Chemical Engineering: Heat Exchangers in Aspen Plus & HYSYS

Name: Chemical Engineering: Heat Exchangers in Aspen Plus & HYSYS
Rating: 4.8 (13 reviews)

Design, rate, and simulate shell-and-tube heat exchangers using Aspen Plus, Aspen HYSYS, and Aspen EDR.

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Created byVítor Vanzolin Bento

Last updated 3/2026

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What you'll learn

Size and rate heat exchangers for industrial applications using Aspen Exchanger Design and Rating (EDR).
Solve real industrial case studies related to heat exchanger selection and troubleshooting.
Apply basic mechanical design considerations and TEMA standards.
Simulate heat exchangers using Aspen Plus V14 and Aspen HYSYS V15.

Course content

6 sections • 35 lectures • 3h 57m total length

Welcome to the Course!0:09
Begin your journey in chemical engineering with an introduction to heat exchangers in Aspen Plus and HYSYS.
Introduction7:24
Explore the simulation of heat exchangers, reviewing conduction, convection, radiation, and selecting thermodynamic models like Peng-Robinson for oil and gas, with parallel versus counter flow for optimal heat transfer.
Important notice0:16

Heat exchangers in Aspen Plus with an example7:21
Demonstrates modeling a heat exchanger in Aspen Plus using Heater Simpler model for a 5000 kg/h ethanol–acetic acid stream heated from 20°c to 40°c at 101.3 kpa, with heat duty.
Models for heat exchangers in Aspen Plus with example (Heater)5:51
Compare heater and HeatX models in Aspen Plus, using Aspen EDR to size two-stream heat exchange, heating ethanol–acetic acid to saturated vapor at 101.3 kPa with the NRTLHOC model.
HeatX model (The vapor fraction of the hot stream at the outlet must be zero)11:51
The HeatX model uses two streams to fully condense the hot outlet (zero vapor fraction) and reports heat duty and LMTD under NRTL, unlike the simple heater model.
Exchanger specification0:02
TEMA and Aspen Exchanger Design & Rating (EDR)3:41
Explore shell and tube heat exchangers, including counter current flow, the TEMA three-letter nomenclature (BEM, AEP, CFU), and design guidance for fouling, turbulence, baffles, and sizing with the EDR module.
Fouling factors3:16
Understand fouling factors that increase thermal resistance and reduce heat exchanger performance, and see how water, oils, steam, and gases influence design choices.
Cooling of anhydrous ethanol in sugar and alcohol plants (EDR) – Part 110:03
Explore cooling of anhydrous ethanol from 65 to 35 C using cooling water in a shell and tube exchanger, modeled with NRTL in EDR, including heat duty and shortcut validation.
Cooling of anhydrous ethanol in sugar and alcohol plants (EDR) – Part 213:35
Convert the simulation from shortcut to a rigorous shell-and-tube exchanger design. Review fouling factors, baffles, tube layout, and pressure drops to confirm convergence and generate the final drawing.
Results analysis13:54
EDR (Rating) – Checking if an existing heat exchanger works properly6:46
Explore how to use designer sizing mode to obtain ideal exchanger values when size is unknown, and switch to rating mode to verify existing exchangers under simulated heat duty conditions.
Unknown, OK and Risk0:53
A frequently asked question0:37
Design Specs – Finding the exact value of the cold water flow rate6:12
Flowsheeting Options – Design Specs0:09
Shell-and-tube heat exchanger with length constraint – Part 19:04
Shell-and-tube heat exchanger with length constraint – Part 211:22
Demonstrates converting to the rigorous edr mode, applying a 0.5 psi pressure-drop limit, fouling factors, and the BEM sizing to assess a shell-and-tube exchanger under a tight length constraint.
Shell-and-tube heat exchanger with length constraint – Part 35:27
Cooling of methanol using a shell-and-tube heat exchanger12:47
Air-Cooled Heat Exchangers (ACHEs)4:58
Explore air-cooled heat exchangers, where ambient air cools finned tubes, and evaluate fan coverage using api 661 and Aspen EDR to determine heat duty and outlet air temperature.
Air-cooled heat exchanger using Aspen Exchanger Design and Rating (EDR) - Part 15:58
Air-cooled heat exchanger using Aspen Exchanger Design and Rating (EDR) - Part 210:28

Aspen HYSYS Interface – Active and On Hold Modes9:44
Explore the Aspen HYSYS interface heating an equimolar ethanol–acetic acid stream from 20 to 40 C at 1000 kg/h with the NRTL model, where active and on-hold modes govern solving.
Cooling of anhydrous ethanol in sugar and alcohol plants (EDR) – Part 1 (HYSYS)9:06
Cooling of anhydrous ethanol in sugar and alcohol plants (EDR) – Part 2 (HYSYS)15:29
Heat Transfer and Simple End Point2:33
Industrial layout constraints – Heat exchanger length limitation1:19
Explore how to reconcile heat exchanger sizing with layout constraints using Aspen EDR. Learn to reduce tube length and increase diameter to maintain heat duty when overall length is limited.
Interactive sizing in Aspen Exchanger Design and Rating13:15
Demonstrate interactive sizing in Aspen Exchanger Design and Rating, adjusting tube length and fouling factors to fit 5500 mm constraints while preserving heat transfer performance.
Rating a heat exchanger7:15

Requirements

Basic knowledge of thermodynamics.
Fundamental understanding of heat transfer principles.
Basic knowledge of Aspen Plus and Aspen HYSYS simulation software.

Description

Chemical Engineering: Heat Exchanger Design and Simulation

Heat exchangers are critical equipment in chemical plants, refineries, and oil & gas facilities. The ability to design, rate, and simulate shell-and-tube heat exchangers is a core skill for chemical and process engineers working in industry.

This course provides a practical and industry-focused approach to heat exchanger design and simulation using Aspen Plus and Aspen HYSYS.

This course is exclusively focused on heat exchangers and their simulation, providing an in-depth, practical approach to design, rating, and performance analysis. Participants will work extensively with Aspen Plus, Aspen HYSYS, and Aspen Exchanger Design & Rating (EDR) to model, evaluate, and optimize heat exchanger systems.

The course emphasizes hands-on simulation and engineering insights, enabling professionals to confidently design and assess heat exchangers in real industrial scenarios.

You will learn how to configure equipment, define parameters, analyze results, and troubleshoot performance issues — exactly as done in real engineering projects.

This course effectively bridges the gap between academic theory and real-world industrial practice, providing a comprehensive learning experience that connects fundamental concepts to their practical implementation. Throughout the program, you will develop hands-on technical skills, critical problem-solving abilities, and industry-relevant competencies that can be directly applied in professional process engineering environments.

Whether you are a chemical engineering student, a junior process engineer, or a professional looking to strengthen your heat exchanger expertise, this course will give you the technical confidence to design and simulate shell-and-tube heat exchangers using industry-standard software.

Enroll now and start mastering heat exchanger design and simulation today.

Who this course is for:

Chemical engineering students who want to master heat exchanger design and analysis.
Mechanical engineering students interested in thermal systems.
Process engineers working in oil & gas, petrochemical, energy, or manufacturing industries.
Professionals who want practical, industry-oriented knowledge of heat exchangers.

Chemical Engineering: Heat Exchangers in Aspen Plus & HYSYS

What you'll learn

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Course content

Heat Exchangers3 lectures • 8min

Heat Exchanger Simulation in Aspen Plus21 lectures • 2hr 24min

Heat Exchanger Simulation in Aspen HYSYS7 lectures • 59min

Simulating a Plate Heat Exchanger Using EDR1 lecture • 10min

Aspen HYSYS Practical Activity2 lectures • 16min

Course Wrap-Up1 lecture • 1min

Requirements

Description

Who this course is for: