Aspen Plus to study pressure relief capacity...
Jump Start: Pressur Pressure e Relief Scenario in Aspen Plus Dynamics ® V 8 A Brief Tutorial Tutorial (and supplement supplement to training training and online documentation) documentation) Zachary Peers, Product Management, Aspen Technology, Inc.
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Jump Start: Pressure Relief Scenario in Aspen Plus Dynamics ® V8
Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Example Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Steady State Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Isolating the Unit Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Creating a Pressure Gradient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Preparing the Dynamic Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Entering the Vessel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Entering the Heat Transfer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Adding Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Exporting the Dynamic Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Configuring the Dynamic Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Adding Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Adding a Split Range Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Testing the Steady-State Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Creating a Pressure Relief Scenario . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Adding a PSV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Adding Emergency Scenario . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Analyzing a Pressure Relief Scenario . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Adding Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Running the Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Configuring Aspen Properties in Aspen Plus Dynamics if you are Running Aspen Plus V8.2 . . . . . . . . . . . . . . . . . . . . . . . 15
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Jump Start: Pressure Relief Scenario in Aspen Plus Dynamics ® V8
Introduction Engineers use Aspen Plus Dynamics ® to quickly create dynamic models of processing equipment and to apply these equipment models to simulate and optimize continuous, batch, and semi-batch processes. In this guide, we will provide an example to help you get started using Aspen Plus Dynamics quickly and effectively. We will follow one example, the development of a phenolic-resin model, to illustrate how you can: transition a steady-state Aspen Plus® model to an Aspen Plus Dynamics model and evaluate a pressure relief valve. This is not meant to be used as a stand-alone reference document. We recommend that you use a range of other resources including: • AspenTech support website (support.aspentech.com) • AspenTech courseware available in on-line and in-person versions • AspenTech knowledgebase items, training, and sample models available in aspenONE® Exchange • AspenTech business consultants This document covers dynamic modeling in Aspen Plus Dynamics. It assumes that the user has Aspen Plus V8.2 1 or higher and Aspen Plus Dynamics V8.0 2 installed on her or his computer, as well as some experience building process models. We will follow the analysis of a reactor from the steady-state Aspen Plus model to the Aspen Plus Dynamics model.
Example Files There are two example files used in this tutorial, Phenolic Resin Case 1 and Phenolic Resin Case 2. Phenolic Resin Case 1 is a steady state Aspen Plus model and Phenolic Resin Case 2 is the same model after it has been transferred into Aspen Plus Dynamics. This guide shows an overview of how to transform Phenolic Resin Case 1 into Phenolic Resin Case 2, but it does not show every individual change. To get more familiar with upgrading steady state models to dynamic ones, we recommend you try to accomplish this on your own. These files are also featured in the On-Demand Webinar “Reactor Relief Analysis with Aspen Plus Dynamics” (Additional Resources, page 19). Both example files are available for free through the instant download through aspenONE Exchange. To access aspenONE Exchange in Aspen Plus V8.0, click the Exchange button in the Get Started tab on the ribbon (Figure 1). In Aspen Plus V8.2 and higher, aspenONE Exchange automatically launches when you open the program.
Figure 1: Open aspenONE Exchange
1
To upgrade to Aspen Plus V8.2, visit: http://www.aspentech.com/products/v8-release/
2
If you have never run Aspen Plus Dynamics V8.0 with Aspen Plus V8.2, see the appendix for important information on configuring properties
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Jump Start: Pressure Relief Scenario in Aspen Plus Dynamics ® V8
Type the file names into the search bar and click on the appropriate flowsheets in the search results (Figure 2). You can also find other example files, knowledgebase tips, training modules, and more using similar queries. To learn more about how to use aspenONE Exchange, see the associated Jump Start in the Additional Resources section (page 19).
Figure 2: Search for example files
Steady State Model Aspen Plus Dynamics is a tool used for dynamic simulation. Although flowsheets can be built in the dynamic environment, it is easier to start from a working steady-state model. This helps to keep properties consistent and eliminates the need to duplicate the process. This is also an advantage for Aspen Plus users because models do not have to be redesigned for dynamic evaluation. The following section explains how to prepare and import a steady state Aspen Plus model into Aspen Plus Dynamics. If you are only interested in configuring the dynamic model, you can skip ahead to Configuring the Dynamic Model (page 7).
Isolating the Unit Operations Open your Aspen Plus model. If the model contains multiple unit operations, decide what units you want to use for the dynamic analysis. To isolate a unit, right-click on its feed streams and select Reconcile to set the stream variables as stream specifications (Figure 3). After all of the unit’s feeds have been reconciled, delete the remaining unit operations and leave the units that will be used in the dynamic simulation. In this example, the reactor has already been isolated.
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Jump Start: Pressure Relief Scenario in Aspen Plus Dynamics ® V8
Figure 3: Reconciling a Stream to isolate a unit operation
Creating a Pressure Gradient After isolating the units, you must decide if you want to perform a pressure or flow driven analysis. Pressure driven analysis requires the addition of pumps or valves to each stream to establish a pressure gradient across the model. Flow driven analysis does not have this requirement. For a simple model where you do not need to analyze the pressure gradient, you can use a flow driven analysis. This example is about pressure relief, so pressure driven analysis is necessary. You will read more about this in Exporting the Dynamic Model (page 6). To add valves to an existing stream, right-click on it and select Insert Block. Under common types, select Valve (Figure 4).
Figure 4: Adding a valve to a s tream
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Jump Start: Pressure Relief Scenario in Aspen Plus Dynamics ® V8
This will split the stream and reconnect it to the valve. Next, specify the valve’s outlet pressure. For this example, the inlets are set at 2 bar and the outlets are set at 1 bar. These values will set the valve size. You will later add controllers to these valves in the dynamic environment.
Preparing the Dynamic Model In Aspen Plus, Dynamic Mode can be activated on the Dynamics tab on the ribbon. This mode allows you to input dynamic specifications before entering Aspen Plus Dynamics. Adding the specified controllers, equipment sizing, and the heat transfer beforehand helps to simplify the transition to the dynamic environment. Select the Dynamics tab and click the Dynamic Mode button (Figure 5). This will activate the dynamic forms for the unit operations on the navigation pane. This is where you will enter the dynamic specifications.
Figure 5: The Dynamic Mode button
Entering the Vessel Specifications Specifications required for steady-state differ from specifications required for dynamics. In dynamics, you must also specify the size of, heat-transfer for, and how you want to control the equipment. In this model, only the reactor is isolated, so you only have to specify its dynamics. The valves require no dynamic specifications. Go to the navigation pane and find the reactor (R-101). Open the folder and select “Dynamic” to open a new form for the reactor (Figure 6).
Figure 6: Open the Dynamic form for a block
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Jump Start: Pressure Relief Scenario in Aspen Plus Dynamics ® V8
Select the “Vessel” tab and specify the size of the reactor. The reactor has been set as a vertical vessel with elliptical heads and a length of 2m (Figure 7).
Figure 7: Enter dynamic specifications
Entering the Heat Transfer Specifications Next, click on the “Heat Transfer” tab and select the “Evaporating” option. Set the medium specific latent heat as 2270 kJ/kg. Next, add the equipment heat transfer. Click on the tab titled “Equipment Heat Transfer” and check the option for “Model equipment heat capacity.” Specify the equipment mass and heat capacity. Use an equipment mass of 1000kg and heat capacity of 500J/kg-K.
Adding Controllers Aspen Plus Dynamics will automatically add controllers after the file is sent. You can specify what types these will be beforehand in Aspen Plus on the “Controllers” tab for each unit operation. For this model, include the pressure and overall liquid level controllers. You will add the temperature controller in the dynamics environment later.
Exporting the Dynamic Model You can export a model from Aspen Plus to Aspen Plus Dynamics in one click. After the model’s dynamic specifications have been made and it has been run, navigate to the Dynamics tab. All of the buttons will now be active. Now, you must specify either a pressure or flow driven analysis as discussed earlier. To do this, click the Pressure Checker button to see if the flowsheet is configured. If it is properly configured, export the model by clicking on the Pressure Driven button (Figure 8). This will raise the save form. After naming the file, click save. The model will now open in Aspen Plus Dynamics.
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Jump Start: Pressure Relief Scenario in Aspen Plus Dynamics ® V8
Figure 8: Exporting the model to Aspen Plus Dynamics
Configuring the Dynamic Model You now have a working model in Aspen Plus Dynamics that is prepared to run a dynamic analysis. You can now further configure the model to better reflect the process. This can involve adding additional controllers, resizing equipment, and adding tasks.
Adding Controllers Although there are a pressure and level controller on the reactor, you also need to add flow and temperature controllers. To add the temperature controller, select the Controls tab on the Dynamics model library. Add a “PIDIncr” to the flowsheet near the product stream and the reactor (Figure 9).
Figure 9: Add a PIDIncr controller
On the model library, select the dropdown next to streams and select “ControlSignal” (Figure 10).
Figure 10: Add a ControlSignal
The flowsheet will display the ports that can be used. You are trying to control the temperature of the product, so connect the ControlSignal to the port leaving the ID (name) on the stream POUT. Select the control variable Temperature (Figure 11).
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Jump Start: Pressure Relief Scenario in Aspen Plus Dynamics ® V8
Figure 11: Set the control variable
Click OK. Now connect the ControlSignal to the controller inlet. Set it as a process variable (Figure 12).
Figure 12: Connect the signal to the controller
Add a ControlSignal leaving the controller and set the control variable as controller output. Since the goal is to maintain the temperature of the product leaving the reactor, you must control the reactor duty. This duty will represent the cooling water in the reactor jacket. Connect the ControlSignal to the reactor and select QCool (specified heat duty) as the control variable. Finally, name the controller “TC-101” to follow the naming convention in the model. Figure 13 shows what the flow sheet looks like after properly adding the controller.
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Jump Start: Pressure Relief Scenario in Aspen Plus Dynamics ® V8
Figure 13: Flowsheet after adding controller TC-101
The last step is tuning the controller. Right-click on TC-101 and go to Forms>Configure. Click the Initialize Values button on the form to update the controller to the current conditions. The controllers should be configured as seen in Table 1.
Controller
B2
B4
TC-101
FORMALIN
CRESOL
POUT
Output
V-F
V-C
R-101
PV
Fm
Fm
T
Input
OP Set Point
Qcoolr 1000
1750
90
50
50
0
5
5
10
Integral Time
20
20
10
Derivative Time
0
0
0
Reverse
Reverse
Reverse
PV Range Minimum
0
0
0
PV Range Maximum
2000
3500
180
Output Range Minimum
0
0
-10
Output Range Maximum
100
100
10
Initial Output Gain
Controller Action
Table 1: Controller configurations
The controller action here denotes in which direction the controller will act. The easiest way to understand how to configure the action is to imagine in what direction the action takes place when the disturbance occurs. For example, if the temperature increases, the duty needs to decrease to maintain the temperature. This is a reverse action. Using V2 as an example, if the level increases, the valve opening will increase. This is a direct action. Use the same method to add the flow controllers. Configure them using Table 1. The final flowsheet is shown in Figure 14. © 2013 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved. 11-3795-0713
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Jump Start: Pressure Relief Scenario in Aspen Plus Dynamics ® V8
Figure 14: PFD with added flow and temperature controllers
Adding a Split Range Controller Aspen Plus Dynamics automatically adds a pressure controller acting on V1. This controller changes the vent flowrate based on the pressure change in the reactor. In this model, a split range controller would provide better results. The split range controller changes two variables depending on whether they are above or below a given value. This model requires a pressure of 2 bar to be maintained within the vessel. Thus, the V1 will be opened when the pressure is above 2 bar and V3 will be activated when the pressure is below 2 bar. Choose a “SplitRange” controller from the Controls tab on the Dynamics model library. Add it to the flowsheet near the reactor. Delete “R-101_PC” and connect a split range controller to the reactor. Add a control signal from the split range controller to V3 and select this as Output 1. Add a control signal from the split range controller to V1 and select this as Output 2. To configure the split range controller, right-click on it and select Forms>Configure. When the form opens, match the configurations to the data in Table 2.
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Jump Start: Pressure Relief Scenario in Aspen Plus Dynamics ® V8
Description
Value
Units
Output1Action
Action for Output 1
Reverse
Output1Min
Minimum value of Output 1
0.0
%
Output1Max
Maximum value of Output 1
100.0
%
Output1InMin
Value of input above which Output 1 starts to change
0.0
bar
Output1InMax
Value of input above which Output 1 stops changing
2.0
bar
Output2Action
Action for Output 2
Output2Min
Minimum value of Output 2
0.0
Output2Max
Maximum value of Output 2
100.0
Output2InMin
Value of input above which Output 2 starts to change
2.0
bar
Output2InMax
Value of input above which Output 2 stops changing
100.0
bar
Direct
Table 2: Split range controller configurations
Testing the Steady-State Model Now that these changes have been made, the model should be tested to make sure it is still at steady-state. To visualize this, view the forms for the product, vent, and the reactor. Right-click on the reactor and select Forms>ResultsReliefSummary. A form will open that displays the status of the reactor. Next, open TPFPlot (temperature, pressure, flowrate plot) for the streams VOUT and “POUT” (Figure 15).
Figure 15: Open plots and Relief Summary Results
Now, make sure the mode is set to Dynamic on the toolbar at the top of the screen (Figure 16). It is best to first run the model in dynamic mode and let it find its steady-state before running in steady-state mode.
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Jump Start: Pressure Relief Scenario in Aspen Plus Dynamics ® V8
Figure 16: Run controls in Aspen Plus Dynamics
Click play and monitor the plots and the reactor conditions. Let the data run for some time and see if they stabilize. If the plots continue to fluctuate, check the conditions listed in this document or the completed case file. Once the variables stabilize, change the mode to “Steady-State” and run it again. If the solution fails, rewind the simulation back to the last converged case and try running in dynamics for a longer period of time. When the steady-state solution passes, you can add the pressure safety valve (PSV).
Creating a Pressure Relief Scenario Now that the model is configured and works in steady-state, the next step is to add a PSV to the reactor to test if the valve size can handle the pressure relief scenario.
Adding a PSV To add a PSV, select “PSV2” from the Pressure Relief tab on the Dynamic model library. Drop this unit near the top of the reactor. Connect the inlet of the PSV to the reactor vapor outlet, and add a stream to the outlet of the PSV (Figure 17).
Figure 17: Add the PSV
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Jump Start: Pressure Relief Scenario in Aspen Plus Dynamics ® V8
Now you must size the valve. Right-click on the PSV and select Forms>Configure. This will open the form in Figure 18. You can size the valve here.
Figure 18: Size the PSV
Use an E sized valve with an inlet diameter of 0.5 in, an outlet diameter of 0.625 in, and a throat diameter of 0.625 in. Now, move to the “Hysteresis” tab to set the pressures. If you change the Set Pressure, the rest of the pressures will automatically update based on the valve type specified. This example will use the “Conventional” valve type with a set pressure of 5 bar (Figure 19).
Figure 19: Set the pressures for the PSV © 2013 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved. 11-3795-0713
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Jump Start: Pressure Relief Scenario in Aspen Plus Dynamics ® V8
Adding Emergency Scenario Now that the PSV has been added, you are ready to run an emergency scenario to see how the model reacts. This example will simulate a cooling water failure on the reactor. A task will be used to automatically have an event occur at a designated time. To add a new task, click on the New Task button (Figure 20).
Figure 20: Add a new task
For this task, you want to manipulate the temperature controller to turn off. Table 3 shows the sequence of events and associated code. 1
Name the task CoolingWaterFailure and set it to occur at 0.1 hrs
Task CoolingWaterFailure Runs At 0.1
2
Set the controller in manual mode
Blocks (“TC-101”).AutoMan: 1;
3
Set the operating parameter to zero
Blocks (“TC-101”).OPMan: 0;
4
Set the duration of the event to 2 hours
wait 2.0
5
Change the controller to automatic
Blocks (“TC-101”).AutoMan: 0;
6
Revert to the original set point to turn on the cooling water
Blocks (“TC-101”).Sp: 90;
7
End the task
End
Table 3: Sequence of events for CoolingWaterFailure
Figure 21 shows how the code appears in the text editor.
Figure 21: Code for CoolingWaterFailure
Right-click on the text editor and select Compile. If no errors are present, exit out of the text editor.
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Jump Start: Pressure Relief Scenario in Aspen Plus Dynamics ® V8
Analyzing a Pressure Relief Scenario You can now run the pressure relief scenario and see how the equipment reacts. This involves adding forms to visualize the pressures and operating the model.
Adding Forms To open a form for a unit: right-click on it, go to Forms, and select the form you would like. Add a plot for the PSV, a plot for the reactor, and a reactor summary form. When the forms are set-up, save the screen layout by clicking on the Save Layout button. You can reopen a saved layout at any time by clicking on Flowsheet on the simulation explorer and finding the saved layout below. Saved layouts appear as pencil shaped icons, as seen in Figure 22.
Figure 22: Save and reopen layouts
Running the Simulation Make sure the task is activated by clicking on the Flowsheet button on the simulation explorer, finding the task, and checking to see if symbol has a lightning bolt in front of it (Figure 23). If it is not, double-click on the symbol to activate it. After the task is active, make sure the mode is dynamic and run the model.
Figure 23: Make sure the task is active
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Jump Start: Pressure Relief Scenario in Aspen Plus Dynamics ® V8
View the forms you have set up and see how the model reacts to the pressure relief. Figure 24 below shows what the model should look like after 3 hours.
Figure 24: Example model after 3 hours
Additional Resources Public Website Aspen Plus www.aspentech.com/products/aspen-plus.aspx Aspen Plus Dynamics www.aspentech.com/products/aspen-dynamics.aspx
Online Training www.aspentech.com/products/aspen-online-training
YouTube Channel: www.youtube.com/user/aspentechnologyinc
Appendix Configuring Aspen Properties in Aspen Plus Dynamics if you are Running Aspen Plus V8.2 If you are running an Aspen Plus V8.2 model and have never used Aspen Plus Dynamics, you may have to configure the properties for Aspen Plus Dynamics. To do this, open the start menu and go to All Programs>AspenTech>Process Modeling V8.0>Aspen Plus Dynamics>Aspen Properties Version Selector. In “Version,” select Aspen Properties V8.2 and click OK (Figure A1).
Figure A1: Configure properties
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About AspenTech AspenTech is a leading supplier of software that optimizes process manufacturing—for energy, chemicals, 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.
Worldwide Headquarters Aspen Technology, Inc. 200 Wheeler Road Burlington, MA 01803 United States phone: +1–781–221–6400 fax: +1–781–221–6410
[email protected]
Regional Headquarters Houston, TX | USA phone: +1–281–584–1000 São Paulo | Brazil phone: +55–11–3443–6261 Reading | United Kingdom phone: +44–(0)–1189–226400 Singapore | Republic of Singapore phone: +65–6395–3900 Manama | Bahrain phone: +973–17–50–3000 © 2013 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved. 11-3795-0713
For a complete list of offices, please visit www.aspentech.com/locations
