Aspen Utilities Planner Jump Start Final

Jump Start: Aspen Utilities Planner V8 A Brief Tutorial (and supplement to training and online documentation) Nicholas Brownrigg, Product Marketing, Aspen Technology, Inc. Jack Zhang, Product Management, Aspen Technology, Inc.

© 2013 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved. 11-3370-0513

Jump Start: Aspen Utilities Planner V8

Table of Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Interface Layout and Flowsheet Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Variable Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Running a Flowsheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Optimization of Utilities Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Specify Database Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Specify Demand, Availability, Cost Constraints, and Utility Contracts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . …...9 Executing Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Microsoft® Excel Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17



Introduction In the process industry, utilities are supremely important to the functionality of a plant. Utilities provide the heating and cooling, electricity, fuel, etc. used by machinery to ensure continued generation of a process’ desired product. Plants have a variety of options available in terms of acquiring utilities. Oftentimes, utility commodities are able to be purchased and imported from an outside source, while some plants may choose to implement methods of producing their own utilities, depending on cost. With many utility options available, choosing a schedule that has the correct blend between purchasing and producing utilities to minimize cost becomes exceedingly challenging. Aspen Utilities Planner is a tool that can be used to solve this coordination problem. Users can model the required utilities system for a process, as well as specify the quantity and timeframe of when utilities are needed. From a designated utility purchasing contract, Aspen Utilities Planner will optimize around utility need to find the cheapest method of acquirement, whether it be through in-plant production, outside purchase, or a combination of the two. This is not meant to be used as a stand-alone reference document. We recommend that a range of other resources be called upon to give the new user a comprehensive view of how to use Aspen Utilities Planner. These may include: • AspenTech support website (support.aspentech.com) • AspenTech courseware available on-line and in-person • AspenTech business consultants This document covers operation of Aspen Utilities Planner V8. It assumes that the user has Aspen Utilities Planner V8 or higher installed on a computer.

Interface Layout and Flowsheet Construction Opening Aspen Utilities Planner initializes a new, blank utilities model. Inside the modeling environment lies the process flowsheet window, the utilities model palette, and the simulation explorer, shown in Figure 1. The simulation explorer contains properties for the components used in the model. In Aspen Utilities Planner V8, the properties for the components are automatically imported upon starting the program, whereas in previous versions, the user had to manually load the properties files.

Figure 1: Location of Process Flowsheet Window, Model Palette, and Simulation Explorer


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Utility models can be placed in the flowsheet window by selecting the appropriate option from the model palette, according to a user’s specific utility requirement, then scrolling up to the flowsheet and clicking. Included in the model palette are blocks labeled ‘Feeds’ and ‘Demands’. If a utility supply is being brought into the plant externally, a feed block should be placed in the flowsheet. Similarly, a demand block represents an output of a utility needed for use in a plant. Once the model blocks have been placed, all appropriate streams must be connected. On the left-hand side of the model palette are the stream options that include fuel, steam, power, air, connection, and control. Shown in Figure 2 is a sample flowsheet showing an example utilities set up for a plant.

Figure 2: Sample Flowsheet of Process Utilities Setup for a Plant

It is important to connect the appropriate stream type with its corresponding port on a block. Placing an incorrect stream between two blocks will result in a simulation error when attempting to run a model. For this reason, the user must only use fuel, power, steam, and air streams when constructing a flowsheet in Aspen Utilities Planner. When connecting streams to certain blocks, the user will be prompted to select from a menu of possible port options. For example, for a steam stream exiting a boiler, the user is asked to distinguish the connection as being a blowdown port or steam outlet port. This menu of options is shown in Figure 3. It is important to choose the appropriate option in order to have a correct simulation.

Figure 3: Options for Steam Stream Leaving a Boiler


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Another example of having to choose between port types occurs when connecting a steam stream to the outlet port of a steam header block. The exit stream can be connected as either a water outlet port, blowdown port, or steam outlet, shown in Figure 4.

Figure 4: Options for Steam Stream Leaving a Steam Header

Ensure that all streams and ports are properly placed and defined—then continue to input simulation variables.

Variable Input In an Aspen Utilities Planner simulation, the user has the option to set variables as ‘Fixed’ or ‘Free’. By fixing a variable, the user provides a specific value to which a variable must adhere. The free variables are adjusted in a simulation such that the fixed variables are met, if feasible. To adjust the variables in a simulation, click on a block to open its corresponding summary table. Figure 5 displays the summary table for the steam feed block. While Aspen Utilities Planner does allow the user to modify variables in a stream summary table, it is advised to only make value adjustments in block summary tables.

Figure 5: Summary Table for Steam Feed Block

Values in the summary tables can be adjusted by clicking and highlighting the existing value, and then typing in the new desired quantity. To adjust a variable as free or fixed, click the appropriate box under the ‘Spec’ heading and a scroll menu appears. Select either ‘Free’ or ‘Fixed’ as it pertains to the simulation being modeled. Note that the ‘Initial’ option is only intended for a dynamic simulation and thus should not be selected in a steady state simulation. For fuel feeds, Aspen Utilities Planner is capable of calculating fuel properties given a provided fuel composition. To initiate this, open the summary table for a fuel feed block, and select yes under the value box next to the ‘CalculatePropsFromComp’ listing, shown below. Once yes is selected, the summary table expands to include the mass fractions of various fuel components. Once the fuel composition is specified, the mass and mole flowrates, the Cv , and molecular weight values for the fuel will be updated upon running the simulation.


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Figure 6: Fuel Feed Summary Table with Custom Fuel Specifications

Aspen Utilities Planner model is built on an equation oriented system. As a result, the number of free variables must be equal to the number of equations specified by the model, commonly referred to as a ‘square’ system. Some model variables must be specified in order to keep the model “square”. In order to know how many fixed variables must be set to run a simulation, Aspen Utilities Planner displays an indicator at the bottom of the program, below the models palette. A green square, shown in Figure 7, represents a sufficient number of fixed variables being set.

Figure 7: Representation of Sufficient Variables Fixed

If too few variables are fixed, a downward pointing red arrow is displayed. Similarly, if too many variables are fixed, an upward pointing red arrow is displayed. These situations are shown in the following figures.

Figure 8: Arrow Indicating Too Few Fixed Variables

Figure 9: Arrow Indicating Too Many Fixed Variables


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Running a Flowsheet Once all variables are specified as fixed or free, click the run button circled below. By running the flowsheet, the free variables are calculated based on the model equations and the values input for the fixed variables. Results of a run can be viewed by clicking on individual blocks or streams, which brings up the respective summary table for the item selected.

Figure 10: Location of Run Button

Optimization of Utilities Schedule After running a simulation, the utilities schedule can be optimized. In order to perform an optimization, utility demand and equipment availability constraints need to be specified and utility contracts must be defined. The objective of the optimization is to minimize the total operating cost of the utilities system. To begin optimization, select the ‘Optimization’ option from the Aspen Utilities Planner dropdown menu, and the click ‘Editors…’. This will bring up the data editors window in which optimization constraints can be set.

Figure 11: How to Open Optimization Editing Window


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Figure 12: Optimization Editing Window

In this window, the demand and availability profiles are viewed by selecting the appropriate option under the ‘Profile’ section, shown below.

Figure 13: How to Toggle Between Demand and Availability Profiles

Specify Database Locations To properly run an optimization, database locations must be configured. After opening the data editors window, click the ‘Configure’ button, circled in Figure 14. This will bring up a ‘Configure databases’ window in which profile, tariff, demand, and interface data can be imported. To do so, choose ‘Browse’ and select the location of the respective database file. The Optimization file location can be left unchanged. Sample database files to use for optimization can be found in an Online Training module, or on the C: drive in the Aspen Utilities Planner folder.


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Figure 14: Configuring Databases in Optimization Editor Window

After the database locations have been properly specified, click ‘OK’ to accept the changes. Then, click ‘Yes’ when prompted to save data before changing databases. After importing databases, a demand and availability profile will appear, allowing you to edit. To start a new blank flowsheet, a new set of blank databases should be used. They can be downloaded from Aspen Utilities Online Training Page or downloaded directly from the AspenTech support website using solution ID: 135845. The blank database template’s location in the Online Training Page is shown in Figure 15.

Figure 15: Location of Blank Database Templates

Figure 16: Update Option in Optimization Editing Window


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The user is then prompted to choose whether to edit the demand profile, availability profile, or the cost profile for a utility. Use the demand profile to define fixed utility demand such as steam, fuel and power consumption, utility creation from a production process, or any utility stream variable that cannot be varied in the optimization, such as ambient temperature used to correct the gas turbine performance. The availability profile is used to model capacity constraints on utilities equipment, such as steam production from a boiler, power generation from a gas turbine, etc., or the availability of a piece of equipment (i.e. a boiler must be in service for a safety reason, a steam turbine is out of service for a period due to the maintenance schedule, etc.). The cost profile must be defined in order to connect the utility contracts to a particular port and block in the flowsheet. The following figures show constraints to optimize the cost of operating the boiler and producing high pressure steam in the process from Figure 2, with set production limits of high pressure steam and restricted availability of power to the boiler.

Figure 17: Demand Profile to Optimize Utilities Flowsheet

Figure 18: Availability Profile to Optimize Utilities Flowsheet

Figure 19: Cost Profile to Optimize Utilities Flowsheet © 2013 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved. 11-3370-0513

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After adding constraints, tariff contracts should be constructed by clicking the ‘Tariff’ icon in the Data Editors window.

Figure 20: Tariff Contract Construction and Example

Figure 20 shows a sample tariff contract in two tiers where natural gas is purchased for consumption. Tier 1 of the contract specifies that the natural gas cost is 5 cost units for a rate of up to 100 tonnes per hour, while in tier 2, the natural gas price rises to 10 cost units for any rate over 100 tonnes per hour. When finished setting up the demand, availability, cost profiles, and the tariff schedule, save the profile by clicking the ‘Save’ option and then click the ‘Commit’ option followed by ‘Apply’ to continue optimization of the utilities schedule.

Figure 21: Save and Commit Options to Run Optimization

Executing Optimization When finished setting up and saving optimization constraints, execute the optimization by selecting the ‘Optimization’ option from the Aspen Utilities Planner dropdown menu, and then click ‘Optimize Flowhsheet…’, as shown below. The results of the optimization can then be seen by double clicking a stream or block in the flowsheet and viewing updated summary tables, introduced in the ‘Variable Input’ section of this guide.


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Figure 22: Running an Optimization

Microsoft Excel Compatibility Aspen Utilities Planner can be used in conjunction with Microsoft Excel. This provides the user a spreadsheet environment from which to optimize a plant’s utilities, if so desired. To get started, the user must load the Aspen Utilities Microsoft Excel add-in from the computer’s C: drive. In order to run the Aspen Utilities add-in, it is essential to ensure that Microsoft Excel has the macros feature enabled. Open the File menu in Excel, and select ‘Options’. In the ‘Options’ screen, select ‘Trust Center’, and then click ‘Trust Center Settings…’. This will bring up a Trust Center window. Make sure that the macroenabling options as shown in Figure 23 are activated and then click ‘OK’.

Figure 23: Enabling Macros in Excel

After enabling macros, load the Aspen Utilities add-in by opening the File menu in Excel, and selecting ‘Options’. In the ‘Options’ screen, select ‘Add-Ins’, and click the ‘Go...’ button. This brings up the ‘Add-Ins’ window in which Excel add-ins can be selected or unselected. To import the Aspen Utilities add-in, click browse, then locate the Aspen Utilities Planner folder on the computer’s C: drive. Click the ‘bin’ folder, and then open the Utilities270 add-in file. The Aspen Utilities Planner add-in will now be able to be added in the ‘Add-Ins’ window.


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Figure 24: Excel Options Menu

Figure 25: ‘bin’ Folder and Add-In File

Figure26: Add-Ins Window with Aspen Utilities Add-In Present

After loading the Aspen Utilities add-in, select the ‘Add-Ins’ option on the Excel taskbar. To open an Aspen Utilities Planner simulation, click the ‘Aspen Utilities’ add-in drop down menu, click ‘Open Aspen Utilities’, and select a simulation.


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Figure 27: Opening Aspen Utilities Planner Simulation in Excel

After opening an Aspen Utilities Planner file, return to the ‘Aspen Utilities’ drop down menu, and scroll over the ‘Simulation’ option to select ‘Load Simulation Links’. This brings up a prompt informing that the Simulation Links spreadsheet cannot be found. Click ‘Yes’ to create the Simulation Links sheet.

Figure 28: Create Simulation Links Flowsheet in Excel

On the simulation links sheet, two tables appear. The left-hand side table allows the user to set simulation values in Excel to be sent to the utilities simulation in Aspen Utilities Planner. The right-hand side table retrieves values from a simulation to be displayed. In order to control which variables and values are shown in the tables, use the toolbar above the spreadsheet. The left portion of the toolbar is used for the left-hand side table, and the right portion of the toolbar is used for the right-hand side table. First, select the appropriate model in the ‘Model Names’ drop down menu and then press the corresponding ‘Load Variables’ button. This will populate the ‘Variable Names’ drop down menu. Selecting a model and variable will place both in the corresponding spreadsheet along with a value. Shown below is a layout of the simulation links sheet, along with sample tables showing current values of variables from a simulation and new values for these variables to be sent to Aspen Utilities Planner.


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Figure 29: Simulation Links Spreadsheet with Data Retrieved from Aspen Utilities Planner

After inputting information into the Simulation Links flowsheet, return to the ‘Aspen Utilities’ drop down menu. Scroll over the ‘Simulation’ option—selecting ‘Send Values’ will input the values from the Send Values to Aspen Utilities table and runs a new simulation, while ‘Get Latest Values’ will update the Retrieve latest values from Aspen Utilities table.

Figure 30: Send Values and Get Latest Value Options

Scroll to the ‘Optimization’ option in the ‘Aspen Utilities’ drop down menu and select ‘Editors…’ to create the Energy Cost Summary, Demand, and Availability sheets. Here, input information regarding the demand, availability, and cost profiles to perform an optimization by way of Excel. Sample sheets are shown in the following figures.


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Figure 31: Demand Table in Excel

Figure 32: Availability Table in Excel

Figure 33: Energy Cost Summary Table in Excel

After setting up the Simulation Links and Optimization tables, the Simulate Flowsheet or Optimize Flowsheet options from the ‘Aspen Utilities’ drop down menu can be run.

Figure 34: Simulate and Optimize Flowsheet Options in Excel © 2013 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved. 11-3370-0513

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Once the simulation and optimization are executed, many users typically develop custom worksheets in Excel to display the results by connecting the cells to the corresponding cells in the Simulation Links worksheet or optimization worksheets (Energy Cost Summary, Demand, and Availability). A sample custom worksheet is shown below in Figure 35.

Figure 35: Example Custom Excel Worksheet Developed to Display Optimization Results

Additional Resources Public Website: http://www.aspentech.com/products/aspen-utilities-planner.aspx

Online Training: http://www.aspentech.com/products/aspen-online-training

Online Brochures: http://www.aspentech.com/brochures/Aspen_Utilities.pdf

On-Demand Webinars: Optimize Utility Cost with Aspen Utility Planner

AspenTech YouTube Channel: http://www.youtube.com/user/aspentechnologyinc


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About AspenTech AspenTech is a leading supplier of software that optimizes process manufacturing—for energy, chemicals, pharmaceuticals, engineering, and construction, and other industries that manufacture and produce products from a chemical process. With integrated aspenONE® solutions, process manufacturers can implement best practices for optimizing their engineering, manufacturing, and supply chain operations. As a result, AspenTech customers are better able to increase capacity, improve margins, reduce costs, and become more energy efficient. To see how the world’s leading process manufacturers rely on AspenTech to achieve their operational excellence goals, visit www.aspentech.com.

Worldwide Headquarters Aspen Technology, Inc. 200 Wheeler Road Burlington, MA 01803 United States phone: +1–781–221–6400 fax: +1–781–221–6410 [email protected]

Regional Headquarters Houston, TX | USA phone: +1–281–584–1000 São Paulo | Brazil phone: +55–11–3443–6261 Reading | United Kingdom phone: +44–(0)–1189–226400 Singapore | Republic of Singapore phone: +65–6395–3900 Manama | Bahrain phone: +973–17–50–3000 © 2013 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved. 11-3370-0513

For a complete list of offices, please visit www.aspentech.com/locations

Aspen Utilities Planner Jump Start Final

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