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PROBLEM Through guided practice, you will build a simulation of the process shown
below. This is part of a chiller plant typical in natural gas processing. In subsequent
parts of this example, you will add other sections of the plant to this simulation.
Figure 1:
Schematic of
Chiller Plant
Part 1
SOLUTION
Step 1 Create a New Simulation
¾ Select New... from the File menu.
Note that several buttons on the toolbar, including the Run button have red borders.
When you have satisfied PRO/II’s input requirements all red borders will disappear.
Step 2 Build the Process Flow Diagram
If the PFD palette is not already visible, click the PFD Palette button on the toolbar to
bring it up. Click on the appropriate unit icons on the PFD palette to draw the PFD. To
select and position a unit, just click on its icon.
A pointer with a box and flash drum attached appears. Move this to the main window
and click again when the unit is in position.
In this manner, select and position the units as shown in the diagram using these
PFD buttons:
Note: Although not critical in this example, it is good practice to connect the FLASH
DRUM hydrocarbon liquid product to the side port and to reserve the bottom
port for a decanted water or second liquid product.
¾ Double-click on each stream and unit and change its name to that shown on the
diagram above. Do not change any other data in the dialog box.
¾ Click OK to exit the dialog box. Note that spaces are not allowed in unit or stream
names.
The completed PFD should now look like Figure 5 below.
Step 3 After you finish building the flowsheet, the labels of all the internal streams are black
and the available ports of all the units are green. At this point, all the unit labels have
red borders and the border of the feed stream label is also red because you must still
add data. Note that the border of Streams is black, indicating that you have entered
all necessary data for this function. To exit the stream connection mode, right-click, or
click on Streams so that it turns gray, indicating that the mode is no longer active.
For this example you will use either modified SI Units or modified English units.
Click Initialize from Library.... and select ENGLISH-SET1 or SI-SET1 from the
drop-down list.
¾ Check each item that it matches the input data given in the tables above.
¾ Make any necessary changes and click OK
PRO/II Getting Started Work Book
Notice that the border of the UOM button is now blue indicating that you
have modified the data.
Figure 5: Transport
Properties
¾ Click OK in each of the three dialog boxes to save the entered data.
¾ Enter the individual component mole percentages into the component grid.
You can move down the list using the <Tab> key. After entering the
composition data, check that the total equals 100.
¾ Click OK to exit each dialog box and return to the PFD.
You do not need to enter data for any streams other than the INLET_GAS (the external feed
stream to the process) because PRO/II calculates the others for you, based on your process
conditions.
Note: As you return to the PFD after each unit operation, its unit
identifier has changed from red (data missing) to black (data
satisfied).
Note: By default, the horizontal stream is the hot side and the vertical
stream is the cold side. Here this means that the utility stream
is the cold side. You could use this dialog box to change the
stream allocations if the reverse were true.
The new equipment data and operating conditions are provided below. Table 5:
Equipment Data
Unit Description Data
HX-2 Gas to Gas Hotside ∆P 5 psi 35 kPa
Exchanger Coldside ∆Pi 5 psi 35 kPa
Approach Temp (Hot In - Cold Out) 10°F 5°C
HX-3 Chiller Hotside Outlet Temp -13'F 25"C
Hotside ∆P 5 psi 35 kPa
Coldside refrigerant saturated liquid
Propane at -22°F -30"C
D-3 Cold Separator Adiabatic Separation
V-1 Valve Outlet Pressure 245 psig 1800 kPa
SOLUTION Use the previous example, CHILLI.PRZ as the basis for this example.
¾ Select File/Save As... from the menu bar and save the example as CHILL2.PRZ.
In the Heat Exchanger dialog box for HEAT EXCHANGER HX-3 (Chiller), click Utility
Stream... and choose Refrigerant as the Utility Type. Select Propane from the Component
list and enter the saturation temperature.
Note: PRO/H's refrigerant utility, used in unit HX-3, considers only latent heat effects, so
the refrigerant inlet and outlet conditions are a saturated liquid and a saturated vapor,
respectively.
At this point there should not be any red borders on the flowsheet. All stream and unit
labels should have black borders. If any of the unit or stream labels has a red border,
double-click on it and check the data.
Figure 8:
Schematic of
Chiller Plant-Part 3
Component Mole%
Ethane 2.5
Propane 97
i-Butane 0.5
Pressure 11.5 psig 180 kPa
Condition Bubble Point
SOLUTION Use the previous example, CHILL2.PRZ, as the basis for this example and save the
example as CHILL3.PRZ.
¾ Remove the utility stream on HEAT EXCHANGER HX-3 by double-clicking on the unit
and deactivating the check box for the utility stream.
Even though the flowrate of this stream is going to be calculated by the controller,
you must enter a flowrate here. This not only satisfies the data requirements of the
dialog box but also serves as an initial estimate.
¾ Use the propane refrigerant rate from the previous example as the initial flowrate
for this stream.
You want to vary stream 50 flowrate so that the temperature of stream 9 is-15°F (-
26°C).
¾ Click on Parameter.
¾ Click on Parameter.
PRO/II Getting Started Work Book
¾ Choose stream 50 as the stream to vary. Click on Parameter and choose
Flowrate as the variable.
¾ When complete, the Feedback Controller dialog box looks like Figure 16.
¾ Create a STREAM PROPERTY TABLE for stream 50 with the Stream Summary list
selected.
A portion of this table is shown below. Compare the quantity of refrigerant required to
that obtained in the previous example. Why are the results different?
Figure 11:
Schematic of
Chiller Plant
Part 4
SOLUTION Use the previous example, CHILL3.PRZ, as the basis for this example and save
the example as CHILL4.PRZ.
Step 1 Add to the Process Flow Diagram
¾ Place a COMPRESSOR, two MIXERs and a COLUMN on the PFD. Connect the streams
as shown in Figure 11. Name the units and stream.
PRO/II Getting Started Work Book
When you place the column, you will be asked to give the number of theoretical trays
and to state whether the column has a condenser and a reboiler. Note that the Table 7
gives actual trays and tray efficiency. From this you must calculate the number of
theoretical trays in the body of the column (22*55% =12 stages). The kettle reboiler is
simulated as a theoretical stage and thus is stage 13. This column has no condenser.
The mixers require no data. Enter the COMPRESSOR data from the table.
¾ Double-click on the COLUMN. Check that the Number of Trays is correct and that
the default selections for Algorithm and Calculated Phases are appropriate to your
simulation.
¾ Click Pressure Profile... and enter the Top Tray Pressure and the Pressure Drop for
the entire Column.
¾ Click Feeds and Products.... to set the feed tray number. Check that the default
entry for the Phase of each Product is correct.
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PRO/II Getting Started Work Book
he rate of the overhead product. You can make a good guess from the results of the
previous run. You could also use the Define procedure, assuming that the overhead
stream consists of all the Nitrogen through Methane from the column feed (Figure 13).
Figure 13:
Overhead
Flowrate
Definition
¾ In the Variables grid, click on Parameter, choose Column and select Heat Duty of
the Reboiler from the lists. The completed dialog box is shown in Figure 14.