Aspen Process Simulation Software

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Aug 3, 2024, 3:59:36 PM8/3/24

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Aspen HYSYS (or simply HYSYS) is a chemical process simulator currently developed by AspenTech used to mathematically model chemical processes, from unit operations to full chemical plants and refineries. HYSYS is able to perform many of the core calculations of chemical engineering, including those concerned with mass balance, energy balance, vapor-liquid equilibrium, heat transfer, mass transfer, chemical kinetics, fractionation, and pressure drop.[2] HYSYS is used extensively in industry and academia for steady-state and dynamic simulation, process design, performance modeling, and optimization.[3][4]

HYSYS was first conceived and created by the Canadian company Hyprotech, founded by researchers from the University of Calgary.[5][6] The HYSYS Version 1.1 Reference Volume was published in 1996.[7]In May 2002, AspenTech acquired Hyprotech, including HYSYS.[8] Following a 2004 ruling by the United States Federal Trade Commission, AspenTech was forced to divest its Hyprotech assets,[9] including HYSYS source code, ultimately selling these to Honeywell. Honeywell was also able to hire a number of HYSYS developers, ultimately mobilizing these resources to produce UniSim.[10] The divestment agreement specified that Aspentech would retain rights to market and develop most Hyprotech products (including HYSYS) royalty-free.[11] As of late 2016, AspenTech continues to produce HYSYS.[12]

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A novel process simulation model (PSM) was developed for biogas production in anaerobic digesters using Aspen Plus. The PSM is a library model of anaerobic digestion, which predicts the biogas production from any substrate at any given process condition. A total of 46 reactions were used in the model, which include inhibitions, rate-kinetics, pH, ammonia, volume, loading rate, and retention time. The hydrolysis reactions were based on the extent of the reaction, while the acidogenic, acetogenic, and methanogenic reactions were based on the kinetics. The PSM was validated against a variety of lab and industrial data on anaerobic digestion. The P-value after statistical analysis was found to be 0.701, which showed that there was no significant difference between discrete validations and processing conditions. The sensitivity analysis for a 10% change in composition of substrate and extent of reaction results in 5.285% higher value than the experimental value. The model is available at (Rajendran et al., 2013b).

It takes an existing design that the user adds/inputs via new flowsheet or existing templates in order to simulate and improve its performance. A good process engineer will be required, as real life applications must be used while using the software. The chemical engineering principles are still required (sorry guys!)!

Fun Fact: On July 15, 2004, AspenTech was required by the Federal Trade Commission to make divestitures in regard to an anti-trust ruling against its acquisition of HyproTech (they worked on HYSYS). This included divestment of batch and continuous simulation systems and integrated engineering software business (AXSYS).

Unfortunately, the cost of a single license varies from 30K to more than 100K depending on the industry and market, so its hard to get access to the software itself if you do not own it or your company.

I would like to couple my Life Cycle Assessment (LCA) with process simulation made in Aspen. Basically, I would like for my program, created within Brightway2 framework, to take data from Aspen simulation (provided in JSON file) for Life Cycle Inventory (LCI), and ecoinvent ones for Life Cycle Assessment (LCIA).

As I investigated provided documentation and examples, it seems that only specifying 'name', 'input', 'output', 'location', 'type', 'unit' is possible (activity data format), and rest data are taken from Biosphere3 and Ecoinvent databases. I would like to include there also 'pressure', 'temperature', 'energy usage', 'emmission', 'waste', and etc. I'm afraid that even though the data would be provided to brightway2, it won't use it and will use for example Ecoinvent database.

You can create new activities (your foreground database) based on the results from Aspen. I am not familiar with Aspen, but one option could be to create an importer that picks that json file and creates the (foreground) database with your activities modelled in Aspen connected to background processes (e.g. ecoinvent) if needed. There are several examples of importers in bw2io. (all examples starting by IO here

In the end is a way to generate a dictionary (like the one you provide in the comments) but step by step. First you build an extractor that picks the data you need from the json file (a json is very easy to de-serialize into a dictionary). Then you use strategies to transform the data so it meets the requirements of activities. This is all wrapped as an Importer. There are examples of Importers and Extractors in bw2io. Finally you save it as a database.

As a side note, Brightway does not need the pressure to calculate anything. But you can add it as metadata or use it as variable to calculate your technosphere and biosphere flows. Furthermore, ecoinvent is esentially LCI. Although they provide an implementation of commonly used impact assessment methods linked to their list of elementary flows, and these methods are provided by brightway by default. I guess you meant that.

Aspen Plus Dynamics enables users to gain a detailed understanding of the unique dynamics of their processes and potential scenarios. Users can leverage this knowledge during design and operation to optimize safety, operability, and productivity within plants - and to minimize capital and operating costs.

The Control Design Interface, included in Aspen Plus Dynamics, enables a linear state space model to be extracted from the Aspen Plus Dynamics rigorous non-linear simulation. This can be loaded into MATLAB and used with the Control System Toolbox in designing a process control system. Once the user has designed a control system, they can use the Simulink Interface, also included with Aspen Plus Dynamics, to test its performance. The interface enables an Aspen Plus Dynamics process simulation to be used as a block within a Simulink model. This means the user can test the controller performance on the full, rigorous, non-linear dynamic model of the process. Without this interface, the control design can only be tested using the linear dynamic model within MATLAB. This leaves uncertainties about how the controller will perform on the real, non-linear process.

Please note that MATLAB uses 64-bit in releases starting with R2015b and Aspen Plus Dynamics uses 64-bit after V10. As a result, Aspen Plus Dynamics prior to V10 will not work with MATLAB R2015b and above.

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For the ever-evolving world of industrial processes and engineering, the importance of accurate and efficient simulations cannot be overstated. And, with the increasingly complex nature of interconnected industries, the need for reliable and versatile simulation tools has never been more critical. Modern advanced software empowers engineers to explore, analyze, and optimize complex processes across diverse disciplines, seamlessly bridging the gap between chemical, mechanical, electrical, and other engineering domains. You agree that they open the door to boundless possibilities, empowering engineers to model, analyze, and optimize various systems with unparalleled accuracy and efficiency. One such company that is making significant strides in the process modeling and simulation software industry is AspenTech Software. They are today synonymous with innovation, precision, and reliability.

Aspen Technology, Inc is a prominent industrial software partner for Rishabh Engineering. They offer remarkable solutions that cater to intricate environments, where optimizing asset design, operation, and maintenance lifecycle plays a pivotal role. Further, Aspen Hysys and Aspen Plus are two highly sought-after software solutions in process flow simulation utilized by our designers & engineers. Renowned for their manufacturing simulation capabilities, these tools present engineers with many advantages, enabling them to streamline the design process, optimize operations, and elevate overall efficiency to new heights.

As an award-winning multi-discipline engineering services company, we cater to various industries, including oil and gas, chemical, petrochemical, and power. We provide engineering & design solutions using process simulation software tools for process industries, including modeling, optimization, and design. Here are some common ways how we utilize Aspen Hysys and Aspen Plus for manufacturing process simulation:

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