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BTE 4417

PROCESS PLANT DESIGN AND SAFETY


3 Credit-Hour Course

Lecturer :

Dr Azlin Suhaida Azmi


Dr Sarina Sulaiman

Lecture Time : MONDAY & WEDNESDAY 11.30 to 12.50pm


Venue
: E0-01-16 (1 section)
Semester 1 2014/15

BTE 4417 PROCESS PLANT DESIGN AND SAFETY


Dress Code in IIUM

http://www.iium.edu.my/legaladviser/articles-4
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BTE 4417 PROCESS PLANT DESIGN AND SAFETY

Course Content & Delivery


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

Weeks

Topics

Integrated process design

Process synthesis by hierarchical approach

Synthesis of separation system

Reactor/separation/recycle systems

Learning
Hours
9
9
9

Task/Reading
Chapter 1
Chapter 2
Chapter 3
Chapter 4

9
5

Cost analysis of process plant design and operations

Hands out
9

6-7
8-10
11-14

*MIDTERM*
Safety of integrated process plant design
Case study: Biochemical processes, biodiesel and bioethanol
manufacturer
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

25

Hands out
Chapter 12, 14, 15

20
Hands out (design
hand book, journal
papers)

33.5
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BTE 4417 PROCESS PLANT DESIGN AND SAFETY

Course Content & Delivery


Weeks

Topics

Task/Reading

Overview/ Introduction

Chapter 1

Process Design Development

Chapter 3

Flowsheet Synthesis and Development

Chapter 4

Software Use in Process Design

Chapter 5

General Design Consideration

Chapter 2

6-7

*MIDTERM*
Optimum Design and Design Strategy

Chapter 9

Costing and Project Evaluation

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)
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BTE 4417 PROCESS PLANT DESIGN AND SAFETY

Assessment
Overall Assessment
Quiz
Assignment
Midterm
Final Exam

10%
10%
30%
50%

BTE 4481 Separation Process II


Pre-requisites
BTE 4412 - Biological Reactor Design and Analysis

Peters M.S., Timmerhaous K.D., West R.E. (2003). Plant Design and Economic for
Chemical Engineers (5 ed.)
1.
2.
3.
4.

Dimian, A. C. Bildea, C. S. (2008), Chemical Process Design, Wiley-VCH Verlag GmbH &
Co.
Smith, R. (1995), Chemical Process Design, McGraw Hill Inc.
Seider, W. D., Seader, J. D., Lewin, D. R. (1999). Process Design Principles: Synthesis,
Analysis and Evaluation. Wiley, New York.
Chemical Engineering Design Vol. 6 by Sinnot R.K.
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BTE 4417 PROCESS PLANT DESIGN AND SAFETY

1. OVERVIEW PROCESS PLANT DESIGN AND SAFETY


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

How to do so ?

Energy
In

Raw Materials
+ Other Feeds

CHEMICAL
PROCESS

Products + Wastes

Energy
Out

WHAT CAN YOU SAY ABOUT THIS CHEMICAL PROCESS ?

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)
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BTE 4417 PROCESS PLANT DESIGN AND SAFETY

1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS

Raw Materials
+ Other Feeds

BIOCHEMICAL
PROCESS

Energy

Products + 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 Process7

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BTE 4417 PROCESS PLANT DESIGN AND SAFETY

1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS

Raw Materials
+ Other Feeds

CHEMICAL
PROCESS

Energy

Products + Wastes

Energy

DESIGN IS THE NAME OF THE GAME !


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

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 design8
problem is available from the problem statement. (Douglas, Conceptual Design of Chemical Processes 1988)

BTE 4417 PROCESS PLANT DESIGN AND SAFETY

1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS

THUS,
A SYSTEMATIC APPROACH OR METHOD IS REQUIRED
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?


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)
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BTE 4417 PROCESS PLANT DESIGN AND SAFETY

1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS

In general, any systematic approach/method used for process design have to consider two major
activities,
1. ADDRESS THE INDIVIDUAL
PROCESS/TRANSFORMATION STEP

RECYCLE

STEAM

FEED

REACTOR
PRODUCT 1

CW

PRODUCT 2

2. ADDRESS THE REQUIRED


INTERCONNECTION BETWEEN THE STEPS

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BTE 4417 PROCESS PLANT DESIGN AND SAFETY

1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS

.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.
RECYCLE

STEAM

REACTOR

FEED

PRODUCT 1

CW
Str1

Str2

Str3

Str4

Str5

Str6

Str7

Str8

Str9

F
T
P
x

PRODUCT 2

WHAT OTHER INFORMATIONS SHOULD BE


AVAILABLE IN A FLOWSHEET ?
AND HOW DO YOU GET SUCH INFORMATION ?

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THIS IS WHAT YOU WANT


AT THE END OF THE DAY!
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BTE 4417 PROCESS PLANT DESIGN AND SAFETY

1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS

What criteria should be adopted during the activities?


1. ADDRESS THE INDIVIDUAL
PROCESS/TRANSFORMATION STEP

RECYCLE

STEAM
FEED

REACTOR
PRODUCT 1

CW

FLOWSHEET

PRODUCT 2

2. ADDRESS THE REQUIRED


INTERCONNECTION BETWEEN THE STEPS

QUANTIFIABLE
FACTOR !

VERSUS

NON - QUANTIFIABLE
FACTOR !

MINIMISE COST

HIGH SAFETY & INTEGRITY

MINIMISE WASTES GENERATION

GOOD OPERATIONAL ASPECTS

MINIMISE ENERGY CONSUMPTION

..... BUT HOW TO OPTIMISE ?


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BTE 4417 PROCESS PLANT DESIGN AND SAFETY

1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS

Consider back the flowsheet !


RECYCLE

STEAM

FEED

REACTOR
PRODUCT 1

CW

PRODUCT 2

OPTIMISING A SINGLE UNIT/STEP


IN THE PROCESS

OPTIMISING THE INTERCONNECTIONS


BETWEEN THE UNITS/STEPS IN THE PROCESS

EG. PIPE DIAMETER

TOTAL
COST

Fixed charges based


on capital investment
for installed pipe

MANY POSSIBLE CONNECTIONS WHICH LEAD


TO DIFFERENT IN STRUCTURE OF FLOWSHEET
THUS DIFFERENT ECONOMIC IMPACT EVEN TO THE
EXTENT OF THE INDIVIDUAL UNIT ITSELF!

Cost for pumping


power
PIPE DIAMETER
CONTINUOUS FUNCTION

DIS-CONTINUOUS FUNCTION

STRUCTURAL OPTIMISATION

PARAMETER OPTIMISATION

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And how do we tackle this ?

BTE 4417 PROCESS PLANT DESIGN AND SAFETY

1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS

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

HEURISTIC METHOD

MATHEMATICAL METHOD
MIXED INTEGER LINEAR/
NON-LINEAR PROGRAMMING

ONION MODEL
USE A SEQUENTIAL/HIERARCHICAL METHOD
ACCORDING TO FOLLOWING SEQUENCE ;
1. REACTOR
2. SEPARATION AND RECYCLE SYSTEM
3. HEAT EXCHANGER NETWORK
4. UTILITIES

USE A MATHEMATICAL PROGRAMMING METHOD TO


SOLVE AND GIVE SOLUTION FOR THE PROCESS.
SIMULTANEOUS SOLUTION OF ALL THE SYSTEM.

DECISION ARE BASED ON SOLELY MATHEMATICAL


OPTIMISATION CRITERIA

DECISION ARE BASED ON ENGINEERING GUIDELINES


ESTABLISHED AND MATHEMATICAL OPTIMISATION

CONCEPT IS BASED ON
"CREATING AND OPTIMISING A REDUCIBLE
STRUCTURE"

CONCEPT IS BASED ON
"BUILDING AN IRREDUCIBLE STRUCTURE"

Smith R.,Chemical Process Design 1995

Biegler, Grossman & Westerberg, Systematic


Method of Chemical Process Design 1997

HIERARCHICAL
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

Grossman I. E, Comp. Chem. Eng., 9: 463, 1985

Douglas.,Conceptual Design of Chemical Process 1988


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BTE 4417 PROCESS PLANT DESIGN AND SAFETY

1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS

HEURISTIC METHOD The Onion Model


- FOLLOWS ONION LOGIC

REACTOR

SEPARATION
& RECYCLE
SYSTEM

HEAT EXCHANGER
NETWORK

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

UTILITIES

ENVIRONMENTAL
PROTECTION

SAFETY &
OPERABILITY

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BTE 4417 PROCESS PLANT DESIGN AND SAFETY

1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS

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

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 !

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.

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BTE 4417 PROCESS PLANT DESIGN AND SAFETY

1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS

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 ?
Disadvantages

Advantages

other process
alternatives

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BTE 4417 PROCESS PLANT DESIGN AND SAFETY

Generalized block diagram of downstream processing

BTE 4417 PROCESS PLANT DESIGN AND SAFETY

Design Database
Literature Survey
Patent Search

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BTE 4417 PROCESS PLANT DESIGN AND SAFETY

1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS

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 ?

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BTE 4417 PROCESS PLANT DESIGN AND SAFETY


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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