ASPEN 10.2WhatsNew

Part Number: Aspen Engineering Suite 10.2February 2000Copyright (c) 1981-2000 by Aspen Technology, Inc. All rights reserved.

Aspen Adsim, Batch Plus®, Aspen B-JAC, Aspen Hetran, Aspen Teams, Aspen Aerotran, AspenChromatography, Aspen Custom Modeler, Aspen Dynamics, Aspen Engineering Suite, Aspen OLI, AspenPEP Process Library, Aspen Pinch, Aspen Plus®, Polymers Plus®, Aspen Properties, Aspen Split, AspenTech®,Aspen Water, Aspen Zyqad, DMCplus®, ModelManager®, the aspen leaf logo and Plantelligence are trademarksor registered trademarks of Aspen Technology, Inc., Cambridge, MA.

BATCHFRAC and RATEFRAC are trademarks of Koch Engineering Company, Inc.

All other brand and product names are trademarks or registered trademarks of their respective companies.

This manual is intended as a guide to using AspenTech's software. This documentation contains AspenTechproprietary and confidential information and may not be disclosed, used, or copied without the prior consent ofAspenTech or as set forth in the applicable license agreement. Users are solely responsible for the proper use of thesoftware and the application of the results obtained.

Although AspenTech has tested the software and reviewed the documentation, the sole warranty for the softwaremay be found in the applicable license agreement between AspenTech and the user. ASPENTECH MAKES NOWARRANTY OR REPRESENTATION, EITHER EXPRESSED OR IMPLIED, WITH RESPECT TO THISDOCUMENTATION, ITS QUALITY, PERFORMANCE, MERCHANTABILITY, OR FITNESS FOR APARTICULAR PURPOSE.

CorporateAspen Technology, Inc.Ten Canal ParkCambridge, MA 02141-2201USAPhone: (617) 949-1000Fax: (617) 949-0130URL: http://www.aspentech.com

DivisionDesign, Simulation and Optimization SystemsAspen Technology, Inc.Ten Canal ParkCambridge, MA 02141-2201USAPhone: (617) 949-1000Fax: (617) 949-1030

What's New in AES 10.2 Contents •••• iii

Contents

1 Introduction 1-1Enhanced Engineering Workflow Support throughout the Engineering Lifecycle .........1-2

Integrated Engineering .........................................................................................1-2Enhanced Integration of AES Products................................................................1-2Enhanced Workflow Features ..............................................................................1-2

Enhanced Model Deployment throughout the Enterprise ................................................1-3Extended Properties Usage...................................................................................1-3Extended Process Model Usage ...........................................................................1-3Open Standards Support.......................................................................................1-3Web Deployment..................................................................................................1-3

PlantelligenceTM Compliance...........................................................................................1-3Technical Support ............................................................................................................1-4

2 Aspen Properties 2-1New Capabilities ..............................................................................................................2-1

Standalone Aspen Properties Application............................................................2-2Excel Property Calculator ....................................................................................2-2Web-Based Application .......................................................................................2-3Open Systems.......................................................................................................2-3

Compatibility Notes .........................................................................................................2-3Toolkit Number ....................................................................................................2-3File Extension.......................................................................................................2-4

3 Aspen OLI 3-1New Capabilities ..............................................................................................................3-2

New Viscosity Model...........................................................................................3-2Flexibility in Dealing with Salt Precipitation.......................................................3-2Consistent Installation with Other AES Products ................................................3-2New On-Line Documentation ..............................................................................3-2

Compatibility Notes .........................................................................................................3-3

4 Aspen Plus 4-1New Capabilities ..............................................................................................................4-2

Engineering Workflow.........................................................................................4-2Open Systems.......................................................................................................4-3Integration with AES Products.............................................................................4-4

iv •••• Contents What's New in AES 10.2

Engineering Capabilities ......................................................................................4-6GUI Usability .......................................................................................................4-6

Compatibility Notes .........................................................................................................4-7Saving Simulations...............................................................................................4-7Subflowsheet Block..............................................................................................4-7Valve Model.........................................................................................................4-7Flowsheet Hierarchy ............................................................................................4-7Physical Properties ...............................................................................................4-8OLE Automation Methods ...................................................................................4-9Fortran Error Handling.........................................................................................4-9New Binary Parameter Systems.........................................................................4-10Revised Binary Parameter Systems....................................................................4-11

5 Aspen Dynamics 5-1New Capabilities ..............................................................................................................5-1

Integration with Polymers Plus ............................................................................5-2Estimation of Kinetic Parameters.........................................................................5-2Support for Pump Performance Curves ...............................................................5-2Petroleum Property Calculations..........................................................................5-2Increased Model Robustness................................................................................5-2Other Model Enhancements .................................................................................5-2On-line Links Using OLE for Process Control (OPC).........................................5-2Streamlined Snapshots and Use ...........................................................................5-3Automatic DMCplus Model Generation ..............................................................5-3

Compatibility Notes .........................................................................................................5-3.dynf Files.............................................................................................................5-3.dynd Files ............................................................................................................5-3Coexistence with Aspen Dynamics 10.1..............................................................5-3Compatibility with Aspen Plus ............................................................................5-3

6 Aspen Custom Modeler 6-1New Capabilities ..............................................................................................................6-1

Easier Formulation of PDE Models .....................................................................6-2Extensions to Dynamic Optimization ..................................................................6-2Parameter Estimation GUI and Other Extensions................................................6-2On-line Links Using OLE for Process Control (OPC).........................................6-3Streamlined Snapshots and Use ...........................................................................6-3Automatic DMCplus Model Generation ..............................................................6-3Open Non-linear Algebraic Equation Solver Interface ........................................6-3

Compatibility Notes .........................................................................................................6-3.acmf Files ............................................................................................................6-3.dynd Files ............................................................................................................6-3Dynamic Optimization .........................................................................................6-4Coexistence with ACM 10.1 ................................................................................6-4Compatibility with Aspen Plus ............................................................................6-4

What's New in AES 10.2 Contents •••• v

7 Aspen B-JAC 7-1Aspen Hetran........................................................................................................7-1Aspen Aerotran ....................................................................................................7-1Aspen Teams ........................................................................................................7-1

New Capabilities ..............................................................................................................7-2User Interface .......................................................................................................7-2Aspen Hetran........................................................................................................7-3Aspen Teams ........................................................................................................7-6Aspen Aerotran ....................................................................................................7-8

Compatibility Notes .........................................................................................................7-9Aspen Hetran........................................................................................................7-9Aspen Teams ......................................................................................................7-10Aspen Aerotran ..................................................................................................7-12

8 Aspen Pinch 8-1New Capabilities ..............................................................................................................8-2Compatibility Notes .........................................................................................................8-2

9 Aspen Split 9-1New Capabilities ..............................................................................................................9-1

Split Component...................................................................................................9-1

10 Aspen Water 10-1New Capabilities ............................................................................................................10-1Compatibility Notes .......................................................................................................10-1

11 Aspen Zyqad 11-1New Capabilities ............................................................................................................11-1

Intergraph Product Interfaces .............................................................................11-1ICARUS Interface ..............................................................................................11-1HTRI, HTFS Interface........................................................................................11-2Excel-based Datasheet Definer ..........................................................................11-2License Manager ................................................................................................11-2

Compatibility Notes .......................................................................................................11-2Datasheets...........................................................................................................11-2

12 Aspen Adsim 12-1New Capabilities ............................................................................................................12-1

2-D Adsorbent Bed Model .................................................................................12-2Particle Material Balance ...................................................................................12-2New Mass Transfer Coefficient Models ............................................................12-2Additional Isotherms ..........................................................................................12-2Internal/external Column Heat Exchangers .......................................................12-2Enhanced Reporting ...........................................................................................12-2Cycle Organizer Enhancements .........................................................................12-2

vi •••• Contents What's New in AES 10.2

Batch Run Toolkit ..............................................................................................12-3Easier Formulation of PDE Models ...................................................................12-3On-line Links Using OLE for Process Control (OPC).......................................12-3Streamlined Snapshots and Use .........................................................................12-3Automatic DMCplus Model Generation ............................................................12-4Open Non-linear Algebraic Equation Solver Interface ......................................12-4

Compatibility Notes .......................................................................................................12-4

13 Aspen Chromatography 13-1New Capabilities ............................................................................................................13-1

Rigorous Pressure Drop Calculation ..................................................................13-2Additional Isotherm............................................................................................13-2Enhanced Reporting ...........................................................................................13-2New Unit Operations..........................................................................................13-2Cycle Organizer Enhancements .........................................................................13-2Easier Formulation of PDE Models ...................................................................13-2On-line Links Using OLE for Process Control (OPC).......................................13-3Streamlined Snapshots and Use .........................................................................13-3Automatic DMCplus Model Generation ............................................................13-3Open Non-linear Algebraic Equation Solver Interface ......................................13-3

Compatibility Notes .......................................................................................................13-4

14 Batch Plus 14-1New Capabilities ............................................................................................................14-1

Route Selection for Chemical Development......................................................14-2Equipment Independent Recipe .........................................................................14-2Expanded Comments for Steps and Operations.................................................14-2Vapor Emission Calculations .............................................................................14-3Custom Excel/VBA Model ................................................................................14-3Models and Operations.......................................................................................14-3Batch Plus as an Automation Server ..................................................................14-4Enhancements to Simulation Engine..................................................................14-4Ease-of-Use ........................................................................................................14-4

Compatibility Notes .......................................................................................................14-5Project Files........................................................................................................14-5Additional Products Required ............................................................................14-5

15 Polymers Plus 15-1New Capabilities ............................................................................................................15-1

Integration of Polymers Plus with Aspen Dynamics .........................................15-1Expanded Polymer Databank .............................................................................15-1Integration of Polymers Plus with Third Party Software ...................................15-2Four-phase Equilibrium (TP-Flash) Model........................................................15-2

Compatibility Notes .......................................................................................................15-2Properties and Property Analysis .......................................................................15-2Step-growth Model.............................................................................................15-2

What's New in AES 10.2 Contents •••• vii

Emulsion Model .................................................................................................15-2Ziegler-Natta Model...........................................................................................15-2Streams...............................................................................................................15-3Unit Operation Models.......................................................................................15-3Applications Examples.......................................................................................15-3

16 Aspen PEP Process Library 16-1New Capabilities ............................................................................................................16-1

Models in Aspen PEP Process Library ..............................................................16-2

viii •••• Contents What's New in AES 10.2

What's New in AES 10.2 Introduction •••• 1-1

1 Introduction

The Aspen Engineering Suite (AES) is an integrated engineeringenvironment that provides business value through the creation,management, and deployment of process knowledge throughoutthe engineering enterprise.AES 10.2 provides, on a single CD, the latest versions of thefollowing AspenTech design, simulation, and optimizationtechnologies:

Physical Properties:Aspen Properties Chapter 2Aspen OLI Chapter 3

Simulation:Aspen Plus® Chapter 4Aspen Dynamics Chapter 5Aspen Custom Modeler Chapter 6

Design and Synthesis:Aspen B-JAC Chapter 7(Aspen Hetran, Aspen Teams, Aspen Aerotran)Aspen Pinch Chapter 8Aspen Split Chapter 9Aspen Water Chapter 10

Engineering Workflow:Aspen Zyqad Chapter 11

Vertical Applications:Aspen Adsim Chapter 12Aspen Chromatography Chapter 13Batch Plus® Chapter 14Polymers Plus® Chapter 15Aspen PEP Process Library Chapter 16

1-2 •••• Introduction What's New in AES 10.2

AES 10.2 provides a number of exciting new advances:

Enhanced Engineering WorkflowSupport throughout the EngineeringLifecycleAES 10.2 supports the integration of engineering work processes,from conceptual design to process design to detailed design, andinto operations. Using Aspen Zyqad as the integration platform,AES products such as Aspen Plus and Aspen Hetran can worktogether with in-house tools and 3rd party products such as detaileddesign programs from Intergraph, and ICARUS cost estimationtools. Integrated engineering enhances the quality andeffectiveness of engineering, resulting in lower costs and betteroperations.AES 10.2 provides tighter integration among the AES products.Enhanced integration exists between:

• Aspen Split and Aspen Plus. The Aspen Split component cannow be launched from within the Aspen Plus environment, toperform azeotrope analyses and distillation boundarycalculations.

• Aspen OLI and AES. Aspen OLI is now available as part of theAES Suite CD, thereby reducing the effort required to installthe Aspen OLI product for use with AES.

• Aspen Dynamics and Polymers Plus. Aspen Dynamics andPolymers are now integrated, allowing you to convert aPolymers Plus steady-state model to run in dynamics in amatter of minutes.

• Aspen Pinch and Aspen Hetran. You can now use AspenHetran to design or rate a heat exchanger from within theAspen Pinch environment.

These integration enhancements greatly facilitate the workprocesses in the different phases of the engineering lifecycle.AES 10.2 provides a number of features to support the engineeringworkflow in a multi-user engineering environment. For example,Aspen Plus provides support for hierarchical flowsheets and thecapability to pre-configure process flowsheet sections. Thesefeatures enable the development, use, and distribution of pre-engineered and standardized plant sections as templates throughouta company, thereby reducing duplication and enhancingengineering productivity.

IntegratedEngineering

Enhanced Integrationof AES Products

Enhanced WorkflowFeatures


Enhanced Model Deploymentthroughout the EnterpriseConsistent representation of thermodynamic properties is key foraccurate engineering results. AES 10.2 premieres a new product,Aspen Properties. Aspen Properties allows all AES products, aswell as other common engineering tools (such as Excel) to use aconsistent set of property models wherever engineeringcalculations are performed.AES 10.2 features an unprecedented capability for utilizingprocess models throughout the suite. Process models developedusing Excel or Visual Basic can now be used in Aspen Plus andBatch Plus. In addition, Aspen Plus can run models developedusing the Aspen Custom Modeler as part of an Aspen Plussimulation.AES 10.2 takes a major step forward in supporting open standards:Aspen Plus includes new COM interfaces for unit operations andphysical property models based on the CAPE-OPEN interfacestandards. Aspen Properties supports the CAPE-OPEN-basedinterfaces to enable plug-and-play use in process simulators orother applications, such as spreadsheets. Aspen Properties andAspen Plus include interfaces for incorporating external propertymodels that are CAPE-OPEN compliant.In addition, Aspen Dynamics and Aspen Custom Modeler providesupport for OPC to facilitate the deployment of process models inplant operation. Aspen Zyqad supports the pdXi standards tofacilitate data exchange between AES products and third-partyprograms. Finally, Aspen Custom Modeler has a new interfaceallowing users to supply external non-linear algebraic equationsolvers.AES 10.2 takes a first step toward providing support for thedeployment of AES products via the Web. Aspen Propertiesprovides a Web-based property calculator, enabling users access toa subset of the Aspen Properties functionality.

PlantelligenceTM ComplianceAES 10.2 is the first AES release that is compliant withAspenTech’s new Plantelligence™ software. Compliance withPlantelligence ensures that the entire Aspen Engineering Suite hasbeen designed and developed to use the same installation,licensing, and integration framework. In addition to providing anintegration platform for these and other AspenTech tools, it also

Extended PropertiesUsage

Extended ProcessModel Usage

Open StandardsSupport

Web Deployment


ensures that the products are thoroughly tested to work together onthe same computer system.Each of the individual products in AES 10.2 also has substantialfunctionality enhancements. These are described in the remainingchapters of this guide.

Technical SupportWorld Wide Web For additional information about AspenTechproducts and services, check the AspenTech World Wide Webhome page on the Internet at:http://www.aspentech.com/Technical resources AspenTech customers with a valid licenseand software maintenance agreement can register to access theOnline Technical Support Center athttp://support.aspentech.com/This web support site allows you to:• Access current product documentation• Search for tech tips, solutions and frequently asked questions

(FAQs)• Search for and download application examples• Submit and track technical issues• Send suggestions• Report product defects


Registered users can also subscribe to our Technical Support e-Bulletins. These e-Bulletins are used to proactively alert users toimportant technical support information such as:• Technical advisories• Product updates and Service Pack announcementsThe most up-to-date contact information for your nearest supportoffice is also available on AspenTech's web page athttp://support.aspentech.com/The following contact information was current when this productwas released:

If you are located in: Phone Number Fax Number E-Mail Address

North America & theCaribbean

+1-617/949-1021

+1-888/996-7001 (toll free)

+1-617/949-1724 [email protected]

South America (Argentina office)

(Brazil office)

+54-11/4393-5308

+55-11/5012-0321

+54-11/4394-8621

+55-11/5012-4442

[email protected]

[email protected]

Europe, Gulf Region, & Africa (Brussels office)

(UK office)

+32-2/724-0100

+44-1223/312220

+32-2/705-4034

+44-1223/366980

[email protected]

Japan +81-3/3262-1743 +81-3/3262-1744 [email protected]

Asia & Australia(Singapore office)

+65/295-83-30 +65/295-83-25 [email protected]


What's New in AES 10.2 Aspen Properties •••• 2-1

2 Aspen Properties

Aspen Properties is AspenTech's physical property data andanalysis tools. You can use Aspen Properties to prepare a completeproperty package to represent an industrial process for use withAspen Plus, Aspen Dynamics, Aspen Custom Modeler and AspenB-JAC. It is also used to provide rigorous physical properties forBatch Plus.You can use Aspen Properties to estimate a wide range ofproperties from molecular structure, regress parameters fromlaboratory data, and analyze the behavior of chemical andpetroleum systems. You can also use the Aspen Properties ExcelProperty Calculator to develop specialized Excel applications. TheExcel Property Calculator provides rigorous thermodynamic andtransport properties as well as phase equilibrium calculations usingdata you define in Excel.This chapter describes the key capabilities in Aspen Properties10.2.

New CapabilitiesAspen Properties 10.2 is a major new product with key features inthe following areas:1 Standalone application2 Excel property calculator3 Web-based application4 Open systemsThe following sections detail the new features in each of theseareas. Please see the Aspen Properties on-line help for furtherdetails of these new features.

2-2 •••• Aspen Properties What's New in AES 10.2

The standalone Aspen Properties product is a new 32-bit Windowsapplication, which can be run on your desktop PC or can be run asa client/server application. Aspen Properties is based on AspenPlus 10.2. It contains all the physical property capabilities ofAspen Plus, including:• Databanks• Property methods and models• Electrolyte• Reactions• Property estimation• Data regression• Property analysis and table generation• Petroleum assay data analysisAspen Properties can be used in many diverse ways, including:• Perform tasks such as component data look up, and generation

of pure component property tables and plots• Analyze behavior of a system of components, such as phase

equilibrium behavior, azeotrope formation, or residue curvemaps

• Estimate property and parameters from group-contributionmethods

• Regress parameters from laboratory data• Prepare a complete property package to represent the behavior

of a set of components over the conditions relevant to aprocess. The property package can then be used in othermodeling tools such as Batch Plus and Aspen B-JAC.

Aspen Properties can import and export data in the backup fileformat used by Aspen Plus.Aspen Properties 10.2 provides a powerful set of Excel Add-Incapabilities, which allow rigorous thermodynamic, transport andphase-equilibrium calculations using Excel functions. The propertycalculations are defined for a cell using input data such ascomponents, compositions, temperature and pressure, which havebeen defined in other cells.This capability allows specialized engineering models to be builtusing Excel while accessing the rigorous properties provided byAspen Properties.

Standalone AspenPropertiesApplication

Excel PropertyCalculator

What's New in AES 10.2 Aspen Properties •••• 2-3

Aspen Properties 10.2 provides a Web-based property calculator,which consists of a subset of the full capabilities of the standalonedesktop application. The Web-based property calculator has thefollowing features:• Select components• Select property methods• View pure component data• Generate tables and plots of pure component propertiesThe Web-based calculator is a first step in the development of anenterprise-wide property calculation application intended forIntranet deployment. We expect to extend this application toinclude the full capabilities of Aspen Properties in the future.Aspen Properties 10.2 has an open architecture, which allowscomplete flexibility in the customization of property methods,models, and databanks. Aspen Properties also provides support forCOM-based interfaces for physical properties, based on thestandard interfaces developed by the CAPE-OPEN consortium.The COM interfaces provide additional flexibility for developmentand re-use of property models.

Compatibility NotesAspen Properties will be delivered to existing customers ofProperties Plus. There are two key compatibility issues with AspenProperties that affect customers who use the Properties Plustoolkit. These are:Current Properties Plus customers use a license key 110 that has aunique property toolkit number assigned by Aspen Technology.Starting with this version of Aspen Properties, the toolkit numbermust be 400. You will get a 110 license key that has beengenerated with the toolkit number of 400. For your applications,you will need to change your existing toolkit numbers in theProperties Plus initialization routine (PPEXEC_APINIT) to 400.

Web-BasedApplication

Open Systems

Toolkit Number

2-4 •••• Aspen Properties What's New in AES 10.2

The file extensions used by Aspen Properties are different fromthose used in Properties Plus. In particular, when callingPPEXEC_APINIT to initialize Aspen Properties, the new fileextension, aprpdf, must be used for the problem definition file.

File Type File Extension forProperties Plus

File Extension forAspen Properties

Problem Definition Appdf Aprpdf

Document Apw Aprop

Backup Bkp Aprbkp

Input Inp Aprinp

Application Template Apt Aprt

File Extension

What's New in AES 10.2 Aspen OLI •••• 3-1

3 Aspen OLI

Aspen OLI, is a software solution that enables process engineers toquickly and reliably perform process modeling and analysis ofaqueous electrolyte systems within the Aspen Engineering suite.Together with AspenTech’s in-house solids and electrolytesmodeling technology, Aspen OLI provides the chemical processindustries with comprehensive capability to model and designaqueous electrolyte systems over the complete concentration range,including most of the elements in the periodic table. The AspenOLI property method provides accurate results for thethermodynamic and transport properties of aqueous mixtures andassociated immiscible organic mixtures.The significant features of Aspen OLI include:• The chemistry model is automatically and reliably generated

for a broad range of species in water, including a significantfraction of elements in the periodic table.

• The parameter database is comprehensive so that accurateresults are expected for most aqueous applications.

• Many customers, particularly in the R&D and environmentalareas, have relied on the power of the OLI Engine (chemistrygeneration model, thermodynamic framework, and database).Aspen OLI now permits access to the same capabilities to theentire research and engineering community within the powerfuland familiar environment of the Aspen Engineering Suite.

• Aspen OLI is complementary to AspenTech’s in-houseelectrolyte capability. In particular, AspenTech’s in-housecapability is the preferred choice for the following cases:• Highly concentrated electrolytes (xH2O < 0.65) such as

sulfuric acid• Mixed-solvent systems

3-2 •••• Aspen OLI What's New in AES 10.2

• Cases where in-house experts have developed specializedfits of data

• Cases where one of AspenTech’s Electrolytes Insertsapplies

The combination of Aspen OLI and AspenTech’s in-housecapability provides unrivaled electrolyte modeling and simulationcapability to customers of the Aspen Engineering Suite.This chapter describes the new capabilities in Aspen OLI 10.2. Italso summarizes compatibility considerations in migrating fromthe previous version of Aspen OLI, which was delivered by OLISystems, Inc. as part of their software suite.

New CapabilitiesAspen OLI is a major release. Considerable effort was devoted tofixing bugs reported by customers; all known bugs have beenresolved. Special focus was devoted to the following areas:1 New viscosity model2 Flexibility in dealing with salt precipitation3 Consistent installation with the other AES products4 New on-line documentationThe following sections detail the new features in each of theseareas. Please see the Aspen Plus on-line help for further details inusing these Aspen OLI features in Aspen Plus.OLI’s viscosity model has been added to the OLI option set. TheOLI option set now includes OLI’s proprietary models for thethermodynamic properties as well as one transport property(viscosity). The other transport properties in the OLI option set arestandard models in Aspen Properties.The chemistry paragraph for use with the OLI option now permitsflexibility in dealing with precipitation of salts; the salts may betreated as dissociated (that is, no precipitation occurs) or asstandard precipitated salts. These options are available in the OLIsetup program. The options are useful in simulating saltprecipitation in distillation simulations.Aspen OLI is now installed as an integral part of the AspenEngineering suite. In previous versions, Aspen OLI was deliveredas a separate add-on layered product by OLI Systems, Inc.On-line documentation on the use of Aspen OLI within Aspen Plushas been added to the Aspen Plus on-line help.

New Viscosity Model

Flexibility in Dealingwith Salt Precipitation

ConsistentInstallation withOther AES ProductsNew On-LineDocumentation

What's New in AES 10.2 Aspen OLI •••• 3-3

Compatibility NotesThere are no significant compatibility differences between AspenOLI 10.2 and the previous version of the software.

3-4 •••• Aspen OLI What's New in AES 10.2

What's New in AES 10.2 Aspen Plus •••• 4-1

4 Aspen Plus

Aspen Plus is AspenTech's state-of-the-art steady-state simulationsystem that can be used for modeling a variety of industrialprocesses including chemical, petrochemical and refining. AspenPlus contains a comprehensive library of unit operation models andalso allows you to easily plug in proprietary custom models. Inaddition, Aspen Plus provides full Windows® interoperability tofacilitate the process and design engineer’s work processes.Aspen Plus also supports the following layered products:BatchFrac™ is AspenTech’s batch distillation model thatsimulates the operation of a multi-stage batch column. It modelsthe batch distillation process as a series of operation steps.BatchFrac handles all types of column systems, ranging from ideal,highly-nonideal, three-phase and reactive systems.RateFrac™ is AspenTech’s non-equilibrium distillation modelthat simulates the behavior of a distillation column using the rate-based approach. RateFrac is applicable to reactive distillation,absorption, and stripping columns, with a variety of trays andpackings.Aspen Plus 10.2 is an important new release that providessignificant new engineering workflow support and increasedusability. In addition, Aspen Plus 10.2 takes a major step forwardin support of open system standards with the introduction of theCAPE-OPEN consortium’s Unit and Thermo interfaces.This chapter provides an overview of the new capabilities in AspenPlus 10.2. It also summarizes compatibility considerations inmigrating from previous Aspen Plus versions.

4-2 •••• Aspen Plus What's New in AES 10.2

New CapabilitiesAspen Plus 10.2 contains new features in the following areas:• Improved engineering workflow support• Open Systems support• Integration with other products in the Aspen Engineering Suite

(AES)• Engineering capabilities• GUI usabilityThe following sections detail the new features in each of theseareas. Please see the Aspen Plus on-line help for further details ofthese new features.Aspen Plus 10.2 offers several exciting features to provideimproved engineering workflow support.Aspen Plus 10.2 fully supports hierarchical flowsheets to enhanceease-of-use with large flowsheets and support the engineeringworkflow in a multi-user engineering environment. Hierarchyprovides containers for simulation objects and can consist offlowsheet objects (such as streams, unit operation blocks, otherhierarchies, etc.) as well as non-flowsheet objects (such as Design-Spec, Calculator blocks, convergence blocks, etc.). A simulationmay contain up to ten hierarchy levels, each appearing as a singleblock in its parent and each capable of being used as a standalonesimulation by other users. Hierarchies can be nested; multipleProcess Flowsheet windows can be opened to view different partsof the flowsheet concurrently.Aspen Plus 10.2 supports the capability to pre-configure processflowsheet sections, and distribute for re-use as a “template”. Thisfeature enables the use and distribution of pre-engineered andstandardized plant sections as templates throughout a company,thereby reducing duplication and enhancing engineeringproductivity. The flowsheet templating capability in Aspen Plus10.2 builds on the model templating capability delivered withAspen Plus 10.1. Any flowsheet can now be saved in an AspenPlus model library as a single unit operation model; this model canthen be used in any Aspen Plus 10.2 simulation. This flowsheettemplating capability, combined with hierarchy, greatly facilitatesthe creation and analysis of simulations modeling large, complexprocesses.In Aspen Plus 10.2, you can activate and deactivate simulationobjects. This feature allows you to focus on problem areas of asimulation by modifying or converging parts of a flowsheet at atime. You can also use this capability to easily simulate alternative

EngineeringWorkflowHierarchy

Flowsheet Templating

Flowsheet De-activation


process configurations. Simulation objects that can be deactivatedinclude unit operation blocks, streams, convergence blocks, etc.Aspen Plus intelligently deactivates other objects which referencedeactivated blocks or streams. Deactivated objects do not take partin a simulation; they can still be examined and modified.A new unit operation model has been added to allow switchingbetween different inlet streams. The selected inlet stream is copiedto the outlet stream. The stream selector block can be used withmaterial, heat or work streams. You can use the selector blockwhen examining different feed options for a process or analyzingdifferent process configurations.Aspen Plus 10.2 takes a major step forward to supporting opensystems.Aspen Plus 10.2 features an expanded flowsheet Calculator blockthat supplements and replaces the existing Fortran block. Thiscapability allows you to use either an embedded Excel 97spreadsheet in an Aspen Plus flowsheet or in-line Fortran toperform user-defined calculations and then write the results to anyflowsheet variable. With the new Excel option, the Calculatorblock eliminates the need for Aspen Plus users to have knowledgeof Fortran or to have Fortran installed on their computer. TheCalculator supports the full functionality of Microsoft Excel 97,including support for Visual Basic for Applications (VBA).Aspen Plus 10.2 uses the CAPE-OPEN unit operation interfacestandards to provide support for custom unit operation modelsdeveloped using Microsoft Component Object Model (COM)development tools such as Visual Basic, Visual C++ and VisualJ++. This capability allows you to create unit operation models thatare open and portable components and plug them into Aspen Plus.Access to Aspen Plus stream data and thermodynamic propertiesfor the COM models is provided through support for the CAPE-OPEN Thermo interfaces.Aspen Plus 10.2 supports the standards for CAPE-OPENThermodynamic Interfaces. CAPE-OPEN compliant physicalproperty system and property packages can be used in Aspen Plusto perform property calculations. A CAPE-OPEN compliant UnitOperation Model will request all property and phase equilibriumcalculations using the CAPE-OPEN Thermodynamic Interfaces.You can also use Aspen Plus 10.2 to prepare a CAPE-OPENproperty package for use in other applications, such as aspreadsheet, an in-house program, or another process simulatorwhich is CAPE-OPEN compliant.

Stream Selector

Open Systems

Calculator

CAPE-OPEN UnitOperation Interfaces

CAPE-OPENThermodynamicInterfaces


Aspen Plus 10.2 has implemented a COM Interface and methodsfor updating pseudocomponent characterization parameters andpetroleum properties during the simulation. This feature isimportant in modeling petroleum refining reactor units. Typicallypseudocomponents in a reactor effluent undergo changes whichneed to be reflected in their characterization parameters andpetroleum properties. You can use this capability within a CAPE-OPEN model to manipulate the characterization parameters ofpseudocomponents and the petroleum properties of the outletstreams of a CAPE-OPEN block.Interfaces and methods have been added or enhanced in thefollowing areas to improve the usability of running Aspen Plusfrom external applications using the OLE automation server:• The Automation server now supports an outgoing dispatch

interface that provides events to support control panelmessages, warning messages, and data changes.

• Most warning messages and option dialogs can be suppressedwhen running Aspen Plus 10.2 as an automation server.

• All file formats available from the File/Export dialog are nowavailable for export through automation

• Selective User Interface Menu items and their hot keys can bedisabled with an automation method.

• An ActiveX interface has been added to Aspen Plus 10.2 toallow selection and manipulation of user model libraries for asimulation problem.

• Full access to the flowsheet, including flowsheet connectivity,is now possible through OLE Automation. Using thiscapability, you can construct a simulation from scratch usingVisual Basic, Excel VBA, or a C/C++ program.

Aspen Plus 10.2 provides enhanced integration with other AESproducts.A steady-state simulation can be exported from Aspen CustomModeler (ACM) 10.2 and used as a custom unit operation in AspenPlus 10.2. This feature allows you to easily develop custom modelsusing the ACM modeling language and deploy them in Aspen Plussimulations. ACM compiles the model to a dynamic link library(DLL) and generates an Aspen Plus User Model Library (.apm)file to allow the simulation to be available as a unit operation in theAspen Plus Model Library. Selected input and result variables canbe defined in ACM for presentation on Aspen Plus forms.Aspen Plus 10.2 calculates mixture properties when there aremultiple feeds to a block. The Aspen Pinch interface will thenuse these mixture properties rather than performing the stream

COM Interfaces for OilCharacterization andBlending

OLE AutomationInterfaces and Methods

Integration with AESProductsIntegration with AspenCustom Modeler

Integration with AspenPinch


mixing itself. This feature is useful when you have distillationmodels with interheaters or intercoolers or feeds to condensers orreboilers where the heating or cooling curve is non-linear. You canactivate this feature on the Startup tab of the Tools/Options menuin the Aspen Plus User Interface.Aspen Split™ is AspenTech’s state-of-the-art software for thesynthesis and conceptual design of distillation processes. A newanalysis component in Aspen Split 10.2 enables the user to:• Locate all the azeotropes (homogeneous and heterogeneous)

present in any multicomponent mixture• Automatically compute distillation boundaries and residue

curve maps for ternary mixtures• Compute multiple liquid phase envelopes (liquid-liquid and

vapor-liquid-liquid) for ternary mixturesThis new Aspen Split component has been fully integrated withAspen Plus 10.2 so that these powerful analyses can be performeddirectly in the flowsheeting environment. The results can then beused to:• Assess separation feasibility in azeotropic mixtures• Synthesize feasible separation sequences for achieving a

desired separation• Develop strategies for retrofit of existing separation sequences• Identify potential operating problems for distillation columns

and strategies for correcting themThe Aspen Split analyses can be launched directly from the AspenPlus Tools menu.Aspen OLI enables process engineers to quickly and reliablymodel aqueous electrolyte systems by providing an interfacebetween Aspen Plus and the thermodynamic framework anddatabase for aqueous electrolytes developed by OLI Systems, Inc.Aspen OLI has been fully integrated into the Aspen EngineeringSuite.OLI’s viscosity model has been added to the OLI option set inAspen Plus 10.2. The OLI option set now includes OLI’sproprietary models for the thermodynamic properties as well asone transport property (viscosity). In addition, the chemistryparagraph for use with the OLI option set permits flexibility indealing with precipitation of salts; the salts may be treated asdissociated or as standard precipitated salts.

Integration with AspenSplit

Integration with AspenOLI


Aspen Plus 10.2 contains new features in the HeatX model and anew vapor phase association model.The Shortcut option in the HeatX model will now calculate anLMTD correction factor for multiple-tube-pass heat exchangersand a number of identical single shell-passes in series. You willneed to supply the number of shells in series. The heat transfercoefficient will be taken as identical for each shell.A new Vapor Phase Association (VPA) model of IK-CAPE (aconsortium of German companies which cooperate to define keystandard property models and data exchange format for use inComputer-Aided Process Engineering) has been added to AspenPlus. This VPA model is more general than the existing vaporphase association models, such as the Nothnagel, Hayden-O’Connell, and Hydrogen Fluoride (HF) hexamerization models.The new VPA model can account for the formation of dimers,trimers, and hexamers.Aspen Plus 10.2 contains several new features to improve theusability of the Aspen Plus User Interface. Some of them are:• You can now disable a warning message when saving

simulations in bkp format. The warning message indicates thatbkp format does not support restart.

• When connecting to the Simulation Engine, the Connect OKmessage box that appeared before the simulation was openedhas been removed.

• A “Purge Messages” button has been added to the ControlPanel. This feature can be used to reduce the size of the AspenPlus Document (.apw) file, for very large simulations, bypurging the Control Panel messages without re-initializing thesimulation.

• Time stamps that are inserted in the Process Flowsheet andPlots can now be optionally inserted as symbols, rather than astext strings. This will allow the time stamps to be updatedautomatically, based on the current date, time, run ID, version,and user.

• The user can now control the line thickness in the ProcessFlowsheet drawing.

• Improvements have been made to reduce the automatic streamrouting that is done when a connected block is moved in theProcess Flowsheet. If possible, only the last leg of the streamwill be adjusted.

EngineeringCapabilitiesLMTD Correction Factorfor HeatX

Physical Properties

GUI Usability


Compatibility NotesThis section describes the differences that you might encounterbetween Aspen Plus 10.2 and Aspen Plus 10.1. In almost all cases,previous Aspen Plus input files and backup files are completelycompatible with Aspen Plus 10.2. AspenTech makes every effortto avoid making changes that result in incompatibilities withprevious versions. The changes discussed in this section werenecessary to correct problems, to implement new features, or toimprove ease-of-use.The most important areas where you might encounter differencesbetween Aspen Plus 10.2 and Aspen Plus 10.1 are:When you save a simulation as an Aspen Plus Document (.apw)file, the default behavior on installation has been changed to alsosave the simulation as an Aspen Plus Backup (.bkp) file. This wasdone since the .bkp files are saved in ASCII format that iscompatible across versions of Aspen Plus. You can change thedefault behavior by selecting the Tool/Options menu item and un-checking Always Create A Backup Copy on the General tab.

Important: When you save a simulation as an .apw file, the .bkpfile is saved in the same directory. If you want to save a previousversion of the .bkp file for a simulation, rename it or move it toanother directory.

The Subflowsheet block from Aspen Plus 10.1 is no longersupported in Aspen Plus. This capability has been replaced andenhanced by the Hierarchy block. If you have used theSubflowsheet block for simulations, you will need to delete theSubflowsheet block and save the bkp file in Aspen Plus 10.1. Youcan then open the bkp file in Aspen Plus 10.2 and use theHierarchy block to build flowsheets with a hierarchical structure.The built-in Valve Library has been corrected to display the valvefactors correctly. The pressure drop ratio factor (Xt) and pressurerecovery factor (Fl) data were juxtaposed in the previous versionsof Aspen Plus. If you used a valve from the built-in Valve Libraryin your simulation, you should open the simulation and re-selectthe valve from the built-in Library. This will likely cause somechanges in the results of your simulation.Aspen Dynamics™, Aspen Zyqad™, and Aspen Plus’ SummaryFile Toolkit do not currently support flowsheet hierarchies.Simulations run in Aspen Plus 10.2 will still work properly inAspen Dynamics, Aspen Zyqad, and the Summary File Toolkit aslong as the Aspen Plus flowsheet does not contain any Hierarchy

Saving Simulations

Subflowsheet Block

Valve Model

Flowsheet Hierarchy


blocks. The Aspen Engineering Suite will fully support flowsheethierarchies in the future.The following are some of the changes and bug-fixes in thePhysical Property system that may lead to differences in resultswith previous Aspen Plus versions:• Binary parameters for the Wilson, NRTL, and UNIQUAC

models have been revised for 24 systems. Parameters for 14systems have also been added. The revision was part of thesystematic review of built-in binary parameters to removeunreasonable parameters, which produce incorrect phasediagrams, such as false azeotropes. See lists of systems withnew and revised binary parameters at the end of this chapter.

• Corrected usage of the Pitzer ternary parameters (GMPTPS)• Corrected the temperature used to compute the RT term in the

solubility parameter (DELTA) estimation method. Thetemperature should be 25 C if the critical temperature is above25 C, and should be the normal boiling point, if the criticaltemperature is below 25 C. Estimated DELTA can be different.This change can affect the results of the Scatchard-Hildebrandactivity coefficient model, and the results of property methodsthat use the Scatchard-Hildebrand model, e.g. Chao-Seader andGrayson-Streed property methods.

• Fixed UNIFAC group definition for trans-2-butene inASPENPCD, PURE10, PURE93 and PURE856 databanks.

• Corrected UNIFAC R and Q parameters for groups 2000 and2450

• Corrected UNIFAC group interaction parameters for 10 pairs.Corrections were made for consistency with published data.

• Fixed incorrect name for component therminol 60 in the UserInterface. Changed name from THERMINOL-66 toTHERMINOL-60.

• Fixed incorrect calculation of compressibility factor (Z andZMX) in the HF model

The true molecular weight parameter (TRUEMW) can no longerbe entered as PROP-DATA. This parameter was not intended foruse by the users of Aspen Plus but rather to be used as private databy Polymers Plus models. You will need to remove this parameterfrom any input files that contain it.

Physical Properties


Some of the potential compatibility issues when using the OLEAutomation interface in Aspen Plus 10.2 are:• The name of the node for Fortran blocks has changed to

“Calculator” to be consistent with new Calculator functionality.Any references to “Fortran” nodes for OLE Automation orVBA should be changed to “Calculator”.

• The method IHapp::Restore() has been deprecated and replacedwith Happ::Restore2().

• The updated version of the ActiveX Automation type library,supplied with Aspen Plus 10.2, is 1.3, “ASPEN PLUS GUI10.2 Type Library”. Version 1.3 is backward compatible withversion 1.1; any client program compiled against version 1.1will run with version 1.3. Recompiling client programs writtenfor version 1.1 using version 1.3 may require somemodifications. Existing programs that are to be recompiledshould also be checked for any deprecated interfaces.

Fortran error handling has been implemented in the Windowsversion of Aspen Plus for the first time in Aspen Plus 10.2. Thisbehavior is consistent with previous versions of Aspen Plus onnon-Windows platforms, but may result in differences in thebehavior of certain simulations compared to that in previousversions of Aspen Plus on Windows:• Fortran error messages (for instance, division by zero) which

were not tracked and logged in the history file in earlierversions may appear in the control panel and history file.

• Aspen Plus will now terminate execution when a number ofFortran errors (by default, 100) occur while performingcalculations for a single block. This default value can bechanged using the Maximum number of Fortran errors field onthe Setup/Simulation Options/Limits sheet.

OLE AutomationMethods

Fortran ErrorHandling


Alias 1 Alias 2 Name 1 Name 2 CommentC2H4O2-1 C6H14-1 ACETIC-ACID N-HEXANE new

C4H6O2-D5 C8H14O2 METHACRYLIC-ACID N-BUTYL-METHACRYLATE new

C2H4CL2-2 C4H6O2-D5 1,2-DICHLOROETHANE METHACRYLIC-ACID new

CH2O2 C8H10-3 FORMIC-ACID P-XYLENE new, based onLLE data

C4H6O2-B1 H2O 2,3-BUTANEDIONE WATER new, based onLLE data

C4H10O2-D4 H2O 2-ETHOXYETHANOL WATER new, based onLLE data

C4H10O2-D4 C4H6O-D1 2-ETHOXYETHANOL TRANS-CROTONALDEHYDE new

C6H7N-D1 C6H12O3-D2 2-METHYLPYRIDINE PARALDEHYDE new

C7H8 C4H6O-D1 TOLUENE TRANS-CROTONALDEHYDE new

C10H22-1 C6H14O3-D1 N-DECANE DIETHYLENE-GLYCOL-DIMETHYL-ETHER new

C6H14O-D1 C4H10O2 DI-N-PROPYL-ETHER 1,2-DIMETHOXYETHANE new

C8H18O C5H8-6 DI-TERT-BUTYL-ETHER 2-METHYL-1,3-BUTADIENE new

CH3NO2 C2CL3F3 NITROMETHANE 1,2,2-TRICHLORO-1,1,2-TRIFLUOROE new

C8H12O4-E2 C5H10O2-3 DIETHYL-MALEATE N-PROPYL-ACETATE new

New BinaryParameter Systems


Alias 1 Alias 2 Name 1 Name 2 CommentC2H4O2-1 C10H22-1 ACETIC-ACID N-DECANE

C5H10O2-D1 CH2O2 N-BUTYL-FORMATE FORMIC-ACID

C4H8O2-1 C8H10-2 N-BUTYRIC-ACID M-XYLENE

C5H10O-B2 H2O 2-METHYL-3-BUTEN-2-OL WATER Revised based onLLE data

C5H11N H2O PIPERIDINE WATER

C6H15N-2 H2O TRIETHYLAMINE WATER

C8H16-16 C5H10O-1 1-OCTENE VALERALDEHYDE

C4H8O2-2 C4H10O-3 1,4-DIOXANE ISOBUTANOL

C6H12O-1 C6H10O CYCLOHEXANOL CYCLOHEXANONE

C6H10O C6H11NO-D1 CYCLOHEXANONE CYCLOHEXANONE-OXIME

C7H14-7 C4H8O-3 1-HEPTENE METHYL-ETHYL-KETONE

C3H6O-2 C4H10O-2 ALLYL-ALCOHOL 2-BUTANOL

C12H24-2 C9H20O-D2 1-DODECENE 1-NONANOL

C8H10-4 C4H10O-3 ETHYLBENZENE ISOBUTANOL

C2H6O2 C7H13NO-B3 ETHYLENE-GLYCOL N-METHYL-6-CAPROLACTAM

C9H12-2 C5H12O-2 ISOPROPYLBENZENE 2-METHYL-1-BUTANOL

C8H16O4-B1 C6H14O4 TRIETHYLEN-GLYCOL--MONOVINYL-ETHER TRIETHYLENE-GLYCOL

C7H13NO-B3 C10H12 N-METHYL-6-CAPROLACTAM 1,2,3,4-TETRAHYDRONAPHTHALENE

C6H12-3 C6H10-E2 1-HEXENE 1-HEXYNE

C3H5BR-B1 C6H12-3 3-BROMO-1-PROPENE 1-HEXENE

C4H7N C7H14-6 BUTYRONITRILE METHYLCYCLOHEXANE

C7H16-1 C8H18-13 N-HEPTANE 2,2,4-TRIMETHYLPENTANE

C8H18O-1 C10H22O 1-OCTANOL 1-DECANOL

C8H8 C9H12-1 STYRENE N-PROPYLBENZENE

Revised BinaryParameter Systems


What's New in AES 10.2 Aspen Dynamics •••• 5-1

5 Aspen Dynamics

Aspen Dynamics is AspenTech's easy-to-use dynamic modelingtool for plant operations and process design. It enables users tostudy and understand the dynamics of real plant operations,thereby achieving increased operability, safety and productivity.Aspen Dynamics is closely integrated with other AspenTechproducts. With Aspen Dynamics you can transform an Aspen Plussteady-state simulation into a rigorous dynamic simulation within afew minutes. You can also use Aspen Custom Modeler tocustomize the Aspen Dynamics models.This chapter describes the new capabilities in Aspen Dynamics10.2. It also summarizes compatibility considerations in migratingfrom previous Aspen Dynamics versions.

New CapabilitiesAspen Dynamics 10.2 contains new features in the following areas:• Integration with Polymers Plus• Estimation of kinetic parameters using calorimeter results• Support for pump performance curves• Petroleum property calculations• Increased model robustness• Other model enhancements• On-line links using OLE for process control (OPC)• Streamlined Snapshots and Use• Automatic DMCplus® model generationThe following sections detail the new features in each of theseareas. Please see the Aspen Dynamics on-line help for furtherdetails of these new features.

5-2 •••• Aspen Dynamics What's New in AES 10.2

You can now use Aspen Dynamics to create rigorous dynamicsimulations from steady state simulations that you have createdusing Aspen Plus and Polymers Plus. This represents a major stepforward in ease of use for dynamic simulation of polymerprocesses.A new model is included for use in estimating kinetic parametersusing results from reaction calorimeter experiments.In the Pump model, support for the existing Aspen Plus pumpperformance curve capability has been added. In addition a defaultcurve is used when none is specified in Aspen Plus. Thisdevelopment increases both the realism and robustness of dynamicsimulations.Support for the calculation of selected petroleum properties hasbeen added to the Stream Sensor.A number of changes have been made to fine tune both the modelsand the flash algorithms that they use. These are designed toimprove robustness, particularly in simulations that move througha wide range of operations, such as simulation of start-up and shut-down.A number of models have been enhanced:• The option to select Constant Temperature or LMTD heat

transfer options when using instantaneous dynamics has beenadded to the Flash2, Flash3 and Heater models.

• A global switch for liquid head calculations has been added.This enables you to switch on calculations for the effect ofliquid head in a vessel on liquid outlet pressure for all blocks inthe flowsheet.

• The liquid level controllers that are added automatically whenyou create the dynamic simulations now manipulate mass flowinstead of molar flow.

OPC is a Windows based standard for communicating with processcontrol systems. Many control vendors and third parties supplyOPC servers. Aspen Dynamics 10.2 is an OPC client. This enablesAspen Dynamics to exchange data with any control system orother application that has an OPC server, without the need for anycustom interface programming. This capability can be used to helpbuild applications for:• Training• Inferential measurement and state estimation• Dynamic look-ahead models which are automatically

initialized from current plant conditions

Integration withPolymers Plus

Estimation of KineticParametersSupport for PumpPerformance Curves

Petroleum PropertyCalculationsIncreased ModelRobustness

Other ModelEnhancements

On-line Links UsingOLE for ProcessControl (OPC)

What's New in AES 10.2 Aspen Dynamics •••• 5-3

A number of changes have been made to simplify the use ofSnapshots, and the Use environment. These include:• Integration of the Use and Snapshots dialogs• A single list of all available Snapshots and Results• Ability to specify which snapshots are savedThe existing integration between Aspen Dynamics and DMCplus®

has been further extended to allow automatic creation of aDMCplus linear model (.mdl file) from an Aspen Dynamics non-linear dynamic model. This removes the need to perform steptesting on the model. The DMCplus linear model can then be usedto develop a DMCplus controller. This approach does not removethe need for plant step testing, but can be used for applicationssuch as:• Benefits studies to predict the benefits from using a DMCplus

controller• Testing alternative combinations of dependent and independent

variables for the DMCplus controller• Training staff in the development and use of DMCplus

controllers

Compatibility NotesAspen Dynamics Language (.dynf) files generated using AspenDynamics 10.0 and 10.1 are compatible with Aspen Dynamics10.2, and do not need to be re-exported from Aspen Plus. You maysee some warning messages when loading an Aspen Dynamics10.0 or 10.1 .dynf file into Aspen Dynamics 10.2. This is a resultof improvements to some of the Aspen Dynamics models, andshould not be cause for concern.Aspen Dynamics Document (.dynd) files exported from previousreleases of Aspen Dynamics cannot be loaded in Aspen Dynamics10.2. Please load these files into the previous release and exportthem as .dynf files, which can then be loaded into Aspen Dynamics10.2.This version can be installed and used at the same time as AspenDynamics Version 10.1.Aspen Dynamics 10.2 is compatible with Aspen Plus 10.2. AspenDynamics 10.2 is not compatible with earlier versions of AspenPlus.An .appdf file is created when you export a dynamic simulationfrom Aspen Plus. This contains all of the physical property

StreamlinedSnapshots and Use

Automatic DMCplusModel Generation

.dynf Files

.dynd Files

Coexistence withAspen Dynamics 10.1Compatibility withAspen Plus

5-4 •••• Aspen Dynamics What's New in AES 10.2

information required for the dynamic simulation. The .appdf filesare not compatible between different versions of Aspen Plus.If you try to load a physical properties file (.appdf) which wasgenerated using an earlier version of Aspen Plus you will get thefollowing error:SAIPIN-F-Error in APPDF file handling.Please refer to the Properties Plus errormessages first or it may be due to anincompatible APPDF file version.

After you receive this error you will need to exit Aspen Dynamicsbefore you can load any further simulations.To continue you must regenerate the .appdf file using Aspen Plus10.2. To do this:1 Make a copy of your .dynf file.2 Load the simulation backup file into Aspen Plus 10.2.3 Run the simulation.4 Export the dynamic simulation.5 Delete the .dynf file created and replace it with your saved

copy.

What's New in AES 10.2 Aspen Custom Modeler •••• 6-1

6 Aspen Custom Modeler

Aspen Custom Modeler (ACM) is an easy-to-use tool for creating,editing and re-using models of process units. You build simulationapplications by combining these models on a graphical flowsheet.Models can use inheritance and hierarchy and can be re-useddirectly or built into libraries for distribution and use. Dynamic,steady-state, parameter estimation and optimization simulations aresolved in an equation-based manner which provides flexibility andpower.ACM uses an object-oriented modeling language, editors for iconsand tasks, and Microsoft Visual Basic for scripts. ACM iscustomizable and has extensive automation features, making itsimple to combine with other products such as Microsoft Excel andVisual Basic. This allows you to build complete applications fornon-experts to use.This chapter describes the new capabilities in ACM 10.2. It alsosummarizes compatibility considerations in migrating from earlierversions.

New CapabilitiesACM 10.2 contains new features in the following areas:• Easier formulation of PDE models• Extensions to dynamic optimization• Parameter estimation GUI and other extensions• On-line links using OLE for process control (OPC)• Streamlined Snapshots and Use• Automatic DMCplus model generation• Open non-linear algebraic equation solver interface

6-2 •••• Aspen Custom Modeler What's New in AES 10.2

The following sections detail the new features in each of theseareas. Please see the Aspen Custom Modeler on-line help forfurther details of these new features.This new capability supports easy formulation of models solvingpartial differential equations (PDEs) in 1, 2, or 3 dimensions, usingeither rectangular or polar coordinates.The available discretization methods are:• 4th order Central finite differences (CFD4)• 1st order Backward finite differences (BFD1)• 4th order Upwind-biased finite differences (UBFD4)• 2nd order Orthogonal collocation on finite elements (OCFE2)• 4th order Orthogonal collocation on finite elements (OCFE4)You can use different discretization methods in differentdimensions, e.g. a collocation method for the radial direction in areactor, and a finite difference method for the axial direction. Nodespacing can be either constant or variable. It is very easy to switchbetween different discretization methods to see which is best suitedto your application.The new features added to the existing dynamic optimizationcapabilities are:• Minimization of final time• Option of variable control element sizes• Option of piecewise linear control elements - control variable

values are linearly interpolated between control elements• Option to restrict maximum move of control variable between

elements• Final time equality constraints• Easier formulation of inequality constraints using >=, <=

operatorsACM 10.2 features a full GUI for steady state and dynamicestimation, and data reconciliation. This GUI supports:• Easy entry of experimental data• Selection of run options• Display of results, including comparison of measurements and

fitted valuesA Maximum Likelihood estimation option has been added to theexisting least squares option.Additional statistics are provided, including confidence intervalsfor estimated parameters, and F-values for use in comparingdifferent models.

Easier Formulation ofPDE Models

Extensions toDynamicOptimization

Parameter EstimationGUI and OtherExtensions

What's New in AES 10.2 Aspen Custom Modeler •••• 6-3

OPC is a Windows based standard for communicating with processcontrol systems. Many control vendors and third parties supplyOPC servers. ACM 10.2 is an OPC client. This enables ACM toexchange data with any control system or other application that hasan OPC server, without the need for any custom interfaceprogramming. This capability can be used to help buildapplications for:• Training• Inferential measurement and state estimation• Dynamic look-ahead models which are automatically

initialized from current plant conditionsA number of changes have been made to simplify the use ofSnapshots, and the Use environment. These include:• Integration of the Use and Snapshots dialogs• A single list of all available Snapshots and Results• Ability to specify which snapshots are savedThe existing integration between ACM and DMCplus has beenfurther extended to allow automatic creation of a DMCplus linearmodel (.mdl file) from an ACM non-linear dynamic model. Thisremoves the need to perform step testing on the model. TheDMCplus linear model can then be used to develop a DMCpluscontroller. This approach does not remove the need for plant steptesting, but can be used for applications such as:• Benefits studies to predict the benefits from using a DMCplus



controllersThis interface enables users to add their own preferred non-linearalgebraic equation solver to those already built into ACM.

Compatibility NotesAspen Custom Modeler Language (.acmf) files generated usingAspen Custom Modeler 10.0 and 10.1 are compatible with ACM10.2.Aspen Custom Modeler Document (.dynd) files exported fromprevious releases of ACM cannot be loaded in ACM 10.2. Pleaseload these files into the previous release and export them as .acmffiles, which can then be loaded into ACM 10.2.




Open Non-linearAlgebraic EquationSolver Interface

.acmf Files

.dynd Files

6-4 •••• Aspen Custom Modeler What's New in AES 10.2

If you used the dynamic optimization capability in ACM 10.1, youmay need to make some small changes to your input file to use it inACM 10.2. Please see the help topic. Upgrading from ACM 10.0or ACM 10.1 for more details.This version can be installed and used at the same time as ACM10.1.If you are using Properties Plus with ACM 10.2, you must useAspen Plus 10.2. ACM 10.2 is not compatible with earlier versionsof Aspen Plus.Physical properties files (.appdf) created with earlier versions ofAspen Plus cannot be used with ACM 10.2. If you try to load an.appdf which was generated using an earlier version of Aspen Plusyou will get the following error:SAIPIN-F-Error in APPDF file handling.Please refer to the Properties Plus errormessages first or it may be due to anincompatible APPDF file version.

After you receive this error you will need to exit Aspen CustomModeler before you can load any further simulations. You mustregenerate the .appdf file using Aspen Plus 10.2.

DynamicOptimization

Coexistence withACM 10.1Compatibility withAspen Plus

What's New in AES 10.2 Aspen B-JAC •••• 7-1

7 Aspen B-JAC

Aspen B-JAC is a suite of integrated programs for the thermal andmechanical design of process heat exchangers. The Aspen B-JACprograms are used to evaluate design alternatives, minimize capitalcosts, and expedite heat exchanger fabrication. Together withAspen Plus process simulator and Aspen Pinch network analysis,the Aspen B-JAC programs help companies reduce operatingcosts, minimize process downtime, and utilize process resourcesmore effectively. Aspen B-JAC uses its own physical propertydatabanks for chemical compounds and materials of constructionas well as the Aspen Properties databanks.B-JAC consists of 3 programs:Aspen Hetran is a software tool for the thermal design, rating, andsimulation of shell and tube heat exchangers. It covers all majorindustrial shell and tube heat exchanger types and applicationsincluding single phase, condensation, and vaporization. AspenHetran can be used as a stand-alone program for the analysis ofindividual exchangers. In addition, it is integrated with the AspenPlus simulator and the Aspen Pinch network analysis tools toenable the detailed analysis of exchangers in a process flowsheet.Aspen Aerotran is a software tool for the thermal design, rating,and simulation of air-cooled heat exchangers, economizers and theconvection section of fired heaters. It covers heat exchangersconsisting of a rectangular tube bank with gas flowing across theoutside of the tubes. It can design air-coolers and economizers forsingle phase, condensation, and vaporization. Aspen Aerotran canbe used as a stand-alone program for the analysis of individualexchangers. In addition, it is integrated with the Aspen Plussimulator to enable the detailed analysis of exchangers in a processflowsheet.Aspen Teams is a software tool for the complete mechanicaldesign and rating of shell and tube heat exchangers and basicpressure vessels. It covers a wide range of construction alternatives

Aspen Hetran

Aspen Aerotran

Aspen Teams

7-2 •••• Aspen B-JAC What's New in AES 10.2

including most types of heads, flanges, nozzles, and expansionjoints. Aspen Teams conforms to the TEMA standards andinternational mechanical engineering codes including ASME,CODAP, and AD Merkblatter. In design mode, Aspen Teamsdetermines the optimum dimensions for all components based onthe specified design conditions. In rating mode, Aspen Teamschecks the specified dimensions of each component for compliancewith the applicable codes and standards.This chapter describes the new capabilities in the Aspen B-JACprograms. It also summarizes compatibility considerations inmigrating from previous B-JAC versions.

New CapabilitiesAspen B-JAC 10.2 contains new features in the following areas:• User interface• Aspen Hetran• Aspen Teams• Aspen AerotranThe following sections detail the new features in each of theseareas. Please see B-JAC on-line help for further details of thesenew features.User interface enhancements include the following:New customization features for the program printout have beenadded. You can now define the heading format to appear on eachpage of output. Items such as date, time, filename, page numbers,or customized heading lines containing the company name andaddress can now be specified.Input summaries can now be printed or viewed regardless ofwhether the calculation program has been executed successfully.Previous versions would not allow printing or viewing thesummary until the program had been executed successfully.Added the capability to permit you to construct lists of frequentlyused construction materials or chemical compounds. These listswould contain only those materials or compounds typically used inyour work. These lists can be accessed from the databank searchutilities and will make specification of construction materials andchemical compounds quicker and easier. A utility has beenprovided under “Tools – Data Maintenance – Frequently usedmaterials” and “Tools – Data Maintenance – Frequently usedchemical compounds”.

User InterfaceCustomization of Reports

Input Summaries

User Defined ChemicalCompound and Materialsof Construction Lists


Added the capability to toggle between insert mode and overwritemode using the “insert” key for all B-JAC input fields.Redesigned the cost database maintenance utility to make it moreuser-friendly and to comply with the standard guidelinesestablished for the other user interfaces.Aspen Hetran enhancements include the following:Aspen Hetran now has an interface to Aspen Pinch. AspenHetran’s rigorous heat exchanger analysis techniques can be usedto design or simulate the exchanger. This capability extendsbeyond the interface currently available for Aspen Plus in that youcan also design the heat exchanger from within Aspen Pinch. Anabbreviated set of design constraints can be specified from withinAspen Pinch and fed to the Hetran program running in designmode. The Hetran program will establish a Hetran input file,design the exchanger, and set the resulting design geometry in theHetran input file. Subsequent calls to Hetran will use this geometryfor a simulation analysis of the exchanger.Added a new program mode to Aspen Hetran. The “Select fromstandard table” mode allows you to specify a predefined table ofexchanger configurations from which Aspen Hetran can select theoptimum design. This feature is very useful for designers whomust select designs from a series of standard configurations.A utility has been provided under “Tools – Data Maintenance –Heat Exchanger Standards” to allow you to define any number ofstandard heat exchanger configurations which could be evaluated.You can specify the standard rating parameters such as shell ID,OD, tube passes, tube number, baffle spacing, tube length, etc. aswell as different head types, shell types, baffle types, tube patterns,tube pitches, and tube ODs.You may create one or more standard files, which can be specifiedin the Aspen Hetran input. Aspen Hetran evaluates each exchangerin the specified standard file. If an exchanger meets the specifiedphysical design constraints, Aspen Hetran will determine itsthermal and hydraulic performance for the given application.Aspen Hetran will then select the optimum price exchanger thatmeets all process design constraints.Added detailed thermosiphon piping specification to the Hetranprogram. The actual pipe inside diameter, horizontal length,vertical length, number/type of elbows, and valve types can now bespecified for the inlet and outlet piping. For shell sidethermosiphons using the TEMA J, H, or X type shells with amanifold, the manifold inside diameter can also be specified. Youstill have the option of using the program default piping or specifyequivalent piping lengths for both inlet and outlet piping.

“Insert” key Usage

Aspen HetranInterface to Aspen Pinch

“Select from StandardTable” Design Mode

Thermosiphon PipingSpecification Options


However, if the piping inside diameter and any actual pipe lengthsare specified, they will override any equivalent piping lengthsspecified.The 1999 Addenda of the ASME Boiler and Pressure Vessel CodeSection II Part D Properties of Materials has been incorporated intoAspen Hetran. In this addenda the allowable stress calculationfactor has been changed from 4.0 to 3.5 for many materials. Thischange has resulted in approximately 15% higher allowablestresses, which in turn allows the designer to use thinner and lessexpensive equipment components.The new TEMA 1999 eighth edition standards have beenincorporated into Aspen Hetran. The most significant changeaffecting Aspen Hetran are the revisions to the vibration analysis.New vibration analysis criteria have been added and a number ofrevisions have been made to the previously published methods.The vibration analysis output has been expanded to include thesenew parameters.Improved the tube costing correlations for enhanced tubing. Thecosting correlation will provide an improved basis for comparingalternative designs. However detailed costing of enhanced tubingshould always be obtained from the manufacturer.Added logic to determine which components should be consideredas non-condensables for the mass transfer analysis when the AspenProperties interface is used. Aspen Hetran now extracts thosecomponents defined as Henry components within Aspen Plus andconsider them as non-condensables. Previous Aspen Hetranversion did not attempt to make this distinction and programresults would have been conservative.Revised logic for determining which components should beconsidered non-condensables when B-JAC vapor-liquid-equilibrium calculations are selected. Aspen Hetran now evaluatesthe amount of each component that has condensed at the inlettemperature of the cold side to determine if the component shouldbe considered as a non-condensable.The shell/bundle entrance and exit area calculations have beenrevised to conform to the TEMA 1999 eighth edition standards.This change may result in a different shell side velocity, RhoV2,and pressure drop for these areas. Most likely candidates forsignificant changes in results are very large nozzles with respect tothe shell size.Added the capability to specify the stream diffusivity for complexcondensation applications in which the condensing curve isspecified in the input. Previous versions estimated the diffusivityfrom other stream properties. The stream diffusivity is an

The 1999 Addenda of theASME Boiler andPressure Vessel CodeSection II Part DProperties of Materials

TEMA 1999 EighthEdition Standards

Enhanced TubingCosting Correlations

Non-condensableComponents in AspenProperties Interface

Non-condensableComponentDetermination

Bundle Entrance/ExitArea Calculations

Stream Diffusivity forComplex Condensation


important parameter used in the mass transfer analysis and somein-house vapor-liquid equilibrium programs provide it in theiroutput.Added the capability to adjust vaporization curves for pressurewhen the inlet pressure on the cold side is specified. Since thepressure is reduced along the length of the exchanger fromentrance to exit, the bubble point in the exchanger will besomewhat lower than that specified at the inlet pressure. As thepressure continues to drop, the stream will begin to flash. If this isconsidered, the calculated MTD may be somewhat higher,resulting in lower heat transfer area requirements. This optionshould be used with some caution however since two-phasepressure drop correlations are not 100% accurate.Added the capability to specify the number of design iterationsAspen Hetran attempts prior to stopping and asking if optimizationshould continue. Aspen Hetran now defaults to 30 for themaximum number of iterations.Changed the default setting for the allowable pressure drop forfalling film exchanger. Aspen Hetran now uses the specifiedallowable pressure drop to design the unit. The previous AspenHetran version selected an allowable pressure drop based on theoperating pressure on the tube side.Added a warning message to indicate that shell side nozzleslocated on the sides of the exchanger have been moved to eitherthe top or bottom of the exchanger. This will occur whenimpingement protection is specified for nozzles placed on the sideof exchanger. Currently, Aspen Hetran cannot accommodateremoving tubes for an impingement plate on just one side of theexchanger. To provide a reasonable answer, Aspen Hetran nowmoves these nozzles to either the top or bottom of the exchangerwhere tubes can be removed on just one side. Additional programrevisions must be made to accommodate tube removal on just oneside of the exchanger.Added an error message if falling film vaporization is specified forthe shell side of the exchanger. This is not a validapplication/equipment arrangement for Aspen Hetran at this time.Added error messages if the specified allowable pressure drop isgreater than the operating pressure for the shell or tube side of theexchanger. The previous Aspen Hetran version only checked thisinconsistency for complex condensation applications.

Vaporization CurvesAdjusted for Pressure

Control Number ofDesign Iterations

Falling Film AllowablePressure Drop

Shell Side NozzlePlacement

New Error Messages


Aspen Teams enhancements include the following:The 1999 Addenda of the ASME Boiler and Pressure Vessel CodeSection VIII Division 1 has been incorporated into Aspen Teams.Among the significant changes affecting Aspen Teams are:• Section UG-37. The nominal and specified thicknesses in the

reinforcement calculations for openings in pressure vesselshave been redefined. The nominal corroded thickness lessmanufacturing under tolerance is now used except in the areacalculations. Nozzle weld calculations may now result indifferent weld sizes.

• Section UG-99. The standard hydrostatic test pressuremultiplier has been changed from 1.5 to 1.3.

• Section UCS-66. The reduction in temperature for theminimum design metal temperature calculation has beenchanged. New charts and equations have been provided.

• Mandatory appendix 2: Equations in the calculation of theflange design factors have been changed.

• Appendix A. New rules for tube-to-tubesheet shear load testinghave been provided.

In addition, the 1999 Addenda of the ASME Boiler and PressureVessel Code Section II Part D Properties of Materials has beenincorporated into Aspen Teams. In this addenda, the allowablestress calculation factor has been changed from 4.0 to 3.5 for manymaterials. This change has resulted in approximately 15% higherallowable stresses, which in turn allows the designer to use thinnerand less expensive equipment components.The new TEMA 1999 eighth edition standards have beenincorporated into Aspen Teams. Among the significant changesaffecting Aspen Teams are:• The maximum unit size covered by the standards has been

increased from 60 inches to 100 inches.• The maximum acceptable product covered by the standards

(nominal pressure x diameter in psi and inches) has beenincreased from 60,000 to 100,000.

• The recommended maximum shell wall thickness covered bythe standards has been increased from 2 inches to 3 inches.

• The design temperature calculation procedure for parts incontact with both fluids has been changed.

• A new section for the design of floating head backing rings hasbeen added. Now Aspen Teams will design floating headbacking rings per the ASME code rules and per TEMAstandards.

Aspen TeamsThe 1999 Addenda of theASME Boiler andPressure Vessel Code

TEMA 1999 EighthEdition Standards


• The mandatory TEMA R confined gasket joint constructioncan now be satisfied with flat flange faces using spiral woundgaskets with outer metal rings. Aspen Teams has three newgasket materials to be used for this purpose. The materialnumbers for the new gaskets are 1383, 1384, and 1388 (spiralwound CS, SS, and Nickel alloy, respectively).

• The formula for the tubesheet flange extension in RCB-7.1341has been revised.

• A new section for the design of double tubesheets has beenadded. Three full design cases are included: integral doubletubesheets, connected double tubesheets, and separate doubletubesheets. Several new geometry configurations are availablefor fixed tubesheet and U-tube exchangers. The doubletubesheets have not been included in the drawings. Singletubesheets will appear in the drawings for this release.

• A new elastic modulus calculation for kettle type shells hasbeen added.

• The calculation of the flexible element stiffness in expansionjoints has been modified. The spring rate calculation now has astiffness multiplier factor, which is a function of the flexibleshell element geometry.

Added the capability to export the Teams detailed calculationoutput to a file in Rich Text Format (.RTF). This Rich Text Formatretains the text formatting shown in the Teams output and the filecan be easily edited from most standard word processing programs.The export function can be accessed from the “Files – Export”menu.Added a new input parameter for hub flanges. Now the user canspecify either the flange hub height or the flange hub slope. TheUser Interface will gray-out the input not used to avoid over-specifying the flange geometry.The wind and seismic loads calculated by the program can now beapplied to the design of the vertical supports. Previous AspenTeams versions would display the result but would notautomatically modify the vessel geometry to withstand theadditional loads.Expanded the user interface with an input grid for individualnozzle external loads and moments. For each of the maximum tennozzles, the user can enter 3 external loads and 3 externalmoments. Previous Aspen Teams version had one input set of threeexternal loads and three external moments for all nozzles.

Detailed Calculations in.RTF Format

Hub Flange Design

Wind and Seismic Loads

Nozzle External Loads


Changed default corrosion allowance for code-only vessels to 1/8inch or 3 mm. Previous Aspen Teams version used the TEMAdefaults even if the vessel was non-TEMA.Improved processing for pipe materials with vessel diameters up to42" OD. Now Aspen Teams accepts all pipe diameters and pipethickness shown on TEMA table D-1, including 42" OD. AspenTeams also automatically switches to equivalent plate material (ifavailable) or carbon-steel plate if a pipe thickness is not available.Previous Aspen Teams version would switch to plate material forpipe diameters greater than 24” OD.Added the calculation of compression rings for cones in kettles,fixed tubesheet with kettle shells and channel cones. Addedcompression ring and stiffening ring pricing to the cost module.Improved the placement logic for saddles in horizontal vessels.Aspen Teams now attempts to place the saddles as close aspossible to adjacent stiffening elements. This placement willminimize stresses on the shell caused by the saddles.Changed the shell thickness to calculate the maximum shellcompressive stress in the tubesheet design section. Previous AspenTeams versions used the calculated shell minimum thickness. NowAspen Teams uses the actual shell thickness. This change willresult in higher shell compressive allowable stresses.Improved the method to calculate the vessel weight allocated toeach saddle. Aspen Teams now uses the method based on therelative position of each saddle with respect to the center ofgravity.Aspen Aerotran enhancements include the following:Added logic to determine which components should be consideredas non-condensables for the mass transfer analysis when the AspenProperties interface is used. Aspen Aerotran now extracts thosecomponents defined as Henry components within Aspen Plus andconsider them as non-condensables. Previous Aspen Aerotranversions did not attempt to make this distinction and programresults would have been conservative.Revised logic for determining which components should beconsidered non-condensables when B-JAC vapor-liquid-equilibrium calculations are selected. Aspen Aerotran nowevaluates the amount of each component that has condensed at theinlet temperature of the cold side to determine if the componentshould be considered as a non-condensable.Extended the detailed vapor-liquid-equilibrium calculation resultsdown to the inlet temperature of the opposite side. The previousAspen Aerotran version limited the calculation to the specified

Corrosion Allowances

Pipe Tables Expanded

Compression Rings

Saddle Placement onHorizontal Vessels

Shell Compressive Stress

Saddle Design

Aspen AerotranNon-condensableComponents in AspenProperties Interface

Non-condensableComponentDetermination

Extended VLECalculations


outlet temperature of the stream. In simulation mode, the programwould sometimes have to extrapolate the heat release curve beyondthe last point calculated.

Compatibility NotesThis section describes the differences that you might encounterbetween B-JAC 10.2 and earlier versions. The changes discussedin this section were necessary to correct problems, to implementnew features or to improve ease of use.Changes for Aspen Hetran include the following:Corrected the selection of the viable baffle spacings for anexchanger when intermediate supports were specified at inlet,outlet, or center to center. Aspen Hetran did not take the supportsinto account when selecting the spacings, which met maximumunsupported spans. This would only occur in design mode.Revised the U-bend bundle entrance area calculation for nozzlesentering beyond the U-bend of a U-tube unit. In the previousAspen Hetran version, entrance area estimation was tooconservative. Aspen Hetran now calculates the entrance area on thesame premise TEMA uses for entrance areas when nozzles arenormal to the bundle axis.Corrected a problem in determining stream physical properties forproperty curves that must be extended beyond the temperaturepoints supplied. This would normally only occur in simulationmode when Aspen Hetran attempted to extrapolate property databeyond that specified in the input. The previous Aspen Hetranversion would sometimes maintain constant physical propertiesbeyond the last specified temperature point.Revised the static head pressure drop calculation for tube sidefalling film vaporizer exchangers. New pressure drop calculationwill give results that are somewhat less than those in the earlierAspen Hetran versions.Corrected a problem with determining the correct shell insidediameter when both the shell outside and inside diameter arespecified. Aspen Hetran would sometimes allow the front headinside diameter to override the specified shell inside diameter if thehead inside diameter were less than the shell inside diameter. Theincorrect shell inside diameter would appear in the output.Corrected a problem associated with specifying the vapor beltinside or outside diameters. Aspen Hetran would sometimes usethe calculated diameter rather than the specified vapor beltdiameter.

Aspen HetranBaffle Space Selectionwhen IntermediateSupports are Specified

U-bend Bundle EntranceAreas

Extrapolation of PhysicalProperties

Falling Film VaporizersStatic Head PressureDrop

Shell Inside Diameters

Vapor Belt Diameters


Corrected the setting plan drawing for shell-side pool boiling unitswith different numbers of inlet and outlet nozzles. Aspen Hetran’sthermal and hydraulic calculation were correct but the setting plandrawing would show the same number of nozzles entering andleaving the exchanger or show extra inlet nozzles entering the topof the exchanger.Corrected the calculation of vapor-liquid equilibrium curves usingthe Aspen Properties interface when running under units other thanUS. Aspen Hetran would determine erroneous dew and bubblepoints unless the input was supplied in US units. Also corrected thevapor-liquid equilibrium calculation details output. Details onamounts of each component condensed at each temperature pointwere not available.Aspen Teams changes include the following:Corrected the MAWP (maximum allowable working pressure)calculation for U-tubes when the user specified TEMA-onlytubesheet design. Previous Aspen Teams versions used the ASMEU-tube design method and consequently did not find a properMAWP when the user specified the TEMA design method. Nowthe program uses the TEMA method to calculate the MAWP forTEMA-only cases.Corrected a problem with the calculation of the MAWP for thefront shell flange in certain U-tube units. Aspen Teams decreasedthe pressure used in the search for the front shell flange MAWPwithout a proper exit of the loop.Corrected a problem with the generic material specification(material numbers less than 50) for liner material. Aspen Teamsdid not convert the generic material specification to the proper4-digit designator. The costing module might fail because it couldnot find the material for the liner.Corrected a problem with calculating the liner thickness for abolted flat cover with a user-specified liner material.Corrected the display unit magnitude for wind and seismicmoments in US units. The calculation engine sent lbf-ft and theuser interface converted this number to lbf-in but displayed lbf-ftunits.Changed the nozzle thickness used in the nozzle fillet weld sizecalculation. The nozzle thickness is now corroded but with thematerial (pipe) tolerance included.Corrected a problem with the calculation of the weld size betweenthe reinforcing pad and the vessel wall. The previous Aspen Teamsversion included the nozzle cylinder thickness in the minimumweld size search when in fact the nozzle cylinder is not applicable

Setting Plan Drawing forPool Boilers

Vapor-Liquid EquilibriumCalculation with AspenProperties

Aspen TeamsMAWP for U-tubes

MAWP for Flanges

Liners

Wind & Seismic Analysis

Nozzle Welds


for this weld (only the vessel wall thickness and the reinforcingpad thickness are applicable).Corrected a problem with the calculated reinforcement pad area. Ifyou entered a pad OD greater than the maximum allowable by thecode, the program used the entered OD even though it was greaterthan the maximum OD allowed by the ASME code. Now AspenTeams uses the entered pad OD or the maximum pad OD allowedby the ASME code.Corrected a problem with large nozzles on heads with user-specified non-center nozzle locations (angles other than 360degrees). The offset calculation formula used a number greaterthan 1 for the calculation of the arccosine.Corrected the logic for calculating the U-tube tubesheet flangedextension per TEMA RCB-7.1342. The previous Aspen Teamsversion exits when the argument of the square root for Tr isnegative. New logic makes a negative argument in this areaimpossible.Changed the logic in the calculation of the flanged extension forintegral U-tube units. Now Aspen Teams only uses the side that isgasketed to calculate the flanged extension thickness. Prior logicreviewed both sides (the gasketed side as well as the welded side)and selected the larger thickness. It was determined that the weldedside should not contribute to the calculation of the flangedextension thickness.Corrected a problem in the vessel volume calculation routine. Ifhub flanges were welded to the channel or shell cylinders, theflange lengths were not included in the cylinder volumecalculation.Corrected a problem with the calculation of torispherical headvolumes. The program used the dish-only head volume formula.Corrected a problem related to the specification of bellowsexpansion joints. Aspen Teams calculated an un-reinforcedbellows type even if the user selected a reinforced bellows type.Corrected a problem with the calculation of the allowable flangestresses when factor B was less than 20×g1. The ASME codeallows the calculation of the longitudinal flange stress using factorB1 instead of B when B is less than 20×g1. The other stresses,tangential and radial, should still use B. The program used B1 forall stresses when B was less than 20×g1 (it should only use B1 forthe longitudinal stress, not the tangential and radial stresses).Corrected a problem with the external pressure calculation for thedished-only head in a floating head. Aspen Teams used the

Reinforcement Pad Areas

Large Nozzles Offsetfrom C/L of Heads

U-tube Tubesheet FlangeExtension

Vessel Volumes

Bellows Expansion Joints

Flange Design

Dished Head ExternalPressure


torispherical head formulas when it should have been using thehemispherical head formulas.Aspen Aerotran changes include the following:Corrected a problem in determining stream physical properties forproperty curves that must be extended beyond the temperaturepoints supplied. The previous Aspen Aerotran version wouldsometimes fail to extrapolate the physical properties and maintainthem constant based on the last specified temperature point.

Aspen AerotranExtrapolation of PhysicalProperties

What's New in AES 10.2 Aspen Pinch •••• 8-1

8 Aspen Pinch

Aspen Pinch is a powerful tool for designing minimum-costprocesses for chemical plants and refineries. It can be used toretrofit existing plants as well as to develop new designs. AspenPinch incorporates into one integrated system all the tools youneed to develop the most cost-effective design - pinch technology,heat recovery network design, heat and power models, andsimulation capabilities.Aspen Pinch can query an Aspen Plus simulation model andautomatically create the stream and physical property data neededfor a pinch study – ensuring consistent handling of data. AspenPinch has a heat exchanger network design option for interactivelycreating the heat recovery scheme. As an option, heat exchangerscan be simulated or designed using Aspen B-JAC. This interfacebridges the gap between simple, short-cut heat exchangercalculations and detailed ones by calculating heat transfercoefficients, pressure drops, detailed costs and so on, therebyenabling the creation of realistic designs.This chapter describes the new capabilities in Aspen Pinch 10.2. Italso summarizes compatibility considerations in migrating fromearlier versions.

8-2 •••• Aspen Pinch What's New in AES 10.2

New CapabilitiesNew capabilities in Aspen Pinch 10.2 include:• Hierarchical flowsheet support. Aspen Plus 10.2 supports

hierarchical blocks which contain flowsheet sections or entireflowsheets. The data extraction interface with Aspen Plus fullysupports hierarchical flowsheets nested at any number oflevels.

• Performance improvements for:• Data extraction interface with Aspen Plus• Stream data editor• Network simulation

• Improved heat exchanger summary table in Network Design• Improved text handling in Network Design

Compatibility NotesWith one exception, Aspen Pinch 10.2 is fully compatible withAspen Pinch 10.1. The format of one Aspen Pinch table – StreamData source – has been changed to support hierarchicalflowsheets. Any Aspen Pinch case that contains stream data fromthe Aspen Plus interface (using File→Import→Aspen Plus…)must be converted to the new format. To convert a case:1 Select (click on) the case in Aspen Pinch.2 Select Manager→Convert Data…

What's New in AES 10.2 Aspen Split •••• 9-1

9 Aspen Sp lit

Aspen Split is a state-of-the-art program for the synthesis andconceptual design of distillation processes. It can be used to assessseparation feasibility in azeotropic mixtures, synthesize newseparation sequences that achieve a desired separation, anddevelop strategies for the retrofit of existing distillation processes.Aspen Split’s conceptual design capabilities can be used to quicklyand efficiently design optimal distillation columns for binary andternary homogeneous mixtures. Aspen Split can also be used toscreen and identify feasible entrainers for separating azeotropicmixtures.This chapter describes the new capabilities in Aspen Split 10.2.

New CapabilitiesAspen Split 10.2 introduces the first Aspen Split component that ishosted by and seamlessly integrated with Aspen Plus 10.2. Thefollowing sections detail the new features of the Aspen Splitcomponent. Please see the Aspen Plus on-line help for details onusing the Aspen Split component in Aspen Plus.The engineering features of this component include:• Locating all the azeotropes (homogeneous and heterogeneous)

present in any multicomponent mixture. In addition, theazeotropes are also classified as stable nodes, unstable nodes,or saddles.

• Automatically compute distillation boundaries for ternarymixtures. These boundaries are impassible barriers fordistillation and are used to assess separation feasibility.

• Interactively compute residue and distillation curves and addthem to the ternary maps.

• Computing multiple liquid phase envelopes (liquid-liquid andvapor-liquid-liquid) for ternary mixtures. The envelopes can

Split Component

Engineering Features

9-2 •••• Aspen Split What's New in AES 10.2

also be superimposed on the residue curve maps. This is usefulin determining if decanters are required for achieving a desiredseparation as well as the manner in which they are coupledwith distillation columns.

• Interactively adding liquid-liquid-equilibrium tie lines to themultiple liquid phase envelope.

The component has a number of usability features to enhance theengineering productivity. These include:• The ternary diagrams and plots can be copied to other

Windows applications (e.g. Microsoft Word) as a Windowsmetafile. Consequently these plots can be further edited in anappropriate drawing program.

• The azeotrope search results are presented in a spreadsheetformat and can be sorted by temperature, miscibility,classification, composition, etc. The results can also be copiedto Microsoft Excel or other spreadsheet programs.

• The azeotrope search report can be saved as either a Webdocument or a standard text file, or sent directly to the printer.

• As the mouse is moved over the ternary diagram, thecomposition and boiling point temperature are displayed on thescreen.

• Initial conditions for residue and distillation curves can beinput either by using the mouse or by specifying thecomposition directly.

• The ternary diagrams can be plotted either in equilateral orright-angled triangular coordinates. Both modes support a truezoom facility, and the ability to rotate and/or flip the diagrams.

• Graphic properties (e.g., color, line thickness, etc.) of theternary map and its components are fully customizable.

• Markers and material balance lines can be interactively addedto the residue curve maps.

Since the Aspen Split component is hosted by and seamlesslyintegrated with Aspen Plus, it can be accessed directly from withinthe Aspen Plus environment. Consequently the Split componentautomatically has access to all relevant information (e.g.,component list, physical property models, etc.) that is alreadypresent in an Aspen Plus run. It is also possible to have multipleinstances of the Aspen Split component running simultaneouslywithin the same Aspen Plus session.

Usability Features

Access to Aspen PlusCapabilities

What's New in AES 10.2 Aspen Water •••• 10-1

10 Aspen W ater

Aspen Water enables companies to reduce operating costs by usingless water and by reducing the capital cost of the effluent treatmentplant. Aspen Water enables you to:• Define the current operation (by producing a current water and

contaminant balance)• Identify opportunities for improvement in a systematic way• Test future scenarios (operational, environmental)Using Aspen Water, you first produce a model of the site (or plant)water and effluent system in a flowsheeting environment using adrag-and-drop system. In constructing the flowsheet, you candeploy Aspen Water models of water operations such as coolingtowers, boilers, vessels, pumps, and filters. Aspen Waterrigorously models water chemistry and energy issues. It containsdata reconciliation capabilities that produce a water balance whennot all data are available or when some data are conflicting.Once the balance is complete Aspen Water uses an MILPoptimization routine to define all options for water re-use.Sensitivity analysis within Aspen Water, linked to a database oftreatment technologies, allows you to define the most appropriatelocation (and the benefit) of treatment options within the overallwater and effluent system.

New CapabilitiesAspen Water has been updated to be compatible with otherproducts in the Aspen Engineering Suite.

Compatibility NotesThere are no compatibility differences between Aspen Water 10.2and previous versions.

10-2 •••• Aspen Water What's New in AES 10.2

What's New in AES 10.2 Aspen Zyqad •••• 11-1

11 Aspen Zyqad

Aspen Zyqad is an integrated multi-user environment that allowsengineers and applications to store, share, and use process data andknowledge throughout the engineering lifecycle of a process.This chapter describes the new capabilities in Aspen Zyqad 10.2. Italso summarizes compatibility considerations in migrating fromAspen Zyqad 10.1 to Aspen Zyqad 10.2.

New CapabilitiesAspen Zyqad 10.2 is an update release with new features in thearea of application interfaces.Aspen Zyqad 10.2 provides a number of interfaces withIntergraph’s suite of design products. These interfaces enhance thefront-end engineering & design (FEED) workflow by supportingthe electronic transfer of data between process engineering anddetailed engineering.The specific interfaces in Aspen Zyqad 10.2 are listed below:

SmartPlant P&ID Aspen Zyqad exports equipment data forvessels, rotating equipment, heat exchangeequipment, and stream data to SmartPlantP&ID

PDS P&ID Aspen Zyqad exports stream data to PDSP&ID

INTools/IDM Aspen Zyqad exports stream data to theINTools and IDM instrumentation packages

Aspen Zyqad 10.2 provides a bi-directional interface with theICARUS K-Base server. This interface supports the transfer of

Intergraph ProductInterfaces

ICARUS Interface

11-2 •••• Aspen Zyqad What's New in AES 10.2

equipment objects and data to and from ICARUS and AspenZyqad.In addition to the existing Aspen B-JAC interface, Aspen Zyqad10.2 provides bi-directional interfaces with the HTRI and HTFSheat exchanger design programs.Aspen Zyqad 10.2 features a new utility that will allow you todefine datasheets using Excel as an authoring tool. This newfeature allows companies to more easily convert their existingExcel-based datasheets into the Aspen Zyqad format.Aspen Zyqad 10.2 supports the AspenTech License Manager thatmanages simultaneous user access to the Aspen Zyqad server.

Compatibility NotesThe following section describes compatibility issues betweenAspen Zyqad 10.2 and Aspen Zyqad 10.1.

Datasheets that were created using the Aspen Zyqad 10.1AutoCAD-based datasheet definer will still be usable in AspenZyqad 10.2. You will still be able to use the AutoCAD-baseddatasheet definer to create and modify AutoCAD-based datasheets.However, you will not be able to edit AutoCAD-based datasheetswith the new Excel-based datasheet definer.

HTRI, HTFS Interface

Excel-basedDatasheet Definer

License Manager

DatasheetsUse of AutoCAD-basedDatasheets

What's New in AES 10.2 Aspen Adsim •••• 12-1

12 Aspen Adsim

Aspen Adsim (ADS) is an easy-to-use dynamic tool for the design,simulation, and operation of adsorption processes. Rigoroussimulations for gas and liquid adsorption and ion-exchangeprocesses can be rapidly constructed by use of the intuitivegraphical user interface. Dynamic and parameter estimationsimulations are solved in an equation-based manner that providesflexibility and power.This chapter describes the new capabilities in ADS 10.2. It alsosummarizes compatibility considerations in migrating from earlierversions.

New CapabilitiesADS 10.2 contains new features in the following areas:• 2-D adsorbent bed model• Particle material balance• New mass transfer coefficient models• Additional isotherms• Enhanced reporting• Cycle Organizer enhancements• Internal/external column heat exchangers• Batch run toolkit• Easier formulation of PDE models• On-line links using OLE for process control (OPC)• Streamlined Snapshots and Use• Automatic DMCplus model generation• Open non-linear algebraic equation solver interface

12-2 •••• Aspen Adsim What's New in AES 10.2

The following sections detail the new features in each of theseareas. Please see the ADS on-line help for further details of thesenew features.For vertical gas adsorbent beds only, it is now possible to modelboth the composition and temperature distributions in 2dimensions, axial and radial.For gas phase only, the rigorous calculation of loading profilewithin an adsorbent particle has been provided. This is onlyapplicable if:• All components are adsorbed• The mass transfer can be attributed to the adsorbed phase only• The boundary layer mass transfer resistances are accounted forAdditional methods have been provided for supplying masstransfer coefficients (lumped resistance models only). These are:• Arrhenius• Pressure dependent ArrheniusThese models can be used to account for the variation of masstransfer coefficients with respect to temperature and pressure.Through on-going development and communications with clients,2 new isotherms for gas phase models have been introduced. Theseare:• Langmuir 3, improved handling of cases where the effective

transfer decreases with increasing temperature.• Multi-layer BET, ability to explicitly define the number of

adsorbed layers. It provides a stopgap alternative should eitherLangmuir or BET with infinite layers (standard BET) provesunsuitable.

For gas phase models only, internal or external heat exchange witha heating/cooling medium has been provided. The medium can bespecified to be either a single or dual phase.Additional information with respect to the overall energy balanceis now provided in the global report. The report accounts for:• Total energy passing the flowsheet boundaries• Energy losses through column and void walls• Compressor energy requirementsEnhancements to the Cycle Organizer include:• Ability to modify the units of measurements• Should an entered value be beyond the current bounds of the

given variable type, it is now possible to automatically modifythe bounds to take into account the new value.

2-D Adsorbent BedModel

Particle MaterialBalance

New Mass TransferCoefficient Models

Additional Isotherms

Internal/externalColumn HeatExchangersEnhanced Reporting

Cycle OrganizerEnhancements

What's New in AES 10.2 Aspen Adsim •••• 12-3

A toolkit has been provided to simplify the configuration ofautomated batch runs. The set of common methods can be usedwithin scripts hosted by the Windows Scripting Host or withinother COM enabled applications. Through the use of VB Scriptswith WSH, it is possible to configure batch runs of ADS problems.For example if you wish to execute one or more problemsovernight, it is possible to create a batch script that will automatethis process.This new capability supports easy formulation of models solvingPDEs in 1, 2, or 3 dimensions, using either rectangular or polarcoordinates.The available discretization methods are:• 4th order Central finite differences (CFD4)• 1st order Backward finite differences (BFD1)• 4th order Upwind-biased finite differences (UBFD4)• 2nd order Orthogonal collocation on finite elements (OCFE2)• 4th order Orthogonal collocation on finite elements (OCFE4)You can use different discretization methods in differentdimensions, e.g. a collocation method for the radial direction in areactor, and a finite difference method for the axial direction. Nodespacing can be either constant or variable. It is very easy to switchbetween different discretization methods to see which is best suitedto your application.OPC is a Windows based standard for communicating with processcontrol systems. Many control vendors and third parties supplyOPC servers. ADS 10.2 is an OPC client. This enables ADS toexchange data with any control system or other application that hasan OPC server, without the need for any custom interfaceprogramming. This capability can be used to help buildapplications for:• Training• Inferential measurement and state estimation• Dynamic look-ahead models which are automatically

initialized from current plant conditionsA number of changes have been made to simplify the use ofSnapshots, and the Use environment. These include:• Integration of the Use and Snapshots dialogs• A single list of all available Snapshots and Results• Ability to specify which snapshots are saved

Batch Run Toolkit




12-4 •••• Aspen Adsim What's New in AES 10.2

The existing integration between ADS and DMCplus has beenfurther extended to allow automatic creation of a DMCplus linearmodel (.mdl file) from an ADS non-linear dynamic model. Thisremoves the need to perform step testing on the model. TheDMCplus linear model can then be used to develop a DMCpluscontroller. This approach does not remove the need for plant steptesting, but can be used for applications such as:• Benefits studies to predict the benefits from using a DMCplus



controllersThis interface enables users to add their own preferred non-linearalgebraic equation solver to those already built into ADS.

Compatibility NotesThe .ada files created with ADS 10.1 should load into ADS 10.2after little modification:• The word EXPERIMENT is now a simulation engine keyword.

If you have used the Estimation Module in 10.1, in conjunctionwith a text editor, execute a search and replace for“EXPERIMENT(” to “EXPERIMENTS(” on the 10.1 inputfile to be loaded.

• Owing to modeling enhancements within the gas adsorbentlayer models, please check the initial conditions after loading.

The .adb files created with previous versions are not compatiblewith ADS 10.2. You must load these files into the previousversion, and save them as .ada files before loading them into ADS10.2.



What's New in AES 10.2 Aspen Chromatography •••• 13-1

13 Aspen Chromatography

Aspen Chromatography (CHM) is an easy-to-use dynamic tool forthe design, simulation, and operation of batch and continuouschromatographic processes. Rigorous simulations of trace liquidand ion-exchange based chromatographic processes can be rapidlyconstructed by the use of the intuitive graphical user interface. Themodels can be applied to processes widely found in the high puritypharmaceutical, biotechnology, sugar, and fine chemicalsbusinesses.This chapter describes the new capabilities in CHM 10.2. It alsosummarizes compatibility considerations in migrating from earlierversions.

New CapabilitiesCHM 10.2 contains new features in the following areas:• Rigorous pressure drop calculation• Additional isotherm• Enhanced reporting• New unit operations• Cycle Organizer enhancements• Easier formulation of PDE models• On-line links using OLE for process control (OPC)• Streamlined Snapshots and Use• Automatic DMCplus model generation• Open non-linear algebraic equation solver interfaceThe following sections detail the new features in each of theseareas. Please see the CHM on-line help for further details of thesenew features.

13-2 •••• Aspen Chromatography What's New in AES 10.2

For trace liquid assumption models, it is now possible to accuratelypredict the pressure drop through the column packing with respectto the change in solvent composition.Through on-going development and communications with clients,an additional isotherm has been provided for ion-exchangechromatography. This new isotherm is based on the modelproposed by Yamamoto et al. It relates the loading to the bulksolvent ionic strength.The injection unit report is now displayed in the main simulationmessages window.The overall report provides information with respect to therecoveries of each product unit and each feed unit, product purities,and information on the injection or continuous counter-currentseparation unit configuration.Additional unit operations that have been added to trace liquidchromatographic processes include:• Multi-ported splitter• Multi-ported mixer• Simple valve• Alternative injection unit to allow for non-Dirac pulses and

automated repeating of pulsesEnhancements to the Cycle Organizer include:• Ability to modify the units of measurement.• Should an entered value be beyond the current bounds of the

given variable type, it is now possible to automatically modifythe bounds to take into account the new value.

This new capability supports easy formulation of models solvingPDEs in 1, 2, or 3 dimensions, using either rectangular or polarcoordinates.The available discretization methods are:• 4th order Central finite differences (CFD4)• 1st order Backward finite differences (BFD1)• 4th order Upwind-biased finite differences (UBFD4)• 2nd order Orthogonal collocation on finite elements (OCFE2)• 4th order Orthogonal collocation on finite elements (OCFE4)You can use different discretization methods in differentdimensions, e.g. a collocation method for the radial direction in areactor, and a finite difference method for the axial direction. Nodespacing can be either constant or variable. It is very easy to switch

Rigorous PressureDrop Calculation

Additional Isotherm

Enhanced Reporting

New Unit Operations

Cycle OrganizerEnhancements


What's New in AES 10.2 Aspen Chromatography •••• 13-3

between different discretization methods to see which is best suitedto your application.OPC is a Windows based standard for communicating with processcontrol systems. Many control vendors and third parties supplyOPC servers. CHM 10.2 is an OPC client. This enables CHM toexchange data with any control system or other application that hasan OPC server, without the need for any custom interfaceprogramming. This capability can be used to help buildapplications for:• Training• Inferential measurement and state estimation• Dynamic look-ahead models which are automatically

initialized from current plant conditionsA number of changes have been made to simplify the use ofSnapshots, and the Use environment. These include:• Integration of the Use and Snapshots dialogs• A single list of all available Snapshots and Results• Ability to specify which snapshots are savedThe existing integration between CHM and DMCplus has beenfurther extended to allow automatic creation of a DMCplus linearmodel (.mdl file) from a CHM non-linear dynamic model. Thisremoves the need to perform step testing on the model. TheDMCplus linear model can then be used to develop a DMCpluscontroller. This approach does not remove the need for plant steptesting, but can be used for applications such as:• Benefits studies to predict the benefits from using a DMCplus



controllersThis interface enables users to add their own preferred non-linearalgebraic equation solver to those already built into CHM.





13-4 •••• Aspen Chromatography What's New in AES 10.2

Compatibility NotesThe .cra files created with CHM 10.1 should load into CHM 10.2after little modification:• The word EXPERIMENT is now a simulation engine keyword.

If you have used the Estimation Module in 10.1, in conjunctionwith a text editor, execute a search and replace for“EXPERIMENT(” to “EXPERIMENTS(” on the 10.1 inputfile to be loaded.

The .crb files created with previous versions are not compatiblewith CHM 10.2. You must load these files into the previousversion, and save them as .cra files before loading them into CHM10.2.

What's New in AES 10.2 Batch Plus •••• 14-1

14 Batch Plu s

Batch Plus is a process modeling and simulation system for thebatch process industries. While it has been specifically designedfor the simulation of pharmaceutical, biotech, and agriculturalchemical processes, it can also be used to simulate other complex,recipe-based batch processes.This chapter describes the new capabilities in Batch Plus 2.1. Italso summarizes compatibility considerations in migrating fromprevious versions.

New CapabilitiesBatch Plus 2.1 is a major release with special focus in thefollowing areas:• Route selection for chemical development• Equipment independent recipe• Expanded comments for Steps and Operations• Vapor emissions calculations• Models and operations• Custom Excel/VBA model for the Custom operation• Batch Plus as an automation server• Aspen Framework integration• Simulation Engine• Ease-of-useThe following sections detail the new features in each of theseareas. Please see the Batch Plus on-line help for further details ofthese new features.

14-2 •••• Batch Plus What's New in AES 10.2

A new chemist view is now available. It includes:• Process level user interface where a process is represented by a

block diagram• Minimal recipe inputs (no recipe development required)• Dynamic cost calculations• Optimal route algorithm• Set of reports in Excel• Integration with Batch Plus recipeFeatures to support equipment independent recipe include:• A New “Generic” equipment class. Generic equipment has no

detailed input parameters apart from the name. You can:• Use the Generic class in any Operation in Batch Plus• Replace Generic equipment with equipment from any other

class and vice versa• A new "Conceptual" facility that contains equipment in the

Generic class• Redesigned Data/Equipment dialog which includes a Required

tab, Optional tab, etc.• Batch Plus recalculates vessel capacity at the end of a

simulation so that Generic vessels are not size limiting• When user saves the Chemist recipe, Batch Plus automatically

puts all Operations in the Conceptual facility.Expanded Comments support allows you to:• Define multiple Comment types for a Project• Specify comments of each type for Operations and Steps• Paste formatted text (or rich text) with different fonts,

bold/italic characters, etc. from Word into the Comments field• Drag and drop short-cuts from the desktop to the Comments

field• View one or more of these types of Comments in the Text

Recipe using Tools/Options/Text Recipe.• Print the different comments in Microsoft Word

Route Selection forChemicalDevelopment

EquipmentIndependent Recipe

Expanded Commentsfor Steps andOperations


Features to support vapor emission calculations include:• Simplified user interfaces for Emission Control• Default emission control paths for equipment• Control efficiencies for each control device either by chemical

or by category• Generated components for non-condenser emission control

devices• Process condensers in emission control paths• Complete implementation of the Pharma. MACT equations• Activity coefficient models and Henry’s constants from Aspen

Properties• A list of partially soluble and insoluble HAPs in the regulatory

categories database• Display of default emission models in Operation dialogsBatch Plus now supports a user-written Excel/VBA model for theCustom operation. With this feature, you can:• Run a custom model that may exist locally or on a network• Use the custom model to simulate an operation as part of the

Recipe• Use the custom model to calculate final vessel contents,

streams, utilities, and commentsBatch Plus 2.1 features many enhancements to the models andoperations:• You can specify measured density for predefined mixtures• You can specify either the transfer time or rate in Decant and

Extract operations• Reactor mass is taken into account in Heating/Cooling• You can specify measured heat capacity for operations• Extended Measured Amount/Composition to Filter, Filter-In-

Place, and Centrifuge• Added particle size distribution to Filter, Filter-In-Place, and

Centrifuge• Added temperature ramp to sublimation/desorption phases of

Freeze-Drying• Added U-Based model to React and React-Distill• Added external heat exchanger model to React and React-

Distill

Vapor EmissionCalculations

Custom Excel/VBAModel

Models andOperations


Batch Plus now exposes:• Key automation functions so that you can start a Batch Plus

session from VBA, open a project, select astep/process/production plan, run simulation.

• Key data elements of Operations so that you can use VBA tochange parameters from an external program

Simulation enhancements include:• Scale-up based on key input intermediate• Process scale-up• Advanced scale-up for MultiDrop Centrifuge and Filter

operations• Improved end-of-simulation message with summary of

warnings and errorsBatch Plus 2.1 features many ease-of-use enhancements. Theseinclude:• Launch of custom reports• More flexible costing calculations• Filtering of vent streams in the Material Balance report• Documentation in PDF format

Batch Plus as anAutomation Server

Enhancements toSimulation Engine

Ease-of-Use


Compatibility NotesBatch Plus 2.1 will convert projects that were created in previousversions of Batch Plus to the current version.Some of the new Batch Plus capabilities require additional AESand 3rd party products to be installed:

Capability Products RequiredKinetic reactor model Aspen Plus 10.2 and Aspen Dynamics 10.2BatchFrac Aspen Plus 10.2 with BatchFracProperty estimation Aspen Properties 10.2 or Aspen Plus 10.2MACT vapor emission equations (whichrequire Henry’s constants and activitycoefficients)

Aspen Properties 10.2

Importing plant data InfoPlus.21 2.5 and AspenTech Desktop 2.5Excel reports Microsoft Excel 97 or 2000Custom Excel/VBA model Microsoft Excel 97 or 2000Viewing Operating Instructions and formattedComments

Microsoft Word 97 or 2000

Editing Step, Equipment, Materials, andResults databases

Microsoft Access 97 or 2000

Viewing Project charts MS Project 98Viewing Equipment and Block diagrams Visio Technical 5.0c or 2000Viewing Chemist Recipe document ChemDraw 4.5Administering licenses AspenTech License Manager 2.0-3

Please note that Batch Plus and integrated AspenTech productsmust use the same licensing scheme for the integration to work,that is, they must either all use Activator licensing, or must all useAspenTech License Manager licensing. Otherwise, you will get alicensing error when the integrated product is launched from BatchPlus. In addition:• Internet Explorer 4.0 or higher is required to install Batch Plus.• An Aspen Dynamics license is not required to run the Kinetic

Reactor Model• An Aspen Properties license is required to run properties

estimation, and to compute Henry’s constants and activitycoefficients. However, the Aspen Properties license will bemade available to all Batch Plus users free of cost.

All other products will require the appropriate licenses to run.

Project Files

Additional ProductsRequired


What's New in AES 10.2 Polymers Plus •••• 15-1

15 Polymers Plus

Polymers Plus is a general-purpose process modeling system forthe simulation of polymer manufacturing processes. Polymers Plusincludes models for polymer property estimation, polymerizationkinetics, and mass and energy balance calculations.This chapter describes the new capabilities in Polymers Plus 10.2.In addition to the new capabilities in Polymers Plus, you will alsobenefit from the new capabilities in Aspen Plus 10.2, such asflowsheet hierarchy and Excel Calculator. This chapter alsosummarizes the compatibility considerations in migrating fromprevious versions of Polymers Plus.

New CapabilitiesPolymers Plus 10.2 contains new features in the following areas:• Integration of Polymers Plus with Aspen Dynamics 10.2.• Expanded polymer databank• Integration of Polymers Plus with third party software• Four-phase Equilibrium TP-Flash User ModelPolymers Plus is now integrated with Aspen Dynamics 10.2. Formost Polymers Plus applications, this capability enables you torapidly convert your existing steady state model to a dynamicmodel. You can then use the dynamic model to improve thecontrol, operability, and safety of the process, and to help trainplant support engineers.The polymer segment databank has been expanded with theaddition of more than forty segments corresponding to commonlyused monomers and additives for polyester, nylon, and EPDMprocesses.

Integration ofPolymers Plus withAspen Dynamics

Expanded PolymerDatabank

15-2 •••• Polymers Plus What's New in AES 10.2

A User2-based Excel User Model template is provided to integratethird party software into Polymers Plus. For example, you can nowintegrate Predici into Polymers Plus for detailed polymerizationkinetics modeling. The template calls Predici through a User2Excel block and passes the basic stream data and polymerattributes between the two products.A User2 model is provided to address the need to simulate 4-phasebehavior encountered in polymerization processes. Such processesmay involve four equilibrium phases: a polymer-rich liquid, anorganic (monomer-rich) liquid, and a water-rich liquid, all inequilibrium with a vapor phase. The User2 model calculatesequilibrium phase composition and amount for a given feed atconstant temperature and pressure.

Compatibility NotesThe following section describes the differences between PolymersPlus 10.1 and Polymers Plus 10.2. The engine input files andModel Manager backup files have complete compatibility betweenthe two versions. However, due to the modification and bug fixesof physical property models, minor changes may be observed inyour simulation results, especially for enthalpy and heat duty.Property changes include:• POLYNRTL property method. The model was extended to

Henry components for activity coefficient and enthalpycalculations in a way that is consistent with the classical NRTLmethod.

• POLYSAFT property method. Improved heat capacitycalculation with the SAFT EOS.

Changes for the Step-growth Model include:• Added an option in ModelManager to enable the switching

between rate constant assignment methods. You can assign rateconstant sets globally or individually and switch betweenmethods without losing data entries.

• Moved the rate constant summary form for user reactions to atab-sheet to improve the usability

• Improved the model to support the gel effect user subroutine• Improved the model to support the variable access and input

restore when catalyst activation reaction is specified.

Integration ofPolymers Plus withThird Party Software

Four-phaseEquilibrium (TP-Flash) Model

Properties andProperty Analysis

Step-growth Model

Emulsion ModelZiegler-Natta Model

What's New in AES 10.2 Polymers Plus •••• 15-3

Changes to the stream attributes include:• Component attribute measurement units are now displayed on

the Stream Summary form and the values are reported usingthe locally defined units. Previous versions of Polymers Plusreported attributes using Global out-units.

• A completeness check is implemented for the catalystcomponent attributes. Catalyst site fraction must sum to unity.

• Component attribute profiles are now reported in local out-units and the units are displayed. Previous version of PolymersPlus reported attributes profiles in SI units.

A number of changes have been made to the application examples:• Heat transfer user subroutine usrhpe.f for LDPE application

example is modified. A viscosity correlation, outside film heat-transfer coefficient, wall heat-transfer coefficient, and foulingresistance have been incorporated into this example. The logicfor calculating Nusselt numbers for turbulent or transition flowregions has been corrected.

• LDPE Process. Modified the flowsheet and parameters toreflect a “real life” process.

• HDPE Process. Changed the convergence method to improvethe speed of calculation.

Streams

Unit OperationModels

ApplicationsExamples

15-4 •••• Polymers Plus What's New in AES 10.2

What's New in AES 10.2 Aspen PEP Process Library •••• 16-1

16 Aspen PEP Process Library

Aspen PEP Process Library is a new product of the AspenEngineering Suite. It is a library of individual process modules inwhich each module contains a set of pre-built Aspen Plus orPolymers Plus models representing the various processtechnologies used for a particular chemical or polymer product.These models are based on SRIC’s Process Economics Program(PEP) process descriptions and flowsheets, which represent theindustry standard for process information derived from publicsources and SRIC’s engineering expertise.The models give engineers a head start in generating conceptualdesign cases and can be customized for specific plants to helpimprove the understanding of plant behavior. Aspen PEP ProcessLibrary is designed for decision-makers in planning departments,front-end engineering and design users, and operational engineerswith little discretionary time for building models from scratch.

New CapabilitiesThe Aspen PEP Process Library interface provides you with:• Flowsheet models for existing and emerging process

technologies. The information for units and streams can beaccessed easily by double clicking on the associated graphicobject.

• The ability to quickly run case studies through the power ofAspen Plus® and/or Polymers Plus®.

• Parameter customization capability to enable non-technicalusers to perform case studies by making changes to keyparameters without a detailed working knowledge of AspenPlus/Polymers Plus. Variables such as throughput, reactorconditions, and product purity represent a typical set ofparameters that are accessible through the interface.

16-2 •••• Aspen PEP Process Library What's New in AES 10.2

• A margin calculator and economic data which allow basiceconomic evaluation of multiple case studies and cross-technology issues.

• Detailed process description contains a discussion on theprocess and key aspects of how the process was modeled.

Processes Model Names Short DescriptionAcetic Acid Acetic Acid Production of acetic acid by an Acetica process (Chiyoda/UOP

process)AcryloNitrile AcryloNitrile1 Production of acrylonitrile by ammoxidation of propylene (SOHIO

Process)AcryloNitrile2 Production of acrylonitrile by ammoxidation of propane (SOHIO

Process)AcryloNitrile3 Production of acrylonitrile by ammoxidation of propylene

Cumene Cumene1 Production of cumene using solid phosphoric acid catalyst (UOPprocess)

Cumene2 Production of cumene using aluminum chloride catalyst (Monsanto-Kellogg process)

Cumene3 Production of cumene using zeolite catalyst (Dow-Kellogg Process)Ethylbenzene Ethylbenzene1 Production of ethylbenzene from benzene and ethylene by vapor-

phase alkylation: third-generation (Badger process)Ethylbenzene2 Production of ethylbenzene from benzene and ethylene by liquid-

phase alkylation using zeolite catalysts (Lummus/Unocal/UOPprocess)

Ethylene Ethylene Production of ethylene from propane by conventional cracking (C.F.Braun process)

Methanol Methanol1 Production of methanol from natural gas by ICI’s LP process (HighEfficiency Design)

Methanol2 Production of methanol via ICI Leading Concept Methanol (LCM)Process

Methanol3 Production of methanol from natural gas by Lurgi’s processMethanol4 Production of methanol from natural gas by Haldor Topsoe's

combined reforming processPolypropylene Polypropylene1 Production of polypropylene by a slurry stirred tank reactor process

Polypropylene2 Production of polypropylene by a vertical stirred-bed gas phasereactor

Polypropylene3 Production of polypropylene by a loop reactor process (UCC loopprocess)

Polypropylene4 Production of polypropylene by a combination of vertical stirred bedand gas phase polymerization (Himont process)

Styrene Styrene1 Reduction of styrene by adiabatic dehydrogenation: two reactors withinterstage reheat (Fina/Badger process)

Styrene2 Production of styrene by adiabatic dehydrogenation: a two-stagereactor with steam reheat (Lummus/Monsanto/UOP process)

VinylChloride

Vinyl ChlorideMonomer

Production of vinyl chloride from ethylene dichloride by pyrolysis(Hoechst process)

Models in Aspen PEPProcess Library

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