11-3532-Rigorous Sizing Shell and Tube - Aspen HYSYS

Jump Start: Rigorous Shell & Tube Exchanger Sizing
in Aspen HYSYS V8
A Brief Tutorial for Autosizing and Interactive Sizing in Aspen HYSYS V8
Lauren Sittler, Product Management, Aspen Technology, Inc.
Tom Ralston, Director, Equipment Design and Rating, Aspen Technology, Inc.
2013 Aspen Technology, Inc. AspenTech, aspenONE, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved. 11-3816-0713
Jump Start: Rigorous Shell & Tube Exchanger Sizing in Aspen HYSYS V8
Table of Contents
Introduction to Autosizing and Interactive Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Scope of this Document. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overview of the Example Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Autosizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sizing the Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Viewing the Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Interactive Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Sizing the Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Introduction to Autosizing and Interactive Sizing

Aspen HYSYS V8 features streamlined workflows for transforming any simple heat exchanger model in a simulation
flowsheet into a rigorous EDR Shell & Tube or Air Cooled model. One click sizes an exchanger using the full design
optimization logic of EDR, resulting in a rigorous exchanger model which you can choose to embed in your simulation. You
can benefit from a more precise model which will respond to process changes to help you optimize your overall process
design and process operations. You can easily view a summary of thermal hydraulic results from the model and even view
the exchanger setting plan, tube layout or temperature profiles.
These workflows are mainly focused on the preliminary design of heat exchangers where the objective is to rapidly assess
the size and cost of exchangers required for a given process duty, including requirements for multiple shells in series and in
parallel. Design templates can be used to tailor the design constraints to specific process requirements such as materials
of construction, stream fouling resistances, allowable pressure drops and company standards for exchanger head types or
shell types. The preliminary designs obtained can be an excellent basis for subsequent detailed thermal and mechanical
design of exchangers.
Scope of this Document

This Jump Start guide will provide step-by-step instructions for completing automatic and interactive sizing in Aspen
HYSYS.
You will learn how to:
Autosize a Shell & Tube exchanger in HYSYS
Interactively size a Shell & Tube exchanger in HYSYS
We will use an Aspen HYSYS case file to demonstrate the integrated workflows. We have also included an EDR solution
case for the final EDR designs. The files associated with this example are available for download on the Customer Support
& Training website.
Overview of the Example Case

Open the case RefSYS CDU for Autosizing in HYSYS. In this case we are modeling a crude refining process. The exchanger
that we will design is located in the Preheat Train subflowsheet. In the preheat train the raw crude is heated by a series of
exchangers before entering the crude furnace. Our example will focus on exchanger E103.
Figure 1. E-103 in the Aspen HYSYS Crude Preheat Train
Autosizing
Sizing the Exchanger
1. Double click on the Preheat Train subflowsheet to open the form. Click the Sub-flowsheet Environment button at the
bottom.
2. Locate exchanger E103, immediately downstream of the Desalter. Double-click to open E-103.
3. Click on the Design tab > Connections form. Note that the crude stream from the previous exchanger is the Shell Side
Inlet, and the recycled residual stream is the Tube Side Inlet. Lets change this so that our crude stream is on the tube
side. Click the Switch Streams button, located in the center of the form below the exchanger diagram.
4.Click on the Parameters form under the Design tab. You can see that the model type is currently a Simple End Point
Model.
5. The pre-specified allowable pressure drops for E-103 are unrealistic. Lets increase both shell-side and tube-side values
to 0.5 bar (50kPa). A reasonable pressure drop allowance is essential for realistic sizing of exchangers. If you find that
the design requires multiple shells in series it is always worth considering allowing more pressure drop to see if that
results in a cheaper optimum design.
6. We are now ready to run the automatic sizing. Click on the Size Rigorous Shell & Tube button at the bottom of the form.
The EDR progress bar will display, indicating that designs are being evaluated to identify which are feasible. You will see
a numerical read out of the designs being explored. When optimization is complete, results will be updated to the
Aspen HYSYS exchanger Parameters form.
Note: You may see a pop-up message asking if you wish to override existing outlet stream
specifications with the outlet stream conditions calculated by EDR. This occurs because, in this
case, temperature was a user-specified variable. When we transitioned from a simple end point
model to a rigorous model we can calculate the outlet temperature of both streams. Click Yes to
accept this new definition for the outlet temperature.
Figure 2. Heat Exchanger: E103 Parameters Form after Sizing
Viewing the Results

You have now completed autosizing this exchanger and your simple End Point model has been replaced by a rigorous EDR
model. You can see some of the results in the Rigorous Model section at the bottom of the form. You can see that we now
have values for the Effective Surface Area, and Overall Heat Transfer Coefficient. In this case there is an indication of a
vibration risk in this exchanger.
To view more exchanger details click on the Rigorous Shell & Tube tab at the top right of the form. Click on Exchanger in
the vertical form list. Here you can see that we have a BEM TEMA-type exchanger, with 1 shell, 589 tubes in one tube pass
and a 30-Triangular Tube Pattern. The geometry specifications that are italic blue, such as the TEMA type and tube
pattern, are EDR defaults. These configuration defaults may not be appropriate for this crude pre-heat application. We can
elect to use an EDR Design Template file to customize the Auto-sizing constraints specifically for our process. Checking
the box marked Select a Design Template File in Figure 2 above will open a dialogue where we can browse to a suitable
template file (designated: filename.EDT)
In interactive sizing we will see how to adjust key constraints before running Sizing.
Scroll through the forms in the Rigorous Shell & Tube tab to view more information about the Process, Results Summary,
Setting Plan, and etc.
To view full details of the design, click on the Model Details button at the bottom of the form. The full EDR Shell & Tube
User Interface can be accessed. You will see that the model is in Simulation mode. Any changes you make to your model
will cause Aspen HYSYS to re-solve.
Figure 3. Rigorous Shell & Tube Exchanger Results
Interactive Sizing
Sizing the Exchanger
Interactive sizing allows greater flexibility than autosizing. In this mode you can adjust design constraints before the initial
sizing and you can explore the effects of changing constraints on the optimum design found.
Interactive sizing uses the EDR Sizing Console to allow you to adjust some key geometric and process design constraints.
You can adjust your settings and view summary sizing results in this environment. You can save your design at any stage
as an EDR file, accept the most recent design and revert to your simulation, open a template or an initial EDR file prepared
with your required design constraints or choose to cancel your sizing process and revert to your simple model in Aspen
HYSYS.
To interactively size the exchanger complete steps 1-5 for autosizing, listed above, and then follow the steps below.
Figure 4. Interactive Size Rigorous Shell & Tube
1. On the Design tab> Parameters Form you will notice that the Size Rigorous Shell & Tube button has a dropdown arrow
on the right size. Click on the dropdown arrow and choose Interactive Size Rigorous Shell & Tube. The EDR Sizing
Console appears.
2. The console has four tabs: Geometry, Process, Errors & Warnings, and Run Status. The Geometry tab contains a
summary of the exchanger design specifications and constraints. The Process tab lists the process stream conditions
and key process constraints. We will make all of our changes on these two tabs, starting with Geometry. If you wanted
to view all of the user-input you could click on the Full EDR Browser button on the top right. This will expand the
navigation pane to show all folders. For now, click on the Geometry tab and make the following adjustments for this
crude process exchanger:
Change the TEMA type to AET
The Tube pattern to 45-Rotated Square
The Baffle cut orientation to vertical
Figure 5. Set Geometry Specifications
Click on the Process tab.

Set the fouling resistance to 0.001 hF/BTU for both the Hotside and the Coldside
Return to the Geometry tab.
Figure 6. Set Process Specifications
3. Click the Size Exchanger button to run the sizing optimization.

4.After the sizing is complete, we can review the overall results on the Geometry tab. If we compare our new design
(Most Recent Run) with the previous one, we see that by changing the TEMA type for easier cleaning, and inputting a
realistic fouling factor, we require a larger diameter shell and our exchanger cost has increased. We now have an
exchanger configuration which is better suited to our crude-pre heat application.
Figure 7. EDR Interactive Sizing Results
5. You can continue adjusting this design by changing parameters and re-sizing until you are satisfied. If you choose to
Accept Design you will return to Aspen HYSYS with a rigorous exchanger model inside your simulation. If you select
Cancel we can return to the Aspen HYSYS simulation and revert to the simple model.
Additional Resources
Check out other training materials specifically for this product:
Public Website
www.aspentech.com/products/aspen-edr.aspx
Online Training
www.aspentech.com/products/aspen-online-training
www.aspentech.com/products/edr-tutorials
Video Tutorials
Autosizing Shell & Tube Exchangers in Aspen HYSYS V8
https://www.brainshark.com/aspentech1/autosize-shell-tube-HYSYS
New Interactive Sizing in Aspen Plus
https://www.brainshark.com/aspentech1/edr-integration-aspen-plus
Jump Start Tutorial

Getting Started in Aspen Shell & Tube Exchanger V8
http://www.aspentech.com/Jump_Start_Shell_Tube.pdf
Jump Start: Rigorous Sell & Tube Sizing in Aspen Plus
www.aspentech.com/Shell_Tube_Aspen_Plus.pdf
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2013 Aspen Technology, Inc. AspenTech, aspenONE, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen
Technology, Inc. All rights reserved.
11-3816-0713
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www.aspentech.com/locations

11-3532-Rigorous Sizing Shell and Tube - Aspen HYSYS

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Jump Start: Rigorous Shell & Tube Exchanger Sizing

Introduction to Autosizing and Interactive Sizing

Scope of this Document

Overview of the Example Case

Figure 1. E-103 in the Aspen HYSYS Crude Preheat Train

Figure 2. Heat Exchanger: E103 Parameters Form after Sizing

Viewing the Results

Figure 3. Rigorous Shell & Tube Exchanger Results

Figure 4. Interactive Size Rigorous Shell & Tube

Figure 5. Set Geometry Specifications

Click on the Process tab.

Figure 6. Set Process Specifications

3. Click the Size Exchanger button to run the sizing optimization.

Figure 7. EDR Interactive Sizing Results

Jump Start Tutorial

For a complete list of offices, please visit

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