APPLICATION OF ASPEN HYSYS PROCESS SIMULATOR IN

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VOL. 13, NO. 2, JANUARY 2018ISSN 1819-6608ARPN Journal of Engineering and Applied Sciences 2006-2018 Asian Research Publishing Network (ARPN). All rights reserved.www.arpnjournals.comAPPLICATION OF ASPEN HYSYS PROCESS SIMULATOR INGREEN ENERGY REVOLUTION: A CASE STUDY OFBIODIESEL PRODUCTION1ChemicalAbdulwahab Giwa1, Saidat Olanipekun Giwa2 and Ebenezer Ajibola Olugbade1and Petroleum Engineering Department, College of Engineering, Afe Babalola University, Afe Babalola Way, Ado-Ekiti,Ekiti State, Nigeria2Chemical Engineering Department, Faculty of Engineering and Engineering Technology, Abubakar Tafawa Balewa University, TafawaBalewa Way, Bauchi, NigeriaEmail: agiwa@abuad.edu.ngABSTRACTGreen economic revolution is a system that brings about improved human well-being and social equity whilesignificantly reducing carbon emissions, enhancing energy efficiency and lessening environmental degradation. One of itssectors is renewable energy production, which is energy development from naturally replenished resources. Renewableenergy types include solar power, wind power, hydroelectricity, biomass and biofuels. The most common biofuel isbiodiesel, which can be produced from oils/fats using transesterification process or from fatty acids using esterificationprocess. The process of biodiesel production can be simulated with the aid of a process simulator via either theconventional method of a reaction followed by separation or an integrated method known as reactive distillation. Todemonstrate the simulation, this work has been carried out to achieve production of biodiesel for green economicrevolution using the two methods with the aid of Aspen HYSYS process simulator. The performances of the two methodsin biodiesel production were evaluated, and it was discovered that reactive distillation approach was more efficient andeffective than the conventional one because more amount, and, of course, better purity, of biodiesel was given by thereactive distillation process compared to the conventional method. Thus, Aspen HYSYS has been successfully applied inanalysing biodiesel production by the two methods to know which of the alternatives the best is effectively and efficiently.It is, therefore, recommended that scientists should apply the process simulator to study chemical reactions prior to anylaboratory experiment.Keywords: green economic revolution, biodiesel, conventional method, reactive distillation, Aspen HYSYS.1. INTRODUCTIONGreen economy is one that leads to improvementin the well-being and social equity of humans, whilesignificantly reducing environmental risks and ecologicalscarcities. This economy is a model based on sustainabledevelopment and knowledge of ecological economics [1].At present, Green economy can be said to be a substitutevision for growth and development; that is, one throughwhich growth and improvements in people’s lives can begenerated in ways that are reliable with sustainabledevelopment. A green economy involves a triple bottomline, viz. sustaining and advancing economics,environmental, and social wellbeing [1], and it isbuttressed by three major pillars, which are (1) low-carbontechnology (2) resource – use efficiency and (3) sociallyinclusive growth [2].The severe poverty amid plenty as well as theextensive environmental degradation across all regions arelinked to a high dependence on the exploitation of naturalresources in inefficient ways for livelihood activities, andthis reinforces the cycle of underdevelopment. With a shiftto a green economy framework, tremendous opportunitiesthat will bring out the benefits from rich natural resourceendowments in pursuance of sustainable developmentwould be provided [2].The transition to a green economy, based on theconcept of sustainable development, has beeninternationally recognized as a way of combiningeconomic development, social welfare and environmentalprotection. The green economy is argued to lead toimproved human well-being, social equity, as well assignificantly reduced environmental risks [3, 5]. A greeneconomy has an inner relationship with a clean energypolicy and has a more politically applied focus [3]. Thereal value of environmental services and the real costs tothe environment are included in national policies [3, 4]. Asa practical matter, integrated green energy policies need,for being sustainable, to be founded both on energydiversification through the promotion of renewable energy(solar energy, wind energy, biomass energy or hybridsystems) and on energy management putting the accent onenergy transport and distribution, energy savings, orthermal insulation and green buildings [6].There is almost undisputed agreement that energyplays a pivotal role in national development. By and large,there is a high degree of relationship between energy use,economic growth, and level of development. The climatechange due to greenhouse gas emissions and turbulence inoil and gas prices have turned global attention to greenenergy sources, which are environmentally friendly. Thefirst sector of the green economy is renewable energy [4],and this has also been discovered to be the majorcomponents of the green energy sources [7, 8].Renewable energy is a regenerative energyderived from sources that are not prone to depletion in thehuman time scale, and they include biomass, solar, hydro,569

VOL. 13, NO. 2, JANUARY 2018ISSN 1819-6608ARPN Journal of Engineering and Applied Sciences 2006-2018 Asian Research Publishing Network (ARPN). All rights reserved.www.arpnjournals.comand geothermal energy [9]. These types of energy cannotbe exhausted and they constantly and automatically renew[11].Biomass, being a renewable organic matter, includesbiological material derived from living, or recently livingorganisms, such as wood, waste, alcohol fuels andbiodiesel [8,9].Biodiesel, as a renewable energy, is a fuel madefrom plant oils and can be used in diesel engines [9]. It canbe directly used to replace petroleum diesel withoutmodifying diesel engines because their properties aresimilar [10-16]. Also, it is a promising alternative toconventional petroleum based diesel fuel, and it has anumber of other benefits such as reducing carbon dioxideemissions by about 78%, nontoxicity and biodegradability.These benefits have made biodiesel a very goodenvironmentally benign one. Furthermore, biodiesel hasproperties that are more superior to those of petro-dieselfuel such as nontoxicity. Researches involving theproduction of biodiesel are being embarked on nowadaysbecause it is very important for today’s world to identifyan alternative to fossil fuel to meet the future demands forenergy while satisfying the concept of green economybased on the fact that diesel fossil fuel reserves aredwindling and, at a time, they may run out [15-17]especially for use in internal combustion engines [8].Biodiesels have been discovered to be typicallymade from renewable organic raw materials such asjatropha, soybean or rapeseed oils, animal fats, wastevegetable oils or microalgae oils. Their productionmethods include direct use and blending, micro emulsions,thermal cracking and transesterification is the mostpopular method of biodiesel production, and in thatmethod, fatty acids/vegetable oils and animal fats are usedas feed stocks. The production of biodiesel y,beaccomplished through either conventional method of areactor followed by series of separation or reactivedistillation [11, 13, 18].The conventional method of biodiesel productionis carried out by esterification or transesterificationprocess in the presence of a catalyst using a stirred tankreactor followed by purification [19] while reactivedistillation is a process that is capable of combining bothseparation and chemical reaction in a single equipmentunit[20-23].Reactive distillation has a lot of advantagesespecially for those reactions occurring at suitable andappropriate conditions for the distillation of the reactioncomponents [11-12, 24-31]. Apart from that, this processcombines the benefits of equilibrium reaction withdistillation in order to achieve a substantial progress inpromoting reaction conversion as a result of constantrecycling of unconverted materials and removal ofproducts. As such, the process is able to reduce capital andoperating costs as a result of the reduction that occurs inthe number of equipment units of the plant [11, 31-33]. Inaddition to the advantages mentioned before, basically, thecombination of reaction and distillation in the sameequipment unit gives rise to suppression of side reaction(s)and utilization of heat evolved from an exothermicreaction for mass transfer operation. These synergisticeffects of the process result in low energy cost and highproduct yields [9, 31-34]. The accomplishment of thisprocess can be achieved theoretically via the application ofa process simulator like Aspen HYSYS.Aspen HYSYS is a process simulationenvironment designed to serve many processing industries.It is an interactive, intuitive, open and extensible program.It also has many add-on options to extend its capabilitiesinto specific industries. With this program, rigoroussteady state and dynamic models for plant design can becreated. Apart from that, monitoring, troubleshooting,operational improvement, business planning and assetmanagement can be performed with the aid of the processsimulator. Through its completely interactive interface,process variables and unit operation topology can be easilymanipulated [35-36].The information obtained from the literature hasrevealed that some researches have been carried out on theapplication of this process simulator (Aspen HYSYS) toproduction of biodiesel, which is a renewable energy type.For instance, West et al. [37] modelled and simulated fourcontinuous biodiesel processes using Aspen HYSYS. Thefirst two processes employed traditional homogeneousalkali and acid catalysts while the third and the fourthprocesses used a heterogeneous acid catalyst and asupercritical method, respectively, to convert a wastevegetable oil feedstock into biodiesel. Santana et al. [38]designed and simulated a continuous biodiesel plant usingcastor oil as feedstock with the aid of Aspen HYSYSsimulator. Simasatitkul et al. [10] used Aspen HYSYS toinvestigate the production of biodiesel from thetransesterification reaction between soybean oil andmethanol in a reactive distillation column and analysed theeffects of some operating and design parameters onbiodiesel production. Lee et al. [39] simulated threecontinuous biodiesel processes with production capacity of40,000 tonne/yr, including a convention alalkali-catalyzedprocess using both fresh and waste vegetable oil and asupercritical methanol process using waste vegetable oil asthe raw material with the aid of Aspen HYSYS. Ravindraet al. [40] employed Aspen HYSYS to develop model forenzyme catalyzed and conventional alkali-catalyzedbiodiesel production processes in order to investigate theenvironmental performance of the enzyme-catalyzedprocess in comparison with the conventional alkalicatalyzed one using life cycle analysis (LCA). Orifici et al.[41] used Aspen HYSYS to simulate and optimize theprocess of biodiesel production from the transesterificationreaction of crude palm oil with methanol. Karacan andKaracan [42] employed Aspen HYSYS for the simulationof reactive distillation that was used for the production ofa fatty acid methyl ester (a biodiesel) at optimumconditions. According to the work, canola oil andmethanol were used as feedstocks while potassiumhydroxide and potassium methoxide were used as differentformulations of catalysts. Giwa et al. [43] investigated theperformance of some fatty acids used for the production offatty acid methyl ester in a reactive distillation columnwith the aid of Aspen HYSYS. Giwa et al. [12] also570

VOL. 13, NO. 2, JANUARY 2018ISSN 1819-6608ARPN Journal of Engineering and Applied Sciences 2006-2018 Asian Research Publishing Network (ARPN). All rights reserved.www.arpnjournals.comdeveloped a prototype reactive distillation process forbiodiesel production from which the data used for artificialneural network modelling of the process were generated.Furthermore, Giwa et al. [44] used the combination ofAspen HYSYS and Minitab to carry out the production ofpalmitic acid methyl ester, which is also a biodiesel.Ibrahim and Maraire [45] also used Aspen HYSYS tocarry out the production of biodiesel from waste cookingoil. Tuluc et al. [46] carried out simulation andoptimisation study for biodiesel synthesis process based onrapeseed oil transesterification with methanol inhomogeneous catalysis by performing all necessarycalculations with Aspen HYSYS process simulator. Farraget al. [47] used some optimal process conditions todevelop an Aspen HYSYS rigorous model for biodieselproduction. Abdurakhman et al. [26] used Aspen HYSYSto carry out the simulation of biodiesel production fromwaste cooking oil using membrane reactor and studyingthe effect of free fatty acid content and membraneseparation effectiveness on biodiesel yield.From the literature review, it has been discoveredthat no work has used Aspen HYSYS process simulator tocarry out the simulation of biodiesel production comparingboth the conventional and the reactive distillationprocesses. Therefore, this work is carried out to bridge thisgap by applying Aspen HYSYS process simulator tobiodiesel production using the method of reactor followedby separation and the integrated one involving thesimultaneous occurrence of reaction and separation in asingle unit.2. METHODOLOGYThe approach used in carrying out this study isthe application of Aspen HYSYS [48] process simulator todevelop and simulate the models of biodiesel productionprocess via the conventional and the integrated (reactivedistillation) methods.The model developed for the conventionalmethod of biodiesel production process with the aid ofAspen HYSYS is given in Figure-1. As can be seen fromthe figure, the process had two equipment units - a reactorand a distillation column. Two feed streams (linoleic acidand methanol) entering the reactor at the same temperatureand pressure of 25 oC and 1 atm, respectively. The flowrate of the linoleic acid was 50 mL/min while that of themethanol was 10 mL/min. The fluid package used for thesimulation of the conventional process was UNIversalQUAsi Chemical model (UNIQUAC).The reaction (Equation 1) occurring in the reactorwas modelled as an equilibrium type, the basis of whichwas activity in vapour phase and the equilibrium constantof which was estimated using Gibbs Free Energy.Furthermore, the distillation column used to purify thebottom product having higher amount of methyl linoleate(the desired product) was modelled to have 30 stages withits feed entering at the 15th stage. The pressure of each ofits condenser and the reboiler was set to be 1 atm. Also,the reflux ratio of the distillation operation was3kmol/kmol and the reboiler duty was 0.7kJ/s.(1)C 18 H 32 O 2 CH 3 OH C 19 H 34 O 2 H 2 OFor the reactive distillation, the developed modelobtained with the aid of Aspen HYSYS is given in Figure2. Just as in the case of the reactor of the conventionalmodel of the process, this one also had two feed streams.The upper feed stream, which was linoleic acid, enteredthe reactive distillation column at a temperature of 350 oCand a pressure of 5 atm while the lower feed stream, whichwas methanol, was passed into the column at atemperature and a pressure of 150 oC and 1 atmrespectively. The reactive distillation column also had 30stages, and the upper and the lower feed streams entered atthe 8th and the 19th stages respectively. Similarly, thepressures of the condenser and the reboiler of the reactivedistillation was 1 atm.Figure-1. Aspen HYSYS conventional biodiesel production process model.571

VOL. 13, NO. 2, JANUARY 2018ISSN 1819-6608ARPN Journal of Engineering and Applied Sciences 2006-2018 Asian Research Publishing Network (ARPN). All rights reserved.www.arpnjournals.comFigure-2. Aspen HYSYS reactive distillation biodiesel production process model.The reaction given in Equation (1) was alsooccurring between the two feed stages of the column.Being a reactive distillation process, the developed AspenHYSYS was simulated using Sparse Continuation Solver.For the purpose of comparison, the reflux ratio and thereboiler duty of the reactive distillation column were alsomade to be 3 kmol/kmol and 0.7 kJ/s, respectively whilethe fluid package was also selected to be UNIversalQUAsiChemical model (UNIQUAC).3. RESULTS AND DISCUSSIONSThe results obtained from the simulation of themodel developed with the aid of Aspen HYSYS simulatorfor the production of biodiesel for green energy revolutionfrom the esterification reaction between linoleic acid andmethanol showed that a reaction conversion ofapproximately 73% can be achieved in the reactor of theconventional process. The value of the conversion wasfound not to be bad for a system like this.Apart from the reaction conversion that wasconsidered as the result of the simulation, the balancesaround each equipment of the process were as wellinvestigated to ascertain the proper working of the processsimulator.Given in Table-1 are the molar flowrates of thecomponents involved in the reaction taking place in theconventional process. As can be seen from the table, onlylinoleic acid and methanol entered the reactor while themixture coming out of the reactor was containing all thefour components involved in the process, but at differentmolar flow rates. It was also discovered from the resultsgiven in Table 1 that the desired product of the reaction,which was methyl linoleate (biodiesel) had the highestmolar flow rate as the liquid (bottom) product of thereaction. The component with the highest mole flow rateat the top of the reactor, which was coming out as vapour,was methanol. That methanol was, actually, the unreactedone of the process. It was also noticed from the results thatthe system was operating at steady state because the totalmolar flow rate of the input was equal to that of the output.572

VOL. 13, NO. 2, JANUARY 2018ISSN 1819-6608ARPN Journal of Engineering and Applied Sciences 2006-2018 Asian Research Publishing Network (ARPN). All rights reserved.www.arpnjournals.comTable-1. Molar flowrates of the components involved in the reaction of the conventional process.gmol/minComponentInputOutputTotalLinoleic acidMethanolTop productBottom productInputOutputLinoleic 00000.24830.12840.00210.24830.1305Methyl 4830.28830.12210.41040.4104Table-2 gives the mass flow rates of thecomponents involved in the reaction of the conventionalprocess of biodiesel production for green energyrevolution, which has been simulated with the aid ofAspen HYSYS process simulator. The observations madein the case of this mass flow rate of the components werefound to be similar to those of the molar flow rates. Forinstance, in this case also, the total mass flow rates of boththe input and the output of the reactor were approximatelythe same. This was another indication that the system wasoperating at steady state, and that the law of conservationof mass has been obeyed by the process simulator. Inaddition, the component with the highest mass flow rate inthe liquid product of the reaction was discovered to be thedesired product, which was methyl linoleate.Table-2. Mass flowrates of the components involved in the reaction of the conventional process.g/minComponentInputOutputTotalLinoleic acidMethanolTop productBottom productInputOutputLinoleic ol0.00007.95724.11570.06627.95724.1819Methyl 17.957219.245134.149053.396353.3942Also, considered as the results of this work werethe volume flow rates of the components involved in thereaction of the conventional process. In the case, thehighest volume flow rate was observed to be possessed bymethyl linoleate in the liquid product of the processreaction. Unreacted linoleic acid and methanol were foundto dominate the vapour product volume of the reactor.Table-3. Volume flow rates of the components involved in the reaction of the conventional process.mL/minComponentInputOutputTotalLinoleic acidMethanolTop productBottom productInputOutputLinoleic ol0.000010.00005.17230.083210.00005.2555Methyl 010.000021.911438.154360.000060.0657573

VOL. 13, NO. 2, JANUARY 2018ISSN 1819-6608ARPN Journal of Engineering and Applied Sciences 2006-2018 Asian Research Publishing Network (ARPN). All rights reserved.www.arpnjournals.comTable-4. Molar compositions of the components involved in the reaction of the conventional process.Molar fractionComponentInputOutputLinoleic acidMethanolTop productBottom productLinoleic 44560.0169Methyl 0.39990.0207Total1.00001.00001.00001.0000Table-5. Mass compositions of the components involved in the reaction of the conventional process.Mass fractionComponentInputOutputLinoleic acidMethanolTop productBottom product1.00000.00000.06420.3268Linoleic acidMethanol0.00001.00000.21390.0019Methyl 0.10790.0013Total1.00001.00001.00001.0000Table-6. Volume compositions of the components involved in the reaction of the conventional process.Volume fractionComponentInputOutputLinoleic acidMethanolTop productBottom productLinoleic 23610.0022Methyl 0.09500.0012Total1.00001.00001.00001.0000Given in Tables 4, 5 and 6 are respectively themolar, the mass and the volume compositions of thecomponents involved in the reaction of the conventionalprocess of the biodiesel production. As can be seen fromthe tables, based on the fact that biodiesel (methyllinoleate) was given from the bottom of the reactor, it wasfound to have the highest molar, mass and volumefractions as the liquid bottom product of the processwhereas the unreacted methanol had the highest molar,mass and volume fractions in the vapour top product of theprocess.Table-7. Molar flow rates of the components involved in the separation of the conventional process.ComponentLinoleic acidMethanolMethyl 1221Top m product0.01300.00000.00000.00000.0130Total input0.03980.00210.07770.00250.1221Total output0.03980.00210.07770.00250.1221574

VOL. 13, NO. 2, JANUARY 2018ISSN 1819-6608ARPN Journal of Engineering and Applied Sciences 2006-2018 Asian Research Publishing Network (ARPN). All rights reserved.www.arpnjournals.comOwing to the fact that it was deemed necessary topurify the product given at the bottom of the reactor, inwhich the desired product was present in large amount, it(the liquid product) was passed into a distillation columnso as to distil the mixture and obtain higher purity of thedesired product (biodiesel), and the results of thedistillation are given thus.Table-8. Mass flowrates of the components involved in the separation of the conventional process.g/minComponentInputTop productBottom productTotal inputTotal outputLinoleic 20.06620.00000.06620.0662Methyl 43234.149034.1490Table-9. Volume flowrates of the component mixtures involved in the separation.mL/minComponentInputTop productBottom productTotal inputTotal outputLinoleic 20.08320.00000.08320.0832Methyl 08938.154338.1543Tables 7, 8 and 9 respectively give the molar, themass and the volume flow rates of the componentsinvolved in the distillation operation of the conventionalprocess of biodiesel production for green energyrevolution. It was noticed from the results given in Tables7-9 that the desired product, which was methyl linoleate,was coming from the top section of the column as acondensed liquid. According to the tables, the distillationoperation was also found to occur at steady state becausethe total molar, the total mass and the total volume flowrates of the components in the input and the output of thedistillation column were found to be approximately thesame. This was also another point showing that theprocess simulator was obeying the law of conservation ofmass, and this was observed to be an indication that theprocess simulator was functioning correctly.Table-10. Molar compositions of the components involved in the separation of the conventional process.ComponentLinoleic acidMolar fractionInputTop productBottom 0Methyl Total1.00001.00001.0000575

VOL. 13, NO. 2, JANUARY 2018ISSN 1819-6608ARPN Journal of Engineering and Applied Sciences 2006-2018 Asian Research Publishing Network (ARPN). All rights reserved.www.arpnjournals.comTable-11. Mass compositions of the components involved in the separation of the conventional process.ComponentMass fractionInputTop productBottom productLinoleic thyl Total1.00001.00001.0000Table-12. Volume compositions of the components involved in the separation of the conventional process.ComponentVolume fractionInputTop productBottom productLinoleic thyl Total1.00001.00001.0000The compositions of the components entering andleaving the distillation (separation) column of theconventional process of the biodiesel production revealedthat the aim of the separation was achieved because,comparing the mole fraction, the mass fraction and thevolume fraction of methyl linoleate entering the column,an improvement was seen as there was an increase in thecompositions between the input and the output streams ofthe distillation column. The improvement in thecompositions of the streams leaving the distillation columnas compared to the one entering it was an indication thatseparation actually took place effectively.Now, considering the results obtained from thereactive distillation process of the production of biodiesel,it can be noticed from Figure-3 showing the conversionprofile of the column that, it was possible to achieve aconversion of more than 90% within the column.Comparing this conversion with the one obtained from theconventional production method, it was observed thathigher conversion could be achieved in the reactivedistillation column than that obtainable in the reactor ofthe conventional process alone. It can also be seen fromFigure-3 that the reaction conversion decreased down thecolumn towards the reboiler. It means that, for theproduction of biodiesel with very high conversion, thereaction should be made to occur at the stages of thereaction close to the upper feed stream.576

VOL. 13, NO. 2, JANUARY 2018ISSN 1819-6608ARPN Journal of Engineering and Applied Sciences 2006-2018 Asian Research Publishing Network (ARPN). All rights reserved.www.arpnjournals.com1009080Conversion (%)70605040302010089101112131415Column stage number16171819Figure-3. Conversion profile of the reactive distillation process.Table-13. Molar flowrates of the components involved in the reactive leic acidMethanolTop productBottom productInputOutputLinoleic 00000.62080.28400.01290.62080.2968Methyl 2080.59370.35120.94490.9449Given in Table-13 is the molar flow rates of thecomponents involved in the reactive distillation process ofthe biodiesel production for green energy revolution. Asshown in the table, it was noticed that the system, in thiscase also, was operating at steady state because the totalmolar flow rates of both the input and that of the outputwere the same, despite the differences in the molar flowrates of the components. It should be noted that thedifferences in the molar flow rates of the components weredue to the reaction (consumption and generation)occurring in the reaction (middle) section of the column.Table-14. Mass flowrates of the components involved in the reactive c acidMethanolTop productBottom productInputOutputLinoleic 0.000019.89309.09890.412419.89309.5113Methyl 19.893014.679096.0863110.7711110.7653577

VOL. 13, NO. 2, JANUARY 2018ISSN 1819-6608ARPN Journal of Engineering and Applied Sciences 2006-2018 Asian Research Publishing Network (ARPN). All rights reserved.www.arpnjournals.comTable-15. Volume flowrates of the components involved in the reactive ic acidMethanolTop productBottom productInputOutputLinoleic ol0.000025.000011.43480.518325.000011.9531Methyl 00025.000017.0262108.1546125.0000125.1808The observations made for

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