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ChE 491 – PLANT DESIGN

INTRODUCTION TO
PROCESS DESIGN

Prof. Christopher Baker


DESIGN:

Design is a creative activity in which


processing concepts are translated into
flowsheet and equipment specifications.

We are going to undertake a preliminary


design, the key objective of which is
screening.

Only 1% of process concepts become


plants.

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KEY DIFFERENCES BETWEEN
DESIGN AND ANALYSIS

• Open-ended problem

• No single “right” answer

• Underdefined

- Important information is often


missing.
- We often have to make
assumptions.

• We focus on the effective screening of


alternatives.

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The Process Design Task:

Needs

Synthesis

Flowsheet

Analysis:
Heat & Material
Balances
Sizing & Costing
Economic Evaluation

Final
Flowsheet

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FLOWSHEETING PACKAGES

These are software packages, which


perform material and energy balances,
and equipment sizing (and possibly)
costing calculations for process
flowsheets.

Calculations may be performed at several


levels:

• Material and energy balances and


sizing calculations.

• Material and energy balances alone.

• Material balances alone.

Typical size 50,000 – 150,000 lines coding


(usually FORTRAN).

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TYPES OF DESIGN

1) Preliminary or quick-estimate design.

2) Detailed-estimate design.

3) Firm process design.

THROUGHOUT THE DESIGN EXERCISE


YOU MUST ALWAYS CONSIDER:

• Safety (Hazop)
• Environmental Impact
• Relevant legislation
• Overall economic yield
• Energy and water conservation

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FACTORS TO BE CONSIDERED IN
PROCESS DESIGN

1. Technical Factors
a. Process flexibility
b. Continuous, semi-continuous, or
batch operation.
c. Special controls involved
d. Commercial yields
e. Technical difficulties involved
f. Energy requirements
g. Special auxiliaries required
h. Possibility of future developments
i. Health and safety hazards
involved
2. Raw materials
a. Present and future availability
b. Processing required
c. Storage requirements
d. Materials
3. Waste products and by-products

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a. Amount produced
b. Value
c. Potential markets and uses
d. Manner of discard
e. Environmental aspects

4. Equipment
a. Availability
b. Materials of construction
c. Initial costs
d. Maintenance and installation
costs
e. Replacement requirements
f. Special designs

5. Plant location
a. Amount of land required
b. Transportation facilities
c. Proximity to markets and raw
material sources
d. Availability of service and power
facilities

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e. Availability of labor
f. Climate
g. Legal restrictions and taxes

6. Costs
a. Raw materials
b. Energy
c. Depreciation
d. Other fixed charges
e. Processing and overhead
f. Special labor requirements
g. Real estate
h. Patent rights
i. Environmental controls

7. Time factors
a. Project completion deadline
b. Process development required
c. Market timeliness
d. Value of money
8. Process considerations
a. Technology availability

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b. Raw materials common with other
processes
c. Consistency of product within
company
d. General company objectives

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STEPS IN THE DESIGN PROCESS

1) Evaluation of options (feedstock,


product, capacity, process, location).

2) Selection of process; Writing the


“mission statement”.

3) Preparation of process flowsheet

- basic flowsheet
- process conditions
- mass and energy balances
- ancillary equipment

4) FREEZING THE PROCESS


FLOWSHEET

5) Process equipment design


- sizing
- materials of construction

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6) Simulation/optimization
- steady state
- dynamic

7) Specification of ancillaries (pipes and


fittings, utilities, pumps,
instrumentation, controls, etc.

8) FREEZING OF DETAILED FLOWSHEET

9) Estimation of capital cost


- major items of equipment
- ancillary equipment, pipework,
etc.
- civils, installation, etc.

10) Estimation of operating cost

11) Estimation of manufacturing cost of


product

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12) Estimation of return on investment

13) DECISION TO PROCEED

14) Preparation of ITT (invitation of


tender) documentation; invite
tenders

15) Construction

16) Commissioning and handover

17) START PRODUCTION

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