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CHEMCAD SOFTWARE
CHEMCAD PROCESS DESI GN
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PROCESS DEVELOPMENT
DESIGN SPECIFICATION

Hazards
Assess
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PROCESS DEVELOPMENT
Process
Chemistry
Thermodynamics
Reaction Kinetics
Physical
Properties
Optimize
Process
Process
Concept
Environment
& Hazards
Process
Economics
Raw Material
Assessment
Process
Simulations
HAZID
Mass - Energy
Balances
Flowsheet
Developed
Process Flow
Diagrams
Scale-up
Process Steps
Test UnitOps Budget
Concept
Design
Process Inst
Diagrams HAZOP
Process Flow
Updates
Planning &
Compliance
Detailed
Design
Equipment
Specification
LOPA
Plant & Piping
Layouts
Implement
Phase
Project
Management
Testing
Calibration
Start up
Troubleshoot
Optimization
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PROCESS CHEMI STRY
Chemical
Input
Process Chemical
Output
Chemical processes that originate from a laboratory all have the
following features.
The Input and output issues for scale up are usually dictated by the
physical state of the material SOLID, LIQUID or GAS
The process issues can be many and varied and relate to the
demands and constraints surrounding the chemical reaction,
purification and subsequent work up.
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CHEMI CAL I NPUT
Chemical
Input
Gas
Form
Liquid
Form
Solid
Form
Each physical state requires
consideration against a series of
potential issues.
This in turn will impact on plant,
process, engineering and design.
I ssue
Physical Form
Quantity
Alternative states
Stability
Toxicity
Flammability
Common Impurities
Corrosive
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CHEMI CAL I NPUT I SSUES
I ssue Considerations I mpact
Physical Form Prills, chips, crystals, flakes,
turnings, briquettes, polymers,
dimers, chain length, bridging,
angle of repose,
particle size distribution
Material Handling equipment
Equipment selection
Materials of construction
Lifting equipment
Milling, pre breaking
Equipment cleaning
Static control
Reaction profile
Reaction stalling
Reaction initiation/completion
Charge order
I ssue
Physical Form
Quantity
Alternative states
Stability
Toxicity
Flammability
Common Impurities
Corrosive
Chemical Input
SOLID
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PHYSI CAL PROPERTY DATA
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PROCESS CHEMI STRY
Process
Prepare
React
Extract
I ssue
Mixing
Solvation
Heating/Cooling
pH Adjustment
Reaction
Distillation
Phase separate
Crystallise
Filtration /Slurry/ wash
Dry
The reaction stage typically has a large impact on
engineering design. However, other areas, although
less challenging, can have a major impact.
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REACTI ON CONSI DERATI ON
I ssue
Mixing
Solvation
Heating/Cooling
pH Adjustment
Reaction
Distillation
Phase separate
Crystallise
Filtration /Slurry/ wash
Dry
I ssue Considerations I mpact
Reaction Kinetics
Reaction stalling
Reaction run away
Exotherm
Endotherm
Critical parameters
Safe control
Sampling
Scale up concerns
Reflux/ evaporation
Off gas
Catalysts
Homogeneity
Phase Change
Cooling design
Heating system design
Temperature control system
Instrumentation & control
Addition rate profile
Vessel design
Agitation and Mixing
Safety system design
Emergency relief
Blowdown design
Safe sampling systems
Condenser design
Scrubbing systems
Catalyst handling
Catalyst recovery
Catalyst storage
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REACTOR Rx STABI LI TY
EXCEL : Batch Reactor Exotherm Stability
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REACTI ON STABI LI TY
JOB : Batch Reactor Exotherm Stability
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CHEMI CAL OUTPUT
Chemical
Output
Gas
Form
Liquid
Form
Solid
Form
Essentially the same as Chemical
Input, each physical state requires
consideration against a series of
potential issues.
I ssue
Physical Form
Quantity
Alternative states
Stability
Toxicity
Flammability
Common Impurities
Corrosive
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CHEMI CAL OUTPUT I SSUES
I ssue
Physical Form
Quantity
Alternative states
Stability
Toxicity
Flammability
Common Impurities
Corrosive
Chemical Output
SOLID
I ssue Considerations I mpact
Drying See crystal form
Temperature issues
Vacuum
Is drying required?
Re use as a slurry
Re dissolve in situ
Choice of wash solvents
Attrition
Balling
Milling
PSD
Isolation from water
based system
Oversize
Homogeneity
Temperature control system
design
Safety backup systems
Dryer Design/ selection
Heat transfer system design
Agitation/mixing
Milling requirement
Packing requirement
Sieving
Dust categories
Area Class
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DESI GN SEQUENCE
User
Requirement
Specification
Functional
Specification
Process &
Instrument
Diagrams
Process
Concept
PFD
HAZID
Process
Design
HAZOP
Simulate
Model
UnitOps
Vendor
Sizing
Detailed
Design
Layouts
P & I
Software
Vendor
Feedback
Assess
Procure
Equipment
Sizing &
Specification
Audit
Trail
Design
Changes
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DESI GN COST DRI VER
PROJECT COST IMPACTS
0
0.2
0.4
0.6
0.8
1
0 0.2 0.4 0.6 0.8 1
PROJECT TIME
C
O
S
T

I
M
P
A
C
T
Problem Discovery Design Decisions
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DOCUMENTATI ON
Simulations
Calculations
Specifications
Sub-Folders:
Process
Instrumentation
Drawings
Sub-folders
Process
Instrumentation
Software
Testing
Vendor
Documents
Certificates
User Requirement
Functional
Process Equipment
Instrumentation
Control Panels
Electrical
Motor Control Centre
Software
Test Procedures
Process Flow Diag.
P&I Diagram
Utility Line Diagram
Plant GA & Layouts
Piping Layout
Piping Isometrics
Electrical Zoning
Instrument System
Instrument Loop
Instrument Logic
Control Panel Layout
Electrical & Cable
Process
Instrumentation
Electrical
Functional Test
Loop Checks
Installation
Operation
Maintenance
Communications
Programming
Spares
Compliance
Calibration
Hazardous Area
Material Test
Pressure Test
Process
HAZID
HAZOP
LOPA
Plant Modelling
Instrumentation
Electrical
Mechanical
Line Surge
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DOCUMENT NUMBERI NG
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2. CLIENT IDENTIFICATION
3. PROJ ECT IDENTIFICATION
4. DOCUMENT IDENTIFIER
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