Summary and objectives

The second year content builds up on the ideas and aspects of the formalin
process which were derived and discussed in the first year. The second year
however focusses more on designing the process using more accurate data and
fewer assumptions. Using more accurate data on the conditions in each part of
process and more information about the reactions in the reactor, calculation of a
more accurate mass balance can be done. With the accurate data on the
conditions in each part of the process an energy balance can be done to assess
the energy needs of the process. It was found that the process was a net
producer of energy and methods of using this energy are discussed in the energy
balance section.
The utilities were also discussed to have a complete account of all the aspects
needed to run the process. After, the designing of the plant layout and main
plant items was done including the materials of construction. Positioning of
different main plant items was done for various reasons for example ease of
transport access. .Designing of the reactor, waste heat boiler, fluid movers and
the absorber was done using various engineering equations. A hazop was also
carried out to ensure that procedures were in place just in case anything
happened that would disrupt the running of the plant.
Employability skills are also gone discussed with lessons om how to write a
proper cv, how to behave in an interview and other methods of career
management. Then the whole module was topped off with a talk by a special
guest who was the plant manager of an existing formalin plant for many years.
He shared more specific details about the day to day running of the plant and
general advice about the career of a chemical engineer.
Note: the Notes were made duirng lectures therefore some calculations will be repeated over the lectures. The
layout of the work may not be neat but the conent is legible and accurate.

Conclusions and reflections

The module led to the development of many career management skills and
design skills. The aims laid out at the start of the course were met. Material from
the Seperation processes, reaction kinetics and thermodynamics and transfer
processes was used in the design process which allowed me to get a deeper
understanding of the modules. Group work aided my learning and It llowed me to
develop communication skills and teamworking skills. Also covered are the safety
aspects of process design which are essential ensure the health and safety of the
operators.Overall I found the talk with the former plant manager to be the most
beneficial because it covered all aspects of career management and general day
to day running of a plant.