RECYCLE

Exterran Office
Jakarta, Dec 1
ST
2012

UNDERSTANDING
HYSYS
Understanding process with recycle stream
Understanding process design

Objectives
Case : Refrigeration System
Typical refrigeration system
Typical single stage Vapor
Compression Refrigeration
Refrigeration System using Economizer
Do you know economizer function? I believe you know the function
by its name. To get clearer information, lets start the simulation.
The green box on picture above represents Economizer.
A refrigeration system, capacity 4 MMBtu/hr, using 2-
stage compressor.
Process gas composition :
- Ethane : 0.04 %
- Methane : 99.91 %
- i-Butane : 0.06 %
Compressor pressure ratio : 3.0
Psuction : 40 psia
Tsuction : 2.2 F

Build a simulation using data above.
Problem
Problem Solving
1. Make equipment arrangement as per Refrigeration System using
Economizer process. Do not connect recycle to main stream
before main stream can be simulate.
2. Set compressor compression ratio to 3. Ensure pressure unit in
psia.
3. Input pressure drop on each equipment (Cooler, Scrubbers).
4. Put P, Molar Flow and gas composition to suction compressor as
initial trial value. Find Tsuction which is limited by condenser
performance.
Note : outlet temperature of condenser is limited to 120 F due to
approach temperature of air process gas.
Command : adjust inlet temperature of condenser to 120 F with
suction temperature as variable. <Adj-T>.
Please note that the result is the minimum temperature, raise few
degrees above the result. Fluid condition shall be superheated
(gas only).




Result of step 1 - 4:
2-phase, so the governing is fluid phase
Fluid at suction
compressor shall
be in gas phase
(vapour fraction =
1).

For this case, take
out ADJ-1 and set
Tsuction at 5 F.
5. To get maximum refrigeration capacity, set pressure drop VLV-100 to 0
(zero) psi. Set vapour fraction at Stream 6 = 1.

6. Set pressure at recycle with main stream as reference
P6 = P11; P12 = P11; P13 = P14.
5 MMSCFD at 40 psia/ 5 F Refrigeration -2.28 MMBtu/hr.
6. Connect recycle stream to main stream.
7. To get refrigeration duty 4 MMBtu/hr, Adjust Molar Flow at Stream 11
with target Q-ref at -4 MMBtu/hr.
The result is 8.743 MMSCFD for refrigeration capacity 4 MMBtu/hr.
Compressor duty is 2.554 MMBtu/hr.
Closing
The simulation is just an approach, you can optimize by change
some variables.
If you have real case that will be very helpful to understand real
process design.