Integrating Aspen Fired Heater

with Aspen HYSYS®

Technical Solution Review
Aspen Engineering Excellence Webinar

Host: Steve Noe, Industry Marketing, AspenTech 29 November 2011

Presenter: Julien Cazenave, Business Consultant, AspenTech

© 2011 Aspen Technology, Inc. All rights reserved

 Disclaimer

Aspen Technology may provide information regarding possible

future product developments including new products, product
features, product interfaces, integration, design, architecture,
etc. that may be represented as “product roadmaps.” Any
such information is for discussion purposes only and does not
constitute a commitment by Aspen Technology to do or deliver
anything in these product roadmaps or otherwise. Any such
commitment must be explicitly set forth in a written contract
between the customer and Aspen Technology, executed by an
authorized officer of each company.

© 2011 Aspen Technology, Inc. All rights reserved | 2 2

Aspen Exchanger Design & Rating Products

Aspen Shell & Tube Exchanger

Aspen Shell & Tube Mechanical

Aspen Fired Heater Aspen Air Cooled

Exchanger

Aspen HTFS Research

Network

Aspen Plate Fin Exchanger Aspen Plate Exchanger

© 2011 Aspen Technology, Inc. All rights reserved | 3

 Aspen Fired Heater™
New product replacing Aspen FIHR™

 First release: FIHR in 1989, Aspen Fired Heater in 2007

 New Aspen Exchanger Design & Rating user interface
− Flexibility and interactive data checking
 For designers and operators
− Simplified geometric specifications
 For firebox and convection section tubes, and tube arrangements
 Expanded property capabilities
− COMThermo®, B-JAC databanks, and Aspen Properties®
− Handling one, two and three phase (with two liquid phases)
 Modern flexible output reports (incl. API 560 datasheet)
− Tabulated results for:
 Overall performance
 Combustion
 Streams
 Tubes
− Categorized errors and warnings
 For rapid assessment of modeling accuracy

© 2011 Aspen Technology, Inc. All rights reserved | 4

Aspen EDR Common User Interface (UI)

© 2011 Aspen Technology, Inc. All rights reserved | 5

Aspen Fired Heater – Overall Arrangement

© 2011 Aspen Technology, Inc. All rights reserved | 6

Aspen Fired Heater – Functionality

© 2011 Aspen Technology, Inc. All rights reserved | 7

 Aspen Fired Heater – Firebox Models

 Long Furnace Model (LFM) Bridge-wall

− More realistic variation in combustion
gas temperature
− Hence variation of heat flux on tubes
− Hence tube metal temperature
− Needs burner heat release characteristic

 Well-Stirred Model (WSM)

− Considers single combustion gas
temperature
− Hot gas at exit from firebox below
mean radiating temperature

Tg
− Hottel model
• Proportional to firebox load
LFM WSM
Long Furnace Well-Stirred
Model Model
 To model operating heater can
specify bridge-wall temperature

© 2011 Aspen Technology, Inc. All rights reserved | 8

 Aspen Fired Heater – Flow Stability Warnings

 9 Warnings for:
 Slug flow in firebox
 Slug flow in convection bank
 Two-phase flow at exit from two-path
convection bank
 Based on HTFS two-phase flow patterns
 Avoid flow instabilities (pre-cursors to
tube over-temperature and/or coking)

© 2011 Aspen Technology, Inc. All rights reserved | 9

 Aspen Fired Heater
User-specified operational limits

Specify limits for

 Firebox tube temperature
– avoid tube failure
 Firebox tube heat flux
– avoid tube failure, avoid coking
 Firebox process fluid outlet temperature
– Avoid coking
 Convection section fluid outlet temperature
– Avoid acid gas condensation
 Convection section gas velocity
 Convection section gas pressure drop

© 2011 Aspen Technology, Inc. All rights reserved | 10

Aspen Fired Heater – Diagrams

© 2011 Aspen Technology, Inc. All rights reserved | 11

 Aspen Fired Heater V7.2 – Improvements

 Improved gas emissivity model

– Improved 4-grey gas emissivity model

 Option to select peak tube temperature calculation

methods
– New “Adjusted Heat Flux Ratio” better for very high tube
temperatures

 Changes to input and output items and some

calculation defaults
– In convection banks, radiative heat transfer is now “on” by
default

© 2011 Aspen Technology, Inc. All rights reserved | 12

 Aspen Fired Heater V7.3 – Improvements

 Specification of fouling factors for tube-groups and

convection banks
– Tube-side and gas-side
fouling factors can now be
specified separately
for each tube-group and
convection bank
Industry recognised AspenTech
correlation Research based
correlation
 Additional correlations for gas-side heat transfer
– An option to select the ESCOA or HTFS3A correlations in
addition to the pre-existing PFR correlation for gas-side heat
transfer to high finned tubes

© 2011 Aspen Technology, Inc. All rights reserved | 13

Aspen HYSYS and Aspen Fired Heater Link

• Rigorous Model
• EDR UI inside Aspen HYSYS

© 2011 Aspen Technology, Inc. All rights reserved | 14

 Demonstration

© 2011 Aspen Technology, Inc. All rights reserved | 15

 Aspen Fired Heater Demo Outline

 Set up an Aspen Fired Heater model in both

stand alone mode and in Aspen HYSYS

 Import the Aspen Fired Heater rigorous model

 Explore detailed modelling results

 Change the crude to a heavy blend

 Consider potential revamp options

and associated economics

© 2011 Aspen Technology, Inc. All rights reserved | 16

Case Study Results

100% Iranian 10% Soroosh Revamp

Warm Crude Temp. 254.7 C 249.3 C 249.3 C

Duty 63.91 MW 68.95 MW 68.89 MW

Fuel Flow Rate 5606 kg/h 5873 kg/h 5688 kg/h

Fuel Cost 80.7 k$/day 84.6 k$/day 81.9 k$/day

© 2011 Aspen Technology, Inc. All rights reserved | 17

 Aspen Fired Heater Summary

 Release V7.3 allows

rigorous fired heater
models in Aspen HYSYS

 Allows effect of crude

switching to be modelled

 Explore revamp option

 For more information:

AspenTech support
website Knowledge Base
solution No. 131572

© 2011 Aspen Technology, Inc. All rights reserved | 18

 Just Released! Aspen Fired Heater V7.3.2
aspenONE 28-Nov-2011 Update

 Calculation of flue gas properties using Aspen Properties

 Detailed reporting of draft calculation and flue gas properties

 Improved treatment of the air pre-heater

 Detailed reporting of peak tube calculation parameters

 Improvements to firebox diagrams (inclusion of roof tubes)

 Increased allowance for pressure losses in U-bends and fittings

aspenONE V7.3.2 Now Available!

Innovations to Make Optimization Faster and Easier

© 2011 Aspen Technology, Inc. All rights reserved | 19

Want to see similar results?

Consider a training class from AspenTech

http://support.aspentech.com/training

© 2011 Aspen Technology, Inc. All rights reserved | 20

 Aspen Exchanger Design and Rating (EDR)
Training

Design and Simulation of Fired Heaters

Using Aspen Fired Heater (EHX1031)
January 17, 2012 – Virtual- Americas

February 9, 2012 – Virtual-Americas

http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=EHX1031

• Learn the fundamentals of rating and simulating a fired heater

• Understand the requirements for design checking and simulation of fired heaters
• Efficiently use the Aspen Fired Heater application to evaluate:
− Vertical Cylindrical Unit (VCU) with convection bank
− Twin cabin firebox
− Single cabin fired heater with roof tubes

© 2011 Aspen Technology, Inc. All rights reserved | 21

 Aspen HYSYS Training

Aspen HYSYS: Process Modeling (EHY101)

December 5, 2011 – Jakarta, Indonesia

December 5, 2011 – Virtual-Latin America

December 5, 2011 – Houston, TX

December 6, 2011 – Reading, UK

December 12, 2011 – Calgary AB, Canada

http://support.aspentech.com/supportpublictrain/CourseInfo.asp?course=EHY101
• Optimize engineering work processes using the full power and flexibility of
Aspen HYSYS to build, evaluate and optimize flowsheets.
• Learn the shortcuts for efficient use of the software to build steady state
simulations processes.

© 2011 Aspen Technology, Inc. All rights reserved | 22

 New in
Aspen Online Training aspenONE
28-Nov-2011
Fast, easy access to training content Update

 Convenient, on-demand
access from inside the product
– Aspen Plus, Aspen HYSYS
– Aspen EDR, Aspen Economics
– Aspen Basic Engineering

 Library of rich training content

 Superior user experience
– Getting Started
– What’s New
– Multiproduct Integration
– Best Practices

 Links to additional support

and training resources

All from within the product!

For more information: http://www.aspentech.com/v7/aspen-online-training.aspx

© 2011 Aspen Technology, Inc. All rights reserved | 23

 New in
Aspen Search – Process Industry First aspenONE
28-Nov-2011
Search, navigate and filter for information Update

Benefits:
• Reuse of intellectual and
informational assets
• Solve design, operational,
business problems faster
Quickly find the • Enterprise-wide collaboration
best model and consistency

Links
models,
people
and data
Currently available
with Aspen Plus
and Aspen HYSYS

http://www.aspentech.com/v7/aspen_search.aspx
© 2011 Aspen Technology, Inc. All rights reserved | 25
Questions?

© 2011 Aspen Technology, Inc. All rights reserved | 27

Contact Information

Steve Noe, Industry Marketing, AspenTech

Email: Steve.Noe@aspentech.com

Julien Cazenave, Business Consultant, AspenTech

Email: Julien.Cazenave@aspentech.com

For any Aspen Exchanger Design & Rating communication:

Email: AspenEDR@aspentech.com

THANK YOU!

© 2011 Aspen Technology, Inc. All rights reserved | 28