Covenant University

KM. 10 Idiroko Road, Canaan Land, Ota, Ogun State, Nigeria

Department of Chemical Engineering

CHE 524: PRINCIPLES OF PLANT

DESIGN II

PROF. J.O ODIGURE

DR O.A MAMUDU
ENGR (MRS) OLADIMEJI

Chemical Engineering Design

 Course Outline
• General Design Considerations

• Siting of Plants

• Process Services

• Materials Handling

• Industrial Hazards and Environmental Pollution

• Process Design Methodology

Chemical Engineering Design

 Course Compact
• Week 1-2: General Engineering • Week 8: Material handling
Design Consideration
• Week 9: Industrial hazards and
• Week 3: Process design principles, environmental pollution
Flow sheets
• Week 10: Industrial hazards and
• Week 4: Sitting of Plants (Part1) environmental pollution

• Week 5: Sitting of Plants (Part 2) • Week 11: Process Design

methodology (Part 1)
• Week 6: Process services
• Week 12: Process Design
• Week 7: Mid Semester Assessment methodology (Part 2)

• Week 13: Revision

Chemical Engineering Design

 Recommended Reading/Test
• Sinott, R.K. (2005). “Chemical Engineering Design” , 4th
Edition, Volume 6 , Elsevier Butterworth- Heinemann

• Sinott, R.K and Towler, G (2013). “ Chemical

Engineering Design: Principles, Practice and Economics
of Plant and Process Design”, 2nd Edition, Elsevier
Butterworth- Heinemann

• Felder, R.M and Rousseau, R.W (2005). “Elementary

Principles of Chemical Processes”, 3rd Edition, John
Wiley & Sons.

Chemical Engineering Design

General Design Considerations

Chemical Engineering Design

Why Did You Study Chemical
Engineering?

“Chemical Engineering has

Consistently been one of the
Highest Paid Engineering
Profession” How true is this statement???

Chemical Engineering Design

 Why Are ChE’s Paid So Well
To Work in So Many Different Industries?
• They can start from a vaguely defined problem statement such as a
customer need or a set of experimental results

• From the problem statement they develop an understanding of the important

underlying physical science relevant to the problem

• Using this understanding they can develop a plan of action and set of
detailed specifications, which if followed will lead to a predicted financial
outcome

Chemical Engineering Design

 Why Are ChE’s Paid So Well
To Work in So Many Different Industries?
• They can start from a vaguely
defined problem statement such as a
customer need or a set of
experimental results

• From the problem statement they

develop an understanding of the All the other ChE
important underlying physical science classes you took
relevant to the problem

• Using this understanding they can

develop a plan of action and set of The design course
detailed specifications, which if addresses these
followed will lead to a predicted
financial outcome

Chemical Engineering Design

 The Design Process
Problem statement

XYZ Co.

Plan
Financial
outcome

Implementation

Chemical Engineering Design

 Is Design Easy or Difficult?
Design is Easy! Design is Hard!

• Simple math • Needs experience and practice

• Good software • Lots of rules and constraints

• Many “right” answers • Requires creativity

• Everyone thinks they can do it (though few • Iterative process with lots of re-work
do it well)
• Difficult to learn from books and lectures

Chemical Engineering Design

Either way, design is how chemical engineers
create new products and processes

always challenging
often frustrating
usually very satisfying

Some ChEs do this their whole career!

Chemical Engineering Design

 Nature of Design and Design
Objective
• Design is a creative activity

• The synthesis, the putting together, of ideas to achieve a

desired purpose.

• “the conversion of an ill-defined requirement into a

satisfied customer”

• Main Objective: Profit

• Sub Objectives: Minimize Production cost, minimize heat

loss, maximize conversion or yield etc.

Chemical Engineering Design

Stages in the Development of Design
Determine Set Design
Customer Needs Specifications
Build Performance
Models
Generate Design
R&D if Needed
Concepts
Predict Fitness
For Service

Evaluate Economics
& Select Design
Customer
Approval
Detailed Design & Procurement
Begin Operation
Equipment Selection & Construction

Common to all design problems in all industries

Chemical Engineering Design
 *The Design Basis
Determine Set Design
Customer Needs Specifications Build Performance
Models
Generate Design
R&D if Needed
Concepts Predict Fitness
For Service
Evaluate Economics
& Select Design
Customer
Approval
Detailed Design & Procurement
Begin Operation
Equipment Selection & Construction
Customer Need
• Most important Step Ultimate goal in clear terms
• Differentiate between “ must have” and “should have”
Design Specifications
• More precise statement of the problem to be solved-production rate, purity
specification, units to be adopted
• How much of it do we want? What are the boundary conditions?

Chemical Engineering Design

 Design Constraints
External Constraints

• Fixed

• Cant be changed by the designer

• Outer boundary of possible designs

Internal Constraints

• The designer has some level of

control

• Within the boundary

• Plausible design
Chemical Engineering Design
 *Design Work Process
Determine Set Design
Customer Needs Specifications
Build Performance
Models
These steps Generate Design
have to R&D if Needed
Concepts
come first Predict Fitness
For Service

Evaluate Economics
& Select Design
Customer
Approval
Detailed Design & Procurement
Begin Operation
Equipment Selection & Construction

This also needs time This takes time

Chemical Engineering Design

 Design Work Processes
Generate Design Concepts

Chemical engineering projects can be divided into three types:

• Modifications, and additions, to existing plant; usually carried

out by the plant design group. (50%)

• New production capacity to meet growing sales demand, and

the sale of established processes by contractors. Repetition of
existing designs, with only minor design changes. (45%)

• New processes, developed from laboratory research, through

pilot plant, to a commercial process. Even here, most of the
unit operations and process equipment will use established
designs. (5%)

Chemical Engineering Design

 The Design Work Processes
Generate Design Concepts

• Previous experience from designers and

members of the project team in general

• It is doubtful that any design is entirely novel

• Tried and tested methods are preferred to

untried novel designs. ????

Chemical Engineering Design

Economic Evaluation, Optimization
and Selection
Design Selection
Selection process can be considered to go
through the following stages:
• Possible designs (credible) within the external
constraints.
• Plausible designs (feasible) within the internal
constraints.
• Probable designs likely candidates.
• Best design (optimum) judged the best
solution to the problem

Chemical Engineering Design

Economic Evaluation, Optimization and Selection
• Main criteria for selection is economic performance

• Economic analysis can be used to optimize the design process

• Several designs with close economic performance???? Safest design and best
commercial track record

Chemical Engineering Design

 Detailed Design and Equipment Specification

• Detailed specification of equipment

• Collaboration with other Engineering disciplines

• Not concerned with changes to flowsheet

Chemical Engineering Design

 What’s in a Spec Sheet? Project Name
Company Name Project Number Sheet 1 of 1

• Project info & rev tab

Address REV DATE BY APVD REV DATE BY APVD

SHELL & TUBE HEAT EXCHANGER

Form XXXXX-YY-ZZ
Owner's Name
Plant Location Units English Metric
Case Description
Equipment label Equipment name

• Equipment service and

Plant section
Process service
Design code TEMA Exchanger type
Shells per unit Series Parallel
Surface per unit ft2 Surface per shell ft2

summary information DATA PER UNIT

IN
SHELL SIDE
OUT IN
TUBE SIDE
OUT
Stream No.
Fluid
Total fluid flow lb/h

• Stream data needed

Total vapor flow lb/h
Total liquid flow lb/h
Total steam flow lb/h
Fluid vaporized / condensed lb/h
Density lb/cu ft
Dynamic viscosity lbm/ft.s

for design Specific heat capacity

Thermal conductivity
Latent heat
Normal temperature
Btu/lb.F
Btu.ft/h.ft2.F
Btu/lb
ºF
Max temperature ºF
Min temperature ºF
Pressure psia

• Calculated design
Pressure drop allowed psi
Pressure drop calculated psi
Flow velocity ft/s

Number of passes

information for the

Film transfer coefficient Btu/h.ft2.F
Fouling coefficient Btu/h.ft2.F
Heat duty Btu/h
FT factor
Effective mean temperature difference ºF

equipment Minimum surface required

CONSTRUCTION & MATERIALS PER SHELL

ft2

Tubes
Material
Count Pitch in Square Triangular Welded

• Dimensions and
Length ft O.D. in Wall thickness in
Design pressure at max temp psia Test pressure psia Max external pressure psia
Number of tubes blanked

Shell
Material

construction details Length

Design pressure at max temp
Baffle material
Tubesheet material
ft
psia
I.D.
Test pressure
Baffle type
in
psia
Wall thickness
Min internal pressure
Baffle pitch
Tubesheet thickness
in
psia
in
in
Bonnet material Bonnet type

Branches

• Notes
Shell side inlet in N.B. Shell side outlet in N.B.
Tube side inlet in N.B. Tube side outlet in N.B.

NOTES

1.
2.
3.
4.
5.

Chemical Engineering Design

ORGANISATION OF A CHEMICAL
ENGINEERING PROJECT

Chemical Engineering Design

*ORGANISATION OF A CHEMICAL
ENGINEERING PROJECT

Chemical Engineering Design

ORGANISATION OF A CHEMICAL ENGINEERING
PROJECT
Process Design Plant Design
• Initial selection of the • Detailed mechanical
process to be used design of equipment

• Development of process • Specialist design groups

flowsheets will be needed

• Selection, Specification • Cost estimation ,

and Chemical Engineering purchase and
design of equipment procurement
• Preparation of Piping and
Instrumentation Diagram
Chemical Engineers

Chemical Engineering Design

Anatomy of a Chemical Engineering
Manufacturing Process

Chemical Engineering Design

 Anatomy of a Chemical Engineering
Manufacturing Process
• Generalized process- flexibility depending on the output

• Raw Material: Availability of storage when intermediate products are

not used. Storage required will depend on the nature of raw materials,
method of delivery and assurance of continuity.

• Feed Preparation: Method of purification

• Reaction: Heart of the chemical manufacturing process

• Product Separation: Separation of products and byproducts, possibility

of recycling and existence of multiple reaction steps

• Product Storage: Nature, packaging and mode of transportation

• Ancillary Processes: Added support-process water, cooling water,

compressed air and steam

Chemical Engineering Design

 Continuous and Batch Processes
Continuous processes

• Designed to operate 24 hours a day, 7 days a week,

throughout the year.

• Some down time will be allowed for maintenance and,

for some processes, catalyst regeneration.

• The plant attainment usually 90 to 95%.

Chemical Engineering Design

 Continuous and Batch Processes
Batch Processes

• Designed to operate intermittently. Some, or all, the process units being

frequently shut down and started up.

• Used where some flexibility is wanted in production rate or product

specification.

Chemical Engineering Design

 Continuous Versus Batch
Continuous Processes Batch Processes
• Production rate greater • Production rate less than
than 5 X 106 kg/h 5 X 106 kg/h

• Single product • A range of products or

product specifications
• Good catalyst life
• Short catalyst life
• Proven processes design
• New product
• Established market
• Uncertain design

Chemical Engineering Design

 *The Design Team
Everybody has
a role to play
Project Business
Sponsor Input

Project
Manager

Process Technical Control

Cost Engineer Consultants
Engineer(s) Specialists Engineer

R&D Mechanical Civil

Contractors
Specialists Engineer(s) Engineers

Chemical Engineering Design

 * Design Practices: Codes & Standards
• Methods and rules for designing processes and equipment are given in
design codes of practice
• Codes are set by national or international industry panels (e.g., ISO, ASME, API, ISA)
• Codes are reviewed and reissued frequently
• Codes specify practices for design, construction, testing and operation of equipment and processes, that are
expected to lead to a safe design, based on the experience of the code committee
• Design in accordance with code is usually required by the company or by law

• Standard sizes for piping & equipment, compositions, etc. are given in
standards
• Tubing dimensions, valve sizes, exchanger layouts, screw threads, wire gauges, screens, …

• The two terms tend to be used interchangeably

• Always consult the current (latest) edition of the code. Always make
sure that the codes and standards used comply with local legal
requirements.

Chemical Engineering Design

 Design Practices: Codes & Standards
Organizations that issues standards of interest to chemical engineers:

• Standards Organization of Nigeria (SON)

• Nigerian Society of Chemical Engineers (NSChE)

• Council for the Regulation of Engineering in Nigeria (COREN)

• The American National Standards Institute (ANSI),

• The American Petroleum Institute (API)

• The American Society for Testing Materials (ASTM)

• The American Society of Mechanical Engineers (ASME) (pressure vessels).

• British Standards Institute

• The International Organization for Standardization (ISO) coordinates the

publication of international standards.

Chemical Engineering Design

 Design Practices: Codes & Standards
Pros

• Protection of consumers

• Saves time and money

• Ensures conformity between projects

Cons

• Impose constraints on the designer

• Might not necessarily incorporate the latest technique.

Chemical Engineering Design

Design Practices: Design Factors (Design Margins)

• Equipment is usually sized greater than the

design throughput
– Allows for uncertainty in the design method and data
– Leaves some room for expanding output
– Ensures the plant can run at design capacity

• Companies usually have a policy on design

margins
– Typically size equipment for 110% of design basis
– Be careful to add design margin only once!

Chemical Engineering Design

 Design Documentation
The design documentation for a process usually includes a minimum of:

1. The design basis

2. A written description of the process
3. A process flow diagram
4. At least one mass & energy balance
5. Product specifications and properties
6. A list of major plant equipment
7. Equipment specification sheets
8. A piping and instrumentation diagram
9. A cost estimate
10.HS&E information (e.g., HAZAN, HAZOP, MSDS forms)

Additional information such as techno-economic analysis, market information,

analysis of competing technologies or alternative design options may also be
included if within the scope of the project

Chemical Engineering Design

 Design Documentation
1. The design basis
2. A written description of the process • The PFD or flowsheet
3. Process flow diagram identifies all the
4. At least one mass & energy balance equipment items and
5. Product specifications and properties process streams
6. A list of major plant equipment
7. Equipment specification sheets
• Usually broken into
8. A piping and instrumentation diagram
9. A cost estimate several separate sheets,
10.HS&E information defining plant sections

• By convention, feeds
enter at left, products exit
right

• Usually also indicates

stream temperature &
pressure
XYZ Co.

Chemical Engineering Design

 Design Documentation
1. The design basis
2. A written description of the process • Mass & energy balances
3. Process flow diagram are usually given for each
4. At least one mass & energy balance design case (e.g.,
5. Product specifications and properties SOR/EOR, different
6. A list of major plant equipment
feeds, winter /summer,
7. Equipment specification sheets
8. A piping and instrumentation diagram etc.)
9. A cost estimate
10.HS&E information • Usually mass flow, mole
flow, wt% and mole% are
given for every
component in every
stream

• Often summarized as a
table at the bottom of the
PFD
1 2 3 4 5 6 7 8 9 10 11 12
25C 25C 25C 25C 25C 25C 25C 25C 25C 25C 25C 25C
120 kPa 121 kPa 122 kPa 123 kPa 124 kPa 125 kPa 126 kPa 127 kPa 128 kPa 129 kPa 130 kPa 131 kPa
kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol%
Hydrogen
Helium
Lithium
Beryllium
Boron
Nitrogen
Carbon
Nitrogen
XYZ Co.
Oxygen
Fluorine
Neon
Total

Chemical Engineering Design

 Design Documentation
1. The design basis
2. A written description of the process
3. Process flow diagram
4. At least one mass & energy balance 1
5. Product specifications and properties 25C
120 kPa
6. A list of major plant equipment kg/h kmol/h wt% mol%
Hydrogen
7. Equipment specification sheets Methane
8. A piping and instrumentation diagram Ethane
Ethylene
9. A cost estimate Propane
10.HS&E information Propylene
Butanes
n-butylene
i-butylene
Water
Carbon dioxide
Total

1 2 3 4 5 6 7 8 9 10 11 12
25C 25C 25C 25C 25C 25C 25C 25C 25C 25C 25C 25C
120 kPa 121 kPa 122 kPa 123 kPa 124 kPa 125 kPa 126 kPa 127 kPa 128 kPa 129 kPa 130 kPa 131 kPa
kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol% kg/h kmol/h wt% mol%
Hydrogen
Helium
Lithium
Beryllium
Boron
Nitrogen
Carbon
Nitrogen
XYZ Co.
Oxygen
Fluorine
Neon
Total

Covenant University Department of Chemical Engineering-

Mamudu Angela, PhD.
Chemical Engineering Design
 Design Documentation
• Defines equipment names
1. The design basis
2. A written description of the process
3. Process flow diagram • Indicates which equipment is
4. At least one mass & energy balance “spared”
5. Product specifications and properties
6. A list of major plant equipment
7. Equipment specification sheets
• Often used to summarize
8. A piping and instrumentation diagram equipment costs and serve as
9. A cost estimate
10. HS&E information
a starting point for the capital
cost estimate
No. of Capacity Capacity Equipment Cost per
Plant Section Label Equipment Name Type Metallurgy Items Measure Capacity Units Measure Capacity Units Item (k$)
Air cooler Area m2
Boiler Steam rate kg/h
Column Diameter m No. of trays
Compressor Flow m3/s Power kW
Cooling tower Flow m3/h
Dryer Evap duty kg/h
Ejector Gas flow kg/h
Exchanger Area m2
Heater (fired) Duty MW
Air cooler
Mixer Drive power kW
Air cooler
Motor Power kW
Air cooler
Pump Flow litre/min Power kW
Air cooler
Tank Volume m3
Air cooler
Vessel Volume m3

Chemical Engineering Design

 Design Documentation
Project Name
Company Name Project Number Sheet 1 of 1
Address REV DATE BY APVD REV DATE BY APVD

SHELL & TUBE HEAT EXCHANGER

Form XXXXX-YY-ZZ

1. The design basis Owner's Name

Plant Location
Case Description
Equipment label
Plant section
Equipment name
Units English Metric

2. A written description of the process Process service

Design code
Shells per unit
Surface per unit
DATA PER UNIT
TEMA

ft2
Exchanger type
Series
Surface per shell
Parallel
ft2

3. Process flow diagram Stream No.

Fluid
IN
SHELL SIDE
OUT IN
TUBE SIDE
OUT

Total fluid flow lb/h

4. At least one mass & energy balance Total vapor flow

Total liquid flow
Total steam flow
Fluid vaporized / condensed
lb/h
lb/h
lb/h
lb/h
Density lb/cu ft

5. Product specifications and properties Dynamic viscosity

Specific heat capacity
Thermal conductivity
Latent heat
Normal temperature
lbm/ft.s
Btu/lb.F
Btu.ft/h.ft2.F
Btu/lb
ºF

6. A list of major plant equipment Max temperature

Min temperature
Pressure
Pressure drop allowed
Pressure drop calculated
ºF
ºF
psia
psi
psi
Flow velocity ft/s

7. Equipment specification sheets Number of passes

Film transfer coefficient
Fouling coefficient
Heat duty
FT factor
Btu/h.ft2.F
Btu/h.ft2.F
Btu/h

8. A piping and instrumentation diagram Effective mean temperature difference

Minimum surface required

CONSTRUCTION & MATERIALS PER SHELL

ºF
ft2

9. A cost estimate
Tubes
Material
Count Pitch in Square Triangular Welded
Length ft O.D. in Wall thickness in
Design pressure at max temp psia Test pressure psia Max external pressure psia

10. HS&E information

Number of tubes blanked

Shell
Material
Length ft I.D. in Wall thickness in
Design pressure at max temp psia Test pressure psia Min internal pressure psia
Baffle material Baffle type Baffle pitch in
Tubesheet material Tubesheet thickness in
Bonnet material Bonnet type

Branches
Shell side inlet in N.B. Shell side outlet in N.B.
Tube side inlet in N.B. Tube side outlet in N.B.

NOTES

1.
2.
3.
4.
5.

• Give detailed design information (stream properties, dimensions) for each

major piece of equipment

• Occasionally include mechanical drawings if the equipment is not standard

• Sometimes substituted with vendor specification sheets for sourced items

Chemical Engineering Design
 Design Documentation
1. The design basis • The P&ID is more detailed
2. A written description of the process
3. Process flow diagram than the PFD and almost
4. At least one mass & energy balance always runs to several
5. Product specifications and properties sheets
6. A list of major plant equipment
7. Equipment specification sheets • It shows all the plant
8. A piping and instrumentation diagram instruments, control
9. A cost estimate
10.HS&E information systems, control logic and
shutdown systems

• It also shows pipe sizes

and metallurgy (but not
pipe layout)

• The P&ID is critical for

performing design safety
XYZ Co.
reviews
Chemical Engineering Design
 Design Documentation
1. The design basis
• Variable costs of production
2. A written description of the process
3. Process flow diagram – Raw materials
4. At least one mass & energy balance – Utilities
5. Product specifications and properties – Consumables
6. A list of major plant equipment – Packaging & shipping
7. Equipment specification sheets
8. A piping and instrumentation diagram
• Fixed costs of production
9. A cost estimate
– Wages
10.HS&E information
– Taxes
– Maintenance
– Overheads

• Capital costs
– Working capital
– Installed capital cost
– Royalty costs
– Annual capital charge

Chemical Engineering Design

 Design Documentation
• HAZID: Early identification of potential
hazards and threats affecting people,
1. The design basis
2. A written description of the process environments, assets or reputation.
3. Process flow diagram
4. At least one mass & energy balance • HAZOP: Hazard and Operability Study-
5. Product specifications and properties
6. A list of major plant equipment
Identifies abnormalities in the working
7. Equipment specification sheets environment and pinpoint the root
8. A piping and instrumentation diagram causes.
9. A cost estimate
10.HS&E information • Material Safety Data Sheets (MSDSs)
must be provided to employees and
customers

• Information also needs to be collected to

begin applying for emissions permits

• The type of information needed and level

of detail varies locally

Chemical Engineering Design