Course Instructions - CHE4036Z (Design Project) 2012

Introduction The Chemical Engineer who is required to develop a first estimate for the manufacture of a particular product seeks the most economical process that complies with safety and environmental legislation. These estimates are typically used by companies to assess the viability of new manufacturing opportunities. Accurate and detailed designs are not normally undertaken for this kind of estimate, since there are still many uncertainties, such as: material feed composition and physical properties may be variable or unknown reaction kinetics and other thermodynamic data are not available pilot plant trials may be needed. The preparation of such an estimate is a multi-component task and involves: review of available technical and commercial data selection of a preferred process for economic and safe manufacture sizing and specification of process equipment, including materials of construction design of a control system and specification of the required instrumentation estimation of capital and operating costs with sensitivity / uncertainty analysis The purpose of this course is to introduce students to these various tasks, and allow them to develop the ability to deal with these uncertainties, so that a viable process is specified within a limited time period. Course Structure Refer to the Course Program, which gives a timetable for this years course in the form of a Gantt chart. Extensive use will be made of Vula for the dissemination of documents and announcements, and you should check the course site every day during the course of the project. This years Design Brief will be given to all students several weeks before the commencement of the course, via Vula, giving you an opportunity to undertake background research. The course is split into two phases: 1. Preparation and written/oral presentation of an initial feasibility study, undertaken individually 2. Preparation and written/oral presentation of a detailed design, undertaken in design groups of 5 or 6 The initial individual feasibility study phase will give you the opportunity to evaluate alternative processes and present an argument for your process of choice. During this phase, Course Supervisors will be available for consultation on two days, as shown on the course program. Individual 10-minute appointments may be made for these days using the sign-up sheets on the CHE4036Z notice board. Your Individual Feasibility Report should include: Cover sheet [Available on Vula, including word count and signed plagiarism declaration] Executive summary Introduction and problem definition Critical evaluation of process options This is a review of all potentially viable processing routes reported in the literature, worldwide. Advantages and disadvantages should be summarised, in view of the design duty and location for this project. Preliminary flow sheet (block diagram) for chosen process Include a basic stream table and some explanation of the flow sheet in the body of the text Preliminary mass balance and stream table for chosen process Document format: Spiral bound Maximum 1500 words, Arial 11 point font, 1.5 x line spacing Flow sheet and stream tables to be A3 landscape orientation, Z-folded to A4 (as demonstrated) 2 copies to be submitted to CHE4036Z hand-in box by 17h00 on Thursday 26 July 2012

In your Individual Oral Examination you will be expected to present your feasibility report using a short MS PowerPoint presentation (10 min max.), followed by 8 min of questions from the examiner. These oral examinations will take place on Wednesday 1 August 2012. On the day after submitting your individual feasibility report, you will attend a series of short seminars in which the Course Supervisors will present an overview of the process configuration that must be used for remaining group phase of the course. This preferred process will be divided into 6 unit-operation areas. You will be (non-negotiably) assigned to one of up to 20 Design Groups (A,B,CT) within which you will have two main responsibilities a unit operation design function (Area 1,2,3,4,5 or 6) and a specialist engineering function, defined as follows:

Specialist Engineering Function

Process Co-ordinator Lead and co-ordinate the finalisation of the flow sheet, P&ID, heat and mass balances between all 6 Unit Operation Areas Analysis of heat integration opportunities Prepare PFD, stream tables, P&ID diagrams for Final Report Plant Layout /Utilities Engineer Obtain information on equipment sizes and safety issues from each group member Classify safety risk in each area of the plant Develop the complete process layout as plan view and side elevations Create a schedule of utility requirements with start-up, operational and shutdown consumptions
Safety and Environmental Officer

Communicate relevant safety standards and legislation to group members Co-ordinate HazOp study and submit findings for inclusion in Final Report Environmental impact report Obtain information on equipment and operating costs from each group member Develop the complete project costing and DCF evaluation with sensitivity analysis Based on information provided by other team members, generate the Final Report Organise all information from team members into the Calculation Folder.
(6-member groups only)

Project accountant

Report Editor

Marketing Analyst

Identify existing and potential new markets Estimate price achievable for materials produced by the process

You should decide who does what within your group at your first group meeting, on the day that the groups are announced. Those design groups with only 5 members will not be required to submit a market analysis or a detailed design for Area 6, which is typically a product purification step and is deliberately defined in such a way that it does not impact the other 5 unit operation areas. The Group Design Phase of the course will be supervised through: a) Weekly meetings of all Unit Operation Engineers with the nominated Supervisor (refer to Course Timetable). Matters relating to clarification of the course organisation and information provided to all Design Groups on Vula will be raised and discussed as a group. Matters relating to a particular groups chosen design route may be discussed briefly 1-on-1 with the Supervisor at the end of the meeting, subject to time availability of the Supervisor. b) Weekly meetings of all Specialist Engineers with the nominated supervisor (refer to Course Timetable). Matters relating to clarification of the course organisation and information provided to all Design Groups on Vula will be raised and discussed as a group. Matters relating to a particular groups chosen design route may be discussed briefly 1-on-1 with the Supervisor at t the end of the meeting, subject to time availability of the Supervisor. c) Weekly meetings of each Design Group with their nominated Mentor (refer to Course Timetable). The Mentor will give guidance on upcoming deadlines, what the group should be focusing on at different stages of the

course, and address any issues relating to the allocation of responsibilities within the group. Each of the Course Supervisors will be allocated 1 or 2 Design Groups for which they will act as Mentor. Students will take it in turn to act as meeting chairman and write up the meeting minutes, which are included in the final report.

Name A.Lewis K. Moller E. van Steen T. Franklin D.Deglon M.Williamson* H.Heydenrych J.Fletcher H. van Blottnitz A.Mainza A.Isafiade T.Franklin

Specialist Engineering

Function

Unit Operation Design Function Area 1 Area 2 Area 3 Area 4 Area 5 Area 6

Group Mentor A B C D E F,R G,H I,J K,L M,N O,P Q

Process Co-ordinator Report Editor Plant Layout/Utilities Engineer Project Accountant Safety and Environmental Officer Marketing Analyst

A Frozen flow sheet and mass balance must be submitted by each group after 1 week, i.e. by 17h00 on Friday 3 August 2012. These submissions will be marked immediately by the responsible supervisor. This will allow an opportunity to check that all groups are proceeding in a reasonable direction with their designs. It is expected that each group will cut-andpaste this information into their final reports with few, if any, changes. The written submission for this phase of the course will be as a Group Final Written Report, comprising a final report (max 15,000 words) and a calculations folder. The final report, prepared as a group document, will include: Section Cover sheet Synopsis Contents Introduction Process description Notes On Vula, including plagiarism declaration to be signed by all group members Objective, outline of chosen design, quantitative cost outcomes Using a coherent page-numbering system Problem definition, existing technologies, reasons for process choice PFD / mass balance / stream tables Heat balance, heat integration strategy (refer to required presentation format) Referring to PFD, start-up/operation/shut-down procedures CAD drawings, plans, elevations, utility requirements for start-up, operation and shutdown. Hazard inventory, environmental impact, HazOp study Capital and operating costs, DCF evaluation with sensitivity / uncertainty analysis Existing markets, potential new markets
(6-member groups only)

Written by Report Editor Report Editor Report Editor Process Co-ordinator Process Co-ordinator

Control strategy Layout and utilities Safety and environmental Capital cost Marketing Analysis Conclusions References List of symbols used

Process Co-ordinator Layout /Utilities Engineer Safety & Environmental Officer Accountant Marketing Analyst Report Editor Report Editor Report Editor

Critical evaluation of recommendations Using Harvard system S.I units preferable

design,

uncertainties,

Document format: A4 lever-arch file with Group designation (A,B,C etc.) clearly identified on the spine Maximum 15,000 words for 6-member groups (12,500 words for 5-member groups) (Arial 11 point font, 1.5 x line spacing with all pages numbered Each diagram, graph or photograph, table should be labelled e.g. Fig. 1, Fig. 2 Table 1, Table 2 etc The specification, sizes and costs of equipment should contain references to the appropriate page in the Calculation Folder where the relevant calculation has been made. Sufficient details should be provided so that the method of calculation can be followed. Flow sheet and stream tables to be A3 landscape orientation, folded to A4 (as demonstrated) 1 copy to be submitted to reception by 17h00 on Thursday 23 August 2012 The accompanying Calculations Folder will include: Section Cover sheet Area 1 calculations Notes On Vula, including plagiarism declaration to be signed by all group members Discussion of methods for estimation of physical and chemical properties Design calculations including discussion of design methods P&ID (A3 CAD drawing, refer to required format) showing control loops, instrumentation, line sizes, vents, drains, etc. Control strategy, including start-up and shut-down Equipment list incorporating pump / compressor schedule Equipment data sheets for major items Layout sketches, plan and side elevation Cost estimate Utilities requirements Schedule of safety / hazard issues As Area 1 calculations As Area 1 calculations As Area 1 calculations As Area 1 calculations As Area 1 calculations Mass balance calculations, computer model output Heat balance and heat integration calculations Calculations relating to layout Discussion of applicable safety considerations Calculations relating to utilities Background information Financial calculations and analysis DCF calculations Sensitivity analysis Background information Material safety data sheets Minutes from weekly design meetings in the Group Design Phase Written by Report Editor Area 1 Design Engineer

Area 2 calculations Area 3 calculations Area 4 calculations Area 5 calculations Area 6 calculations
(6-member groups only)

Area 2 Design Engineer Area 3 Design Engineer Area 4 Design Engineer Area 5 Design Engineer Area 6 Design Engineer Process Co-ordinator Layout / Utilities Engineer Marketing Analyst Accountant Safety & Environmental Officer Report Editor

Process definition Layout / Utilities

Marketing Analysis
(6-member groups only)

Capital cost Safety and environmental Project meetings

Document format: A4 lever arch file with Group designation (A,B,C etc.) clearly identified on the spine Arial 12 point font, 1.5 x line spacing with a page numbering system that can be easily referenced from the final report Hand-written calculations to be legible with sufficient explanatory notes incorporated Flow sheet and stream tables to be A3 landscape orientation, folded to A4 (as demonstrated) 1 copy to be submitted to reception by 17h00 on Thursday 23 August 2012 The Group Final Presentation is an opportunity for you to present your work to your fellow students and the course supervisors. Your design group must: Present your design in 10 minutes, using a MS PowerPoint presentation Answer questions for 5 minutes These presentations will take place on Tuesday 28th August 2012 Course Marking Scheme Your work during this course is assessed through consideration of: Activity 1 2 3 Individual written feasibility study (1,500 words max.) Presentation of your feasibility report in an individual oral examination (10 minutes + 8 minutes questions) Group final written report (15,000 words max.) a) your individual unit operation area design b) your individual specialist engineering function Group Supervisors mark for team working Group final presentation Total Weighting (%) 25 10

30 20

50 5 10 100

4 5

There is a sub-minimum of 50% for sections 1, 3a) and 3b) ECSA requirements This course has four ECSA exit level outcomes, which will be assessed in accordance with details given on the CHE4036Z Course Outline.