Process Simulation using Aspen HYSYS / Aspen Plus Training Course

Course Overview

Learning Objectives

• Analyze the role of process simulation in process design, operational optimization, energy efficiency, troubleshooting, safety review, and asset performance during the course.
• Assess process objectives, available data, operating conditions, stream information, and equipment requirements before developing a simulation model.
• Develop a structured simulation workflow that defines system boundaries, assumptions, thermodynamic methods, unit operations, streams, and performance criteria.
• Evaluate the suitability of common thermodynamic property methods for selected hydrocarbon, chemical, water, utility, and separation applications.
• Apply Aspen HYSYS or Aspen Plus to create material streams, energy streams, process equipment models, and connected process flowsheets.
• Design simulation cases for heat exchangers, separators, distillation columns, pumps, compressors, valves, reactors, and utility systems.
• Improve model quality by applying convergence checks, mass and energy balance verification, data reconciliation, sensitivity analysis, and engineering review.
• Assess process performance using simulation outputs such as flow, pressure, temperature, composition, heat duty, energy consumption, recovery, and equipment loading.
• Implement scenario analysis to evaluate operating changes, capacity constraints, energy-saving opportunities, equipment modifications, and process optimization options.
• Strengthen technical decision-making by communicating model assumptions, uncertainties, limitations, findings, and recommended actions clearly.
• Evaluate the relationship between simulation models, process flow diagrams, P&IDs, operating procedures, equipment data sheets, and plant data.
• Develop a time-bound action plan for applying Aspen HYSYS or Aspen Plus process simulation in the participant’s organization.

Who Should Attend

Learning Outcomes

• Explain the purpose and business value of process simulation using Aspen HYSYS and Aspen Plus in design, operations, optimization, and technical decision-making.
• Define process objectives, model boundaries, assumptions, available data, and acceptance criteria for a selected simulation case.
• Select an appropriate thermodynamic property method based on fluid composition, operating conditions, phase behaviour, and process requirements.
• Create and connect material streams, energy streams, unit operations, and utility systems within a process simulation flowsheet.
• Develop steady-state models for common process equipment, including separators, heat exchangers, pumps, compressors, valves, distillation columns, and reactors.
• Apply mass and energy balance checks to validate simulation results and identify inconsistent data or assumptions.
• Interpret simulation outputs related to flow rate, pressure, temperature, composition, heat duty, energy use, recovery, capacity, and equipment loading.
• Conduct sensitivity analyses and scenario comparisons to evaluate operating changes, process constraints, and improvement opportunities.
• Assess the effect of changes in feed conditions, operating pressure, temperature, utility duty, equipment capacity, and control targets on process performance.
• Identify model limitations, uncertainties, convergence issues, and data-quality risks that require engineering judgement or field verification.
• Present simulation findings, assumptions, risks, and recommendations clearly to technical teams, managers, and decision makers.
• Produce an initial workplace roadmap for using Aspen HYSYS or Aspen Plus to support process improvement and engineering analysis.

Course Outline