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sponsive supplier collaborate beyond the ennterprise B llaboration profitable-to-trade support supply chain execution manage ort scalable connectivity supply chain execution efficiency digital marketpl ency digital marketplace decision support availabble-to-promise speed ecision support monitor analyze real time data = betteer decisions trading partners collaborative workflow business pro ocess integrat ™ aspen B-JAC Family Aspen Aerotran™, Aspen Hetran™, Aspen Teams™ Solutions for the thermal and mechanical design of heat exchangers. An integrated set of tools that accelerates the design process and ensures design process integrity by enabling users and applications throughout the enterprise and beyond to share consistent process information. The Challenge: Eliminating heat exchanger bottlenecks The petrochemical industry is changing. Companies are focused on conserving energy and resources, and at the same time are concerned about operating their plants as efficiently and safely as possible. To stay ahead of the competition, companies must ensure that heat exchangers are optimally designed and operated. Plant personnel must be able to identify the effects that heat exchangers have on process bottlenecks and to evaluate opportunities for process improvements in a timely manner. The process of designing air-coolers or shell and tube heat exchangers is arduous and time-consuming. Different groups within a company are often required to submit heat exchanger designs with different levels of detail. Process engineers develop the process design and complete the heat and material balances on a process simulator, typically using conceptual exchanger designs at this stage of the project. The resulting process conditions are then turned over to thermal engineers to create a preliminary detail heat exchanger design using a stand-alone design package. This workflow takes the process-knowledgeable engineer out of the equipment design loop at an early stage, which results in a lost opportunity to minimize the cost of the heat exchangers by utilizing the decision making authority of the process engineers. When the preliminary design is completed, it is sent to several fabricators for bids. Thermal engineering evaluates returned bids and selects a design, which is then sent to the mechanical engineering department. Mechanical engineers may prepare a complete mechanical design for the unit or merely extract information to begin piping and support designs. If a complete mechanical design is created, the final iteration must be returned to thermal engineering, where the thermal design is rechecked. This entire process can take anywhere from weeks to months to complete and can be further delayed by ever-changing mechanical design pressure codes and project specification requirements or mistakes discovered along the way. To maintain an efficient and competitive design process, companies must provide designers with access to consistent design information throughout the various design stages. They need an interactive solution incorporating detailed thermal and mechanical design specifications and drawings of the heat exchangers. And all this information must be accurate, secure and available in real time. To achieve these objectives, companies need a set of integrated tools that allow the various applications to share process data and knowledge throughout the engineering and manufacturing lifecycles as well as the extended supply chain and beyond—into digital marketplaces. AspenTech® provides these tools. and completing a project on time. design specifications. The Solution: Integrated tools to streamline design A design optimization process must be used to select a heat exchanger that will satisfy process requirements at the lowest capital and operating costs. Time is money. and reporting capabilities) to analyze heat exchangers in a process flowsheet. A heat exchanger design finalized with Aspen Hetran can be sent directly to the Aspen Teams program. automatic sequencing and convergence methods. More and more companies involved in the design and fabrication of equipment rely on AspenTech solutions to assist in communicating design and fabrication status. Today. They can be used as stand-alone programs for analysis of individual exchangers or integrated with the Aspen Plus® process simulator (a steady-state simulation environment equipped with an extensive unit-operation library. This could result in incompatible designs as well as significant project delays. Aspen Hetran incorporates all applicable Tubular Exchanger Manufacturing Association (TEMA) standards and can be used to design all TEMA exchanger types. AspenTech’s integrated family of solutions provides design engineers with the opportunity to obtain accurate thermal and mechanical designs for equipment with minimal engineering hours and minimal capital investment. thereby reducing redundant efforts and improving overall efficiencies. engineers can use their expertise together with simulation and design tools to find the most cost-effective solution. condensation and evaporation. including single phase. The best design tools automate the design process. Without an integrated tool set. Product Description Aspen Aerotran and Aspen Hetran provide process engineers with these integrated tools. Aspen Hetran and Aspen Teams—is the one solution that meets the needs of all groups involved in equipment design. The Aspen B-JAC family—which includes Aspen Aerotran. accurately and efficiently will optimize profitability. cost estimate and detailed drawings for the exchanger. analysis. Aspen Hetran performs the design for all major industrial shell and tube heat exchanger equipment types and applications.The Opportunity: Improve efficiency and cut costs The design process must include five essential elements in order to meet the needs of all engineering departments involved: • design optimization • rigorous rating • mechanical design • detailed costing • integration with simulation and synthesis tools Design tools must be integrated in order to provide an automatic transfer of information. Producing safe. This transfer of process data. provide information on both process performance and cost. Aspen Hetran can also be used in conjunction with Aspen Pinch™ (a technology that identifies opportunities to reduce operating costs and increase throughput using energy utilization analysis) for heat integration studies. and allow engineers to quickly evaluate a number of prospective designs. engineering firm and fabricator each need efficient design tools to avoid costly rework and mistakes. The process company. equipment experts made the selections. the odds of mistakes being made among the various groups through the access of inconsistent data increase. construction materials and exchanger geometry eliminates time-consuming and error-prone data transfer between design groups—allowing firms to meet construction deadlines by designing pressure vessel equipment in-house. accurate and low-cost designs is critical to keeping projects on budget. . sensitivity. Previously. which produces a detailed mechanical design. It can design air-coolers and economizers for single phase. Performance results allow the designer to determine the controlling parameters for a design as well as determine how that design will perform under different operating conditions. Full details on any of these designs can be recalled at any time. allowable pressure drops and maximum velocities. It performs the pressure vessel design code according to ASME Section VIII. Geometric results provide a complete mechanical description of the exchanger. including a complete API 661 specification sheet. Aspen Hetran optimizes on a number of parameters—including shell diameter. These intermediate cases indicate the constraints that are controlling the design. Zick. A recap of design alternatives provides a concise summary of the Aspen B-JAC programs provide extensive graphics to allow users to see the equipment being designed. to arrive at the smallest required heat transfer area. or AD-Merkblätter. Aspen Teams Aspen Teams enables the complete mechanical design and rating of shell and tube heat exchangers and basic pressure vessels. tube length and number of tube passes—to arrive at the smallest required heat transfer area. tube length and number of tube passes. baffle spacing. Aspen Hetran evaluates all viable configurations that will arrive at the final desired solution and produces a detailed optimization path. Summary sections provide a comprehensive overview of exchanger performance and geometry. including a complete TEMA specification sheet. including the cost impact of design changes. Performance results allow the designer to determine the controlling parameters for a design as well as how that design will perform under different operating conditions. A cost estimate is provided for each case. Summary sections provide a comprehensive overview of exchanger performance and geometry. Aspen Aerotran optimizes on tubes-per-row. Aspen Aerotran Aspen Aerotran produces a detailed optimization path that shows the alternatives considered by the program as it searched for the best design. including the cost impact of design changes. CODAP. Both programs utilize extensive graphics at the input and output phases. and it incorporates all applicable API 661 standards for air-cooled exchangers. A cost estimate is provided for each case. Aspen Aerotran also provides detailed output. Aspen Teams also provides supplemental calculations. These intermediate cases indicate the constraints that are controlling the design. Division 1. which shows the alternatives considered by the program as it searched for the best design. Geometry results provide a complete mechanical description of the exchanger. geometry and cost of all designs. Aspen Hetran and Aspen Aerotran determine the optimum heat exchanger configurations that satisfy the specified heat duty. condensation and vaporization. allowing the engineer to see the equipment being designed.Aspen Aerotran provides the thermal and basic mechanical design for heat exchangers consisting of a rectangular tube bank with gas flowing across the outside of the tubes. performance. such as wind and seismic. Aspen Hetran Aspen Hetran provides detailed output. . number of tube rows. For a given set of process requirements and constraints. including a complete TEMA specification sheet with an overview of exchanger performance and geometry. Process improvements such as heat integration can be evaluated for their operability and energy recovery. the program finds the best equipment size and configuration at the lowest cost. Now. Aspen Teams provides a code-compliant design for the entire vessel at the lowest cost and optimizes the design. In the design mode. provides detailed drawings and generates a complete bill of materials. This in turn can lead to better maintenance practices. tubesheets. Aspen Teams automatically accepts thermal design output. it checks specified dimensions of each component for compliance with applicable codes and standards under the design Aspen Hetran provides detailed output. while optimizing flanges. Traditionally. accounting for interactions of various components. Maximum Allowable Working Pressure (MAWP). resulting in lower operating costs. eliminating the need for data re-entry. A client can use the design tool to rate designs from competing vendors and in turn realize capital cost savings if the design from the low bidder proves to be acceptable. and integration with other AspenTech products results in faster design cycles. nozzle reinforcements and expansion joints. It can be used as a stand-alone program or integrated with Aspen Hetran for thermal design and rating of heat exchangers. Aspen Teams determines optimum dimensions for all components based on design conditions. Minimum Design Metal Temperature (MDMT). It provides a high degree of flexibility for the placement of nozzles. thermal and mechanical design. couplings. expansion joints and lifting lugs. over design has been used to compensate for uncertainties in the equipment rating. Aspen Teams can also be used to design each mechanical component separately. conditions. When used with Aspen Hetran. These design tools provide optimized equipment designs. flooding. The combination of design optimization. This capability also allows the user to simulate how the process will behave during major upset conditions or changing process operating conditions—and investigates if the equipment is suitable for different design. the engineer can estimate model parameters such as fouling factors and efficiencies. Every project can benefit from the increased engineering efficiency provided by the Aspen B-JAC family.external nozzle loadings. overpressure and/or faulty initial design. Integration with process simulation and synthesis allows the user to analyze a variety of process alternatives utilizing “as-built” equipment models. upset and shutdown conditions. supports. vibration. In the rating mode. the amount of over design is reduced. start-up. Aspen Teams also produces a detailed cost estimate. The rigorous rating capability can allow the engineer to anticipate equipment problems caused by conditions including excess velocity. A comprehensive design tool can also lead to better process operations. . hydrostatic test pressure and external pressure calculations. the rigorous rating capability can provide a more accurate prediction of a given design’s performance so that as accuracy improves. By rating the equipment and comparing predicted performance against plant measurements. We chose to use Aspen Hetran because of the accuracy of the heat exchanger designs to actual performance. We estimated a savings of over 1. A series of shell and “We realized considerable savings by using the Aspen B-JAC programs in the design and fabrication of heat exchangers for a chemical plant in Louisiana. Other heat exchanger design programs predicted heat transfer coefficients up to 30% lower.An engineer can quickly check a candidate design to assess mechanical feasibility and determine what effect that design will have on the rest of the process. means that design information can be stored in a central data repository that’s accessible to all members of the project team. Different stages of the design may be handled by different skill groups within a company or via client/vendor relationships. We used Aspen Hetran for the design of over 75 different heat exchangers. synthesis and database tools. The comprehensive design tool provides electronic transfer of information in a standard format.500 man-hours in the design phase alone. Energy use for the process was the primary focus of the project. The process consisted of several feed streams taken off a column. Errors due to miscommunication can be reduced or eliminated. Upon investigation. Aspen Plus was used to determine that the extra energy cost associated with the . After completing the initial flowsheet. it was learned that the regularly scheduled cleaning for the two exchangers Integration with other AspenTech products allows the design to be used with simulation. Our engineering team successfully completed the project with a high degree of process engineering efficiency. the project team was puzzled. The furnace was required to heat the crude to approximately 700˚F before it entered the crude column. such as Aspen Zyqad™. The fouling factors were much higher than would normally be expected. which would have resulted in significantly higher fabrication costs. involved had been skipped at the last shutdown. The furnace duty was identified at approximately 293 MMBTU/hr. The first step required for the project was to set up a simulation flowsheet within Aspen Plus to accurately model how the existing process was operating. The flowsheet contained ten key heat exchangers with known geometry that were modeled using Aspen Hetran blocks. One of the project engineers used the Aspen Plus simulator to fit the fouling factors for the heat exchangers involved at the problem area in the process. Integration with a project database tool. Using a single tool or an integrated set of tools for design enables the engineer working on a design to utilize a consistent set of data and properties at each stage.” Jim Brocato Manager of Process Engineering BASF tube heat exchangers were required to preheat the crude prior to it going to a furnace. Case Study A major operating company had a revamp project for a preheat train for an atmospheric crude unit. The model was able to match the measured temperatures in the process except at the point where the crude splits were combined before entering the furnace. A heat integration study was needed to identify areas where energy could be utilized more efficiently. The fuel required to heat the crude costs $8 million USD per year. developed in partnership with the world’s leading companies.000 USD on the cost of the initially recommended heat exchanger. rating and simulation of industrial heat exchangers and pressure vessels. the operating company was able to determine that excess fouling in two key heat exchangers was causing a problem. They have been validated against both laboratory and plant data. supply. production. 23 of the 25 largest refining companies and 18 of the 20 largest pharmaceutical companies. The second step in the project involved passing the process from Aspen Plus to Aspen Pinch to provide a heat integration study.000 USD per year. . saving over $12. not years. Why AspenTech? AspenTech is the only supplier of real-time value chain management solutions and a process industry veteran with exclusive focus on the process industry for over two decades.000 USD per year. as well as heat exchanger fabricators and engineering companies around the world. They are the result of many years of experience and consistently high standards of quality.000 USD per year. the energy cost was further reduced by $500. Aspen Aerotran. and Aspen Teams are recognized industry standards in the design. More importantly. is a time-tested. We have deployed solutions for 46 of the 50 largest chemical companies. which corresponded to an additional cost of $250. The programs identified savings through operation costs of $500. Aspen Plus was used to recognize that with the addition of this new heat exchanger. Aspen Hetran and Aspen Aerotran customers have been using these programs for their thermal designs for more than a quarter of a century. bestin-class solution that provides a payback period of months.missed cleaning schedule of the two heat exchangers amounted to 9 MMBTU/hr. resulting in heat exchanger designs that work effectively. assets and value chain design. The Aspen ProfitAdvantage solution provides your company with a competitive advantage by optimizing business processes between the value chain components of demand. With this model. The process company was able to identify two process improvements by using the Aspen B-JAC program in combination with Aspen Plus and Aspen Pinch. Such customers include major chemical and petrochemical companies. The programs are comprehensive and written for a broad range of applications and construction types. It was also able to quantify the consequences in real dollar terms. while linking strategic vendors. Aspen Hetran was used to optimize the size of the new heat exchanger. This experience assures customers that our Aspen ProfitAdvantage™ solution. Aspen Pinch recommended that a new heat exchanger be added to recover additional energy from the residual stream by matching it against the crude stream upstream of the second split. trading partners and customers. Our Promise Aspen Hetran. Hardware and Software System Requirements • IBM® compatible PC with an Intel® Pentium® III 500MHz Processor • Super VGA monitor with 1024 x 768 resolution or higher • 128-256MB RAM • 512MB virtual memory (RAM plus swap file) • Up to 2.0GB (100MB minimum) of hard disk space depending on AES products installed • Mouse or other pointing device • CD-ROM drive • Windows NT® 4.0 (SP6a) or Windows® 2000 (SP2) • Network Operating System – Windows NT® or Novell® . Causeway Bay. Chiyoda-ku Tokyo 102-0083 JAPAN [phone] +81 3 3262 1710 +81 3 3262 1765 [fax] [e-mail] info@aspentech. 1-5..com [phone] [fax] [e-mail] +852 2838 6077 +852 2836 0165 info@aspentech. 33rd floor.com houston office Aspen Technology. Inc. PB 113 08/01 US . Aspen ProfitAdvantage. HONG KONG japan headquarters AspenTech Japan Co.com europe/middle east/africa headquarters AspenTech Europe SA/NV Avenue Reine Astrid 92 1310 La Hulpe BELGIUM asia headquarters AspenTech Asia Ltd. Ltd. Shell Tower. Suites 3312-14. Kojimachi Shimura Bldg. Ten Canal Park Cambridge.aspentech.com worldwide headquarters Aspen Technology.com [phone] [fax] [e-mail] +32 2 701 94 50 +32 2 701 95 00 ATE_info@aspentech. Inc. AspenTech. Aspen Teams. Massachusetts USA. Aspen Zyqad. TX 77077 USA [phone] [fax] [e-mail] +1 281 584 1000 +1 281 584 4329 [email protected] Copyright © 2001. Aspen B-JAC. Aspen Aerotran. Times Square 1 Matheson Street. All rights reserved.. Aspen Hetran. Aspen Plus.[world wide web] www. Kojimachi 4-chome. Aspen Pinch. and the aspen leaf logo are trademarks or registered trademarks of Aspen Technology. Inc. MA 02141-2201 USA [phone] +1 617 949 1000 +1 617 949 1030 [fax] [e-mail] info@aspentech. Cambridge. All other brand and product names are trademarks or registered trademarks of their respective companies. 1293 Eldridge Parkway Houston.