SUMMARY This CD-ROM contains

* Encyclopedic, self-paced instruction with tutorials on ASPEN PLUS, HYSYS.Plant and MATLAB, in a multimedia format, featuring audio, video, and animations.

* ASPEN PLUS backup (.bkp) and HYSYS.Plant (.hsc) files for the simulation examples in the text. * MATLAB files to support examples in the text * PDFs for:

Chapter 8 Reactor-Separator-Recycle Networks (Chapter 8.pdf) Chapter 9 Second Law Analysis (Chapter 9.pdf) Section 16.7 Equipment Sizing and Capital Cost Estimation Using the

Aspen Icarus Process Evaluator (IPE) – (Section 16_7.pdf) Section 17.8 Profitability Analysis Spreadsheet (Section 17_8.pdf)

Introduction to the General Algebraic Modeling System (GAMS) by James R. Phimister (GAMS.pdf) 50 Design Problem Statements (Design Problem Statements.pdf) Aspen IPE Course Notes – to accompany Section 16.7 (Aspen IPE Course Notes.pdf) * Profitability Analysis Spreadsheet by Holger Nickisch (described in Section 17.8) – (Profitability Analysis-1.1.xls)

The multi-media instructional materials are intended to provide self-paced instruction on process simulators for use in the core courses in chemical engineering, including “Material and Energy Balances,” “Thermodynamics,” “Heat Transfer,” “Separations,” “Reactor Design,” and “Process Design.” Currently, they provide coverage of ASPEN PLUS, Version 11 and HYSYS.Plant Version 3.0.1.

The materials are presented in two interconnected formats:

(a) An encyclopedia-like source of reference materials on the subjects listed below, delivered on many subtopics in the form of instructional modules. When using the CD, the subject areas in the table below are accessed in a pull-down menu, each of which expands into its listing of subtopics. Double-clicking on its title accesses the instructional material for each subtopic.

CONTENTS OF REFERENCE MATERIALS Principles of Process Flowsheet SimulationSeparators Heat Exchangers Pumps, Compressors and Expanders Chemical Reactors Physical Property Estimation Dynamic Simulation (HYSYS only) Tutorials

(b) A series of tutorials that are used in a self-paced fashion as part of the core chemical engineering courses, with which the

student builds up his or her capability with one of the commercial flowsheet simulators, while reinforcing his or her knowledge of the chemical engineering principles. These tutorials use the two simulators.

These resources (Reference modules and tutorials) need to be installed on a hard disk from the CD using the intsaller. The software consists of SHOCKWAVE files, which can be accessed from a network server using Microsoft Internet Internet EXPLORER (Version 6.0 or higher is recommended). In addition to the pull-down menu and the index, the instructional material for each subtopic can be accessed from the tutorials designed to augment the core courses in chemical engineering.

INSTALLATION and SETUP INSTRUCTIONS

1. Install the software, by double clicking on the install.exe icon:

This program assists you to install the software onto your hard disk.

2. On completion of the installation, the installer program runs a setup module, whose purpose is to check that drivers for Macromedia Shockwave 8, Acrobat Reader and QuickTime 5.0, and the special fonts required by the multimedia, are installed on your computer. If the setup module detects that any of these are missing, you will be prompted to install them, as shown below. To install the drivers and fonts, follow the instructions that appear on the screen. Once all of the required driver and font installations are completed, click on the "Done" button, to continue.

After installation of the drivers, the following menu is displayed:

The menu provides navigation instructions, suggestions for first-time users and access to the multimedia itself. Note that if "Run multimedia" is activated, Windows XP equipped with the new Service Pack 2 will issue a warning as shown on the right. Click on "Run" to operate the software.

When operating the encyclopedia, navigation is effected by using buttons of the lower bar, as indicated by pressing the “Navigation Tips” option on the Setup menu, which causes the frame below to be displayed. Note that the encyclopedia is operated in one of three modes: ASPEN PLUS, HYSYS.Plant or MATLAB, and the Contents and Index pop-up menus are specific to each mode selected.

By pressing “Tips for New Users” on the menu, the following screen is presented to the user. First-time navigation hints are provided for users of the two commercial simulators, which are accessed by pressing the symbol of the selected simulator.

For example, suggestions for first-time ASPEN PLUS users are given in the following frame:

The instructions continue onto a new page on pressing the “next” button.

For first-time HYSYS users, the recommendations are as follows:

Furthermore, a page describing the new features for HYSYS users is displayed on pressing the “next” button.

For first-time MATLAB users, the recommendations are as follows:

PORTABLE DOCUMENT FORMAT (PDF) FILES

The CD contains several PDF files with two complete chapters, and other supporting materials for the textbook, Product and Process Design Principles, by Seider, Seader, and Lewin (Wiley, 2004). Click on the links in the table below to access the materials directly from this document or click on the file icons in the subdirectory /PDF files:

Chapter 8 Reactor-Separator-Recycle Networks (Chapter 8.pdf) Chapter 9 Second-Law Analysis (Chapter 9.pdf) Section 16.7 Equipment Sizing and Capital Cost Estimation Using the

Aspen Icarus Process Evaluator (IPE) – (Section 16.7.pdf) Aspen IPE Course Notes Aspen IPE Course Notes – to accompany Section 16.7

(Aspen IPE Course Notes.pdf) Section 17.8 Profitability Analysis Spreadsheet (Section 17.8.pdf) GAMS Introduction to the General Algebraic Modeling System

(GAMS) by James R. Phimister (GAMS.pdf) Design Problems 50 Design Problem Statements (Design Problem

Statements.pdf)

SIMULATION FILES AND FOLDERS

The following pages list simulation files and folders, supplied in support of the textbook, Product and Process Design Principles, by Seider, Seader, and Lewin (Wiley, 2004). The simulation files cover the following programs:

The Aspen Engineering Suite, including ASPEN PLUS Version 11, BATCH PLUS, and Aspen IPE

HYSYS, Version 3.0.1

GAMS

MATLAB Version 5.3 and above

Profitability Analysis Spreadsheet

The directory: /Simulation Files/Aspen Eng. Suite contains the following files and folders:

The ASPEN directory on this CD-ROM contains all of the files and folders listed below. Two tables are provided. The first lists the files and folders referred to in the textbook (Seider et al., 2004). The second lists the files used in preparing the ASPEN PLUS multimedia instruction modules on the CD-ROM (Lewin et al., 2003). Many of the files were prepared using ASPEN PLUS Version 9. When using these files, you may choose to maintain complete upward compatibility to Version 11 or to use the new pure component databanks.

ASPEN ENGINEERING SUITE FILES AND FOLDERS – LISTED BY CHAPTER

Chapter Page Item Topic File or Folder Name

3 64 Exam. 3.1 EtOH-Water x-y Diagrams EXAM3-1.bkp

3 64 Exam 3.2 CH4-H2S T-P Phase Envelope EXAM3-2.bkp 4, 16 143, 557 Figs. 4.23, 4.24, Sec. 16.7 MCB Process MCB.bkp

4 154 Exam. 4.5 TPA Cultivator Process BATCH PLUS-EXAM 4-5 Folder 5 167 Exam. 5.1 Liquid Vapor Pressures EXAM5-1.bkp 5 170 Exam. 5.3 Ammonia Process - Purge/Recycle EXAM5-3.bkp 5 180 Exam. 5.6a Heat of Reaction EXAM5-6A.bkp 5 180 Exam. 5.6b Adiabatic Reaction Temperature EXAM5-6B.bkp 5 180 Exam. 5.7 Reaction Temp. - Excess Reactant EXAM5-7.bkp 5 180 Exam. 5.8 Reac. Temp. - Dodecane Diluent EXAM5-8.bkp 5 189 Exam. 5.9 Feed Preparation of Ethylbenzene EXAM5-9.bkp

6 220 Exam. 6.3 Ammonia Synthesis Converter NH3_CONVERTOR_OPT.bkp

7 260 Fig. 7.18 Benzene-Toluene - Pxy, xy Diags. FIG7-18.bkp (5-18) 7 261 Fig. 7.19 IPE-IPA - Pxy, xy, Txy Diagrams FIG7-19.bkp (5-19) 7 262 Fig. 7.20 Acetone-Chloroform - Pxy,xy,Txy FIG7-20.bkp (5-20) 7 273 Fig. 7.32 Ethanol-H2O - Txy, xy Diagrams FIG7-32.bkp (5-32)

12 391 Exam. 12.3 Batch Distillation EXAM12-3.bkp

13 437 Exam. 13.7 HEATX – Shell-and-tube HX Design EXAM13-7.bkp

13 438 Exam. 13.8 BJAC – Shell-and-tube HX Design EXAM13-8.bjt

16 557 Sec. 16.7 Dist. Sim. - Unabridged MESH Eqn – Depropanizer RADFRAC.bkp 16 557 Sec. 16.7 Dist. Sim. - Unabridged MESH Eqn – Depropanizer –

File Prepared for Aspen IPE RADFRAC-IPE.bkp

16 557 Sec. 16.7 Dist. Sim. - Unabridged MESH Eqn – Depropanizer – Report File Prepared by PROPSETS.apt for Aspen IPE

RADFRAC-IPE.rep

16 557 Sec. 16.7 Dist. Sim. - Unabridged MESH Eqn – Depropanizer – Aspen IPE Folder – Does not include a reboiler pump

DEC3 Folder

16 557 Sec. 16.7 Dist. Sim. - Unabridged MESH Eqn – Depropanizer – Aspen IPE Folder – Includes a reboiler pump

DEC3RP Folder

16 557 Sec. 16.7 File to Insert Poperty Sets in ASPEN PLUS Simulation Files in Preparation for Use with Aspen IPE

PROPSETS.apt

4, 16 143, 557 Figs. 4.23, 4.24, Sec. 16.7 MCB Process MCB.bkp 4, 16 143, 557 Figs. 4.23, 4.24, Sec. 16.7 MCB Process – File Prepared for Aspen IPE MCB-IPE.bkp 4, 16 143, 557 Figs. 4.23, 4.24, Sec. 16.7 MCB Process – Report File Prepared by PROPSETS.apt

for Aspen IPE MCB-IPE.rep

4, 16 143, 557 Figs. 4.23, 4.24, Sec. 16.7 MCB Process – Aspen IPE Folder MCB Folder 16 559 Exer. 16.4 Dist. Sim. - Unabridged MESH Eqn – Benzene-Toluene BENTOLDIST.bkp 17 614 Exer. 17.21 Toluene Hydrodealkylation Process HDA.bkp

17 614 Exer. 17.21 Toluene Hydrodealkylation Process – File Prepared for Aspen IPE

HDA-IPE.bkp

18 639 Exam. 18.5 Optim. of Dist. Col. with Sidedraws MULTIDRAW_OPT.bkp

ASPEN PLUS FILES – ASSOCIATED WITH THE MULTIMEDIA MODULES

Module (ASPEN → ) Topic File× Separators → Phase Equilibria and Flash → Flash Vessels → FLASH 2 C5-C6 Flash Separation FLASH.bkp Separators → Phase Equilibria and Flash → Flash Vessels → Using a Heat Stream

C5-C6 Flash Sepn. - Heat Stream FLASHQ.bkp

Heat Exchangers → Heat Requirement Models → Introduction Cooling Require. - Vin. Chlor. Proc. FIGA3-5.bkp Chemical Reactors → Kinetic Reactors → Plug Flow TubularReactors (PFTRs) → Introduction

Plug Flow Reac. – Tol. Hydrodealk. EXAMA3-3.bkp

Chemical Reactors → Kinetic Reactors → Continuous Stirred Tank Reactors (CSTRs) → Introduction

CSTR – Propylene Glycol Reactor EXAMA3-4.bkp

Separators → Distillation → FUG Shortcut Design → Introduction Winn-Underwood-Gilliland Distil. DSTWU.bkp Separators → Distillation → Edmister Method → Introduction Edmister Simulation of Distillation DISTL.bkp Separators → Distillation → MESH Equations → Introduction Dist. Sim. - Unabridged MESH Eqn –

Depropanizer RADFRAC.bkp

Physical Property Estimation → Equilibrium Diagrams → Binary Phase Diagrams → Introduction

Ethanol-Benzene - Txy Diagram FIGA4-1.bkp

Physical Property Estimation → Equilibrium Diagrams → Residue-Curve Maps → Introduction

MeOH-MTBE- C4= Residue Curves FIGA4-2.bkp

Physical Property Estimation → Equilibrium Diagrams → Phase Envelopes → Introduction

CH4-CO2-H2S T-P Phase Envelope FIGA4-3B.bkp

Physical Property Estimation → Equilibrium Diagrams → Thermodynamic Properties → Introduction

EtOH-Benzene Vap. Heat Capacity FIGA4-4.bkp

Physical Property Estimation → Equilibrium Diagrams → Estimating Parameters for Pure Species → Introduction

Estim. of Params. for C3H3F3 FIGA4-5.bkp

Physical Property Estimation → Equilibrium Diagrams → Property Data Regression → Introduction

Regression of EtOH-Water Data EXAMA4-1.bkp

Physical Property Estimation → Equilibrium Diagrams → Property Data Regression → Introduction

Regression of CH4- H2S Data EXAMA4-2.bkp

× File names are associated with Appendixes III and IV of the first edition of the textbook (Seider, Seader, Lewin, Process Design Principles: Synthesis, Analysis, and Evaluation, Wiley, 1999.

Seider, W. D., J. D. Seader, and D. R. Lewin, Product and Process Design Principles: Synthesis, Analysis, and Evaluation, Second Edition, Wiley, 2004. Lewin, D. R., W. D. Seider, J. D. Seader, E. Dassau, J. Golbert, D. N. Goldberg, M. J. Fucci, and R. B. Nathanson, Using Process Simulators in Chemical Engineering: A Multimedia Guide for the Core Curriculum, Version 2.0, Wiley, 2003.

The directory: /Simulation Files/HYSYS.Plant contains the following files for HYSYS.Plant Version 3.0.1, listed by chapter:

Chapter Item Topic File Name

MM Ammonia – water Separation Steady-state solution AMMONIA.hsc Feasible steady-state solution NH3_CONVERTOR.hsc

6/MM NH3 Converter Design, Example 6.3 Constrained optimization of VP using SQP NH3_CONVERTOR_OPT.hsc

Steady-state solution before heat integration TOLUENE.hsc 10/MM Toluene Manufacture

Steady-state solution after heat integration TOLUENE _HEX.hsc Styrene process – steady-state solution STYRENE.hsc

MM HEN Synthesis MER targetting using LNG STYRENE_MER.hsc Steady-state solution ETHYLCHLORIDE.hsc Venture profit calculation ETHYLCHLORIDE_VP.hsc 18/MM Ethylchloride Manufacture,

Example 18.4 Constrained optimization of VP using SQP ETHYLCHLORIDE_OPT.hsc Feasible steady-state solution MULTIDRAW.hsc

18/MM Multidraw Tower Optmization, Example 18.5 Constrained optimization of VP using SQP MULTIDRAW_OPT.hsc

Dynamic simulation of single CSTR CSTR_1.hsc 21/MM Propylene Oxide Manufacture,

Case Study 21.1 Dynamic simulation of two CSTRs in series CSTR_2.hsc Dynamic simulation of base-case design with no bypass

HEN_1.hsc 21 Heat Exchanger Networks,

Case Study 21.2 Dynamic simulation of improved design with bypass HEN_2.hsc Dynamic simulation of single column METH_SC.hsc Dynamic simulation of heat integrated columns in FS configuration

METH_FS.hsc 21 Methanol Dehydration,

Example 21.7 Dynamic simulation of heat integrated columns in LSR configuration

METH_LSR.hsc

Dynamic simulation of closed-loop system subjected to load change

MCB_1.hsc

21 Monochlorobenzene (MCB)

Separation Process, Case Study 21.3 Dynamic simulation of closed-loop system subjected to

composition disturbance MCB_2.hsc

*MM – indicates that the file is also associated with multimedia modules

The directory: /Simulation Files/MATLAB contains the following MATLAB scripts and functions used in Chapter 21: MATLAB file Description Used in… crsys1.mdl Simulink model file for distillation column in LV configuration Example 21.2 crsys2.mdl Simulink model file for Shell process Example 21.6 crsys3.mdl Simulink model file for Example 21.3 Example 21.3 f_HEN1.m, g_HEN1.m State and output equations for hen_1.m Case Study 21.2 f_HEN2.m, g_HEN2.m State and output equations for hen_2.m Case Study 21.2 f_PO.m, g_PO.m State and output equations for fig21_25.m Case Study 21.1 f_PO2.m, g_PO2.m State and output equations for fig21_26.m Case Study 21.1 fig21_3.m Computes and plots the closed loop response of a distillation column in LV configuration Example 21.2 fig21_4.m Computes and plots the DRGA for a distillation column in LV configuration Example 21.2 fig21_5.m Computes and plots the DRGA for Example 21.3 Example 21.3 fig21_6.m Computes and plots the servo response for Example 21.3 Example 21.3 fig21_10.m Computes and plots the regulatory response for the Shell Process Example 21.6 fig21_11.m Computes and plots DC maps for the Shell Process Example 21.6 fig21_12.m Computes and plots DC maps for a distillation column in LV configuration Example 21.7 fig21_13.m Computes and plots the regulatory response for for Example 21.7 Example 21.7 fig21_17.m Computes and plots DC maps for alternative configuarions for methanol dehydration Example 21.8 fig21_23.m Computes and plots the parametric analysis for a single CSTR (single solution) Case Study 21.1 fig21_24.m Computes and plots the parametric analysis for a single CSTR (solution multiplicity) Case Study 21.1 fig21_25.m Linearizes the single CSTR, and computes and plots the DC map Case Study 21.1 fig21_26.m Linearizes the system of two CSTRs, and computes and plots the DC maps Case Study 21.1 fig21_39.m Computes and plots DC maps for the LSF configuarion for methanol dehydration Example 21.12 fig21_DC_FS.m Computes and plots DC maps for the FS configuarion for methanol dehydration Example 21.8 fig21_DC_LSR.m Computes and plots DC maps for the LSR configuarion for methanol dehydration Example 21.8 fig21_DC_SC.m Computes and plots DC maps for the SC configuarion for methanol dehydration Example 21.8 hen_1.m Solution of state equations and DC anslysis for original HEN in Case Study 21.2. Case Study 21.2 hen_2.m Solution of state equations and DC anslysis for HEN with bypass in Case Study 21.2. Case Study 21.2 LTBXJAC.m Function to compute Jacobian matrices LTBXSOLV.m Function to solve nonlinear state equations using the Newton-Raphson method

Case Studies 21.1 and 21.2

In additon, the subdirectory /Simulation Files/CRGUI contains files for the interactive module CRGUI, which assists the user to carry out C&R analysis and closed-loop simulation on three multivariable control problems. See C&R_Exercises.pdf for details.

The directory: /Simulation Files/GAMS contains the following files:

Chapter Page Item Topic File Name 10 313 Exam. 10.4 LP – Minimization of Utilities for HEN CASC.1 10 313 Exam. 10.4 LP – Minimization of Utilities for HEN CASC.2 10 323-5 Exam. 10.8 MILP – Stream Matching – Transhipment Model MATCH.1 10 340-1 Exam. 10.16 NLP – Superstructure Optimization for HEN COST.1

pdf.GAMS PDF file For details of the usage of GAMS, see the

The profitability analysis spreadsheet by Holger Nickisch is in the file, Profitability Analysis-1.0.xls. As indicated in the file, Section 17.8.pdf, this spreadsheet must be opened with a user name and password. Built-in values are “student” and “engineer”. The files below, MCB.xls and MCB-IPE.xls files, must be loaded into the Profitability Analysis-1.0 spreadsheet. After entering your user name and password, in the Save/New dialog box, check Load Existing Analysis. This produces the Browse for Folder dialog box, on which you select the appropriate file. When working within the Profitability Analysis-1.0 spreadsheet, this procedure can be carried out by pressing the Save/New button on the Menu. Report files, for example, MCB_Report.xls and MCB-IPE_Report.xls, are generated by pressing the Create Report button on the Menu. These can be opened directly by clicking on the file name. See Section 17.8 for additional details.

PROFITABILITY ANALYSIS SPREADSHEET FILES

Section Page Item Topic File Name

17.8 Profitability Analysis Spreadsheet

Spreadsheet carries out profitability analysis using the methods of Chapters 16 and 17 in the book Profitability Analysis-1.0.xls

17.8 CD-17.8-9 Example 17.32 Profitability analysis of the MCB separation process using purchase costs and bare module factors MCB.xls

17.8 CD-17.8-9 Example 17.32 Contains results of profitability analysis MCB_Report.xls 17.8 CD-17.8-9

Example 17.32 Profitability analysis of the MCB separation process using purchase and installation costs estimated by Aspen IPE

MCB-IPE.xls

17.8 CD-17.8-9 Example 17.32 Contains results of profitability analysis MCB-IPE_Report.xls

MINIMUM HARDWARE SPECIFICATIONS

Version 2.2 of the multimedia software requires installation on a hard disk. After hard disk installation, the multimedia will execute under WINDOWS 2000 and WINDOWS XP operating systems. The software requires Internet Explorer to operate (Version 6 or higher is recommended). Since it intended that the multimedia CD-ROM will be used in parallel with one of the supported simulators, it is strongly recommended that a Pentium-III or better processor be employed, with 128 MB of RAM, and a 17" screen.

UPGRADES

As additional modules are developed in support of the usage of ASPEN PLUS, HYSYS.Plant, and MATLAB, we will post free upgrades to the multimedia on our website: http://www.seas.upenn.edu/~dlewin/CD_ROM_updates.htm .

TECHNICAL SUPPORT

We will provide technical support as related to the operation of the CD-ROM. If you have problems, please send e-mail to: pse_mmm@tx.technion.ac.il Please note: Questions concerning the operation of the ASPEN PLUS and HYSYS.Plant simulators and MATLAB, that are not covered by our instructional materials should not be addressed to us. Please refer to User and Reference Manuals and Help Screens. If help is still needed, you might consider using the Hotlines provided by Aspen Tech and Mathworks.