3/3/2014

ECH 3702

Process and Plant Design

Rekabentuk Proses dan Loji
化学プロセスとプラントの設計

Ir. Dr.
D Shamsul
h l Izhar
h

Week 1:
A) Introduction to course
B) E l ti
Evaluation
C) Learning Outcome
D) Reference book
E) Teaching Plan
F) Examples of Plant Process

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A) Introduction of Course
• This course encompasses chemical
engineering design concepts that include:
– Process Design – e.g. your Lab works?
– Engineering economics
– Mechanical design
– Equipment/instrument selection and design
– Plant design

B) Evaluation

• Exercises
• Attendance
• Punctuality (class, work submission)
• Group organization
• Effort
• Personality (as a professional …)

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C) Learning Outcomes (univ.)
• Formulate suitable process from various 
sources
• Develop a complete process flow sheet
• Design process equipment
• Solve material & Energy Balance calculations
• Demonstrate team work

Program Objective (Univ.)

• Apply knowledge of mathematics and engineering sciences (PO1)
• Analyze and interpret data (PO3)
• Design a system, component or process to meet the design requirement
(
(PO4) )
• Use principles of sustainable design and development (PO5)
• Function effectively as an individual in a group (PO6)
• Demonstrate leadership or managerial characteristics (PO7)
• Identify, formulate and provide creative/innovative/effective solution to a
problem (PO8)
• Explain professional and ethical responsibility (PO9)
• Recognize the need for and able to engage in lifelong learning. (PO12)
• Discuss relevant contemporary issues (PO13)
• Use necessary skills, techniques and modern engineering tools for
engineering practice (PO14)

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Course Objectives (univ.)

• To apply a structured preliminary design approach to the design
processes.

• To write and solve an integrated material and energy balance

calculations on selected flow sheet manually and using computer
simulation software such as Aspen Plus

• To apply short cut methods in preliminary equipment sizing and

costing and analyze economic viability of the proposed flow
sheet.

• To prepare detailed design on selected process equipment and

preliminary mechanical design by considering the aspects of
materials of construction, and safety.

D) Reference Book

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E) TEACHING PLAN

Delivery Methods
• Lecture - Time & Venue
• E
Exercises
i
• Group discussion
• Assignments
• Presentations
• Computer-aided design
• Industrial visit (Polyplastics, Kuantan)
• Industrial lecture by professionals

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Mgu Date Konsentrasi Lecture Assignment Remark

Pengenalan kpd Proses dan Loji – umum Shamsul Chap-1

1 Jurutera, Jenis Proses, Loji kimia,
Yield, Stream eff., Production Rate, Batch & Continuous,
Operations, real samples engineering work
Material Balance Shamsul Project: Chap-2
2 Yield, reactor conversion, volumetric and molal flowrates, Formaldehyde
Losses, compositions (mol%, wt%), phase change (Break to production
groups, supervisors)
Amali: Material Balance using spreadsheet Shamsul / Musab

Material Balance with PFD Shamsul Chap-2

3 Presentations
Amali: Material Balance using spreadsheet Shamsul/ Musab

4 Costing and Project Evaluation / Engineering economics Ir. Juares Chap-6

Amali: Dr Musab

5 Process Safety Ir.

Razmahwata
Amali: Computer-aided Software Dr Musab

Energy Balance Shamsul Chap-3

6 Heat capacity, enthalpy, heats of reaction, heats of combustion

Amali: Energy Balance using spreadsheet Dr Musab

Energy Balance Shamsul Chap-3

7 Steam usage, steam tables, sensible and latent heat of saturated
steam
Amali: Energy Balance using spreadsheet Dr Musab

CUTI Semester Break (8 – 14 Apr 2013)

8 LAWATAN INDUSTRI TO POLYPLASTICS Shamsul

Industrial Visit to Polyplastics, Gebeng
Amali: Dr Musab
Flowsheets, diagrams and lists : types and differences Shamsul Chap-4
9 zPFD
zP&ID – pipe sizes, materials, process-utility
Amali: computer aided diagrams Dr Musab

Flowsheets, diagrams and lists : types and differences Shamsul Chap-4

10 zPFD
zP&ID – pipe sizes, materials, process-utility
Amali: computer aided diagrams Dr Musab

Piping and Instrumentation Shamsul Chap-5

11 zInstrument – CV, indicators, elements, Control loops, gauges.
zEquipment – pumps, rotating machines

Amali Dr Musab
Piping and Instrumentation Shamsul Chap-5
12 zInstrument – CV,, indicators,, elements,, Control loops,
p , gauges.
g g
zEquipment – pumps, rotating machines
Amali: Dr Musab

13 Heat exchangers, Energy recovery & Process integration Shamsul Chap-3

Amali

14 Heat exchangers, Energy recovery & Process integration Shamsul Chap-3

Amali

15 Final exam

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Pembahagian Markah Ujian
• Mark distribution (Evaluation)
– Coursework + Lab Project + Excercise = 60%
C k+L bP j t+E i 60%
– Final Examination = 40%

• Assessment work settings (60%)
– Presentation 1 (Week 6)
– Presentation 2 (Week 11)
– Assignments
• Assignment 1 (5%) – unit & common sense
• Assignment 2 (10%) – distillation column, heat exchangers, Aspen Plus
• Assignment 3 (5%) – oral presentation, sustainable design, contemporary issues

Process and Plant Design

Brief introduction

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Can design be taught?

Life-long learning
Design is a creative activity

DESIGN

• Design is a creative activity

• Defined as the conversion of an ill-
defined requirement into a satisfied
customer
• Designer must assemble all the relevant
facts and data required

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What do chemical engineers

learn?

Fundamental Science:
Mathematics, Chemistry, Physics, Biology

Chemical Engineering Science topics:

Chemical Thermodynamics, Transport Phenomena,
Reaction Engineering, Separation Processes

Process Design

Academicians & Practitioners
• Philosophical discussions of the nature and 
methodology of the design process –
of the design process usually 
usually
of little practical use (Academicians)
• Use design methods and techniques needed 
for the design of a chemical manufacturing 
process
– Engineers –
E i prefer the tried and tested methods, 
f th t i d d t t d th d
rather than possibly more exciting but untried 
novel designs

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Academicians & Practitioners
• The art and practice of design cannot be 
l
learnt from books. The intuition and judgment 
tf b k Th i t iti dj d t
necessary to apply theory to practice will 
come only from practical experience
• However when innovation is wanted, previous 
experience, through prejudice can inhibit the 
p , g p j
generation and acceptance of new ideas; the 
“not invented here” syndrome – Example?

Engineers in Chemical Plant

• Process
• Production
• Electrical / Instrument
• Mechanical / Piping
• Safety
• QA
• Sales/purchasing

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What is Chemical Engineering?

Chemical engineers use the principles of engineering analysis
and knowledge of science (even though we may not have an
perfect
p f understandingg) to design,
g , build and operate
p
processes that provide society with :

petroleum fuels, toothpaste, paint, polymer, bio-diesel,

pharmaceuticals, computer chips, and many more…

We also operate under constraints caused by a need to

produce a p
p product or service that is timely,
y competitive,
p reliable,
and consistent with the philosophy and within the financial
means of their company.

We use all that we know to produce

the best answer to a problem!!

Constraints
• Problems that engineers need to solve
invariably have more than one solution
• Engineers find the optimal solution
limited by constraints e.g., $$ and …
– What are the constraints you find in Lab 3?

No Answer, only solution (best after

consideration
id ti off many f factors,
t some
you can control, but many you can’t)

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Design Constraints

Acceptable

The design process

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Proses & Loji

Process & Plant

Anatomy of a chemical process

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Raw Material Storage

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Simple Process Flow Diagram

Waste

Recycled

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Anatomy of a chemical process

Choice of continuous versus batch production

• Continuous
– Production rate greater than 5 x 106 kg/h
– Single product
– No severe fouling
– Good catalyst life
– Proven processes design
Proven processes design
– Established market
– Complicated for Start‐up and Shut‐Down
– More profitable

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Choice of continuous versus batch production

• Batch
– Production rate less than 5 x 106 kg/h
– A range of products or product specifications
– Severe fouling
– Short catalyst life
– New product
New product
– Uncertain design
– Easy Start‐up and Shut‐down

Projects

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Chemical Engineering Projects
• Can be divided into three types, depending on the novelty 
involved:
1. Modifications, and additions, to existing plant; usually carried 
out by the plant design group.
2. New production capacity to meet growing sales demand, and 
the sale of established processes by contractors. Repetition of 
existing designs, with only minor design changes.
3 New processes, developed from laboratory research, through 
3. New processes developed from laboratory research through
pilot plant, to a commercial process. Even here, most of the 
unit operations and process equipment will use established 
designs.

From Lab to real PLANT

The “scale-up” of a laboratory
reaction (~grams) to a
profitable commercial process
106 grams) is usually not a
matter of just making bigger
laboratory equipment
(flasks,beaker and Bunsen
burners), but more….

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The design work in Chemical 
Engineering Projects
• Process Design
• P
Process Flow‐sheets
Fl h t
Phase 1 •
•
Specific design of equipment
Chemical engineers

• Detail mechanical design
• Structural, civil and electrical design
Phase 2 • Cost estimation, purchase of 
equipments
• Various engineers, contractors

Multidisciplinary

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Project Organization

Effective cooperation
depends on effective
communications.

Project Documentation
• All design organizations have formal 
procedures for handling project information 
d f h dli j ti f ti
and documentation.

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General Documentation for 
government department

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A‐Unit

B‐Unit

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A‐Unit

B‐Unit

C Unit
C‐Unit

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Plant

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Equipment Vendors

Calculation Sheets

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Piping Diagrams

Plot / Site plans Drawing
Legends
Buildingg
LOCKER ROOM Process Area
Utility Supply/Service
MAIN
GATE GATE
Warehouse
HOUSE

CENTRAL
CONTROL INCINERATOR
BUILDING
ADMIN. BUILDING

COMP. REFUSE
CHAMBER
WAREHOUSE
COMMON
CAFETERIA TANKYARD
PROCESS TANK WASTEWATER
TOX YARD TREATMENT
FIN. POL /DO PLANT
F N
LOADING AREA
FIRE PUMP HOUSE
PW UNIT
PN
MAINTENANCE
CONTAINER CHILLER GUARD HOUSE
YARD IWTANK
CONTAINERYARD SUB RAW BOILER HOUSE DW TANK
WEIGHBRIDGE
MATERIA SUB GATE
L

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Plot / Site Plan Drawing

Architectural Drawing

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Operating Manual

Numbers and Figures

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Units and Dimensions

• If I asked how you how far it is to KLCC
you wouldld nott answer, “5”!
• Your answer would involve length, ~ 50
km !
Imperial vs. SI
U it mustt b
Units be consistent!
i t t! Check!
Ch k!

Exercise
• 35 gal/min Æ m3/s
• 65 lb/in2 Æ bar
• 65 lb/in2 Æ barG
• Water flowrates
• (90 degC) 10 m3/h Æ Ton/h
• (20 degC) 10 m3/h Æ Ton/h

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Exercise
• 35 gal/min Æ m3/s
• 65 lb/in2 Æ bar (absolute)
• 65 lb/in2 Æ barG
• Water flowrates
• (90 degC, dens = 0.950 g/cm3) 10 m3/h Æ Ton/h
• (20 degC
degC, dens = 0 996 g/cm3) 10 m3/h Æ Ton/h
0.996

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Order of magnitude
analysis
• Estimate
• Feel
• Lower and upper bound
• Pen and pencil
• e.g. How big? How small? How long?

Back-of-the-envelope calculation

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