Episode 7 : iCON Basic Training

1
SAJJAD KHUDHUR ABBAS
Chemical Engineering , Al-Muthanna University, Iraq
Oil & Gas Safety and Health Professional – OSHACADEMY
Trainer of Trainers (TOT) - Canadian Center of Human
Development
Episode 7 : iCON
Basic Training

© 2012 PETROLIAM NASIONAL BERHAD (PETRONAS)
SKG 16 - iCON Basic Training – Itinerary
2
Day Training Modules
22 October 2013 Slides presentation
1. Compressor Train
2. Demethanizer Column
3. Fractionation Train
4. Propane Loop
5. Steam Reformer
23 October 2013 1. Oil Characterization
2. Refinery Separation
3. Amine System
24 October 2013 1. Utility Optimizer Module 1
2. Utility Optimizer Module 2
3. Column Optimization
4. Property Regression
2013 PETROLIAM NASIONAL BERHAD (PETRONAS)

Outline
3
• Introduction to Process Simulation
• iCON Software
• Thermodynamic Property Package
• Modeling Approach
• Hands On Training

4
Introduction to Process Simulation

Introduction
Process simulation is the representation/replication of the real world
process behavior through mathematical models.
Process Simulator is a software that predicts the condition, composition
and properties of a particular point (stream) from an initial condition through
mass and energy balances and thermodynamic principles.
iCON is based squarely on fundamental thermodynamic principles
(equation based).
These principles are used in two main features of the process simulator:
 The thermodynamic calculation engine
 The simulation solver for unit operation and flowsheet.

Introduction
 The thermodynamic engine provides:
 Rigorous thermodynamic equilibrium and physical property estimation
for industrially important systems
The simulation solver continually monitors:
 The degrees of freedom of the flow sheet,
 Immediately invokes the necessary calculations when the degrees of
freedom are complete,
 Solved the system of equations describing the flow sheet.

Steady State Vs Dynamics
7
Steady State Dynamic
Mass & Energy
Balance
Always balance Not always balance
Time dependence No Yes
Accumulation i.e.
level simulation
No Yes
Equipment
dimension
Not required Required
Pressure profile No impact Impacts flow
Typical applications • Process Design
•Equipment Rating & Monitoring
• Utility Balance
• Process Control Optimization
• Plant Startup & Shutdown
•Operator Training Simulator

© 2012 PETROLIAM NASIONAL BERHAD (PETRONAS) 8
Process Simulation & Optimization Cycle
1
2
3
45

9
PETRONAS Official Process Simulation Software

What is iCON?
10
iCON is an innovative steady-state &
dynamic simulation software modeling
tool for oil, gas, petrochemical, utilities
and power generation industries.
iCON is capable of solving a wide range
of engineering problems and is
industry driven. It has been proven in
reliability in oil gas production, oil
refinery, petrochemicals, utility &
power generation

11
Thermodynamic Property Package

Property Package
A property package is a collections of equations that define (given set of
physical conditions) :
1. State of matter i.e vapor/mix/liquid phase
2. Physical properties.
Derived by fitting experimental data.

Why proper property selection is crucial?
13
• To calculate the component properties at certain T&P (e.g. density, heat capacity etc.)
• To determine the phase of the component at certain T&P (e.g. V/L/V+L)
• To determine the in what proportion the component would exist in each phase (equilibrium)
• The accuracy of the calculated/simulated results will greatly depend on the accuracy of the
thermodynamic package prediction.

Types of Property Package
Equation of State Model
• Good for non polar
liquid and gas phase
since can calculate
critical point.
• Covers a wide
temperature & pressure
range
• Advance Peng-Robinson,
Soave-Redlich-Kwong
• Hydrocarbon application
Activity Coefficient Model
• Good to represent non-
ideal liquid due to
presence of polar
components, but cannot
predict critical point
• Limited T & P range
• Non Random Two
Liquids (NRTL), UNIFAC,
UNIQUAC, Wilson
• Chemicals with high
polarity i.e. water,
alcohol
Special Packages
• Customized to represent
specific process which
may include kinetics
data in addition to
equilibrium data
• Limited T & P range
• Urea, Amine, Steam97

Property Package Selection Guideline
15
PETRONAS Technical Standards : Property Package Selection
(PTS 20.00.10.37 ) is available in AXIS

Example
Objective:
To give an indication of NH3 purity, an online calculation can be implemented as part of
ELMS, to enable operators to take necessary action to drain any contaminants i.e.
compressor oil from NH3.
Actual saturation Pressure &
Temperature
Actual saturation Pressure &
Temperature

Example
• The figure above shows multiple plots of pure NH3 using 21 different
thermodynamic packages and a plot of actual DCS data.
• Lee-Kesler-Plöcker (LKP) is found to be the best suited thermo-package.
1400
1450
1500
1550
1600
1650
1700
33 34 35 36 37 38 39 40
Pressure(kPaA)
Temp (deg C)
Pure Ammonia Temp VS Pressure
APR
APR-NG
Refinery SRK
APR-LK
NGL-PR
API SOUR
CHAO SEADER
GRAYSON
STREED
MAXWELL
BONELL
LKP
UNIQUAC
wilson
TK-WILSON
NRTL
VAN LAAR
Actual
DCS data
NGL-PR
Thermo
Lee Kesler
Plocker
Thermo

Modeling Approach – Degree of Freedom
19
Unit Operation in
iCON
Degree of Freedom • No. of specification required for the calculation to complete
• Inadequate specification  calculation will not progress
• Overspecified  inconsistency error will created

Modeling Approach – Degree of Freedom
20
Unit Operation Typical Specification
Stream Pressure, Temperature, Flow, Composition
Separator With feed stream, separator will converged without having to
specify anything
Cooler/Heater With feed stream, user needs to specify either:
1. Temperature outlet, Delta P
2. Temperature outlet, Pressure outlet
Heat Exchanger User needs to have both fluids properties (2 streams; shell
and tube)
Other specifications are similar to cooler/heater
Compressor/Pump
/Expander
With feed stream, user needs to specify either:
1. Pressure outlet, Efficiency
2. Pressure outlet, Temperature outlet
If with compressor curve, speed is required as specification

24
#1 Property package: Advance Peng Robinson
#2 Add components:
Water; Nitrogen; Carbon Dioxide; Methane; Ethane; Propane; iso-Butane; n-Butane;
iso-Pentane; n-Pentane; n-Hexane;
h2o;n2;co2;c1;c2;c3;ic4;nc4;ic5;nc5;nc6;
1 Water
2 Nitrogen
3 Carbon
Dioxide;
4 Methane
5 Ethane
6 Propane
7 Iso-Butane
8 n-Butane
9 iso-Pentane
10 n-Pentane
11 n-Hexane

25
#1 Property package: Advance Peng Robinson
#2 Add components:
Water; Nitrogen; Carbon Dioxide; Methane; Ethane; Propane; iso-Butane; n-Butane;
iso-Pentane; n-Pentane; n-Hexane;
h2o;n2;co2;c1;c2;c3;ic4;nc4;ic5;nc5;nc6;
1 Water
2 Nitrogen
3 Carbon
Dioxide;
4 Methane
5 Ethane
6 Propane
7 Iso-Butane
8 n-Butane
9 iso-Pentane
10 n-Pentane
11 n-Hexane

26
#3 Flash a material stream
Unit
Temperature Deg C 30
Pressure Kpa 1000
Mass Flow Kg/h 125
Water Mol %
1
Nitrogen Mol %
0.5
Carbon
Dioxide;
Mol %
0.5
Methane Mol %
1
Ethane Mol %
1
Propane Mol %
5
Iso-Butane Mol %
45
n-Butane Mol %
40
iso-Pentane Mol %
2
n-Pentane Mol %
2
n-Hexane Mol %
2

27
# 4 Flash options
P-T Flash
Vapor Fraction (VF)
Flash Calculation
P-H Flash
Temperature , Pressure , Flow ,Composition
Enthalpy, Pressure , Flow ,Composition
Vapor Fraction, Pressure , Flow ,Composition

28
# 5 Pseudo component: Min data: Normal Boiling Point or Molecular Weight + Liquid Density

29
Getting started
Starting iCON from desktop.
Selecting thermo.
Selecting components.
Converging a stream.
Units.
Bubble / dew points.
Phase diagram.
Special properties.
Making a copy
• Spec from
•Clone
•Copy stream
•Show datasheet
•Table
•Writing
Controller
• Temperature control
Process Calculator
•Totalizer
Pseudo component
Ammonia ref – choosing thermo

Modeling Approach – Data Propagation
30
• In port has a mass flow
of 200 kg/hr (mole flow =
4.84 kg-mole/hr)
• Since the cooler has a
single In and a single Out
material port:
No accumulation
of matter
 No chemical
reactions
•Therefore, the:
Mole Flow
Mass Flow
of In and Out port must be
IDENTICAL

31
• Note that even though
the mole and mass flows are
NOT known, the
thermodynamic state of the
In port IS known.
• Click on the
node and inspect the
physical properties of the In
port.
• Now click on the (Mass
Flow, In) cell and press the
<Delete> key.
• You will notice that the
since the mass flow is not
specified, the mole flow is
automatically forgotten.

32
• Click on the (MassFlow,
Out) cell and specify a
mass flow of 2000 kg/h as
shown below
• Hit the <Enter> key

33
• Note that the Out port
mass flow is now specified
(blue background),
• And the mole flow is
automatically calculated at
4.84 kgmole/h.
• Also, note that the
available information is
propagated backwards to
the In port.

34
Flash Calculations • Rigorous three-phase calculations except for Wilson (only vapor
liquid)
• Type of flash calculation based on degree of freedom concept
depending on specifications imposed on the system
• Independent Variables: Pressure (P), Enthalpy (H)
• Dependent Variables: vapor fraction, Temperature and entropy
P-T Flash
• Independent Variables: Vapor Fraction (VF) and Temperature (T)
or Vapor Fraction (VF) and Pressure (P)
• Dependent Variables: Pressure (P) or Temperature (T) and
enthalpy and entropy
• Examples:
• Dew Points: VF = 1.0, and either P or T
• Bubble Points: VF = 0.0, and either P or T
Vapor Fraction (VF)
Flash Calculation
• Independent Variables: Temperature (T), Pressure (P)
• Dependent Variables: vapor fraction, enthalpy and entropy
P-H Flash

35
Thanks for Watching
Please follow me / SAJJAD KHUDHUR ABBAS

Episode 7 : iCON Basic Training

Recommended

Recommended

More Related Content

What's hot

What's hot (20)

Viewers also liked

Viewers also liked (20)

Similar to Episode 7 : iCON Basic Training

Similar to Episode 7 : iCON Basic Training (20)

More from SAJJAD KHUDHUR ABBAS

More from SAJJAD KHUDHUR ABBAS (20)

Recently uploaded

Recently uploaded (20)

Episode 7 : iCON Basic Training