design project steps 20 july 2007 - lecture 2
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PSE
Process,Process,
Product DesignProduct Design& Process Creation& Process Creation
PSE
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PSE
ZainuddinZainuddin Abdul Manan, PhDAbdul Manan, PhDAssociate Professor and Head,Associate Professor and Head,Dept of Chemical Engineering, UTMDept of Chemical Engineering, UTM
Dr. Zainuddin Abdul Manan holds a BSc degreein Chemical Engineering from University ofHouston, USA, a master degree in ProcessIntegration from Centre for ProcessIntegration, UMIST, Manchester, and PhD inChemical Engineering from the University ofEdinburgh, Scotland. He has worked as aproduction engineer with Hume Industries.
[email protected]:07-5535512
His research interests include Process Systems Design and ProcessImprovement with emphasis on efficient energy utilisation and wasteminimisation (cleaner production). He has ten years research and consultancyexperience in the area of process design, process improvement, energyconservation and cleaner production; having completed over 30 research andconsultancy projects involving petrochemicals, fine chemicals, pulp and paperand food production industries in Malaysia and abroad. He is also anexperienced instructor for professional courses related to chemical andprocess engineering, having taught over 250 companies nationwide.
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PSELearning OutcomesLearning Outcomes
After studying this topic, participants should:
Recognise the significance of design project for chemical/processengineers
Be able to describe the life cycle of a chemical process and identify theactivities associated with it
Have an appreciation of the key steps in carrying out a product and / orprocess design.
Be knowledgeable about the kinds of design decisions that challengeproduct and process design teams
Be familiar with the key roles of a chemical/process engineerBe aware of the various techniques and steps involve during processcreation
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PSE
Process Design whose job? Design project in the context of a chemical
process engineers role
Process Design Definition Process Design Procedure Process Design Activities Process Life Cycle Levels of Design Accuracy
Intro to Process Design
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PSE One day in a job interviewOne day in a job interview
...
...
What is your
field of study?ChemicalEngineering!
Then, our
chemistry lab might be the best place for you ?Oh no!
Not again...
ThemanagerThe
freshgrad
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PSE Chemical/ProcessChemical/ProcessEngineeringEngineering
..is the field of study
that involves the processof converting resourcesinto value-added products
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PSE A design project A design project A design project A design project A design project A design project A design project A design project
Survey/feasibility studies
Project teamProject structure/planning (milestone)Process and Product Design
DesiredProducts
PROCESS ?
Raw materials?
Process Structure
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PSE
Methane
Ammonia
Methanol
EthyleneOxide
ChloralkaliPlant
Ethane
Propane
Ammonia
MTBE
UreaFormadehyde
Ammonia Urea
Ammonium Nitrate
Ammonium Phosphate
Polyvinyl Chloride
Titanium Dioxide
Silicones
Polyethylene LDPE
Glycol
Surfactant
Polypropylene
Acrylics
Acrylonitrile
Caprolactam Terephthalic Acid
Polystyrene
ABS, SAN
MTBE
Unsaturated Esters
Butane
Benzene
e.g. End Uses ofFractionated Raw
Natural Gas
Middle Distillates
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PSE
E.g. Naphtha Utilisation For Petrochemicals (1/2)
Cl2
EDC/VCM Polyvinyl Chloride
LDPE Acetic Acid
Vinyl Acetate Polyvinyl AcetateLLDPE/HDPE
Ethylene O2 H2O PTA Polyester Polyethylene
Ethylene Oxide Ethylene Glycol Chips Terephthalate
Benzene (PET)
Ethylbenzene Styrene Polystyrene
Naphtha H2O O2Cracker Ethyl Alcohol Ethyl Aldehyde Acetic Acid
Polypropylene
H2O O2 HCN
Propylene Isopropanol Acetone Methyl Methacrylate Polymethylmethacrylate
Benzene Isopropylbenz O2 Cumene Hydroperoxide Cleavage Phenol /
(Cumene) (CHP) Acetone
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PSE
E.g. Naphtha Utilisation For Petrochemicals (2/2)O2
(By Products) n - Butane Acetic Acid
Acrylonitrile
Butene - 1
Mixed C 4Butadiene Polybutadiene (Synthetic Butadiene Rubber)
H2
HMDA Nylon 6,6
Adiponitrile
Nylon 6
Butene - 2 Isobutene Polybutene
MTBE (ABS)
Naphtha
Cracker Toluene Toluene Diisocyanate (TDI) Nylon-6
C2Benzene Ethylbenzene Styrene Polystyrene
Pyrolysis C3 O2Gasoline Mix-xylene Phenol Cyclohexanone Caprolactam
Acetic Acid EGPara - xylene Pure Terephthalic Acid (PTA) Polyester Fiber
Fuel Oil
Fuel Gas
Caprolactam
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(Seider et al. , 2004)
Process Life Cycle Process Life Cycle Process Life Cycle Process Life Cycle Process Life Cycle Process Life Cycle Process Life Cycle Process Life Cycle A Bird A Bird A Bird A Bird A Bird A Bird A Bird A Bird s Eye View s Eye View s Eye View s Eye View s Eye View s Eye View s Eye View s Eye View
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Process DesignProcess DesignProcess DesignProcess DesignProcess DesignProcess DesignProcess DesignProcess Design Basic Components Basic Components Basic Components Basic Components Basic Components Basic Components Basic Components Basic Components at Project Team Level at Project Team Level at Project Team Level at Project Team Level at Project Team Level at Project Team Level at Project Team Level at Project Team Level
Steps in the design of a chemical process:1. Project Conception
2. Process Synthesis/Creation
3. Equipment Design4. Economic Analysis
5. Optimisation
(Ulrich, 1984)
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Process DesignProcess DesignProcess DesignProcess DesignProcess DesignProcess DesignProcess DesignProcess Design ProcessProcessProcessProcessProcessProcessProcessProcessSynthesis/Creation Synthesis/Creation Synthesis/Creation Synthesis/Creation Synthesis/Creation Synthesis/Creation Synthesis/Creation Synthesis/Creation
Process Simulation
parameteroptimisation
Optimised Design
Material and Energy Balances(manual & simulation)
Process Synthesis/
Flowsheeting
Process Modelling/Analysis
(Manan, 2001)
structural optimisation
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PSE
Process Creation (details) Process Creation (details) Process Creation (details) Process Creation (details) Process Creation (details) Process Creation (details) Process Creation (details) Process Creation (details)
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PSE
Process Creation and Detailed Design Process Creation and Detailed Design Process Creation and Detailed Design Process Creation and Detailed Design Process Creation and Detailed Design Process Creation and Detailed Design Process Creation and Detailed Design Process Creation and Detailed Design
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PSE
Final Design & Operation Final Design & Operation Final Design & Operation Final Design & Operation Final Design & Operation Final Design & Operation Final Design & Operation Final Design & Operation
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Construction and Operation Construction and Operation Construction and Operation Construction and Operation Construction and Operation Construction and Operation Construction and Operation Construction and Operation
Layout and3-D Modelling
Construction
Startup andCommissioning
Plant Operation
Debottlenecking
Decommisioning
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PSE What aWhat a Chemical ProcessChemical ProcessEngineer Engineer * Does for a Living* Does for a Living
1. Process Design2. Process Development3. Construction4. Manufacturing/Operation5. Technical Sales6. Research
*A person whose job is related to the process of transforming materialsinto value-added products
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PSE2. Process Development 2. Process Development 2. Process Development 2. Process Development 2. Process Development 2. Process Development 2. Process Development 2. Process Development
Design
Construction Operation - testing
- reaction & catalyst- process conditions- process control scheme- materials of construction
Pilot Plant(10 kg/hr)Chemical
Lab(10g)
CommercialScale
(100 tonne/hr)
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3. Construction & Commissioning3. Construction & Commissioning3. Construction & Commissioning3. Construction & Commissioning3. Construction & Commissioning3. Construction & Commissioning3. Construction & Commissioning3. Construction & Commissioning- -- - - -- - Moment of Truth Moment of Truth Moment of Truth Moment of Truth Moment of Truth Moment of Truth Moment of Truth Moment of Truth
Chemical Engineers:
Ascertain that equipment operates correctly? Are involved in plant commissioning, start up Identify any problems with process and equipment Specify redesign requirements (as required)
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PSE4. Commercial Production 4. Commercial Production 4. Commercial Production 4. Commercial Production 4. Commercial Production 4. Commercial Production 4. Commercial Production 4. Commercial Production
ChemicalEngineer
Troubleshooting
SupervisionQuality ControlDebottlenecking
Energy ConservationRaw material conservationPollution controlProcess control
RoutineOperation
Process
Improvement
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PSE
5. Technical Sales 5. Technical Sales 5. Technical Sales 5. Technical Sales 5. Technical Sales 5. Technical Sales 5. Technical Sales 5. Technical Sales
Chemical Engineer
Provide process and product recommendations Provide advice on development of new process & products Networking with experts from other fields in solving
process/equipment problems to meet customer needs
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PSE 6. Research 6. Research 6. Research 6. Research 6. Research 6. Research 6. Research 6. Research
Chemical engineers:
Cooperate with chemist, scientists andengineers from other fields to producenew products
Develop new processing techniques
Improve & optimise process operations
Design new equipment or improve the
existing ones
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PSE
Have you ever worked as aHave you ever worked as aHave you ever worked as aHave you ever worked as aHave you ever worked as aHave you ever worked as aHave you ever worked as aHave you ever worked as a chemical engineer chemical engineer chemical engineer chemical engineer chemical engineer chemical engineer chemical engineer chemical engineer ? ?? ? ? ?? ?
Please take about 10 minutes to recollect a challenging task that you haveperformed in your company, related to one of the six areas that a chemicalengineer may work in - i.e. process design, process development,construction, manufacturing*, sales and research .
Please share with us your particular experience by writing it down briefly ona piece of paper. Please include your name if you dont mind.
*manufacturing may involve process (product and quality) monitoring ,troubleshooting, improvement and debottlenecking .
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PSELevels of Design AccuracyLevels of Design AccuracyLevels of Design AccuracyLevels of Design AccuracyLevels of Design AccuracyLevels of Design AccuracyLevels of Design AccuracyLevels of Design Accuracy- -- - - -- - 11111111
Types of Design estimates
1. Order of magnitude estimate - based on similar or previous cost data;probable accuracy exceeds 40%
2. Study estimate - based on knowledge of major items of equipment; probableaccuracy up to 25%
3. Preliminary/budget authorization/scope estimate -based on sufficient datato allow the estimate be budgeted; probable accuracy within 12%4. Definitive estimate (project control estimate) based on almost complete data,
but before completion of drawings and specifications; accuracy within 6%5. Detailed estimate (contractors estimate) based on complete engineering
drawings, specifications, and site surveys; probable accuracy within 3%
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PSE
b u d g e t
a u t h o r
i z a t i o n
e s t i m a
t e
Levels of Design Accuracy Levels of Design Accuracy Levels of Design Accuracy Levels of Design Accuracy Levels of Design Accuracy Levels of Design Accuracy Levels of Design Accuracy Levels of Design Accuracy
10
20
30
40
Cost for an economic estimate for a $1M to 5M plant (thousands of $)1.0 5 10 50 100 5000.5
E r r o r r a n g e
( % )
F i r m o r
c o n t r a c t o r s
e s t i m a t e
P r o
j e c t
c o n
t r o l
e s t
i m a t eOrder of
magnitudeestimate
S t u d y
e s t i m a t e
Definitive Estimate
Predesign Estimates
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PSE Assignment G2PSS Assignment G2PSS Assignment G2PSS Assignment G2PSS Assignment G2PSS Assignment G2PSS Assignment G2PSS Assignment G2PSS - -- - - -- - ProcessProcessProcessProcessProcessProcessProcessProcess
Screening and Synthesis Screening and Synthesis Screening and Synthesis Screening and Synthesis Screening and Synthesis Screening and Synthesis Screening and Synthesis Screening and Synthesis
Methanol is an important raw material for the production offormaldehyde, acetic acid and for gasoline blending (as fuel formotor vehicle). Several routes* exist for the production ofmethanol. Make an initial selection of the best process route +and develop a preliminary flowsheet for the production of100KMT/annum of methanol based on the process route youhave selected.
(Due: Aug 7, 2005)
*these include conventional (from the 60s and 70s) as well as modern technologies (late 90sand early 2000)
+ based on various process screening criteria
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PSE Assignment I1PS Assignment I1PS Assignment I1PS Assignment I1PS Assignment I1PS Assignment I1PS Assignment I1PS Assignment I1PS Process Simulation Process Simulation Process Simulation Process Simulation Process Simulation Process Simulation Process Simulation Process Simulation
Refer to problem 4.29 (3 rd edition) of Felder and Rousseau. Perform manual mass balance calculations for the separation of
1000 tons of 30% B, 40% T and 30% X . Confirm this results using Design II simulation software*,
complete the mass balance for the separation sequence.
Compare the results among your group members* www.winsim.com
The password is:The password decodes to: Serial Number:
Type of security: Name / Location / PasswordLevel: Academic (Professional privileges)Name: University of Technology of MalaysiaLocation: Skudai, Malaysia Password for DIIW
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PSE Assignment I1PS (cont Assignment I1PS (cont Assignment I1PS (cont Assignment I1PS (cont Assignment I1PS (cont Assignment I1PS (cont Assignment I1PS (cont Assignment I1PS (cont ) )) ) ) )) )
Estimate the operating conditions (temperatures and pressures)*for the two columns, assuming cooling water is to be used in a pressure drop of 0.01 bara throughout each column
* These conditions are essential to facilitate process simulation
Specify the (i) reflux ratio (ii) number of stages for eachcolumn to achieve the desired product specifications
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PSEGroup Assignment 1Group Assignment 1Group Assignment 1Group Assignment 1Group Assignment 1Group Assignment 1Group Assignment 1Group Assignment 1- -- - - -- - A AA A A AA A
Refer to the project for the manufacture of 100KMT methanol.For the processes available on the market,(a) Find the prices for the materials having commercial value.
(b) If all the limiting reactant could be converted to product, what is the maximumattainable gross profit?(c) Using the conversion and selectivity found in the literature, adjust the
maximum gross profit attainable for each reaction. Compare the maximumgross profit and identify the reaction giving the highest maximum gross profit
(d) For the reaction that you have selected, tabulate several of the physicalproperties (as in Table 1.3, Chapter 1, Biegler) for all the species you wouldexpect in this process.
(e) Develop the hierarchy of flowsheets for this process, until the final separation
system.(f) Summarise the advantage and disadvantages of the various processesfor producing methanol. Weigh these factors and choose your processaccordingly. (Due: )
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PSESome common terminology Some common terminology Some common terminology Some common terminology Some common terminology Some common terminology Some common terminology Some common terminology
Process flow diagram (PFD) / process flowsheet -interconnections of the individual process operations(e.g. drying, mixing, etc.) together with the quantitativevariables (e.g. P, T, flowrates and composition).
DFCY1
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PSEExample: vinyl chloride production Example: vinyl chloride production Example: vinyl chloride production Example: vinyl chloride production Example: vinyl chloride production Example: vinyl chloride production Example: vinyl chloride production Example: vinyl chloride production
Raw materials
(C 2H 4, Cl 2)
ProcessFlowsheet?
Desired Product
(C 2H 3Cl)
Needed to define the state of each:1) Mass (flowrate)2) Composition3) Phase (solid, liquid, gas)4) Form (particle size, etc.)5) Temperature6) Pressure (Seider et al. , 1998)
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DFCY1 An example to differentiate process synthesis & analysisDominic Foo Chwan Yee, 6/29/2004
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PSEPossible scheme of production Possible scheme of production Possible scheme of production Possible scheme of production Possible scheme of production Possible scheme of production Possible scheme of production Possible scheme of production
DirectChlorination Pyrolysis
242242 Cl H C Cl H C + HCl Cl H C Cl H C + 32242
Cl2113,400 lb/hr
C2H444,900 lb/hr
HCl58,300 lb/hr
C2H3Cl100,000 lb/hr
Dichloroethane
(Seider et al. , 1998)
DFCY2
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PSEProcess flow diagram (PFD) Process flow diagram (PFD) Process flow diagram (PFD) Process flow diagram (PFD) Process flow diagram (PFD) Process flow diagram (PFD) Process flow diagram (PFD) Process flow diagram (PFD)
(Seider et al. , 1998)
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DFCY2 Process synthesis is what we learn in process design courseDominic Foo Chwan Yee, 6/29/2004
DFCY3
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PSE Analysis approach Analysis approach Analysis approach Analysis approach Analysis approach Analysis approach Analysis approach Analysis approach
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DFCY3 Process synthesis is what we learn in process design courseDominic Foo Chwan Yee, 6/29/2004
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PSETypical icons use in a PFDTypical icons use in a PFDTypical icons use in a PFDTypical icons use in a PFDTypical icons use in a PFDTypical icons use in a PFDTypical icons use in a PFDTypical icons use in a PFD
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PSETypical icons use in a PFD Typical icons use in a PFD Typical icons use in a PFD Typical icons use in a PFD Typical icons use in a PFD Typical icons use in a PFD Typical icons use in a PFD Typical icons use in a PFD
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Introduction to Computer AidedIntroduction to Computer AidedIntroduction to Computer AidedIntroduction to Computer AidedIntroduction to Computer AidedIntroduction to Computer AidedIntroduction to Computer AidedIntroduction to Computer Aided
Process Design & Simulation Process Design & Simulation Process Design & Simulation Process Design & Simulation Process Design & Simulation Process Design & Simulation Process Design & Simulation Process Design & Simulation
Wh ih ih iWh i P Si l iSi l iSi l iP Si l i ????
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PSEWhat isWhat isWhat isWhat isWhat isWhat isWhat isWhat is Process Simulation Process Simulation Process Simulation Process Simulation Process Simulation Process Simulation Process Simulation Process Simulation ? ?? ? ? ?? ?
Building a process modelPredicting how a process would actually behavePerforming an experiment (on computer)
Incentives:Highly cost effectiveReasonably accurateProactive approach
Q: What does the word simulate mean?
h ihhh iWh iWh iWh iWh i d ld ld ld ld ld ld ld l??????
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PSEWhat is aWhat is aWhat is aWhat is aWhat is aWhat is aWhat is aWhat is a model model model model model model model model ? ?? ? ? ?? ?
A model should be as simple as possible and no simpler~ Albert Einstein
Th f i l iTh f i l iTh f i l iTh f i l iTh f i l iTh f i l iTh f i l iTh f i l i
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PSEThe purpose of simulation The purpose of simulation The purpose of simulation The purpose of simulation The purpose of simulation The purpose of simulation The purpose of simulation The purpose of simulation
Typical purpose is to provide stream and unitoperation size parameters for entire processincluding such things as:
Flowrates.Compositions.Temperatures.
Duties.Equipment performance.Power requirements.Physical and thermodynamic properties of streams.
Secondary purpose is to determine preliminary size& cost estimates of individual pieces of equipment.
Role of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in product
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PSE
Role of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in productRole of CAPD & simulation in productdevelopment &development &development &development &development &development &development &development &commercialisation commercialisation commercialisation commercialisation commercialisation commercialisation commercialisation commercialisation
IDEA GENERATIONProject Screening, Strategic Planning
PROCESS DEVELOPMENTEvaluation of Alternatives
Common Language of Communication
FACILITY DESIGNEquipment & Utility Sizing and Design
MANUFACTURINGOn-Going Optimization, DebottleneckingProcess Scheduling, Production Planning
Development Groups
Development GroupsProcess EngineeringCorporate EnvironmentalManufacturing
Manufacturing(Demetri, Koulouris & Siletti, 2002)
Obj ti f i l tiObj ti f i l tiObj ti f i l tiObj ti f i l tiObj ti f i l tiObj ti f i l tiObj ti f i l tiObj ti f i l ti
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PSEObjectives of process simulation Objectives of process simulation Objectives of process simulation Objectives of process simulation Objectives of process simulation Objectives of process simulation Objectives of process simulation Objectives of process simulation
PROCESS
UTILITIES
Rawmaterials By-products
Fuel
Electricity
WASTETREATMENT Wastewater
Air Solid
Products Products
(Marechal & Kalitventzeff, 1998)
S h d li g tiS h d li tiS h d li tiS h d li g tiSched ling q estionsS h d li g q tiS h d li g q tiSched ling q estions
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PSEScheduling questions Scheduling questions Scheduling questions Scheduling questions Scheduling questions Scheduling questions Scheduling questions Scheduling questions
How can I schedule production during thenext 6-18 months?
How can I schedule operations in an R&Dfacility?How to adjust scheduling if priorities change?
Can I fit a new product into my facility?
S i l i l tS i l i l tS i l i l tS i l i l tSome commercial process simulatorsSome commercial process simulatorsSome commercial process simulatorsSome commercial process simulators
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PSESome commercial process simulators Some commercial process simulators Some commercial process simulators Some commercial process simulators Some commercial process simulators Some commercial process simulators Some commercial process simulators Some commercial process simulators
Oil, Gas &Petrochemicals
Specialty Chemicals
Oleo Chemicals
SS Simulation
Optimisation
Sensitivity Analysis
Dynamic simulation
Rating
Physical properties
Batch operation
Pinch analysis
Economics
Sizing & costing
Solid handlingHysis/Hysim
Aspen Plus
PRO/II
SuperProDesigner
Design II forWindows
Design II for WindowsDesign II for WindowsDesign II for WindowsDesign II for WindowsDesign II for WindowsDesign II for WindowsDesign II for WindowsDesign II for Windows
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PSEDesign II for Windows Design II for Windows Design II for Windows Design II for Windows Design II for Windows Design II for Windows Design II for Windows Design II for Windows
SuperPro DesignerSuperPro DesignerSuperPro DesignerSuperPro DesignerSuperPro DesignerSuperPro DesignerSuperPro DesignerSuperPro Designer
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PSESuperPro Designer SuperPro Designer SuperPro Designer SuperPro Designer SuperPro Designer SuperPro Designer SuperPro Designer SuperPro Designer
Process design stepsProcess design stepsProcess design stepsProcess design stepsProcess design stepsProcess design stepsProcess design stepsProcess design steps
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PSEProcess design steps Process design steps Process design steps Process design steps Process design steps Process design steps Process design steps Process design steps
Synthesis
Modelling &Simulation
Evaluation
Final Design
Structural
Optimisation
ParameterOptimisation
(Smith, 1995)
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