Professional Documents
Culture Documents
Product Design
& Process Creation &
Sustainability
Product Performance
Application
process? Integrate Process-Product
Application Equipment & Application
conditions? parameters?
Product centric chemical process design
Examples of Product-Process Integration
Process Design Product Design
Product Performance
Applicationp
rocess? Production process needs to
Application Equipment be reliable first time right is
conditions? parameters? important
Chemical Product-Process Connection
Product
development
Product development
In-use properties
and manufacturing
Product function
Process
Physico-chemical properties
Solvent (S)
Initiator (I)
Transfer
agent (T)
Process
MIXER
Inhibitor (Z)
REACTOR
SEPARATOR
Copolymer
product
Introduction & definition of concepts
Flowsheet?
Operating Equipment
condition? parameters?
out as goods
and services
scope for
significant
improvements
(Adapted from Driolli,
2005)
Chemical Chemical
Raw Material Process ?? Product
Reserve
Sustainability limit
time
Sustainability of total system and sub-systems
Concept of Sustainabilty - II
Measure of sustainability
Raw Products,
material, solvents, water,
solvents, Chemical Process power, steam,
water, power, unconverted
steam, materials,
Boundary: process and its connections
Compared to a base-case design, generate alternatives
that improve the following
Operability, energy consumption, waste reduction,
environmental impact, safety, cost, .
Sustainability metrics (as defined by IChemE): 49 Environmental
(resource usage; emissions, effluents, waste), economic (profit, value, tax;
investments), societal (workplace, society)
Concept of Sustainabilty - III
How to achieve sustainability?
Raw Products,
material, solvents, water,
solvents, Chemical Process power, steam,
water, power, unconverted
steam, materials,
Improve the following
Operability, energy consumption, waste reduction,
environmental impact, safety, cost, .
Sustainability metrics (as defined by IChemE)
manager
The What is your
fresh
Chemical-polymer grad field of study?
Engineering!
Then, our
chemistry lab
might be the
Oh no! best place for you ?
Not again...
Introto
PD - 18
Chemical/Process Engineering
1. Process Development
2. Process Design
3. Construction
4. Manufacturing
5. Technical Sales
6. Research
Pilot Plant
Chemical (10 kg/hr) Commercial
Lab Scale
(10g) Design (100 tonne/hr)
Construction
Operation - testing
- reaction & catalyst
- process conditions
- process control scheme
- materials of construction
2. Process Design
Introto
PD - 21 OUTPUT
CHEMICAL ENGINEER:
Process Flowsheet
INPUT equipment & streams
P & I Diagram
Process Parameters: Equipment Specifications
production rate size
process conditions (T, P) dimension
type of vessels materials of construction
control systems min/max capacity
safety & pollution
control system
3. Construction - Moment of Truth
Chemical Engineers:
Introto
PD - 22
Troubleshooting
Routine Supervision
Operation Quality Control
Debottlenecking
Chemical
Engineer
Energy Conservation
Process Raw material conservation
Improvement Pollution control
Process control
5. Technical Sales
Introto
PD - 24
Chemical Engineer
Chemical engineers:
Cooperate with chemist, scientists and
engineers from other fields to produce
new products
1. Process Development
2. Process Design
3. Construction
4. Manufacturing
5. Technical Sales
6. Research
PROCESS ?
Raw materials?
Process Structure Desired
Products
Survey/feasibility studies
Project team
Project structure/planning (milestone)
Process and Product Design
Basic Chemical
Manufacturing Products
Natural
Resources Process (Commodity and
Specialty Chemicals,
Biomaterials,
Polymeric Material)
Customer Products
Manufacturing (Paper bag, Dialysis
Industrial
Process Devices, Post-it Notes,
Products Transparencies, Drug
delivery Patches,
Cosmetics,..)
Middle Distillates
MTBE
Methanol Urea
Methane Formadehyde
Ammonia Urea
Ammonia Ammonium Nitrate
Ammonium Phosphate
Polyvinyl Chloride
Chloralkali Titanium Dioxide
Oxide Surfactant
Polypropylene
Acrylics
Propane
Acrylonitrile
Ammonia
Caprolactam Terephthalic Acid
Polystyrene
Cl2
EDC/VCM Polyvinyl Chloride
LLDPE/HDPE
Benzene (PET)
Naphtha H2O
O2
Cracker Ethyl Alcohol Ethyl Aldehyde Acetic Acid
Polypropylene
H2O O2 HCN
H2
HMDA Nylon 6,6
Adiponitrile
Caprolactam
Nylon 6
MTBE (ABS)
Naphtha
Cracker Toluene Toluene Diisocyanate (TDI) Nylon-6
C2
Benzene Ethylbenzene Styrene Polystyrene
Pyrolysis C3 O2
Gasoline Mix-xylene Phenol Cyclohexanone Caprolactam
Acetic Acid EG
Para - xylene Pure Terephthalic Acid (PTA) Polyester Fiber
Fuel Oil
Fuel Gas
Process/ Product Design
Introto
PD - 33
(Ulrich, 1984)
Process Design Process
Synthesis/Creation
Introto
PD - 37
Process
Modelling/Analysis Process Simulation
Optimised Design
(Manan, 2001)
Process Creation (details)
Introto
PD - 38
Process Creation and Detailed Design
Introto
PD - 39
Final Design & Operation
Construction and Operation
Layout and
Plant Operation
3-D Modelling
Construction Debottlenecking