5.

0 Calculation and verification

The material and energy balance that calculated manual has been compared with the
result obtain from ASPEN HYSYS simulation. It is important to compare manual calculation
with ASPEN HYSYS in order to obtain a satisfied and comparable result, so that the process
plant work in a proper manner.

In this verification, one mass transfer unit and one energy transfer unit is run in
simulation and the result was compared with manual calculation. For mass transfer unit,
mixer M-101 simulated in ASPEN HYSYS and compare with manual calculation. However
for energy transfer, heat exchanger of E-101 is used to compare with ASPEN HYSYS data.
The result that obtain is compare up to 4 significant figures.

Fluid Package Selection

Non- Random Two Liquid (NRTL) was chosen in the ASPEN HYSYS simulation. NRTL is
used when the mixture is assume and consider as an ideal gas.

Peng-Robinson (PR) fluid package was chosen in the simulation. As PR property

package rigorously solve any single, two or three phase system with high degree of efficiency
and reliability and is applicable over a wide range of condition. For temperature range > -271
and pressure range <100,000 kPa. Moreover PR properties also contains enhanced

binary interaction parameters for all library hydrocarbon-hydrocarbon pairs, as well as for
most hydrocarbon and non- hydrocarbon binaries.

Ali (2015) reported that for mixture non-polar gases, equation of state such as Peng-
Robinson, Soave-Redlich- Kwong (SRK), and Lee-Kesler-Plocker can be uses. For light
hydrocarbon gas, Peng-Robinson fluid package is suggested to be used. However for other
package like NRTL, Wilson, UNIQUAC is for polar compound. NTRL is also pool model for
hydrocarbon Engcom, (2009).

In our process it only involved single gas phase of ethylene, hydrogen and nitrogen
gas only where 3 component are light hydrocarbon and non-polar compound. The gas

mixture is also operate at 76 and 20 bar in the mixing chamber. Therefore fluid
 package of Peng-Robinson is used in this simulation. As Peng-Robinson fluid package also
the industry standard for simulating gas streams for purpose of gas processing facility design.

5.1 Manual calculation for mixer M-101

S14 = 17149.86 kg/h S11 = 52095.35 kg/h

m C 2 H 4 = 698.90 m C 2 H 4 = 35643.73
M-101
kg/h kg/h
mH 2 = 0.01 kg/h mH 2 = 0.67 kg/h
m
N 2 = 16450.95 m
N 2 = 16450.95 kg/h
kg/h 68.42% C2H4

S10 = 34945.49 kg/h

m C 2 H 4 = 34944.83

kg/h
mH 2 = 0.66 kg/h
99.99% C2H4

Figure 2.9: Mass balance of mixer (M-101)

Stream Componen Mass Mass Molar Mass Total

t flow rate flow flow rate compositio mass
(kg/hr) rate (kmol/hr n (mass %) flow rate
(ton/hr) ) (kg/h)
Input S14 Ethylene 698.90 6.99 1024.91
1
4.08 52095.35
Hydrogen 0.01 1.00 1056.53 103 5.83 105
Nitrogen 16450.9 16.45 587.26 95.92
5
S10 Ethylene 34944.8 34.94 1245.66 99.99
 3
Hydrogen 0.66 4
6.60 10 3.27 10
1
1.89 10
3

output S11 Ethylene 35643.7 35.64 1270.58 68.42 52095.35

3
Hydrogen 0.67 6.70 1043.33 1011.29

103
Nitrogen 16450.9 16.45 587.26 31.58
5

Mass balance for mixer (M-101):

Input = output

S14 = 16450.9491616237 kg/hr + 698.8965330102 kg/hr +0.0131678565 kg/hr

17149.8588624903kg /hr 4

1.715 104 kg /hr 4 significant figure

S10 = 34944.8266505078 kg/hr +0.6583928246 kg/hr

= 34945.4850433324kg/hr
4
3.495 10 kg /hr significant figure

S 14+ S 10=S 11

kg kg
17149.8588624903 +34944.4850433324
h h

kg
52095.349058227
h

5.210 104 4 significant figure

16450.9491616237
Mass composition of nitrogen in S14 17149.8588624903

= 0.9592 4 significant figure

 0.0131678565
Mass composition of hydrogen in S14 17149.8588624903

7
= 7.678 10 4 significant figure

698.8965330102
Mass composition of ethylene in S14 17149.8588624903

2
=4.075 10 4 significant figure

34944.8266505078
Mass composition of ethylene in S10 34945.4850433324

1
=9.999 8 10

1.000 4 significant figure

0.6583928246
Mass composition of hydrogen in S10 34945.4850433324

5
=1.884 1 10

1.884 1 105 4 significant figure.

35643.7231835179
Mass composition of ethylene in S11 52095.349058227

=0.684201
6.842 101 4 significant figure
 0.6715606811
Mass composition of hydrogen in S11 52095.349058227

5
=1.2891 10

1.289 105 4 significant figure.

16450.9491616237
Mass composition of nitrogen in S11 52095.349058227

=0.3157854028
3.158 101 4 significant figure

5.1.1 Process Data from ASPEN HYSYS

In the simulation of the process using HYSYS, 3 component is chosen in the component list
which is ethylene, hydrogen and nitrogen. The step is then continue with the choice of fluid
package. In this simulation NRTL is chosen as the process and the gas is assumed to be in
ideal gas behaviour. The data of the inlet stream (S10 and S14) such as temperature, pressure,
mass flow rate and mass composition was insert and the HYSYS will automatically
calculated the output stream (S11) information such as mass flow rate, temperature, pressure,
composition and other information. The table below show the data obtain from ASPEN
HYSYS.
 Object Variable Value (4s.f) Units
4
S14 Mass flow 1.715 10 kg/hr
S14 Mass composition ethylene 9.999 10
1

S14 Mass composition hydrogen 7.678 10

7

S14 Mass composition nitrogen 9.9592 10

1

4
S10 Mass flow 3.495 10 kg/hr
S10 Mass composition ethylene 9.999 10
1

S10 Mass composition hydrogen 1.884 10

5

4
S11 Mass flow 5.210 10 kg/hr
S11 Mass composition ethylene 6.842 10
1

S11 Mass composition hydrogen 1.289 105

S11 Mass composition nitrogen 3.158 101
Table : Process Data Obtain from ASPEN HYSYS.

5.1.2 Comparison between manual calculation and ASPEN HYSYS Data

Objec Variable ASEN HYSYS Manual Difference

t Data calculation
4 4
S14 Mass flow (kg/hr) 1.715 10 1.715 10 0
S14 Mass composition 9.999 10
1
9.999 10
1
0
ethylene
S14 Mass composition 7.678 107 7.678 107 0
hydrogen
S14 Mass composition 9.9592 10
1
9.9592 10
1
0
nitrogen
 4 4
S10 Mass flow (kg/hr) 3.495 10 3.495 10 0
S10 Mass composition 9.999 101 9.999 101 0
ethylene
S10 Mass composition 1.884 10
5
1.884 10
5
0
hydrogen
4 4
S11 Mass flow (kg/hr) 5.210 10 5.210 10 0
S11 Mass composition 6.842 10
1
6.842 10
1
0
ethylene
S11 Mass composition 1.289 105 1.289 105 0
hydrogen
S11 Mass composition 3.158 101 3.158 101 0
nitrogen
Table : the comparison between manual calculation and ASPEN HYSYS Data

From the table show above, it can be seen that there is no difference between the manual
calculation and ASPEN HYSYS Data obtain from the simulation. The show a good result to
verify the correct calculation of material balance during manual calculation and maybe be
consistence to all other stream as well.

5.2 Energy balance for heat exchanger E-101

S20=9345.95 kg/hr
m H 2 O=9345.95 kg/hr
100% H2O
T=298 K
P= 2.0 bar
S14 = 17149.86 kg/h
S13 = 17149.86 kg/h
m C 2 H 4 = 698.90 kg/h
m C 2 H 4 = 698.90
E-101 m
H = 0.01 kg/h
kg/h 2

mH = 0.01 kg/h m
N
2
2 = 16450.95 kg/h
m
N 2 = 16450.95 4.08% C2H4
95.92% N2
kg/h 5
4.08% C2H4 5.83 10 H2
95.92% N2 T= 317 K
 S21=9345.95 kg/hr
m H 2 O=9345.95 kg/hr
100% H2O
T=313 K
P= 1.5 bar

Mass flow rate Mole flow rate Enthalpy Temperature Pressure (

(kg/hr) (kmol/hr) (MJ) (C) bar)

Input 17149.86 612.18 1384.45 76 21.5

S13
Input 9345.95 519.22 976.65 25 2
S20
Output 17149.86 612.18 798.53 44 20.5
S14
Output 9345.95 519.22 1562.27 40 1.5
S12
Heat duties of each unit (MJ) 585.92

Power requirement of each unit kWh 0

At 44

hC 2 H4 =67.8658073 kJ /kg

h N =
2
45.6554241 kJ /kg

h H =630.1654686 kJ /kg
2

Enthalpy of mixture
k
hm = mf i hi kJ/kg
i=1

2
Mass fraction of C2H4= 4.08 10
7
Mass fraction of H2 = 5.83 10

Mass fraction of N2 = 0.9592

 hm=mf C H hC2 4 2 H4 +mf H hH +mf N h N
2 2 2 2

kJ 630.1654686 kJ
h14=4.08 102 67.8658073 +5.83 107 +0.9592 45.6554241 kJ /kg
kg kg

46.56197512 kJ /kg

h14
14=m
H

kg kJ
17149.86 46.56197512
hr kg

kJ
798531.3546
hr

MJ
798.5313546
hr

MJ
798.53 2.dp
hr

H
H= 14 H

13

kJ kJ
798531.3546 1384452.428
hr hr

kJ
585921.0734
hr

Heat exchanger involving no work interaction and no shaft work, w=0 and negligible kinetic
and potential energy change for each fluid.
W
Q = H
, and W
=0 as there is no moving part

Q=
H

585921.0734 kJ /hr

585.9210734 MJ /hr

585.92 MJ /hr 2d.p


The negative value for Q represent that the system release energy to the surrounding.
However the energy is carried away by the cooling water in the heat exchanger.
1 hr 1 kW
Power= 585921.0734 kJ /hr 3600 s 1 kJ /s

162.75584 kW

5.2.1 Process data from ASPEN HYSYS

Object Variable Value (4.sf) Units

Qout Power 163.4 kW
5
Qout Heat Flow 5.883 10 kJ/hr
4
S13 Mass Flow 1.715 10 Kg/hr
4
S14 Mass Flow 1.715 10 Kg/hr
S13 Temperature 349.0 K
S14 Temperature 317.0 K

5.2.2 Comparison between the manual calculation and ASPEN HYSYS Data

Object Variable ASEN HYSYS Data Manual calculation Difference

Qout Power (kW) 163.4 162.8 0.6
5
Qout Heat Flow ( kJ/hr) 5.883 10 5.859 105 0.024
5
10
4 4
S13 Mass Flow (kg/hr) 1.715 10 1.715 10 0
4 4
S14 Mass Flow (kg/hr) 1.715 10 1.715 10 0
S13 Temperature (K) 349.0 349 0
S14 Temperature (K) 317.0 317 0

It can be seen that the result for Heat flow and Power for Q out obtain from the ASPEN
HYSYS is different to that from manual calculation. The different of heat flow for the Q out is
5
0.024 10 kJ/hr, where the different is insignificant. The percentage of difference is just

0.41% only. Same goes to the power, the different between the ASPEN HYSYS and manual
calculation difference with amount of 0.6kW, where the percentage of different is 0.37% only.
The difference maybe due to the limitation of manual calculation where the large number of
decimal place was unable to take in account my manual calculation. The parameter uses for
example specific heat capacity of component may also differ from ASPEN HYSYS in term of
decimal place. This result in the different in the calculation between the manual calculation
result and ASPEN HYSYS Data.