Chemical Engineering Plant Design (CHE 441)

Dr. Imran Hassan

Assistant Professor
Department of Chemical Engineering COMSATS,
Lahore.

PROGRAMME OUTCOMES CIIT 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 CIIT 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.

PROGRAMME OUTCOMES CIIT 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.

PRE-REQUISITE

Have Strong grip on fundamentals of:

Unit operation
Unit processes
Thermodynamics
Mass & energy balances
Economics
Reaction engineering
Basic sciences

REFERENCE BOOKS

REFERENCE BOOKS

REFERENCE BOOKS

REFERENCE BOOKS

Chemical Engineering Plant Design

Plant design is central to chemical

engineering
The design starts at a conceptual
level (basic idea)
Project ends in the form of
fabrication and working of plant
Chemical Engineer: Design
Engineer/Cost Engineer
Process Engineering/ Design
Engineering
Coordination and team work

Plant Design Project Stages

1. Inception
2. Preliminary evaluation of economics and market
3. Development of data necessary for final design
4. Final economic evaluation
5. Detailed engineering design

capitalized engineering and expensed engineering

6. Procurement
7. Erection
8. Startup and trial runs
9. Production

NATURE OF DESIGN

DESIGN
CONSTRAINTS

FACTORS INVOLVED

Plant location
Plant layout
Materials of construction
Structural design
Utilities
Buildings
Storage
Materials handling
Safety
Waste disposal
Federal, state, and local laws or codes
Patents

PLANT LOCATION

1. Raw materials availability

2. Markets
3. Energy availability
4. Climate
5. Transportation facilities
6. Water supply
7. Waste disposal
8. Labor supply
9. Taxation and legal restrictions
10. Site characteristics
11. Flood and fire protection
12. Community factors

RAW MATERIALS AVAILABILITY

The source of raw materials is the most important factors

Near location of the raw-materials source permits
considerable reduction in:
Transportation
Storage charges

If requirement of large volumes of raw materials, so attention

should be given to:

Purchased price of the raw materials

Distance from the source of supply
Transportation expenses
Availability and reliability of supply
Purity of the raw materials
Storage requirements

MARKETS

The location of markets affects:

Cost of product distribution
Time required for shipping

Markets is an important consideration in the

selection of a plant site:
Advantageous to buyer

Markets are needed for by-products as well

ENERGY AVAILABILITY

High requirements of power and steam in

industries
Fuel required to supply power and steam
For Example:
Electrolytic processes require a cheap source of electricity so;
Location must be near by large hydroelectric installations
Plant requires large quantities of coal or oil
Location near a source of fuel

Local cost of power can help to determine

whether:
Power should be purchased
or self-generated

CLIMATE
If the plant is located in a cold climate, costs may be
increased:
Construction of protective shelters around the equipment

If the plant is located in hot climate:

Special cooling towers
Air-conditioning equipment may be required

If there is excessive humidity or extremes of hot or

cold weather:
Serious effect on the economic operation of a plant

Climate factors must be examined when selecting a

plant site

TRANSPORTATION FACILITIES

Rail tracks, roads, and highways are the common

Products and raw materials required transportation facilities.
Possibility of canal, river, lake, or ocean transport must be considered.
If possible, the plant site should have access to all three types of
transportation or at least two types should be available.
Water
Road
Rail

Air transportation facilities between the plant and the main company
headquarters

WATER SUPPLY
The process industries use large quantities of water for;

Cooling
Washing
Steam generation
Raw material

Plant, must be located, where, water is available

River or lake is preferable
Deep wells are satisfactory if the amount of water required is not too
high
Try to drill several standby wells
Factors considered during choosing water supply:

Temperature
Mineral content
Sand content
Bacteriological content
Cost for supply
Purification

WASTE DISPOSAL
Legal restrictions have been placed on the methods for disposing of waste
materials from the process industries
Site selected for a plant should have capacity and facilities for correct waste
disposal.
Attention should be given to potential requirements for additional wastetreatment facilities

LABOR SUPPLY

Labor availability must be examined

Consideration should be given to:
Pay scales
Restrictions on number of hours worked per week

Competing other industries

Productivity of the workers
Welfare of workers

Avoid

TAXATION & LEGAL RESTRICTIONS

State and local tax rates:
Property income
Unemployment insurance

Local regulations on:

Building codes
Transportation facilities
Required permits

FLOOD AND FIRE PROTECTION

Many industrial plants are located along rivers and there are risks of flood
Before selecting a plant site:
Regional history of natural events of this type should be examined
Protection from losses by fire is another important factor
In case of a major fire, assistance from outside fire departments should be available

COMMUNITY FACTORS
Character and facilities of a community can have quite effect on the location of
the plant
Cultural facilities of the community are important to sound growth
Masjids, libraries, schools, colleges, theaters and other similar groups, are
important for recreation

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