Sept 2019 Semester

CDB4323 : Energy and Process Utility System

Lecturer : Dr. Shuhaimi Mahadzir

Meeting Time : Wednesday 11:00 am – 1:00 pm
: Friday 8:00 – 10:00 am

Venue : 05-02-16
D-05
About your Course Instructor

Dr. Shuhaimi Mahadzir

Associate Professor of Chemical Engineering
BSc Chemical Engineering
MSc Process Integration
PhD Chemical Engineering (Refinery & Petrochemical Integration)
Process Engineer
Plant Engineer
Certified Energy Manager Trainer

Interests (Research Studentship Available: GA and GRA)

Process Design Development
Energy and Environmental Conservation

Dr. Shuhaimi Mahadzir

Lecture 0: Course Overview

Dr. Shuhaimi Mahadzir

Dr. Shuhaimi Mahadzir
PROGRAMME OUTCOMES – UTP CHEMICAL ENGINEERING
Graduates from the UTP Bachelor of Chemical Engineering Hons. Program shall be able to:
Apply knowledge of mathematics, science, engineering fundamentals and engineering specializations to the solution of
PO2
1
complex chemical engineering problems.
Analyze
2 complex
Identify, chemical
formulate, research literature engineering
and analyze complexproblems using
chemical engineering firstreaching
problems principles ofconclusions
substantiated
using first principles of mathematics, natural sciences and engineering sciences.
mathematics,
Design solutionssciences and engineering
for complex to reaching
chemical engineering problems substantiated
and design systems,conclusions.
components or
3 processes that meet specified needs with appropriate consideration for public health and safety,
cultural, societal, and environmental considerations
PO3 Investigate complex chemical engineering problems using research-based knowledge and research methods including design
4
Design solutions
of experiments, forandcomplex
analysis interpretationchemical engineering
of data, and synthesis of information problems and design
to provide valid conclusions

systems,
5
Selectcomponents
and to evaluateorcomplex processes chemicalthatengineering
meet specified needsmodern
activitiesapply with engineering
appropriate
and IT
tools
consideration for public health and safety, cultural, societal, and environmental
Apply reasoning informed by contextual knowledge to assess societal, health, safety, legal and cultural issues and the
6
considerations
consequent responsibilities relevant to professional engineering practice
Understand the relationship of professional engineering solutions in societal and environmental contexts and demonstrate
7
knowledge of and need for sustainable development
8 Apply ethical principles and commit to professional ethics, responsibilities and norms of chemical engineering practice

PO5
9 Communicate clearly on complex chemical engineering activities with the engineering community and society

Select
10 and
Function evaluate
effectively complex
as an individual, chemical
and as a member or leader in engineering activities settings
diverse teams and in multi-disciplinary and apply
Recognize the need for, and have the preparation and ability to engage in independent and life-long learning in the broadest
modern
11
contextengineering tools
of technological change
Demonstrate knowledge and understanding of engineering management, business acumen and entrepreneurship in
12
multidisciplinary environments

Dr. Shuhaimi Mahadzir

COURSE OUTCOMES – UTP CHEMICAL ENGINEERING
Program Outcomes
PO2 PO3 PO5
Integrate and optimize utilities network and chemical process
CO1
design for energy and environmental conservation.

Example: design of cooling system using minimum compressor X

energy (refrigeration) and minimum freshwater flowrate (cooling
water).

CO2 Identify various utility requirements for the process.

Example: determine fuel requirement for power supply by gas X
Course Outcomes

turbine to process plant

X
CO3 Perform steam balancing calculation in the utility system.

Example: finding optimum boiler operation load for steam

distribution to process plant

CO4 identify improvement opportunities in process utility designs.

Example: analyzing thermodynamic performance improvement of X

utility process

Dr. Shuhaimi Mahadzir

Course Contents, Delivery & Assessment

Assessment Strategy
(Constructive Alignments to CO-PO)

CO1 CO2 CO3 CO4

Assignment 1 (1.5%) Assignment 1 (1.5%) Assignment 2 (1.5%) Assignment 2 (1.5%)

Quiz 1 (2%) Quiz 2 (2%) Quiz 3 (2%) Quiz 4 (2%)

Individual Project Individual Project Individual Project Individual Project

(3%) (3%) (3%) (3%)

Test 1 (6%) Test 1 (6%) Test 2 (6%) Test 2 (6%)

FE Q1 (2.5%) FE Q1 (2.5%) FE Q1 (2.5%) FE Q1 (2.5%)

FE Q2 (10%) FE Q3 (10%) FE Q4 (10%) FE Q5 (10%)

Dr. Shuhaimi Mahadzir

COURSE ASSESSMENT

CONTINUOUS ASSESSMENT (50%)

Homework: 6%

Quizzes: 8%

Individual Project: 12

Tests: 24%

FINAL EXAMINATION (50%)

Final Exam: 50%

Dr. Shuhaimi Mahadzir

RULES AND POLICY OF THIS COURSE

Attendance:
90% qualifying rule to sit for final examination.

F
Honesty:
Dishonesty = F

Assignments:
On-time submission. Keep one copy for your revision.

Quizzes & Tests:

Compulsory. No make-up policy.

Dr. Shuhaimi Mahadzir

THE ROLE OF UTILITY PROCESS ENGINEERS

A Process Engineer
Process Engineer is responsible for the process design, operation and improvement of industrial processes
in order to maintain efficiency, reduce cost, improve sustainability and maximize profitability.

A Utility Process Engineer

Utility Process Engineers provide high value engineering technical support to Utility Facilities, such as
boilers, furnaces, gas and steam turbines, and air, water and refrigeration systems, in order to achieve
safe, optimum, efficient, and reliable performance, reduce costs and maximize profitability.

Dr. Shuhaimi Mahadzir

AMMONIA SYNTHESIS LOOP

This example illustrates the difference boundary of responsibilities between a process engineer and a utility
process engineer.

Ammonia
Synthesis
Reactor

130 MW

Source: Krupp Uhde Ammonia process

Design the utility process to produce liquid ammonia product.

Dr. Shuhaimi Mahadzir

AMMONIA SYNTHESIS LOOP

Ammonia synthesis heat flow profile

Total cooling load = 130 MW

Dr. Shuhaimi Mahadzir

AMMONIA SYNTHESIS LOOP

Selecting DT = 3oC between the process stream and cooling utilities

 Decision: refrigeration cooling = -5oC saturated liquid.

Dr. Shuhaimi Mahadzir

AMMONIA SYNTHESIS LOOP

Propane is a possible refrigerant at 4.1 bar, -5oC saturation.

Psat = 4.1 bar,

Tsat = -5oC

Dr. Shuhaimi Mahadzir

AMMONIA SYNTHESIS LOOP

Propane Refrigeration Loop Design

PL = 4.1 bar
Select PH = 15 bar (Pr = 3.7) for propane vapour compression

Dr. Shuhaimi Mahadzir

AMMONIA SYNTHESIS LOOP

Propane Refrigeration Loop Design

Select TCW, supply = 27oC, TCW, return = 34oC, DTmin = 10oC

High pressure propane refrigerant gas can be condensed to saturated liquid at 44oC

Dr. Shuhaimi Mahadzir

AMMONIA SYNTHESIS LOOP

Propane Refrigeration Loop Design

High pressure liquid propane is expanded to low pressure through an expansion valve.
A sudden pressure change across the expansion valve also results in a temperature
change: Joule-Thomson effect.
The process is isenthalpic.

Dr. Shuhaimi Mahadzir

AMMONIA SYNTHESIS LOOP

To provide Qrefrigeration = 130 MW,

Required flow rate of propane refrigerant, mrefrigerant = 2590 t/h

Required compressor power = Wcompressor = 56.1 MW

Coefficient of Performance, COP = Qrefrigeration / Wcompressor = 2.3

Evaluation:
 Very high Refrigerant flow rate
 Very large compressor
 Explore cheaper utilities above 30oC (e.g. cooling water)

Dr. Shuhaimi Mahadzir

AMMONIA SYNTHESIS LOOP

Cooling utilities design above ambient and refrigeration loop.

Dr. Shuhaimi Mahadzir

AMMONIA SYNTHESIS LOOP

To provide Qrefrigeration = 22 MW,

Required flow rate of propane refrigerant, mrefrigerant = 440 t/h

Evaluation:
 Refrigerant flow rate reduced by more than 80%
 Compressor size reduced by more than 80%

 Explore further opportunities to reduce utility costs:

o Heat Integration
o Steam Generation (Grand Composite Curve)

Dr. Shuhaimi Mahadzir

AMMONIA SYNTHESIS LOOP

As-built utilities design

Dr. Shuhaimi Mahadzir