Towler - Chemical - Engineering - Design - MS Powerpoint PDF

Chemical Engineering Design
Principles, Practice and Economics of Plant and Process Design

Towler & Sinnott, Elsevier, 2008, ISBN: 978-0-7506-84231
A practical design text for the Senior

Design Course plus introduction to
chemical engineering courses
Teaches commercial engineering tools

for simulation and costing
Strong emphasis on HS&E issues,

codes and standards
108 realistic commercial design

projects from diverse industries
1170 lecture slides on CD, solutions

manual, Excel spreadsheets
For more information and to register

for an examination copy visit
http://textbooks.elsevier.com
2007 G.P. Towler / UOP. For educational use in conjunction with

Sinnott & Towler Chemical Engineering Design only. Do not copy
2009 Elsevier Ltd. All rights reserved
ChEs Are Paid Well to Work in Diverse
Industries Because
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 This is all the
develop an understanding of the other ChE
important underlying physical science
classes
relevant to the problem
Using this understanding they can
develop a plan of action and set of
detailed specifications, which if followed The design
will lead to a predicted financial course
outcome teaches these
key skills
The Design Process
Problem statement
XYZ Co.
Plan
Financial
outcome
Implementation

Key Features of Towler & Sinnott
Practical emphasis, based on authors industrial
experience
Towler ICI, UOP
Sinnott DuPont, Davy
Teaches real-world engineering tools & methods

Process simulators: AspenPlus, UniSim
Costing software: Aspen ICARUS
Heat exchangers: HTFS TASC, AspenPinch
Lots of spreadsheet examples & problems

Key Features of Towler & Sinnott
Emphasis on safety, environment, industry

codes and standards
Ch 9: safety issues in design
Ch 14: environmental issues in design
Relevant industry codes introduced in every

chapter
ASME boiler and pressure vessel code (Ch 13) pipe codes (Ch 5)
API codes for safety, relief valve design (Ch 9)
NFPA codes for electrical installations and fire safety (Ch 9)
OSHA standards for safety (Ch 9)
Name of Manufacturer
ISA codes for P&IDs (Ch 5) psi at F
TEMA codes for exchangers (Ch 12) Max. Allowable Working Pressure
F at psi
W (if arc or gas welded)
ISO codes for life-cycle analysis (Ch 13) RT (if Radio graphed)
HT (if Postweld heat treated)
Min. Design Metal Temperature
Manufacturers Serial Number
Year Built

Extensive Support Materials
Over 100 realistic industrial design projects from diverse
industries
Commodity chemicals (25)
Devices (2)
Electronics and electrochemical processes (3)
Foods and formulated products (14)
Fuels (5)
Gas processing (7)
Inorganic chemicals (8)
Pharmaceuticals (29)
Pulp and paper (5)
Specialty chemicals (7)
Waste treatment and recovery (4)
14 of the projects involve biological processing (across

almost all the industry sectors)

Supporting Lectures in MS PowerPoint
22 presentations with 1170

slides
Lots of industrial pictures and

diagrams (with copyright
approval!)
Step-by-step guides to problem

solving using commercial
software

1. Introduction (Ch 1)
1. Overview
2. Industrial process design
3. Product design
4. Optimization in ChE design
2. Process flowsheet development

(Ch 2, 3, 4)
1. Flowsheet overview
2. Process simulation
3. Pinch analysis

Vapor
5. The P&ID (Ch5) FIC
LIC
1. Process hydraulics FT
FV
LV
2. Instrumentation & control Feed

LT
Steam
6. Process Economics (Ch6) Trap

Condensate
1. Capital costs
2. Operating costs
3. Economic analysis
4. Project financing
Company Name Project Name Adipic acid from phenol
Address Project Number Sheet 1
REV DATE BY APVD REV DATE BY APVD
ECONOMIC ANALYSIS 1 1.1.07 GPT
PX contract PX spot PET bottle resin contract TPA contract TPA spot Adipic Acid from Phenol
120.00 Form XXXXX-YY-ZZ

Owner's Name Capital Cost Basis Year 2006
Plant Location Northeast Asia Units Metric
Case Description On Stream 8,000 hr/yr 333.33 day/yr
REVENUES AND PRODUCTION COSTS CAPITAL COSTS CONSTRUCTION SCHEDULE
$MM/yr $MM Year % FC % WC % FCOP % VCOP

100.00 Main product revenue
Byproduct revenue
560.0
4.4
ISBL Capital Cost
OSBL Capital Cost
206.5
82.6
1
2
30%
70%
0%
0%
0%
0%
0%
0%
Raw materials cost 410.8 Engineering Costs 28.9 3 0% 100% 100% 50%
Utilities cost 47.3 Contingency 43.4 4 0% 0% 100% 100%
Consumables cost 13.1 Total Fixed Capital Cost 361.3 5 0% 0% 100% 100%
VCOP 466.8 6 0% 0% 100% 100%
Salary and overheads 16.4 Working Capital 59.5 7+ 0% 0% 100% 100%
80.00 Maintenance 10.8
Price (cents/lb)
Interest 3.6
Royalties 3.0
FCOP 33.8
ECONOMIC ASSUMPTIONS
60.00 Cost of equity

Cost of debt
25%
5%
Debt ratio 0.5 Tax rate
Depreciation method
35%
Straight-line
Cost of capital 15.0% Depreciation period 10 years
CASH FLOW ANALYSIS
All figures in $MM unless indicated

40.00 Project year
1
Cap Ex
108.4
Revenue
0.0
CCOP
0.0
Gr. Profit
0.0
Deprcn
0.0
Taxbl Inc
0.0
Tax Paid
0.0
Cash Flow
-108.4
PV of CF
-94.3
NPV
-94.3
2 252.9 0.0 0.0 0.0 0.0 0.0 0.0 -252.9 -191.2 -285.5
3 59.5 280.0 267.2 12.8 36.1 -23.3 0.0 -46.7 -30.7 -316.2
4 0.0 560.0 500.6 59.4 36.1 23.3 0.0 59.4 34.0 -282.2
5 0.0 560.0 500.6 59.4 36.1 23.3 8.1 51.3 25.5 -256.8
6 0.0 560.0 500.6 59.4 36.1 23.3 8.1 51.3 22.2 -234.6
20.00 7
8
0.0
0.0
560.0
560.0
500.6
500.6
59.4
59.4
36.1
36.1
23.3
23.3
8.1
8.1
51.3
51.3
19.3
16.8
-215.3
-198.6
9 0.0 560.0 500.6 59.4 36.1 23.3 8.1 51.3 14.6 -184.0
10 0.0 560.0 500.6 59.4 36.1 23.3 8.1 51.3 12.7 -171.3
11 0.0 560.0 500.6 59.4 36.1 23.3 8.1 51.3 11.0 -160.3
12 0.0 560.0 500.6 59.4 36.1 23.3 8.1 51.3 9.6 -150.7
13 0.0 560.0 500.6 59.4 0.0 59.4 8.1 51.3 8.3 -142.4
0.00 14 0.0 560.0 500.6 59.4 0.0 59.4 20.8 38.6 5.5 -136.9
15 0.0 560.0 500.6 59.4 0.0 59.4 20.8 38.6 4.7 -132.2
16 0.0 560.0 500.6 59.4 0.0 59.4 20.8 38.6 4.1 -128.1
Jan-1990 Jan-1992 Jan-1994 Jan-1996 Jan-1998 Jan-2000 Jan-2002 Jan-2004 Jan-2006 17 0.0 560.0 500.6 59.4 0.0 59.4 20.8 38.6 3.6 -124.5
18 0.0 560.0 500.6 59.4 0.0 59.4 20.8 38.6 3.1 -121.4
19 0.0 560.0 500.6 59.4 0.0 59.4 20.8 38.6 2.7 -118.7
Time 20 -59.5 560.0 500.6 59.4 0.0 59.4 20.8 98.1 6.0 -112.7
ECONOMIC ANALYSIS
Average cash flow 44.7 $MM/yr NPV 10 years -171.3 $MM IRR 10 years -2.0%
Simple pay-back period 9.4 yrs 15 years -132.2 $MM 15 years 5.6%
Return on investment (10 yrs) 3.32% 20 years -112.7 $MM 20 years 8.4%
Return on investment (15 yrs) 5.77% NPV to yr 19 -118.7 $MM

9. Health, Safety & Environment

(Ch 9, 13, 14)
1. Process safety
2. Pressure relief
3. Environmental impact
Source: EPA

10. Equipment Design (Ch 10, 11,

13)
1. Reactor design
2. Separation column design
3. Pressure vessel design

12. Heat transfer equipment (Ch12)

1. Heat exchangers
2. Boiling and condensing
3. Heaters and coolers
Source: Riggins Company: www.rigginscompany.com

How to Use the Book
Sinnott & Towler, 2007
Ch 1, 2, 3
Introduction and background material
Should have been covered in earlier classes can skim for revision
Ch 4, 5, 6, 9, 14
Essentials of process design
Recommended reading before lectures
Ch 7, 8
Reference material useful for projects
Ch 10, 11, 12, 13

Essentials of equipment design
Needed for project work
Recommended reading before equipment design lectures


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Chemical Engineering Design

Principles, Practice and Economics of Plant and Process Design

A practical design text for the Senior

Teaches commercial engineering tools

Strong emphasis on HS&E issues,

108 realistic commercial design

1170 lecture slides on CD, solutions

For more information and to register

2007 G.P. Towler / UOP. For educational use in conjunction with

2007 G.P. Towler / UOP. For educational use in conjunction with

Teaches real-world engineering tools & methods

2007 G.P. Towler / UOP. For educational use in conjunction with

Emphasis on safety, environment, industry

Relevant industry codes introduced in every

Manufacturers Serial Number

2007 G.P. Towler / UOP. For educational use in conjunction with

14 of the projects involve biological processing (across

2007 G.P. Towler / UOP. For educational use in conjunction with

22 presentations with 1170

Lots of industrial pictures and

Step-by-step guides to problem

2007 G.P. Towler / UOP. For educational use in conjunction with

2. Process flowsheet development

2007 G.P. Towler / UOP. For educational use in conjunction with

2. Instrumentation & control Feed

6. Process Economics (Ch6) Trap

120.00 Form XXXXX-YY-ZZ

$MM/yr $MM Year % FC % WC % FCOP % VCOP

60.00 Cost of equity

CASH FLOW ANALYSIS

All figures in $MM unless indicated

2007 G.P. Towler / UOP. For educational use in conjunction with

9. Health, Safety & Environment

2007 G.P. Towler / UOP. For educational use in conjunction with

10. Equipment Design (Ch 10, 11,

2007 G.P. Towler / UOP. For educational use in conjunction with

12. Heat transfer equipment (Ch12)

2007 G.P. Towler / UOP. For educational use in conjunction with

Ch 10, 11, 12, 13

2007 G.P. Towler / UOP. For educational use in conjunction with

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