, do one of the following:
• Click the Enter Simulation Environment button on the 
Simulation Basis Manager.
• Click the Enter Simulation Environment icon on the 
toolbar.
When you enter the Simulation environment, the initial property 
view that appears is dependent on your current preference 
setting for the Initial Build Home View. Three initial property 
 Figure 3.31
Enter Simulation 
Environment Icon3-28
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Thviews are available, namely the PFD, Workbook and Summary. 
Any or all of these can be displayed at any time, however, when 
you first enter the Simulation environment, only one is 
displayed. For this tutorial, the initial home property view is the 
Workbook (Aspen HYSYS default setting).   
There are several things to note about the Main Simulation 
environment. 
• In the upper right corner, the Environment has changed 
from Basis to Case (Main). 
 Figure 3.323-29
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3-30 Steady State Simulation
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Th• A number of new items are now available on the Menu 
and Toolbar, and the Workbook and Object Palette are 
open on the Desktop. These two latter objects are 
described below.
Before proceeding any further to install streams or unit 
operations, save your case.
1. Do one of the following:
• Click the Save icon on the toolbar.
• From the File menu, select Save.
• Press CTRL S.
If this is the first time you have saved your case, the Save 
Simulation Case As property view appears. By default, the 
File Path is the Cases sub-directory in your Aspen HYSYS 
directory.
2. In the File Name cell type a name for the case, for example 
GLYCOL. You do not have to enter the.hsc extension; 
Aspen HYSYS automatically adds it for you.
3. Once you have entered a file name, press the ENTER key or 
the OK button. 
Aspen HYSYS will now save the case under the name you 
have given it when you Save in the future. 
The Save As property view will not appear again unless you 
choose to give it a new name using the Save As command.
Features  Description
Workbook A multiple-tab property view containing information about 
the objects (streams and unit operations) in the simulation 
case. 
By default, the Workbook has four tabs, namely Material 
Streams, Compositions, Energy Streams and Unit 
Ops. You can edit the Workbook by adding or deleting 
tabs and changing the information displayed on any tab.
Object 
Palette 
A floating palette of buttons that can be used to add 
streams and unit operations.
You can toggle the palette open or closed by pressing F4, 
or by choosing Open/Close Object Palette from the 
Flowsheet menu.
If you enter a name that already exists in the current 
directory, Aspen HYSYS will ask you for confirmation before 
over-writing the existing file.
Save Icon3-30
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Th3.2.6 Using the Workbook
Installing the Feed Streams
In general, the first task you perform when you enter the 
Simulation environment is to install one or more feed streams. 
In this section, you will install feed streams using the Workbook.
1. Click the Workbook icon on the toolbar to make the 
Workbook active.
2. On the Material Streams tab, click in the **New** cell in 
the Name row.
3. Type the new stream name Prop Oxide, then press ENTER. 
Aspen HYSYS automatically creates the new stream. 
When you pressed ENTER after typing in the stream name, 
Aspen HYSYS automatically advanced the active cell down 
one cell, to Vapour Fraction.
Next you will define the feed conditions for temperature and 
pressure, in this case 75°F and 1.1 atm. 
4. Click in the Temperature cell for Prop Oxide.
Aspen HYSYS accepts blank spaces within a stream or 
operation name.
 Figure 3.33
Workbook Icon3-31
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3-32 Steady State Simulation
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Th5. Type 75 in the Temperature cell. In the Unit drop-down 
list, Aspen HYSYS displays the default units for temperature, 
in this case F.      
6. Since this is the correct unit, press ENTER. Aspen HYSYS 
accepts the temperature. 
7. Click in the Pressure cell for Prop Oxide.
If you know the stream pressure in another unit besides the 
default of psia, Aspen HYSYS will accept your input in any 
one of a number of different units and automatically convert 
to the default for you. For example, you know the pressure 
of Prop Oxide is 1.1 atm. 
8. Type 1.1.
 Figure 3.343-32
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Chemicals Tutorial 3-33
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Th9. Press the SPACE BAR or click on . Begin typing ‘atm’. 
Aspen HYSYS will match your input to locate the unit of your 
choice.  
10.Once atm is selected in the list, press the ENTER key, and 
Aspen HYSYS accepts the pressure and automatically 
converts to the default unit, psia.
Alternatively, you can specify the unit simply by selecting it 
from the unit drop-down list.
11.Click in the Molar Flow cell for Prop Oxide, enter 150 
lbmole/hr, then press ENTER.
 Figure 3.353-33
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3-34 Steady State Simulation
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ThProviding Compositional Input
Now that the stream conditions have been specified, your next 
task is to input the composition.
1. In the Workbook, double-click the Molar Flow cell of the 
Prop Oxide stream.
The Input Composition for Stream property view appears. 
This property view allows you to complete the compositional 
input.
The Input Composition for Stream property view is Modal, 
indicated by the thick border and the absence of the 
Minimize/Maximize buttons in the upper right corner. 
When a Modal property view is visible, you will not be able to 
move outside the property view until you finish with it, by 
clicking either the Cancel or OK button.
 Figure 3.363-34
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ThThe following table lists and explains the features available 
to you on the Input Composition for Stream property view.
2. In the Composition Basis group, ensure that the Mole 
Fractions radio button is selected.
3. Click on the input cell for the first component, 12C3Oxide. 
This stream is 100% propylene oxide.
4. Type 1 for the mole fraction, then press ENTER.
In this case, 12C3Oxide is the only component in the 
stream.
Features Description
Composition 
Basis Radio 
Buttons
You can input the stream composition in some 
fractional basis other than Mole Fraction, or by 
component flows, by selecting the appropriate radio 
button before providing your input.
Normalizing The Normalizing feature is useful when you know the 
relative ratios of components; for example, 2 parts 
N2, 2 parts CO2, 120 parts C1, etc. Rather than 
manually converting these ratios to fractions summing 
to one, simply enter the individual numbers of parts 
and click the Normalize button. Aspen HYSYS 
computes the individual fractions to total 1.0.
Normalizing is also useful when you have a stream 
consisting of only a few components. Instead of 
specifying zero fractions (or flows) for the other 
components, simply enter the fractions (or the actual 
flows) for the non-zero components, leaving the 
others . Click the Normalize button, and 
Aspen HYSYS forces the other component fractions to 
zero.
Calculation 
status/colour
As you input the composition, the component fractions 
(or flows) initially appear in red, indicating the final 
composition is unknown. These values become blue 
when the stream composition is calculated. 
Three scenarios result in the stream composition being 
calculated:
• Input the fractions of all components, including 
any zero components, such that their total is 
exactly 1.0000. Click the OK button.
• Input the fractions (totalling 1.000), flows or 
relative number of parts of all non-zero 
components. Click the Normalize button, then 
click the OK button.
• Input the flows or relative number of parts of all 
components, including any zero components, 
then click the OK button.
The colours mentioned above are the default colours; 
yours may appear differently depending on your 
settings on the Colours page of the Session 
Preferences.3-35
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3-36 Steady State Simulation
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Th5. Click the Normalize button to force the other values to 
zero. The composition is now defined for this stream. 
6. Click the OK button. Aspen HYSYS accepts the composition. 
The stream specification is now complete, so Aspen HYSYS 
will flash it at the conditions given to determine the 
remaining properties.
The values you specified are a different colour (blue) than 
the calculated values (black). 
 Figure 3.37
 Figure 3.38
If you want to delete a stream, click on the Name cell for the 
stream, then press DELETE. Aspen HYSYS asks for 
confirmation of your action.3-36
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ThAdding Another Stream
Next, you will use an alternative method for adding a stream.
1. To add the second feed stream, do any one of the following:
• Press F11.
• From the Flowsheet menu, select Add Stream.
• Double-click the Material Stream icon on the Object 
Palette.
• Click the Material Stream icon on the Object Palette, 
then click the Palette's Add Object button.
A new stream appears in the Workbook and is named 
according to the Auto Naming setting in your Session 
Preferences settings. The default setting names new 
material streams with numbers, starting at 1 (and energy 
streams starting at Q-100).
When you create the new stream, the stream’s property 
view also appears, displaying the Conditions page of the 
Worksheet tab.
2. In the Stream Name cell, change the name to Water 
Feed.
3. In the Temperature cell, enter 75°F.
These parameters are in default units, so there is no need to 
change the units.
Material 
Stream Icon
Add Object 
Icon3-37
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3-38 Steady State Simulation
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Th4. In the Pressure cell, enter 16.17 psia. 
5. Select the Composition page to enter the compositional 
input for the new feed stream.   
6. Click the Edit button near the bottom of the Composition 
page. The Input Composition for Stream property view 
appears.
 Figure 3.39
 Figure 3.403-38
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ThFor the current Composition Basis setting, you want to 
enter the stream composition on a mass flow basis.
7. In the Composition Basis group, change the basis to Mass 
Flows by selecting the appropriate radio button, or by 
pressing ALT A.
8. In the CompMassFlow cell for H2O, type 11,000 (lb/hr), 
then press ENTER.  
9. Since this stream has no other components, click the OK 
button. The other component mass flows are forced to zero.
Aspen HYSYS performs a flash calculation to determine the 
unknown properties of Water Feed, and the status bar 
 Figure 3.41
 Figure 3.423-39
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3-40 Steady State Simulation
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Thdisplays a green OK message. Use the horizontal scroll bar in 
the table to view the compositions of each phase. 
The compositions currently appear in Mass Flow, but you can 
change this by clicking the Basis button and choosing 
another Composition Basis radio button. 
10.Click the Conditions page to view the calculated stream 
properties. You can display the properties of all phases by 
resizing the property view
11. Place the cursor over the right border of the property view. 
The cursor changes to a double-ended sizing arrow.
 Figure 3.43
Sizing Arrow Icon3-40
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Th12.With the sizing arrow visible, click and drag to the right until 
the horizontal scroll bar disappears, making the entire table 
visible. 
In this case, the aqueous phase is identical to the overall 
phase.
13.Close the Water Feed property view to return to the 
Workbook.
Installing Unit Operations
Now that the feed streams are known, your next task is to 
install the necessary unit operations for producing the glycol.
 Figure 3.44
New or updated information is automatically and instantly 
transferred among all locations in Aspen HYSYS.3-41
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ThInstalling the Mixer
The first operation is a Mixer, used to combine the two feed 
streams. As with most commands in Aspen HYSYS, installing an 
operation can be accomplished in a number of ways. One 
method is through the Unit Ops tab of the Workbook.
1. Click the Workbook icon to ensure the Workbook is active.
2. Click the Unit Ops tab of the Workbook.
3. Click the Add UnitOp button. The UnitOps property view 
appears, listing all available unit operations.
When you click the Add button or press ENTER inside this 
property view, Aspen HYSYS adds the operation that is 
currently selected.
4. Select Mixer by doing one of the following:
• Start typing mixer.
• Scroll down the list using the vertical scroll bar, then 
select Mixer. 
You can also filter the list by selecting the Piping Equipment 
radio button in the Categories group, then use one of the 
above methods to install the operation.
To add an operation, you can double-clicking on a listed 
operation.
5. With Mixer selected, click the Add button, or press ENTER.
 Figure 3.45
Workbook Icon3-42
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ThThe property view for the Mixer appears.  
The unit operation property view contains all the information 
required to define the operation, organized into tabs and 
pages. The Design, Rating, Worksheet, and Dynamics 
tabs appear in the property view for most operations. 
Property views for more complex operations contain more 
tabs. Aspen HYSYS has provided the default name MIX-100 
for the Mixer.
Many operations, like the Mixer, accept multiple feed 
streams. Whenever you see a table like the one in the Inlets 
group, the operation will accept multiple stream connections 
at that location. When the Inlets table is active, you can 
access a drop-down list of available streams.
Next, you will complete the Connections page for the Mixer.
6. In the Inlets table, click in the <> cell. The status 
indicator at the bottom of the property view indicates that 
the operation needs a feed stream.
 Figure 3.46
The default naming scheme for unit operations can be 
changed in your Session Preferences.3-43
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3-44 Steady State Simulation
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Th7. Open the drop-down list of inlets by clicking on the down 
arrow icon  or by pressing the F2 key then the DOWN 
arrow key.
8. Select Prop Oxide from the drop-down list. The Prop Oxide 
stream appears in the Inlets table, and <> 
automatically moves down to a new empty cell.
Alternatively, you can connect the stream by typing the 
exact stream name in the <> cell, then pressing 
ENTER. 
9. In the Inlets table, click the new empty <> cell 
and select Water Feed from the list. The status indicator now 
displays ‘Requires a product stream’. 
10.Move to the Outlet field by pressing TAB, or by clicking in 
the cell.
 Figure 3.473-44
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Chemicals Tutorial 3-45
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Th11.Type Mixer Out in the cell, then press ENTER. Aspen HYSYS 
recognizes that there is no existing stream with this name, 
so it creates the new stream.    
The status indicator displays a green OK, indicating that the 
operation and attached streams are completely calculated. 
The Connections page is now complete.
12.Click the Parameters page.
13. In the Automatic Pressure Assignment group, keep the 
default setting of Set Outlet to Lowest Inlet. 
 Figure 3.48
 Figure 3.493-45
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3-46 Steady State Simulation
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Th14.Click the Worksheet tab in the MIX-100 property view to 
view the calculated outlet stream. This tab is a condensed 
Workbook tab displaying only those streams attached to the 
operation. 
Aspen HYSYS has calculated the outlet stream by combining 
the two inlets and flashing the mixture at the lowest 
pressure of the inlet streams. In this case, both inlets have 
the same pressure (16.17 psia), so the outlet stream is set 
to 16.17 psia.
15.Close the MIX-100 property view and UnitOps property view 
to return to the Workbook.
16. The new operation appears in the table of the Workbook 
Unit Ops tab.
 Figure 3.50
 Figure 3.513-46
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ThThe table shows the operation Name, Object Type, the 
attached streams (Inlet and Outlet), whether it is Ignored, 
and its Calc. Level. When you click the View UnitOp button, 
the property view for the currently selected operation 
appears. Alternatively, by double-clicking on any cell (except 
Inlet or Outlet) associated with the operation, will also open 
its property view.
You can also open a stream property view directly from the 
Workbook Unit Ops tab. When any of the cells Name, 
Object Type, Ignored or Calc. Level are selected, the gray 
box at the bottom of the property view displays all the 
streams attached to the current operation. Currently, the 
Name cell for MIX-100 has focus, so the box displays the 
three streams attached to this operation.
For example, to open the property view for the Prop Oxide 
stream attached to the Mixer, do one of the following:
• Double-click on Prop Oxide in the box at the bottom of 
the property view.
• Double-click on the Inlets cell for MIX-100. The property 
view for the first listed feed stream, in this case Prop 
Oxide, appears.
Workbook Features
Before installing the remaining operations, you will examine a 
number of Workbook features that allow you to access 
information quickly and change how information is displayed.
Accessing Unit Operations from the 
Workbook
While you can easily access the property view for a unit 
operation from the Unit Ops tab of the Workbook, you can also 
access operations from the Material Streams, Compositions, and 
Energy Streams tabs.
When your current location is a Workbook streams tab, the gray 
box at the bottom of the Workbook property view displays the 
operations to which the current stream is attached. 3-47
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3-48 Steady State Simulation
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ThFor example, click on any cell associated with the stream Prop 
Oxide. The field displays the name of the mixer operation, MIX-
100. 
If the stream Prop Oxide was also attached to another unit 
operation, both unit operations would be listed in the field. 
Adding a Tab to the Workbook 
When the Workbook is active, the Workbook item appears in 
the Aspen HYSYS menu bar. This item allows you to customize 
the Workbook.
Next you will create a new Workbook tab that displays only 
stream pressure, temperature, and flow.
1. Do one of the following:
• From the Workbook menu item, select Setup.
• Object inspect (right-click) the Material Streams tab in 
the Workbook, then select Setup from the menu that 
appears.
Any utilities attached to the stream with focus in the 
Workbook are also displayed in (and are accessible from) 
this field.
 Figure 3.52
You can access the 
property view for the 
Mixer, double-click 
on its name in the 
field.3-48
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ThThe Workbook Setup property view appears. 
The four existing tabs are listed in the Workbook Tabs 
area. When you add a new tab, it will be inserted before the 
highlighted tab (currently Material Streams). You will insert 
the new tab between the Materials Streams tab and the 
Compositions tab.
2. In the Workbook Tabs list, select Compositions, then click 
the Add button. The New Object Type property view 
appears.
3. Click the Plus icon  beside Stream to expand the branch.  
 Figure 3.53
 Figure 3.543-49
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3-50 Steady State Simulation
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Th4. Select Material Stream, then click the OK button. You 
return to the Setup property view and the new tab, Material 
Streams 1, appears after the existing Material Streams 
tab.
5. In the Object group, click in the Name field and change the 
name for the new tab to P,T,Flow to better describe the tab 
contents.
The next task is to customize the tab by removing the 
variables that are irrelevant.
6. In the Variables table, select the first variable, Vapour 
Fraction.
7. Press and hold the CTRL key.
8. Select the following variables: Mass Flow, Heat Flow, and 
Molar Enthalpy.
9. Release the CTRL key.
 Figure 3.553-50
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Th10.Click the Delete button beside the table to remove the 
selected variables from this Workbook tab only. The 
finished Setup appears in the figure below.  
If you want to remove variables from another tab, you must 
edit each tab individually.
11.Close the Setup property view. The new tab appears in the 
Workbook. 
12.Save the case.
 Figure 3.56
 Figure 3.573-51
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3-52 Steady State Simulation
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Th3.2.7 Installing Equipment on 
the PFD
Besides the Workbook, the PFD is the other main property view 
in Aspen HYSYS you will use to build the simulation.
1. To open the PFD, click the PFD icon on the toolbar. The PFD 
item appears in the Aspen HYSYS menu bar whenever the 
PFD has focus.
When you open the PFD property view, it appears similar to 
the one shown below. 
As a graphical representation of your flowsheet, the PFD shows 
the connections among all streams and operations, also known 
as objects. Each object is represented by a symbol, also known 
as an icon. A stream icon is an arrow pointing in the direction of 
flow, while an operation icon is a graphic representing the actual 
physical operation. The object name, also known as a label, 
appears near each icon.
The PFD shown above has been rearranged by moving the Prop 
Oxide feed stream icon up slightly so it does not overlap the 
Water Feed stream icon. To move an icon, simply click and 
drag it to a new location. You can click and drag either the icon 
(arrow) itself, or the label (stream name), as these two items 
are grouped together.
 Figure 3.58
PFD Icon
Like any other 
non-modal 
property view, 
the PFD 
property view 
can be re-sized 
by clicking and 
dragging 
anywhere on the 
outside border.3-52
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ThOther functions that can be performed while the PFD is active 
include the following:
• Access commands and features through the PFD toolbar.
• Open the property view for an object by double-clicking 
its icon.
• Move an object by clicking and dragging it to the new 
location.
• Access “fly-by” summary information for an object by 
placing the cursor over it.
• Size an object by clicking the Size icon, selecting the 
object, then clicking and dragging the sizing "handles" 
that appear.
• Display the Object Inspection menu for an object by 
placing the cursor over it and right-clicking. This menu 
provides access to a number of commands associated 
with the particular object.
• Zoom in and out, or display the entire flowsheet in the 
PFD window by clicking the zoom buttons at the bottom 
left of the PFD property view.
Some of these functions will be illustrated in this tutorial.
Calculation Status
Aspen HYSYS uses colour-coding to indicate calculation status 
for objects, both in the object property views, and in the 
flowsheet. If you recall, the status bar indicator at the bottom of 
a property view for a stream or operation indicates the current 
state of the object.
 Figure 3.59
Example of a fly-by information:
Icon Name Icon Name
Zoom Out 25% Zoom In 25%
Display Entire PFD
Size icon
For more information on 
manipulating PFD, refer to 
the Aspen HYSYS User 
Guide.3-53
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3-54 Steady State Simulation
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ThThe following table lists and describes the three colour status: 
When you are in the PFD, the streams and operations are 
colour-coded to indicate their calculation status. If the 
conditions of an attached stream for an operation were not 
entirely known, the operation would have a yellow outline 
indicating its current status. For the Mixer, all streams are 
defined, so it has no yellow outline.
Another colour scheme is used to indicate the status of streams. 
For material streams, a dark blue icon indicates the stream has 
been flashed and is entirely known. 
A light blue icon indicates the stream cannot be flashed until 
some additional information is supplied. 
Similarly, a dark red icon is for an energy stream with a known 
duty, while a purple icon indicates an unknown duty.
Indicator Status  Description
Red Status A major piece of defining information is missing from 
the object. For example, a feed or product stream is 
not attached to a Separator. The status indicator is red 
and an appropriate warning message is displayed.
Yellow Status All major defining information is present, but the 
stream or operation has not been solved because one 
or more degrees of freedom is present. 
For example, a Cooler whose outlet stream 
temperature is unknown. The status indicator is yellow 
and an appropriate warning message is displayed.
Green Status The stream or operation is completely defined and 
solved. The status indicator is green and an OK 
message is displayed.
The above status colours are the Aspen HYSYS default 
colours. You can change the colours in the Session 
Preferences.
Notice that the icons for all streams installed to this point 
are dark blue.3-54
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ThInstalling the Reactor
Next, you will install a continuously-stirred-tank reactor 
operation (CSTR). You can install streams or operations by 
dropping them from the Object Palette onto the PFD.
1. Open the Object Palette by pressing F4.
2. Find a empty space in the PFD to add the CSTR to the right 
of the Mixer. If necessary scroll to the right using the 
horizontal scroll bar on the PFD property view.
3. In the Object Palette, click the CSTR icon.
4. Position the cursor in the PFD to the right of the Mixer Out 
stream. The cursor changes to a special cursor with a plus 
(+) symbol attached to it. The symbol indicates the location 
of the operation icon. 
5. Click to “drop” the Reactor onto the PFD. Aspen HYSYS 
creates a new Reactor with a default name, CSTR-100. The 
Reactor has red status (colour), indicating that it requires 
feed and product streams.
 Figure 3.60
 
CSTR Icon3-55
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3-56 Steady State Simulation
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ThAttaching Streams to the Reactor
1. Click the Attach Mode icon on the PFD toolbar to enter 
Attach mode. 
2. Position the cursor over the right end of the Mixer Out 
stream icon. A small white box appears at the cursor tip with 
a pop-up description ‘Out’, indicating that the stream outlet 
is available for connection. 
3. With the pop-up ‘Out’ visible, click and hold the mouse 
button. The transparent box becomes solid black, indicating 
that you are beginning a connection.
4. Move the cursor toward the left (inlet) side of the CSTR-100 
icon. A line appears between the Mixer Out stream icon and 
the cursor, and multiple connection points (blue) appear at 
the Reactor inlet.
The Attach Mode button stays active until you click it again 
to return to Move mode.
When you are in Attach mode, you will not be able to move 
objects in the PFD. 
You can temporarily toggle between Attach and Move mode 
by holding down the CTRL key.
 Figure 3.61
Multiple connection points appear on the Reactor object 
because the reactor accepts multiple feed streams.
Attach Mode Icon3-56
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Chemicals Tutorial 3-57
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Th5. Place the cursor near a connection point until a solid white 
box appears at the cursor tip, indicating an acceptable end 
point for the connection. 
6. Release the mouse button, and the connection is made 
between the stream and the CSTR-100 inlet.
7. Position the cursor over top right-hand corner of the CSTR-
100 icon. The white box and the pop-up ‘Vapour Product’ 
appear.
8. With the pop-up visible, left-click and hold. The white box 
again becomes solid black.
9. Move the cursor to the right of the CSTR-100. A stream icon 
appears with a trailing line attached to the CSTR-100 outlet. 
The stream icon indicates that a new stream will be created 
when you complete the next step.  
10.With the stream icon visible, release the left mouse button. 
Aspen HYSYS creates a new stream with the default name 1.
 Figure 3.62
If you make an incorrect connection, break the connection and try 
again. To break a connection:
1. Click the Break Connection icon on the PFD toolbar.
2. Place the cursor over the stream line you want to break.
The cursor shows a checkmark, indicating an available connection to 
break.
3. Click once to break the connection.
 Figure 3.63
Break Connection Icon3-57
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3-58 Steady State Simulation
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Th11. Place the cursor over the bottom right connection point on 
the reactor labeled ‘Liquid Product’, then click and drag to 
the right to create the reactor’s liquid product stream. The 
new stream is given the default name 2.
12. Place the cursor over the bottom left connection point on the 
reactor labeled ‘Energy Stream’, then click and drag down 
and to the left to create the reactor’s energy stream. The 
new stream is automatically named Q-100. 
The reactor still displays a red warning status, indicating 
that all necessary connections have been made, but the 
attached streams are not entirely known. 
13.Click the Attach Mode icon again to return to Move mode.
14.Double-click the stream icon 1 to open its property view.
15. In the Stream Name cell, enter the new name Reactor 
Vent, then close the property view.
16.Double-click the stream 2 icon. Rename this stream Reactor 
Prods, then close the property view.
17.Double-click the Q-100 icon, rename it Coolant, then close 
the property view.
The reactor outlet and energy streams are unknown at this 
point, so they are light blue and purple, respectively.
Completing the Reactor 
Specifications
1. Double-click the CSTR-100 icon to open its property view.
2. Click the Design tab, then select the Connections page (if 
required). The names of the Inlet, Outlet, and Energy 
streams that were attached before appear in the appropriate 
cells.
 Figure 3.643-58
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Chemicals Tutorial 3-59
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Th3. In the Name cell, change the operation name to Reactor.  
4. Select the Parameters page. For now, the Delta P and the 
Volume parameters are acceptable at the default values.
5. Select the Cooling radio button. This reaction is exothermic 
(produces heat), so cooling is required.
6. Click the Reactions tab. Next you will attach the Reaction 
Set that you created in the Basis Environment.
 Figure 3.65
 Figure 3.663-59
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3-60 Steady State Simulation
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Th7. From the Reaction Set drop-down list, select Set-1. The 
completed Reactions tab appears below.     
The next task is to specify the Vessel Parameters. In this 
Tutorial, the reactor has a volume of 280 ft3 and is 85% full.
8. Click the Dynamics tab, then select the Specs page.
9. In the Model Details group, click in the Vessel Volume cell. 
Type 280 (ft3), then press ENTER. 
10. In the Liq Volume Percent cell, type 85, then press 
ENTER.
 Figure 3.673-60
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Chemicals Tutorial 3-61
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ThAspen HYSYS automatically calculates the Liquid Volume in 
the vessel (280 ft3 x 85% full = 238 ft3), displayed on the 
Parameters page of the Design tab.
11.Click on the Worksheet tab. 
At this point, the Reactor product streams and the energy 
stream Coolant are unknown because the Reactor has one 
degree of freedom. At this point, either the outlet stream 
temperature or the cooling duty can be specified. 
 Figure 3.68
 Figure 3.693-61
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3-62 Steady State Simulation
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ThFor this example, you will specify the outlet temperature.
Initially the Reactor is assumed to be operating at 
isothermal conditions, therefore the outlet temperature is 
equivalent to the feed temperature, 75°F.
12. In the Reactor Prods column, click in the Temperature cell. 
Type 75, then press ENTER. Aspen HYSYS solves the 
Reactor. 
There is no phase change in the Reactor under isothermal 
conditions since the flow of the vapour product stream 
Reactor Vent is zero. In addition, the required cooling duty 
has been calculated and is represented by the Heat Flow of 
the Coolant stream. The next step is to examine the Reactor 
conversion as a function of temperature.
 Figure 3.703-62
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Chemicals Tutorial 3-63
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Th13.Click the Reactions tab, then select the Results page. The 
conversion appears in the Reactor Results Summary table. 
Under the current conditions, the Actual Percent Conversion 
(Act.% Cnv.) in the Reactor is 40.3%. You will adjust the 
Reactor temperature until the conversion is in the 85-95% 
range. 
14.Click the Worksheet tab.
15. In the Reactor Prods column, change the Temperature to 
100°F.
16.Return to the Reactions tab to check the conversion, which 
has increased to 72.28% as shown below.  
17.Return to the Worksheet tab, and change the 
Temperature of Reactor Prods to 140°F.
 Figure 3.71
 Figure 3.723-63
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3-64 Steady State Simulation
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Th18.Click the Reactions tab again and check the conversion. 
The conversion at 140°F is approximately 95%, which is 
acceptable. 
19.Close the Reactor property view. 
Installing the Column
Aspen HYSYS has a number of pre-built column templates that 
you can install and customize by changing attached stream 
names, number of stages, and default specifications. For this 
example, a Distillation Column will be installed.
1. Before installing the column, click the Tools menu and 
select Preferences. 
2. On the Simulation tab, click on the Options page and 
ensure that the Use Input Experts checkbox is selected, 
then close the property view.
3. Double-click the Distillation Column icon on the Object 
Palette. 
 Figure 3.73
Distillation Column Icon3-64
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ThThe first page of the Input Expert appears. 
The Input Expert is a logical sequence of input property 
views that guide you through the initial installation of a 
Column. Complete the steps to ensure that you have 
provided the minimum amount of information required to 
define the column.
The Input Expert is a Modal property view, indicated by the 
absence of the Maximize/Minimize icons. You cannot exit or 
move outside the Expert until you supply the necessary 
information, or click the Cancel button.
4. For this example, 10 theoretical stages are used, so leave 
the # Stages at its default value.
When you install a column using a pre-built template, Aspen 
HYSYS supplies certain default information, such as the 
number of stages. The # Stages field contains 10 (default 
number of stages). 
5. In the Inlet Streams table, click in the <> cell.
 Figure 3.74
These stages are theoretical stages, as the Aspen HYSYS 
default stage efficiency is one.
The Condenser and Reboiler are considered separate from 
the other stages, and are not included in the Num of Stages 
field.3-65
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3-66 Steady State Simulation
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Th6. From the drop-down list of available inlet streams, select 
Reactor Prods as the feed stream to the column. Aspen 
HYSYS supplies a default feed location in the middle of the 
Tray Section (TS), in this case stage 5 (indicated by 5_Main 
TS). 
7. In the Condenser group, ensure the Partial radio button is 
selected, as the column will have both Vapour and Liquid 
Overhead Outlets.
8. In the Column Name field, change the name to Tower.
9. In the Condenser Energy Stream field, type CondDuty, 
then press ENTER.
10. In the top Ovhd Outlets field, type OvhdVap, then press 
ENTER.
In the bottom Ovhd Outlets field, type RecyProds, then 
press ENTER.
11. In the Reboiler Energy Stream field, type RebDuty, then 
press ENTER.
12. In the Bottoms Liquid Outlet field, type Glycol, then press 
ENTER.
When you are finished, the Next button becomes active, 
indicating sufficient information has been supplied to 
advance to the next page of the Input Expert. 
The first page of the Input Expert should appear as shown in 
the following figure.
 Figure 3.753-66
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Chemicals Tutorial 3-67
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Th13.Click the Next button to advance to the Pressure Profile 
page.
14. In the Condenser Pressure field, enter 15 psia.
15. In the Reboiler Pressure field, enter 17 psia.
Leave the Condenser Pressure Drop at its default value of 
zero. 
16.Click the Next button to advance to the Optional 
Estimates page. For this example, no estimates are 
required.
Although Aspen HYSYS does not require estimates to 
produce a converged column, you should provide estimates 
for columns that are difficult to converge.
17.Click the Next button to advance to the fourth and final 
page of the Input Expert. This page allows you to supply 
values for the default column specifications that Aspen 
HYSYS has created.
In general, a Distillation Column has three default 
specifications. The overhead Vapour Rate and Reflux 
Ratio will be used as active specifications, and later you will 
create a glycol purity specification to exhaust the third 
degree of freedom. The third default specification, overhead 
Liquid Rate, will not be used.
18. In the Vapour Rate field, enter 0 lbmole/hr. 
 Figure 3.763-67
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ThThe Flow Basis applies to the Vapour Rate, so leave it at 
the default of Molar.
19. In the Reflux Ratio field, enter 1.0.  
20.Click the Done button. The Column property view appears. 
21.On the Design tab, select the Monitor page. 
 Figure 3.77
 Figure 3.783-68
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Chemicals Tutorial 3-69
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ThThe Monitor page displays the status of your column as it is 
being calculated, updating information with each iteration.
You can also change specification values, and activate or 
deactivate specifications used by the Column solver directly 
from the Monitor page.
Adding a Column Specification
The current Degrees of Freedom is zero, indicating the column is 
ready to be run, however, the Distillate Rate (Overhead Liquid 
Rate for which no value was provided in the Input Expert) is 
currently an Active specification with a Specified Value of 
. For this example, you will specify a water mole 
fraction of 0.005 in the Glycol product stream.
1. Since it is not desirable to use this specification, clear the 
Active checkbox for the Distillate Rate. The Degrees of 
Freedom increases to 1, indicating that another active 
specification is required.
2. On the Design tab, select the Specs page. 
3. In the Column Specifications group, click the Add button. 
The Add Specs property view appears.
4. Select Column Component Fraction as the Specification 
Type.
5. Click the Add Spec(s) button. The Comp Frac Spec property 
view appears.
6. In the Name cell, change the name to H2O Fraction.
 Figure 3.793-69
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3-70 Steady State Simulation
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Th7. In the Stage cell, select Reboiler from the drop-down list.  
8. In the Spec Value cell, enter 0.005 as the liquid mole 
fraction specification value.
9. In the Components list, click in the first cell labeled 
<>, then select H2O from the drop-down list 
of available components. 
10.Close this property view to return to the Column property 
view. The new specification appears in the Column 
Specifications list on the Specs page. 
11.Return to the Monitor page, where the new specification 
appears at the bottom of the Specifications list.
 Figure 3.80
 Figure 3.813-70
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Th12.Click the Group Active button to bring the new specification 
to the top of the list, directly under the other Active 
specifications. 
The Degrees of Freedom has returned to zero, so the 
column is ready to be calculated.
 Figure 3.82
If you want to view the entire Specifications table, re-size 
the property view by clicking and dragging its bottom 
border.
Aspen HYSYS automatically made the new specification 
Active when you created it.3-71
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ThRunning the Column
1. Click the Run button to begin calculations, and the 
information displayed on the page is updated with each 
iteration. The column converges quickly, in five iterations.  
The converged temperature profile appears in the upper 
right corner of the property view.
2. Select the Press or Flows radio button to view the pressure 
or flow profiles.
 Figure 3.833-72
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Th3. To access a more detailed stage summary, click the 
Performance tab, then select the Column Profiles page.
Accessing the Column Sub-flowsheet
When considering the column, you might want to focus only on 
the column sub-flowsheet. You can do this by entering the 
column environment.
1. Click the Column Environment button at the bottom of the 
property view. While inside the column environment, you 
can do the following:
• View the column sub-flowsheet PFD by clicking the PFD 
icon.
• View a Workbook of the column sub-flowsheet objects by 
clicking the Workbook icon.
• Access the "inside" column property view by clicking the 
Column Runner icon. This property view is essentially 
the same as the "outside", or Main Flowsheet, property 
view of the column.
 Figure 3.84
PFD icon
Workbook icon
Column Runner icon3-73
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ThThe column sub-flowsheet PFD and Workbook appear in 
the following figures. 
2. When you are finished in the column environment, return to 
the Main Flowsheet by clicking the Enter Parent 
Simulation Environment icon. 
 Figure 3.85
 Figure 3.86
Enter Parent Simulation 
Environment Icon3-74
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Th3. Open the PFD for the Main Flowsheet and select Auto 
Position All from the PFD menu. Aspen HYSYS arranges 
your PFD in a logical manner. 
Moving Objects and Labels in a PFD
The PFD below has been customized by moving some of the 
stream icons. To move an icon, simply click and drag it to the 
new location.
You can also move a stream or operation label (name).
1. Right-click on the label you want to move.
2. From the menu that appears, select Move/Size Label. A 
box appears around the label.
3. Click and drag the label to a new location, or use the arrow 
keys to move it. 
 Figure 3.873-75
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Th3.2.8 Viewing Results
1. Click the Workbook icon to access the calculated results for 
the Main Flowsheet.
The Material Streams tab and Compositions tab of the 
Workbook appears below. 
 Figure 3.88
Workbook icon3-76
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ThUsing the Object Navigator
If you want to view the calculated properties of a particular 
stream or operation, you can use the Object Navigator to 
quickly access the property view for any stream or unit 
operation at any time during the simulation.
1. To open the Navigator, do one of the following:
• Click the Object Navigator icon.
• Press F3.
• From the Flowsheet menu, select Find Object.
• Double-click on any blank space on the Aspen HYSYS 
Desktop.
The Object Navigator property view appears. 
The UnitOps radio button in the Filter group is currently 
selected, so only the Unit Operations appear in the list of 
objects.
2. To open a property view, select the operation in the list, then 
click the View button or double-click on the operation name.
3. You can also search for an object by clicking the Find button.
4. When the Find Object property view appears, enter the 
object name, then click the OK button. Aspen HYSYS opens 
the property view for the object you specified.
You can start or end the search string with an asterisk (*), 
which acts as a wildcard character. This lets you find 
 Figure 3.89
You can control which objects appear by selecting a different 
Filter radio button. For example, to list all streams and unit 
operations, select the All button.
Object Navigator Icon3-77
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Thmultiple objects with one search. 
For example, searching for VLV* will open the property view 
for all objects with VLV at the beginning of their name.
Using the Databook
The Aspen HYSYS Databook provides you with a convenient way 
to examine your flowsheet in more detail. You can use the 
Databook to monitor key variables under a variety of process 
scenarios, and view the results in a tabular or graphical format.
1. Before opening the Databook, close the Object Navigator 
and any property views you might have opened using the 
Navigator.
2. To open the Databook, do one of the following:
• Press CTRL D.
• From the Tools menu, select Databook.
The Databook property view appears.
The first task is to add key variables to the Databook. For this 
example, the effects of the Reactor temperature on the 
Reactor cooling duty and Glycol production rate will be 
examined.
 Figure 3.90
To edit existing variables/objects in the Databook:
1. Select the Object you want to edit. 2. Click the Edit button.3-78
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Th3. On the Variables tab, click the Insert button. The Variable 
Navigator appears.
4. In the Object Filter group, select the UnitOps radio button. 
The Object list is filtered to show unit operations only.
5. In the Object list, select Reactor. The variables available for 
the Reactor object appear in the Variable list.
6. In the Variable list, select Vessel Temperature. Vessel 
Temperature appears in the Variable Description field. You 
can edit the default variable description. 
The Variable Navigator is used extensively in Aspen HYSYS 
for locating and selecting variables. The Navigator operates 
in a left-to-right manner—the selected Flowsheet determines 
the Object list, the chosen Object dictates the Variable list, 
and the selected Variable determines whether any Variable 
Specifics are available.
 Figure 3.913-79
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Th7. In the Variable Description field, rename the variable 
Reactor Temp, then click the OK button. The variable now 
appears in the Databook. 
8. To add the next variable, click the Insert button. The 
Variable Navigator appears.
9. In the Object Filter group, select the Streams radio button. 
The Object list is filtered to show streams only.
10. In the Object list, select Coolant in the Object list. The 
variables available for this stream appear in the Variable list.
11. In the Variable list, select Heat Flow. 
 Figure 3.92
 Figure 3.933-80
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Th12. In the Variable Description field, change the description to 
Cooling Duty, then click the Add button. The variable now 
appears in the Databook and the Variable Navigator 
property view remains open.
13. In the Object list, select Glycol. In the Variable list, select 
Liq Vol Flow@Std Cond. Change the Variable 
Description for this variable to Glycol Production, then 
click the Add button. 
14.Click the Close button to return to the Databook property 
view. The completed Variables tab of the Databook 
appears below. 
Now that the key variables have been added to the 
Databook, the next task is to create a data table in which to 
display these variables.
15.Click the Process Data Tables tab.
 Figure 3.943-81
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Th16. In the Available Process Data Tables group, click the Add 
button. Aspen HYSYS creates a new table with the default 
name ProcData1. 
The three variables that you added to the Databook appear 
in the table on this tab.
17. In the Process Data Table field, change the name to Key 
Variables.
18. In the Show column, activate each variable by selecting on 
the corresponding checkbox.
19.Click the View button to view the new data table.
 Figure 3.95
 Figure 3.96
 Figure 3.973-82
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ThThis table will be accessed again later to demonstrate how 
its results are updated whenever a flowsheet change is 
made.
20. For now, click the Minimize icon  in the upper right corner 
of the Key Variables Data property view. Aspen HYSYS 
reduces the property view to an icon and places it at the 
bottom of the Desktop.
Before you make changes to the flowsheet, you will record 
the current values of the key variables. Instead of manually 
recording the variables, you can use the Data Recorder to 
automatically record them for you.
21.Click the Data Recorder tab in the Databook.
When using the Data Recorder, you first create a Scenario 
containing one or more of the key variables, then record the 
variables in their current state.
22. In the Available Scenarios group, click the Add button. 
Aspen HYSYS creates a new scenario with the default name 
Scenario 1.
 Figure 3.983-83
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Th23. In the Data Recorder Data Section group, activate each 
variable by selecting on the corresponding Include 
checkbox.
24.Click the Record button to record the variables in their 
current state. The New Solved State property view appears, 
prompting you for the name of the new state.
25. In the Name for New State field, change the name to 
Base Case, then click OK. You return to the Databook.
26. In the Available Display group, select the Table radio 
button, then click the View button. The Data Recorder 
property view appears, showing the values of the key 
variables in their current state.  
 Figure 3.99
 Figure 3.1003-84
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ThNow you can make the necessary flowsheet changes and 
these current values remain as a permanent record in the 
Data Recorder unless you choose to erase them.
27.Click the Minimize icon  on the Data Recorder property 
view.
28.Click the Restore Up icon  on the Key Variables Data 
title bar to restore the property view to its regular size.
Next, you will change the temperature of stream Reactor 
Prods (which determines the Reactor temperature), then 
view the changes in the process data table.
29.Click the Object Navigator icon in the toolbar.
30. In the Filter group, select the Streams radio button.
31. In the Streams list, select Reactor Prods, then click the 
View button. The Reactor Prods property view appears.
32. Ensure you are on the Worksheet tab, Conditions page of 
the property view.
33.Arrange the Reactor Prods and Key Variables Data property 
views so you can see them both.
Currently, the Reactor temperature is 140°F. The key 
variables will be checked at 180°F.
Object Navigator Icon
 Figure 3.1013-85
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Th34. In the Reactor Prods property view, change the value in the 
Temperature cell to 180. Aspen HYSYS automatically 
recalculates the flowsheet. The new results appears below.       
As a result of the change, the required cooling duty 
decreased and the glycol production rate increased.
35.Click the Close button on the Reactor Prods stream 
property view to return to the Databook. You can now 
record the key variables in their new state.
36.Click on the Data Recorder tab in the Databook.
37.Click the Record button. The New Solved State property 
view appears.
38. In the Name for New State field, change the name to 
180F Reactor, then click the OK button.
 Figure 3.1023-86
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Th39. In the Available Display group, click the View button. The 
Data Recorder appears, displaying the new values of the 
variables.
40.Close the Data Recorder property view, then the Databook 
property view, and finally the Key Variables Data property 
view. 
This completes the Aspen HYSYS Chemicals Steady State 
Simulation tutorial. If there are any aspects of this case that 
you would like to explore further, feel free to continue 
working on this simulation on your own.
Further Study
For other chemical case examples, see the Applications section. 
Applications beginning with “C” explore some of the types of 
chemical simulations that can be built using Aspen HYSYS.
 Figure 3.1033-87
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3-88 Dynamic Simulation
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Th3.3 Dynamic Simulation
In this tutorial, the dynamic capabilities of Aspen HYSYS will be 
incorporated into a basic steady state chemicals model. In the 
steady state simulation, a continuously-stirred tank reactor 
(CSTR) converted propylene oxide and water into propylene 
glycol. The reactor products were then fed into a distillation 
tower where the glycol product was recovered in the tower 
bottoms.
The dynamic simulation will take the steady state CSTR 
simulation case and convert it into dynamic mode. If you have 
not built the simulation for the steady state simulation, you can 
open the pre-built case included with your Aspen HYSYS 
package.
A flowsheet of the completed dynamic simulation is shown in the 
figure below. 
This tutorial follows these basic steps for setting up a dynamic 
simulation case:
1. Obtain a simplified steady state model to be converted to 
A completed dynamic case has been pre-built and is located 
in the file DynTUTOR3.hsc in your Aspen HYSYS\Samples 
directory.
 Figure 3.1043-88
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Thdynamic mode.
2. Use the Dynamic Assistant to set pressure-flow 
specifications, modify the flowsheet topology, and size the 
equipment.
3. Modify the Reactor vent stream to account for reverse flow 
conditions.
4. Set up temperature and level controllers around and in the 
Reactor vessel.
5. Set up the Databook. Make changes to key variables in the 
process and observe the dynamic behaviour of the model.
Only the CSTR reactor will be converted to dynamic mode. The 
Column operation will be deleted from the simulation flowsheet.
The Dynamics Assistant will be used to make pressure-flow 
specifications, modify the flowsheet topology, and size pieces of 
equipment in the simulation flowsheet. This is only one method 
of preparing a steady state case for dynamic mode. It is also 
possible to set your own pressure-flow specifications and size 
the equipment without the aid of the Dynamic Assistant.
3.3.1 Simplifying the Steady 
State Flowsheet
The distillation column in the Chemicals Tutorial will be deleted 
in this section.
1. Open the pre-built case file TUTOR3.hsc located in your 
Aspen HYSYS\Samples directory (if you are not continuing 
from the Steady State Simulation section of this tutorial).
2. From the Tools menu, select Preferences.
3. Click the Variables tab, then select the Units page.
4. In the Available Unit Sets group, select Field. Close the 
Session Preferences property view.
5. From the File menu, select Save As.
Save the case as DynTUT3-1.hsc.3-89
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Th6. Delete all material streams and unit operations downstream 
of the Reactor Prods stream. The following 6 items should be 
deleted: 
When you delete a stream, unit or logical operation from the 
flowsheet, Aspen HYSYS will ask you to confirm the deletion. 
To delete the object, click the Yes button. If not, click the 
No button.
7. The steady state simulation case should solve with the 
deletion of the above items. The PFD for the dynamic tutorial 
should appear as shown below.
Before entering dynamics, the pressure specification on the 
Water Feed stream should be removed so that the MIX-100 
unit operation can calculate its pressure based on the Prop 
Oxide stream specification.
8. Double-click the Water Feed stream icon to open its property 
view.
9. On the Conditions page of the Worksheet tab, click in the 
Pressure cell, then press DELETE.
10.Close the Water Feed stream property view.
11.Double-click the MIX-100 icon to open its property view.
12.Click the Design tab, then select the Parameters page.
13. In the Automatic Pressure Assignment group, select the 
Equalize All radio button. Aspen HYSYS solves for the 
stream and mixer operation.
14.Close the mixer property view. 
Material Streams Energy Streams Unit Operations
• Ovhd Vap
• RecyProds
• Glycol
• CondDuty
• RebDuty
Tower
 Figure 3.1053-90
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Th15.Save the case.
3.3.2 Using the Dynamics 
Assistant
The Dynamics Assistant makes recommendations as to how the 
flowsheet topology should change and what pressure-flow 
specifications are required in order to run a case in dynamic 
mode. In addition, it automatically sets the sizing parameters of 
the equipment in the simulation flowsheet. Not all the 
suggestions the Dynamics Assistant offers need to be followed. 
The Dynamics Assistant will be used to do the following:
• Add Pressure Flow specifications to the simulation case.
• Add Valves to the Boundary Feed and Product streams.
• Size the Valve, Vessel, and Heat Exchange operations.
For this tutorial, the Session Preferences will be set so that the 
Dynamics Assistant will not manipulate the dynamic 
specifications.
1. Open the Tools menu and select Preferences. The Session 
Preferences property view appears.
2. Click the Simulation tab, then select the Dynamics page.
 Figure 3.1063-91
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Th3. Ensure that the Set dynamic stream specifications in 
the background checkbox is cleared.  
4. Close the Session Preferences property view, then close all 
open property views on the Aspen HYSYS desktop except for 
the PFD property view.
Next, you will initiate the Dynamics Assistant to evaluate the 
specifications required to run in dynamic simulation.
5. Click the Dynamics Assistant icon. Browse through each 
tab in the Dynamic Assistant property view to inspect the 
recommendations.
All recommendations in the Dynamic Assistant will be 
implemented by default unless you deactivate them. You can 
choose which recommendations will be executed by the 
Dynamic Assistant by selecting or clearing the OK 
checkboxes beside each recommendation.
 Figure 3.107
 Figure 3.108
Dynamic Assistant 
icon
An Active recommendation will 
be implemented by the Dynamic 
Assistant.
An Inactive recommendation will 
not be implemented by the 
Dynamic Assistant.3-92
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Th6. Click the Streams tab. The Streams tab contains a list of 
recommendations regarding the setting or removing of 
pressure-flow specifications in the flowsheet. 
7. For each page in the Streams tab, activate or deactivate the 
following recommendations.
The Dynamics Assistant will insert valves on all the boundary 
flow streams except the Reactor Vent stream. This 
recommendation was deactivated since it is assumed that 
the CSTR reactor is exposed to the open air. Therefore, the 
pressure of the reactor is constant. A constant pressure can 
be modeled in the CSTR reactor by setting the Reactor Vent 
stream with a pressure specification. A valve should not be 
inserted on this stream.
 Figure 3.109
Page Recommendation Stream OK Checkbox
Pressure 
Specs
Remove Pressure 
Specifications
Prop Oxide Select
Flow Specs Remove Flow 
Specifications
Prop Oxide Select
Water Feed Select
Insert Valves Insert Valves Prop Oxide Select
Reactor Prods Select
Reactor Vent Clear
Water Feed Select3-93
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Th8. Click the Make Changes button once only. All the active 
suggestions in the Dynamics Assistant are implemented. 
Close the Dynamics Assistant property view.
9. Switch to Dynamic mode by pressing the Dynamic Mode 
icon. When asked if you want to resolve the dynamics 
assistant items before moving into dynamics, click the No 
button.
Since the suggestion to insert a valve on the Reactor Vent 
stream was deactivated, you must set a pressure 
specification on this stream.
10.Double-click the Reactor Vent stream icon in the PFD. The 
property view appears.
11.Click the Dynamics tab, then select the Specs page.
12. In the Pressure Specification group, select the Active 
checkbox to activate the specification.
13.Close the Reactor Vent stream property view.  
14. The PFD for the dynamic tutorial (before the addition of the 
controllers) should look like the following figure.  
15.Save the case as DynTUT3-2.hsc.
In order for the CSTR to operate in steady state and dynamic 
mode, the vessel must be specified with a volume. Since the 
Dynamic Assistant detected that a volume was already 
specified for the CSTR reactor, it did not attempt to size it.
 Figure 3.110
Dynamic Mode 
Icon3-94
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Th3.3.3 Modeling a CSTR Open 
to the Atmosphere
The CSTR reactor is open to the atmosphere and the liquid level 
of the reactor can change in dynamic mode. This means that the 
vapour space in the liquid reactor also varies with the changing 
liquid level. In order to model this effect, the Reactor Vent 
stream was set with a constant pressure specification. However, 
one additional modification to the Reactor Vent stream is 
required.
Since the liquid level in the CSTR can move up and down, 
regular and reverse flow can be expected in the Reactor Vent 
stream. When vapour exits the reactor vessel (regular flow), the 
composition of the Reactor Vent stream is calculated from the 
existing vapour in the vessel. When vapour enters the vessel 
(reverse flow), the composition of the vapour stream from the 
atmosphere must be defined by the Product Block attached to 
the Reactor Vent stream. It is therefore necessary to specify the 
Product Block composition.
The original steady state Chemicals tutorial used a Fluid 
Package which did not include any inert gases. Therefore, it is 
now necessary to return to the Simulation Basis Manager and 
add the required components to the Fluid Package.
1. Click the Enter Basis Environment icon. The Simulation 
Basis Manager property view appears. 
The Simulation Basis Manager allows you to create, modify, 
and otherwise manipulate Fluid Packages in the simulation 
case. 
Enter Basis Environment 
icon3-95
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Th2. Click the Fluid Pkgs tab. In the Current Fluid Packages 
group, the Fluid Package associated with the Chemical 
Tutorial appears.
3. In the Current Fluid Packages group, select the fluid 
package, then click the View button. The Fluid Package: 
Basis-1 property view appears.
 Figure 3.111
 Figure 3.1123-96
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Th4. Click the Set Up tab. In the Component List Selection group, 
click the View button. The Component List property view 
appears.
5. In the Components Available in the Component Library 
group, select the Full Name/Synonym radio button.
6. In the Match field, start typing Nitrogen. Aspen HYSYS 
filters the component list to match your input. 
7. When Nitrogen is selected in the list, press the ENTER key. 
Nitrogen is added to the Selected Components list. Close the 
Component List property view.
8. Close the Fluid Package: Basis-1 property view.
9. In the Simulation Basis Manager property view, click on the 
Return to Simulation Environment button.
10.On the PFD, double-click the Reactor Vent stream icon to 
open its property view.
 Figure 3.1133-97
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Th11.Click the Product Block button or the View Downstream 
Operation icon. The ProductBlock property view appears.    
12.Click the Composition tab.
13. In the Compositions table, specify the composition of the 
reverse flow stream as follows:
14.Click the Conditions tab.
15. In the Flow Reversal Conditions group, select the 
Temperature radio button.
 Figure 3.114
Component Mole Fraction
12C3Oxide 0.0
12-C3diol 0.0
H2O 0.0
Nitrogen 1.0
View Downstream 
Operation icon3-98
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Th16. In the field beside the Temperature radio button, enter 77oF. 
These stream conditions will be used to flash the pure 
nitrogen stream when the Reactor Vent flow reverses. 
17.Close the ProductBlock_Reactor Vent property view.
18.Close the Reactor Vent stream property view.
19.Save the case as DynTUT3-3.hsc.
3.3.4 Adding Controller 
Operations
In this section you will identify and implement key control loops 
using PID Controller logical operations. Although these 
controllers are not required to run in dynamic mode, they will 
increase the realism of the model and provide more stability.
 Figure 3.1153-99
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ThLevel Control
First you will install a level controller to control the liquid level in 
the CSTR Reactor operation.
1. Press F4 to access the Object Palette, if required.
2. In the Object Palette, click the Control Ops icon. A sub-
palette appears.
3. In the sub-palette, click the PID Controller icon. The cursor 
changes to include a frame and a + sign.
4. In the PFD, click near the Reactor icon. The IC-100 icon 
appears. This controller will serve as the Reactor level 
controller.
5. Double-click the IC-100 icon. The controller’s property view 
appears.
6. In the Connections tab, click in the Name field and change 
the name to Reactor LC.
7. In the Process Variable Source group, click the Select PV 
button. The Select Input PV property view appears.
8. In the Object group list, select Reactor. 
 Figure 3.116
Control Ops icon
PID Controller icon3-100
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Th9. In the Variable list, select Liquid Percent Level. 
10.Click the OK button.    
11. In the Output Target Object group, click the Select OP 
button. The Select OP Object property view appears.
12. In the Object list, select VLV-Reactor Prods.
13. In the Variable list, select Percentage open, then click the 
OK button.
14. In the Reactor LC property view, click the Parameters tab, 
then select the Configuration page. 
15.On this page, enter the following information:
16.Click the Face Plate button at the bottom of the property 
view. The Reactor LC face plate property view appears.
17. From the drop-down list, select Auto to change the controller 
mode.
18.Double-click in the PV value field, type 85, then press 
ENTER.
 Figure 3.117
In this cell... Enter...
Action Direct
Kc 2
Ti 10 minutes
PV Minimum 0%
PV Maximum 100%3-101
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3-102 Dynamic Simulation
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Th19.Close the Reactor LC face plate property view, then close the 
Reactor LC property view.
Flow Control
Next you will add flow controllers to the feed streams in the 
process.
1. The Control Ops sub-palette should still be open. If it isn’t, 
click the Control Ops icon in the Object Palette.
2. In the sub-palette, click the PID Controller icon.
3. In the PFD, click above the Prop Oxide stream icon. The IC-
100 icon appears. This controller will serve as the Prop Oxide 
flow controller.
4. Double-click the IC-100 icon to open its property view.
5. Specify the following details:
6. Click the Face Plate button. Change the controller mode to 
Auto, and input a set point of 8712 lb/hr.
7. Close the PropOxide FC face plate property view and 
property view.
8. In the Object sub-palette, click the PID Controller icon.
9. In the PFD, click below the Water Feed stream icon. The 
controller icon appears. This controller will serve as the 
Water Feed flow controller.
Tab [Page] In this cell... Enter...
Connections Name PropOxide FC
Process Variable Source Prop Oxide, Mass Flow
Output Target Object VLV-Prop Oxide, 
Percentage open
Parameters 
[Configuration]
Action Reverse
Kc 0.1
Ti 5 minutes
PV Minimum 0 lb/hr
PV Maximum 18,000 lb/hr
Control Ops icon
PID Controller icon3-102
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Chemicals Tutorial 3-103
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Th10.Double-click the controller icon, then specify the following 
details:
11.Click the Face Plate button. Change the controller mode to 
Auto and input a set point of 11,000 lb/hr.
12.Close the WaterFeed FC face plate property view and 
property view.
Temperature Control
Next you will install temperature controller to control the 
temperature of the CSTR reactor. The control will be 
implemented using an energy utility stream.
1. In the Object sub-palette, click the PID Controller icon, 
then click in the PFD above and to the left of the Reactor 
icon. 
The controller icon appears. This controller will serve as the 
Reactor temperature controller.
2. Double-click the controller icon, then specify the following 
details.
Tab [Page] In this cell... Enter...
Connections Name WaterFeed FC
Process Variable Source Water Feed, Mass Flow
Output Target Object VLV-Water Feed
Parameters 
[Configuration]
Action Reverse
Kc 0.1
Ti 5 minutes
PV Minimum 0 lb/hr
PV Maximum 22,000 lb/hr
Tab [Page] In this cell... Enter...
Connections Name Reactor TC
Process Variable Source Reactor, Vessel 
Temperature
Output Target Object Coolant3-103
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3-104 Dynamic Simulation
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Th3. Click the Control Valve button. The FCV for Coolant 
property view appears.
4. In the Duty Source group, select the Direct Q radio button.
5. In the Direct Q group table, enter the following information
6. Close the FCV for Coolant property view.
7. Click the Face Plate button. Change the controller mode to 
Auto and input a set point of 140oF.
8. Close the Reactor TC face plate property view and property 
view.
9. Save the case as DynTUT3-4.hsc.
10. The integrator can be run at this point. Click the Integrator 
Active icon in the toolbar.
11.When you are given the option to run the dynamic assistant 
first before running the integrator, click the No button.
Parameters 
[Configuration]
Action Direct
Kc 1.75
Ti 5 minutes
PV Minimum 70oF
PV Maximum 300oF
 Figure 3.118
In this cell... Enter...
Minimum Available 0 Btu/hr
Maximum Available 1 x 107 Btu/hr
Tab [Page] In this cell... Enter...
Integrator icons
Green=Active
Red=Holding3-104
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Chemicals Tutorial 3-105
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ThWhen the integrator is initially run, Aspen HYSYS will detect 
that the Reactor does not have a vapour phase at the 
specified process conditions. You have the option to select 
either the default, which is to Increase Temperature, or 
choose 100% Liquid in the Reactor.
 
12.Select the default setting, which is Increase Temperature.
13. Let the integrator run for a while, then click the Integrator 
Holding icon to stop the Integrator.
At this point you can make changes to key variables in the 
process then observe the changes in the dynamic behaviour 
of the model.
Next you will monitor important variables in dynamics using 
strip charts.
3.3.5 Monitoring in Dynamics
Now that the model is ready to run in dynamic mode, you will 
create a strip chart to monitor the general trends of key 
variables.
Add all of the variables that you would like to manipulate or 
model. Include feed and energy streams that you want to 
modify in the dynamic simulation.
1. Open the Databook by using the hot key combination CTRL 
D. The following is a general procedure to install strip charts 
in Aspen HYSYS. 
 Figure 3.119
Integrator Holding icon3-105
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3-106 Dynamic Simulation
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Th   
2. On the Variables tab, click on the Insert button. The 
Variable Navigator appears.     
Select the Flowsheet, Object, and Variable for any of the 
suggested variables. For Reactor Prods also select the 
Variable Specifics indicated. 
 Figure 3.120
 Figure 3.1213-106
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Chemicals Tutorial 3-107
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ThSee the tables below for a list of suggested variables:        
3. Click on the OK button to return to the Databook. The 
variable will now appear on the Variables tab.
4. Repeat the procedure to add all remaining variables to the 
Databook.
5. Click the Strip Charts tab in the Databook property view.    
6. Click the Add button. Aspen HYSYS will create a new strip 
chart with the default name DataLogger1.
7. In the Logger Name field, change the name to Key 
Variables1.
Variables to Manipulate
Object Variable
Prop Oxide Mass Flow
Water Feed Mass Flow
Variables to Monitor
Object Variable Variable Specifics
Reactor Vessel Temperature
Reactor Prods Comp Molar Flow 12C3Oxide
Reactor Liquid Percent Level
 Figure 3.1223-107
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3-108 Dynamic Simulation
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Th8. Click the Active checkbox for each of the variables that you 
would like to monitor. Keep the number of variables per 
Strip Chart to four or fewer, for easier viewing.
9. If required, add more strip charts.
You can change the configuration of each strip chart by 
clicking the Setup button.
10.Click the Strip Chart button to view each strip chart.
To view a legend for the Strip Chart variables, right-click 
inside the Strip Chart property view and select Legend from 
the menu.
You can also maximize/resize the Strip Chart property views 
to see the details.
11.Click the Start Integrator icon and observe as the variables 
line out. If you see a warning regarding the Dynamics 
Assistant, click the No button.
When you are finished, click the Integrator Holding icon to 
stop the integrator. 
12.At this point you can manipulate various variables within the 
design and observe the response of other variables.
 Figure 3.123
Start Integrator icon
Integrator Holding icon3-108
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Aspen HYSYS Applications B-1
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ThB  Aspen HYSYS 
Applications
This section contains examples that illustrate many of the 
features in Aspen HYSYS. The applications include aspects of 
Conceptual Design, Steady State modeling, and Optimization. 
All aspects are not illustrated in every example, so the areas of 
interest in each application are highlighted in the sections 
below.
The Aspen HYSYS Applications describe, in general terms, how 
to completely model particular processes using various features 
of Aspen HYSYS—detailed methods of constructing the models 
are not provided. If you require detailed descriptions on how to 
construct models in Aspen HYSYS, see the comprehensive 
Tutorial section of this guide.
The examples in the Applications section provide a broad range 
of problems related to various segments of industry and are 
organized as follows.
Gas Processing
G1 Acid Gas Sweetening with DEA – Steady 
State Modeling, Optional Amines Package
A sour natural gas stream is stripped of H2S and CO2 in a 
Contactor (absorber) tower. The rich DEA (diethanolamine) is 
regenerated in a Stripping tower and the lean DEA is recycled 
back to the Contactor. To solve this example, you must have the 
Amines property package, which is an optional property 
package. A spreadsheet is used to calculate various loadings 
Contact your Aspentech 
agent for more 
information, or e-mail us 
at info@hyprotech.com.B-1
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B-2 
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Thand verify that they are within an acceptable range. 
Refining
R1 Atmospheric Crude Tower – Steady State 
Modeling, Oil Characterization
A preheated (450°F) light crude (29 API) is processed in an 
atmospheric fractionation tower to produce naphtha, kerosene, 
diesel, atmospheric gas oil (AGO) and atmospheric residue 
products. A complete oil characterization procedure is part of 
this example application.
R2 Sour Water Stripper – Steady State 
Modeling, Sour Thermo Options, Case Study
Sour water is fed to a distillation tower for NH3 and H2S 
removal. The use of the Sour Peng Robinson (Sour_PR) is 
highlighted. Aspen HYSYS's built-in Case Study tool is used to 
examine the effects of varying column feed temperatures.
Petrochemicals
P1 Propane/Propylene Splitter – Steady 
State Modeling, Column Sub-flowsheet
The individual Stripper tower and Rectifier tower components of 
a propane/propylene splitter system are modeled. Two separate 
towers in the same Column sub-flowsheet are used in this 
The Amines Property Package is an optional property 
package. It is not included in the base version of Aspen 
HYSYS. B-2
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Aspen HYSYS Applications B-3
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Thexample to illustrate the simultaneous solution power of Aspen 
HYSYS's Column sub-flowsheet. 
Chemicals
C1 Ethanol Plant – Steady State Modeling
An ethanol production process is modeled right from the 
fermentor outlet through to the production of low grade and 
high grade (azeotropic) ethanol products.
C2 Synthesis Gas Production – Steady State 
Modeling, Reaction Manager, Reactors
Synthesis gas (H2/N2 on a 3:1 basis) is the necessary feedstock 
for an ammonia plant. The traditional process for creating 
synthesis gas is explored in this example. Air, steam, and 
natural gas are fed to a series of reactors, which produces a 
stoichiomtrically correct product. Extensive use of Aspen 
HYSYS's Reaction Manager is illustrated as four individual 
reactions are grouped into three reaction sets that are used in 
five different reactors. This example also demonstrates the use 
of an Adjust operation to control a reactor outlet temperature. 
The case is then converted to a dynamics simulation by adding 
valves and assigning pressure flow specifications on the 
boundary streams. Reactors are sized using the actual gas flow 
and the residence time. A spreadsheet operation imports the 
H2/N2 molar ratio to a ratio controller, controlling the Air 
flowrate. Temperature controllers are used to achieve the 
reactors setpoint by manipulating the duty streams.B-3
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B-4 
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ThAspen HYSYS Extensibility
X1 Case Linking – Steady State Modeling
This case explores the use of the User Unit Operation to link two 
Aspen HYSYS simulation cases such that the changes made to 
the first case are automatically and transparently propagated to 
the second case. Within each User Unit Op, two Visual Basic 
macros are used. The Initialize() macro sets the field names 
for the various stream feed and product connections and 
created two text user variables. The Execute() macro uses the 
GetObject method to open the target link case and then it 
attempts to locate the material stream, in the target case, 
named by the Initialize() macro.B-4
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Acid Gas Sweetening with DEA G1-1
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ThG1 Acid Gas Sweetening 
with DEAG1-1
G1.1  Process Description ..................................................................... 2
G1.2  Setup ........................................................................................... 4
G1.3  Steady State Simulation............................................................... 4
G1.3.1  Installing the DEA CONTACTOR ................................................ 5
G1.3.2  Regenerating the DEA............................................................. 9
G1.4  Simulation Analysis ................................................................... 15
G1.5  Calculating Lean & Rich Loadings .............................................. 15
G1.6  Dynamic Simulation................................................................... 17
G1.6.1  Converting from Steady State................................................ 18
G1.6.2  Adding a Control Scheme ...................................................... 28
G1.6.3  Preparing Dynamic Simulation ............................................... 33
G1.7  References................................................................................. 34
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G1-2 Process Description
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ThG1.1 Process Description
In this example, a typical acid gas treating facility is simulated. 
A water-saturated natural gas stream is fed to an amine 
contactor. For this example, Diethanolamine (DEA) at a strength 
of 28 wt% in water is used as the absorbing medium. The 
contactor consists of 20 real stages. The rich amine is flashed 
from the contactor pressure of 1000 psia to 90 psia to release 
most of the absorbed hydrocarbon gas before it enters the lean/
rich amine exchanger. In the lean/rich exchanger, the rich amine 
is heated to a regenerator feed temperature of 200°F. The 
regenerator also consists of 20 real stages. Acid gas is rejected 
from the regenerator at 120°F, while the lean amine is produced 
at approximately 255°F. The lean amine is cooled and recycled 
back to the contactor.
Recommended amine strength ranges:   
 Figure G1.1
Lean Amine Strength in Water
Amine Wt%
MEA 15-20
DEA 25-35G1-2
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Acid Gas Sweetening with DEA G1-3
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ThThere are three basic steps used in modeling this process:
1. Setup. The component list includes C1 through C7 as well 
as N2, CO2, H2S, H2O and DEA.
2. Steady State Simulation. The case will consist of an 
absorber scrubbing the inlet gas using a DEA solution, which 
will be regenerated in a distillation column. Sweet gas will 
leave the top of the absorber, whereas the rich amine stream 
from the bottom will be sent to a regenerator column. An 
analysis on both the SWEET GAS and the ACID GAS will be 
performed to satisfy the specified criterion.
3. Dynamics Simulation. The steady state solution will be 
used to size all the unit operations and tray sections. An 
appropriate control strategy will be implemented and the key 
variables will be displayed. 
TEA, MDEA 35-50
DGA 45-65
Lean Amine Strength in Water
 Figure G1.2  Figure G1.3G1-3
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G1-4 Setup
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ThG1.2 Setup
1. In the Session Preferences property view, clone the Field 
unit set.
2. Change the default units for the Liquid Volume Flow to 
USGPM for the cloned unit set.
3. In the Component List property view, select the following 
components: N2, CO2, H2S, C1, C2, C3, i-C4, n-C4, i-C5, 
n-C5, C6, C7, H2O, and DEAmine.
4. In the Fluid Package property view, select the following 
property package: Amines. 
The Amines property package is required to run this 
example problem. This is a D.B. Robinson proprietary 
property package that predicts the behaviour of amine-
hydrocarbon-water systems.
5. Use the Li-Mather/Non-Ideal Thermodynamic model.
G1.3 Steady State 
Simulation
There are two main steps for setting up this case in steady 
state:
1. Installing the DEA Contractor. A 20 stage absorber 
column will be used to scrub the SOUR GAS stream with DEA 
solution (DEA TO CONT). 
The SWEET GAS will leave the tower from the top whereas 
the pollutant rich liquid will be flashed before entering the 
REGENERATOR.
The Amines property package has a limit temperature range. 
So during the construction of the simulation/flowsheet, 
some streams will appear yellow in colour. A warning 
property view will also appear to warn you that the stream 
has exceeded the temperature range.
For this application, you can ignore these warnings.G1-4
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Acid Gas Sweetening with DEA G1-5
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Th2. Regenerating the DEA. The liquid stream from the 
absorber will be regenerated in a 18 tray distillation column 
with a condenser and reboiler. The ACID GAS will be rejected 
from the top and the regenerated DEA will be send back to 
the DEA CONTACTOR.
G1.3.1 Installing the DEA 
CONTACTOR
Before the amine contactor can be solved, an estimate of the 
lean amine feed (DEA TO CONT) and the inlet gas stream (SOUR 
GAS) must be provided. The DEA TO CONT stream will be 
updated once the recycle operation is installed and has 
converged.
Add Feed Streams
Define the following material streams:   
DEA TO CONT material stream
In this cell... Enter...
Name DEA TO CONT
Temperature 95 F
Pressure 995 psia
Std Ideal Liq Vol Flow 190 USGPM
CO2 Mass Frac. 0.0018
Water Mass Frac. 0.7187
DEA Mass Frac. 0.2795
DEA to Cont uses Mass fractions; Sour Gas uses Mole 
fractions.
SOUR GAS material stream
In this cell... Enter...
Name SOUR GAS
Temperature 86.0000 F
Pressure 1000.0000 psia
Molar Flow 25 MMSCFDG1-5
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G1-6 Steady State Simulation
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ThAdd a Separator
Any free water carried with the gas is first removed in a 
separator operation (V-100). Add and define the following 
separator operation:
Add an Absorber Column
The Amines property package requires that real trays be 
modeled in the contactor and regenerator operations, but in 
order to simulate this, component specific efficiencies are 
required for H2S and CO2 on a tray by tray basis. These 
proprietary efficiency calculations are provided in the column as 
part of the Amines package. Tray dimensions must be supplied 
to enable this feature.
N2 Mole Frac. 0.0016
CO2 Mole Frac. 0.0413
H2S Mole Frac. 0.0172
C1 Mole Frac. 0.8692
C2 Mole Frac. 0.0393
C3 Mole Frac. 0.0093
iC4 Mole Frac. 0.0026
nC4 Mole Frac. 0.0029
iC5 Mole Frac. 0.0014
nC5 Mole Frac. 0.0012
nC6 Mole Frac. 0.0018
nC7 Mole Frac. 0.0072
H2O Mole Frac. 0.005
DEAmine Mole Frac. 0.000
Separator [V-100]
Tab [Page] In this cell... Enter...
Design 
[Connections]
Inlets SOUR GAS
Vapour Outlet GAS TO CONTACTOR
Liquid Outlet FWKO
Design [Parameters] Pressure drop 0 psi
SOUR GAS material streamG1-6
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Acid Gas Sweetening with DEA G1-7
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ThBefore installing the column, ensure that the Use Input 
Experts checkbox is selected (from the Session Preferences 
property view, Simulation tab, Options page).
1. Install an Absorber column operation with the specifications 
shown below.
Using the above information, the component specific tray 
efficiencies can be calculated.
2. Run the Column.
3. Once it has converged, click the Parameters tab and select 
the Efficiencies page.
Absorber Column [DEA CONTACTOR]
Page In this cell... Enter...
Connections No. of Stages 20
Top Stage Inlet DEA TO CONT
Bottom Stage Inlet GAS TO CONTACTOR
Ovhd Vapour Outlet SWEET GAS
Bottoms Liquid Outlet RICH DEA
Pressure Profile Top 995 psia
Bottom 1000 psia
Temperature 
Estimates
Top Temperature 100 F
Bottom Temperature 160 FG1-7
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G1-8 Steady State Simulation
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Th4. Click the Component radio button and note the efficiency 
values for CO2 and H2S on each tray. Aspen HYSYS provides 
an estimate of the component tray efficiencies but allows 
you to specify the individual efficiencies if required.
Next, add a valve and another separator.
Add a Valve
The stream Rich DEA from the absorber is directed to valve VLV-
100, where the pressure is reduced to 90 psia; close to the 
regenerator operating pressure.
 Figure G1.4
Valve [VLV-100]
Tab [Page] In the cell... Enter...
Design 
[Connections]
Inlet RICH DEA
Outlet DEA TO FLASH TK
Worksheet 
[Conditions]
Pressure (DEA TO FLASH TK) 90 psiaG1-8
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Acid Gas Sweetening with DEA G1-9
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ThAdd a Separator
Gases that are flashed off from the RICH DEA stream are 
removed using the rich amine flash tank (FLASH TK) which is 
modeled using a Separator operation. 
G1.3.2 Regenerating the DEA
Add a Heat Exchanger
The stream RICH TO L/R is heated to 200°F (REGEN FEED) in 
the lean/rich exchanger (E-100) prior to entering the 
regenerator, which is represented by a distillation column. Heat 
is supplied to release the acid gas components from the amine 
solution, thereby permitting the DEA to be recycled back to the 
contactor for reuse.
The heat exchanger is defined below.
Separator [FLASH TK]
Tab [Page] In this cell... Enter...
Design 
[Connections]
Inlet DEA TO FLASH TK
Vapour Outlet FLASH VAP
Liquid Outlet RICH TO L/R
Heat Exchanger [E-100]
Tab [Page] In this cell... Enter...
Design 
[Connections]
Tube Side Inlet RICH TO L/R
Tube Side Outlet REGEN FEED
Shell Side Inlet REGEN BTTMS
Shell Side Outlet LEAN FROM L/R
Design 
[Parameters]
Tubeside Delta P 10 psi
Shellside Delta P 10 psi
Rating [Sizing] Tube Passes per Shell 1
Worksheet 
[Conditions]
Temperature (REGEN FEED) 200 FG1-9
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G1-10 Steady State Simulation
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ThAdd a Distillation Column
The amine regenerator is modeled as a distillation column with 
20 real stages - 18 stages in the Tray Section plus a Reboiler 
and Condenser.
1. Add a distillation column, configured as shown in the 
following table.  
For this tower, the component efficiencies will be fixed at 
0.80 for H2S and 0.15 for CO2. The efficiencies of the 
condenser and reboiler must remain at 1.0, so enter the 
efficiencies for stages 1-18 only. 
2. Select the Component radio button in the Efficiency Type 
group (Parameters tab, Efficiencies page), then click the 
Reset H2S CO2 button.
3. Type the new efficiencies into the matrix.
4. Specify a Damping Factor of 0.40 (Parameters tab, 
Solver page) to provide a faster, more stable convergence. 
Distillation Column [Regenerator]
Page In this cell... Enter...
Connections No. of Stages 18
Inlet Streams (Stage) REGEN FEED (4)
Condenser Type Full Reflux
Ovhd Vapour ACID GAS
Bottoms Liquid REGEN BTTMS
Reboiler Energy Stream RBLR Q
Condenser Energy Stream COND Q
Pressure Profile Condenser Pressure 27.5 psia
Cond Pressure Drop 2.5 psi
Reboiler Pres. 31.5 psia
Distillation Column [Regenerator]
Tab [Page] In this cell... Enter...
Parameters 
[Efficiencies]
Condenser 1.0
Reboiler 1.0
1_TS to 18_TS CO2 0.15
1_TS to 18_TS H2S 0.80
Parameters [Solver] Damping Factor 0.40G1-10
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Acid Gas Sweetening with DEA G1-11
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Th5. Add two new column specifications, Column Temperature 
(called TTop) and Column Duty (called Reboiler Duty).
6. Set the default specifications as shown below.
7. Delete the Reflux Rate and REGEN Bttms Rate 
specifications from the Column Specification list in the 
Column property view.
8. Set the T Top and Reboiler Duty specifications to Active; 
the Reflux Ratio and Ovhd Vap Rate specifications should be 
set as Estimates only.
The reboiler duty is based on the guidelines provided below, 
which should provide an acceptable H2S and CO2 loading in 
the lean amine. 
Water make-up is necessary, since water will be lost in the 
absorber and regenerator overhead streams.
Regenerator Specifications
Tab [Page] In this cell... Enter...
Design [Specs] Name
Stage
Spec Value
T Top
Condenser
179.6 F
Name
Energy Stream
Spec Value
Reboiler Duty
RBLR Q@COL2
1.356e7 BTU/hr
Name
Stage
Flow Basis
Spec Value
Reflux Ratio
Condenser
Molar
0.5
Name
Draw
Flow Basis
Spec Value
Ovhd Vap Rate
ACID GAS@COL2
Molar
2.0 MMSCFD
Recommended Steam Rates lb Steam / USGAL Lean Amine 
(based on 1000 BTU / lb Steam)
Primary Amine (e.g., MEA) 0.80
Secondary Amine (e.g., DEA) 1.00
Tertiary Amine (e.g., MDEA) 1.20
DGA 1.30G1-11
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G1-12 Steady State Simulation
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Th9. Install a Mixer operation to combine the lean amine from the 
regenerator with the MAKEUP H2O stream. These streams 
mix at the same pressure.
10.Define the composition of MAKEUP H2O as all water, and 
specify a temperature of 70°F and pressure of 21.5 psia. The 
flow rate of the total lean amine stream will be defined at the 
outlet of the mixer, and Aspen HYSYS will calculate the 
required flow of makeup water.
11.Set the overall circulation rate of the amine solution by 
specifying a Standard Ideal Liquid Volume Flow of 190 
USGPM in stream DEA TO COOL. Aspen HYSYS will back-
calculate the flow rate of makeup water required.  
When you have finished specifying the DEA TO COOL stream 
you will receive a warning message stating that the 
temperature of the Makeup H2O stream exceeds the range 
of the property package and the stream will turn yellow. 
Since there is no DEA present in this stream, the warning 
can be ignored without negatively affecting the results of 
this case.
Mixer [MIX-100]
Tab [Page] In this cell... Enter...
Design 
[Connections]
Inlets MAKEUP H2O
LEAN FROM L/R
Outlet DEA TO COOL
Design 
[Parameters]
Automatic Pressure Assignment Set Outlet to 
Lowest Inlet
Worksheet 
[Conditions]
Temperature (MAKEUP H2O)  70 F
Pressure (MAKEUP H2O) 21.5 psia
Std Liq Vol Flow
(DEA to Cool) 
190.5 USGPM
Worksheet 
[Composition]
H2O Mass Frac. 
(MAKEUP H2O) 
1.0G1-12
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Acid Gas Sweetening with DEA G1-13
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ThAdd a Cooler
Add a cooler and define it as indicated below. Cooler E-101 cools 
the lean DEA on its way to the main pump. 
The Cooler operation will remain unconverged until the Set 
operation has been installed.
Add a Pump
Add a pump and define it as indicated below. Pump P-100 
transfers the regenerated DEA to the Contactor. 
The Pump operation will remain unconverged until the Set 
operation has been installed.
Cooler [E-101]
Tab [Page] In this cell... Enter...
Design 
[Connections]
Inlet DEA TO COOL
Outlet DEA TO PUMP
Energy Stream COOLER Q
Design [Parameters] Delta P 5 psi
Pump [P-100]
Tab [Page] In this cell... Enter...
Design 
[Connections]
Inlet DEA TO PUMP
Outlet DEA TO RECY
Energy PUMP Q
Worksheet 
[Conditions]
Temperature [F] (DEA TO RECY) 95°FG1-13
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G1-14 Steady State Simulation
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ThAdd a Set Operation
Install a Set operation (SET-1) to maintain the pressure of 
stream DEA TO RECY at 5 psi lower than the pressure of the gas 
feed to the absorber. 
Add a Recycle Operation
A Recycle operation is installed with the fully defined stream 
DEA TO RECY as the inlet and DEA TO CONT as the outlet. The 
lean amine stream, which was originally estimated, will be 
replaced with the new, calculated lean amine stream and the 
contactor and regenerator will be run until the recycle loop 
converges. 
To ensure an accurate solution, reduce the sensitivities for flow 
and composition as indicated below.
Set [SET-1]
Tab [Page] In this cell... Enter...
Connections Target DEA TO RECY
Target Variable Pressure
Source GAS TO CONTACTOR
Parameters Multiplier 1
Offset -5
Recycle [RCY-1]
Tab [Page] In this cell... Enter...
Connections Inlet DEA TO RECY
Outlet DEA TO CONT
Parameters 
[Variables]
Flow 1.0
Composition 0.1G1-14
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Acid Gas Sweetening with DEA G1-15
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ThG1.4 Simulation Analysis
The incoming sour gas contains 4.1% CO2 and 1.7% H2S. For 
an inlet gas flow rate of 25 MMSCFD, a circulating solution of 
approximately 28 wt.% DEA in water removes virtually all of the 
H2S and most of the CO2. A typical pipeline specification for the 
sweet gas is no more than 2.0 vol.% CO2 and 4 ppm (volume) 
H2S. If you look at the property view of the Sweet Gas stream 
you will see the sweet gas produced easily meets these criteria.
G1.5 Calculating Lean & 
Rich Loadings
Concentrations of acid gas components in an amine stream are 
typically expressed in terms of amine loading—defined as moles 
of the particular acid gas divided by moles of the circulating 
amine. The Spreadsheet in Aspen HYSYS is well-suited for this 
calculation. Not only can the loading be directly calculated and 
displayed, but it can be incorporated into the simulation to 
provide a “control point” for optimizing the amine simulation. 
Also for convenience, the CO2 and H2S volume compositions for 
the Sweet Gas stream are calculated.G1-15
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G1-16 Calculating Lean & Rich Loadings
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ThThe following variables are used for the loading calculations.
The following formulas will produce the desired calculations. 
 Figure G1.5
 Figure G1.6G1-16
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Acid Gas Sweetening with DEA G1-17
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ThThe acid gas loadings can be compared to values recommended 
by D.B. Robinson as shown below.
G1.6 Dynamic Simulation
In the second part of the application, the steady state case will 
be converted into dynamics. 
 Figure G1.7
Maximum Acid Gas Loadings (moles acid gas/mole of amine)
CO2 H2S
MEA, DGA 0.5 0.35
DEA 0.45 0.30
TEA, MDEA 0.30 0.20
The Amines property package used in this application has a 
limit temperature range. So when a stream exceeds the 
temperature range, a warning property view will appear and 
the stream becomes yellow in colour.
For this application, you can ignore this warning.G1-17
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G1-18 Dynamic Simulation
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ThThe general steps that will be used to navigate through this 
detailed procedure are as follows:
1. Converting from Steady State. To prepare the case for 
dynamic simulation, valves will be installed to define 
pressure flow relations and PF specifications will be added to 
selected streams. The tray sizing utility will be implemented 
for sizing tray sections; all other unit operations will be 
sized.
2. Adding Controllers. In this step, appropriate controllers 
will be installed and defined manually.
3. Preparing the Dynamics Simulation. In the last step, the 
Databook will be set up. Changes will be made to key 
variables in the process and the dynamic behaviour of the 
model will be observed.
G1.6.1 Converting from 
Steady State
Changing the PFD
A few changes will have to be made to the PFD in order to 
operate in Dynamic mode. 
1. Delete the Set-1 unit operation.
2. Set the pressure of the DEA TO RECY stream to 995 psia.
3. Install a Recycle operation between the REGEN BTTMS 
stream and the E-100 exchanger.  
Icon Description
Use the Break Connection icon to break the connection 
between streams and unit operations. 
Use the Attach Mode icon to reconnect unit operations and 
streams.
Recycle RCY-2
Page In this cell... Enter...
Connections Inlet REGEN BTTMS
Outlet REGEN BTTMS TO L/RG1-18
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Th4. Delete the Std. Ideal Liq Vol Flow value in stream DEA TO 
COOL.
5. Specify the Std. Ideal Liq. Vol. Flow in stream MAKEUP H2O 
at 2.195 USGPM.
6. Delete MIX-100 and replace it with a tank, V-101. Name the 
vapour outlet from the tank Nitrogen Blanket.
7. Change the Heat Exchanger model of the E-100 exchanger 
from Exchanger Design (End Point) to Dynamic Rating. 
Delete the temperature of the REGEN FEED stream, since it 
will be calculated by the exchanger. Use the following table 
to set the new specifications for the exchanger.
Add Pumps
Two pumps are added because Dynamics mode performs rating 
calculations that consider pressure differences and flow 
resistance. To accommodate this, you need to add equipment 
that significantly impacts the pressure and drives flow.
Add the following pumps to define the pressure flow relation.  
The Recycle operation only functions in Steady State mode. 
Its sole purpose in this case is to provide a suitable solution 
before entering Dynamic mode.
Heat Exchanger E-100
Tab [Page] In this cell... Enter...
Design 
[Connections]
Shell Side Inlet REGEN BTTMS TO L/R
Design 
[Parameters]
Heat Exchanger Model Dynamic Rating
Rating 
[Parameters]
Model Basic
Overall UA 100270 Btu/F-hr
Pump Name P-101
Tab [Page] In this cell... Enter...
Design 
[Connection]
Inlet RICH TO PUMP
Outlet RICH TO VALVE
Energy Q-100G1-19
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G1-20 Dynamic Simulation
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ThAdd Valves
1. Add the following valves to define the pressure flow relation.
 
Design 
[Parameters]
Duty 3739.72 Btu/hr
Comments Add this pump between the separator FLASH TK and 
the stream RICH to L/R.
Pump Name P-102
Tab [Page] In this cell... Enter...
Design 
[Connection]
Inlet REGEN BTTMS
Outlet REGEN BTTMS TO VALVE
Energy Q-101
Design 
[Parameters]
Power 1.972e5 Btu/hr
Comments Add this pump between the stream REGEN BTTMS and 
the recycle RCY-2.
Valve Name VLV-FWKO
Tab [Page] In this cell... Enter...
Design 
[Connection]
Inlet FWKO
Outlet FWKO-1
Worksheet 
[Conditions]
Pressure (FWKO-1) 986.5 psia
Rating [Sizing] Valve Opening 50%
VLV-Flash Vap
Tab [Page] In this cell... Enter...
Design 
[Connection]
Inlet FLASH VAP
Outlet FLASH VAP-1
Worksheet 
[Conditions]
Pressure (Flash Vap-1) 89.99 psia
Rating [Sizing] Valve Opening 50%
Valve Name VLV-101
Tab [Page] In this cell... Enter...
Design 
[Connection]
Inlet RICH TO VALVE
Outlet RICH TO L/R
Pump Name P-101
Tab [Page] In this cell... Enter...G1-20
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Acid Gas Sweetening with DEA G1-21
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ThDesign 
[Parameters]
Delta P 5.8 psi
Rating [Sizing] Valve Opening 50%
Comments Add this valve between the pump P-101 and the 
stream RICH TO L/R.
VLV-102
Tab [Page] In this cell... Enter...
Design 
[Connection]
Inlet REGEN BTTMS TO VALVE
Outlet REGEN BTTMS-2
Design 
[Parameters]
Delta P 13.53 psi
Rating [Sizing] Valve Opening 50%
Comments Add this valve between the stream REGEN BTTMS TO 
VALVE and the recycle RCY-2.
VLV-103
Tab [Page] In this cell... Enter...
Design 
[Connection]
Feed DEA TO VALVE
Product DEA TO COOL
Design 
[Parameters]
Delta P 1 psi
Rating [Sizing] Valve Opening 50%
Comments Add this valve between V-101 and the stream DEA TO 
COOL.
VLV-100@COL1
Tab [Page] In this cell... Enter...
Design 
[Connection]
Feed 1@COL1
Product SWEET GAS@COL1
Design 
[Parameters]
Delta P 1 psi
Rating [Sizing] Valve Opening 50%
Comments Add this valve between the vapour outlet of the 
absorber DEA Contactor and the stream SWEET GAS in 
the absorber sub-flowsheet.
Valve Name VLV-100@COL2
Tab [Page] In this cell... Enter...
Design 
[Connection]
Feed 2@COL2
Product ACID GAS@COL2
Design 
[Parameters]
Delta P 1 psiG1-21
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G1-22 Dynamic Simulation
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ThBefore proceeding any further, ensure that the case is 
completely solved.
For the Regenerator, you may need to click the Reset button 
before clicking the Run button to get the distillation column 
to solve.
2. Open the valves property view and move to the Sizing page 
of the Rating tab. 
3. Select the User Input radio button and specify the Valve 
Opening as indicated. 
4. Click the Size Valve button.
5. Repeat for all valves in the simulation.
Adding Pressure Flow Specifications
In order to run the integrator successfully, the degrees of 
freedom for the flowsheet must be reduced to zero by setting 
the pressure-flow specifications. Normally, you would make one 
pressure-flow specification per flowsheet boundary stream, 
however, there are exceptions to the rule.
One extra pressure flow specification is required for the 
condenser attached to the column Regenerator. This rule applies 
only if there are no pieces of equipment attached to the reflux 
stream downstream of the condenser. Without other pieces of 
the equipment (i.e., pumps, coolers, valves) to define the 
pressure flow relation of these streams, they must be specified 
with a flow specification.
1. In the Main flowsheet, add the following pressure-flow 
Rating [Sizing] Valve Opening 50%
Comments Add this valve between the vapour outlet of the 
distillation column REGENERATOR and the stream 
ACID GAS in the Regenerator Column sub-flowsheet.
For more information 
regarding Pressure-Flow 
specifications in Column 
unit operations see 
Chapter 2 - Column 
Operations in the Aspen 
HYSYS Operations 
Guide.G1-22
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Thspecifications to the boundary streams.  
The pressure-flow specification can be activated in the 
Dynamics tab on the Specs page by selecting the Active 
checkbox. The steady state pressure-flow values should be 
used as a specification.
2. Ensure the PF Relation checkbox for all the valves is 
selected (Dynamics tab, Specs page).
3. Select the Efficiency and Power checkboxes for pumps 
(you may have to clear the Pressure Rise checkbox).
4. On the E-100 property view, click the Calculate K’s button 
(Dynamics tab, Specs page).
5. Clear the Delta P checkbox and select the k checkbox for 
both the Shell and Tube sides of E-100.
6. Also on the cooler E-101 property view, set the pressure flow 
option instead of the pressure drop by selecting the Overall 
k Value checkbox and clearing the Pressure Drop 
checkbox. 
Equipment Sizing
In preparation for dynamic operation, both column tray sections 
and the surrounding equipment must be sized. In steady state 
simulation, the column pressure drop is user specified. In 
dynamics, it is calculated using dynamic hydraulic calculations. 
Complications will arise in the transition from steady state to 
Material Stream
Pressure 
Specification
Flow 
Specification
Value
SOUR GAS Inactive Molar Flow 25 MMSCFD
FWKO-1 Active Inactive 986.5 psia
FLASH VAP-1 Active Inactive 89.99 psia
MAKEUP H2O Inactive Ideal Liq Vol Flow 2.195 USGPM
SWEET GAS Active Inactive 994 psia
ACID GAS Active Inactive 26.5 psia
REFLUX@COL2 Inactive Mass Flow 2983 lb/hr
Nitrogen Blanket Active Inactive 21.5 psia
DEA TO RECY Inactive Inactive
DEA TO FLASH 
TK
Inactive InactiveG1-23
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G1-24 Dynamic Simulation
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Thdynamics if the steady state pressure profile across the column 
is very different from that calculated by the Dynamic Pressure-
Flow solver.
Column Tray Sizing
1. From the Tools menu, select Utilities. Add a Tray Sizing 
utility to size the DEA Contactor tray section.
2. Click the Select TS button. The Select Tray Section property 
view appears.
3. From the Flowsheet list, select DEA Contactor. 
4. From the Object list, select TS-1.
5. Click the Auto Section button to calculate the tray section 
dimension. Accept all the defaults. 
6. Select the Trayed radio button in the Section Results group 
(Performance tab, Results page).
7. Confirm the following tray section parameters for Section_1. 
8. Calculate the Actual Weir Length using the Weir Length 
divided by the number of flow paths for the vapour.
9. Open the DEA Contactor column property view.
10.Click the Rating tab, then select the Tray Sections page. 
11. Enter the tray section parameters for TS-1 obtained from the 
tray sizing utility. 
12.Size the Regenerator tray section following the same 
procedure described above for the DEA Contactor. The Auto 
Section function may create two tray sections; ensure that 
Variable Value
Section Diameter 3.5 ft
Weir Height 2 in
Tray Spacing 24 in
Weir Length 34.81 in
Number of Flow Paths 1
Variable Value
Actual Weir Length (Weir Length/1) 34.81 inG1-24
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Acid Gas Sweetening with DEA G1-25
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Ththe column is sized with only one tray section for all trays. 
Delete the section that does not match the specifications 
below.
13.Confirm the following tray section parameters for Main TS in 
the Regenerator: 
14. In the Regenerator column property view, click the Rating 
tab, then select the Tray Sections page.
15.Enter the Section Diameter value shown above.
Vessel Sizing
The Condenser and Reboiler operations in the Regenerator 
column sub-flowsheet require proper sizing before they can 
operate effectively in Dynamics mode. The volumes of these 
vessel operations are determined using a 10 minute liquid 
residence time.
1. Open the Regenerator property view, then enter the Column 
Environment.
2. Open the Condenser property view.
3. Click the Worksheet tab, then select the Conditions page.
4. Confirm the following Std Ideal Liquid Volumetric Flow. 
5. Calculate the vessel volume as follows, assuming a 50% 
liquid level residence volume.
Variable Value
Section Diameter 3.5 ft
Weir Height 2 in
Tray Spacing 24 in
Total Weir Length 33.75 in
Number of Flow Paths 1
Actual Weir Length 33.75 in
Stream Std Ideal Liquid Volume Flow
Reflux 5.975 USGPM
(G1.1)Vessel Volume Total Liquid Exit Flow Residence Time⋅
0.5
------------------------------------------------------------------------------------------------------------=G1-25
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G1-26 Dynamic Simulation
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Th6. Click the Dynamics tab, then select the Specs page.
7. In the Model Details group, specify the vessel volume as 
15.97 ft3 (as calculated with the above formula).
8. Specify the Level Calculator as a Horizontal cylinder.
9. Open the Reboiler property view.
10.Click the Worksheet tab, then select the Conditions page. 
Confirm the following Std Ideal Liquid Volume Flow.
11.Calculate the vessel volume using Equation (G1.1) and 
assuming a 50% liquid level residence time.
12.Click the Dynamics tab, then select the Specs page.
13. In the Model Details group, specify the vessel volume as 641 
ft3 and the Level Calculator as a Horizontal cylinder.
Separator Sizing
The vapour flow rate through V-100 is large as compared to the 
liquid flow rate, therefore Separator V-100 is sized according to 
the terminal vapour velocity (Vertical Cylinder).
1. Use a residence time of 5 min and a 50% liquid level to size 
the separator FLASH TK.
2. Confirm the Std Ideal Liquid Volume flow in the table below 
and enter the vessel volume.
3. Click the Rating tab, then select the Sizing page. Select the 
Vertical orientation radio button for the separator.    
Stream Std Ideal Liquid Volume Flow
To Reboiler 239.7 bbl/day
Separator Name FLASH TK
Tab [Page] In this cell... Enter...
Worksheet 
[Conditions]
Std Liq Vol Flow (RICH TO 
PUMP)
498.27 USGPM
Rating [Sizing] Volume 660 ft3
V-100
Tab [Page] In this cell... Enter...
Rating [Sizing] Diameter 5.94 ft
Height 29.7 ftG1-26
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ThTank Sizing
The tank V-101 will be sized with a 10 minute liquid residence 
time and a 75% liquid level. Confirm the volumetric flow rate of 
the exit stream and specify the vessel volume (Rating tab, 
Sizing page).  
Heat Exchanger Sizing
The Shell and Tube heat exchanger E-100 will be sized with a 10 
minute residence time for both the shell and the tube side (enter 
respective sizes on the Rating tab, Parameters page). 
A 10 minute liquid residence time will also be used for sizing the 
cooler E-101 (Dynamics tab, Specs page).   
Tank V-101
Tab [Page] In this cell... Enter...
Worksheet 
[Conditions]
LiqVol Flow (DEA TO VALVE) 194.4 USGPM
Rating [Sizing] Volume 346.4 ft3
Design [Parameters] Liquid Level 75%
Heat Exchanger E-100
Tube Side Sizing
Worksheet 
[Conditions]
Std Ideal Liq Vol Flow (RICH TO 
L/R)
498.27 USGPM
Rating 
[Parameters]
Volume 666 ft3
Shell Side Sizing
Worksheet 
[Conditions]
Std Ideal Liq Vol Flow (REGEN 
BTTMS TO L/R)
691.3 USGPM
Rating 
[Parameters]
Volume 925.2 ft3
Cooler E-101
Tab [Page] In this cell... Enter...
Worksheet 
[Conditions]
Std Ideal Liq Vol Flow (DEA 
TO COOL)
194.4 USGPM
Dynamics 
[Specs]
Volume 259.8 ft3G1-27
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G1-28 Dynamic Simulation
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ThRunning the Integrator
1. Switch to the Dynamic mode by clicking the Dynamic Mode 
button. Click No when asked if you want the Dynamics 
Assistant to help you resolve items in Steady State before 
switching to Dynamic mode.
2. Open the Product Block for stream Nitrogen Blanket.
3. Ensure that the radio button for temperature is selected, and 
the value is specified as 70°F.
4. Click the Composition tab and set the composition to 
100% Nitrogen.
5. Return to the Conditions tab, and press the Export 
Conditions to Stream button. 
6. Open the Integrator property view and change the Step 
Size to 0.2 sec on the General tab.
7. Click the Options tab and make sure that the Singularity 
analysis before running checkbox is selected.
8. Run the integrator for 2 minutes to ensure that the degrees 
of freedom for pressure flow specification is zero and all the 
vessels are sized. Select Non-Equilibrium Vapour when 
asked how you want to initialize V-101.
G1.6.2 Adding a Control 
Scheme
The following Controllers will be used in the Dynamics model:
• Level
• Temperature
• Pressure
• FlowG1-28
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Acid Gas Sweetening with DEA G1-29
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ThLevel Controllers 
Level Controller Name V100-LC
Tab [Page] In this cell... Enter...
Connections Process Object V-100
Process Variable Liquid Percent Level
Output Variable VLV-FWKO
Parameters 
[Configuration]
PVmin 0%
PVmax 100%
Action Direct
Mode Auto
SP 50%
Kc 2
Ti 2
FLASH TK-LC
Tab [Page] In this cell... Enter...
Connections Process Object FLASH TK
Process Variable Liquid Percent Level
Output Variable VLV-101
Parameters 
[Configuration]
PVmin 0%
PVmax 100%
Action Direct
Mode Auto
SP 50%
Kc 2
Ti 2
Level Controller Name LIC-100
Tab [Page] In this cell... Enter...
Connections Process Object V-101
Process Variable Liquid Percent Level
Output Variable MAKEUP H2O
To size the Control Valve for the MAKEUPH2O stream, select the 
Control Valve button.
FCV for MAKEUP H2O Flow Type Mass Flow
Min Available 0.0 lb/hr
Max Available 1200 lb/hrG1-29
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G1-30 Dynamic Simulation
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ThParameters 
[Configuration]
PVmin 0%
PVmax 100%
Action Reverse
Mode Auto
SP 50%
Kc 2
Ti 2
Reb-LC@COL2
Tab [Page] In this cell... Enter...
Connections Process Object Reboiler@COL2
Process Variable Liquid Percent Level
Output Variable VLV-102@Main
Parameters 
[Configuration]
PVmin 0%
PVmax 100%
Action Direct
Mode Auto
SP 50%
Kc 2
Ti 2
Level Controller Name Cond-LC@COL2
Tab [Page] In this cell... Enter...
Connections Process Object Condenser@ COL2
Process Variable Liquid Percent Level
Output Variable Reflux
To size the Control Valve for the Reflux stream, select the Control 
Valve button.
FCV for Reflux Flow Type Mass Flow
Min Available 0.0 lb/hr
Max Available 5512 lb/hr
Parameters 
[Configuration]
PVmin 0%
PVmax 100%
Action Direct
Mode Auto
SP 50%
Kc 1
Ti 2
Level Controller Name LIC-100
Tab [Page] In this cell... Enter...G1-30
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ThTemperature Controllers 
Temperature Controller 
Name
TIC-100
Tab [Page] In this cell... Enter...
Connections Process Object DEA TO PUMP
Process Variable Temperature
Output Variable COOLER Q
To size the Control Valve for the Cooler Duty stream, select the 
Control Valve button. To filter high frequency disturbances, click the 
Parameter tab, select the PV Conditioning page, and change the First 
Order Time Constant from 15 to 50.
FCV for COOLER Q Duty Source Direct Q
Min Available 0.0 Btu/hr
Max Available 2.4e7 Btu/hr
Parameters [Configuration] PVmin 32 F
PVmax 122 F
Action Direct
Mode Auto
SP 91 F
Kc 10
Ti 10
TIC-103@COL2
Tab [Page] In this cell... Enter...
Connections Process Object Main TS
Process Variable Stage Temperature
Variable Specifics 18_Main TS
Output Variable RBLR Q
To size the Control Valve for the Reboiler Duty stream, select the 
Control Valve button.
FCV for RBLR Q Flow Type Direct Q
Min Available 0 Btu/hr
Max Available 1.9e7 Btu/hr
Parameters [Configuration] PVmin 176 F
PVmax 302 F
Action Reverse
Mode Auto
SP 255°F
Kc 2
Ti 5G1-31
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G1-32 Dynamic Simulation
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ThPressure Controllers 
Pressure Controller Name PIC-100@COL1
Tab [Page] In this cell... Enter...
Connections Process Object TS-1@COL1
Process Variable Top Stage Pressure
Output Variable VLV-100@COL1
Parameters [Configuration] PVmin 950 psia
PVmax 1050 psia
Action Direct
Mode Auto
SP 995 psia
Kc 2
Ti 2
PIC-100@COL2
Tab [Page] In this cell... Enter...
Connections Process Object Condenser @COL2
Process Variable Vessel Pressure
Output Variable VLV-100@COL2
Parameters [Configuration] PVmin 0 psia
PVmax 50 psia
Action Direct
Mode Auto
SP 31 psia
Kc 2
Ti 2G1-32
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ThFlow Controller
G1.6.3 Preparing Dynamic 
Simulation
Now that the case is ready to run in Dynamic mode, the next 
step is installing a strip chart to monitor the general trends of 
key variables.
Monitoring in Dynamics 
You may use several variables in the same chart. If you have a 
large number of variables that you would like to track, use 
several Strip Charts rather than use all of the variables on one 
chart. You may use the same variable in more than one Strip 
Chart.
For this simulation case, use the Databook (CTRL D) to set up 
two strip charts as defined below:
• StripChart1 - Contactor 
Flow Controller Name RECY-FC
Tab [Page] In this cell... Enter...
Connections Process Object DEA TO CONT
Process Variable Mass Flow
Output Variable VLV-103
Parameters 
[Configuration]
PVmin 0 lb/hr
PVmax 220460 lb/hr
Action Reverse
Mode Auto
SP 97700 lb/hr
Kc 0.5
Ti 0.20
Flowsheet Object Variable
Case DEA TO CONT Mass Flow
Case GAS TO CONTACTOR Mass FlowG1-33
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G1-34 References
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Th• StripChart2 - Regenerator 
1. Start the Integrator and allow the variables to line out. 
If you get an initial numerical error after you start the 
integrator, start the integrator again. In the Session 
Preferences property view (Simulation tab, Errors group), 
you can direct these errors to the trace window and have the 
simulation continue regardless.
After a few minutes the integrator will stop and an error 
message will appear in the trace window.
2. From the Simulation menu, select Equation Summary 
View.
3. Click the Uncoverged tab and click the Update Sorted List 
button.
The top equation refers to pump P-102. If you examine this 
pump in the PFD you will see that it is fully on, but its 
downstream valve has been completely shut by a controller. 
As an advanced exercise, you can refine the control scheme 
to address this issue.
G1.7 References
Gerunda, Arthur. How to Size Liquid-Vapour Separators 
Chemical Engineering, Vol. 88, No. 9, McGraw-Hill, New York, 
(1981).
Case SWEET GAS Mass Flow
Case RICH DEA Mass Flow
Case SWEET GAS Pressure
Flowsheet Object Variable
Case REGEN FEED Mass Flow
Case ACID GAS Mass Flow
Case REGEN BTTMS Mass Flow
Case ACID GAS Pressure
Flowsheet Object VariableG1-34
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Atmospheric Crude Tower R1-1
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ThR1 Atmospheric Crude 
TowerR1-1
R1.1  Process Description ..................................................................... 2
R1.2  Setup ........................................................................................... 5
R1.3  Steady State Simulation............................................................... 8
R1.3.1  Simulate the Pre-Fractionation Train.......................................... 9
R1.3.2  Install Atmospheric Crude Fractionator .................................... 11
R1.4  Results....................................................................................... 16
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R1-2 Process Description
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ThR1.1 Process Description
After passing through a preheat train, 100,000 barrel/day of 
29.32o API crude is fed into a pre-flash separator operating at 
450o F and 75 psia. The vapour from this separator bypasses the 
crude furnace and is re-mixed with the hot (650o F) pre-flash 
liquids leaving the furnace. The combined stream is then fed to 
the atmospheric crude column.
 Figure R1.1R1-2
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Atmospheric Crude Tower R1-3
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ThThe column operates with a total condenser, three coupled side 
strippers, and three pump around circuits.
A naphtha product is produced overhead, a kerosene product is 
produced from the first side stripper, a diesel product is 
produced from the second side stripper, and an atmospheric gas 
oil (AGO) is produced from the third side stripper. Both the AGO 
side stripper and the diesel side stripper are ‘steam stripped’, 
while the kerosene side stripper has a reboiler.
The following Assay data is used to characterize the oil for this 
example:  
 Figure R1.2
Assay Liq Volume % Boiling Temperature (°F)
0.0 15.0
4.5 90.0
9.0 165.0
14.5 240.0
20.0 310.0
30.0 435.0R1-3
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R1-4 Process Description
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ThThere are two basic steps in this process simulation:
1. Setup. The component list must include C1 to C4 light ends 
components as well as the hypocomponents that will be used 
to represent the C5+ portion of the crude oil. The Oil 
Characterization procedure in Aspen HYSYS will be used to 
convert the laboratory data into petroleum 
hypocomponents.
2. Steady State Simulation. This case will be modeled using 
a Pre-Fractionation Train consisting of a Separator and 
Heater. The Outlet stream will then fed to an Atmospheric 
Crude Fractionator. The results will be displayed. Dynamic 
Simulation - The steady state solution will be used to size 
all the unit operations and tray section. An appropriate 
control strategy will be implemented and the key variables 
will be displayed on a strip chart.
40.0 524.0
50.0 620.0
60.0 740.0
70.0 885.0
76.0 969.0
80.0 1015.0
85.0 1050.0
Bulk Properties
Standard Density 29.32o API
Light Ends Liq Volume %
Methane 0.0065
Ethane 0.0225
Propane 0.3200
i-Butane 0.2400
n-Butane 0.8200
H2O 0.0000
Any other library components required for the overall 
simulation (for example, H2O) should be selected as well.
Assay Liq Volume % Boiling Temperature (°F)R1-4
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Atmospheric Crude Tower R1-5
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ThR1.2 Setup
1. In the Session Preferences property view, set the unit set to 
Field units.
2. In the Component List property view, select the following 
components: methane, ethane, propane, i-butane, n-
butane, and water.
3. In the Fluid Package property view, define a fluid package 
with Peng-Robinson as the property package.
Oil Characterization
Click the Oil Environment icon to enter the Oil Characterization 
Environment, using the fluid package you just created. Three 
steps are required for characterizing the oil:
1. Define the Assay.
2. Create the Blend.
3. Install Oil in the Flowsheet.
Define the Assay
1. On the Assay page of the Oil Characterization property view, 
click the Add button. This will create a new assay, and you 
will see the Assay property view.
2. Change the Bulk Properties setting to Used.
3. Complete the Input data for the Bulk Properties as shown 
below:
4. Since the TBP data is supplied, select TBP from the Assay 
Data Type drop-down list.
 Figure R1.3
 
Oil Environment iconR1-5
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R1-6 Setup
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Th5. Select Liquid Volume% from the Assay Basis drop-down 
list.
6. Click the Edit Assay button and enter the data as follows. 
7. In the Assay Definition group, click the Light Ends drop-
down list and select Input Composition.
8. In the Input Data group, click the Light Ends radio button.
9. Enter the light ends data as follows.
 Figure R1.4
 Figure R1.5R1-6
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Atmospheric Crude Tower R1-7
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Th10.Upon completion of characterizing the assay, select the 
Calculate button. Aspen HYSYS will calculate the Working 
Curves, which can be viewed on the Working Curve tab.
You can scroll through this table to view all 50 points of the 
Working Curve.
11.Close the Assay property view.
Create the Blend (Cut the Oil)
1. Click the Cut/Blend tab (Oil Characterization property view) 
and click the Add button. The Blend: Blend-1 view appears. 
2. Click the Data tab, then select the Assay you created in the 
Available Assays column.
3. Click the Add button. Aspen HYSYS will transfer that Assay 
to the Oil Flow Information table.
As a guideline, each Outlet stream from the crude column 
should contain a minimum of 5 hypocomponents where the 
composition is greater than 1.0%. Therefore, a total of 30 
components should fulfil this requirement.
4. From the Cut Option Selection drop-down list, select User 
Points, then specify the Number of Cuts at 30. Aspen 
HYSYS will calculate the hypocomponents.
 Figure R1.6R1-7
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R1-8 Steady State Simulation
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Th5. Click the Tables tab to view the hypocomponents.
6. From the Table Type group drop-down list, select Molar 
Compositions.
7. Close the Blend property view.
Install Oil in the Flowsheet
The final step is to install the oil in the flowsheet.
1. Click the Install Oil tab of the Oil Characterization property 
view.
2. In the Stream Name cell, type Raw Crude. This is the 
stream name where you would like to “install” the oil.
3. On the Oil Characterization property view, click Return to 
Basis Environment button.
4. Click the Enter Simulation Environment button on the 
Simulation Basis Manager property view to enter the Main 
Environment. The Raw Crude stream has been installed.
R1.3 Steady State 
Simulation
The following major steps will be taken to set up this case in 
steady state:
1. Simulate the Pre-Fractionation Train. This determines 
the feed to the atmospheric fractionator, and includes the 
pre-flash separation, crude furnace, and mixer which 
recombines the pre-flash vapour and furnace outlet stream.
2. Install the Atmospheric Crude Fractionator. Add the 
column steam inlets to the flowsheet and install the crude 
fractionator using the rigorous distillation column operation.R1-8
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Atmospheric Crude Tower R1-9
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ThR1.3.1 Simulate the Pre-
Fractionation Train
Inlet Stream
Specify the Inlet stream (Raw Crude) as shown below. 
Because the composition has been transferred from the Oil 
Characterization, the stream is automatically flashed.
Pre-Flash Operations
Install the Separator, Heater, and Mixer and provide the 
information displayed below:     
Stream [Raw Crude]
In this cell... Enter...
Temperature [F] 450.0°F
Pressure [psia] 75.0 psia
Std Ideal Liq Vol Flow [barrel/day] 100,000 barrel/day
Separator [PreFlash]
Tab [Page] In this cell... Enter...
Design 
[Connections]
Inlet Raw Crude
Vapour Outlet PreFlash Vap
Liquid Outlet PreFlash Liq
Heater [Crude Heater]
Tab [Page] In this cell... Enter...
Design 
[Connections]
Inlet PreFlash Liq
Outlet Hot Crude
Energy Crude Duty
Design [Parameters] Delta P 10.00 psi
Worksheet 
[Conditions]
Temperature (Hot Crude) 650 °FR1-9
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R1-10 Steady State Simulation
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ThThe calculated specifications for the Pre-Fractionation Atm Feed 
stream appear below.  
The Pre-Fractionation train is shown as follows:
Mixer [Mixer]
Tab [Page] In this cell... Enter...
Design 
[Connections]
Inlets Hot Crude, PreFlash Vap
Outlet Atm Feed
 Figure R1.7
 Figure R1.8R1-10
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Atmospheric Crude Tower R1-11
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ThR1.3.2 Install Atmospheric 
Crude Fractionator
Steam and Trim Duty Streams
Before simulating the atmospheric crude tower, the steam feeds 
and the energy stream (Q-Trim - representing the side 
exchanger on stage 28) to the column must be defined.
The Q-Trim stream does not require any specifications, this will 
be calculated by the Column.
Three steam streams are fed to various locations in the tower. 
Specify the steam streams as shown below. Define the 
composition for each as H2O = 1.0000. 
These streams could be installed inside the Column Build 
Environment as well. By taking this approach, you will need 
to “attach” these streams to the Column Flowsheet so that 
they can be used in the calculations.
Column
In this application, the Input Experts option have been turned 
off, and the Column is being configured directly through the 
Column property view.
An energy stream can be installed by selecting the 
appropriate icon from the palette, or a material stream 
converted to an energy stream on the Util page of the stream 
property view.
Stream Name Temperature [F] Pressure [psia] Mass Flow [lb/hr]
Main Steam 375.00 150.00 7500.00
Diesel Steam 300.00 50.00 3000.00
AGO Steam 300.00 50.00 2500.00R1-11
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R1-12 Steady State Simulation
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ThThe main column, Atms Tower, is represented by the following:
• Number of stages is 29 ideal stages (not including the 
condenser).
• The overhead condenser operates at 19.7 psia and the 
bottom stage at 32.7 psia.
• The condenser experiences a 9 psi pressure drop.
• The temperature estimates for the condenser, top stage, 
and bottom stage are 100oF, 250oF and 600oF, 
respectively.
• Condensed water is removed via a water draw from the 
three-phase condenser.
Aspen HYSYS comes with a 3 Stripper Crude Column template. 
A Refluxed Absorber template could also be used, but this would 
add the procedure of installing Side Strippers and Pump 
Arounds.
For this example, install the 3 Stripper Crude Column custom 
template.
1. Select the Custom Column icon in the Object Palette, then 
click the Read an Existing Column Template button. The 
Available Column Templates finder property view appears.
2. In the Files of type drop-down list, select Column 
Templates (*.col).
3. From the list, select the 3sscrude.col template file, then 
click the Open button.
The 3sscrude.col template installed 40 trays, 29 in the Main 
Tray section, 3 trays in each of the 3 Side Strippers (1 
reboiled and 2 steam stripped), a reboiler, and a condenser. 
Custom Column iconR1-12
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Atmospheric Crude Tower R1-13
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Th4. In the Column Property view, connect the Inlet and Outlet 
streams to the column sub-flowsheet as shown (Design tab, 
Connections page).
5. Modify the Draw and Return stages of the Pump Arounds and 
Side Strippers on the corresponding page of the SideOps 
tab. 
 Figure R1.9
 Figure R1.10R1-13
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R1-14 Steady State Simulation
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Th6. In the Atmos Tower Column property view, specify the 
column information below. 
Field units are used for column preferences.
Specifications
On the Monitor page of the Design tab, make the following 
changes and input the values into the default set of 
specifications supplied with the pre-built 3-Side Stripper 
Column.
1. Change all the Pump Around delta T specifications to a 
Duty specification.
2. Delete the Kero SS BoilUp Ratio and the Residue Rate 
specs.
Open the specification property view by clicking the View 
button, then click Delete to delete the specification.
3. Specify the Reflux Ratio spec to have a value of 1. Clear 
the Reflux Ratio Active checkbox and make it an Estimate 
only. 
4. Change the following default specifications by selecting the 
specification in the table and clicking the View button.
Change the Flow Basis to Std Ideal Volume before entering 
values.
Column [Atms Tower]
Tab [Page] In this cell... Enter...
Parameters 
[Profiles]
Condenser Pressure 19.7 psia
29_Main TS Pressure 32.7 psia
Condenser Temperature 100°F
1_Main TS Temperature 250°F
29_Main TS Temperature 600°F
Specification Flow Basis Spec Type Spec Value
Kero_SS Prod Flow Volume 9300 barrel/day
Diesel_SS Prod Flow Volume 1.925e+04 barrel/day
AGO_SS Prod Flow Volume 4500 barrel/day
PA_1_Rate(Pa) Volume 5.000e+04 barrel/day
PA_1_Duty(Pa) Duty -5.500e+07 Btu/hrR1-14
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Atmospheric Crude Tower R1-15
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Th5. On the Specs page of the Design tab, add the following new 
specifications by clicking the Add button in Column 
Specifications group.
The final specification table will appear as shown below:
6. Once you have provided all of the specifications, run the 
column.
PA_2_Rate(Pa) Volume 3.000e+04 barrel/day
PA_2_Duty(Pa) Duty -3.500e+07 Btu/hr
PA_3_Rate(Pa) Volume 3.000e+04 barrel/day
PA_3_Duty(Pa) Duty -3.500e+07 Btu/hr
Naptha Prod Rate Volume 2.300e+04 barrel/day
Specification Type Variable (Field) Value
Column Liquid Flow Name Overflash Spec
Stages 27_Main TS
Flow Basis Std Ideal Vol
Spec Value 3500.00 barrel/day
Column Duty Name Kero Reb Duty
Energy Stream Kero_SS_Energy @Col1
Spec Value 7.5e+6 Btu/hr
Column Vapour Flow Name Vap Prod Flow
Stage Condenser
Flow Basis Molar
Spec Value 0.00 lbmole/hr
 Figure R1.11
Specification Flow Basis Spec Type Spec ValueR1-15
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R1-16 Results
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ThR1.4 Results
Workbook Case (Main)
The material stream results for the Workbook Case[Main] 
appear below.   
 Figure R1.12R1-16
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Atmospheric Crude Tower R1-17
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ThWorkbook Case (Atms Tower)
The material stream results for the Workbook Case [Atms 
Tower] appear below. 
 Figure R1.13R1-17
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R1-18 Results
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ThR1-18
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Sour Water Stripper R2-1
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ThR2 Sour Water StripperR2-1
R2.1  Process Description ..................................................................... 2
R2.2  Setup ........................................................................................... 4
R2.3  Steady State Simulation............................................................... 4
R2.3.1  Installing the SW Stripper........................................................ 5
R2.4  Results......................................................................................... 7
R2.5  Case Study................................................................................... 9
R2.5.1  Results ............................................................................... 11
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R2-2 Process Description
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ThR2.1 Process Description
The sour water stripper configuration shown in the above PFD is 
a common unit in refineries. It processes sour water that comes 
from a variety of sources including hydrotreaters, reformers, 
hydrocrackers, and crude units. The sour water is often stored in 
crude tanks, thereby eliminating the need for special vapour 
recovery systems.
 Figure R2.1
To see this case completely solved, see your Aspen 
HYSYS\Samples\ directory and open the R-2.hsc file.R2-2
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Sour Water Stripper R2-3
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ThA sour water stripper either uses the direct application of 
stripping steam (usually low quality, low pressure) or a steam-
fired reboiler as a heat source. 
The intent is to drive as much H2S and NH3 overhead in the 
stripper as possible. The sizing of a sour water stripper is very 
important since its capacity must equal or exceed the normal 
production rates of sour water from multiple sources in the 
refinery. Often, refiners find their strippers undersized due to a 
lack of allowance for handling large amounts of sour water, 
which can result from upset conditions (like start-up and 
shutdown). Consequently, there is often a backlog of sour water 
waiting to be processed in the stripper. With the increasing 
importance of environmental restrictions, the sour water 
stripper plays a greater role in the overall pollution reduction 
program of refiners.
The Sour Water feed stream goes through a feed/effluent 
exchanger where it recovers heat from the tower bottoms 
stream (Stripper Bottoms). This new stream (Stripper Feed) 
enters on tray 3 of an 8 tray distillation tower with a reboiler and 
a total reflux condenser. A quality specification of 10 ppm wt. 
ammonia on the tower bottoms (Stripper Bottoms) is specified. 
The tower bottoms, Stripper Bottoms, exchanges heat with the 
incoming feed and exits as Effluent.
 Figure R2.2R2-3
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R2-4 Setup
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ThThere are two basic steps in this process simulation:
1. Setup. This case uses the Sour Peng-Robinson package and 
the following components: H2S, NH3 and H2O. 
2. Steady State Simulation. The case will consist of an 8 
stage stripper, used to separate H2S and NH3, and a heat 
exchanger to minimize heat loss.
R2.2 Setup
1. In the Session Preferences property view, set the unit set to 
Field units.
2. In the Component List property view, select the following 
components: H2S, NH3 and H2O.
3. In the Fluid Package property view, select the Sour Peng-
Robinson property package. 
Sour Peng-Robinson combines the PR equation of state and 
Wilson’s API-Sour model for handling sour water systems.
R2.3 Steady State 
Simulation
The following general steps will be taken to setup this case in 
steady state:
1. Installing the SW Stripper. An 8 stage distillation column 
will be used to strip the sour components from the feed 
stream. The liquid leaving the bottom of the column heats 
the incoming feed stream in a heat exchanger.
2. Case Study. A case study will be performed to obtain steady 
state solutions for a range of stripper feed temperatures.R2-4
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Sour Water Stripper R2-5
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ThR2.3.1 Installing the SW 
Stripper
Feed Stream
Specify the feed stream as shown below. 
Operations
1. Install and specify the Heat Exchanger as shown below. 
2. Install a Distillation Column. This column will have both a 
reboiler and an overhead condenser.
Material Stream [SourH2O Feed]
In this cell... Enter...
Temperature 100°F
Pressure 40 psia
Std Ideal Liq Vol Flow 50,000 barrel/day
Comp Mass Frac [H2S] 0.0070
Comp Mass Frac [NH3] 0.0050
Comp Mass Frac [H2O] 0.9880
Heat Exchanger [Feed Bottoms]
Tab[Page] In this cell... Enter...
Design 
[Connections]
Tube Side Inlet Sour H2O Feed
Tube Side Outlet Stripper Feed
Shell Side Inlet Stripper Bottoms
Shell Side Outlet Effluent
Design 
[Parameters]
Heat Exchanger Model Exchanger Design 
(Weighted)
Tube Side Pressure Drop 10 psi
Shell Side Pressure Drop 10 psi
Worksheet 
[Conditions]
Temperature (Stripper 
Feed)
200°FR2-5
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R2-6 Steady State Simulation
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Th3. Define the Column configuration as shown below.     
If messages appear regarding loading an older case or 
installing property sets, click the OK button. They will not 
affect the case.
4. In the Column property view, click the Design tab, then 
select the Monitor page.
In the present configuration, the column has two degrees of 
freedom. For this example, the two specifications used will 
be a quality specification and a reflux ratio.
5. Modify the existing specification based on the information 
below:
6. Add a Component Fraction specification, and enter the 
following information in the Comp Frac Spec property view: 
Column [SW Stripper]
Page In this cell... Enter...
Connections No. of Stages 8
Inlet Stream Stripper Feed
Inlet Stage 3
Condenser Type Full Reflux
Ovhd Vapour Off Gas
Bottoms Liquid Stripper Bottoms
Reboiler Energy Stream Q-Reb
Condenser Energy Steam Q-Cond
Pressure Profile Condenser Pressure 28.7 psia
Reboiler Pressure 32.7 psia
Column [SW Stripper]
Tab [Page] Variable Spec Modify
Design [Specs] Ovhd Vap Rate Active = clear
Reflux Ratio Active = selected
Spec Value = 10 Molar
Tab In this cell... Enter...
Parameters Name NH3 Mass Frac (Reboiler)
Stage Reboiler
Spec Value 0.000010
Component AmmoniaR2-6
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Sour Water Stripper R2-7
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ThTo add a new specification, click the Add Specs button.
7. Click the Parameters tab, then select the Solver page. 
Change the Fixed Damping Factor to 0.4. 
A damping factor will speed up tower convergence and 
reduce the effects of any oscillations in the calculations (the 
default value is 1.0). 
8. Run the column to calculate the values by clicking the Run 
button.
R2.4 Results
Workbook Case (Main)
Materials Streams Tab
Summary Active Selected
Reflux Ratio
Spec Value
Active
10 Molar
 Figure R2.3
Tab In this cell... Enter...
For more information on 
which damping factor is 
recommended for 
different systems, refer to 
Chapter 2 - Column 
Operations of the 
Aspen HYSYS R2-7
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R2-8 Results
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ThCompositions Tab  
Energy Streams Tab
 Figure R2.4
 Figure R2.5R2-8
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Sour Water Stripper R2-9
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ThR2.5 Case Study
The simulation can be run for a range of Stripper Feed 
temperatures (e.g., 190°F through 210°F in 5 degree 
increments) by changing the temperature specified for Stripper 
Feed in the worksheet.
You can automate these changes by using the Case Studies 
feature in the DataBook.
1. Open the DataBook property view (Tools menu).
2. On the Variables tab, enter the variables as shown below. 
3. Click the Case Studies tab.
4. In the Available Case Studies group, click the Add button to 
create Case Study 1.
Flowsheet Object Variables Variables Description
Case Q-Cond Heat Flow Cooling Water
Q-Reb Heat Flow Steam
Stripper Feed Temperature Temperature
Feed Bottoms UA UA
T-100 
SW Stripper
Main TS Stage Liq Net Mass 
Flow (2__Main TS)
Liq MF Tray 2
Main TS Stage Liq Net Mass 
Flow (7__Main TS)
Liq MF Tray 7
Main TS Stage Vap Net Mass 
Flow (2__Main TS)
Vap MF Tray 2
Main TS Stage Vap Net Mass 
Flow (7__Main TS)
Vap MF Tray 7R2-9
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R2-10 Case Study
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Th5. Select the checkboxes under the Independent and 
Dependent variable columns as shown below.
To automate the study, the Dependent Variable range and 
Step Size must be given.
6. Click the View button to access the Case Studies Setup 
property view. Define the range and step size for the 
Stripper Feed Temperature as shown below.
Temperature values are given in °F.
7. To begin the Study, click the Start button.
8. Click the Results button to view the variables. If the results 
are in graphical form, click the Table radio button on the 
Case Studies property view.
 Figure R2.6
 Figure R2.7R2-10
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Sour Water Stripper R2-11
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ThR2.5.1 Results
The results of this study appear below.
 Figure R2.8R2-11
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R2-12 Case Study
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ThR2-12
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Propylene/Propane Splitter P1-1
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ThP1 Propylene/Propane 
Splitter P1-1
P1.1  Process Description ..................................................................... 2
P1.2  Setup ........................................................................................... 4
P1.3  Steady State Simulation............................................................... 4
P1.3.1  Starting the Simulation ........................................................... 4
P1.3.2  Adding the Stripper (Reboiled Absorber) .................................... 6
P1.3.3  Adding the Rectifier (Refluxed Absorber).................................... 7
P1.3.4  Adding the Specifications......................................................... 8
P1.4  Results......................................................................................... 9
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P1-2 Process Description
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ThP1.1 Process Description 
A propylene-propane splitter is generally an easy column to 
converge. The critical factor in producing good results, however, 
is not the ease of solution, but the accurate prediction of the 
relative volatility of the two key components. Special 
consideration was given to these components, and others, in 
developing the binary interaction coefficients for the Peng 
Robinson and Soave Redlich Kwong Equations of State to ensure 
that these methods correctly model this system.
 Figure P1.1P1-2
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Propylene/Propane Splitter P1-3
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ThThese splitters have many stages and are often built as two 
separate columns. This simulation will contain two Columns, a 
Stripper, and a Rectifier. The Stripper is modeled as a Reboiled 
Absorber and contains 94 theoretical stages. The Rectifier is a 
Refluxed Absorber containing 89 theoretical stages. The Stripper 
contains two feed streams, one is the known stream, FEED, and 
the other is the bottoms from the Rectifier. Propane is recovered 
from the Stripper bottoms (95%) and Propene is taken off the 
top of the Rectifier (99%).
There are two basic steps in this process simulation:
1. Setup. The Soave Redlich Kwong (SRK) property package 
will be used and the component list includes Propane and 
Propene.
2. Steady State Simulation. The case will consist of a column 
divided into two tray sections: a Refluxed Absorber as a 
Rectifier and a Reboiled Absorber as a Stripper.
 Figure P1.2P1-3
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P1-4 Setup
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ThP1.2 Setup
1. In the Session Preferences property view, set the unit set to 
Field units.
2. In the Component List property view, select the following 
two components: Propane and Propene. 
It may be easier to search by chemical formula (C3H8 and 
C3H6), as the entire list is quite extensive.
3. In the Fluid Package property view, select the Soave 
Redlich Kwong (SRK) equation of state (EOS) as the 
property method for this case. 
Ensure that the selected component you just created 
appears in the Component List Selection drop-down list. 
P1.3 Steady State 
Simulation
The case will be setup in steady state using the Custom Column 
option. Both the Rectifier and Stripper columns will be built in 
the same column environment. 
P1.3.1 Starting the Simulation
Defining the Feed Stream
In the Main Simulation environment, define the conditions and 
compositions of the Feed stream as shown in the following table.
Material Stream [Feed]
In this cell... Enter...
Name Feed
Vapour Frac 1.0
Pressure 300 psia
Molar Flow 1350 lbmole/hrP1-4
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Propylene/Propane Splitter P1-5
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ThInstalling the Column
1. Click the Custom Column icon on the Object Palette. The 
Custom Column feature will be used to build both columns in 
a single column environment.
2. Click the Start with a Blank Flowsheeet button. The 
column appears in the PFD.
3. Double-click the column in the PFD to open the Column 
property view. 
4. Click the Design tab and select the Connections page. 
5. In the Inlet Streams group, enter stream Feed as an 
External Feed Stream, making this stream accessible to the 
Template Environment.
6. Enter the Column Environment by clicking the Column 
Environment button at the bottom of the Column property 
view.
For this example, you will need a Total Condenser, Reboiler and 
two Tray Sections. A Tray Section and a Condenser will be used 
for the Refluxed Absorber (Rectifier), a Reboiler and another 
Tray Section will be used for the Reboiled Absorber (Stripper). 
The overhead product from the Stripper will serve as the feed to 
the Rectifier, and the bottoms product from the Rectifier 
provides a second feed to the Stripper, entering at Stage 1.
Comp Mole Frac [Propane] 0.4
Comp Mole Frac [Propene] 0.6
Material Stream [Feed]
In this cell... Enter...P1-5
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P1-6 Steady State Simulation
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ThP1.3.2 Adding the Stripper 
(Reboiled Absorber)
Install the Reboiled Absorber before the Reboiler. This column 
has 94 ideal stages and a Reboiler.
Ensure that you are within the Column Environment. The PFD 
property view and the Column Object Palette should be visible 
(as shown on the left).
Installing the Tray Section
For this Column a new Tray Section has to be installed.
1. Double-click the Tray Section icon on the Column Object 
Palette. The tray section appears in the PFD and the Tray 
Section property view appears.
2. Supply the following information.
3. Close the Tray Section property view.
Tray Section [Stripper]
Tab [Page] In this cell... Enter...
Design 
[Connections]
Column Name Stripper
Liquid Inlet Rect Out
Vapour Inlet Boilup
Vapour Outlet To Rect
Liquid Outlet To Reboiler
Optional Feed Streams Feed (Stage 47)
Design 
[Parameters]
Number of Trays 94
Comments Define the Number of Trays on the 
Parameters page first.
Design 
[Pressures]
Tray 1 290 psia
Tray 94 300 psia
Column Object Palette
Tray Section iconP1-6
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Propylene/Propane Splitter P1-7
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ThInstalling the Reboiler
The Reboiler for the Absorber must be installed with the Stripper 
Column.
1. Double-click the Reboiler icon on the Column Object 
Palette. The Reboiler appears in the PFD and the Reboiler 
property view appears.
2. Enter the following information.
P1.3.3 Adding the Rectifier 
(Refluxed Absorber)
Next, you will install the Rectifier. This column has 89 ideal 
stages and a Total Condenser.
Installing the Tray Section
Install a new Tray Section for the Absorber. 
1. Double-click the Tray Section icon on the Object Palette.
2. In the Tray Section property view, supply the parameters as 
shown below. 
Reboiler [Reboiler]
Tab [Page] In this cell... Enter...
Design 
[Connections]
Name Reboiler
Boilup Boilup
Inlets To Reboiler
Bottoms Outlet Propane
Energy Reboiler Duty
Tray Section [Rectifier]
Tab [Page] In this cell... Enter...
Design 
[Connections]
Name Rectifier
Liquid Inlet Reflux
Vapour Inlet To Rect
Vapour Outlet To Condenser
Liquid Outlet Rect Out
Reboiler icon
Tray Section iconP1-7
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P1-8 Steady State Simulation
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Th3. Close the Tray Section property view.
Installing the Total Condenser
A Total Condenser is required for the column.
1. Double-click the Total Condenser icon in the Object 
Palette. The condenser icon appears in the PFD, and the 
condenser property view appears.
2. Supply the following information.
P1.3.4 Adding the 
Specifications
Two specifications are required for this column.
• Flow of the Rectifier Distillate (Propene) is 775 lbmole/hr.
• Rectifier Top Stage Reflux Ratio is 16.
1. Return to the Parent environment and ensure the Column 
property view is visible.
2. Click the Design tab and select Monitor page.
3. Add a Column Draw Rate and Column Reflux Ratio 
specifications.
To add a specification, click the Add Spec button.
Design 
[Parameters]
Number of Trays 89
Design 
[Pressures]
Tray 1 280 psia
Tray 89 290 psia
Total Condenser [Condenser]
Tab [Page] In this cell... Enter...
Design 
[Connections]
Name Condenser
Inlets To Condenser
Distillate Propene
Reflux Reflux
Energy Condenser Duty
Tray Section [Rectifier]
Tab [Page] In this cell... Enter...
Total Condenser iconP1-8
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Propylene/Propane Splitter P1-9
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Th4. Enter the following information for the appropriate 
specification: 
If the column has not converged at this point, ensure the 
Run Column Solver icon is active.
P1.4 Results
Go to the Workbook of the Column:T-100 column environment 
to check the following results.
• Material Streams Tab
Column Draw Rate
Tab In this cell... Enter...
Parameters Draw Propene
Flow Basis Molar
Spec Value 775 lbmole/hr.
Column Reflux Ratio
Tab In this cell... Enter...
Parameter Stage Condenser
Flow Basis Molar
Spec Value 16.4
 Figure P1.3
Run Column Solver icon 
(green)
Hold Column Solver icon 
(red)P1-9
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P1-10 Results
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Th• Compositions Tab
• Energy Streams Tab 
 Figure P1.4
 Figure P1.5P1-10
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Ethanol Plant C1-1
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ThC1 Ethanol PlantC1-1
C1.1  Process Description ..................................................................... 2
C1.2  Setup ........................................................................................... 5
C1.3  Steady State Simulation............................................................... 5
C1.3.1  Adding Streams ..................................................................... 5
C1.3.2  Installing Equipment............................................................... 6
C1.3.3  Draw Stream Location........................................................... 12
C1.4  Results....................................................................................... 13
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C1-2 Process Description
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ThC1.1 Process Description
Typically, an ethanol fermentation process produces mainly 
Ethanol plus small quantities of several by-products: methanol, 
1-propanol, 2-propanol, 1-butanol, 3-methyl-1-butanol, 2-
pentanol, acetic acid, and CO2. 
Ethanol and Water form an azeotropic mixture at 1 atm. 
Therefore, with simple distillation, the ethanol and water 
mixture can only be concentrated up to the azeotropic 
concentration.
 Figure C1.1
To see this case completely solved, see your Aspen 
HYSYS\Samples\ directory and open the C-2.hsc file.C1-2
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Ethanol Plant C1-3
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ThThe CO2 produced in the fermentation vessel carries some 
ethanol. This CO2 stream is washed with water in a vessel (CO2 
Wash) to recover the Ethanol, which is recycled to the 
fermentor. 
The Ethanol rich product stream from the fermentor is sent to a 
concentration (Conc) tower. An absorber with a side vapour 
draw can be used to represent this tower. 
The top vapour is fed to a light purification tower (Lights) where 
most of the remaining CO2 and some light alcohols are vented. 
The bottom product of this light tower is fed to the Rectifier.
 Figure C1.2
 Figure C1.3C1-3
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C1-4 Process Description
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ThThe side vapour draw from the Concentrator is the main feed for 
the Rectifier. The Rectifier is operated as a conventional 
distillation tower. The product of this tower is taken from Stage 
2 so to have an azeotropic ethanol product with a lesser 
methanol contamination. Methanol concentrates towards the top 
stages, so a small distillate draw is provided at the condenser. 
Also, a small vent for CO2 is provided at the condenser.
Another factor of interest is the concentration of heavy alcohols 
in the interior of the Rectifier. These alcohols are normally 
referred to as Fusel oils, and a small side liquid draw is provided 
in the Rectifier to recover these components.
 Figure C1.4
Fusel oils are a mixture of propanols, butanols, and 
pentanols that have a potential value superior to that of 
ethanol. Accumulation of fusel oils in the Rectification Tower 
can cause the formation of a second liquid phase and 
subsequent deterioration of performance for these trays, so 
small side liquid draws of fusel oils are installed on the 
rectifier to avoid this problem.C1-4
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Ethanol Plant C1-5
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ThThere are two general steps in this process simulation:
1. Setup. The NRTL property package and the UNIFAC VLE 
estimation method will be used for this case. The 
Components list includes Ethanol, H2O, CO2, Methanol, 
Acetic Acid, 1- Propanol, 2-Propanol, 1-Butanol, 3-M-1-C4ol, 
2-Pentanol and Glycerol. 
2. Steady State Simulation. This case will use a separator, 
two absorbers, a refluxed absorber and a distillation column.
C1.2 Setup
1. In the Session Preferences property view, set the unit set to 
SI.
2. In the Component List property view, select the following 
components: Ethanol, H2O, CO2, Methanol, Acetic Acid, 
1- Propanol, 2-Propanol, 1-Butanol, 3-M-1-C4ol, 2-
Pentanol, and Glycerol. 
3. In the Fluid Package property view, select NRTL as the 
property package.
4. On the Binary Coeffs tab of the Fluid Package property 
view, select the UNIFAC VLE radio button and click the 
Unknowns Only button to estimate the missing interaction 
parameters.
C1.3 Steady State 
Simulation
C1.3.1 Adding Streams
Enter the Simulation environment and add the material streams 
defined below. 
Name Wash H2O FromFerm Steam A
In this cell... Enter... Enter... Enter...
Temperature [C] 25 30 140
Pressure [kPa] 101.3250 101.3250 101.3250
Molar Flow [kgmole/hr] 130 2400C1-5
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C1-6 Steady State Simulation
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ThC1.3.2 Installing Equipment
CO2 Vent Separator
The CO2Vent Separator separates the products from the 
fermentor. The bottom liquid of the separator is sent to the 
distillation section of the plant (Concentrator Tower), while the 
overhead vapour goes to the CO2Wash Tower.
Install a Separator and make the connections shown below. 
Mass Flow [kg/hr] 11000
Comp Mole Frac [Ethanol] 0.0000 0.0269 0.0000
Comp Mole Frac [H2O] 1.0000 0.9464 1.0000
Comp Mole Frac [CO2] 0.0000 0.0266 0.0000
Comp Mole Frac [Methanol] 0.0000 2.693e-05 0.0000
Comp Mole Frac [Acetic Acid] 0.0000 3.326e-06 0.0000
Comp Mole Frac [1-Propanol] 0.0000 9.077e-06 0.0000
Comp Mole Frac [2-Propanol] 0.0000 9.096e-06 0.0000
Comp Mole Frac [1-Butanol] 0.0000 6.578e-06 0.0000
Comp Mole Frac [3-M-1-C4ol] 0.0000 2.148e-05 0.0000
Comp Mole Frac [2-Pentanol] 0.0000 5.426e-06 0.0000
Comp Mole Frac [Glycerol] 0.0000 6.64e-06 0.0000
Once you have entered the Mole Fractions for the stream 
FromFerm, the Mole Fractions will not add up to 1.00. Click 
the Normalize button and the total Mole Fraction will equal 
1.00.
SEPARATOR [CO2 Vent]
Tab [Page] In this cell... Enter...
Design 
[Connections]
Inlets FromFerm
Vapour Outlet To CO2Wash
Liquid Outlet Beer
Name Wash H2O FromFerm Steam AC1-6
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Ethanol Plant C1-7
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ThCO2 Wash Tower
Water is used to strip any Ethanol entrained in the off gas 
mixture, thus producing an overhead of essentially pure CO2. 
The bottom product from the tower is recycled to the Fermentor, 
however, the recycle is not a concern in this example.
1. Before installing the column, select Preferences from the 
Aspen HYSYS Tools menu. 
2. On the Options page of the Simulation tab, ensure that 
the Use Input Experts checkbox is selected, then close the 
property view.
3. Install the CO2 Wash Tower as a simple Absorber. 
4. Click the Run button in the Column property view to 
calculate the CO2 Wash Tower product streams.
Absorber [CO2WASH]
Tab [Page] In this cell... Enter...
Connections No. of Stages 10
Top Stage Inlet Wash H2O
Bottom Stage Inlet To CO2Wash
Ovhd Vapour CO2 Stream
Bottoms Liquid To fermentor
Pressure 
Profile
Top Stage 101.325 kPa
Bottom Stage 101.325 kPaC1-7
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C1-8 Steady State Simulation
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ThConcentrator
1. Install the Concentrator as an Absorber with a side vapour 
draw.
2. Create and define the following specifications to fully specify 
the column.
You might have to deactivate the default Rect Feed Rate 
specification to converge the column.
3. Click the Run button in the Column property view to 
calculate the Concentrator product streams.
Absorber [CONC]
Tab [Page] In this cell... Enter...
Connections No. of Stages 17
Top Stage Inlet Beer
Bottom Stage Inlet Steam A
Ovhd Vapour To Light
Bottoms Liquid Stillage A
Side Draw Vapour Rect Feed (Stage 6)
Pressure Profile Condenser 101.325 kPa
Reboiler 101.325 kPa
Temperature 
Estimates
Condenser Temperature 90°C
Reboiler Temperature 110°C
Specifications
Tab [Page] In this cell... Enter...
Design [Specs] Comp Recovery
Draw
SpecValue
Component
Active
Rect Feed
0.95
Ethanol
Draw Rate 1
Draw
Flow Basis
Spec Value
Estimate
Rect Feed
Mass
5000 kg/h
Draw Rate 2
Draw
Flow Basis
Spec Value
Estimate
To_Light
Molar
1000 kgmole/hC1-8
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Ethanol Plant C1-9
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ThLights
1. Add the Lights Tower purification tower, modeled as a 
Refluxed Absorber, and define as indicated below.
2. Delete the default Btms Prod Rate and Reflux Rate 
specifications from the Column Specification group.
3. Add the following new column specifications (Design tab, 
Specs page).  
Refluxed Absorber [Lights]
Tab [Page] In this cell... Enter...
Connections No. of Stages 5
Bottom Inlet Streams To Light
Condenser Type Partial
Ovhd Vapour Light Vent
Ovhd Liquid 2ndEtOH
Bottoms Liquid To Rect
Cond. Energy CondDuty
Pressure Profile Condenser Pressure 101.325 kPa
Reboiler Pressure 101.325 kPa
Specifications
Tab [Page] In this cell... Enter...
Design [Specs] Vap Prod Rate
Draw
Flow Basis
Spec Value
Active
Light_Vent
Molar
1.6 kgmole/hr
Comp Fraction
Stage
Flow Basis
Phase
Spec Value
Component
Active
Condenser
Mass Fraction
Liquid
0.88
Ethanol
Reflux Ratio
Stage
Flow Basis
Spec Value
Estimate
Condenser
Molar
5.00
Distillate Rate
Draw
Flow Basis
Spec Value
Estimate
2ndEtOH
Molar
2.10 kgmole/hrC1-9
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C1-10 Steady State Simulation
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Th4. If required, click the Run button in the Column property 
view to calculate the Light Tower product streams.
Rectifier
The primary product from a plant such as this would be the 
azeotropic mixture of ethanol and water. The Rectifier serves to 
concentrate the water/ethanol mixture to near azeotropic 
composition. The Rectifier is operated as a conventional 
distillation tower. It contains a partial condenser as well as a 
reboiler.
1. Add the Rectifier column, modeled as a distillation tower, and 
define it using the following information. 
2. Delete the default Btms Prod Rate and Reflux Rate 
specifications before adding the new specifications. Delete 
all specifications that do not appear in the following table.
Column [RECT]
Tab [Page] In this cell... Enter...
Connections No. of Stages 29
Inlet Streams [Stage] To Rect [19], 
Rect_Feed [22]
Condenser Type Partial
Ovhd Vapour Rect Vap
Ovhd Liquid Rect Dist
Bottoms Liquid Stillage B
Reboiler Energy Rect RebQ
Condenser Energy Rect CondQ
Side Draw Liquid [Stage] 1st Prod [2], Fusel [20]
Pressure Profile Condenser Pressure 101.325 kPa
Reboiler Pressure 101.325 kPa
Temperature 
Estimates
Condenser 79°C
Reboiler 100°CC1-10
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Ethanol Plant C1-11
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Th3. Define the following specifications (Design tab, Specs 
page). Also, set the damping factor to accelerate the 
convergence. 
4. Click the Run button to solve the column.
Specifications
Tab [Page] In this cell... Enter...
Design [Specs] Reflux Ratio
Stage
Flow Basis
Spec Value
Active
Condenser
Molar
7100
Ovhd Vap Rate
Draw
Flow Basis
Spec Value
Active
Rect_Vap
Molar
0.100 kgmole/hr
Draw Rate
Draw
Flow Basis
Spec Value
Active
Rect _Dist
Mass
2.00 kg/hr
Comp Frac
Stage
Flow Basis
Phase
Spec Value
Component
Active
2_Main TS
Mass Fraction
Liquid
0.95
Ethanol
Fusel Draw Rate
Draw
Flow Basis
Spec Value
Active
Fusel
Mass
3.00 kg/hr
1stProd Draw Rate
Draw
Flow Basis
Spec Value
Estimate
1stProd
Molar
68.00 kgmole/hr
Parameters [Solver] Damping Factor
Fixed
0.25
Azeotrope Check ONC1-11
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C1-12 Steady State Simulation
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ThC1.3.3 Draw Stream Location
The side liquid draw, Fusel, is added at stage 20. To determine if 
this is an appropriate stage to recover the heavy alcohols, view 
the stage-by-stage composition profile.
1. To examine this information, click the Parameters tab in 
the Column property view.
2. Select the Estimates page. In this property view you can 
see the Composition Estimates of each tray. 
3. To view the 1-Propanol composition on Tray 20, scroll 
through the group until you can see Tray 20 and the 1-
Propanol component.
Stage 20 has a high concentration of 1-Propanol (which has 
the greatest concentration among the heavy alcohols). 
Therefore, we have selected the appropriate stage for the 
Fusel draw.
 Figure C1.5C1-12
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Ethanol Plant C1-13
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ThC1.4 Results
Workbook Case (Main)
• Material Streams Tab
 Figure C1.6C1-13
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C1-14 Results
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Th• Compositions Tab 
• Energy Streams Tab  
 Figure C1.7
 Figure C1.8C1-14
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Synthesis Gas Production C2-1
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ThC2 Synthesis Gas 
ProductionC2-1
C2.1  Process Description ..................................................................... 2
C2.2  Setup ........................................................................................... 4
C2.3  Steady State Simulation............................................................... 7
C2.3.1  Building the Flowsheet ............................................................ 8
C2.3.2  Installing Adjust Operations ................................................... 12
C2.4  Results....................................................................................... 14
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C2-2 Process Description
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ThC2.1 Process Description
The production of synthesis gas is an important part of the 
overall process of synthesizing ammonia. The conversion of 
natural gas into the feed for the ammonia plant is modeled 
using three conversion reactions and an equilibrium reaction. To 
facilitate the production of ammonia, the molar ratio of 
hydrogen to nitrogen in the synthesis gas is controlled near 3:1. 
This ratio represents the stoichiometric amounts of the 
reactants in the ammonia process.
In a typical synthesis gas process, four reactors are needed. 
This model requires five reactors since the conversion and 
equilibrium reactions cannot be placed in the same reaction set 
and thus cannot be placed in the same reactor. The Combustor 
is separated into a conversion reactor and an equilibrium 
reactor.
 Figure C2.1C2-2
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Synthesis Gas Production C2-3
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ThDesulfurized natural gas is the source of hydrogen in this 
example, which is reformed in a conversion reactor (Reformer) 
when combined with steam. Air is added to the second reactor 
at a controlled flow rate such that the desired ratio of H2:N2 in 
the synthesis gas is attained.
The oxygen from the air is consumed in an exothermic 
combustion reaction while the inert nitrogen passes through the 
system. The addition of steam serves the dual purpose of 
maintaining the reactor temperature and ensuring that the 
excess methane from the natural gas stream is consumed. In 
the last two reactors, the water-gas shift equilibrium reaction 
takes place as the temperature of the stream is successively 
lowered. 
There are two general steps in this process simulation:
1. Setup. In this step the Fluid package, Reaction sets and 
Reaction components are selected. The Reaction Component 
list includes CH4, H2O, CO, CO2, H2, N2 and O2.
2. Steady State Simulation. The case will be built in steady 
state with the following key unit ops:
• Reformer. A conversion reactor in which most of the 
methane is reacted with steam to produce hydrogen, 
carbon monoxide and carbon dioxide. 
• Combustor. A second conversion reactor, which takes 
the product of the Reformer, an Air stream and a Comb. 
Steam stream as the feeds to the reactor. 
• Shift Reactors. A series of equilibrium reactors in which 
the water gas shift reaction occurs.C2-3
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C2-4 Setup
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ThC2.2 Setup
1. In the Session Preferences property view, select Field unit 
set for this application.
2. In the Component List property view, select the following 
components: methane, water, carbon monoxide, carbon 
dioxide, hydrogen, nitrogen, and oxygen.
3. In the Fluid Package property view, select the following 
property package Peng-Robinson.
4. Go to the Rxns tab, and add the Global Rxn Set to the 
current reaction sets.
Defining the Reactions
In this application, there are three conversion reactions and one 
equilibrium reaction. 
Conversion Reactions
The reforming reactions are as follows:    
The combustion reaction is as follows: 
Equilibrium Reaction
The water-gas shift reaction is as follows: 
(C2.1)
(C2.2)
(C2.3)
(C2.4)
Refer to Chapter 5 - 
Reactions in the Aspen 
HYSYS Simulation 
Basis guide for more 
information about how to 
define reactions and 
reaction sets.
CH4 H2O+ CO 3H2+→
CH4 2H2O+ CO2 4H2+→
CH4 2O2+ CO2 2H2O+→
CO H2O+ CO2 H2+↔C2-4
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Synthesis Gas Production C2-5
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ThTo define the reaction:
1. In the Simulation Basis Manager property view, go to the 
Reactions tab.
The reaction components are attached based on the 
associated fluid package and are listed in the Rxn 
Components group.
2. Add the two reforming reactions using the following data: 
The Rxn Components group only shows the components 
associated with the Fluid Package(s).
To add or edit components, select the Add Comps button. 
The new components will automatically be added to any fluid 
package that uses the reaction.
Reaction [Rxn-1]
Property View Type Conversion
Tab In this cell... Enter...
Stoichiometry Component (Stoich. 
Coeff.)
Methane (-1)
Water (-1)
CO (1)
Hydrogen (3)
Basis Base Component Methane
Rxn Phase VaporPhase
Conversion 40% (Co)
Comments CH4 + H2O  CO + 3H2
Reaction [Rxn-2]
Property View Type Conversion
Tab In this cell... Enter...
Stoichiometry Component (Stoich. 
Coeff.)
Methane (-1)
Water (-2)
CO2 (1)
Hydrogen (4)
Basis Base Component Methane
Rxn Phase VaporPhase
Conversion 30% (Co)
Comments CH4 + 2H2O  CO2 + 4H2C2-5
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C2-6 Setup
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Th3. Add the combustion reaction using the following data: 
Aspen HYSYS contains a library of equilibrium reactions. To 
add the equilibrium reaction:
4. On the Reactions property view, select Equilibrium and 
click the Add Reaction button.
5. In the Equilibrium Reaction property view, go to the Library 
tab, select CO + H2O = CO2 + H2, and click the Add 
Library Rxn button. 
Aspen HYSYS provides the equilibrium data and all other 
pertinent information for the reaction.
Defining Reaction Sets
In Aspen HYSYS, each reactor operation may have only one 
reaction set attached to it, however, a reaction may appear in 
multiple reaction sets. In this case, you only have to provide 
three reaction sets for all five reactors.
1. On the Reactions tab of the Simulation Basis Manager 
property view, click the Add Set button to add new reaction 
sets. Define the following reactions sets:
Reaction [Rxn-3]
Property View Type Conversion
Tab In this cell... Enter...
Stoichiometry Component (Stoich. 
Coeff.)
Methane (-1)
Oxygen (-2)
CO2 (1)
Water (2)
Basis Base Component Methane
Rxn Phase VaporPhase
Conversion 100%
Comments CH4 + 2O2  CO2 + 2H2O
Reaction Set Name Active Reactions
Reformer Rxn Set Rxn-1, Rxn-2
Combustor Rxn Set Rxn-1, Rxn-2, Rxn-3
Shift Rxn Set Rxn-4C2-6
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Synthesis Gas Production C2-7
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ThIn the table of reaction sets, RXN-1 and RXN-2 appear in 
both the first and second reaction sets.
To attach the reaction sets to the Fluid Package:
2. On the Reactions tab of the Simulation Basis Manager, 
select a Reaction Set and click the Add to FP button.
3. In the Add property view, select a fluid package from the list 
and click the Add Set to Fluid Package button. Repeat the 
procedure for the other two reaction sets.
C2.3 Steady State 
Simulation
Installing Streams
Here you will define the two feed streams to the first reactor 
(Natural Gas and Reformer Steam). The Comb. Steam stream 
and the Air stream will also be defined. The pressures of the 
steam and air streams will be specified later using SET 
operations. Install and define the streams as indicated.
Name Natural Gas Reformer Steam Air Comb. Steam
Temperature[F] 700.0 475.0 60.0 475.0
Pressure [psia] 500.0   
Molar Flow [lbmole/hr] 200.0 520.0 200.0** 300.0**
Comp Mole Frac [CH4] 1.0000 0.0000 0.0000 0.0000
Comp Mole Frac [H2O] 0.0000 1.0000 0.0000 1.0000
Comp Mole Frac [CO] 0.0000 0.0000 0.0000 0.0000
Comp Mole Frac [CO2] 0.0000 0.0000 0.0000 0.0000
Comp Mole Frac [H2] 0.0000 0.0000 0.0000 0.0000
Comp Mole Frac [N2] 0.0000 0.0000 0.7900 0.0000
Comp Mole Frac [O2] 0.0000 0.0000 0.2100 0.0000
COMMENTS: ** signifies initialized values; the molar flows of Air and Comb. Steam will be 
manipulated by Adjust-2 and Adjust-1 respectively.C2-7
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C2-8 Steady State Simulation
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ThC2.3.1 Building the Flowsheet
Set Operations
Install the following Set operations to specify the pressures of 
the steam and air streams. Install these before installing the 
Reformer so the reactor is calculated when you install it.    
An alternative method for setting the steam and air 
pressures is to import the Natural Gas pressure to a 
Spreadsheet, copy the value for each of the other streams 
and export the copied values to the streams.
Set [SET-1]
Tab In this cell... Enter...
Connections Target Object Reformer Steam
Target Variable Pressure
Source Object Natural Gas
Parameters Multiplier 1
Offset 0
Set [SET-2]
Tab In this cell... Enter...
Connections Target Object Comb. Steam
Target Variable Pressure
Source Object Natural Gas
Parameters Multiplier 1
Offset 0
Set [SET-3]
Tab In This Cell... Enter
Connections Target Object Air
Target Variable Pressure
Source Object Natural Gas
Parameters Multiplier 1
Offset 0C2-8
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ThInstalling the Reformer
The Reformer is a conversion reactor in which most of the 
methane is reacted with steam to produce hydrogen, carbon 
monoxide, and carbon dioxide. The outlet gas will also contain 
the unreacted methane and excess water vapour from the 
steam. The overall conversion of the two reactions in the 
Reformer is 70%. Rxn-1, which produces carbon monoxide and 
hydrogen, has a conversion of 40%, while Rxn-2 has a 
conversion rate of 30%.
The two reforming reactions are endothermic, so heat must be 
supplied to the reactor to maintain the reactor temperature. 
Specify the temperature of the outlet stream, Combustor Feed, 
at 1700 °F, so that Aspen HYSYS will calculate the required 
duty.
Install the reactor and define it as indicated below.
Conversion Reactor [Reformer]
Tab [Page] In this cell... Enter...
Design 
[Connections]
Inlets Natural Gas
Reformer Steam
Vapour Outlet Combustor Feed
Liquid Outlet Reformer Liq
Energy Reformer Q
Design [Parameters] Optional Heat Transfer Heating
Worksheet 
[Conditions]
Combustor Feed 
Temperature
1700 °F
Reactions [Details] Reaction Set Reformer Rxn Set
Comments CH4 + H2O  CO + 3H2
CH4 + 2H2O  CO2 + 4H2C2-9
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C2-10 Steady State Simulation
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ThInstalling the Combustor
The Combustor is the second conversion reactor. The feed 
streams for the Combustor include the Reformer product, Air 
stream and Comb. Steam streams. The air stream is the source 
of the nitrogen for the required H2:N2 ratio in the synthesis end 
product. The oxygen in the air is consumed in the combustion of 
methane. Any remaining methane in the Combustor is 
eliminated by this reaction.
Aspen HYSYS automatically ranks the three reactions in the 
Combustor Rxn Set. Since H2O is a reactant in the combustion 
reaction (Rxn-1) and is a product in the two reforming reactions 
(Rxn-2 and Rxn-3), Aspen HYSYS provides a lower rank for the 
combustion reaction. An equal rank is given to the reforming 
reactions. With this ranking, the combustion reaction proceeds 
until its specified conversion is met or a limiting reactant is 
depleted. The reforming reactions then proceed based on the 
remaining methane.
Install the Combustor and define it as indicated below. 
This reactor is adiabatic, so there is no energy stream and 
you do not have to specify the outlet temperature.
Conversion Reactor [Combustor]
Tab [Page] In this cell... Enter...
Design 
[Connections]
Inlets Combustor Feed
Air
Comb. Steam
Vapour Outlet Mid Combust
Liquid Outlet Mid Liq
Reactions 
[Details]
Reaction Set Combustor Rxn Set
Rxn-1 Conversion 35%
Rxn-2 Conversion 65%
Rxn-3 Conversion 100%
Comments CH4 + H2O  CO + 3H2
CH4 + 2H2O  CO2 + 4H2
CH4 + 2O2   CO2 + 2H2OC2-10
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Synthesis Gas Production C2-11
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ThShift Reactors
The three shift reactors are all equilibrium reactors within which 
the water-gas shift reaction occurs. In the Combustor Shift 
reactor, the equilibrium shift reaction takes place and would 
occur with the reactions in the Combustor. A separate reactor 
must be used in the model because equilibrium and conversion 
reactions cannot be combined within a reaction set.
Install the following three equilibrium reactors as shown below:    
Reactions of equal ranking can have an overall specified 
conversion between 0% and 100%.
Equilibrium Reactor [Combustor Shift]
Tab [Page] In this cell... Enter...
Design 
[Connections]
Inlets Mid Combust
Vapour Outlet Shift1 Feed
Liquid Outlet Mid Com Liq
Reactions [Details] Reaction Set Shift Rxn Set
Comments Reaction: CO + H2O  CO2 + H2
Equilibrium Reactor [Shift Reactor 1]
Tab [Page] In this cell... Enter...
Design [Connections] Inlets Shift1 Feed
Vapour Outlet Shift2 Feed
Liquid Outlet Shift1 Liq
Energy Shift1 Q
Design [Parameters] Optional Heat Transfer Cooling
Worksheet [Conditions] Shift2 Feed Temperature 850°F
Reactions [Details] Reaction Set Shift Rxn Set
Comments Reaction: CO + H2O  CO2 + H2
Equilibrium Reactor [Shift Reactor 2]
Tab [Page] In this cell... Enter...
Design 
[Connections]
Feeds Shift2 Feed
Vapour Outlet Synthesis Gas
Liquid Outlet Shift2 Liq
Energy Shift2 QC2-11
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C2-12 Steady State Simulation
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ThC2.3.2 Installing Adjust 
Operations
Steam flow Rate
To control the temperature of the combustion reaction, the flow 
rate of steam to the Combustor is adjusted. Since the 
Combustor is modeled as two separate reactors, the 
temperature of the equilibrium reactor (Combustor Shift) is 
targeted. 
An ADJUST operation is used to manipulate the Comb. Steam 
flow rate to maintain the Combustor Shift temperature at 
1700°F.
The same Adjust could be accomplished by selecting the 
temperature of the stream Shift1 Feed.
Design [Parameters] Optional Heat Transfer Cooling
Worksheet 
[Conditions]
Synthesis Gas Temperature 750°F
Reactions [Details] Reaction Set Shift Rxn Set
Comments Reaction: CO + H2O  CO2 + H2
Adjust [ADJ-1]
Tab In this cell... Enter...
Connections Adjusted Object Comb. Steam
Adjusted Variable Molar Flow
Target Object Combustor Shift
Target Variable Vessel Temp.
Spec. Target Value 1700°F
Parameters Method Secant
Tolerance 0.1°F
Step Size 50 lbmole/hr
Maximum Iterations 25
Equilibrium Reactor [Shift Reactor 2]
Tab [Page] In this cell... Enter...C2-12
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Synthesis Gas Production C2-13
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ThClick the Start button to begin the Adjust operation.
Air Flow Rate
To control the H2:N2 molar ratio in the Synthesis Gas stream, 
calculate the ratio in a Spreadsheet and then use an Adjust 
operation. The Synthesis Gas should have an H2:N2 molar ratio 
slightly greater than 3:1. Prior to entering the ammonia plant, 
hydrogen is used to rid the synthesis gas of any remaining CO 
and CO2.
1. Create a Spreadsheet and change the Spreadsheet Name to 
SSRatio. Import the following variables:
• Synthesis Gas, Comp. Molar Flow, Hydrogen
• Synthesis Gas, Comp. Molar Flow, Nitrogen
2. Assign the Hydrogen value to cell B1, and the Nitrogen value 
to cell B2.
3. In cell B4, calculate the H2:N2 ratio using the following 
formula:
+B1[cell that contains flow of H2]/B2[cell that contains flow of N2]
The Spreadsheet tab of the Spreadsheet property view 
should appear similar to the following.
4. Click the Parameters tab and define the Variable name for 
the B4 cell as H2:N2 Ratio.
 Figure C2.2C2-13
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C2-14 Results
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Th5. Install the Adjust operation as shown below.
6. Click the Start button to begin the Adjust operation.
The Secant method is used for both Adjust operations even 
though each adjusted variable will have an effect on the 
other operation's target variable. The close proximity of the 
logical operations in the flowsheet increases the possibility of 
cycling behaviour if the Simultaneous method is used. 
Therefore, it is advantageous to attempt to iterate on one 
Adjust and then solve the other.
C2.4 Results
Go to the Workbook in the main simulation environment to 
check the calculated results.
• Energy Streams Tab 
Adjust [ADJ-2]
Tab In this cell... Enter...
Connections Adjusted Variable Air Molar Flow
Target Variable SSRatio, B4: H2:N2 Ratio
Spec. Target Value 3.05
Parameters Method Secant
Tolerance 0.005 lbmole/hr
Step Size 39.68 lbmole/hr
Maximum Iterations 20
 Figure C2.3C2-14
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Synthesis Gas Production C2-15
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Th• Material Streams Tab
• Compositions Tab
 Figure C2.4
 Figure C2.5C2-15
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C2-16 Results
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ThC2-16
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Case Linking X1-1
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ThX1 Case LinkingX1-1
X1.1  Process Description ..................................................................... 2
X1.2  Building Flowsheet 1.................................................................... 4
X1.2.1  Setup ................................................................................... 4
X1.2.2  Installing Streams .................................................................. 4
X1.2.3  Installing Unit Operations ........................................................ 5
X1.3  Building Flowsheet 2.................................................................... 7
X1.3.1  Setup ................................................................................... 7
X1.3.2  Installing Unit Operations ........................................................ 8
X1.4  Creating a User Unit Operation .................................................. 10
X1.4.1  Initializing the User Unit Op ................................................... 11
X1.4.2  Operation Execution.............................................................. 13
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X1-2 Process Description
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ThX1.1 Process Description
This example uses the User Unit Operation to link two Aspen 
HYSYS cases together such that changes made to the first case 
(LinkCase1) are automatically and transparently propagated to 
the second (LinkCase2). This application demonstrates a 
method for copying the contents of a stream from one case to 
another automatically.
The User Unit Op is pre-configured with Visual Basic™ code. 
Inside the User Unit Op you will define two subroutines:
• Initialize() macro. The Initialize() macro sets the field 
names for the various stream feed and product 
connections and creates the following two text user 
variables: 
- LinkCase contains the path and file name of the 
target case to be linked. If the variable contains no 
value, the Initialize() code will set it to be the path to 
the currently open case and the file name 
LinkCase2.hsc.
- LinkStream names a stream in the second case that 
will have the T, P, Flow and composition copied to it 
from the User Unit Op’s feed stream. The target case 
and stream may optionally be changed explicitly from 
the Variables page of the User Unit Op.
 Figure X1.1X1-2
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Case Linking X1-3
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Th• Execute() macro. The Execute() macro uses the 
GetObject method to open the target link case, which will 
initially be hidden. It then attempts to locate the material 
stream named by the LinkStream variable in the target 
case. If a stream is attached to the Feeds1 nozzle of the 
User Unit Op, the stream conditions and compositions 
are then copied between the streams. 
Also, the definition of User Unit Op usually involves the 
definition of three macros:
• Initialize() 
• Execute() 
• StatusQuery() 
For this example, the StatusQuery() macro is commented-
out to avoid the overhead of having that macro called. 
Removing the StatusQuery() code entirely would accomplish 
the same thing, but it is highly recommended that 
StatusQuery() be implemented to provide valuable user 
feedback. This implementation is left as an exercise for the 
user. 
All the stream names are in lower case.
The use of the DuplicateFluid method to copy the stream 
parameters requires identical property packages in both 
simulation cases. The example code instead uses a technique 
of explicitly copying T and P and then searches for 
components by name in order to copy their molar flow. 
Components that are not available in the target case are 
ignored.X1-3
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X1-4 Building Flowsheet 1
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ThX1.2 Building Flowsheet 1
X1.2.1 Setup
1. In the Session Preferences property view, set the unit set to 
SI.
2. In the Component List property view, select the following 
components: C1, C2, C3, and i-C4.
3. In the Fluid Package property view, define a Peng Robinson 
Stryjek Vera (PRSV) property package.
X1.2.2 Installing Streams
Specify streams feed and cold_liq2 as shown.    
Stream Name feed cold_liq2
In this cell... Enter... Enter...
Temperature [C] 11 -98
Pressure [kPa] 5066 152
Molar Flow [kgmole/h] 100 7.5
Comp Mole Frac [C1] 0.5333 0.0388
Comp Mole Frac [C2] 0.2667 0.4667
Comp Mole Frac [C3] 0.1333 0.3883
Comp Mole Frac [i-C4] 0.0667 0.1062X1-4
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Case Linking X1-5
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ThX1.2.3 Installing Unit 
Operations
Enter the Simulation Environment and add the following unit 
operations to the flowsheet.
Add Separators
Separator Name V-100
Tab [Page] In this cell... Enter...
Design 
[Connections]
Inlet feed
Vapour Outlet feed_vap
Liquid Outlet feed_liq
Design [Parameters] Delta P 0 kPa
Separator V-101
Tab [Page] In this cell... Enter...
Design 
[Connections]
Inlet precooled
Vapour Outlet cooled_vap
Liquid Outlet cooled_liq
Design [Parameters] Delta P 0 kPa
Separator V-102
Tab [Page] In this cell... Enter...
Design 
[Connections]
Inlet expanded
Vapour Outlet cold_vap
Liquid Outlet cold_liq
Design [Parameters] Delta P 0 kPaX1-5
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X1-6 Building Flowsheet 1
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ThAdd a Heat Exchanger
Add an Expander
 
Add a Compressor
 
Heat Exchanger Name E-100
Tab [Page] In this cell... Enter...
Design [Connections] Tube Side Inlet feed_vap
Tube Side Outlet precooled
Shell Side Inlet cold_liq2
Shell Side Outlet rich gas
Design [Parameters] Heat Exchanger Model Exchanger Design 
(End Point)
Heat Leak/Loss none
Tube Side Delta P 15 kPa
Shell Side Delta P 15 kPa
UA 4000 KJ/C-h
Rating [Sizing] First Tube Pass Flow Counter
Expander Name K-100
Tab [Page] In this cell... Enter...
Design 
[Connections]
Inlet cooled_vap
Outlet expanded
Energy shaft work
Design 
[Parameters]
Efficiency (Adiabatic) 75%
Worksheet 
[Conditions]
Pressure (stream: expanded) 152 kPa
Compressor Name K-101
Tab [Page] In this cell... Enter...
Design 
[Connections]
Inlet cold_vap
Outlet compressed
Energy shaft work
Design [Parameters] Efficiency (Adia) 75%X1-6
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Case Linking X1-7
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ThAdd a Recycle Operation
The case should converge immediately.
Save the case as LinkCase1.hsc.
X1.3 Building Flowsheet 2
X1.3.1 Setup
Now you will create the target case for the linked case.
1. In the Session Preferences property view, set the unit set to 
SI.
2. In the Component List property view, select the following 
components: C1, C2, C3, i-C4, and H2O.
3. In the Fluid Package property view, define a Peng Robinson 
Stryjek Vera (PRSV) property package.
Recycle RCY-1
Tab [Page] In this cell... Enter...
Design 
[Connections]
Inlet cold_liq
Outlet cold_liq2X1-7
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X1-8 Building Flowsheet 2
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ThX1.3.2 Installing Unit 
Operations
Enter the Simulation Environment and enter the following unit 
operations. 
Add Compressors
Add Heat Exchangers
Compressor Name K-100
Tab [Page] In this cell... Enter...
Design 
[Connections]
Inlet compressed
Outlet hot33atm
Energy q1
Design [Parameters] Efficiency (Adia) 75%
Worksheet 
[Conditions]
Pressure (stream: hot33atm) 3344.725 kPa
K-101
Tab [Page] In this cell... Enter...
Design 
[Connections]
Inlet cool33atm
Outlet hot100atm
Energy q2
Design [Parameters] Efficiency (Adia) 75%
Worksheet 
[Conditions]
Pressure (stream: hot100atm) 10150 kPa
Heat Exchanger Name E-100
Tab [Page] In this cell... Enter...
Design [Connections] Tube Side Inlet hot33atm
Tube Side Outlet cool33atm
Shell Side Inlet wtr1
Shell Side Outlet wtr1bX1-8
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Case Linking X1-9
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ThAdd a Tee
Once you have completed specifying this flowsheet, save the 
case as LinkCase2.hsc and close it.
Design [Parameters] Heat Exchanger Model Exchanger Design (End 
Point)
Tube Side Delta P 15 kPa
Shell Side Delta P 15 kPa
Calculate Ft Factor Clear
Rating [Sizing] First Tube Pass Flow Direction Counter
Worksheet [Conditions] Temperature (stream: cool33atm) 17°C
Temperature (stream: wtr1b) 25°C
Heat Exchanger E-101
Tab [Page] In this cell... Enter...
Design [Connections] Tube Side Inlet hot100atm
Tube Side Outlet sales
Shell Side Inlet wtr2
Shell Side Outlet wtr2b
Design [Parameters] Heat Exchanger Model Exchanger Design (End 
Point)
Tube Side Delta P 15 kPa
Shell Side Delta P 15 kPa
Calculate Ft Factor Clear
Rating [Sizing] First Tube Pass Flow Direction Counter
Worksheet
[Conditions]
Temperature (stream: sales) 20°C
Temperature
(stream: wtr2b)
25°C
Heat Exchanger Name E-100
Tab [Page] In this cell... Enter...
Tee T-100
Tab [Page] In this cell... Enter...
Design 
[Connections]
Inlet cooling water
Outlet wtr2, wtr1
Worksheet 
[Conditions]
Temperature (stream: cooling water) 11°C
Pressure (stream: cooling water) 202.6 kPa
Worksheet 
[Composition]
H2O (stream: cooling water) 1.0000X1-9
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X1-10 Creating a User Unit Operation
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ThX1.4 Creating a User Unit 
Operation
Now that both cases have been created, you can create the link 
between them. 
1. Open LinkCase1.hsc. 
2. Add a User Unit Op to the flowsheet. When you add a Unit 
Op, Aspen HYSYS asks you for the type. Click the Create 
Type button, then type Case Linking in the input field and 
click the OK button.
Next you will define the User Unit Op. Defining the User Unit 
Op involves writing two different subroutines.
• Initialize. Defines material and energy feed/product 
streams and creates user variables.
• Execute. Opens the target case, finds the target stream 
and copies the stream conditions from the main case.
3. In the User Unit Op property view, Design tab, select the 
Code page.
4. Click the Edit button. The Edit Existing Code property view 
appears.X1-10
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Case Linking X1-11
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ThX1.4.1  Initializing the User 
Unit Op
The following table contains a listing of the code required to 
implement this operation, along with a brief description of what 
the code means. Partitions placed in the code are made only to 
clearly associate the relevant code with the explanation. Also, 
indentations made in the code are common with standard 
programming practices.
Code Explanation
Sub Initialize () Signifies the Start of the initialization 
subroutine. You do not have to add it as it 
should already be there.
On Error GoTo Catch
' Preparing the interface
ActiveObject.Feeds1Name = "Feed"
ActiveObject.Products1Name = "Unused 
Prod1"
ActiveObject.Feeds2Name = "Unused Feed2"
ActiveObject.Products2Name = "Unused 
Prod2"
If an error occurs during the execution of this 
subroutine, go to the line designated ‘Catch’.
Sets the names that will be associated with 
the energy and material (primary and 
secondary) inlet and exit connections. 
ActiveObject.Feeds2Active = False
ActiveObject.Products2Active = False
ActiveObject.EnergyFeedsActive = False
ActiveObject.EnergyProductsActive = False
Deactivates the secondary inlet and exit 
connections as well as the energy inlet and 
exit connections. After the initialization 
subroutine has been successfully 
implemented, the checkboxes associated with 
the secondary material connections and 
energy connections should be deactivated as 
shown in the figure above.
' Adding user variables
Dim LinkCase As Object ' This UV will hold 
the Linked case name
Set LinkCase = 
ActiveObject.CreateUserVariable("LinkCas
e", "LinkCase", uvtText, utcNull,0)
Creates a text user variables called LinkCase. 
This will appear on the Variables page of the 
Design tab along with the current values. This 
variable holds the path and name of the 
linked case.X1-11
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X1-12 Creating a User Unit Operation
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Th1. Once this code is entered, press the OK button to close the 
Edit Existing Code property view. 
2. On the Code page of the Design tab, click the Initialize 
button.
3. Select the Connections page of the Design tab. It should 
contain their new designations. 
4. Select the Variables page. The LinkCase should contain the 
case LinkCase2, including the path. The LinkStream variable 
should contain ‘feed’.
5. Select the Connections page. If the feed drop-down list is 
empty, the value of LinkStream variable (Variables page) 
should be ‘feed’.
Dim LinkStream As Object ' This UV will 
hold the Linked stream name
Set LinkStream = 
ActiveObject.CreateUserVariable("LinkStr
eam", "LinkStream", uvtText, utcNull,0)
Creates a text user variables called 
LinkStream. This will appear on the 
Variables page of the Design tab along with 
the current values. This variable holds the 
name of the stream to link to.
LinkCase.Variable.Value = 
ActiveObject.SimulationCase.Path & 
"LinkCase2.hsc"
This sets the linked case path to be the same 
as the current case and sets the name to 
‘LinkCase2.hsc’.
Dim myFeeds As Object
Set myFeeds = ActiveObject.Feeds1
Declares the ‘myFeeds’ variable and sets it to 
the feed streams collection of the operation.
' Check if a stream name is already 
defined
If Not LinkStream.Variable.IsKnown Then
Checks if a linked stream name is already 
defined.
If myFeeds.Count > 0 Then
LinkStream.Variable.Value = 
myFeeds.Item(0).name
If a feed stream is connected to the unit 
operation, use that stream name as the linked 
stream name.
else
LinkStream.Variable.Value = "feed"
end if
end if
If no stream is connected as feed, use the 
default listed stream name of ‘feed’.
Exit Sub
Catch:
MsgBox "Initialize Error"
End Sub Signifies the end of the initialization 
subroutine. This line does not need to be 
added.
Code ExplanationX1-12
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ThX1.4.2 Operation Execution
1. Enter the following code in the Execution code section of the 
Edit Existing Code property view:
Code Explanation
Sub Execute () Signifies the Start of the operation execution 
subroutine. You do not have to add this line 
as it should already be there.
On Error Goto EarlyGrave If an error occurs during the execution of this 
subroutine, go to the line of code designated 
‘EarlyGrave’.
Dim Status As String
Dim LinkCase As Object
Set LinkCase = 
ActiveObject.GetUserVariable("LinkCase")
Dim LinkStream As Object ' This UV will 
hold the Linked stream name
Set LinkStream = 
ActiveObject.GetUserVariable("LinkStream
")
Connects the variables LinkCase and 
LinkStream to their corresponding user 
variables.
Dim myFeeds As Object
Set myFeeds = ActiveObject.Feeds1
if myFeeds.Count <>1 Then
Exit Sub
end if
If the number of streams specified in the Feed 
list is not 1 then exit the subroutine.
Dim Case2 As Object
Set Case2 = 
GetObject(LinkCase.Variable.Value)
Creates a reference to the LinkCase user 
variable called Case2. 
Dim Case2FS As Object
Set Case2FS = Case2.Flowsheet
Creates a reference to the flowsheet inside 
Case2 (LinkCase) called Case2FS. 
Dim Case1FS As Object
Set Case1FS = ActiveObject.Flowsheet
Creates a reference to the current flowsheet 
called Case1FS. 
Dim Case2Strm As Object
Set Case2Strm = 
Case2FS.MaterialStreams.Item(CStr(LinkSt
ream.Variable.Value))
Creates a reference to a stream in the other 
case. The stream’s name is the value of the 
user variable LinkStream.
Dim Case1Strm As Object
Set Case1Strm = myFeeds.Item(0)
Creates a reference to stream currently in the 
primary feed list.
Case2Strm.TemperatureValue = 
Case1Strm.TemperatureValue
Case2Strm.PressureValue = 
Case1Strm.PressureValue
Sets the Temperature and Pressure values of 
Case2Strm to those of Case1Strm. X1-13
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X1-14 Creating a User Unit Operation
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Th2. When you are finished entering the code, activate the 
property view by selecting the ‘compressed’ stream as the 
Feed on the Connections page of the Design tab. 
3. Go to the Variables page to ensure that the LinkStream 
stream name is also ‘compressed’.
Dim Case1CMFs As Variant
Case1CMFs = 
Case1Strm.ComponentMolarFlowValue
Creates an array containing the molar flow of 
Case1Strm. Note that Set was not used so 
changes made to Case1CMFs will not affect 
Case1Strm.
Dim Case2CMFs As Variant
Case2CMFs = 
Case2Strm.ComponentMolarFlowValue
Creates an array containing the molar flow of 
Case2Strm. Note that Set was not used so 
changes made to Case2CMFs will not affect 
Case2Strm.
On Error GoTo NoComp
Dim Comp As Object
i = 0
For Each Comp In 
Case2FS.FluidPackage.Components
Case2CMFs(i) = 0.0
CompName = Comp.name
n = 
Case1FS.FluidPackage.Components.index(Co
mpName)
Case2CMFs(i) = Case1CMFs(n)
NoComp:
i = i +1
Next Comp
For every component i in the Case2FS, you 
set the molar flow of component i in the 
Case2CMFs array to the flow of the same 
component in Case1CMFs array.
On Error GoTo EarlyGrave
Case2Strm.ComponentMolarFlowValue = 
Case2CMFs
This passes the value of Case2CMFs to the 
Case2Strm.
ActiveObject.SolveComplete Signifies the Unit Operation has solved. It is 
used to minimize the number of times the 
User Unit Op’s Execute() is called.
Exit Sub
EarlyGrave:
MsgBox "Execute Error"
End Sub Signifies the end of the initialization 
subroutine. This line does not need to be 
added.
Code Explanation
The Unit Op will not appear ‘solved’ on the flowsheet, even 
though it is. This is because Aspen HYSYS expects it to have 
a fully defined product stream.X1-14
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