DESIGN PROJECT 2

an introduction

PREPARED BY
DR. NUGROHO DEWAYANTO
CHEMICAL ENGINEERING SECTION
UniKL - MICET
Chemical Engineers Role in Plant Design
Starting from a vaguely defined problem statement
such as a customer need or a set of experimental
results, chemical engineers can develop an
understanding of the important underlying physical
science relevant to the problem and use this
understanding to create a plan of action and set of
detailed specifications which, if implemented, will lead
to a predicted financial outcome
(Towler & Sinnot, 2008)
 REGION OF ALL DESIGNS
Design Constraint
Resources

External constraint
Internal constraint
POSSIBLE DESIGNS
Government controls
The Design Process
 Types of Design Projects
Modification

Addition to existing plant; usually carried out by the

plant design group

Upscale

New production capacity to meet growing sales demand

and the sale of established processes by contractors

New process

developed from laboratory research, through pilot

plant, to a commercial process
Anatomy of a chemical process
The structure of a design project

A
The structure of a design project
(contd.) A

C
B
The structure of a design project
(contd.) B C
 Project documentation
1. General correspondence within the design group and related
parties:
Government departments
Equipment vendors
Site personnel
The client
2. Calculation sheets
Design calculations
Cost estimates
Material and energy balances
 Project documentation
3. Drawings: 4. Specification sheets:
Flowsheets The design basis
Piping and instrumentation diagrams Feed and product
Layout diagrams specifications
Plot/site plans An equipment list
Equipment details Sheets for equipment,
Piping diagrams (isometrics) such as heat
exchangers, pumps,
Architectural drawings heaters, etc.
Design sketches
 Project documentation
5. Health, Safety and Environmental information:
Materials safety data sheets (MSDS forms)
HAZOP or HAZAN documentation (see Chapter 9)
Emissions assessments and permits
6. Purchase orders
Quotations
Invoices
 Codes and Standards
In engineering practice codes and standards cover
1. Materials, properties, and compositions.
2. Testing procedures for performance, compositions, and quality.
3. Preferred sizes; for example, tubes, plates, sections, etc.
4. Methods for design, inspection, and fabrication.
5. Codes of practice for plant operation and safety.
Some codes and standards related to the plant design:
ANSI, API, ASTM, ASME (pressure vessels, pipes),
NFPA (safety), ISA (process control)
United States standards
 Design Factors
Design is an inexact art; errors and uncertainties arise from uncertainties in the
design data available and in the approximations necessary in design calculations

Required a degree of over-design known as a design factor, design

margin, or safety factor.

Design factors are also applied in process design to give some tolerance in
the design typically 10% of calculation from material balance

In mechanical and structural design, the recommended design factors are

set out in the codes and standards.
Design Optimization Objectives
 Constraints in Optimization
The constraints on the optimization are the set of equations that bound the decision
variables and relate them to each other.

inequality constraints
f (x) > 0; g(x) < a

equality constraints
h(x) = b; k(x) = 0
 Degrees of Freedom
n variables n me
degree of
me equality freedom
constraints
no degrees of freedom
n = me set of me equations can be solved for the n
variables

n < me the problem is overspecified

n me me is the number of parameters that can

n > me be independently adjusted to find the optimum
An over-constrained problem
 Trade-Offs
Why trade off?

better performance in terms of increased purity,

increased recovery, or reduced energy or raw materials
use usually comes at the expense of higher capital
expense, operating expense, or both

The optimization problem must capture the trade-off

between cost and benefit
Some common trade-offs encountered in design of
chemical plants
More separations equipment and operating cost vs. lower product purity

More recycle costs vs. increased feed use and waste formation

More heat recovery vs. cheaper heat exchange network

Higher reactivity at high pressure vs. more expensive reactors and higher
compression costs
Fast reactions at high temperature vs. product degradation

Marketable byproducts vs. more plant expense

Cheaper steam and electricity vs. more off-site capital cost

The capital-energy trade-off in process heat recovery