Getting Started With Relative Economics in Aspen HYSYS

Getting Started with Relative Economics in Aspen HYSYS ®  A Brief Tutorial (and supplement to training and online documentation) By Dan McCarthy McCarthy,, Product Manager; Ron Beck, Marketing Manager; and Glenn Dissinger, Product Director, Aspen Technology, Inc

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About AspenTech AspenTech is a leading supplier of software that optimizes process manufacturing—for energy, chemicals, pharmaceuticals, engineering and construction, and other industries that manufacture and produce products from a chemical process. With integrated aspenONE ® solutions, process manufacturers can implement best practices for optimizing their engineering, manufacturing, and supply chain operations. As a result, AspenTech customers are better able to increase capacity, improve margins, reduce costs, and become more energy efficient. To see how the world’s leading process manufacturers rely on AspenTech to achieve their operational excellence goals, visit www.aspentech.com.

Getting Started with Relative Economics in Aspen HYSYS

1. Introduction The new integrated economics workflow provided by AspenTech enables process modelers to incorporate rigorous relative costs in their process modeling studies. This provides the business benefit of better process designs that take into account capital and operating costs together with technical and process parameters. Integrated economics brings the power of AspenTech’s rigorous economic modeling products (the ICARUS family) to the process model (Aspen HYSYS or Aspen Plus). This enables the process designer to rapidly assess the relative costs of a proposed process design, thereby providing the means to screen alternatives based on a balance of technical, safety, environmental and economic factors. This document serves as a simple “getting started” guide, taking you through the most common progression of how we would envision the process designer to use this integrated functionality. This guide is not meant to be used on a standalone basis. We would recommend that a range of other resources be called upon to give the new user a comprehensive view of how to use this capability. This may include: • Online documentation – which can be accessed through the Aspen HYSYS and Aspen Process Economic Analyzer software user screens. • AspenTech support website ( support.aspentech.com), which contains a wide range of knowledge base items, provides answers to frequently asked questions. • AspenTech courseware available in in-person and on-line versions, which provide formal training on process modeling and economic evaluation. •  AspenTech business consultants. • Pre-recorded tutorials and webinars that provide another view of the information contained in this document (go to http://www.aspentech.com/solutions/industry_solutions/epc/integrated-economics.aspx for many of these

resources). This document covers Aspen HYSYS. This guide assumes that the user has Aspen HYSYS V7.3 and Aspen Process Economic Analyzer® V7.3 installed. A companion document to this one, providing similar information for users of Aspen Plus, is also available. (http://www.aspentech.com/uploadedFiles/Forms/Events/NALA/int_econ_tutorial.pdf)

2. The Work Flow The integrated economics solution is flexible in terms of the work flows that it supports. The work flow that we follow in this guide is as follows: STEP ONE: incorporate operating costs in the Aspen HYSYS model. STEP TWO: converge the model STEP THREE: activate relative costing STEP FOUR: select cost basis

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Getting Started with Relative Economics in Aspen HYSYS

STEP FIVE: map unit operation models to equipment STEP SIX: sizing equipment STEP SEVEN: evaluate economics and report This entire workflow can be performed from WITHIN the familiar Aspen HYSYS user interface.

3. Definition of Operating Cost Parameters within Aspen HYSYS The current release of Aspen HYSYS (V7 and newer) provides the means to define utility (energy), feed and product streams and costs. Feedstock and product stream pricing parameters are only needed if an ROI for the plant is desired. For estimating and comparing capital and operating costs, the process stream costs are not required. Utility cost definition is RECOMMENDED but not a required step. If utility costs are not defined as described below, the economics ‘engine’ will assign the utilities and associated prices for each energy stream using built-in values, which is not as accurate as specifying them if known, but is pretty good at the conceptual design level. Each energy stream in the HYSYS model should be associated with a process utility. The costs of the process utilities should be specified in the Process Utility Manager or HYSYS Workbook. (see Figure 1 for an example of assigning a utility).

Figure 1. Assigning a utility to an Aspen HYSYS energy stream

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Getting Started with Relative Economics in Aspen HYSYS

To enter an individual stream’s cost factors, doubleclick on any screen and scroll down the resulting navigation pane to “cost parameters”. At that point, you may enter data for the price and flow basis of that stream (see Figure 2). In many cases, it is more efficient to enter the cost parameters for a group of streams at once. The stream and utility costs can be conveniently entered, reviewed and modified using the workbook within Aspen HYSYS. To do that, the needed parameters need to be set up in the workbook view (this takes only a few seconds.) With the workbook open (this is a necessary first step to see the pull-down menu), access the workbook setup (see Figure 3). Next enter the needed cost parameters for the feed, product and utility streams (see Figure 4). Figure 2: Assigning costs to an Aspen HYSYS stream

Figure 3: Aspen HYSYS Workbook setup

Figure 4: Add cost parameters to the stream workbook views

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Getting Started with Relative Economics in Aspen HYSYS

Now, the workbook can be used to review and enter/edit cost factors quickly for all the feed, product and utility streams. (see Figure 5). In most cases, a design case will involve multiple utility sources and multiple unit operations. The workbook (see Figure 5) is a convenient way to quickly review the streams and utilities selected and to review and modify utility selections and cost parameters.

Figure 5: Feed and Product Stream Cost Factor Assignment using Workbook View 

Important Note:  Once you have specified utility selections and costs and feed and product pricing within Aspen

HYSYS, the resulting operating cost information produced by the Aspen HYSYS model run  automatically updates the economics module in the subsequent steps in the integrated workflow.

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Getting Started with Relative Economics in Aspen HYSYS

4. The Costing Toolbar and Costing Menu Integrated economics is accessed two ways in Aspen HYSYS. First, there is a “costing toolbar” which is used to perform integrated cost evaluation (see Figure 6). The same functionality may also be

Figure 6: Costing Toolbar in Aspen HYSYS

accessed from the costing pull-down menu which appears as a sub pulldown in the tools menu (see Figure 7). Each step in the integrated economic evaluation is initiated through the toolbar or the menu. First you activate the costing engine, next you map unit operations to equipment and perform sizing, finally you perform the evaluation and review the results. The results can be easily exported to MS Excel ™ or reviewed within Aspen HYSYS. Depending on the level of control that the process engineer would like to maintain over the economic evaluation, steps can be individually performed or can be skipped in favor of a “quick” and “automatic” evaluation based on default-assigned mappings and sizing algorithms. Figure 8 enumerates the work flow actions that each

Figure 7: Pull-down Economics Sub-menu in Aspen HYSYS

button in the toolbar governs. These will each be explained during the course of this tutorial.

5. Best Practice: Use a Converged Aspen HYSYS Model The Aspen HYSYS solver is always working in the background to attempt to solve the flow sheet as it is being constructed. Consequently, whatever process information exists when the economics is activated and mapped will be used in analyzing relative economics. It is a best-practice to work within HYSYS to always complete modeling to convergence prior to proceeding to the integrated economics step of the workflow. You will NOT get any reminder to solve to a converged model first before initiating the economics workflow. This is because there are some valid engineering reasons why you may wish to define the

Figure 8: Costing Toolbar actions in Aspen HYSYS

relative economics without having a converged model.

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Getting Started with Relative Economics in Aspen HYSYS

6. Activate Costing Module Integrated economics functions by linking Aspen HYSYS with Aspen Process Economic Analyzer. The APEA license key is checked out when you activate the integrated economics feature. The APEA license

Figure 9: Costing Activation Button

key is released when you de-activate integrated economics or exit Aspen HYSYS (see Figure 9). Note: The activation enables the other buttons/functions within economics (load simulation data, map, size, evaluate,

equipment summary, deactivate

7. Select a Standard Basis File or Custom Template The economics module functions through use of what estimators call “standard basis files.” These provide company-standardized, projectstandardized, or default cost basis information from which the entire costing is built. For example, “Gulf Coast Standard” is the most commonly used generic process plant “standard basis” for developing estimates. Beyond these standard basis files, the mappings, sizing, and other costing decisions described in the ensuing sections of this guide, can all be captured in re-usable templates to save time and Figure 10: Accessing and Using Templates in the Costing Workflow 

improve consistency in the way that an organization applies this relative economics workflow.

Templates are useful at an organizational level, a project level, a location level, and a technology level to ensure that best practices are applied consistently by all process engineers in an organization. The process of creating templates is beyond the scope of this Getting Started guide. What we do show here is how to access and use templates in the workflow, assuming that they have been created, for instance, by the estimating group within your organization. If your estimating group has established company-specific guidelines or more involved templates, they can make these available to your group as pull-down options within the integrated economics workflow. “Standard Basis” also appears in the workflow as template choices.

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Getting Started with Relative Economics in Aspen HYSYS

After activating the costing module, by pushing the cost activation button, a “Costing Options” window will appear (see Figure 10). Next, click on the “Browse” button to the right of the templates field, and you will be presented with the available list of templates. These may be simply the standard basis provided with the system or specific templates provided by your organization. In the example shown in Figure 10, the available templates are standard, representing the different “out-ofthe-box” geographic cost basis (US Gulf Coast, Europe, Middle East, UK, Japan) and units of measure (metric or Imperial). After you make that selection, provide descriptors for the “Scenario” you are analyzing and a text “Description”. Also on this screen, select the project investment options that will govern the calculation of project ROI and profitability, namely design “Operating Life of Plant,” duration of “Plant Startup,” onset date for “Basic Engineering,” and the design operating hours per year (also shown in Figure 10). After making these selections, a costing file will be created (see Figure 11).

8. Load Simulation Data The simulation run data must be loaded from Aspen HYSYS into the costing engine. When you click on the “load simulation data” button

this task will happen in the background. This transfers key

process information needed for the economics software to define the process flow schema and perform mapping and sizing operations.

9. Economic Evaluation Status Indicators When the simulation data loading task, and other aspects of the economics work flow, are being performed, status messages are presented in the status window in the lower left corner of the Aspen HYSYS screen. During the workflow, you may be prompted to wait for the background model calculations to complete before proceeding (see Figure 12 for a few examples of these messages).

Figure 12: Workflow Status Indicator 

10. Map Unit Operations to Equipment Models A key step in integrated economics is mapping of unit operations models from the simulation to equipment models in Aspen Process Economic Analyzer. The economic work flow is flexible and has both the ability to automatically establish “default” mappings, representing best-engineering judgment contained within the software models, as well as the capability to over-ride these mappings and substitute your own mappings, based on your engineering decisions as to which equipment models you select at this stage of the design process.

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Getting Started with Relative Economics in Aspen HYSYS

Figure 13 summarizes conceptually the operation which is performed during this mapping workflow. Each unit operation that has been defined during the process modeling is mapped to an item of equipment, or a group of equipment items, that most feasibly represent that unit operation. The sample depicted in the example figure is a distillation

Figure 13: Unit Operation to Equipment Model Mapping Scenario

column unit operation in Aspen HYSYS), which maps into the economics software as a collection of equipment models, including a packed column, condenser, exchanger pumps, a reboiler and other complementary equipment i tems. In each case, there is a default mapping, but there are also other mappings that the engineer can select instead. Mapping workflow is invoked by the

mapping button.

This brings up a map dialog box (Figure 14). Here are a few key points to remember when executing the mapping workflow:

Figure 14: Using Default or else already used Mappings

(1)

Select “map all items,” the first time you use relative economic evaluation. The ‘Map selected items’ option is for

changing/updating mappings when you have changed part of an established process design. (2) When you are  first using economics for a  model run you should always select “Default AND simulator data”.  If you don’t select this option, the sizing performed in the simulation will not be carried across to the economics software!

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Getting Started with Relative Economics in Aspen HYSYS

(3) If you change the operating conditions in a model or add equipment to a model, use the “Last Mapping”  option The economic

evaluation case remembers the mappings already established for a given simulation model. If you have made some custom mapping selections during a previous simulation run, and have modified some process parameters, your prior selections will persist in the software, and you can choose “last mapping” to re-use those already selected mappings

Figure 15: Selecting Your Own Mappings

(see Figure 14, right-side). (4) If you delete unit operation models from your HYSYS case, you may need to remove mapped equipment items. Use the “Physical Component Mapping Preview” form to delete any unwanted equipment. (5) Even if you are planning to change some mappings, select, “default and simulator data.” Then a second dialog box will come up (see Figure 15) which will allow you to change mappings. (5) Click on size Icarus project components, to activate the economics sizing algorithms.

Figure 16: Project Component Map Preview Dialog Box

(6) Click OK. (7) The project components map preview dialog box will appear (see Figure 16). (8) To change mappings (away from the default mapping assigned by the system) follow the following steps: •

All items which have been mapped appear in the simulator item window with an asterisk in front of their designation.

•

Select the item in the simulator item window (see Figure 16).

•

Delete the current mapping (select “delete one mapping” button)

Figure 17: Icarus Project Component Selection Dialog Box

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Getting Started with Relative Economics in Aspen HYSYS

•

Click on “new mapping” button.

•

Icarus Project Component selection dialog box will come up (see Figure 19).

•

Navigate the tree of available equipment models/components.

•

Select a component (s).

•

A mapping, of course, can be to more than one component (i.e. to a column and pumps and so forth).

•

Click OK to complete the mapping of each component.

•

Repeat for each item mapped to a given unit operation.

11. Sizing Activity Clicking on the sizing button initiates the sizing evaluation. The system performs the sizing with best available information. Equipment sizes are determined from the simulation data if they are available. Missing data are estimated by the system. You can also override estimate sizes in the equipment grid. To access the equipment sizing grid click on the equipment grid button: You can review the sizing and materials of construction that were assigned during the economic evaluation in the summary grid. The default material of construction for all equipment is Carbon Steel. For example, in Figure 18, we can see the materials of construction and geometry for a heat exchanger. We can use pull

Figure 18: Equipment Summary Grid enables process designer to review and change sizing

down menus to select other materials of

and materials of construction

construction. The tube materials selection pull-down menu is open in this example. If you have better engineering information or assumptions available, or have company-specific sizing algorithms to apply, these can be entered at this point. Note: At this juncture, you may also interface to custom sizing programs that your company may be using that have been

developed in MS Excel or equivalent.  Covering that topic is an advanced topic beyond the scope of this introductory tutorial.

The equipment grid has one tab sheet for each type of equipment. The columns represent individual equipment items. The rows contain the key variables for that equipment. After changing the data you should re-size and re-evaluate the costing. It is important to re-size the equipment first because equipment sizes may depend on the physical properties of © 2011Aspen Technology, Inc.AspenTech®, aspenONE®, theAspen leaflogo, OPTIMIZE,and the 7 BestPractices of EngineeringExcellenceare trademarksof AspenTechnology,Inc. All rights reserved. All other trademarks are property of their respective owners. 11-748-0711

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Getting Started with Relative Economics in Aspen HYSYS

the materials of construction. For example, the area of an exchanger depends on the thermal conductivity of the tubing. Re-sizing the equipment ensures that the estimated costs are based on the changes in equipment size.

12. Materials of Construction Capital costs are very sensitive to the materials of construction selected. Process engineers often have a good idea of the material of construction that may be required due to the chemistry of a particular process that is being selected. The process modeler can make that change at this point if he has that information (see Figure 19).

Note: After you change sizing or

materials of construction data, re-run the sizing and evaluation steps to update the economic results.

Figure 19: Changing Material of Construction from Carbon Steel to Inconel

13. Relative Cost Evaluation Click on the evaluate button

for the economic evaluation to be calculated.

14. Reporting The results of the economic evaluation can be reviewed and manipulated in several ways. Summary and detailed economics can be reviewed by clicking on the equipment grid button. This will give you access to a majority of the economic information that you will need to rapidly review the economic feasibility of a modeling scenario and to compare process alternatives. The report summary tab displays net results as displayed as shown in Figure 20. Further details of the equipment costs can be reviewed in the equipment summary table (see Figure 21). The individual tables by equipment type contain information about the design of each item of

Figure 20: Summary report

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Getting Started with Relative Economics in Aspen HYSYS

equipment. The equipment summaries are presented in a grid form. The Equipment Grid can be copied-and-pasted into external MS Excel ™ spreadsheets for further manipulation. For a more formal relative economics report, you may then click on the report button. This button creates a relative costing report in MS Excel ™ format (see Figure 22). This is a complete project economics report. If, for example, you have put in feedstock pricing at the initial stages, you can get an initial look at a project ROI within this report. The MS Excel ™ reports make it very easy to compare relative costs as the process design evolves. To understand the information available in this

Figure 21: Equipment summary displays “bare” equipment costs and indicates errors identified during the evaluation.

report, run through a scenario, produce a costing report, and explore the contents of the report.

Figure 22: Relative economics report for your process scenario

15. Managing and Transferring Cost Files The costing scenario created by Integrated Economics can be opened directly by Aspen Process Economic Analyzer or by Aspen Capital Cost Estimator for further development. When you run the relative economics, Aspen HYSYS stores the associated economics files in a new working folder, which you will find as a sub-folder within your current HYSYS working folder. The resulting APEA files can be handed over to the estimating department and can be directly opened in the APEA and ACCE estimating software products from AspenTech, for further development or fine tuning of the cost estimate that has been preliminarily produced during this conceptual design workflow.

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Getting Started with Relative Economics in Aspen HYSYS

16. Completion of Your Integrated Economics Session At the completion of your integrated economics session, you can deactivate and “release” the APEA economics software license by clicking the “depressed” activation button to deactivate it.

17. Further Resources For further information on this workflow, or any of the individual products or elements covered briefly in this written tutorial please consult:

Public website: The following web page provides links to a number of useful resources on integrated economics http://www.aspentech.com/solutions/industry_solutions/epc/integrated-economics.aspx

Support website: The support website provides an extensive and growing knowledge base on simulation, economics and the integrated website. The following knowledge base article provides a getting-started location: http://support.aspentech.com/webteamasp/KB.asp?ID=130806

Recorded tutorials are available at: “Brief Tutorial on relative costing during conceptual design with Aspen HYSYS” “Brief Tutorial on relative costing during conceptual design with Aspen Plus“

Technical webinars on integrated economics can be viewed “on-demand” at “DSM Presents how to achieve better process designs with integrated economics” “Step-by-step Technical Webinar: Getting started with Integrated Economics with Aspen Plus” “Step-by-step Technical Webinar: Getting started with Integrated Economics with HYSYS”

Or email us at [email protected] to get your specific questions answered.

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