Complete Process Engineering Course for Chemical Engineers

What is Process Design and Simulation Software?

Process Design and Simulation Software is a type of computer software that is used in engineering and industry to model, analyze, and optimize various processes inside a system. These tools are very useful in chemical engineering, manufacturing, and other industries that use complex processes.

Here are the primary features of Process Design and Simulation Software:

Modeling:With these software tools, engineers can develop detailed mathematical models of physical processes. This includes specifying the system’s components, interactions, and overall process dynamics.

Simulation:After building a model, simulation software allows engineers to conduct virtual experiments. This entails applying the model to forecast how the actual system will react under certain scenarios. This virtual simulation aids in analyzing the system’s functioning, detecting potential problems, and adjusting parameters.

Analysis:Engineers can use simulation data to obtain insight into the system’s efficiency, safety, and overall performance. This analysis may include investigating variables such as temperature, pressure, flow rates, and other pertinent characteristics.

Optimization:Process Design and Simulation Software frequently include optimization capabilities. Engineers can use these tools to determine the optimal set of operating conditions or design parameters for increasing efficiency, lowering costs, or achieving other specific goals.

Visualization: These technologies often show visual representations of simulated processes. Graphs, charts, and 3D models help engineers and stakeholders comprehend the system’s behavior.

Process Design and Simulation Software includes Aspen Plus, COMSOL Multiphysics, and Simulink. These tools are critical for minimizing the time and costs involved with physical prototyping, allowing engineers to iteratively improve and optimize processes in a virtual environment before applying them in the real world.

What is Heat Exchanger Process Design?

Heat exchanger process design involves the systematic and efficient planning, configuration, and specification of heat exchangers to facilitate the exchange of heat between two or more fluids. Heat exchangers are devices designed to transfer thermal energy between fluids while keeping them physically separated. The primary objective of heat exchanger process design is to optimize the heat transfer process to meet specific requirements such as temperature control, energy efficiency, and overall system performance.

Key aspects of heat exchanger process design include:

• Fluid Selection

• Temperature and Pressure Requirements

• Heat Transfer Area

• Flow Configuration

• Material Selection

• Geometry and Design Parameters

• Thermal Performance Optimization

• Cost Considerations

• Regulatory Compliance

What is Shell and Tube Heat Exchanger?

A Shell and Tube Heat Exchanger is a type of heat exchanger that consists of a shell (a large container) and a series of tubes enclosed within the shell. The basic design involves one fluid flowing through the tubes while another fluid flows over the tubes, facilitating the transfer of heat between the two fluids. This type of heat exchanger is widely used in various industrial processes due to its versatility and efficiency.

Here are the main components and features of a Shell and Tube Heat Exchanger:

• Shell: The shell is a large cylindrical vessel that houses the tube bundle. It typically has inlet and outlet connections for the two fluids involved in the heat exchange process.

• Tube Bundle: Inside the shell, there is a bundle of tubes through which one of the fluids flows. These tubes can be arranged in various configurations, such as straight or U-shaped, depending on the application.

• Tube Sheets: The tube sheets are located at both ends of the shell and provide support for the tube bundle. They also serve to seal the shell from the tubes, preventing fluid mixing.

• Baffles: Baffles are plates or disks placed inside the shell to direct the flow of the fluid over the tubes. They enhance heat transfer efficiency by promoting turbulence in the fluid flow.

• Tube Side and Shell Side: The fluid that flows through the tubes is referred to as the “tube side,” while the fluid that flows over the tubes and inside the shell is called the “shell side.”

• Tube Passes: The tubes may be arranged in multiple passes within the shell, allowing the fluid to make several passes through the tube bundle. This arrangement enhances heat transfer efficiency.

• Tube Materials: Tubes are often made of materials that offer good thermal conductivity and corrosion resistance, such as stainless steel, copper, or various alloys.

• Tube Bundle Expansion Joints: These are designed to accommodate the differential thermal expansion between the tube bundle and the shell to prevent damage during temperature variations.

Shell and Tube Heat Exchangers are widely used in applications where high heat transfer efficiency is required, such as in chemical processing, power generation, refrigeration, and oil refining. They are favoured for their reliability, ease of maintenance, and adaptability to handle a wide range of temperature and pressure conditions.

Software for Heat Exchanger Design

• HTRI (Heat Transfer Research, Inc.)

HTRI is a leading provider of software and services for heat exchanger design and analysis. Xchanger Suite includes tools for process simulation, thermal design, mechanical design, and rating of various types of heat exchangers.

• Aspen Exchanger Design & Rating (EDR):

Aspen EDR is part of the Aspen HYSYS process simulation software suite. It provides capabilities for the design and rating of heat exchangers, including shell and tube, air coolers, and plate-fin exchangers.

After Heat Exchanger course you will be able to do?

After completing a heat exchanger design course, students can acquire a range of knowledge and skills that will enable them to perform various tasks related to the design, analysis, and operation of heat exchangers. Here are some of the key competencies and abilities that students may gain:

• Understanding of Heat Transfer Principles

• Knowledge of Heat Exchanger Types and Applications

• Fluid Flow and Thermodynamics Understanding

• Selection of Suitable Materials

• Knowledge of Industry Standards and Codes

• Computer-Aided Design (CAD) and Simulation

• Problem Solving and Troubleshooting

• Project Management Skills

• Awareness of Energy Efficiency

• Safety and Environmental Considerations

• Communication Skills

Overall, a heat exchanger design course provides students with a comprehensive skill set that is valuable in industries such as chemical processing, oil and gas, power generation, HVAC, and more. Whether working in engineering, design, or operations, individuals with expertise in heat exchanger design are essential to ensuring efficient and safe thermal processes.

Dynamic Simulation

Dynamic Simulation for chemical engineers using advanced simulation tools
Welcome to our advanced Dynamic Simulation course using Aspen-HYSYS / Aspen-Plus/ Unisim

What is Dynamic Condition in Plant? Why Dynamic Simulation?

Condition in which parameters are changing with respect to time, it’s called dynamic condition. E.g. when we take start up of the plant, levels in the vessels, temperatures, pressures, flow rates are changing. Shut down of the plant is similar situation as start up where parameters are changing with time. Similar situation is during malfunctioning of either equipment or instruments. E.g. if distillation column in a plant is running in a steady state mode, what happen if there is sudden trip of the pump supplying cooling water to the condenser? suddenly, pressure of the column starts shooting up. This is one example, but there are so many examples in the plant.

Now, the question is how to tackle with dynamic condition. The answer is by introducing control systems, like pressure control, level control, flow control and temperature control. The function of any control system is to suppress the disturbance in the plant and bring plant once again into steady state condition.

Application of Dynamic Simulation

When parameters in the plant are changing, it cannot be modelled as steady state, or we cannot carry out steady state simulation to explain dynamic behavior as well as reliability of control systems to counter dynamic behavior. To study the transient behavior and effectiveness of the control system to control the transient behavior, Dynamic Simulation needs to be carried out.

Dynamic simulation as an engineering tool is being used for carrying out simulation of various chemical, petrochemical plants, refineries, cross country pipelines etc.

Dynamic simulation is also used to check the reliability of the pressure relief systems introduce in the plant i.e. how effectively pressure safety valves are handling abnormal situation.

One of the very important applications of dynamic simulation is for developing Operator Training Simulation (OTS) using which operator will be trained; how to take start-up of the plant or shut down of the plant or identifying the cause for abnormality in the plant and corrective action for the same.

Topics covered.

In this module, following topics will be covered in detail.

1. Introduction to dynamic simulation

2. Application of dynamic simulation

3. What is Pressure Flow Theory

4. Example demonstration with hypothetic flow sheet to configure all basic control system like flow control system, level control system, pressure control system and temperature control system.

5. Demonstration of strip charts i.e. how to configure strip charts, how to change logger size and how to read strip charts

This course is very help to all Chemical Engineers, looking for learning Dynamic Simulation, Process Engineers, Technical Service Engineers, Application Engineers. This module is basic module for Dynamic Simulation.

Tools for Dynamic Simulations are Aspen Hysys, Aspen Plus or UniSim.

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Frequently Asked Questions

How long do I have access to the course materials?

You can view and review the lecture materials indefinitely, like an on-demand channel.

Can I take my courses with me wherever I go?

Definitely! If you have an internet connection, courses on Udemy are available on any device at any time. If you don’t have an internet connection, some instructors also let their students download course lectures. That’s up to the instructor though, so make sure you get on their good side!