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CCB 3024/CBB 3024PROCESS PLANT DESIGNLecturer : Dr Balasubramanian Periyasamy4 Credit-Hour Core CourseLecture Time: Mon 10 am 12 noon ; Tues 12 PM 2:00 PMLocation : LT C2 ; 01-02-04

Semester May 2013

Semester May 2011Sincere thanks to

Prof. Shuhaimi Mahadzir &Prof. Mohamed Ibrahim Abdul Mutalib

for the lecture notes of the first part of this course

PROGRAMME OUTCOMES UTP CHEMICAL ENGINEERING

PO1Engineering Knowledge: Apply knowledge of mathematics, science, engineering fundamentals and engineering specialization to the solution of complex engineering problems PO2Problem Analysis: Identify, formulate, research literature & analyze complex engineering problems reaching substantiated conclusions using first principles of mathematics, natural sciences and engineering sciences.PO3Design & Development of solutions: Design solutions for complex engineering problems and design systems, components or processes that meet specified needs with appropriate consideration for public health and safety, cultural, societal & environmental considerations.PO4Investigation: Conduct investigation into complex problems using research based knowledge & research methods including DOE, analysis and interpretation of data and synthesis of information to provide valid conclusions.PO5Modern Tool Usage: Create, select & apply appropriate techniques, resources & modern engineering & IT tool, including prediction & modeling, to complex engineering activities, with an understanding of the limitations.

PROGRAMME OUTCOMES UTP CHEMICAL ENGINEERING Semester July 2004PO6The Engineer& Society: Apply reasoning informed by contextual knowledge to assess societal, health, safety, legal & cultural issues & the consequent responsibilities relevant to professional engineering practice.PO7Environment & Sustainability: Understand the impact of professional engineering solutions in societal and environmental contexts and demonstrate knowledge of and need for sustainable development.PO8Ethics: Apply ethical principles and commit to professional ethics and responsibilities and norms of engineering practice.PO9Communication: Communicate effectively on complex engineering activities with the engineering community & with society at large, e.g. being able to comprehend & write effective reports & design documents, make effective presentations & give and receive clear instructions. PO10Individual &Team Work: Function effectively as an individual & as a member or leader in diverse teams & in multidisciplinary settings.PO11Life Long Learning : Recognize the need for, and have the preparation and ability to engage in independent and life long learning in the broadest context of technological change.

PROGRAMME OUTCOMES UTP CHEMICAL ENGINEERING Semester July 2004PO12Project Management & Finance : Demonstrate knowledge & understanding of engineering & management principles & apply these to ones own work, as a member & leader in a team, to manage projects and in multidisciplinary environments.

COURSE OUTCOMES CBB 3024 CHEMICAL PLANT DESIGN

KSA3PO1PO2PO3PO4PO5PO6PO7PO8PO3PO9PO7CO1Integrate knowledge from previous chemical engineering courses in designing a chemical process systemxxxCO2Apply conceptual process design and synthesis tools in designing a chemical process systemxxCO3Apply a systematic approach or method to design a chemical process systemxxK KnowledgeS SkillA Attitude

COURSE OUTCOMES CCB 3024 CHEMICAL PLANT DESIGNSemester July 2004KSA3PO3PO5PO7PO3PO5PO7PO3PO5PO7CO1Integrate knowledge from basic/fundamentals Chemical Engineering in designing a chemical process systemxCO2Apply conceptual process design and synthesis tools in designing a chemical process systemxxxxCO3Apply a systematic approach to design a chemical process systemxxxxCO4Execute process design approach by incorporating the concepts of sustainable developmentxxxxC05Demonstrate economics of chemical plants through plant cost estimation investment and time value of moneyxxC06Defend the assigned projects as individuals and as a teamxx

Course Content, Delivery & Assessment

Lecture No.TopicAssessment1-2

3-4Introduction to Plant Design and Economics (Approaches and Stages of Process Design)

General Plant Consideration (Plant Layout/Utility System)Short test 1

5-8Synthesis of Reactor Separation System(Fundamentals and Selection of Reaction System & Separation System) Short test 2/Project/Test 19-12Synthesis of Reactor Separation System(Fundamentals and Selection of Reaction System & Separation System) Short test 2/Project/Test 113-16Synthesis of Reactor Separation System(Process Recycle and Distillation Sequencing)Test 1/Project/Assign 117-20Heat Integration (Composite Curve & Heat Recovery Pinch, Problem Table Algorithm)Assign 1/Test 221-24Heat Integration (Grand Composite Curve & Multiple Utilities)Assign 125-28Heat Integration (HEN Design)Assign 1/Test 229-32Process Flow sheeting (Flow sheet Synthesis & Simulation, Model Formulation, Solution Strategies)Project/ Test 2

Lecture No.TopicAssessment33-36Economics of Chemical PlantsProject/Short test 337-40Equipment Design & Specification (Material Transfer & Handling, Mass Transfer Equipment)Assign 241-44

Equipment Design & Specification (Mass Transfer & Reactor Equipment)Assign 245-48

Equipment Design & Specification (Pressure Vessel Design)

Assign 249-52

Environmental Studies & Consideration Effluent Treatment, Waste Minimization and Life Cycle AnalysisShort test 453-56Plant Wide Control (Material & Quality Control, Pairing of Variables in MIMOS, Typical Unit Operation and Control Strategies)Short test 4Assessment :Quizzes /Short tests 4 (5%) Assignments - 2 (5%) Project - 1 (10%)Tests - 2 (20%) Final Exam - 1 (60%) Course Content, Delivery & Assessment

The purpose of engineering is to create material wealth Douglas, Conceptual Design of Chemical Processes 1988.How to do so ?WHAT CAN YOU SAY ABOUT THE CHEMICAL PROCESS ?

Lecture 1. Introduction to Plant Design and Economics

Raw Materials+ Other FeedsEnergyInCHEMICAL PROCESSProducts + WastesEnergy Out

In a chemical process, the transformation of raw materials into desired products usually cannot be achieved in a single step. Instead, the overall transformation is broken down into a number of steps that provide intermediate transformations. (Robin Smith, Chemical Process Design 1995)The goal of the engineer is to design and produce artifacts and systems that are beneficial to mankind Biegler, Grossman & Westerberg, Systematic Methods of Chemical Process Design 1997.

Raw Materials+ Other FeedsEnergyCHEMICAL PROCESSProducts + WastesEnergySO, A NUMBER OF PROCESSING STEPS MADE UP THE CHEMICAL PROCESS.QUESTIONS?

-WHAT SORT OF PROCESSINGS ARE LOCATED IN THE CHEMICAL PROCESS? - HOW DO WE SEQUENCE THE PROCESSING STEPS?- TO WHAT EXTEND CAN WE EXPECT EACH OF THE PROCESSING STEP TO PERFORM AND WHAT FEATURES ARE REQUIRED? - HOW MUCH ENERGY IS REQUIRED AND HOW MUCH IS PRODUCED?- HOW MUCH FEEDS DO WE NEED AND HOW MUCH PRODUCTS ARE PRODUCED?-HOW MUCH WASTES ARE GENERATED?HOW MUCH PROFIT COULD BE DERIVED?HOW DO WE ADDRESS THIS?Concept Design for Chemical Process

Raw Materials+ Other FeedsEnergyCHEMICAL PROCESSProducts + WastesEnergyPROCESS PLANT DESIGN IS THE NAME OF THE GAME HERE !LITTLE OR LIMITEDINFORMATIONS AREAVAILABLEBut so many possibilitiesor solutions !BEFORE COMING UP WITH A COMPLETE PROCESS

Perhaps, the major features that distinguishes design problems from other types of engineering problems is that they are under defined; i.e., only a very small fraction of the information needed to define a design problem is available from the problem statement. (Douglas, Conceptual Design of Chemical Processes 1988)

Stress on design as open ended problem.12Once the process concept has been designed which produces process flowsheet,

the equipment design then has to be performed..

Distillation

Approach in tackling the open ended design problem13The equipment design comprises of ;Performance/Capacity Rating or Sizing

Vessel Mechanical Design

Equipments Dimensions diameter & height

No. of stages for contact

Heat Transfer Area Needed

Wall thicknessSupport Design

Pipe fittings & Reinforcement

Internal Design

The process safety and control strategy has to be devised;Process Safety

Process Control Strategy

Material Control

Product ControlOverall Plant and Equipment .Hazard and Operability Study (HAZOP)

Risk Assessment

HAZOP studyRisk Assessment Matrix

And Waste Treatment/Minimisation need to also be addressedWaste Treatment (conventional)

Waste Minimisation (sustainability)Suitable end of pipe treatment on the effluent (gases & liquids)

Adjusting processes to minimise the generation of wasteREACTORSEPARATION & RECYCLE SYSTEMHEAT EXCHANGERNETWORKUTILITIES

In finalising the process and equipment design, several stages of economic analysis could be conducted First step;EP 1 = Revenue Cost of Raw Material

Second Step (after mass balance developed)EP 2 = Revenue Cost of Raw Material - UtilityThird Step (after equipments designed)EP 3 = Revenue Cost of Raw Material Utility Annualised Cost of EquipmentThe economics analysis continues with other costs (manpower, insurance etc) .

with profitability analysis conducted at the end to assess project viability

Pay back time,Return on InvestmentInternal Rate of Return

Finally ..

FEEDREACTORCWSTEAMPRODUCT 1PRODUCT 21. ADDRESS THE INDIVIDUAL PROCESS/TRANSFORMATION STEPRECYCLE2. ADDRESS THE REQUIRED INTERCONNECTION BETWEEN THE STEPSLecture 2. Approaches and Stages of Process Plant Design In the first stage, conceptual process design has to be conducted.In general conceptual process design has to address two major activities .

.and the target is to create the best possible feasible flowsheet for the process.THIS IS WHAT YOU WANT AT THE END OF THE STAGE !WHAT OTHER INFORMATIONS SHOULD BE AVAILABLE IN A FLOWSHEET ?AND HOW DO YOU GET SUCH INFORMATION ?FEEDREACTORCWSTEAMPRODUCT 1PRODUCT 2RECYCLEStr1Str2Str3Str4Str5Str6Str7Str8Str9FTPxHDEFINITION OF A FLOWSHEET.FLOWSHEET IS A DIAGRAMMATIC REPRESENTATION OF THE PROCESS STEPS AND ITS INTERCONNECTIONS.

A SYSTEMATIC APPROACH OR METHOD IS REQUIREDHowever, as much as we would like to have a systematic approach or method, we must also recognised that process design is an art !If we reflect on the nature of process synthesis and analysis, . , we recognize that process design actually is an art, i.e., creative process. (Douglas, Conceptual Design of Chemical Processes 1988)The approach or method should be able to help in addressing these questions Why is the unit operation selected ? How are the unit operations connected ? What are the utilities required and approximate amount ? How will it be supplied to the process unit operations ? What wastes will be generated? This course will attempt to develop the art to conduct process design !

1. ADDRESS THE INDIVIDUAL PROCESS/TRANSFORMATION STEP2. ADDRESS THE REQUIRED INTERCONNECTION BETWEEN THE STEPSFEEDREACTORCWSTEAMPRODUCT 1PRODUCT 2RECYCLEFLOWSHEETNow, what criteria should be adopted besides economics during the design activities?MINIMISE COSTMINIMISE ENERGY CONSUMPTIONMINIMISE WASTES GENERATION..... BUT HOW TO OPTIMISE ?HIGH SAFETY & INTEGRITYGOOD OPERATIONAL ASPECTSQUANTIFIABLE FACTOR !NON - QUANTIFIABLE FACTOR !VERSUS

Stress on the various criteria in developing the process design besides economics22FEEDREACTORCWSTEAMPRODUCT 1PRODUCT 2RECYCLEConsider back the flowsheet !OPTIMISING THE INTERCONNECTIONSBETWEEN THE UNITS/STEPS IN THE PROCESS?MANY POSSIBLE CONNECTIONS WHICH LEADTO DIFFERENT STRUCTURES OF FLOWSHEETTHUS DIFFERENT ECONOMIC IMPACT EVEN TO THEEXTENT OF THE INDIVIDUAL UNIT ITSELF!DIS-CONTINUOUS FUNCTIONSTRUCTURAL OPTIMISATIONOPTIMISING A SINGLE UNIT/STEP IN THE PROCESS

EG. DISTILLATION COLUMNTOTALCOSTRRRR --> ENERGYRR --> CAPITALCONTINUOUS FUNCTIONPARAMETER OPTIMISATIONHow do we tackle them ?

Consider the approaches/methods which have been introduced to deal with such complex optimisation ?MIXED INTEGER LINEAR/NON-LINEAR PROGRAMMINGMATHEMATICAL METHODUSE A MATHEMATICAL PROGRAMMING METHOD TOSOLVE AND GIVE SOLUTION FOR THE PROCESS.SIMULTANEOUS SOLUTION OF ALL THE SYSTEM. CONCEPT IS BASED ON"CREATING AND OPTIMISING A REDUCIBLE STRUCTURE"DECISION ARE BASED ON SOLELY MATHEMATICAL OPTIMISATION CRITERIA Grossman I. E, Comp. Chem. Eng., 9: 463, 1985Biegler, Grossman & Westerberg, SystematicMethod of Chemical Process Design 1997ONION MODELHEURISTIC METHODUSE A SEQUENTIAL/HIERARCHICAL METHODACCORDING TO FOLLOWING SEQUENCE ;1. REACTOR2. SEPARATION AND RECYCLE SYSTEM3. HEAT EXCHANGER NETWORK4. UTILITIESCONCEPT IS BASED ON"BUILDING AN IRREDUCIBLE STRUCTURE"DECISION ARE BASED ON ENGINEERING GUIDELINESESTABLISHED AND MATHEMATICAL OPTIMISATION Smith R.,Chemical Process Design 1995HIERARCHICAL APPROACHUSE A SEQUENTIAL/HIERARCHICAL METHODACCORDING TO FOLLOWING SEQUENCE ;1. BATCH VS CONTINUOUS2. INPUT-OUTPUT STRUCTURE OF THE FLOWSHEET3. RECYCLE STRUCTURE OF THE FLOWSHEET4. GENERAL STRUCTURE OF SEPARATION SYSTEM5. HEAT EXCHANGER NETWORKDouglas.,Conceptual Design of Chemical Process 1988

HEURISTIC METHOD The Onion ModelREACTORSEPARATION & RECYCLE SYSTEMHEAT EXCHANGERNETWORKUTILITIES- FOLLOWS ONION LOGICDesign starts from the centre ( heart of process ) which is the reactor.At each layer, decision has to be made to complete the design requirement for the stage. As such, many best local optimal decisions are made since the whole picture is incomplete. Unit/Equipment is added only if it is economically justified based on the current available information. This keeps the process (structure) irreducible and features which are technically/economically redundant are not included.What do you see are the advantages and disadvantages of this method ?AdvantagesDisadvantages

WHAT DO YOU NOTICE ONTHE STATEMENT CONTAIN WITHINTHE SHADED BOX ?Compare these statementsto the onion model !REACTORSEPARATION & RECYCLE SYSTEMHEAT EXCHANGERNETWORKUTILITIESHEURISTIC METHOD The Hierarchical ApproachThe conceptual design is performed based on 5 different stages. The approach is somewhatdifferent by tackling the 5 different level that are classified differently. The 5 levels are ;Level 1 Decision : Batch vs ContinuousLevel 2 Decision : Fixing the Input-Output StructureLevel 3 Decision : Determining the Recycle Structure for the ProcessLevel 4 Decision : Determining the Separation SystemLevel 5 Decision : Determining the Heat Exchanger NetworkAt each level except level 1, alternatives have to be generated and assessed to see its economic and operational potential. Some level of process design has to be conducted on the units/process placed at every stages.

Semester July 2004MATHEMATICAL METHOD The Mixed Integer Linear/Nonlinear ProgrammingWhat are the advantages and disadvantages of this method ?AdvantagesDisadvantages- CREATION OF SUPERSTRUCTURE/HYPERSTRUCTUREA major (super) structure is created which embedded within it all feasibleprocess (including its operations) and all feasible interconnections thatare candidates for an optimal design. The method is completely automatedand depends only on the computer programming to solve it. The design problem is formulated into sets of mathematical equations which has to besolved by the mathematical programming. Started off with many redundant features, the programming optimise and reduce the process (structure) to an optimal solution.other processalternatives

From the conceptual process design, a flowsheet is generated for the process. The next stage would then be to address the equipment design FEEDREACTORCWSTEAMPRODUCT 1PRODUCT 2RECYCLEHeat Exchanger

Type of Exchanger (Plate / Shell & Tube)Heat Transfer CoefficientHeat Transfer AreaPressure DropExchanger ConfigurationReactor

Type of ReactorReaction KineticsReaction SelectivityReactor SizingReactor Temperature & Pressure

No of stagesReflux RatioFeed LocationVapour/Liquid LoadingColumn SizingInternalsColumn Temperature & Pressure

Distillation

There are established methods for performing the design of these equipments .Heat Exchanger

Rating calculation that will enable the sizing of the heat exchanger to be doneKerns methodReactor

ReactorFrom the kinetics obtained from experiment, sizing of reactor could be done based on residence time.

DistillationNo of stages calculation versus reflux ratio could be made and the feed location determined.Results are then simulated in rigorous simulation model for actual design involving capacity calculation for internals.Fenske, Gilliland & Underwood

Heat Exchanger

Reactor

DistillationGiven that each of the equipment will normally involved vessel operated at various pressure and temperature, the design of the pressure vessel has to be conducted. The design is to be done according to standards..

Pressure Vessel Dimension Shell ThicknessFlanges Connection & ReinforcementSupport type and DesignCorrosion AllowanceWelding specification American Society of Mechanical Engineers (ASME)Boiler and Pressure Vessel Code.ASME Boiler and Pressure Vessel Code (BPVC) is a standard that provides rules for the design, fabrication, and inspection of boilers and pressure vessels. It is reviewed every three years.

Health, Safety and Environment aspects are increasingly gaining attention in view of their importance. Therefore the design of process plant has to take into account of the HSE particularly the safety and environment aspects where it has to be integrated with the design activities .Inherent SafetyHazard AnalysisFIREAuto Ignition temp.Flammability LimitsFlash PointsMinimum Oxygen concentration

Flammable liquids are more dangerous than flammable gas

EXPLOSIONChemical Energy vs Physical EnergyDeflagration vs detonationConfined vs Unconfined Explosions (VCE)

TOXIC RELEASETime weighed exposureShort term ExposureCeiling ExposureLC50 & LD50DOW Index

Remove or attenuate conditions that could lead to the 3 incidents such as high P and T ..HAZOPHazard and Operability Study.

EnvironmentHealth, Safety and Environment aspects are increasingly gaining attention in view of their importance. Therefore the design of process plant has to take into account of the HSE particularly the safety and environment aspects where it has to be integrated with the design activities .EnvironmentWaste Minimisation(Clean Process Technology)ReactorIncrease conversion if selectivity is not an issueProduct removal for reversible reaction favoring productSet T & P to improve selectivity

DistillationRecycling waste stream to suppress by product reactionFeed purificationEliminate use of extraneous material for separation (entrainer)

Waste stream recoveryImprove heat recoveryWaste TreatmentAir EffluentParticulate, CO2, CO, SOx, NoxGravity Settlers, Inertial Collectors, Scribbers, Filters, Electrostatic precipitators, catalytic reaction etc.

Water EffluentMembrane, Adsorption, Absorption, thermal oxidation, biological treatment, membrane separation etc.

Finally ..

You will develop the construction details for a process plant .