perancangan pabrik & produk kimia (chs 41032) capstone course preparing for engineering practice...
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PERANCANGAN PABRIK &PRODUK KIMIA
(CHS 41032)
Capstone Course
PREPARING FOR ENGINEERING PRACTICE
Knowledge Skills
Instructors
Prof. Dr. Widodo W. Purwanto (WD)Dr. Setijo Bismo (SB)Dr.rar.nat. Yuswan Muharam (YM)Dosen Tamu dari IndustriAsisten: Mohamad Ibad ST, Akmad Adlan ST
Course Content
SyllabusChemical Industry and design trendsProcess/plant DesignProblem Formulation, Synthesis, Analysis, EvaluationProduct DesignNeeds, Ideas, Selection, Manufacture
Chemical Industry and Design Trends
Role of Chem. Eng.
Expanding the scope in ChE
2008 © Partha S Ghosh
The Promise of Chemical Industry has to be applied in Multiple Scales
Sca
les
of
En
gag
emen
tHolistic /Tera Scale
Perspective
Microscopic Perspective
Three Scales of Knowledge Application
Large Scale Systems Dynamics Issues • Global Ecological Balance ?• Energy Balance ?• Social Structures ?
Raw materials
Cellular /Nano Level functionalities
Tera Scale
Current Scale
Micro Nano Scale
1. Efficiency 2. Conservation
3. Recycling
1
2
3
Socializatio
n Pro
cess of M
ultiple d
isciplin
es
From “Bulk” to “Molecular” Processing
Raw Materials to Consumer Products
Natural Herbs to Healthcare Products
Review Chemical Industry
Scope of Chemical Product and Process industry
Design of chemical products beginswith the identification and creation ofpotential opportunities to satisfysocietal needs and to generate profit
Process operation for 3 types of chemical products
Chemical Product Tree
Source: Gani, 2004
Purity/composition
Performance
Process-Centered Company to Product-Centered Company
Source: Stephanopoulos, 2004
Source: Stephanopoulos, 2004
Source: Stephanopoulos, 2004
What is engineering design?
The process of applying various techniques and scientific principles for the purpose of defining a device, a process or a system in sufficient detail to permit physical realization.
The design engineer makes choices based on a thorough understanding of the engineering fundamental, feasibility constraint, reliability, cost, manufacturability, and human factors.
Good design requires experience, knowledge and a considerable amount of intuition.
Product and Process Synthesis, Design, Analysis
Design Objectives
determine the goal
determine all relevant factors
see the “big picture”
focus on critical issues
economic objective function ++ ecological,
social
Characteristic of Design
Emphasis on synthesis, + analysis & evaluation Creative, Interactive and Iterative, Problem statement ill-posed and open-ended, Team-oriented and multi-disciplinary, More than one right answer, Retrofit or build new grass roots facilities, Always performed with an eye toward the ultimate
benefit, generally economic.
Type and level of design
Preliminary or quick-estimate designs
Detailed-estimate designs
Firm process designs or detailed designs
Levels
order of magnitude estimate, ±40%
study estimate, ±25%
preliminary estimate, ±12%
definitive estimate, ±6%
contractor’s estimate, ±3%
Types
New approach of design
New approach of design
Chemical Process/Plant Design
Process Design Methodology & Innovation Cycle
Design Innovation Cycle
Design methodsProblem Definition
Quality Function Deployment (Sullivan, Reich)
Synthesis and AnalysisGreen Chemistry (Anastas)Hierarchical Method (Douglas)Task Integration (Siirola)Exergetical Heuristics (Hinderink)
EvaluationForum DiscussionLife Cycle Assessment (Goedkoop, Cornellissen)Sustainable Process Index (Narodoslawsky, Krotscheck)
Problem Definition
Process or Products?Life Cycle
Conceptual Process Design
Process Design Considerations
Health and Safety HazardsEnvironmental ProtectionPlant LocationPlant LayoutPlant Operations and ControlUtilitiesStructural DesignStorageMaterials HandlingPatent Considerations
Process Design Scope
Process Selection
Technical factors
Raw materials
HSE
Equipments
Plants location
Costs (Capex, Opex)
Time factors
Process Synthesis
Process Synthesis:
Reactor, separation, Heat exchanger, etc
Operating conditions, Heat & Mass balance
Flowsheeting using Software (BFD, PFD, P&ID)
Process Synthesis via Hierarchical Process Design Methods
Heuristic for Process SynthesisUnderstand the importance of selecting reaction paths that do not involve toxic or hazardous chemicals, and when unavoidable, to reduce their presence by shortening residence times in the process units and avoiding their storage in large quantities.Be able to distribute the chemicals in a process flowsheet, to account for the presence of inert species, to purge species that would otherwise build up to unacceptable concentrations, to achieve a high selectivity to the desired products.Be able to apply heuristics in selecting separation processes to separate liquids, vapors, and vapor-liquid mixtures.Be able to distribute the chemicals, by using excess reactants, inert diluents, and cold shots, to remove the exothermic heats of reaction.Understand the advantages of pumping a liquid rather than compressing a vapor.
BFD & PFD – Core Process Synthesis
Plant Site Selection
Raw material availabilityMarketsEnergy availabilityClimateTransportation facilitiesWater supplyLabor supplyGov. regulation: fiscal regime..Community factors
ECO, Green, Sustainable - Design
Chemical & Energy Route Selections
Green Chemistry and Eng. Inherently Safer Design
Equipment Sizing
Back to principle of unit operation (movers, mixing/separation, reaction)Process simulatorRule of thumbRational
Time value of moneyEstimation of costs Quantitative measures of profitabilitySystematic comparison of alternatives
Engineering Economics
Evaluation
Chemical Product Design
New specialty chemicals that provide a specific benefit, i.e. Pharmaceuticals
Microstructures of product, rather than molecular structures, creates value: processed foods, household products, personal care products i.e. Paint and Ice Cream, margarine, shampoo, toothpaste,
Devices that effect chemical changes, i.e. Blood Oxygenator in Open Heart Surgery
What is CPD?
Why CPD Is Important
Changes in the Chemical Industry
Changes in Employment
Changes in Corporate Culture
Preliminary Product Design
Chemical Process vs. Product Design
PROCESS DESIGN PRODUCT DESIGN
•Batch vs. Continous Process
•Identify Customer Needs
•Inputs and Outputs •Generate Ideas to Meet Needs
•Reactors and Recycles •Select among Ideas
•Separation and Heat Integration
•Manufacture Products
Needs What needs should the product
fulfill ?
Ideas What different products could
satisfy these needs ?
Selection Which idea are the most
promising ?
Manufacture How can we make the product in
commercial quantities ?
The Product Design Procedure
The Industrial Design Process
Product Development Process
Customer Needs Process
Product Specification
Product Specification
Idea/Concept Generation
Concept Selection
• The goal of concept selection is not to select the best concept • The goal of concept selection is to develop the best concept.
Manufacturing
Time value of moneyQuantitative measures of profitabilityEstimation of costsSystematic comparison of alternatives
Engineering Economics
Place of the Designers
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