Week 1 Overview

BTE 4417

PROCESS PLANT DESIGN AND SAFETY

Lecturer : Dr Azlin Suhaida Azmi

Dr Sarina Sulaiman

3 Credit-Hour Course

Lecture Time : MONDAY & WEDNESDAY 11.30 to 12.50pm

Venue : E0-01-16 (1 section)

1Semester 1 2014/15

BTE 4417 PROCESS PLANT DESIGN AND SAFETY

2

Dress Code in IIUM

http://www.iium.edu.my/legaladviser/articles-4


Course Content & Delivery

Content outline of the course / module and the SLT per topic

Weeks TopicsLearning

HoursTask/Reading

1 Integrated process design9

Chapter 1

2 Process synthesis by hierarchical approach9

Chapter 2

3 Synthesis of separation system9

Chapter 3

4 Reactor/separation/recycle systems9

Chapter 4

5 Cost analysis of process plant design and operations

*MIDTERM*

9

Hands out

6-7 Safety of integrated process plant design 25

Hands out

8-10 Case study: Biochemical processes, biodiesel and bioethanol

manufacturer 20Chapter 12, 14, 15

11-14 Preparation and presentation of complete conceptual plant design with

process flow sheet, layout considering the fundamental engineering

principles such as biological systems, thermodynamics, transport

processes, individual design of bioreactor and separator etc 33.5

Hands out (design

hand book, journal

papers)

3

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Course Content & Delivery

Weeks Topics Task/Reading

1 Overview/ Introduction Chapter 1

2 Process Design Development Chapter 3

3 Flowsheet Synthesis and Development Chapter 4

4 Software Use in Process Design Chapter 5

5 General Design Consideration

*MIDTERM*

Chapter 2

6-7 Optimum Design and Design Strategy Chapter 9

8 Costing and Project Evaluation

9 Material and Fabrication Selection Chapter 10

10 Material-Handling Equipment Design and Cost Chapter 12

11 Reactor Equipment Design and Costs Chapter 13

12 Heat-Transfer Equipment Design and Costs Chapter 14

13 Separation Equipment Design and Costs Chapter 15

14 Written and Oral Design Reports Chapter 11

(Self-Reading)

4

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Quiz 10%

Assignment 10%

Midterm 30%

Final Exam 50%

Overall Assessment

Assessment


5

Semester 2 2013/14

Pre-requisites

BTE 4481 Separation Process II

BTE 4412 - Biological Reactor Design and Analysis

1. Dimian, A. C. Bildea, C. S. (2008), Chemical Process Design, Wiley-VCH Verlag GmbH &

Co.

2. Smith, R. (1995), Chemical Process Design, McGraw Hill Inc.

3. Seider, W. D., Seader, J. D., Lewin, D. R. (1999). Process Design Principles: Synthesis,

Analysis and Evaluation. Wiley, New York.

4. Chemical Engineering Design Vol. 6 by Sinnot R.K.

Peters M.S., Timmerhaous K.D., West R.E. (2003). Plant Design and Economic for

Chemical Engineers (5 ed.)

The purpose of engineering is to create material wealth Douglas, Conceptual Design of Chemical Processes 1988.

How to do so ?

Raw Materials

+ Other Feeds

Energy

In

CHEMICAL

PROCESS Products + Wastes

Energy

Out

WHAT CAN YOU SAY ABOUT THIS CHEMICAL PROCESS ?

1. OVERVIEW PROCESS PLANT DESIGN AND SAFETY

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.

6

Semester 2 2013/14



Raw Materials

+ Other Feeds

Energy

BIOCHEMICAL

PROCESSProducts + Wastes

Energy

SO, 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 DO WE ADDRESS

THIS?

Concept Design for Chemical Process

1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS

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IS THE CONCEPTUAL DESIGN OF CHEMICAL PROCESSES IS AN OPEN-ENDED OR CLOSED PROBLEM. WHY ?

Raw Materials

+ Other Feeds

Energy

CHEMICAL

PROCESSProducts + Wastes

Energy

DESIGN IS THE NAME OF THE GAME !

LITTLE OR LIMITED

INFORMATIONS ARE

AVAILABLE

BEFORE COMING UP WITH A

COMPLETE PLANT

But so many possibilities

or solutions !


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)

8


THUS,

A SYSTEMATIC APPROACH OR METHOD IS REQUIRED


However, 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?

9

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1. ADDRESS THE INDIVIDUAL

PROCESS/TRANSFORMATION STEP

2. ADDRESS THE REQUIRED

INTERCONNECTION BETWEEN THE STEPS

FEED REACTOR

CW

STEAM

PRODUCT 1

PRODUCT 2

RECYCLE


In general, any systematic approach/method used for process design have to consider two major activities,

10Semester 2 2013/14


.and the target is to create the best possible feasible flowsheet for the process.

DEFINITION OF A FLOWSHEET.

FLOWSHEET IS A DIAGRAMMATIC

REPRESENTATION OF THE PROCESS

STEPS AND ITS INTERCONNECTIONS.

THIS IS WHAT YOU WANT

AT THE END OF THE DAY!

FEED REACTOR

CW

STEAM

PRODUCT 1

PRODUCT 2

RECYCLE

WHAT OTHER INFORMATIONS SHOULD BE

AVAILABLE IN A FLOWSHEET ?

AND HOW DO YOU GET SUCH INFORMATION ?

Str1 Str2 Str3 Str4 Str5 Str6 Str7 Str8 Str9

F

T

P

x

H




1. ADDRESS THE INDIVIDUAL

PROCESS/TRANSFORMATION STEP

2. ADDRESS THE REQUIRED

INTERCONNECTION BETWEEN THE STEPS

FEED REACTOR

CW

STEAM

PRODUCT 1

PRODUCT 2

RECYCLE

FLOWSHEET

What criteria should be adopted during the activities?

MINIMISE COST HIGH SAFETY & INTEGRITY

MINIMISE ENERGY CONSUMPTION

MINIMISE WASTES GENERATION

..... BUT HOW TO OPTIMISE ?

QUANTIFIABLE

FACTOR !

GOOD OPERATIONAL ASPECTS

NON - QUANTIFIABLE

FACTOR !VERSUS





FEED REACTOR

CW

STEAM

PRODUCT 1

PRODUCT 2

RECYCLE

Consider back the flowsheet !

OPTIMISING A SINGLE UNIT/STEP

IN THE PROCESS

EG. PIPE DIAMETER

OPTIMISING THE INTERCONNECTIONS

BETWEEN THE UNITS/STEPS IN THE PROCESS

TOTAL

COST

Fixed charges based

on capital investment

for installed pipe

Cost for pumping

power

PIPE DIAMETER

?

MANY POSSIBLE CONNECTIONS WHICH LEAD

TO DIFFERENT IN STRUCTURE OF FLOWSHEET

THUS DIFFERENT ECONOMIC IMPACT EVEN TO THE

EXTENT OF THE INDIVIDUAL UNIT ITSELF!

DIS-CONTINUOUS FUNCTION

STRUCTURAL OPTIMISATION

PARAMETER OPTIMISATION


And how do we tackle this ? 13Semester 2 2013/14

CONTINUOUS FUNCTION


What approaches/methods have been introduced to deal with such complex optimisation?

ONION MODEL

HEURISTIC METHOD

MIXED INTEGER LINEAR/

NON-LINEAR PROGRAMMING

MATHEMATICAL METHOD

USE A SEQUENTIAL/HIERARCHICAL METHOD

ACCORDING TO FOLLOWING SEQUENCE ;

1. REACTOR

2. SEPARATION AND RECYCLE SYSTEM

3. HEAT EXCHANGER NETWORK

4. UTILITIES

CONCEPT IS BASED ON

"BUILDING AN IRREDUCIBLE STRUCTURE"

DECISION ARE BASED ON ENGINEERING GUIDELINES

ESTABLISHED AND MATHEMATICAL OPTIMISATION

USE A MATHEMATICAL PROGRAMMING METHOD TO

SOLVE 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, 1985Smith R.,Chemical Process Design 1995

Biegler, Grossman & Westerberg, Systematic

Method of Chemical Process Design 1997HIERARCHICAL APPROACH

USE A SEQUENTIAL/HIERARCHICAL METHOD

ACCORDING TO FOLLOWING SEQUENCE ;

1. BATCH VS CONTINUOUS

2. INPUT-OUTPUT STRUCTURE OF THE FLOWSHEET

3. RECYCLE STRUCTURE OF THE FLOWSHEET

4. GENERAL STRUCTURE OF SEPARATION SYSTEM

5. HEAT EXCHANGER NETWORK

Douglas.,Conceptual Design of Chemical Process 198814

Semester 2 2013/14



HEURISTIC METHOD The Onion Model

REACTOR

SEPARATION

& RECYCLE

SYSTEM

HEAT EXCHANGER

NETWORK

UTILITIES

- FOLLOWS ONION LOGIC

Design 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 ?

Advantages Disadvantages


15

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ENVIRONMENTAL

PROTECTION

SAFETY &

OPERABILITY


HEURISTIC METHOD The Hierarchical Approach

The conceptual design is performed based on 5 different stages. The approach is somewhat

different by tackling the 5 different level that are classified differently. The 5 levels are ;

Level 1 Decision : Batch vs Continuous

Level 2 Decision : Fixing the Input-Output Structure

Level 3 Decision : Determining the Recycle Structure for the Process

Level 4 Decision : Determining the Separation System

Level 5 Decision : Determining the Heat Exchanger Network

At 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.

WHAT DO YOU NOTICE ON

THE STATEMENT CONTAIN WITHIN

THE SHADED BOX ?

REACTOR

SEPARATION

& RECYCLE

SYSTEM

HEAT EXCHANGER

NETWORK

UTILITIES

Compare these statements

to the onion model !




MATHEMATICAL METHOD The Mixed Integer Linear/Nonlinear Programming

- CREATION OF SUPERSTRUCTURE/HYPERSTRUCTURE

A major (super) structure is created which embedded within it all feasible

process (including its operations) and all feasible interconnections that

are candidates for an optimal design. The method is completely automated

and depends only on the computer programming to solve it. The design

problem is formulated into sets of mathematical equations which has to be

solved by the mathematical programming. Started off with many redundant

features, the programming optimise and reduce the process (structure)

to an optimal solution.

What are the advantages and disadvantages of this method ?

Advantages Disadvantages

other process

alternatives





Generalized block diagram of downstream processing



Design Database

Literature Survey

Patent Search

Semester 2 2013/14 19


QUESTIONS TO PONDER......

WHAT ARE THE BASIC PROBLEMS THAT YOU HAVE TO FACE DURING THE

CONCEPTUAL DESIGN OF ANY CHEMICAL PROCESSES ?

STRUCTURE & OPTIMISATION

WHAT ARE THE MAJOR APPROACHES INTRODUCED TO TACKLE THE

CONCEPTUAL DESIGN OF ANY CHEMICAL PROCESSES ?


Semester 2 2013/14 20



General Overall Design Consideration

Process Design Development

Flowsheet Development

Computer-Aided Design

Cost Estimation

Profitability Analysis of Investments

Optimum Design

Safety & Loss Prevention (Chapter 2)

Plant Location and Layout (Chapter 2)

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Documents

Week 1 Overview