Training Manual For Beginners in Process Simulation

PROCESS SIMULATION USING DWSIM 27 August 2022
By Viraj Desai, Process Engineer
PROCESS SIMULATION USING DWSIM:

A FREE AND OPEN-SOURCE CHEMICAL PROCESS SIMULATOR
BY
VIRAJ DESAI, PROCESS ENGINEER
EMAIL: VIRAJ DESAI
LEVEL: BASIC
VERSION: 0.00
AUG 2022
1
PREFACE
The manual “Process Simulation Using DWSIM” presents a set of basic exercises using a free and
open-source chemical process simulator “DWSIM” and can be utilized to establish process
simulation laboratory as part of undergraduate chemical engineering degree or in allied degree
curriculum. Simulation covers topics across the broad spectrum of chemical engineering courses
covering mixing, reaction, phase equilibrium, heat, and mass transfer operations. The problem
statements are rightly placed at the beginner’s level with each exercise completes in terms of
sufficient instructions that enable the learner to perform the exercise with ease on their own.
Supplementary self-learning exercises are also provided for simulation experiments to further aid a
curious learner.
Thanks
Viraj Desai
P.E. O&G
Disclaimer
All the exercises are strictly restricted to learning only and not meant to be used in real world
application.
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PROCESS SIMULATION USING DWSIM: A FREE AND OPEN-SOURCE CHEMICAL

PROCESS SIMULATOR
PREAMBLE
DWSIM is an open-source CAPE-OPEN compliant chemical process simulator. It features a Graphical

User Interface (GUI), advanced thermodynamics calculations, reactions support and petroleum
characterization / hypothetical component generation tools. DWSIM can simulate steady-state,
vapor–liquid, vapor–liquid-liquid, solid–liquid and aqueous electrolyte equilibrium processes and has
built-in thermodynamic models and unit operations (https://en.wikipedia.org/wiki/DWSIM ). It is
available for Windows, Linux and Mac OS.
The objective of the course is to create awareness of the open-source process simulator “DWSIM”
among prospective graduates and practicing process engineers. The course will cover basic aspects
of create flow sheet in DWSIM and simulation of simple units such as Mixer, Splitters, CSTR,
Distillation column, Pumps, Turbines, Compressors, etc.
Target Audience
• Junior Interns in Process Firms

• III / Final year B. Tech. Chemical Engineering students
• M. Tech. Chemical Engineering students
• Practicing Process Engineers
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Table of Contents
1 Mixing of Ideal Liquid Streams ........................................................................................................ 6

2 Determination of Thermo-physical Properties of Pure Component .............................................. 9
3 Generation of VLE Data of Binary Component System................................................................. 13
4 Simulation of a Flash Column........................................................................................................ 17
5 Simulation of a CSTR for Liquid Phase Reaction ........................................................................... 20
6 Simulation of a Distillation Column .............................................................................................. 23
7 Determination of Heat Duty of Heater ......................................................................................... 26
8 Determination of Power for a Pump............................................................................................. 29
9 Determination of Power for a Compressor .................................................................................. 31
10 Power Generated by a Turbine ................................................................................................. 33
11 Pressure Drop across a valve .................................................................................................... 35
12 Residence Time Calculation for a Tank ..................................................................................... 37
13 Flow Split with Splitter .............................................................................................................. 40
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List of Figures
Figure 1 Mixer ......................................................................................................................................... 7

Figure 2 Thermodynamic property of water ........................................................................................ 10
Figure 3 Pure Component property viewer .......................................................................................... 10
Figure 4 Pure Component Property viewer .......................................................................................... 11
Figure 5 Heat Capacity of water............................................................................................................ 12
Figure 6 Benzene-Toluene Stream ........................................................................................................ 13
Figure 7 Add utility Window ................................................................................................................. 14
Figure 8 Binary Envelope Window T vs XY ............................................................................................ 14
Figure 9 Binary Envelope Window P vs XY ............................................................................................ 15
Figure 10 Binary Envelope Window X vs Y ............................................................................................ 16
Figure 11 Flash Column ......................................................................................................................... 18
Figure 12 Reaction window................................................................................................................... 21
Figure 13 CSTR ...................................................................................................................................... 22
Figure 14 Columns Window .................................................................................................................. 24
Figure 15 Distillation ............................................................................................................................. 24
Figure 16 Exchangers Window .............................................................................................................. 27
Figure 17 Heat Duty .............................................................................................................................. 27
Figure 18 Pressure Changes Window ................................................................................................... 29
Figure 19 Pump ..................................................................................................................................... 30
Figure 20 Pressure Changes window .................................................................................................... 31
Figure 21 Compressor ........................................................................................................................... 32
Figure 23 Turbine .................................................................................................................................. 34
Figure 25 Valve...................................................................................................................................... 36
Figure 26 Separator and tank window .................................................................................................. 38
Figure 27 Tank ....................................................................................................................................... 38
Figure 28 Mixer and Splitters Window ................................................................................................. 40
Figure 29 Splitter ................................................................................................................................... 41
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Mixing of Ideal Liquid Streams 27 August 2022
1 MIXING OF IDEAL LIQUID STREAMS
Objective
Develop a simple process sheet to mix two liquid streams and estimate the flow rate and
composition of outlet stream.
Data
• Inlet stream 1: 10 mol % Methanol solutions flowing at 20 kmol/h

• Inlet stream 2: 80 mol % Methanol solutions flowing at 10 kmol/h
• Both the streams are at 30 °C and at 1 bar pressure
• The liquid streams can be considered as ideal
DWSIM Blocks Used
• Mixer
• Material Stream
• Indicators (Digital or Analog)
Procedure
1. Start a new DWSIM Simulation (DWSIM VER 8.0 - CLASSIC UI). Click on “New steady state
Simulation” as a template for new simulation
2. The simulation configuration window will be opened. It shows a specification page. Add
components required to solve the problem statement. In the present case, add Water and
Methanol. Ensure all components are added from the same property database. For instance,
in this case, both components are added from “ChemSep” database.
3. Specify the thermodynamic package as Raoult’s law.
4. Customize the system of units for the simulation and click “Next”.
5. The flow sheeting section of simulation window will be opened. First, let provide input and
output streams for the unit operation to be performed. Drag and drop two Material streams
available at the right, in the object palette. Rename them stream as “Inlet-Stream-1”and
“Inlet-Stream-2”. These serve as input streams.
6. On clicking the “Inlet-Stream-1” and “Inlet-Stream-2” stream, general information about the
stream will be displayed on the left side of screen. Specify the feed compositions,
temperature, and pressure for the inlet streams. Once credentials are specified for the inlet
streams, the color of stream turns blue.
7. Add one more Material stream i.e., Drag and drop it into the flow sheet. Rename the stream
as “Outlet Stream”. This serves as output stream.
8. Below the Unit Operation tab on left, locate the Stream Mixer block. Drag and drop into the
flow sheet. Rename it as “Mixer”.
9. No separate specification is required for the “Mixer” block.
10. Add digital and analog indicators for the material streams and mixer as shown in the figure
below and give targeting properties.
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Figure 1 Mixer
11. Now, all necessary credentials required for simulation are added. It should be connected in a
proper sequence. Click on “Mixer” block, the general information about the block is
displayed on the right. Under “connections” tab, for all streams click the dropdown button
and select the necessary connections. If all the connections are given correctly, all the blocks
will turn blue.
12. Run the simulation by pressing “Solve flow sheet” button on the top corner of the screen.
13. To analyze/display the results, select on “Master property table” icon on the tool bar. A box
will appear which is double clicked to modify it further. Select the streams which have to be
shown in output and click “OK”. The property table will be opened showing all the results as
shown in the figure below.
Properties Methanol Water Mixed

Stream Stream Stream
Temperature (K) 298.15 298.15 298.15
Pressure (Pa) 101325 101325 101325
Mass Flow (kg/s) 0.170218 0.057835 0.228053
Molar Flow (mol/s) 5.55556 2.77778 8.33334
Volumetric Flow (m3/s) 0.000211298 6.11026E-05 0.000269039
Density (Mixture) (kg/m3) 805.584 946.524 847.656
Molecular Weight (Mixture) 30.6392 20.8206 27.3663

(kg/kmol)
Specific Enthalpy (Mixture) -1256.07 -2053.47 -1458.29

(kJ/kg)
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Specific Entropy (Mixture) -4.08201 -6.72148 -4.652

(kJ/[kg.K])
Molar Enthalpy (Mixture) -38485 -42754.6 -39908.2

(kJ/kmol)
Molar Entropy (Mixture) -125.07 -139.945 -127.308

(kJ/[kmol.K])
Thermal Conductivity (Mixture) 0.212675 0.422925 0.248449

(W/ [m.K])
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Determination of Thermo-physical Properties of Pure Component 27 August 2022
2 DETERMINATION OF THERMO-PHYSICAL PROPERTIES OF PURE

COMPONENT
Objective
Determine the thermo-physical properties of pure component as function of temperature and

pressure. For instance, determine the specific heat capacity of liquid water at 1 bar from 30 °C to 90
°C
Data
• Fluid: Water
• Thermodynamic model: Ideal
DWSIM Block
• Material Stream
• Digital indicators
Procedure
1. Start a new DWSIM simulation (DWSIM VER 8.0 - CLASSIC UI). Click on “New steady state
simulation” as a template for new simulation
2. The simulation configuration window will be opened. The specification page will appear.
Select the component required for the simulation. In this case Water is added.
3. Select and add the property package (Raoult’s law) and click “Next”. Add the default flash
algorithm for the simulation. Click “Next”.
4. Choose the desired system of units for the simulation and click “Next”.
5. The flow sheeting section will be opened.
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6. Add a material stream and give the conditions provided in the data and add digital indicators
for targeting the properties
Figure 2 Thermodynamic property of water
7. In the top menu, under the “Tools” tab, click on “Pure component property viewer” to
generate thermo-physical property data.
Figure 3 Pure Component property viewer
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8. On clicking the tab, pure component property window will appear. Select the component for
which the thermo-physical data must be generated. In this case it is water.
9. Once you selected the component, the appearance of window will be changed as shown in
figure.
Figure 4 Pure Component Property viewer
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10. Below the component tab, identify a tab named “Liquid-phase”. On clicking this tab, a graph
for temperature versus specific heat capacity of water will be generated.
Figure 5 Heat Capacity of water
11. Similarly you can also generate for vapourization enthalphym vapour pressure, surface
tension, viscosity,density and so on.
12. To view the results in tabulated form, click on “Data-table” option where, all the thermo-
physical properties are tabulated.
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Generation of VLE Data of Binary Component System 27 August 2022
3 GENERATION OF VLE DATA OF BINARY COMPONENT SYSTEM
Objective
Generate vapour-liquid equilibrium data (VLE) for a binary component system
Data
• Fluid components: Benzene - Toluene
• Pressure = 1 atm
• Thermodynamic model: Ideal
DWSIM Block
• Material Stream
Procedure
1. Start a new DWSIM simulation (DWSIM VER 8.0 - CLASSIC UI). Click on “New steady state
simulation” as a template for new simulation
2. The simulation configuration window will be opened. The specification page will appear.
Select the components required for the simulation, namely “Benzene” and “Toluene”.
Ensure, components are added from same property database. In this illustration, both
components are added from “ChemSep” database.
3. Select and add the property package (Raoult’s law) and click “Next”. Add the default flash
algorithm for the simulation. Click “Next”.
4. Choose the desired system of units for the simulation and click “Next”.
5. The flowsheeting section will be opened.
6. Add a material stream and specify the data.
Figure 6 Benzene-Toluene Stream
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7. To generate binary VLE, at least one material stream is required in the flowsheeting section.
Hence, click on material stream object at the object palette and drag it to the flowsheet
section.
8. Click the “material stream” to open its specification window. Next to the object name, you
will find an icon, click it to attach utility and under utility add an “Binary Envelope” as shown
in the figure below.
Figure 7 Add utility Window
9. A new window opens. Enlarge it. Use the different pull down menus available in the window
to generate the Txy and VLE plot for Benzene and Toluene at given pressure. Provide
settings as shown below and click at “Calculate” to see the Txy plot.
Figure 8 Binary Envelope Window T vs XY
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10. Similarly click on Pxy and then on “Calculate” to generate Pxy plot.
Figure 9 Binary Envelope Window P vs XY
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11. Click on {T}xy and “Calculate” to generate {T}xy plot.
Figure 10 Binary Envelope Window X vs Y
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Simulation of a Flash Column 27 August 2022
4 SIMULATION OF A FLASH COLUMN
Objective
Develop a simple process flow sheet to estimate the liquid and vapour composition of multi-
component mixture undergoing partial vaporization.
Data
• Components: n-pentane, n-hexane, and n-heptane
• Feed composition: 25 mol % n-pentane, 45 mol% n-hexane, and 30 mol% n-heptane
• Basis: 100 kmol/h
• Operating conditions
• Temperature = 69 °C
• Pressure = 1.013 bar
DWSIM Blocks Used

• Gas-Liquid Separator
Procedure
1. Start a new DWSIM Simulation (DWSIM VER 8.0 - Classic UI). Click on “New steady state
Simulation” as a template for new simulation.
2. The simulation configuration window will be opened. It shows a specification page. Add the
three components - n-pentane, n-hexane, and n-heptane. Ensure that all the components
are added from same property package. Example: All the 3 components are selected from
Chemsep database. Click “Next” button.
4. Customize the system of units for the present simulation and click “Next”.
5. The flowsheeting section of simulation window will be opened. It is necessary to provide
input and output streams for the unit operation to be performed. Drag and drop the
Material stream available at the right, in the object palette. Rename the stream as “Feed-
In”. This serves as the input stream.
6. On clicking the “Feed-In” stream, general information about the stream will be displayed on
the left side of screen. Specify the feed compositions, flow rate, temperature, and pressure
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for the stream, once composition and flow rate are specified for the inlet stream, the color
of stream turns blue.

Figure 11 Flash Column
7. Add two more Material streams i.e., Drag and drop it into the flowsheet. Rename those
streams as “Vap-Out”, “Liq-Out” & “Heavy-Out”. These serves as output streams.
8. Below the unit operation tab on left, locate the Gas-Liquid Separator block. Drag and drop
into the flow sheet. Rename it as “Flash Column”.
9. Now, all necessary credentials required for simulation are added. It should be connected in a
proper sequence. Click on “Flash Column” block, the general information about the block is
displayed on the right. Under “connections” tab, for all streams click the dropdown button
and select the necessary connections. If all the connections are given correctly, all the blocks
will turn blue.
10. Add Flow transmitters as indicators in all the streams and target mass flow as property.
11. For column add a pressure transmitter, and target pressure.
12. Run the simulation by pressing “Solve flow sheet” button on the top corner of the screen. It
will be in the shape of Triangle.
will appear which is double clicked to modify it further. Select the streams which must be
Heavy Feed Vapour Liquid

Liquid
Temperature (K) 343.15 343.15 343.15 343.15
Pressure (Pa) 101300 101300 101300 101300
Mass Flow (kg/s) 0 2.41324 1.15056 1.26268
Molar Flow (mol/s) 0 27.7778 13.8003 13.9775
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Volumetric Flow (m3/s) 0 0.390702 0.388664 0.0020377

Density (Mixture) (kg/m3) ∞ 6.17669 2.9603 619.662
Molecular Weight 0 86.8767 83.372 90.3371
(Mixture) (kg/kmol)
Specific Enthalpy 0 -95.2365 79.2048 -254.188
(Mixture) (kJ/kg)
Specific Entropy (Mixture) 0 -0.162612 0.349025 -0.628817
(kJ/[kg.K])
Molar Enthalpy (Mixture) 0 -8273.83 6603.46 -22962.6
(kJ/kmol)
Molar Entropy (Mixture) 0 -14.1272 29.0989 -56.8055
(kJ/[kmol.K])
Thermal Conductivity 0 0.0624136 0.0178495 0.106413
(Mixture) (W/[m.K])
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Simulation of a CSTR for Liquid Phase Reaction 27 August 2022
5 SIMULATION OF A CSTR FOR LIQUID PHASE REACTION
Objective
Develop a simple process sheet to determine the exit composition from a Continous stirred tank
reactor (CSTR)
Data
• Reaction: Ethylene glycol production in CSTR: Ethylene oxide reacts with water to form
Ethylene Glycol
𝐶2 𝐻4 𝑂(𝑙) + 𝐻2 𝑂(𝑙) → 𝐶2 𝐻6 𝑂2(𝑙)
• Inlet stream: 26 m3/h of aqueous solution of Ethylene oxide with a mol fraction of 15% and
rest water. Reaction carried out at 55 °C under atmospheric condition in CSTR of 2 m3
• Reaction rate: −𝑟 = 𝑘𝐶𝐸0
• Where CEO: Molarity of Ethylene oxide; k: rate constant = 0.005 1/s
DWSIM Blocks Used
• Continuous Stirred Tank Reactor (CSTR)
Procedure
2. The simulation configuration window will be opened. Add 3 components for the simulation -
Ethylene oxide, Ethylene Glycol and Water
3. Ensure that all the components are added from same property package. Example: All the 3
components are selected from Chemsep database. Click “Next” button.
4. Select and add the property package and click “Next”. Add the default flash algorithm for the
simulation. Click “Next”.
5. The flowsheeting section of simulation window will be opened. Drag and drop the Material
stream from the object palette and rename the stream as “Feed”. This serves as input.
6. On clicking the “Feed” block, general information about the block will be displayed on the
left of the screen.
7. Specify the feed compositions, flow rate, temperature, and pressure for the inlet streams
once composition and flow rate are specified for the inlet streams, the color of stream turns
blue.
8. Add one more Material stream i.e., Drag and drop it into the flow sheet. Rename it as
“Product”. This serves as output stream.
9. Add an energy stream which is available in the object palette below the Material stream.
10. Below the Unit Operation tab, locate the “Continous Stirred Tank Reactor” CSTR block. Drag
and drop into the flow sheet. Rename it as “CSTR”.
11. Under “Tools” tab in select “Reaction Manager” tab. choose the type of reaction i.e.,
“Equilibrium reaction” for this problem. A dialogue box will appear. Give an appropriate
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name and description about the reaction.
Figure 12 Reaction window
12. Select the checkboxes adjacent to the component names, which has to be included in the
reaction. Give the stoichiometry of the reaction and choose appropriate base component.
13. In this case the base component is “Ethylene Oxide”. Once base component, stoichiometry is
specified, a text “OK” appears in the stoichiometry tab. Specify the rate constant of the
reaction.
14. By default, the basis is activity and liquid phase. In this case it has to be changed to Molar
concentration and specify the phase as liquid.
15. Specify the rate constant of the reaction and click “OK”.
16. Click on “CSTR-REC” block, the general information about the block is displayed on the right.
Under “connections” tab, for all streams click the dropdown button and select the necessary
connections. If all the connections are given correctly, the blocks will turn blue.
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17. Add 2 analyzers from the indicators panel and specify molar fraction (liquid 1) / ethylene
glycol as the targeting property for both feed and product stream.
Figure 13 CSTR
Feed Product
Temperature (K) 328.15 328.15
Pressure (Pa) 101325 101325
Mass Flow (kg/s) 6.91362 6.91362
Molar Flow (mol/s) 315.39 313.125
Volumetric Flow (m3/s) 0.00722222 0.00720902
Density (Mixture) (kg/m3) 957.271 959.023
Molecular Weight (Mixture) (kg/kmol) 21.9209 22.0794
Specific Enthalpy (Mixture) (kJ/kg) -1795.78 -1797.8
Specific Entropy (Mixture) (kJ/[kg.K]) -4.93172 -4.90951
Molar Enthalpy (Mixture) (kJ/kmol) -39365 -39694.4
Molar Entropy (Mixture) (kJ/[kmol.K]) -108.108 -108.399
Thermal Conductivity (Mixture) (W/[m.K]) 0.423148 0.424053
Molar Fraction (Mixture) / Ethylene glycol 0 0.00723287
Mass Fraction (Mixture) / Ethylene glycol 0 0.0203324
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Simulation of a Distillation Column 27 August 2022
6 SIMULATION OF A DISTILLATION COLUMN
Objective
Develop a simple process flow sheet to estimate distillate and bottom composition of a distillation
column
Problem statement
100 kmol/h of an equimolar mixture of benzene and toluene at 70°C and 1 atm pressure is to be
separated by staged distillation column. A reflux ratio of 3 is used. Composition of benzene in the
distillate should be 99% (by mol) toluene in the bottom should be 99% (mol). A total condenser and
reboiler, both at 1 atm pressure are used. Determine the actual no. of stages, minimum reflux ratio
and the minimum no. of stages for the operation.
DWSIM Blocks Used
• Shortcut Column
• Material Streams
• Energy Streams
• Indicators
Thermodynamic Package
• UNIFAC.
Procedure
2. The simulation configuration window will be opened. Add the two components required for
simulation - Benzene and Toluene. Ensure that all the components are added from same
property package. Example: All the 2 components are selected from Chemsep database.
Click “Next” button.
3. Select and add the property package and click “Next”. Add the default flash algorithm for the
simulation. Click “Next”.
4. The flow sheeting section of simulation window will be opened. Drag and drop the Material
stream from the object palette. Rename it as “Feed”. This serves as input stream.
5. On clicking the “Feed” stream, general information about the block will be displayed on the
left of the screen. Specify the feed compositions, flow rate, temperature, and pressure for
the inlet streams. Once composition and flow rate are specified for the inlet streams, the
color of stream turns blue. Specification for the inlet stream
6. Add two more Material streams i.e., Drag and drop them into the flow sheet. Rename them
as “Distillate” and “Bottoms”. These serves as output streams.
7. Add two energy streams, one is for condenser duty (C-Duty) and the other is for re-boiler
duty (R-Duty).
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8. Below the Unit Operation tab, locate the “Shortcut Column” block. Drag and drop into the
flow sheet. Rename it as “DC”.
Figure 14 Columns Window
9. Click on “DC” block, the general information about the block is displayed on the left of the
screen. Provide calculation parameters as shown in the screenshot given below
10. Under Column configuration select “connections” tab. Click the dropdown button and give
appropriate connections. If all the connections are given correctly, the blocks will turn blue.
11. Add indicators on column, feed, distillate and bottom streams and target respective
properties.
Figure 15 Distillation
Property Value Units
Minimum Reflux Ratio 1.11363

Minimum Number of Stages 9.15433
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Actual Number of Stages 12.7253
Optimal Feed Stage 6.36267
Stripping Liquid 69.4445 mol/s
Rectify Liquid 41.6667 mol/s
Stripping Vapor 55.5556 mol/s
Rectify Vapor 55.5556 mol/s
Condenser Duty 1694.2 kW
Reboiler Duty 13484.3 kW
Property table
Bottoms Distillate Feed

Temperature (K) 1000.09 353.522 343.15
Pressure (Pa) 1.02668E+10 101325 101325
Mass Flow (kg/s) 1.27775 1.08684 2.36459
Molar Flow (mol/s) 13.8889 13.8889 27.7778
Volumetric Flow (m3/s) 1.12482E-05 0.0016119 0.00287003
Density (Mixture) (kg/m3) 113597 674.255 823.891
Molecular Weight (Mixture) (kg/kmol) 91.9982 78.2521 88.0251
Specific Enthalpy (Mixture) (kJ/kg) 8876.21 -328.694 -340.765
Specific Entropy (Mixture) (kJ/[kg.K]) 0.00688362 -0.905619 -0.831621
Molar Enthalpy (Mixture) (kJ/kmol) 816595 -25721 -29007.7
Molar Entropy (Mixture) (kJ/[kmol.K]) 0.63328 -70.8666 -70.7919
Thermal Conductivity (Mixture) 0.100323 0.126008 0.124969
(W/[m.K])
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Determination of Heat Duty of Heater 27 August 2022
7 DETERMINATION OF HEAT DUTY OF HEATER
Objective
Develop a simple process flow sheet to determine the heat duty required to heat a fluid to a desired
temperature
Data
• Fluid: Water
• Inlet mass flow rate: 50 kg/h
• Inlet temperature: 25 °C
• Outlet temperature: 90 °C
• Pressure: 1 bar
DWSIM Blocks Used
• Heater
• Material stream
• Energy Stream
• Indicator
Procedure
component “Water”
4. Select the system of units for the simulation and click “Next”.
stream available at the right, in the object palette. Rename the stream as “Flow-In”. This serves
as input stream.
6. Double click the “Flow-In” stream. The general information about the stream will be displayed
on the right side of screen. Specify the feed compositions, flow rate, temperature, and pressure
for the inlet streams once composition and flow rate are specified for the inlet streams, the
color of stream turns blue.
7. Add one more Material stream i.e., Drag and drop it into the flow sheet. Rename the stream as
“Flow-Out”. This serves as the output stream.
8. Add an energy stream from the object palette to the flow sheeting section.
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9. Below the Unit Operation tab on left, locate the Heater block. Drag and drop into the flow sheet.
Rename it as “HEATER”.
Figure 16 Exchangers Window
10. Click on “HEATER” block, the general information about the block is displayed on the right.
connections. Under calculation type choose “Outlet Temperature”. If all the connections are
given correctly, all the blocks will turn blue.
11. Add temperature indicators on input and output stream and target the desired properties.
12. Run the simulation by clicking on “Solve flow sheet” icon / button on the top corner of the
screen.
Figure 17 Heat Duty
13. To analyze/display the results, select on “Master property table” icon on the tool bar. A box will
appear which is double clicked to modify it further. Select the streams which have to be shown
in output and click “OK”. The property table will be opened showing all the results as shown in
the figure below.
Input Output
Pressure (Pa) 101325 101325
Mass Flow (kg/s) 0.0138889 0.0138889
Molar Flow (mol/s) 0.770951 0.770951
Volumetric Flow (m3/s) 1.39401E-05 1.43909E-05
27

Molar Enthalpy (Mixture) (kJ/kmol) -43974.4 -39004.7
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Determination of Power for a Pump 27 August 2022
8 DETERMINATION OF POWER FOR A PUMP
Objective
Develop a simple process flow sheet to determine the power required to pressurize a fluid for a
pump.
Data
• Fluid: Water
• Inlet Pressure: 2 bar
• Outlet Pressure: 5 bar
• Temperature: 50 °C
DWSIM Blocks Used
• Pump
• Material stream
• Energy Stream
• Indicators
Procedure
stream available at the right, in the object palette. Rename the stream as “Flow-In”. This
serves as input stream.
6. Double click the “Flow-In” stream. The general information about the stream will be
displayed on the right side of screen. Specify the feed compositions, flow rate, temperature,
and pressure for the inlet streams once composition and flow rate are specified for the inlet
as “Flow-Out”. This serves as the output stream.
9. Below the Unit Operation tab on left, locate thePump block. Drag and drop into the flow
sheet. Rename it as “PUMP”.
Figure 18 Pressure Changes Window
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Determination of Power for a Pump 27 August 2022
10. Click on “PUMP” block, the general information about the block is displayed on the right.
connections. Under calculation type choose “Outlet Pressure”. If all the connections are
11. Add pressure indicators on input and output stream and target the desired properties.
screen.
Figure 19 Pump
Output Input
Pressure (Pa) 500000 200000
Mass Flow (kg/s) 0.0138889 0.0138889
Molar Flow (mol/s) 0.770951 0.770951
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Determination of Power for a Compressor 27 August 2022
9 DETERMINATION OF POWER FOR A COMPRESSOR
Objective
Develop a simple process flow sheet to determine the power required to pressurize steam for a
compressor.
Data
• Fluid: Water (Steam)

DWSIM Blocks Used
• Compressor
• Material stream
• Energy Stream
• Indicators
Procedure
9. Below the Unit Operation tab on left, locate theCompressor block. Drag and drop into the
flow sheet. Rename it as “COMPRESSOR”.
Figure 20 Pressure Changes window
31
Determination of Power for a Compressor 27 August 2022
10. Click on “COMPRESSOR” block, the general information about the block is displayed on the
right. Under “connections” tab, for all streams click the dropdown button and select the
necessary connections. Under calculation type choose “Outlet Pressure”. If all the
connections are given correctly, all the blocks will turn blue.
screen.
Figure 21 Compressor
Input Output
Pressure (Pa) 200000 500000
Mass Flow (kg/s) 0.0138889 0.0138889
Molar Flow (mol/s) 0.770951 0.770951
Specific Enthalpy (Mixture) (kJ/kg) 188.254 439.466
Specific Entropy (Mixture) (kJ/[kg.K]) 0.230405 0.353053
Molar Enthalpy (Mixture) (kJ/kmol) 3391.45 7917.1
Molar Entropy (Mixture) (kJ/[kmol.K]) 4.1508 6.36036
32
Power Generated by a Turbine 27 August 2022
10 POWER GENERATED BY A TURBINE
Objective
Develop a simple process flow sheet to determine the power generated by a turbine.
Data
• Fluid: Water (Steam)

DWSIM Blocks Used
• Turbine
• Material stream
• Energy Stream
• Indicators
Procedure
9. Below the Unit Operation tab on left, locate theTurbine block. Drag and drop into the flow
sheet. Rename it as “TURBINE”.
33
Power Generated by a Turbine 27 August 2022
10. Click on “TURBINE” block, the general information about the block is displayed on the right.
screen.
Figure 23 Turbine
Output Input
Pressure (Pa) 200000 500000
Mass Flow (kg/s) 0.0138889 0.0138889
Molar Flow (mol/s) 0.770951 0.770951
34
Pressure Drop across a valve 27 August 2022
11 PRESSURE DROP ACROSS A VALVE
Objective
Develop a simple process flow sheet to determine the pressure drop across a valve.
Data
• Fluid: Water
DWSIM Blocks Used
• Valve
• Material stream
• Indicators
Procedure
9. Below the Unit Operation tab on left, locate theValve block. Drag and drop into the flow
sheet. Rename it as “VALVE”.
35
Pressure Drop across a valve 27 August 2022
10. Click on “VALVE” block, the general information about the block is displayed on the right.
screen.
Figure 25 Valve
Output Input
Pressure (Pa) 200000 500000
Mass Flow (kg/s) 0.0138889 0.0138889
Molar Flow (mol/s) 0.770951 0.770951
36
Residence Time Calculation for a Tank 27 August 2022
12 RESIDENCE TIME CALCULATION FOR A TANK
Objective
Develop a simple process flow sheet to determine residence time for a given volume of tank.
Data
• Fluid: Water
•
Tank Volume: 5 m3
DWSIM Blocks Used
• Tank
• Material stream
• Indicators
Procedure
37
9. Below the Unit Operation tab on left, locate the Tank block. Drag and drop into the flow
sheet. Rename it as “TANK”.
Figure 26 Separator and tank window
10. Click on “TANK” block, the general information about the block is displayed on the right.
connections. Under calculation type choose “Tank Volume”. If all the connections are given
correctly, all the blocks will turn blue.
11. Add flow indicators on input and output stream and target the desired properties and add
time indicator on tank.
screen.
Figure 27 Tank
Input Output
38
Pressure (Pa) 101325 101325

Mass Flow (kg/s) 0.138889 0.138889
Molar Flow (mol/s) 7.70951 7.70951
39
Flow Split with Splitter 27 August 2022
13 FLOW SPLIT WITH SPLITTER
Objective
Develop a simple process flow sheet to split a given mass flow into equal proportions.
Data
• Fluid: Water
•
Temperature: 50 °C
DWSIM Blocks Used
• Splitter
• Material stream
• Indicators
Procedure
9. Below the Unit Operation tab on left, locate the Splitter block. Drag and drop into the flow
sheet. Rename it as “SPLITTER”.
Figure 28 Mixer and Splitters Window
40
10. Click on “SPLITTER” block, the general information about the block is displayed on the right.
connections. Under calculation type choose “Tank Volume”. If all the connections are given
correctly, all the blocks will turn blue.
11. Add flow indicators on input and output stream and target the desired properties.
screen.
Figure 29 Splitter
Input Output 1 Output 2 Output 3
Temperature (K) 298.15 298.15 298.15 298.15
Pressure (Pa) 500000 500000 500000 500000
Mass Flow (kg/s) 0.025 0.00833333 0.00833333 0.00833334
Molar Flow (mol/s) 1.38771 0.46257 0.46257 0.462571
Volumetric Flow 2.50906E- 8.36353E- 0.00215098 0.00215099
(m3/s) 05 06
Density (Mixture) 996.389 996.389 3.87419 3.87419
(kg/m3)
Molecular Weight 18.0153 18.0153 18.0153 18.0153
(Mixture) (kg/kmol)
Specific Enthalpy -2440.55 -2440.55 -151.963 -151.963
(Mixture) (kJ/kg)
41
Specific Entropy -8.92232 -8.92232 -1.24636 -1.24636

(Mixture) (kJ/[kg.K])
Molar Enthalpy -43967.2 -43967.2 -2737.65 -2737.65
(Mixture) (kJ/kmol)
Molar Entropy -160.738 -160.738 -22.4536 -22.4536
(Mixture)
(kJ/[kmol.K])
Thermal Conductivity 0.610248 0.610248 0.0550495 0.0550495
(Mixture) (W/[m.K])
42

Training Manual For Beginners in Process Simulation

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PROCESS SIMULATION USING DWSIM 27 August 2022

By Viraj Desai, Process Engineer

PROCESS SIMULATION USING DWSIM:

PROCESS SIMULATION USING DWSIM: A FREE AND OPEN-SOURCE CHEMICAL

DWSIM is an open-source CAPE-OPEN compliant chemical process simulator. It features a Graphical

• Junior Interns in Process Firms

1 Mixing of Ideal Liquid Streams ........................................................................................................ 6

Figure 1 Mixer ......................................................................................................................................... 7

1 MIXING OF IDEAL LIQUID STREAMS

• Inlet stream 1: 10 mol % Methanol solutions flowing at 20 kmol/h

DWSIM Blocks Used

Properties Methanol Water Mixed

Temperature (K) 298.15 298.15 298.15

Pressure (Pa) 101325 101325 101325

Mass Flow (kg/s) 0.170218 0.057835 0.228053

Molar Flow (mol/s) 5.55556 2.77778 8.33334

Volumetric Flow (m3/s) 0.000211298 6.11026E-05 0.000269039

Density (Mixture) (kg/m3) 805.584 946.524 847.656

Molecular Weight (Mixture) 30.6392 20.8206 27.3663

Specific Enthalpy (Mixture) -1256.07 -2053.47 -1458.29

Specific Entropy (Mixture) -4.08201 -6.72148 -4.652

Molar Enthalpy (Mixture) -38485 -42754.6 -39908.2

Molar Entropy (Mixture) -125.07 -139.945 -127.308

Thermal Conductivity (Mixture) 0.212675 0.422925 0.248449

2 DETERMINATION OF THERMO-PHYSICAL PROPERTIES OF PURE

Determine the thermo-physical properties of pure component as function of temperature and

Figure 2 Thermodynamic property of water

Figure 3 Pure Component property viewer

Figure 4 Pure Component Property viewer

Figure 5 Heat Capacity of water

3 GENERATION OF VLE DATA OF BINARY COMPONENT SYSTEM

Generate vapour-liquid equilibrium data (VLE) for a binary component system

Figure 6 Benzene-Toluene Stream

Figure 7 Add utility Window

Figure 8 Binary Envelope Window T vs XY

Figure 9 Binary Envelope Window P vs XY

11. Click on {T}xy and “Calculate” to generate {T}xy plot.

Figure 10 Binary Envelope Window X vs Y

4 SIMULATION OF A FLASH COLUMN

DWSIM Blocks Used

of stream turns blue.

Heavy Feed Vapour Liquid

Volumetric Flow (m3/s) 0 0.390702 0.388664 0.0020377

5 SIMULATION OF A CSTR FOR LIQUID PHASE REACTION

DWSIM Blocks Used

• Continuous Stirred Tank Reactor (CSTR)

name and description about the reaction.

Figure 12 Reaction window

6 SIMULATION OF A DISTILLATION COLUMN

DWSIM Blocks Used

Figure 14 Columns Window

Property Value Units

Minimum Reflux Ratio 1.11363

Actual Number of Stages 12.7253

Optimal Feed Stage 6.36267

Stripping Liquid 69.4445 mol/s

Rectify Liquid 41.6667 mol/s

Stripping Vapor 55.5556 mol/s

Rectify Vapor 55.5556 mol/s