[EKC 453]

RANGKA KURSUS (COURSE OUTLINE)

EKC 453 REKABENTUK LOJI DAN EKONOMI [PLANT DESIGN AND ECONOMIC] SEMESTER II, SIDANG AKADEMIK 2011/2012 ([PENSYARAH]: PROF. MADYA ZAINAL AHMAD, DR. SYAMSUL RIZAL ABD. SHUKOR & DR. OOI BOON SENG [PENYELIA PROJEK]: PROF MADYA MOHAMAD ZAILANI ABU BAKAR, PROF. MADYA NORASHID AZIZ, PROF. MADYA ZAINAL AHMAD, PROF. MADYA LEE KEAT TEONG, DR. MOHD HEKARL UZIR, DR. KHAIRIAH ABD KARIM, DR. SYAMSUL RIZAL ABD SHUKOR, DR. MOHD AZMIER AHMAD, DR. OOI BOON SENG, DR. DEREK CHAN JUINN CHIEH, DR. SUZYLAWATI ISMAIL, DR. LIM JIT KANG, DR. TAN SOON HUAT, DR. VEL MURUGAN VADIVELU & DR. TYE CHING THIAN. [ASPEN PLUS II AND GABi4]: DR. SYAMSUL RIZAL ABD. SHUKOR & DR. LEO CHOE PENG) Kod dan Tajuk Kursus (Code and Course Title) Nilai Unit (Credit Unit) Komponen Kerja Kursus (%) (CW Component) Komponen Peperiksaan (%) (EW Component) Asas-asas Menilai Kerja Kursus (CW Assessment) EKC 453 Rekabentuk Loji dan Ekonomi
(Plant Design and Economic)

4 100% 1. 2. 3. 4. 5. 6. Design Tasks report 45%. Final Report 10% ASPEN Plus II and GABi 4 Assignment 10% Quiz 5%, Viva voce and Oral Presentation 20% Student participation 10 %

Prasyarat (Prerequisite) Semester Diajar (Semester Taught) Objektif Kursus (Course Objective)

EKC 451 Plant Design and Analysis

Semester II, 2011/2012

The course utilizes the knowledge gained by the students in earlier courses and applies in the complete design of a Chemical Process Plant. The plant design includes cost estimation, profitability analysis, piping and instrumentation, plant wide control, waste management and life cycle assessment, plant safety, operability and reliability. ASPEN Plus II will be implemented throughout the course in the chemical process plant design and economic analysis and GABi4 for LCA. Students will be able to: Design/Draw a piping and instrumentation diagram (P&ID) of a typical Chemical Process Plant. Calculate the cost estimation of the various types of process equipment, utilities and other facilities required in a typical Chemical Process Plant using correlations and software. Apply different methods of Profitability analysis based on Capital cost and other cost data of a typical chemical Process Plant. Developed an effective/slide presentation and report Perform as an individual and as a team. Outlines a Life Cycle Assessment (LCA) of a typical Chemical Process Plant incorporating safety, environment and health, social and economic issues. Interpret process plant operation, safety, management and day to day trouble shooting problems in a typical chemical process plant.

(Course Outcomes)

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Silibus Kursus (Course Syllabus)

Equipment and Plant Cost Estimation. Engineering Economic Analysis Including Profitability Analysis. Plant Piping Specifications, Control Schemes and Instrumentation, Piping and Instrumentation Diagram (P&ID). Plant Wide Control System Including Alarms. Plant Operability and Reliability, General Site Consideration and Plant Layout. Sustainability, waste minimisation and management, Environment impact and Life Cycle Assessment in design. Plant Start Up, Commissioning and Shutdown. Chemical Plant Design Project and learning of Simulator ASPEN Plus in process design. GABi 4 for Life Cycle Assessment (LCA)

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Perancangan Mengajar (Teaching Planning)

Equipment and Plant Cost Estimation. Engineering Economic Analysis including Profitability Analysis. Plant Piping Specifications, Control Schemes and Instrumentation, Piping and Instrumentation Diagram (P&ID). Plant Wide Control System Including Alarms. Plant Operability and Reliability, General Site Consideration, Code of ethics and Plant Layout. Plant statt up and shutdown Sustainability, waste minimization and management, Environmental impact and Life Cycle Assessment in design.

Jumlah Kuliah (No. Of Lecture) Dr. Ooi Boon Seng 2.5 weeks, 5 hours
Dr. Ooi Boon Seng PM Dr. Zainal Ahmad 2.5 weeks, 5 hours 4 weeks, 8 hours

PM Dr. Zainal Ahmad PM Dr. Zainal Ahmad

1 week , 2 hours 2 weeks, 4 hours

Dr. Syamsul Rizal

2 weeks, 4 hours

Chemical Plant Design Project and learning of Simulator ASPEN PLUS in process and plant design. (Tutorial in the Computer Lab) GABi 4 for Life Cycle Assessment (LCA). (Tutorial in Computer Lab)

Total : 28 hours Dr. Syamsul Rizal & Dr. Leo Choe Peng
Total : 16 hours

Kuiz (Jika ada) Quiz (If any) Design Project (a) Project Supervision

Boleh diberi pada bila-bila masa (Will be given as surprise or at any time)
Plant Design Project already allocated to each group (comprised of 4 to 5 students) in the last Semester. The Plant Design Projects will be supervised by the following Lecturers.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Prof. Madya Mohamad Zailani Abu Bakar Prof. Madya Norashid Aziz Prof. Madya Zainal Ahmad Prof. Madya Lee Keat Teong Dr. Mohd Hekarl Uzir Dr. Khairiah Abd Karim Dr. Syamsul Rizal Abd Shukor Dr. Mohd Azmier Ahmad Dr. Ooi Boon Seng Dr. Derek Chan Juinn Chieh Dr. Suzylawati Ismail Dr. Lim Jit Kang Dr. Tan Soon Huat Dr. Vel Murugan Vadivelu Dr. Tye Ching Thian

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Perancangan Mengajar (Teaching Planning)

Tajuk/Kandungan Kursus (Topic/Course Contents)

The supervisors will monitor the attendance and progress of each group every week. Students will meet with their respective supervisors to discuss about the doubts and clarifications regarding the project during allocated time slot only. 2 hours session were allocated for each week for supervisor for group discussion. Students or Group who will be irregular in meeting their supervisors will be heavily penalized in the course. Design project is a group activity therefore every member of the group must contribute in design project exercise. In case of any problem, groups can contact Assoc. Prof. Dr. Zainal Ahmad (course Instructor in charge) for clarifications and advice.

Jumlah Kuliah (No. Of Lecture)

(b) Design Tasks

Design project shall be carried out throughout the Semester. There will be 3 Design Tasks based on the topics covered in the lecture classes. Design Tasks must be submitted on the Due date. NO late assignments shall be accepted. Group must submit their assignments directly to the respective supervisor on the due date.

(c) Final report

Final copy of the design project will be submitted based on the corrections made in the design tasks before the presentation and oral examination. A soft copy in PDF format will be submitted along with the hard copy. During week 15 to 16, there will be oral presentation of the design project by individual student in a group. Each student will be asked to present a part of design project and followed by question and answer session. Each group will be given 45 minutes for oral presentation followed by question and answer session for 15 minutes (15 minutes presentation by each student plus 5 minutes Q&A). During this Semester 2, industrial talk is planned covering the design aspects of an Industrial Plants. Two industrial talks is planned : 1. Plant start up and shutdown 2. Plant safety and EIA Students attendance is compulsory during the talk and students are encouraged to ask questions and interact with the speaker from Industries. Short assignment will be given after each talks.

(d) Oral Presentation

(e) Industrial Lectures

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(f) ASPEN Plus II Software and GABI Software

ASPEN Plus software will be used through out the course covering various aspects of the design, costing, analysis and control in the plant design. Dr. Syamsul Rizal and Dr. Leo Choe Peng will be running tutorial sessions covering the different tools available under ASPEN Plus II software and GABi4. A project assignment based on ASPEN Plus II and GABi4 will be submitted separately together with Design Project final report. A formal report covering all the tasks covered under ASPEN Plus II software will be submitted along with the final report. GABI software will be used for life cycle assessment analysis and this should be submitted in the report.

(g) Important Dates to remember

Design Task #1 Design Task #2 Design Task #3 & Full Final Report Oral Presentation Industrial Talk

Due Date : 12 March 2012 Due Date : 20 April 2012 Due Date : 25 May 2012 4-6 June 2012 March and April 2012

Rujukan

(a) Senarai Rujukan Sedia Ada : Text Book Seider, Warren D, Seader, J D, and Lewin, Daniel R, Product and Process Design Principles: Synthesis, Analysis and Evaluation, 2nd Edition, New York, Wiley, 2004. Peters,M.S. and Timmerhaus, K.D., Plant Design and Economics for Chemical Engineers, 5th Edition, New York, McGraw-Hill, 2003. Reference Books Richard Turton, Richard C. Bailie, Wallace B. Whiting and Shaeiwitz A. Joseph: Analysis, Synthesis and Design of Chemical Processes, Prentice Hall, N.J. (USA), 1998. Seider W.D, Seader J.D. and Lewin D.R., Process Design Principles: Synthesis, Analysis and Evaluation, John Wiley & Sons, Inc, Singapore (1999). Perry, R.H and D.W. Green, Eds; Chemical Engineers Handbook, 7th edition (latest edition), McGraw-Hill, New York. Lorenz T.B, Grossmann E.I and Westerberg A.W., Systematic Methods of Chemical Process Design, Prentice Hall Int. Inc, 1997. Tweeddale, M., Managing Risk and Reliability of Process Plants, Butterworth Heinemann, UK, 2003. Koolen, J.L.A., Design of Simple and Robust Process Plants, WileyVCH, 2000. Horsley, D., Process Plant Commissioning, Second edition, Institution of Chemical Engineers, UK, 1998. Manual ASPEN Plus II. (b) Senarai rujukan terkini yang perlu diperolehi: (Sila rujuk laman web jika perlu)

Nota penting : Kehadiran pelajar ke kuliah/tutorial/kelas amali adalah wajib. Jika tidak hadir tanpa sebab, pelajar boleh dihalang daripada menduduki peperiksaan akhir.

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