13/3/2018 AspenTech: Knowledge Base

Troubleshooting distillation columns in Aspen HYSYS

Products: Aspen HYSYS
Last Updated: 04-Jan-2018
Versions: V8.4, V7.0, V7.1, V7.2, V7.3, V8.0, V8.2, V8.3, V8.6, V8.8, V9.0
Article ID: 000030572
Primary Subject: Unit Operations

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Problem Statement
What steps should be considered if there are dif culties in converging a distillation column or obtaining the required
performance from the column.

Solution
If the column is not converging the diagnostic output generated in the trace window during the column iterations
provides helpful clues on how the solver is progressing. If the equilibrium errors are approaching zero, but the heat
and spec errors are staying relatively large, the speci cations are likely dif cult to meet. If both the equilibrium
errors and the heat and spec errors do not converge, then the column inputs for example, the initial estimates, the
speci cations, and the column con guration should be examined.

Before starting the troubleshooting steps listed below, rst reset the column and then run it again. The Reset button
will purge all estimates from the previous solution.

Column Con guration

Check the following list for column con guration:

Feed Stage Location: If the feed stage is too high or low from the optimal then the column might be
pinched. Pinching can be best detected by using a x-y diagram by using the McCabe Thiele extension for
Aspen HYSYS, available from solution 110069.
Feed Temperature: Too hot or too cold feed temperature might affect some trays and cause either
pinching or a portion of the column to run dry.
Re ux ratio: Usually distillation columns operate close to the minimum relfux. However numerically this
can be dif cult to converge at minimum re ux condition.You may rst start with a higher re ux ratio and
if the column solves with this then lower this progressively to the actual value.
Impossible speci cations: Some speci cations might not be feasible. If the simulation has problems
meeting an active speci cation, check the Design | Monitor or Spec page of the column:
Extreme purity: The purity speci cation might not be feasible with the current setup of the
column.
Speci cation of more than one purity or recovery for the same component may not be
possible to meet.
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13/3/2018 AspenTech: Knowledge Base

Avoid specifying all the products from the column.

If any product rate is speci ed check that this can be achieved with the given feed rate.
There is no vapor or liquid phase exist at the speci ed temperature.

Bad Estimates: Estimates can help converging the column. A bad estimate might take longer to solve or
may not converge at all.
Two liquid phases: If there is two liquid phases you might need to add water draws for the water to exit
or use Sparse Continuation solver (refer to solution 109406) .

Once a column is solved the results can be viewed from the Performance tab within the column owsheet. In the
Performance tab | Plots Page of the column, you can display temperature, ow composition and Key ratio plots or
tables (LK/HK - Light Key / Heavy Key components).

Initial Estimates

If the column speci cations and feeds are setup correctly the problem might be due to poor initial estimates.
Dif cult separations require temperature and or ow estimates. Temperature and ow estimates can be entered in
the Parameters tab | Pro les page of the column. Composition estimates are available from the Parameters tab |
Estimates Page. Estimates can also be entered as non active speci cations, by ticking the estimate radio button.
However make sure the estimates are reasonable otherwise the column might not converge at all.

To generate estimates you can activate the "Dynamic Integrator for IEG" option from Parameters settings. This will
generate estimates by running the column in dynamics (relaxation method).

Solver

If the solver oscillates it might be useful to decrease the dumping factor or to enable the adaptive damping from the
Parameters tab | Solver page.

Solver methods:

HYSIM Inside-Out General purpose method, which is good for most problems.

Modi ed HYSIM Inside-Out General purpose method, which allows mixer, tee, and heat exchangers inside the
column sub owsheet. Only a simple Heat Exchanger Model (Calculated from
Column) is available in the Column sub owsheet. The Simple Rating, End-Point, and
Weighted models are not available.

Newton Raphson Inside-Out General purpose method, which allows liquid-phase kinetic reactions inside the
Column sub owsheet.

Sparse Continuation Solver An equation based solver. It supports two liquid phases on the trays, and its main use
is for solving highly nonideal chemical systems and reactive distillation.

Simultaneous Correction Simultaneous method using dogleg methods. Good for chemical systems. This
method also supports reactive distillation.

For more details on the various solver methods and further troubleshooting advice consult the Aspen HYSYS F1
Help Menu.

Keywords
Column Convergence, Solver method

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