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CENG3120: Process Design and Integration

Chemical and Biomolecular Engineering Department

The Hong Kong University of Science and technology
Spring Semester, 2018

Learning Outcomes

Students will be able to:

 Select and design chemical processing equipment based upon design heuristics,
guidelines or rules of thumb.
 Use basic chemical engineering principles to design chemical processes conceptually.
 Use Excel and ASPEN+ to simulate and optimization chemical processes.
 Design, simulate and synthesize complex distillation systems with azeotropic mixtures.
 Target and synthesize heat recovery network.
 Perform energy/heat integration study with SPRINT.
 Apply basic chemical engineering principles to design chemical processes

Reference Books:
 Smith, R., Chemical Process Design and Integration, Wiley, ISBN 0-471-48681-7.
 Douglas, J.M., Conceptual Design of Chemical Processes, McGraw-Hill International
Editions, Chemical Engineering Series, 1988.
 Hall, S., Rules of Thumb for Chemical Engineers, 5th Edition, Butterworth-
Heinemann, 2012.
 Sinnott, R. K., Coulson & Richardson’s, Chemical Engineering – Volume 6:
Chemical Engineering Design, Butterworth-Heinemann, 1993.
 Turton R., C.B. Bailie, B.W.Whiting and J.A. Shaeiwtz, Analysis, Synthesis, and
Design of Chemical Processes, 2nd Edition, Prentice Hall.
 Peters, Timmerhaus and West., Plant Design and Economics for Chemical
Engineers, 5th Edition, McGraw Hill.


In-Class/Home Work/Tutorial Exercises 20%

Design Projects 50%
Final Examination 30%
Most of the lecture notes and teaching material are in electronic form and will be available on
the course web for downloading. To make you easier to understand the lectures, you are
recommended to print out and read the lecture notes before attending the classes.

In-class exercises will be conducted during lectures. The exercises will provide some hand-on
experiences in designing or optimizing chemical processes or process equipment.

Course & Lab Schedule

Lectures: Wednesday 9:00pm – 10.50am Venue: LSK1034
Lab Sessions: Monday 9:30noon –11:20pm Venue: Barn A (Room 4402)

Lecture Schedule:

Week Subject
1 Introduction of Process Design, Synthesis and Integration
2-5 Flowsheet development
- The hierarchy of chemical process design
- Input information and Batch vs Continuous
- Input-Output Structure of a process flowsheet
- Recycle Structure of a process flowsheet

5-9 Separation system synthesis

- Selection of separation processes
- Distillation
- Distillation column sequencing
- Complex distillation
- Azeotropic distillation (Residual Curves Map)

9 -11 Energy Integration

- Energy targeting
- Heat exchanger network design
- Utility selection

11-13 Detail equipment sizing by design rules of thumb

- Flash drum
- Piping and pumping
- Heat exchanger
- Distillation column

* Lectures might be re-scheduled for better matching with the design projects
Tutorial Projects:
The objective of the tutorial projects is to provide you practical experiences in developing a
process flowsheet using computer programs such as Excel and Aspen+, and to perform an
energy integration study of the designed flowsheet. You will learn and experience of data
collection, flowsheet development, equipment selection, costing, energy integration and design
optimization, etc. A project team of 2 students will be working together on one project
consists of 3 working sessions including: 1) Flowsheet Development using Excel; 2) Flowsheet
Simulation with Aspen+; 3) Energy Integration. Tutorials will be given at the first week of
each session. Barn A is reserved during the lab sessions with the supports from our teaching

Teaching Assistants:
PG-TAs: Fiona LEE<pyleeab>
Keat Ping YEOH<kpyeoh>
UG-TAs: Min Li YEOH <mlyeoh>
Ka Kin WU <kkwu>

Project Schedule:
Weeks Work Sessions
Week 3 (Feb 23) Group Formation Deadline
Week 4 (Feb 26) – Week 7 (Mar 18) (1) Use Excel for Process Development
Week 7 (Mar 19) – Week 10 (Apr 15) (2) Aspen+ Simulation & Optimization
Week 10 (Apr 15) – Week 13 (May 6) (3) Energy Integration

Important Dates

23/2: Group formation

26/2: WS#1Tutorial 13 Lectures
3 Tutorials
3 Reports
1 Exam
18/3: Submission of WS#1
19/3: WS#3Tutorial

15/4: Submission of WS#2

16/4: WS#4Tutorial

6/5: Submission of WS#3

16-29/5: Final Exam
*Tutorial Sessions on 26/2, 19/3 and 16/4 in Barn A 9:30 – 11:20am. Other tutorial time slots
are reserved for you to work on your project or for consultation with your TAs. You may also
want to make consultation with the course instructor, by email appointment, in these time slots.

Project Team Formation:

Please form a team of 2 and email the names of your team members to Fiona <pyleeab> by Feb