CCB 3024/CBB 3024

PROCESS PLANT DESIGN

4 Credit-Hour Core Course
Semester May 2013

Lecturer : Dr Balasubramanian Periyasamy

Lecture Time
Location

: Mon 10 am 12 noon ; Tues 12 PM 2:00 PM

: LT C2 ;

01-02-04

Sincere thanks to
Prof. Shuhaimi Mahadzir
&
Prof. Mohamed Ibrahim Abdul Mutalib
for the lecture notes of the first part of this course

Semester May 2011

PROGRAMME OUTCOMES UTP CHEMICAL ENGINEERING

Engineering Knowledge: Apply knowledge of mathematics, science,
PO1 engineering fundamentals and engineering specialization to the solution of
complex engineering problems
Problem Analysis: Identify, formulate, research literature & analyze complex
PO2 engineering problems reaching substantiated conclusions using first principles of
mathematics, natural sciences and engineering sciences.
Design & Development of solutions: Design solutions for complex
engineering problems and design systems, components or processes that meet
PO3 specified needs with appropriate consideration for public health and safety,
cultural, societal & environmental considerations.
Investigation: Conduct investigation into complex problems using research
based knowledge & research methods including DOE, analysis and
PO4
interpretation of data and synthesis of information to provide valid conclusions.
Modern Tool Usage: Create, select & apply appropriate techniques, resources
PO5 & modern engineering & IT tool, including prediction & modeling, to complex
engineering activities, with an understanding of the limitations.

PROGRAMME OUTCOMES UTP CHEMICAL ENGINEERING

The Engineer& Society: Apply reasoning informed by contextual knowledge to
PO6 assess societal, health, safety, legal & cultural issues & the consequent
responsibilities relevant to professional engineering practice.
Environment & Sustainability: Understand the impact of professional engineering
solutions in societal and environmental contexts and demonstrate knowledge of and
PO7
need for sustainable development.
Ethics: Apply ethical principles and commit to professional ethics and
PO8 responsibilities and norms of engineering practice.
Communication: Communicate effectively on complex engineering activities with
the engineering community & with society at large, e.g. being able to comprehend &
PO9 write effective reports & design documents, make effective presentations & give and
receive clear instructions.
Individual &Team Work: Function effectively as an individual & as a member or
PO10 leader in diverse teams & in multidisciplinary settings.
Life Long Learning : Recognize the need for, and have the preparation and ability
PO11 to engage in independent and life long learning in the broadest context of
technological change.
Semester July

PROGRAMME OUTCOMES UTP CHEMICAL ENGINEERING

Project Management & Finance : Demonstrate knowledge & understanding of

engineering & management principles & apply these to ones own work, as a
PO12 member & leader in a team, to manage projects and in multidisciplinary
environments.

Semester July

COURSE OUTCOMES CBB 3024 CHEMICAL PLANT DESIGN

Integrate knowledge from previous

CO1 chemical engineering courses in designing
a chemical process system

K
S
A
PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO3 PO9 PO7
x

Apply conceptual process design and

CO2 synthesis tools in designing a chemical
process system
CO3

Apply a systematic approach or method to

design a chemical process system

K Knowledge
S Skill
A Attitude

COURSE OUTCOMES CCB 3024 CHEMICAL PLANT DESIGN

K
S
A
PO3 PO5 PO7 PO3 PO5 PO7 PO3 PO5 PO7

3
CO1

Integrate knowledge from basic/fundamentals

Chemical Engineering in designing a chemical
process system

CO2

Apply conceptual process design and synthesis

tools in designing a chemical process system

CO3

Apply a systematic approach to design a

chemical process system

CO4

C05

C06

Semester July

Execute process design approach by

incorporating the concepts of sustainable
development
Demonstrate economics of chemical plants
through plant cost estimation investment and
time value of money
Defend the assigned projects as individuals
and as a team

Course Content, Delivery & Assessment

Lecture No.

Topic

1-2

Introduction to Plant Design and Economics (Approaches and

Stages of Process Design)

Assessment

Short test 1
3-4

General Plant Consideration (Plant Layout/Utility System)

5-8

Synthesis of Reactor Separation System

Short test 2/
(Fundamentals and Selection of Reaction System & Separation Project/Test 1
System)

9-12

Synthesis of Reactor Separation System

Short test 2/
(Fundamentals and Selection of Reaction System & Separation Project/Test 1
System)

13-16

Synthesis of Reactor Separation System

(Process Recycle and Distillation Sequencing)

17-20

Heat Integration (Composite Curve & Heat Recovery Pinch, Assign 1/Test 2
Problem Table Algorithm)

21-24

Heat Integration (Grand Composite Curve & Multiple Utilities)

Assign 1

25-28

Heat Integration (HEN Design)

Assign 1/Test 2

29-32

Process Flow sheeting (Flow sheet Synthesis & Simulation,

Model Formulation, Solution Strategies)

Test 1/Project/
Assign 1

Project/ Test 2

Course Content, Delivery & Assessment

Lecture No.

Topic

Assessment

33-36

Economics of Chemical Plants

Project/Short
test 3

37-40

Equipment Design & Specification (Material Transfer &

Handling, Mass Transfer Equipment)

Assign 2

41-44

Equipment Design & Specification (Mass Transfer & Reactor

Equipment)

Assign 2

45-48

Equipment Design & Specification (Pressure Vessel Design)

Assign 2

49-52

Environmental Studies & Consideration Effluent Treatment,

Waste Minimization and Life Cycle Analysis

Short test 4

53-56

Plant Wide Control (Material & Quality Control, Pairing of

Variables in MIMOS, Typical Unit Operation and Control
Strategies)

Short test 4

Assessment : Quizzes /Short tests 4 (5%) Assignments - 2 (5%) Project - 1 (10%)

Tests - 2 (20%)
Final Exam - 1 (60%)

Lecture 1. Introduction to Plant Design and Economics

The purpose of engineering is to create material wealth Douglas, Conceptual Design of Chemical
Processes 1988.
The goal of the engineer is to design and produce artifacts and systems that are beneficial to mankind
Biegler, Grossman & Westerberg, Systematic Methods of Chemical Process Design 1997.

How to do so ?
Energy
In

Raw Materials
+ Other Feeds

CHEMICAL
PROCESS

Products + Wastes

Energy
Out
WHAT CAN YOU SAY ABOUT THE CHEMICAL PROCESS ?
In a chemical process, the transformation of raw materials into desired products usually
cannot be achieved in a single step. Instead, the overall transformation is broken down into
a number of steps that provide intermediate transformations. (Robin Smith, Chemical

Raw Materials
+ Other Feeds

CHEMICAL
PROCESS
Energy

Products + Wastes

Energy

SO, A NUMBER OF PROCESSING STEPS MADE UP THE CHEMICAL PROCESS.

QUESTIONS?
- WHAT SORT OF PROCESSINGS ARE LOCATED IN THE CHEMICAL PROCESS?
- HOW DO WE SEQUENCE THE PROCESSING STEPS?
- TO WHAT EXTEND CAN WE EXPECT EACH OF THE PROCESSING STEP TO
PERFORM AND WHAT FEATURES ARE REQUIRED?
- HOW MUCH ENERGY IS REQUIRED AND HOW MUCH IS PRODUCED?
- HOW MUCH FEEDS DO WE NEED AND HOW MUCH PRODUCTS ARE PRODUCED?
- HOW MUCH WASTES ARE GENERATED?
- HOW MUCH PROFIT COULD BE DERIVED?
HOW DO WE ADDRESS
THIS?

Concept Design for Chemical Process

Raw Materials
+ Other Feeds

CHEMICAL
PROCESS
Energy

Products + Wastes

Energy

PROCESS PLANT DESIGN IS THE NAME OF THE GAME

HERE !
LITTLE OR LIMITED
INFORMATIONS ARE
AVAILABLE

BEFORE COMING UP WITH A

COMPLETE PROCESS

But so many possibilities

or solutions !
Perhaps, the major features that distinguishes design problems from other types of
engineering problems is that they are under defined; i.e., only a very small fraction of
the information needed to define a design problem is available from the problem
statement.

Once the process concept has been designed which produces process flowsheet,

the equipment design then has to be performed..

Distillation

The equipment design comprises of ;

1. Performance/Capacity Rating or
Sizing
Equipments Dimensions
diameter & height
Heat Transfer
Area Needed

No. of stages
for contact

2. Vessel Mechanical Design

Internal Design

Wall thickness

Support Design

Pipe fittings &

Reinforcement

he process safety and control strategy has to be devised;

1. Process Safety
-

Hazard and Operability Study (HAZOP)

Risk Assessment
HAZOP study

2. Process Control Strategy

-

Material Control

Product Control

Overall Plant and Equipment .

Risk Assessment
Matrix

And Waste Treatment/Minimisation need to also be addressed

1. Waste Treatment (conventional)

-

Suitable end of pipe treatment on the effluent (gases & liquids)

2. Waste Minimisation (sustainability)

- Adjusting processes to minimise the generation of waste
REACTOR

SEPARATION
& RECYCLE
SYSTEM

HEAT EXCHANGER
NETWORK

UTILITIES

In finalising the process and equipment design, several stages of economic

analysis could be conducted

First step;
EP 1 = Revenue Cost of Raw Material
Second Step (after mass balance developed)
EP 2 = Revenue Cost of Raw Material - Utility
Third Step (after equipments designed)
EP 3 = Revenue Cost of Raw Material Utility Annualised Cost of Equipment
The economics analysis continues with other costs (manpower,
insurance etc) .
Pay back time,
Return on Investment
Internal Rate of Return

with profitability analysis conducted at the end to assess project

viability

Finally ..

Lecture 2. Approaches and Stages of Process Plant Design

In the first stage, conceptual process design has to be conducted.
In general conceptual process design has to address two major activities .
1. ADDRESS THE INDIVIDUAL
PROCESS/TRANSFORMATION STEP

RECYCLE

STEAM

FEED

REACTOR
PRODUCT 1

CW

PRODUCT 2

2. ADDRESS THE REQUIRED

INTERCONNECTION BETWEEN THE STEPS

.and the target is to create the best possible feasible flowsheet for the process.
DEFINITION OF A FLOWSHEET.
FLOWSHEET IS A DIAGRAMMATIC REPRESENTATION OF THE PROCESS
STEPS AND ITS INTERCONNECTIONS.

RECYCLE

STEAM

REACTOR

FEED

PRODUCT 1

CW
Str1

Str2

Str3

Str4

Str5

Str6

Str7

F
T
P
x

Str8

Str9

PRODUCT 2

WHAT OTHER INFORMATIONS SHOULD BE

AVAILABLE IN A FLOWSHEET ?
AND HOW DO YOU GET SUCH INFORMATION ?

THIS IS WHAT YOU WANT

AT THE END OF THE STAGE !

A SYSTEMATIC APPROACH OR METHOD IS REQUIRED

The approach or method should be able to help in addressing these questions
Why is the unit operation selected ?
How are the unit operations connected ?
What are the utilities required and approximate amount ?
How will it be supplied to the process unit operations ?
What wastes will be generated?
However, as much as we would like to have a systematic approach or method, we
must also recognised that process design is an art !
If we reflect on the nature of process synthesis and analysis, . , we recognize that
process design actually is an art, i.e., creative process. (Douglas, Conceptual Design of
Chemical Processes 1988)
This course will attempt to develop the art to conduct process design !

Now, what criteria should be adopted besides economics during the design
activities?
1. ADDRESS THE INDIVIDUAL
PROCESS/TRANSFORMATION STEP

RECYCLE

STEAM
FEED

REACTOR
CW

PRODUCT 1

PRODUCT 2

FLOWSHEE
T

2. ADDRESS THE REQUIRED

INTERCONNECTION BETWEEN THE STEPS

QUANTIFIABLE
FACTOR !

VERSUS

NON - QUANTIFIABLE
FACTOR !

MINIMISE COST

HIGH SAFETY & INTEGRITY

MINIMISE WASTES GENERATION

GOOD OPERATIONAL ASPECTS

MINIMISE ENERGY CONSUMPTION

..... BUT HOW TO

OPTIMISE ?

Consider back the flowsheet !

RECYCLE

STEAM

REACTOR

FEED

PRODUCT 1

CW

PRODUCT 2

OPTIMISING A SINGLE UNIT/STEP

IN THE PROCESS

OPTIMISING THE INTERCONNECTIONS

BETWEEN THE UNITS/STEPS IN THE PROCESS

EG. DISTILLATION COLUMN

RR --> ENERGY

TOTAL
COST

RR

CONTINUOUS FUNCTION

PARAMETER OPTIMISATION

RR --> CAPITAL

MANY POSSIBLE CONNECTIONS WHICH LEAD

TO DIFFERENT STRUCTURES OF FLOWSHEET
THUS DIFFERENT ECONOMIC IMPACT EVEN TO THE
EXTENT OF THE INDIVIDUAL UNIT ITSELF!

DIS-CONTINUOUS FUNCTION

STRUCTURAL OPTIMISATION

How do we tackle them ?

Consider the approaches/methods which have been introduced to deal with such complex optimisation ?
HEURISTIC METHOD
ONION MODEL
USE A SEQUENTIAL/HIERARCHICAL METHOD
ACCORDING TO FOLLOWING SEQUENCE ;
1. REACTOR
2. SEPARATION AND RECYCLE SYSTEM
3. HEAT EXCHANGER NETWORK
4. UTILITIES
DECISION ARE BASED ON ENGINEERING GUIDELINES
ESTABLISHED AND MATHEMATICAL OPTIMISATION
CONCEPT IS BASED ON
"BUILDING AN IRREDUCIBLE STRUCTURE"

Smith R.,Chemical Process Design 1995

HIERARCHICAL APPROACH
USE A SEQUENTIAL/HIERARCHICAL METHOD
ACCORDING TO FOLLOWING SEQUENCE ;
1. BATCH VS CONTINUOUS
2. INPUT-OUTPUT STRUCTURE OF THE FLOWSHEET
3. RECYCLE STRUCTURE OF THE FLOWSHEET
4. GENERAL STRUCTURE OF SEPARATION SYSTEM
5. HEAT EXCHANGER NETWORK

MATHEMATICAL METHOD
MIXED INTEGER LINEAR/
NON-LINEAR PROGRAMMING
USE A MATHEMATICAL PROGRAMMING METHOD TO
SOLVE AND GIVE SOLUTION FOR THE PROCESS.
SIMULTANEOUS SOLUTION OF ALL THE SYSTEM.

DECISION ARE BASED ON SOLELY MATHEMATICAL

OPTIMISATION CRITERIA
CONCEPT IS BASED ON
"CREATING AND OPTIMISING A REDUCIBLE
STRUCTURE"

Grossman I. E, Comp. Chem. Eng., 9: 463, 1985

Biegler, Grossman & Westerberg, Systematic
Method of Chemical Process Design 1997

Douglas.,Conceptual Design of Chemical Process 1988

HEURISTIC METHOD The Onion Model

- FOLLOWS ONION LOGIC

REACTOR

SEPARATION
& RECYCLE
SYSTEM

HEAT EXCHANGER
NETWORK

Design starts from the centre ( heart of process ) which is the reactor.
At each layer, decision has to be made to complete the design
requirement for the stage. As such, many best local optimal decisions
are made since the whole picture is incomplete. Unit/Equipment is
added only if it is economically justified based on the current available
information. This keeps the process (structure) irreducible and features
which are technically/economically redundant are not included.
What do you see are the advantages and disadvantages of this method ?
Advantages

UTILITIES

Disadvantages

HEURISTIC METHOD The Hierarchical Approach

The conceptual design is performed based on 5 different stages. The approach is somewhat
different by tackling the 5 different level that are classified differently. The 5 levels are ;
Level 1 Decision : Batch vs Continuous
Level 2 Decision : Fixing the Input-Output Structure
Level 3 Decision : Determining the Recycle Structure for the Process
Level 4 Decision : Determining the Separation System
Level 5 Decision : Determining the Heat Exchanger Network

WHAT DO YOU NOTICE ON

THE STATEMENT CONTAIN WITHIN
THE SHADED BOX ?
REACTOR

SEPARATION
& RECYCLE
SYSTEM

HEAT EXCHANGER
NETWORK

UTILITIES

Compare these statements

to the onion model !

At each level except level 1, alternatives have to

be generated and assessed to see its economic
and operational potential. Some level of process
design has to be conducted on the units/process
placed at every stages.

MATHEMATICAL METHOD The Mixed Integer Linear/Nonlinear Programming

- CREATION OF SUPERSTRUCTURE/HYPERSTRUCTURE
A major (super) structure is created which embedded within it all feasible
process (including its operations) and all feasible interconnections that
are candidates for an optimal design. The method is completely automated
and depends only on the computer programming to solve it. The design
problem is formulated into sets of mathematical equations which has to be
solved by the mathematical programming. Started off with many redundant
features, the programming optimise and reduce the process (structure)
to an optimal solution.
What are the advantages and disadvantages of this method ?
Advantages

other process
alternatives

Semester July 2004

Disadvantages

From the conceptual process design, a flowsheet is generated for the process. The next stage
would then be to address the equipment design
RECYCLE

STEAM

FEED

REACTOR
PRODUCT 1

CW

PRODUCT 2

Heat Exchanger
Reactor
Distillation

Type of Exchanger (Plate / Shell & Tube)

Heat Transfer Coefficient
Heat Transfer Area
Pressure Drop
Exchanger Configuration

Type of Reactor
Reaction Kinetics
Reaction Selectivity
Reactor Sizing
Reactor Temperature & Pressure

No of stages
Reflux Ratio
Feed Location
Vapour/Liquid Loading
Column Sizing
Internals
Column Temperature &
Pressure

There are established methods for performing the design of these equipments .
Heat Exchanger

Kerns method
Rating calculation that will
enable the sizing of the heat
exchanger to be done

Reactor

Distillation

Reactor

From the kinetics obtained

from experiment, sizing of
reactor could be done based
on residence time.

Fenske, Gilliland & Underwood

No of stages calculation versus reflux ratio
could be made and the feed location
determined.
Results are then simulated in rigorous
simulation model for actual design involving
capacity calculation for internals.

Given that each of the equipment will normally involved vessel operated at various pressure and
temperature, the design of the pressure vessel has to be conducted. The design is to be done
according to standards..
Heat Exchanger
Reactor

Distillation

Pressure Vessel Dimension

Shell Thickness
Flanges Connection &
Reinforcement
Support type and Design
Corrosion Allowance
Welding specification

American Society of Mechanical Engineers (ASME)

Boiler and Pressure Vessel Code.
ASME Boiler and Pressure Vessel Code (BPVC) is a standard that
provides rules for the design, fabrication, and inspection of boilers and
pressure vessels. It is reviewed every three years.

Health, Safety and Environment aspects are increasingly gaining attention in view of their importance.
Therefore the design of process plant has to take into account of the HSE particularly the safety and
environment aspects where it has to be integrated with the design activities .

Inherent Safety
Hazard Analysis

FIRE
Auto Ignition temp.
Flammability Limits
Flash Points
Minimum Oxygen concentration
Flammable liquids are more
dangerous than flammable gas

Remove or attenuate conditions that

could lead to the 3 incidents such as
high P and T ..

EXPLOSION
Chemical Energy vs
Physical Energy
Deflagration vs detonation
Confined vs Unconfined
Explosions (VCE)

TOXIC RELEASE
Time weighed exposure
Short term Exposure
Ceiling Exposure
LC50 & LD50
DOW Index

HAZOP
Hazard and
Operability
Study.

Health, Safety and Environment aspects are increasingly gaining attention in view of their importance.
Therefore the design of process plant has to take into account of the HSE particularly the safety and
environment aspects where it has to be integrated with the design activities .

Environment

Environment

Waste Minimisation
(Clean Process Technology)

Waste Treatment

Reactor
Increase conversion if selectivity is not an issue
Product removal for reversible reaction favoring product
Set T & P to improve selectivity

Air Effluent
Particulate, CO2, CO, SOx, Nox
Gravity Settlers, Inertial Collectors, Scribbers, Filters,
Electrostatic precipitators, catalytic reaction etc.

Distillation
Recycling waste stream to suppress by product reaction
Feed purification
Eliminate use of extraneous material for separation
(entrainer)

Water Effluent
Membrane, Adsorption, Absorption, thermal oxidation,
biological treatment, membrane separation etc.

Waste stream recovery

Improve heat recovery

Finally ..
You will develop the
construction details for a
process plant .