Professional Documents
Culture Documents
Lecturer :
http://www.iium.edu.my/legaladviser/articles-4
2
Weeks
Topics
Reactor/separation/recycle systems
Learning
Hours
9
9
9
Task/Reading
Chapter 1
Chapter 2
Chapter 3
Chapter 4
9
5
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
3
Semester 2 2013/14
Topics
Task/Reading
Overview/ Introduction
Chapter 1
Chapter 3
Chapter 4
Chapter 5
Chapter 2
6-7
*MIDTERM*
Optimum Design and Design Strategy
Chapter 9
Chapter 10
10
Chapter 12
11
Chapter 13
12
Chapter 14
13
Chapter 15
14
Chapter 11
(Self-Reading)
4
Semester 2 2013/14
Assessment
Overall Assessment
Quiz
Assignment
Midterm
Final Exam
10%
10%
30%
50%
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.
5
Semester 2 2013/14
How to do so ?
Energy
In
Raw Materials
+ Other Feeds
CHEMICAL
PROCESS
Products + Wastes
Energy
Out
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)
6
Semester 2 2013/14
Raw Materials
+ Other Feeds
BIOCHEMICAL
PROCESS
Energy
Products + Wastes
Energy
HOW DO WE ADDRESS
THIS?
Semester 2 2013/14
Raw Materials
+ Other Feeds
CHEMICAL
PROCESS
Energy
Products + Wastes
Energy
LITTLE OR LIMITED
INFORMATIONS ARE
AVAILABLE
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 ?
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)
9
Semester 2 2013/14
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
Semester 2 2013/14
10
.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
Semester 2 2013/14
RECYCLE
STEAM
FEED
REACTOR
PRODUCT 1
CW
FLOWSHEET
PRODUCT 2
QUANTIFIABLE
FACTOR !
VERSUS
NON - QUANTIFIABLE
FACTOR !
MINIMISE COST
12
STEAM
FEED
REACTOR
PRODUCT 1
CW
PRODUCT 2
TOTAL
COST
DIS-CONTINUOUS FUNCTION
STRUCTURAL OPTIMISATION
PARAMETER OPTIMISATION
Semester 2 2013/14
13
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
CONCEPT IS BASED ON
"CREATING AND OPTIMISING A REDUCIBLE
STRUCTURE"
CONCEPT IS BASED ON
"BUILDING AN IRREDUCIBLE STRUCTURE"
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
14
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
15
Semester 2 2013/14
SEPARATION
& RECYCLE
SYSTEM
HEAT EXCHANGER
NETWORK
UTILITIES
Semester 2 2013/14
16
Advantages
other process
alternatives
Semester 2 2013/14
17
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 ?
Semester 2 2013/14
20
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21
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22
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23