Lec 1 intro to design

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1. Chemical Engineering Plant Design 1 Introduction to Design Engr. Dr. Farhan Javed Lecturer Chemical Engineering Department UET FSD Campus

2. What do you understand about OBE

3. Course Learning Outcomes (CLOs) CLOs are the skills learnt by the students at the end of each course in the program. The three (3) learning domains characterize by Bloom’s Taxonomy and their respective levels of learning are Cognitive (Knowledge) (6 levels) Psychomotor (Skill) (7 levels) Affective (Attitude) (5 levels)

4. Program learning outcomes (Total=12) Engineering Knowledge Problem Analysis  Design/Development of Solutions Investigation  Modern Tool Usage  The Engineer and Society  Environment and Sustainability  Ethics Individual and Team Work  Communication Project Management  Lifelong Learning

5. MEASURABLE STUDENT LEARNING OUTCOMES CLOs Description PLOs Domain Domain Level CLO-1 Create, design and evaluate alternate processes and equipment for a chemical process and assess various societal, environmental, and safety issues associated with such design PLO-4 Cognitive 6. Create CLO-2 Apply knowledge acquired in core Chemical Engineering courses (e.g., Stoichiometry, Reaction Engineering, Thermodynamics, and Unit Operations) for selection and design of materials handling, heat transfer, and separation process equipment. PLO-3 Cognitive 3. Apply CLO-3 Understand the concept of heat integration for minimization of overall energy footprint of a chemical process PLO-5 Cognitive 3. Apply

6. Course description (1) Introduction to process design and development (2) General design considerations (3) Optimal design (4) Materials of fabrication and their selection (5) Material transfer handling and equipment design (6) Heat transfer equipment design (7) Mass transfer equipment design (8) Application of computer aided design software

7. WEEK-WISE LECTURE PLAN Week Topics CLO’s Week 1 Introduction: General overall design considerations: Process design and flowsheet development, optimum design; practical consideration and engineering ethics in design CLO-1 Week 2 General design considerations: Health and safety hazards, importance and objectives of safety, safety measures in equipment design: Fire and explosion hazards and prevention, Chemical, toxic, electrical hazards, control, precautions and prevention, personnel safety, loss prevention and safety audit. CLO-1 Week 3 Environmental protection and development of pollution control systems. Thermal pollution control, toxicological studies, industrial hygiene, radiation hazards. CLO-1 Week 4 Plant site location and layout of chemical plant, piping layout, plant operation and control, plant considerations and exercise problems. CLO-1 Week 5 Process design development: Process selection/creation, synthesis and design: equipment design and specifications. Preliminary process design: screening of process alternatives; economic decision making. CLO-1 Week 6 Flow sheet synthesis and development: Process information, input-output structure; function and operation diagrams; analysis and development of process flow sheet. CLO-2 Week 7 Optimum design and design strategy: defining the optimum problems, programming optimization problems; optimization solution methodologies; optimization applications and cost analysis. CLO-2 Week 8 Pinch technology an overview, key steps of pinch technology: Targeting of heat exchanger network: Designing of HEN: Pinch design methods, Heuristic rules, stream splitting, design of maximum energy recovery (MER) CLO-3 MID TERM EXAMINATION Week 10 Materials selection and fabrication: Corrosion and factors contributing to corrosion; corrosion prevention; material properties; economics involved in materials selection. CLO-2 Week 11 Materials handling equipment design and cost: Basic concept of fluid transport, frictional losses, selection of piping material, design of piping system. CLO-2 Week 12 Computer aided design, cost estimation and profitability analysis of investments, Transport of fluids: selection, design and cost analysis for pumping, compression, expansion, agitation and mixing of fluids, flow measurement and storage of fluids. CLO-4 Week 13 Heat transfer equipment design and cost: Basic theory of heat transfer in exchanger, heat exchanger selection criterion. CLO-2 Week 14 General methods for the design of heat exchangers: Design of key heat exchangers CLO-1 Week 15 Separation equipment design and costs: Introduction, selection, general design and cost of equipment for separation process. CLO-1 Week 16 Design and cost for multi-component distillation: Absorption, adsorption membrane separation. Selection and design of filtration equipment. CLO-1 FINAL TERM EXAMINATION

8. 1- “Plant Design and Economics for Chemical Engineers” by M. S. Peters, K. D. Timmerhaus , and R. E. West 2- Coulson and Richardson’s Chemical Engineering — Volume 6: Chemical Engineering Text Books:

9. 1- An Applied Guide to process and Plant Design by Sean Moran 2- Process Equipment and Plant Design by Subhabrata Ray 3- Ullmann’s Chemical Engineering and Plant Design Reference Books:

10. Reference Books: “Ludwig’s Applied Process Design for Chemical and Petrochemical Plants” by A. K. Coker “Chemical Engineering Desgin -Volume 6” by R. Sinnott & Cavin Towler “Chemical Process Equipment: Selection and Design” by J. R. Couper , W. R. Penney, J. R. Fair, and S. M. Walas “Equipment Design Handbook: For Refineries and Chemical Engineers” by F. L. Evans “Chemical Process: Design and Integration” by R. Smith “The Art of Chemical Process Design” by G. L. Wells, and L. M. Rose

11. The general term plant design includes all engineering aspects involved in the development of either a new, modified, or expanded industrial plant. In this development, the chemical engineer will be making economic evaluations of new processes, designing individual pieces of equipment, or developing a plant layout. Because of these many design duties, the chemical engineer is many times referred to as a design engineer . Chemical Engineering Plant Design

12. On the other hand, a chemical engineer specializing in the economic aspects of the design is often referred to as a cost engineer . The term process engineering is used in connection with economic evaluation and general economic analyses of industrial processes, while process design refers to the actual design of the equipment and facilities necessary for carrying out the process. Similarly, the meaning of plant design is limited by some engineers to items related directly to the complete plant, such as plant layout, general service facilities, and plant location. Chemical Engineering Plant Design Cont ’ d

13. Design Constraints

14. The Design process:

15. Possible Designs and selection:

16. Continuous vs Batch processes:

17. Batch process:

18. A plant-design project moves to completion through a series of stages 1. Inception 2. Preliminary evaluation of economics and market 3. Development of data necessary for final design 4. Final economic evaluation 5. Detailed engineering design 6. Procurement 7. Erection 8. Startup and trial runs 9. Production 22

19. The chemical engineer is many times referred to here as a design engineer. 23

20. PROCESS DESIGN DEVELOPMENT Inception of the basic idea. Originate new process or modify an existing process. The process-research phase. Pilot plant or a commercial development plant. Complete market analysis. Complete cost-and-profit analysis. 24

21. GENERAL OVERALL DESIGN CONSIDERATIONS Plant location Plant layout Materials of construction Structural design Utilities Buildings Storage 25

22. Cont’d Materials handling Safety Waste disposal Federal, state, and local laws or codes 26

23. COST ESTIMATION Fixed costs Raw materials costs Labor charges Maintenance Power Utilities Costs for plant and administrative overhead Distribution of the final products Other miscellaneous items 27

24. Special Techniques for Cost Estimation 1. Order of magnitude estimate:(ratio estimate) accuracy typically + 30%, usually based on the costs of similar processes and requiring no design information. 2. Preliminary estimates (budget authorization/scope estimate): accuracy typically + 20%, They are based on limited cost data and design detail. 3. Study estimates (factored estimate): based on knowledge of major items of equipment, accuracy of estimate upto + 30% 4. Detailed estimates (contractor’s estimate): accuracy + 5%, Complete specifications, drawings, and site surveys for the plant construction are required 5. Definitive estimates (project control estimate): accuracy + 10%, Based on complete data but before completion of drawings & specifications. 28

25. FACTORS AFFECTING PROFITABILITY OF INVESTMENTS Interest Insurance Taxes Depreciation Manufacturing costs Time value of money Rate of return 29

26. OPTIMUM DESIGN There are several alternative methods which can be used for any given process or operation, optimization is to choose the best process and to incorporate into designing the equipment and methods which will give the best results. If there are two or more methods for obtaining exactly equivalent final results, the preferred method would be the one involving the least total cost. 30

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28. Optimum Operation Design Many processes require definite conditions of temperature, pressure, contact time, or other variables if the best results are to be obtained. It is often possible to make a partial separation of these optimum conditions from direct economic considerations. In cases of this type, the best design is designated as the optimum operation design. 32

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30. THE DESIGN APPROACH Profitable plant design Generally overdesign and safety factors Optimization of the design by using high-speed computers Make necessary assumptions Economic conditions and limitations 34

31. Project structure and organization:

32. Plant documentation:

33. Codes and Standards:

34. Standards Organizations: BSI ANSI API ASTM ASME NFPA TEMA ISA ISO

35. Skills needed for Plant design project Research Market analysis Design of individual pieces of equipment Cost estimation Computer programming Plant-location surveys

36. Organizations involved in providing standards and guidelines for plant layout and piping design American Society for Mechanical Engineers (ASME): Publishes and updates codes for piping design. The code relevant to the design of piping systems is ASME B31.3 – 2016 Process Piping . ( www.asme.org ) Center for Chemical Process Safety (CCPS): Publishes documents and guidelines related to process safety. The focus is on preventing or mitigating catastrophic releases of chemicals, hydrocarbons, and other hazardous materials. CCPS has published guidelines for “Facility Siting and Layout”. ( www.aiche.org/ccps ) Construction Industry Institute (CII): Provides guidelines for cost effective and safe construction methods and has several publications on constructability. ( www.construction-institute.org ) Society of Piping Engineers and Designers (SPED): Promotes excellence and quality in the practice of piping engineering and design. SPED emphasizes education and training and has certification programs for piping designers. ( www.spedweb.org ) Occupational Safety and Health Administration (OSHA): Provides regulations and safety standards for the operation of process plants. ( www.osha.gov ) National Fire Protection Association (NFPA): Provides fire protection standards for process plants and for gas storage and handling. ( www.nfpa.org )