Introduction to commonly used chemical process simulation software

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Currently, the main chemical process simulation software available in China includes PRO/II from the American company SimSci-Esscor, Aspen Plus from AspenTech in the United States, Hysys, gPROMS from the British company PSE, ChemCAD from Chemstations in the United States, and Design II from WinSim Inc. In Canada, VMGSim is offered by Virtual Materials Group. A brief comparison of CHEMCAD, PROII, and ASPEN can be summarized in the following seven points: 1. It is generally believed that PROII is more accurate for use in the oil refining industry, as its database contains a large amount of empirical data； ASPEN performs better in the chemical engineering field. Compared to other software, Aspen Plus has unparalleled advantages; it essentially encompasses all the strengths of the aforementioned software. Some people compare PROII to the empiricist school, while ASPEN is seen as the academic school. 2. Essential for learning Aspen Plus ⑴ Principles of Chemical Engineering ； Unit Operations in Chemical Processes (2): Thermodynamic Approaches ； Describing physical property calculation methods ； ⑶Chemical Systems Engineering ； It explains how to model chemical engineering systems, analyze them, and solve problems. For a basic understanding, points (1) and (2) are sufficient; if one wants to go deeper, point 3 is also necessary. Additionally, it is important to have the guidance of an experienced teacher. 3. HYSYS is mainly used in oil refining. Dynamic simulation is its advantage. ASPEN is intelligent; it is used for process simulation in the chemical industry, particularly for relatively large or complex processes. It features a comprehensive and open database. It is now one with HYSYS. PRO/II can be used for equipment accounting with a short process, or for distillation accounting. Due to its limited physical properties, ChemCAD is inconvenient to use and of relatively poor quality; it can be downloaded from various websites, is not widely used by design firms, but does have a certain market in universities. 4. I think Aspen Plus offers the most accurate calculations, and its database is also the most well-developed. However, I’m not very comfortable using it, as it takes many factors into account, which makes it feel rather difficult to learn. The interface of ChemCAD is very simple to use, and it is easy to operate. But the database isn’t that large; I’m using version 5.0, which contains property data for only 2,000 commonly used substances. PRO/II is in the middle in both aspects. 5. In terms of ease of convergence, chemcad > hysys > proii. 6. From the perspective of industrial practice, PRO/II, HYSYS, and ChemCAD are all engineering simulation software; among them, Aspen, PRO/II, and HYSYS are used by the vast majority of design institutes in China. It seems that Aspen has the widest range of applications; its modules for electrolytes, solids, combustion, etc., are unmatched by other software ； PRO/II is widely used in the petrochemical industry, where extensive experience has been accumulated ； HYSYS, on the other hand, boasts extremely high precision and accuracy in the field of oil and gas engineering. 　　Qingdao University of Science and Technology (formerly Qingdao Institute of Chemical Technology) developed an ECSS. The only way to describe it is as a “domestically produced product”; Qingdao University of Science and Technology itself does not use it. 7. Version introduction: The useful versions of Aspen are 10.2 and 11.1. Version 10.2 has some minor issues when used on WinXP, but it can still be used with workarounds. Version 11.1 has a small issue that is easy to resolve. As for the other versions, they don’t seem to be functional at the moment. 　 The useful versions of Pro/II are 5.6, 6.0, and 7.1. The first two versions are excellent; those who prefer the latest updates might like 7.1, but it may not install on operating systems newer than WinXP. 　　The useful versions of Hysys are 2.4, 3.0, and 3.2; among them, version 3.0 must be installed from a CD, while version 3.2 has some issues – it sometimes shuts down without any reason after being used for half an hour. Introduction to Various Software 3.1 AspenOne AspenOne was introduced by the American company AspenTech at the end of 2004, and it features significant improvements in terms of EO (system of equations). Official website: http://www.AspenTech.com; Hysys, HTFS, and Aspen Plus are its main products. Hysys was originally a product of the Canadian company Hyprotech, which was founded in 1976. It is one of the first multinational companies in the world to develop industrial simulation and modeling technologies for the oil and chemical industries. Its technologies are widely used in fields such as oil extraction, storage and transportation, natural gas processing, petrochemicals, fine chemicals, pharmaceuticals, and refining. It holds a dominant position in the field of petrochemical simulation and modeling technologies worldwide. Hyprotech has over 17,000 users in more than 80 countries, and its number of registered users exceeds that of any other process simulation software company in the world. Currently, the world’s major petrochemical companies are all using Hyprotech’s products, including the top 15 oil and gas companies in the world, 14 of the top 15 oil refining companies, and 13 of the top 15 chemical companies. In 2002, the U.S.-based AspenTech company acquired Hyprotech; thus, HYSYS became a product under AspenTech. In 2004, the American company Honeywell acquired the rights to the Hysys software from AspenTech. Hysys2004 is part of AspenOne; it was the first version released after Aspen acquired Hysys. The Aspen One directory contains information on the development background of Aspen Hysys. Thanks to the rapid advancement of microcomputers and the introduction of Microsoft Windows software, the limitations imposed by DOS on microcomputer resources and single-tasking were overcome, making it possible to run dynamic simulation systems on microcomputers. Living up to expectations, Canada’s HYPROTECH Corporation, leveraging its strong technical capabilities, was the first in the world to develop the microcomputer-based dynamic simulation system HYSYS 1.0. The promotion and application of the dynamic simulation system HYSYS will undoubtedly bring about a profound revolution in the fields of petrochemical design, production, and research, serving as a landmark moment in the petrochemical industry. Chemical process simulation software has generally evolved and improved in two main areas. ⑴First, develop the theory and technology of chemical process simulation, thereby broadening the scope of software applications ； ⑵On the other hand, there is the development of software and computer-aided tools; that is, researching better ways to make it easier for engineers to master and use such software, so they can apply it more flexibly in their research projects. In recent years, the former aspect has developed rapidly, while the latter has progressed slowly. Since the standards of companies in the first aspect are quite high, the second aspect becomes particularly important. By combining these two aspects and using next-generation programming tools to develop new versions of simulation software, it is certain to bring about a revolution in the field of chemical process simulation. Throughout the development of its software, Hyprotech has always adhered to one principle: “to make the software easy and convenient to use, and simple for engineers to learn and understand.” One way to achieve this goal is to allow engineers to change variables at will during use. At any point during the software’s operation, it can be paused to observe changes in the data. This is what’s known as “fully interactive software”; it is HYSIM, Hyprotech’s first-generation product. It was also the world’s first fully interactive chemical engineering simulation software. The company’s success stems from two factors: first, its continuously improving technical capabilities; and second, its awareness of the potential new technologies arising from advances in computer technology, along with its ability to respond quickly to such changes. From interactive simulation to interactive simulation technology on microcomputers, the company has always been a world leader in providing innovative software. HYSYS is built on HYSIM, which has over a decade of application experience in the petrochemical industry around the world. HYSYS includes more and more complex property calculation packages and unit operations, and it features powerful initialization and fast iterative calculation tools to obtain results more quickly and accurately. At the same time, system optimization, reactive distillation, advanced variable calculation tables, controllers for control studies, and transfer function generators were added. Hyprotech, the company that develops and supplies Hysys, has international clients such as BP, Chevron, Dow, DuPont, Exxon Mobil, Fluor Daniel, Monsanto, Glaxo SmithKline, Rohm Hass, Bayer, Shell, PraxAir, UOP, and others. HYSYS is widely used in China, with the total number of domestic users exceeding 50. All oilfield design systems use this software for process design. Below is a list of some usernames from domestic oil fields: Daqing Oil Field Design Institute, Liaohe Oil Field Design Institute, North China Oil Field Design Institute, Dagang Oil Field Design Institute, Sichuan Oil Field Design Institute, Changqing Oil Field Design Institute, Qinghai Oil Field Design Institute, Zhongyuan Oil Field Design Institute, Jianghan Oil Field Design Institute, Karamay Oil Field Design Institute, Karamay Oil Field Research Institute, Dushanzi Refinery, Dushanzi Petrochemical Design Institute, Langfang Pipeline Survey and Design Institute, Production Research Center of China National Offshore Oil Corporation, Petroleum Engineering Company of China National Offshore Oil Corporation (Tanggu, Tianjin). South China Sea Branch of China National Offshore Oil Corporation, Shell China, Liaoyang Chemical Fiber Company, Liaoyang Petrochemical Design Institute, Daqing Petrochemical Design Institute, Yueyang Petrochemical Company, Jiujiang Petrochemical Company, Nanjing Petrochemical Company, Yangzi Petrochemical Company, Yangzi Petrochemical Design Institute, Fushun Petrochemical Design Institute, Fushun Petrochemical Company, Jinling Petrochemical Company, Maoming Petrochemical Design Institute, Zhenjiang Refining and Chemical Engineering Company, etc. Features of HYSYS: 1. The most advanced integrated engineering environment. The use of next-generation goal-oriented programming tools has made integrated engineering simulation software a reality. In such an integrated system, processes and unit operations are independent of each other. A process is simply a collection of various unit operations with such objectives, and the unit operations are connected to each other through the material flow within the process. In engineering design, the same objective is used for both steady-state and dynamic conditions; subsequently, the data related to this objective can be shared without the need for data transmission. Therefore, in such an advanced and user-friendly system, users can achieve the greatest benefits; complex manufacturing processes often need to be divided into several parts for simulation. This is mainly based on: ① Small-process analysis is convenient and fast ； ②To obtain more accurate results using different thermodynamic methods for various systems, the approach commonly adopted by previous software was to simulate small processes separately first, and then manually or via software transfer data from one process to another through files. The mandatory transmission of such data inevitably leads to inconsistencies in the data within the process, resulting in the need for the process to be recalculated. An integrated engineering environment is different; it allows people to divide processes into several sub-processes within a simulated environment, with these sub-processes being of varying sizes. What sets this integrated environment apart is that data between sub-processes and the main process is shared mutually, without the need for any data transfer. Different property calculation packages can also be used between them. Moving from one process to another is as easy as flipping through a book. 2. Powerful dynamic simulation capabilities. The method and process of dynamic simulation involve, after the steady-state simulation of the process has converged, first defining the dynamic data for the unit operations (such as the geometric dimensions of separators, liquid level heights, etc.), installing control instruments, and then proceeding to dynamic mode to start the dynamic simulation. During the dynamic simulation, various process variables such as temperature and pressure can be adjusted at any time (this is what multi-tasking in Windows does), allowing one to observe their impact on the product as well as the patterns of change. You can also stop at any time and return to static. Since dynamics and statics share the same object, the transition between them is very easy. HYSYS provides control units for dynamic simulation, such as PID controllers, transfer function generators, digital control switches, and variable calculation tables. A PID controller can control any variable. ②The transfer function generator can produce process transfer functions of any type, such as first-order elements, second-order elements, differential, and integral elements. They can be used to simulate any controlled object and disturbance source. ③During the dynamic operation of a CNC switch, it is possible to control the on or off state of another variable by checking a certain operating condition, thereby enabling control over the entire device. ○4 Each variable calculation table stores 26 * 50, which is 130 variables. This appears to be a control computer connected online to the actual device; it allows any variable in the process to be introduced and processed within this table (which can perform various mathematical functions and logical operations). The results of these operations are then sent back into the process and assigned to certain variables, thereby enabling the control of those variables. 3. DCS interface. HYSYS is linked to the DCS control system via a Dynamic Link Library (DLL). The DCS data from the unit can be imported into HYSYS, while the process parameters from HYSYS can also be sent back to the unit. This technology makes it possible to achieve: ① online optimal control; ② production guidance; ③ production training; ④ offline debugging of instrument design systems. 4. Process parameter optimizer. The software features a powerful optimizer that offers five algorithms for selection, enabling the solution of problems with unconstrained, constrained, equal constraint, and inequality constraints. Among these, the sequential quadratic programming method is a relatively advanced approach; it can perform both linear and nonlinear optimization with multiple variables. When used in conjunction with a variable calculation table, it allows for the incorporation of more complex economic calculation models into the optimizer, thereby determining the operating conditions that yield maximum economic benefits. In addition to the features mentioned above, HYSYS also includes an event-driven property calculation package, a dry-plate startup function, built-in artificial intelligence, a data regression package, a property calculation package, a property prediction system, event-driven functionality, a narrow-point analysis tool, a scenario analysis tool, hydraulic calculations for various types of trays, calculations for arbitrary towers, and non-sequential simulation techniques. Applications of Hysys: HYSYS software is a large-scale expert system developed by a world-renowned company specializing in oil and gas processing simulation software. The software is divided into two main parts: dynamic and steady-state. Its dynamic and steady-state properties are primarily used in the design of oilfield surface engineering projects as well as in the design, calculation, and analysis of petroleum and petrochemical refining projects. Its dynamic part can be used to control the operation of crude oil production and storage and transportation systems. For onshore oil field construction, this software can address the following issues: ① Applications in onshore oil field engineering • Design, evaluation, and optimization of various transportation processes • Stationary piping networks, long-distance pipelines, and pumping stations • Temperature drop during pipeline shutdown • Prediction of pigging operations and slug flow • Oil and gas separation • Separation of oil, gas, and water phases • Design calculations for oil and gas separators • Prediction of natural gas hydrates • Creation of phase diagrams for oil and gas and prediction of their inversion points • Crude oil dehydration • Design and optimization of crude oil stabilization units • Crude oil dehydration (using glycol or molecular sieves), as well as design and optimization of desulfurization units • Design and optimization of units for recovering light hydrocarbons from natural gas • Selection and calculation of pumps and compressors ② Applications in petroleum refining • Design and optimization of atmospheric and vacuum distillation systems ； ⑵Design and optimization of FCC main fractionator ； ⑶Gas device design and optimization ； ⑷Design and optimization of gasoline stabilization, naphtha separation and stripping, reactive distillation, shift and methanation reactors, acid-water separators, sulfur and HF alkylation, isobutane removal columns, etc ； ⑸In terms of gas treatment: it is capable of carrying out amine desulfurization, multi-stage refrigeration, compressor units, deethanizer and demethanizer towers, expansion devices, gas dehydrogenation, hydrate formation/inhibition, multi-stage processes, platform operations, refrigeration circuits, and turboexpander optimization. Functions of the HYSYS software • Compared to similar software, HYSYS features a very user-friendly interface that is easy to learn, and it boasts a high level of intelligence. • The state-of-the-art integrated engineering environment makes integrated engineering simulation software a reality by utilizing a new generation of goal-oriented programming tools. In such an integrated system, processes and unit operations are independent of one another; a process is merely a collection of various unit operations with common goals, while the unit operations are connected through the material flow within the process. In engineering design, the same objective is used for both steady-state and dynamic cases, and the data for this objective is shared without the need for data transfer. Therefore, users can achieve the greatest benefits in this most advanced and user-friendly system. • Built-in artificial intelligence: An artificial intelligence system is incorporated into the system, playing a very important role in all processes. When the input data meets the system’s computing requirements, the artificial intelligence system will drive the system to perform the calculations automatically. When there is an error in data entry, the system will tell you where the problem lies. • Data regression package: The data regression toolkit provides powerful regression tools. Using experimental data or standard data from libraries, users of this tool can obtain the mathematical regression equations for enthalpy and the gas-liquid equilibrium constant K (the form of the equations can be specified by the user). Using regression formulas can increase the computation speed, and under certain conditions, it can also improve calculation accuracy. • Rigorous property calculation package: HYSYS offers a powerful set of property calculation tools, whose underlying data is derived from world-renowned property data systems and has been thoroughly verified by our company. These data include 16,000 interaction parameters and over 1,800 pure substance data sets. • Powerful property prediction system: For components not included in the HYSYS standard library, it is possible to define fictitious components and then use HYSYS’ property calculation package to automatically compute the basic data. • DCS interface: HYSYS connects to the DCS control system through its dynamic link library DLL. The DCS data of the unit can be imported into HYSYS, while the process parameters of HYSYS can also be sent back to the unit. With this technology, it is possible to achieve: 1) online optimal control ； 2) Production guidance ； 3) Production training ； 4) Offline debugging of the instrument design system. • Event-driven: Combining simulation technology with fully interactive operation methods is what has led to the success of HYSIM. By utilizing object-oriented techniques, the interactive approach of HYSYS is elevated to a higher level, namely event-driven. When working on a research plan, it is necessary to put many process parameters in a table; when one or several variables are changed, other variables should change as well, and the calculated results should also be updated automatically in the table. This technology, in which data at several points changes automatically along with the calculation results, is called event-driven. Through this approach, engineers can gain a more thorough understanding of the process under study. • Process Parameter Optimizer: The software includes a powerful optimizer with five algorithms to choose from, capable of solving problems with unconstrained, constrained, equal constraint, and inequality constraints. Among them, sequential quadratic programming is a relatively advanced method that enables linear and nonlinear optimization of multiple variables. By using variable calculation tables, it is possible to incorporate more complex economic modeling into the optimizer in order to determine the operating conditions that yield the greatest economic benefits. • Narrow-point analysis tool: By utilizing HYSYS’ narrow-point analysis technique, it is possible to analyze and calculate the heat network in a process, enabling its rational design in order to minimize energy losses. • Scenario analysis tool: When certain variables change according to a certain trend, what is the trend of change for other variables? Understanding these is very important for plan analysis. For example, when studying the effects of changes in the reflux ratio and product quality of a tower on heat load, yield, and temperature, in HYSYS’ scenario analysis the reflux ratio and product quality are selected as independent variables; their range of values and step size are specified, after which HYSYS begins the calculations, producing a summary table at the end. • Hydraulic calculations for various tray types: HYSYS includes the capability to calculate trays such as floating valves, packing, and sieve trays, thereby enabling simultaneous treatment of both the thermodynamics and hydraulics of the tower. • Calculation of arbitrary towers: In the software we have used before, all distillation towers came with a fully detailed version provided by the software vendor, allowing users to choose which parts to retain. Question: If a user has a tower with an absorption–analysis section at the upper part and a distillation section at the lower part, how should such a tower be calculated? HYSYS will do. Thanks to the use of goal-oriented programming tools, trays, reboilers, pumps, reflux tanks, and so on are all independent goals. People can combine these targets arbitrarily, making it very convenient to build a variety of custom towers. Thermodynamic methods • Over 1,800 pure components • Property calculation methods: PengRobinson, BK10, Chien, Null, Virial, Soave, Redlich-Kwong, Esso, Tabular, NTRL, Redlich-Kwong, Kabadi, Danner, Chao, Seader, UNIQUAC, Ideal Gas, Zudkevitch, Joffee, Grayson-Streed, Margules, Steam, PRSV, Sour PR, Van Laar, Wilson, Modified Antoine, Sour SRK • Over 16,000 interaction parameters • Pseudo-components • Data regression packages • Crude oil processing: The crude oil manager can handle any experimental data provided by the user, convert crude oil into virtual components for calculation, and offers a large number of correlations for the user to choose from • Assay types —— TBP, D86, D1160, D86-D1160, D2887, EFV, Chromatographic • Assay options —— Barometric correction, cracking correction • Property curves —— Viscosity, Density, Molecular Weight Unit operations • Separators: 2-phase separators, 3-phase separators, solid separators, cyclones, vacuum filters, crystallizers • Distillation columns: Absorption/desorption columns, absorption columns with reboilers, absorption columns with reflux, liquid-liquid extraction columns, atmospheric and vacuum distillation columns, distillation columns for component separation, three-phase distillation columns (all columns can be equipped with reaction units for reactive distillation) • Reactors: CSTR, PFR, Gibbs, equilibrium, conversion rate • Heat exchangers: Heat exchangers, LNG multiphase flow coolers, heaters, coolers • Distribution units: Pipes, mixers, branches • Pressure changes: Pumps, compressors, expanders, valves • Logic units: Equilibrium, pre-processing, PID controllers, electronic calculators, transfer function generators, etc. Extend user capabilities through Microsoft OLE extensions • With OLE, users can carry out the following developments in HYSYS • Create their own property packages • Add their own reaction equations • Develop custom unit operations • Users can develop their own specialized models using VB or C++. Analysis tools • Process analyzers, data recorders • Focal point analysis, heat transfer curves • Property analyzer. Additional module functions of the HYSYS software: ACM Model Export Option. The ACM export module enables the use of HYSYS’ steady-state or dynamic simulation data when creating models in ASPEN series design software ； The Aspen OnLine Option ASPEN interface module allows HYSYS modules to be connected to actual plant data, enabling users to compare the results obtained from process simulations with the actual operating conditions in the plant. The ASPEN Web module of Aspen WebModels allows companies to publish secure, pre-defined modules via the Web. This can allow plant managers, operations engineers, and economic analysts to use more stringent modules to optimize operational parameters and make better business decisions. HYSYS Amines Option: The HYSYS amine treatment module simulates and optimizes gas-phase and liquid-phase amine treatment processes, including single-phase, mixed-phase, or reactive amines. The process of high-precision absorption of hydrogen sulfide and carbon dioxide by industrial solvents was simulated. A more advanced thermodynamic electrolyte module, Li-Mather, can produce more accurate results than the previous modules, especially when dealing with mixed amines. This technology is provided by partner Schlumberger and is based on the AMSIM module in Oilphase-DBR. The HYSYS Crude Module Option simulates the components of crude oil. The virtual components of the constituent petroleum represent the properties of hydrocarbon streams, and predict their thermodynamic and transport properties. The HYSYS Data Rec Option makes use of HYSYS’ online performance monitor and optimization programs to manage data from actual plants. The HYSYS Dynamics Option provides a dynamic simulator entirely based on the HYSYS environment; by comparing the steady-state and dynamic modules, more rigorous and accurate results regarding plant performance can be obtained. The HYSYS Neural Net Option uses data from actual units to simulate processes and operations that are difficult to simulate. Utilizing the data from the HYSYS flow diagram model to form a data network enables the handling of similar situations, which can significantly improve computation speed. The HYSYS OLGAS Option incorporates the industry-standard calculations for pressure changes, fluid stagnation, and flow rules in multiphase pipelines. The HYSYS OLI Interface Option utilizes the advanced technology of the OLI system, enabling HYSYS to analyze complex electrolyte systems. It expands the OLI database and thermodynamic properties, including over 3,000 types of electrolytes. The HYSYS OptimizerOption optimization module employs optimized algorithms based on SQP (Sequential Quadratic Programming) technology. Optimization tools are provided for factory design optimization, online performance monitoring, and optimization programs. The PIPESYS option of HYSYS enables HYSYS to accurately design single-phase and multi-phase fluids, troubleshoot issues, and optimize pipelines. It can analyze the vertical distribution of pipes, inlet devices, the composition of pipe materials, and the properties of fluids. HYSYS Upstream Option provides industry standards for the methods and techniques used to handle petroleum fluids. Product field data can be entered in a user-friendly interface to create the desired capital model. HYSYS Tacite Option provides multiphase flow models for land, offshore, and subsea environments. TACITE is used to simulate multiphase flow with databases that have been proven effective in IFP. It is composed of steady-state modules that calculate pressure changes, fluid stagnation, and flow rules. 3.1.2 HTFS: HTFS was originally a subsidiary of the British engineering consultancy company AEA. In 1997, AEA merged with the Canadian company Hyprotech, and Hyprotech became a subsidiary of AEA; the former HTFS company was taken over by Hyprotech. In July 2002, Hyprotech merged with AspenTech, becoming part of AspenTech. Official website: http://www.AspenTech.com/HTFS2001**7 components: ACOL 6.20 FRAN2.01 TASC 5.00 APLE 2.10 MUSE 3.20 FIHR 2.00 PIPE 5.20 HTFS.ACOL HTFS.ACOL is a highly powerful air-cooled calculation program that can simulate tube banks or finned tubes, with the fluid outside the tubes being air or other gases. The following systems can be simulated and calculated: air cooling, flue gas waste heat recovery systems, air conditioning systems, air dehumidification systems, refrigeration systems, etc. • Calculation mode Design pattern: The interactive graphic design method is an exclusive HTFS technology. This way, you can obtain the optimal air cooler tube bank layout based on the required heat load. It is possible to determine the number of tube banks, the heat exchange units, the number of stages within each unit, and the air flow rate. Multiple options can be provided for the user to choose from. Simulation mode: (1) Given the inlet conditions (gas on the tube side and outside the tube), calculate the outlet conditions; (2) Given the outlet conditions on the tube side and the inlet conditions of the gas outside the tube, calculate the inlet conditions on the tube side; (3) Given the inlet conditions on the tube side along with natural convection outside the tube, calculate the outlet conditions on the tube side and the flow rate of the gas outside the tube; (4) Given the inlet conditions on the tube side and those of the gas outside the tube, calculate the flow rate within the tube. (5) Given the inlet and outlet conditions of the tube side and the inlet condition of the gas on the outside of the tube, calculate the flow rate of the gas outside the tube. (6) Calculate the scaling parameters inside the pipe. • Air cooler types: suction type, forced-air type, and natural convection type, which can be used to heat or cool the tube side. The maximum number of pipe processes can be 50. The heat exchanger can have any number of layers, up to 100. HTFS.MUSE • Calculation mode • Design: Uses a simplified method to calculate the geometric dimensions of the cold box and the number of channel layers, based on the process conditions of each flow stream • Analysis: Determines the characteristics of the heat exchanger given the inlet and outlet conditions • Simulation: Calculates the outlet conditions given the geometric dimensions of the cold box, the number of channel layers, and the inlet conditions • Channel allocation simulation: Computes the operating characteristics of each channel in the cold box (up to 240 channels can be considered). The cross-sectional fin temperature distribution of the cryogenic box can be predicted, thereby enabling the study of various flow channel allocation schemes. • Calculation of heat-siphon cold boxes, analysis of flow distribution schemes, and analysis of co-current and counter-current flow • Cold box types: The maximum number of flow streams in a cold box can be 15. The heat exchange pattern between the flow streams can be counterflow, coflow, or crossflow. Single cold boxes, or composite cold boxes formed by combining multiple units in series or in parallel; these cold boxes can be arranged vertically or horizontally. Thermosiphonic cryogenic tanks can be internal (with a liquid chamber built in) or external (connected through pipes and a liquid chamber at the bottom of the tower). • Types of distributors: Distributors can calculate the pressure drop due to expansion at the inlet and outlet, and they can check whether the flow distribution is uniform. There are combined types and branched types of distributors, and it is also possible to extract a portion of the flow. • The fin characteristic data can be entered manually through the input interface for the heat transfer and pressure drop properties of the fins (straight, porous, corrugated/herringbone, serrated, strip-shaped). If no data is provided by the manufacturer, the fin characteristics can be determined using the characteristic curves built into the software. Thanks to its in-depth and unique research efforts, HTFS has a distinctive approach to dealing with the boiling and condensing fluid flow in finned channels. • Program components:
PFIN – Simplified calculation: Used to determine the basic dimensions of a plate-fin heat exchanger during its initial calculation.
MUSE – Standard calculation: Computes the heat exchanger based on a standard flow channel distribution.
MULE – Correction of the flow channel distribution and manual adjustment of the same.
MUSC – Cross-flow correction.

HTFS.FIHR: This is a program for calculating heating furnaces.
• Functions/Modeling: For a given furnace type, along with its structural dimensions, fuel consumption, excess air coefficient, and the medium to be heated, the software can perform the following calculations: By analyzing heat transfer in the combustion chamber and convection chamber, as well as multi-phase flow dynamics, it is possible to determine the temperature and pressure distributions of the fluid being heated and the exhaust gases. Among them, the pressure distribution of the flue gas is very detailed data ranging from the combustion chamber, through the convection section, to the chimney. The calculation model, for a given furnace type, specifies the heat load in the combustion section (by specifying the exit temperature of the fluid being heated in the combustion zone), and then calculates the required amount of fuel (the input method is the same as that in the simulation mode, but it is necessary to specify the exit temperature of the fluid being heated in the combustion section). Processing capacity: The fluid to be heated can be: • A single-phase fluid (gas phase or liquid phase) • A multiphase fluid (gas-liquid two-phase or gas-liquid-liquid three-phase). The medium to be heated can be distributed in different parts of the heating furnace. This heating furnace can be used for simulation calculations of various refinery and chemical plant cylinder furnaces, box-type heating furnaces, and heat recovery systems. • Technical features • A powerful online help system and graphical interactive input for the structural dimensions of the combustion chamber and convection section. With these functions, users can easily complete modeling tasks. • The medium to be heated can have up to 10 flow paths, which can be distributed arbitrarily throughout the furnace. They can operate in counterflow or co-current relative to the flue gas • The medium being heated can be a single-phase flow or a multi-phase flow. They can operate in multi-channel and multi-pipeline modes • They can use gas fuel or liquid fuel • Cylinder furnaces or box furnaces. The combustion section can have a single row or double rows of furnace tubes. The furnace tubes can be arranged vertically or in a spiral pattern, and can be placed in the center of the furnace or along its circumference. • The box-type furnace can be single-unit or double-unit. • The convection section can be divided into up to 9 sections. The tube can be a plain tube or a finned tube. For convection tubes, radiation heat transfer from the combustion chamber can be taken into account. There are two ways of flue gas discharge: either recovering the energy from the flue gas (by using it to preheat the fuel), or not recovering any energy from the flue gas. The chimney can be of constant or varying diameter. The chimney can be equipped with baffles. The combustion chamber and the convection section can be modeled separately. Various units can be used, such as international units, metric units, and imperial units. The .PSF property file format is supported. Users can transfer data via .PSF files and simulation software. • Physical property database: During the simulation process, the following physical properties of the heated medium are required: density, specific heat, thermal conductivity, and surface tension of liquids. For multiphase flows, a heat load curve (temperature – enthalpy – vaporization rate) is also needed. To obtain these physical properties, HTFS provides the following method: • Thermodynamic property package: Introduce the thermodynamic package from the HYSYS process simulation software into the HTFS system. Over 1,000 pure components, 6 equations of state, and 2 activity calculation models are available. • The NEL40 package includes methods for calculating the properties of 40 pure components. • Property data can be provided by process simulation systems through standard PSF property generation files. • Calculation models: Two calculation models can be used for the combustion chamber: • The homogeneous mixing model (single-zone method), which treats the entire combustion chamber as one fully mixed zone; • The zone method, which divides the combustion chamber into several sections along the axis, with each section considered as a small zone. Radiation heat transfer, convection heat transfer, and various heat balances are calculated for each zone. Finally, detailed data for each region can be obtained: • Temperature distribution of flue gases and furnace walls • Temperature distribution of the heated medium and furnace wall surfaces. The heat distribution of the flame in each region can be automatically calculated by the model or defined by the user himself/herself. In the convective section, the temperature and pressure of the flue gas are calculated section by section along the flow direction of the furnace tubes. The temperature, pressure of the heated medium, and the pipe wall temperature are calculated tube by tube. Radiation heat transfer can also be considered in the convective section. The calculation of the pressure drop in the flue gas takes into account each section from the blower inlet to the chimney outlet. • Simulation result output – ranging from concise summary reports to highly detailed analysis reports for each tube individually, the output options of the FIHR software enable you to examine the performance of the heating furnace from various perspectives. Some very important parameters can also be represented graphically. Such as: pressure distribution maps and temperature pinch point maps, etc. Through various graphs, you can gain a deeper understanding of the furnace’s performance. FIHR can generate the following reports: • Concise summary report • API data report • Heat balance report for each component of the furnace • Thermal intensity report for furnace tubes • Report on the temperature and pressure distribution of flue gases • Report on the temperature of the heated medium and the surface temperature distribution of furnace tubes (analyzed tube by tube) • Calculation of the maximum temperature of furnace tubes • Tube-by-tube pressure distribution of the heated medium. HTFS.TASC is a highly excellent shell-and-tube heat exchanger software worldwide; it has been available in China since the early 1980s. Original member users are found throughout the chemical and petrochemical industries. Renowned for its computational accuracy and engineering practicality. The new generation of TASC is more powerful; it integrates all shell-and-tube heat exchangers and combines heat transfer and mechanical strength calculations. It can be used in multi-component, multiphase flow condensers, tank reboilers, falling-film evaporators, groups of multiple heat exchangers, etc. And provide the tube bundle layout diagram. • Calculation mode • Design: Perform an optimized design for the heat transfer area or cost under given process conditions. Calculation of various parameters of heat exchangers • Verification: Specify the inlet and outlet conditions of the fluid; verify whether the heat exchanger can handle the required load, and calculate the ratio between the actual heat transfer area and the required heat transfer area. • Simulation: For a given heat exchanger, simulate its outlet conditions once the inlet conditions of the process medium are specified, and calculate its operating performance. • Thermal siphon heat exchanger simulation: Simulate the operating performance of thermal siphon heat exchangers, and calculate the circulation rate and pressure drop in the piping. • Types of heat exchangers • All TEMA-type heat exchangers are included, namely front ends (A, B, C, D), rear ends (L, M, N, P, S, T, U, W), and shells (E, F, G, H, J, K, I, X). • Single heat exchangers or groups of heat exchangers (up to 12 units in series; unlimited in parallel) can be used. Heat exchangers can be placed horizontally or vertically. • The tubes and shells can be smooth tubes, low-finned tubes, radially finned tubes, or helically finned tubes, etc. • Non-TEMA-type heat exchangers can also be calculated. Such as double-tube heat exchangers, multi-tube bundle double-shell heat exchangers, etc. • Vertical and horizontal thermosyphon heat exchangers • Vibration inspection • For gaseous, liquid, or two-phase fluids flowing through the shell side, the HTFS.TASC software uses advanced methods developed over many years to assess the possibility of vibrations caused by fluid flow; these methods can predict fluid elastic stability, resonance, fluid shock, etc. It can also predict the flow stability of thermal siphon heat exchangers. • Optimization of tube layout • Can handle smooth tubes, low-finned tubes, and axially finned tubes. Contains a database of low-fin tubes • Baffle types: single-notch, double-notch, tubeless notched baffles, rod-type baffles • Output results include the following: • Detailed results of the optimized design, including total weight and comparison tables of various options • Design report in TEMA format, compatible with Microsoft word processing software • Plan view of the heat exchanger • Various detailed data on the tubes and the shell side • Reasons that may cause vibration along with detailed descriptions • Ability to predict potential unstable flows (in thermosyphon heat exchangers) Cost calculation, optimization of tube array arrangement, and diagrams of heat exchanger tube arrangements 3.1.3 Aspen Plus is a large-scale general-purpose process simulation system, a product of the American company AspenTech. Major global manufacturers in the process industries such as chemicals, petrochemicals, and refining, as well as renowned engineering companies, are all users of Aspen Plus. Official website: http://www.AspenTech.com/ Aspen Plus is a large-scale general-purpose process simulation system that originated from a competition organized by the U.S. Department of Energy in the late 1970s at MIT to develop new third-generation process simulation software. The project was named “Advanced System for Process Engineering” (ASPEN for short) and was completed by the end of 1981. In 1982, AspenTech was founded to commercialize it, and it was named Aspen Plus. Through continuous improvement, expansion, and enhancement over more than 20 years, this software has seen the release of over a dozen versions, becoming a globally recognized standard for large-scale process simulation software, with millions of application cases. Major global manufacturers in the process industries such as chemicals, petrochemicals, and refining, as well as renowned engineering companies, are all users of Aspen Plus. 1. The most comprehensive set of property models: A complete set of property models based on equation of state and activity coefficient methods. There are over 20 types of equation of state models, 15 types of activity coefficient models, more than 10 types of molar volume models, 2 types of vaporization enthalpy models, 13 types of enthalpy, free energy, and entropy models, 4 types of vapor pressure models, and 3 types of gas-liquid equilibrium ratio models. There are also models for the property constants of pure components, two types of density models for composite solids, 5 types of enthalpy models for composite solids, 6 types of thermal conductivity models, 4 types of surface tension models, 10 types of viscosity models, and 3 types of diffusion coefficient models. 2. The Aspen Plus database contains property data for over 5,000 pure components, as well as the following databases: The pure component database includes parameters for 5,000 compounds. An electrolyte aqueous solution database containing parameters for 900 ionic and molecular solutes required to estimate electrolyte properties. A solid database containing the Henry’s constant parameters for compounds in 61 aqueous solution species. A binary interaction database comprising over 4,000 binary interaction parameters for the Ridlch-Kwong Soave, Peng Rinson, Lee Kesler Plocker, BWR Lee Starling, and Hayden O’Connell equation of state, covering 5,000 binary mixtures. The PURE10 database contains property data for 1,727 compounds; it is a relatively comprehensive database based on the DIPPR property database developed by the American Chemical Society. This not only greatly expands on the 1,550-component database of the ninth edition but also features more accurate and reliable parameters. The inorganic substances database includes thermochanical parameters for 2,450 compounds. Combustion database, including parameters for 59 common components and radicals in combustion products. Solid databases, including 3,314 components, are mainly used for components of solids and electrolytes. An aqueous solution database containing 900 ions, primarily used for electrolyte applications. 3. Property data interface with DECHEMA DETHERMA: Aspen is the only software approved for interfacing with DECHEMA’s database, which contains the most comprehensive data on gas-liquid and liquid-liquid equilibria in the world, totaling over 250,000 sets of data. Users can also connect their property data to the Aspen Plus system. 4. A highly flexible data regression system. 5. A property constant estimation system that can estimate the missing physical property parameters by inputting the molecular structure and easily measurable properties. The 6Redlinch-Kwong-UNIFAC equation of state can be used for non-polar, polar, and associative component systems. The Aspen Plus mixed-solid system is applied to issues related to solids in coal purification and liquefaction, fluidized bed combustion, high-temperature metallurgy, as well as in the solid waste, polymer, biological, and food industries. In Aspen Plus, the property data for solids comes from two sources: one is the Solid database, which collects a wide range of thermochchemical data for 3,314 pure inorganic substances and several organic substances ； The second is the interface with the CSIRO database. Aspen Plus for simulating electrolyte systems: Many companies have used Aspen Plus to simulate electrolyte processes such as acid water stripping, caustic salt crystallization and nitric acid production, hydrometallurgy, amine purification of gases, and hydrochloric acid recovery. Aspen Plus provides the Pitzer activity coefficient model and the Chen model for calculating the activity coefficients of substances, including weak electrolytes, salts, and electrolyte systems containing organic compounds. These models have been widely used in industry and have proven to be accurate and reliable. The electrolyte system has three databases of physical property parameters: the water database includes the properties of various ionic and molecular solutes in water ； The data packages for the application of certain special electrolyte systems in acid gas interaction processes were developed jointly by our company’s application department and users. Aspen Plus boasts a comprehensive library of unit operation models. It provides a set of complete models for simulating various processes, ranging from the calculation of individual crude oil distillation towers to the simulation of entire ammonia synthesis plants. Thanks to the advanced PLEX data structure, there are no limits on the number of components, inlet and outlet stream quantities, theoretical plate numbers of the column, or the number of reactions – this is a unique advantage that no other simulation software can match. Furthermore, all models can handle solids and electrolytes. The unit operation model library consists of approximately 50 different unit operation models. Users can add their own custom unit operation models to the Aspen Plus system, which provides them with great convenience and flexibility. The fractionation and reaction models of Aspen Plus are the two most commonly used unit operation models. The multi-stage strict separation model of the distillation model Aspenplus is developed based on a two-layer structure, internal and external, incorporating the latest system of equations and solution methods. The reactor model in Aspenplus can be used across a wide range of applications. The simple stoichiometric model (RSTOIC) can be applied simply by specifying the stoichiometry and the conversion rate of a key component in the reaction. When the reaction kinetics are known, more accurate models can be used, such as the continuously stirred tank reactor (RCSTR) model or the piston reactor model (RPLUG). Unit operation models and key functions in Aspen Plus include mixers and distributors, separators, heaters and heat exchangers, multi-stage separation, reactors, pumps and compressors, solid handling, flow controllers, as well as pipes and valves