概要信息：

Conversion Reactors:  HYSYS Version 3.0 
By Robert P. Hesketh  Spring 2003 
 
In this session you will learn how to install a conversion reactor in HYSYS 3.0. 
 
The references for this section are taken from the 2 HYSYS manuals: 
Simulation Basis:  Chapter 5 Reactions 
Operations Guide:  Chapter 9 Reactors 
 
Reactors. 
Taken from:  Steady-State Modeling 9.1 The Reactor Operation 
 
With the exception of the PLUG FLOW REACTOR (PFR), all of the reactor operations share 
the same basic property view. The primary differences are the functions of the reaction type 
(conversion, kinetic, equilibrium, heterogeneous catalytic or simple rate) associated with each 
reactor. As opposed to a SEPARATOR or GENERAL REACTOR with an attached reaction set, 
specific reactor operations may only support one particular reaction type. For instance, a 
CONVERSION REACTOR will only function properly with conversion reactions attached. If 
you try to attach an equilibrium or a kinetic reaction to a CONVERSION REACTOR, an error 
message will appear. The GIBBS REACTOR is unique in that it can function with or without a 
reaction set. 
 
Thought to remember:  CONVERSION REACTORS must have a CONVERSION 
REACTION SET. 
 
The remainder of this chapter discusses the features of each of these reactors: 
Sections 9.2-9.4 GIBBS REACTOR, EQUILIBRIUM REACTOR, CONVERSION 
REACTOR or (General Reactors) and CSTR. 
 
Reaction Sets (portions from Simulation Basis:  Chapter 5 Reactions) 
Reactions within HYSYS are defined inside the Reaction Manager. The Reaction Manager, 
which is located on the Reactions tab of the Simulation Basis Manager, provides a location from 
which you can define an unlimited number of Reactions and attach combinations of these 
Reactions in Reaction Sets. The Reaction Sets are then attached to Unit Operations in the 
Flowsheet. 
 
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HYSYS Conversion Reactors – Tutorial on Styrene  
 
Styrene is a monomer used in the production of many plastics.  It has the fourth highest 
production rate behind the monmers of ethylene, vinyl chloride and propylene.  Styrene is made 
from the dehydrogenation of ethylbenzene: 
 2256 HCHCHHC5256 HCHC +=−⇔−
 (1) 
 Start a New Case Procedure to Install a Conversion Reaction Set: 
 
1. Start HYSYS 
2. Open a new case by clicking on the blank white page OR use the commands File New.   
Press Add 
button 
3. Since these compounds are hydrocarbons, use the Peng-Robinson thermodynamic package.  
(Additional information on HYSYS 
thermodynamics packages can be 
found in the Simulation Basis 
Manual Appendix A: Property 
Methods and Calculations.  Note an 
alternative package for this system is 
the PRSV)  
3.1. Select the Fluid Pkgs menu tab 
and Press the Add button 
3.2. Select the EOS filter radio 
button to see only Equations of 
State (EOS) 
3.3. Then select the Peng Robinson 
Equation of State. 
tate – This will be discussed in thermodynamics or you 
e 
3.4. Notice that you have a choice in 
calculating the enthalpies.  You 
can either use the equation of s
can use a prediction method called the Lee-Kesler Method which is an extension of th
Pitzer method.  For thi
tutorial we will use th
equation of state method
Press the View button to 
start adding chemical 
compounds 
s 
e 
. 
3.5. 
Press to add 
components
 2
 
4. Install the chemicals for a styrene reactor:  ethylbenzene, styrene, and hydrogen.  If they are 
not in the order given below then use the Sort List… button feature.  
5. Let’s look at one of the components 
ponent 
5.3.  the temperature 
 on the 
5.4. the ideal gas enthalpy 
and see some of the physical 
properties that it is using.  
5.1. Select Ethyl benzene 
5.2. Click on the View Com
button  
Examine
dependent properties given
Tdep page 
Notice that 
has been correlated using a 5th 
order polynomial. 
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6. Now return to the Simulation Basis Manager by closing the Component List View window.  
Press the Close button or X   
7. Select the Rxns tab 
and then press the 
Simulation Basis 
Mgr… button.  Press here to 
start adding 
rxns 
8. The Reaction 
Component Selection 
view will appear.  
9. Press the Add Rxn 
button 
10. To install a reaction, 
press the Add Rxn 
button.  
Add 
Reaction 
11. Then select the Conversion Reaction Refer to Section 4.4 of the Simulation Basis Manual for 
information concerning reaction types and the addition of reactions. 
12. 
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On the Stoichiometry tab add all of the components to the 
component list by using the drop down list.  
.  Select ethylbenzene from the 
drop down list in the Edit Bar. The Mole Weight column 
should automatically provide the molar weight of 
ethylbenzene. In the Stoich Coeff field enter a 
stoichiometric coefficient of -1 (i.e. 1 moles of 
ethylbenzene will be consumed). Notice that the 
coefficient will be negative for reactants and positive for 
products. 
13. Notice that the units of the Reaction Heat or the Heat of 
reaction are SI.  If you do not have this go to Tools 
Preferences and load the styrene.prf that you saved from 
the previous tutorial. 
14. Now define the rest of the Stoichiometry tab as shown in 
the adjacent figure.  Go to Basis tab and set ethylbenzene 
as the Base Component and Conversion to 80%. The 
status bar at the bottom of the property view should now 
show the Ready message.   Note that the conversion 
reaction can be a function of temperature.  This is a 
simple polynomial fit to conversion as a function of 
temperature data.  Using this type of reaction set we will 
be able examine mole and energy balances without knowing the chemical kinetics.   
15. Close the property view. 
16. By default, the Global Rxn Set is present within the Reaction Sets group when you first 
display the Reaction Manager. However, for this procedure, a new Reaction Set will be 
created. Press the Add Set button. HYSYS provides the name Set-1 and opens the Reaction 
Set property view.  
17. To attach the newly 
created Reaction to 
the Reaction Set, 
place the cursor in 
the  cell 
under Active List.  
Add Set Button 
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18. Open the drop down list in 
the Edit Bar and select the 
name of the Reaction. 
The 
Set Type will correspond to 
the type of Reaction which 
you have added to the 
Reaction Set. The status 
message will now display 
Ready. (Refer to Section 5.4 – 
Reaction Sets for details 
concerning Reactions Sets.)  
19. Press the Close button to 
return to the Reaction Manager. 
20. To attach the reaction set to the Fluid 
Package (your peng robinson 
thermodynamics), highlight Set-1 in 
the Reaction Sets group and press the 
Add to FP button. When a Reaction 
Set is attached to a Fluid Package, it 
becomes available to unit operations 
within the Flowsheet using that 
particular Fluid Package.  
21. The Add ’Set-1’ view appears, from 
which you highlight a Fluid Package and press the Add Set to 
Fluid Package button.  
Add to FP (Fluid Package)
22. Press the Close button. Notice that the name of the Fluid 
Package (Basis-1) appears in the Assoc. Fluid Pkgs group w
the Reaction Set is highlighted in the Reaction Sets grou
hen 
p. 
23. Now Enter the Simulation Environment by pressing the button in 
the lower right 
hand portion  
 
Enter Simulation Environment 
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24. Install a conversion reactor.  Either through the 
24.1. Flowsheet, Add operation 
24.2. f12 
24.3. or icon pad.  Click on General Reactors and then a small 
pad pops up with a choice of 3 reactors.  Choose the conversion 
reactor.  Click on the Conversion Reactor icon, then release left 
mouse button.  Move cursor to pfd screen 
and press left mouse button. Double cl
on the 
ick 
reactor to open. 
25. Add stream names and a new reactor name as shown. After naming 
these streams the following errors appear:  Requires a Reaction Set 
and Unknown Duty. 
Conversion Reactor
General Reactors
26. Next add the reaction set by selecting the reactions 
tab and choosing Reaction Set from the drop down 
menu. 
27. Close the Conversion Reactor 
28. Open the workbook 
 
29. Now add a feed composition of pure ethylbenzene 
at 217 gmol/s, 880 K, 1.378 bar.  Remember you 
can type the variable press the space bar and type or 
select the units. 
30. Isn’t it strange that you can’t see the molar flowrate 
in the composition window?  Let’s add the molar f
Workbook Setup using the menu commands at the top of your screen. 
Workbook 
lowrates to the workbook windows.  Go to 
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31. Press the Add button on the right side 
32. Select Component Molar Flow and then press the All radio button. 
Add Button
Comp 
Molar 
Flow 
33. To change the units of the variables go to 
Tools, preferences, variables tab.  Clone the 
SI set and give this new set a name.   
34. Change the component molar flowrate units 
from kmol/hr to gmol/s if needed. 
35. Change the Flow units from kmol/hr to gmol/s 
36. Next change the Energy from kJ/hr to kJ/s. 
37. Save preference set as well as the case.  
Remember that you need to open this 
preference set everytime you use this case. 
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38. Now run the simulation.  For an isothermal reactor specify the outlet temperature. 
39. For the adaiabatic reactor, delete the temperature specification and specify the heat duty as 0.  
The heat duty can be specified in several ways: 
39.1. in the workbook under the Energy Streams tab 
39.2. in the reactor in the Design Tab under the parameters option in Duty. 
 
 
Duty 
Duty 
Unknown Duty Warning 
 
40. Now change the conversion.  The changes that we will make now will only effect this 
reactor.  Go to the reactions tab in the reactor. Select the Conversion% radio button.  Now 
type a new conversion value.  Notice that this is in percent conversion.  Use the spread sheet 
operations to check you conversion values. 
 
Put cursor here and start 
typing 
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At the end of this exercise submit a printout with the following: 
1) Make the following plots from your Conversion reactor simulation:   
a) The effect of conversion of ethylbenzene on the heat duty of an isothermal reactor at a constant temperature 
of 250°C. 
b) The effect of inlet temperature on 
outlet temperature for an adiabatic 
reactor at a conversion of 
ethylbenzene of 80%. 
Push 
2) Printout the following from one 
simulation on HYSYS 
Reactor Summary: 
Double click on reactor  
Undo push pin if present 
Select Print from main menu 
Then select the Datablock(s) shown in 
the second figure: 
   
Property Package 
Simulation, Enter Basis Environment 
Select View 
Print 
Select Preview… 
Then print the one page document 
 
Reactions 
Go to Rxns tab of the fluid 
package view 
Double click on your reaction 
Undo push pin 
Select Print  
Preview 
And printout this one page view 
 
Process Flow Diagram 
Click on pfd and choose print 
 
Workbook 
Select workbook and print. 
 
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