Lecture 4 Process Development

Report

Colin A. Scholes
14 August, 2017
 Housekeeping

Please complete the Peer Assessment for the Feasibility

Study.
Everyone Must Do It.
You have 14 days.

Consultants please continue signing up this week.

Discussion Board please continue to use.

 Next Stage

You are now to prepare two professional engineering design

reports.
A Process Development Report (PDR)
First stage of the design, one per team
A Set of 5 Detailed Design Reports (DDR)
One per person

When drafting these reports they are for a client who is

informed. They are experienced chemical engineers so do not
spare the details (but do not overdo the obvious and do not
need to include text book information).
 Schedule

Submission Dates

Process Development Report 9 am, Monday 11th September 2017

Final Submission 4 pm, Thursday 19th October 2017
 Design Brief

Your team must conduct a detailed design of a CO2

utilisation process for DME production.
Source and Production rates To Be Decided you will be
notified by Wednesday (based on review of Feasibility
Studies).
Product DME will be transported by container truck to
market.
 Design Brief

Utilities must be provided on site: Steam, heating/cooling,

nitrogen, etc
Water available from municipal suppliers.
Mains power supplied, also natural gas supplied for heating.
Hydrogen is to be provided from an Electrolysis Process
based on Renewable Energy.
Wastewater is treated by a third party but you must specify
the wastewater.
Gases are emitted from the stack but hazardous gases must
be treated before emission.
Design Brief

Dotted Line represents

the limit of your design.

EIS/safety assessment
includes gas emissions,
utilities, water discharge.
 Location

Access to Mains Power for 120 V but 400 V 3 phase must be

generated on site.

Water from Municipal Suppliers.

Natural gas from Municipal Suppliers

Access to roads and rail in/out.

Workforce available in local area.

 Project Scope

Scope whats in
All components of the CO2 utilisation process plant.
All emissions control (stack, water treatment)
All storage of chemicals
Internally generated utilities (power), if any
Scope whats out
CO2 source process.
H2 electrolysis plant
Fire water system, external utilities (substation, fresh water
supply).
Pipelines.
 Project Scope

Flow sheet needs to be divided up into five/six sections (one for each
team member).
Each section will have a mass and energy balance.
Each section will have one or more equipment items
You need the overall M&E balances to balance (no discontinuities
between your flow sheets)
You need to consider heat and water integration and optimisation.
You will have to cost the entire plant so all major items must be
included.

CO2 generated from the process can be a potential feedstock material.

Your team needs to consider the potential for this.
 PDR Report Marking

1. Executive Summary, Introduction and Overall appearance

(2 marks, team effort)
2. Process Selection, Description & Evaluation (6.5 marks,
team effort)
3. Health, Safety and the environment (7 marks, team effort)
4. M&E Balances and Process Flow Diagrams (14.5 marks)
Appendices (Gantt Chart & minutes)
Total = 30 marks
 1. Executive Summary, Introduction, Appearance

Executive Summary
As before, 1 page summary of the PDR
What you did, how you did it and what you found
This is an interim report
Introduction
Scope of design and your main assumptions
Pay attention to the appearance especially of the PFDs
 2. Process Selection and Description

Start with an overall process description (block diagram)

What do we need to achieve (input and output
specifications?)
What general principles will we use to select the
process technology?
 2. Process Selection and Description

Process technology selection and justification for each

part of the process
What are the options?
Pressure, temperature ranges
Type of device/unit operation
Type of catalyst
Type of process (recycle, etc)
Multi-step or single step (integrated)
 Process Selection Possible Decision Criteria

Cost per tonne of throughput economics (do I need exotic

materials of construction)
Safety and potential hazards
Energy requirements
Do I need additional chemicals to effect the separation?
By-product generation?
Operability? (does it need integration)
Utilities requirement availability?
 Process Selection Possible Decision Criteria

Proven Technology?
Turn-down capability?
Transportation costs
Pollution generation potential
Public image and Social acceptance
Greenhouse gas impact
Information available?
 Plant Preliminary Hazard Analysis

Preliminary Hazard Analysis

Major Plant hazards (T, P, chemical species)
Emissions, flammability, storage, etc
Toxic information of materials
Chemical Safety
For each material: health hazards, fire-fighting measures,
handling and storage, accidental release measures,
exposure control/PPE
RISK = LIKELIHOOD x CONSEQUENCE
 Plant Preliminary Hazard Analysis

Fire and Explosion

Identify where and measures
Quantify risk
Extreme Operating Pressures/Temperatures
Identify where and measures
Quantify risk
Maintenance and Process Control as Safety Controls
 Plant Preliminary Hazard Analysis

Relevant safety standards for construction and operation.

AS1210 Pressure Vessels
AS4118 Fire sprinkler systems
etc
National Guidelines and Codes of Practise
Australian Code for Transport of Dangerous Goods
etc
Legislation covering operation of plant
Work Health and Safety Acts
etc
 Environment

Environmental Impact Assessment

Emission to land, air, water (what, how much ,effect, dont forget
noise and smell)
Flora, fauna
Social, heritage
Legislation
Environmental Management Plan (how will you manage your
emissions)
Monitoring
Restoration
Construction, operation, decommissioning
 Plant Location

1. Safety is the PRIME consideration in plant siting

2. Access to raw materials and markets
3. Availability of land
4. Availability of labour
5. Availability of utilities: cooling water, electricity
6. Means of effluent disposal
7. Interlinking with other plants
8. Government policies, financial incentives, planning
permission
 Plant Location Safety of the Public

Most important feature is distance between site and built-

up areas.

Geelong Refinery Lucas Heights Reactor

 Plant Location Safety of the Public

Effects of a major accident decay rapidly with distance

Radiation (inverse square law)
Dispersion of chemicals
Blast wave
Noise
Avoid terrain where hazardous liquids/gases can flow down
into populated areas
Contamination of water courses by liquid spills
Site emergencies availability of electric power and water
Availability and experience of external emergency services
and access to site.
 Plant Location Safety of the Public

Once a site has been selected, the following constraints

are important:
Topography and geology (lie of the land and its load
bearing capabilities, drainage)
Weather (temperature, wind conditions, rainfall, solar
radiation, cyclones, etc)
Environmental impact
Transport and services (power, water, effluents)
Legal constraints (planning and building, effluent
levels, bylaws and regulations)
Plant Layout

No Longer Needed
 M&E Balances and Development of PFDs

Global Issues (plant wide) TEAM

What is the design basis (T, P, composition, flow rate) for whole
plant.
What assumptions did you make for your plant M&E Balances? e.g.
on-stream time
Thermodynamic data sources (VLE, Cp, etc)
Assumptions regarding utilities (cooling water temperature, heat
exchanger approach temperature, pressure drop)
How does this tie into the rest of the plant?
Heat and water integration approach TEAM
What optimisation did you do?
What heat integration did you do (pinch analysis?)
 Material and Energy Balances

For each part of the process (5 parts), show the mass and
energy balance.
Will need to do hand calculations to support the M&E
Balances and discuss your assumptions for the major and
minor equipment items.
Show equations you used for determining the energy required,
etc
You do not need to show derivations and do not teach
chemical engineering!
This is not the detailed design yet!
 Hand Calculations

Work in pencil
Write out, in full, all assumptions
Set calculations out neatly and clearly
Separate calculations into sections
Take the time to set work out properly errors easily found
DONT TYPE YOUR HAND CALCULATIONS
Hand calculations go in Appendix REMEBER TO
PHOTOCOPY OR SCAN for use in your detailed design report
Write up the main assumptions and model in the body together
with results in a table
 Hand Calculations

This is not the detail design (no sizing required)

This is where you develop and mass and energy balances
You may need to develop a model of the unit operation in
order to calculate the mass and energy balance
There are various levels of detail in the model
Simple (based on empirical data)
Medium (based on data and some simple rules eg Fenske)
Complex (based on your own model, eg MATLAB)
 Spreadsheet Balances

Plan spreadsheet layout before starting

Separate calculations into sections
Annotate heavily by hand or with text boxes so that the
calculations can be followed.
Check spreadsheet vs hand calculations
Dont just include a spreadsheet of numbers
 Using HYSYS/Excel

You can use Aspen HYSYS or Aspen Plus to do your

simulation
How do you know that the results are correct?
Garbage in = garbage out
Justify results by:
Comparison to literature
Comparison to your own experience and rules of thumb
Simple hand calculations
 4. Process Flow Diagram (PFD)

More complex than Block Flow Diagram

Not as complex as the P&ID (so no control loops, no isolations, no
relief/safety systems)
Idea is to show the equipment items and lines and how they are
connected
Mass and energy balances in simple visual format
Use icons to show equipment shapes
Calculations require that all process streams and blocks be
numbered
Stream numbers needed before and after nodes, junctions, units
 Layout of the PFD - 1

As far as possible:
Flow should be from left to right (and may be continued on several sheets)
Top section for identifiers and description
Sequence same as proposed plant (i.e. Feed treatment first, product finishing last)
Stream numbering should also be left to right
Relative sizes of main items respected (except heat exchangers, pumps, etc)
Tables of stream flows, compositions, etc, presented separately below the diagram
Border, Title Block, Revision notes
Icons for all equipment. Retain relative size as much as possible
Utilities along bottom of drawing
Vapor/vents along top of drawing
Services or Utilities (steam, cooling water, etc)
Connections to equipment items only shown
Service requirements (flowrates etc) can be included in the tabulated data
 Features of PFDs

All equipment has a code (e.g. T-101 = tank 101)

Often company standard
Coding letter relates to equipment (C-column, H-heat exchanger, R-
reactor, V-vessel, T-tank)
An equipment list is included as a table, at one side of the drawing.
Number relates to item in class
First number often plant section (e.g. T-101, T-201)
Visio will generate a number for you edit as require
Coding can include:
P=pump, M=mixer, F=filter, D=dryer, HX=heat exchanger, Q=furnace,
V=Vaporizer.
 Features of PFDs

Typical line thickness

1.2 mm (thick) for main flow streams
1.0 mm (medium) for recycle streams
0.7 mm (medium) for secondary lines
0.4 mm (thin) for tertiary lines
0.5 mm (thin) for services
(use Visio pipelines)
 PFDs

Where possible standard symbols should be used to represent

items. Refer to British Standard BS1553, German Standard
DIN28004. Choose a standard and stick with it.
 Flowsheet Basis

The basis of the flowsheet data must be stated on the

process flowsheet
There is usually more than one design case considered
for any plant design.
This means that there is often more than one set of
flowsheet data.
 Design Cases

Some possible design cases

1. Normal operation (at maximum rated capacity)
2. Operation at maximum turndown
3. Operation at maximum ambient temperature
4. Operation during a phased start-up or expanison
5. Operation for minimum staffing levels (weekends)
6. Operation for different feed or product mixes
7. Operation with new or old catalyst
The flowsheet must show clearly the basis of the calculation.
i.e. Operating hours per year, Reaction yields, Datum temprature
 Common Flow Sheet Errors

Copying flowsheets from simulation packages

Do not show splitting and merging operations which
are required by simulation packages
Do show pumps and critical valves required for
pressure change operations (often not required by
simulation packages)
Where possible use gravity for flow rather than pumps
Give streams a numerical label (rather than a name
which may have been used in the simulation)
 Flowsheet Data

Information to be included on the process flow sheet

Essential Data
Stream compositions as component flowrates or mass fractions
Total stream flowrates (e.g. kg/hr)
Stream temperatures and required operating pressure
Optional Data
Molar compositions
Physical property data (e.g. density, viscosity)
Stream names
Stream enthalpies
 Flowsheet Data

Precision of data
Stream total and component flow to appropriate significant
figures.
Flows should balance
Calculated flows of possible contaminants which are smaller
than the flowsheet precision should be marked as TRACE.
Trace components can be critical in material selection
catalyst poisoning.
 Presentation of PFDs

A3 sheet, landscape (can be done A4 and enlarged)

Font size must be readable
Ensure M&E table covers all major streams and utilities
Fold for report so Title Block always shows
 Dos and Donts

DO
Make intelligent judgements to reduce complexity
Clearly state and justify all of your statements
Use industry standard methods (where possible, use standards)
DONT
Dont waste time on irrelevant details
Dont teach the reader chemical engineering
Dont be lazy. Cannot use justification I didnt have time

WE WILL AWARD QUALITY, NOT QUANTITY

 Appendices

Gantt Chart
Please upload your Gantt Chart to LMS by next Monday
Gantt chart must be included as Appendix 1 of the report
All meeting minutes must be included in the Appendix of
the report
This chart will be the agreed schedule for your team in
case of disagreement refer back to it. Project leaders job
includes keeping team to the schedule.
 Project Planning

A fundamental engineering skill

Identify all tasks
Identify dependencies between tasks
Identify the critical path
Plot as a GANTT chart
Ensure that all team members are kept up to date with
the latest decisions which may impact their M&E
balances
 Design Project Planning

Nine weeks 2 reports

85 marks to be gained
8.5 marks per week (~1 mark per day)
There are team and individual components

PDR Page Limit

100 pages excluding Appendices and PFDs
Includes Exec summary, TOC and references