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INTRODUCTION TO
PROCESS DESIGN
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KEY DIFFERENCES BETWEEN
DESIGN AND ANALYSIS
• Open-ended problem
• Underdefined
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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
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TYPES OF DESIGN
2) Detailed-estimate design.
• 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
- basic flowsheet
- process conditions
- mass and energy balances
- ancillary equipment
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6) Simulation/optimization
- steady state
- dynamic
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12) Estimation of return on investment
15) Construction
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