CH4801 Final Year Design Project (Part 2)

Project Briefing
Poernomo Gunawan (Dr.)
School of Chemical & Biomedical Engineering
N1.2-B2-26A | E-mail: pgunawan@ntu.edu.sg
Instructors
Assoc. Prof. Raymond Lau
• Design variables trade off analysis & optimization

Assoc. Prof. Kunn Hadinoto

• Economics, HEN analysis & design

Dr. Mukta Bansal

• Separation system, simulation

Dr. Poernomo Gunawan

• Reactor system, simulation

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Lectures & Consultation
• Lecture hours:
 Mon 9:30-11:30 at CBE-LT (by external speakers from industry)
 Thu 11:30-12:30 at CBE-LT (Q&A session; please send at least
2 representatives from the group)

• Tutorials hours (6 hrs/week):

 Wed 10:30-14:30 at BIE-CL1 and BIE-CL2
 Fri 14:30-16:30 at CBE-CL2 and BIE-CL2
 Note: Instructors will not be present during these hours.

• Consultation (outside weekly Q&A session):

 By email appointments only (please avoid walk-in).
 Please indicate your group number in the email.

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Lecture Topics
Speaker Topic Date

Sanjeev Jindal (KBR) Plant Process Design 22nd Jan 2018

Tushar Poddar
Process Optimization 19th Feb 2018
(SemCorp Marine)
Lee Ming Yang
Separation Process 26th Feb 2018
(Koch-Glitsch)
Veronica Japri
Process Safety 12th Mar 2018
(Infineum)
Ng Kian Soon
Heat Integration 26th Mar 2018
(Siemens)

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Project Overview
• Analysis and modification of the plant design for methanol
production through carbon dioxide hydrogenation.
• The current process was designed for different methanol
production rates ranging from 0.5 to 2 million tons per annum
(8160 hours of production per annum) with product purity of 99.5
mol%.
• The raw materials used was pure CO2 and H2 that were obtained
elsewhere.
• The reaction was carried out by using Cu-ZnO based catalyst that
was develop in the 1980s.

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Project Overview
Task - Modification on the initial PFD:

• Raw material: Flue gas produced by coal-fired power plant,

that consists of CO2, CO, NOx, H2O, O2, and N2, as raw
material;
• Explore another alternative of newly-developed catalyst; hence
to determine new kinetics parameters;
• Maintain product purity of 99.5% methanol;
• Recovery of H2 from purge streams;
• Design catalyst regeneration system;
• Increase/decrease MeOH production rate by 20% from the
initial production rate.

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Project Overview

Constraints:

• Fixed size and dimensions for reactor, distillation column,

separator vessels and heat exchangers, but they can be
removed/added/displaced when necessary;
• Pumps, compressors, expanders and stream pipes can be
freely modified.

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Project Phases
Phase 1 (4 weeks):
 Literature review
• Introduction
• Recent process development
• Recent catalyst development
• Reaction kinetics & its validation
• Thermodynamic package & validation

 Critique, analysis & modification of the initial PFD

• Develop steady state simulation case based on the
modification of the initial PFD
• Choice of appropriate operating conditions

 Simulation of the modified flowsheet

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Project Phases

Phase 2 (5 weeks):
 Identify and evaluate effect design variables on the plant
economics (J cost)
• Identify DDVs, LDVs
• Understand and demonstrate dominant trade off
analysis

 Equipment re-sizing, costing and economics

 Optimization of design variables

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Project Phases

Phase 3 (4 weeks):
 Heat integration analysis & reconfiguration

 Safety analysis, HAZOP and P&ID on reactor or separation

system

 Final report writing

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Time Line & Assessment
Assessment Date Weightage

Interim Report (wk 5) 15th Feb 2018 10% (phase 1)

Feedback on interim report (wk 7) 2nd Mar 2018 N.A.

20% (phase 2)
Final Report (wk 13) 19th April 2018
10% (phase 3)

Peer Evaluation (wk 13) 19th April 2018 5%

Group Oral Presentation (wk 14) 23rd-26th April 2018 15%

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Interim Report
 Literature review:
• Introduction & objectives
• Recent process development
• Recent catalyst development
• Reaction schemes, reaction kinetics & its validation

 Analysis & critique on the initial design

 Modification of the initial design & overall process description
 A4-size PFD modified flowsheet (drawn using Visio)
 Thermodynamic package and its validation
 HYSYS simulation file

Note: Max 6 pages + A4-size PFD

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Final Report
 Executive summary
 Literature review & analysis on the initial design
 Process description
 Determination of dominant & local design variables
 Optimization of dominant design variables & trade-off analysis (with plots, etc.)
 Optimization of ‘local’ design variables (e.g., column reflux ratio)
 Heat integration analysis and design
 Material balance table
 Summary of operation criteria (e.g., kg feed per kg product, steam consumption per
kg product, conversion, selectivity, etc.)
 Summary of major equipment sizing and costing
 Detailed design (P&ID) and HAZOP of either reactor or distillation column
 Optimized PFD before heat integration (A3 size)
 PFD with heat integration (A3 size)

Maximum no. of pages: 30 pages (all inclusive) + PFD

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Group Formation & Contribution
 Form (9±1) members in a group

 Appoint group leader and vice leader to coordinate group

meetings & discussion

 Each group to submit a 1-page table summarizing each and

every member’s contribution towards the project throughout
the whole semester. All group members to sign on this page.
This form is to be submitted together with the final report.

 Individual peer evaluation form

• Each member will grade the contribution of all members
towards the project including him/herself. This form is to
be individually sent to pgunawan@ntu.edu.sg. Please
clearly indicate your group number.

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All the best!!

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