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