7 replies to this topic

[kaidlut]

Dear all，

 

I  am a plant process engineer of a syngas plant and also a beginner of hysys simulation . Our plant process : SMR + Amdea CO2 removal + cold box + membrane.

 

since Hysys does not have a reformer  module， so i use the Equilibrium Reactor to perform the reform reactions, and Conversion reactor to perform combustion process, and Connect the conversion and combustion reactors with energy stream，is there a better way? If a fire heater is better?  and how to set reformer heat efficiency？

 

I uploaded hysys PFD for your convenience to give me some suggestions. Thank you

 

Attached Files

•  hysys PFD.pdf   379.45KB   17 downloads

Edited by kaidlut, 28 June 2025 - 09:40 PM.

[PingPong]

I have never used Hysys so I can't really be of much help with that.

 

What exactly do you mean by:  how to set reformer heat efficiency 

[kaidlut]

I have never used Hysys so I can't really be of much help with that.

 

What exactly do you mean by:  how to set reformer heat efficiency

Because not all the heat from fuel combustion is supplied to the reaction /raw material preheating / steam generation, there is heat loss on the furnace wall, and  flue gas  leave the stack at a high-temperature. How should I set it in Aspen to ensure consistency between simulated data and actual factory data

[PingPong]

Heat loss from the furnace wall is minor, say 1% on radiant duty, 0.5 % on convection duty.

 

As you work in the plant you should have many operating temperatures of the flue gas available. They are normally shown on the DCS screens as well.

 

So you should know what the flue gas temperature at the top of the radiant section is, which is that of your stream fluegas-100 , and also the flue gas temperature of stream fluegas-106 or fluegas-tostack

 

Without a flow scheme or DCS screenshots it is difficult for outsiders to understand the layout of your specific SMR. 

 

There seems to be no air preheat ?

 

Where does Q110 come from ?

Where do Q114 and Q116 go to ?

 

I would advice you to change your simulation scheme, so as to represent more accurately the actual process flow scheme, by using actual heat exchangers that exchange heat between two streams, instead of using single stream heat exchangers that only yield a duty that you then use in other single stream heat exchanger that absorb that duty.

With your present scheme you can never simulate the unit under different capacity or different ..... (whatever).

[kaidlut]

I upgrade the simulation scheme, so you can understand better.

 

Another question：

 

The simulation results fit well with the H&MB sheet, but there is a certain deviation from the actual factory data，there are a series of reactions in the reformer reactor and high-temperature shift reactor，（CH4+H2O / C2H6+H2O/C3H8+H2O，and so on）,How can I set the Approach to Equilibrium Temperature to match the actual production data？

 

 

Heat loss from the furnace wall is minor, say 1% on radiant duty, 0.5 % on convection duty.

 

As you work in the plant you should have many operating temperatures of the flue gas available. They are normally shown on the DCS screens as well.

 

So you should know what the flue gas temperature at the top of the radiant section is, which is that of your stream fluegas-100 , and also the flue gas temperature of stream fluegas-106 or fluegas-tostack

 

Without a flow scheme or DCS screenshots it is difficult for outsiders to understand the layout of your specific SMR. 

 

There seems to be no air preheat ?

 

Where does Q110 come from ?

Where do Q114 and Q116 go to ?

 

I would advice you to change your simulation scheme, so as to represent more accurately the actual process flow scheme, by using actual heat exchangers that exchange heat between two streams, instead of using single stream heat exchangers that only yield a duty that you then use in other single stream heat exchanger that absorb that duty.

With your present scheme you can never simulate the unit under different capacity or different ..... (whatever).

 

Attached Files

•  PFD.pdf   845.68KB   3 downloads

[PingPong]

 

How can I set the Approach to Equilibrium Temperature to match the actual production data？

 

I have no experience with Hysys so I looked for a user manual on internet and found the 'Aspen HYSYS Unit Operations Reference Guide' of februari 2019 for version V11.

 

I attach a page from that, and highlight in red what you could try:

 

 Approach to equilibrium in Hysys.jpg   101.06KB   1 downloads

Edited by PingPong, 24 July 2025 - 09:00 AM.

[kaidlut]

Could you please send this manual to my email? Or can you provide me with a link? Email：kaidlut@aliyun.com

 

 

How can I set the Approach to Equilibrium Temperature to match the actual production data？

 

I have no experience with Hysys so I looked for a user manual on internet and found the 'Aspen HYSYS Unit Operations Reference Guide' of februari 2019 for version V11.

 

I attach a page from that, and highlight in red what you could try:

 

Approach to equilibrium in Hysys.jpg

 

[PingPong]

https://esupport.asp...a0g0B00000OT6WC