School of Engineering Department of Chemical Engineering

CPS 410 Process Synthesis 410

Name of School

DEPARTMENT OF CHEMICAL ENGINEERING

STUDY GUIDE
CPS420 PROCESS SYNTHESIS

Compiled by: Prof. MD Heydenrych

Date of last revision: Date: 2012-02-02 Copyright reserved

TABLE OF CONTENTS

ORGANISATIONAL COMPONENT Page 1. GENERAL PREMISE AND EDUCATIONAL APPROACH ...................................... 3 2. LECTURERS AND VENUES .................................................................................. 3 3. STUDY MATERIAL ................................................................................................. 3 Text books (prescribed)........................................................................................ 3 Text books (additional reading material) .............................................................. 3 4. LEARNING ACTIVITIES.......................................................................................... 4 4.1 Contact time ................................................................................................. 4 4.2 Lectures.......................................................................................................... 4 4.3 Tutorials and assignments.............................................................................. 4 5. ASSESSMENT ........................................................................................................ 4 6. GENERAL............................................................................................................... 4

STUDY COMPONENT

1. MODULE OBJECTIVES, ARTICULATION AND LEARNING OUTCOMES ........... 5 1.1 General objectives.......................................................................................... 5 1.2 Prerequisite background ................................................................................ 5 2. MODULE STRUCTURE .......................................................................................... 5 3. SYLLABUS THEMES .............................................................................................. 6

ORGANISATIONAL COMPONENT
1. GENERAL PREMISE AND EDUCATIONAL APPROACH

The purpose of the study guide is to give an overview of what is expected of the student in the module CPS 410 PROCESS SYNTHESIS 410 The purpose of this module is to create the environment in which the topics covered in previous modules can be integrated in order to successfully plan and execute a process engineering design.

2.

LECTURER AND VENUES

The contact details of the lecturer responsible for CPS420 are given below: Prof. M.D. Heydenrych Room 8-18 Engineering 1 building e-mail: mike.heydenrych@up.ac.za Tel : (012) 420-2199 (083) 603-1530

3.

STUDY MATERIAL

Text books (prescribed) 1. Seader, W.D., Seider, J.D., Lewin, D.R.; Product and Process Design Principles: Synthesis, Analysis and Evaluation; John Wiley & Sons, 2nd ed., 2004.

Text books (supplementary reading material) 2. 3. Sinnot, R.K.; Coulson & Richardson's Chemical Engineering, Vol. 6: Design, Pergamon, 1993 (2nd ed.) Luyben, W.L.; Process Modeling, Simulation and Control for Chemical Engineers, McGraw-Hill, 1991 (2nd ed.)

4.

LEARNING ACTIVITIES

4.1 Contact time

No. of contact hours: 40 lectures over a period of 14 weeks.

13 of these lectures will be Aspen tutorials and tests, held in the Engineering computer labs. 4.2 Lectures
Lectures are presented on selected topics as set out below: The design process and the synthesis tree Heuristics Separation trains and residue curves PFDs and equipment lists Week 1-3 Week 3-9 Week 9-12 Week 13-14

4.3 Tutorials and assignments

At suitable lecture slots in the lecture schedule, unscheduled class tests may be given, either as individual tests, or as tut-tests. The students must complete these tut-tests in groups of no more than three per group (if four participate in a group, the mark will be multiplied by ). These tut-tests must typically be handed in at the end of the period. Together, the tut-tests will count 20% towards the semester mark. An Aspen test will be given as a class test in one of the normal Aspen practical slots, and this will count 10% of the semester mark. Students must obtain at least 50% for this test to achieve the outcome required for this module. The remaining 70% of the semester mark will be from the standard semester tests.

5.

ASSESSMENT

PASS REQUIREMENTS:
To pass the module, a student has to obtain a final mark of at least 50%, and obtain a mark of at least 50% for the Aspen practical. Calculation of the final mark: The final mark will be calculated as the average of the semester mark and the exam mark. Semester mark: Class tests: Aspen practical: Semester tests (2):

20% 10% 35% each

6.

GENERAL

Guideline: The standard policies, rules and arrangements regarding the following will be applicable: Conduct in class Academic dishonesty Absence from certain scheduled activities Pocket calculator specifications

STUDY COMPONENT
1. MODULE OBJECTIVES, ARTICULATION AND LEARNING OUTCOMES

1.1 General objectives

In this module, you will have the opportunity to integrate all your preceding study modules for the chemical engineering programme into a logical unit. It is the objective of this module to provide the student with the background and practical experience of creating a new process (process synthesis) rather than process analysis, which was the typical type of problem that was presented to the student in previous modules. A further objective is to provide training in the simulation tools necessary to evaluate and optimise a synthesised design.

1.2 Prerequisite background

The study themes discussed in this part of the module build on those preceding them. It is therefore assumed that students doing this course have an adequate knowledge and understanding of previous modules including Transfer Processes, Thermodynamics, Heat Transfer, Mass Transfer, Piping System Design, Reactor Design, Process Control and Chemical Engineering.

2.

MODULE STRUCTURE

The design process Process creation Heuristics for process synthesis Synthesis of separation chains

3. SYLLABUS THEMES
3.1. SYLLABUS THEME 1: Process simulation (ECSA exit level outcome 5: Engineering methods, skills, tools, including information technology) 1. After completing this syllabus theme, the student will have a working knowledge of Aspen+, and understand the capabilities and limitations of process simulation packages such as Aspen+. 2. Understand the role of a process simulator in obtaining data and carrying out mass and energy balances. 3.2. SYLLABUS THEME: Introduction to Process Synthesis (ECSA exit level 3: Engineering Design) 3.2.1 Learning outcomes 1. Understand the key steps in carrying out a process design. 2. Be aware of ethical, environmental and safety issues and how they affect the design of a new chemical process. 3. Be able to create a new process flow diagram by following the steps involving reactions, separations and T-P change operations. 4. Be able to identify alternative process flow diagrams, and assemble a synthesis tree of such alternatives. 5. Understand the importance of selecting reaction paths that do not involve toxic or hazardous chemicals, or otherwise choosing designs that reduce their possible impact. 6. To be able to distribute the chemicals to account for inert species, to purge species, to achieve high reaction selectivities, to remove exothermic heats of reaction and to combine operations effectively in the same piece of equipment. 7. To be able to apply heuristics in selecting separation processes to separate liquids, vapours and vapour-liquid mixtures. 8. Be knowledgeable about conditions in which process streams should be pumped as liquids or as vapours. 9. Be familiar with industrial separation methods and their basis for separation. 10. Understand the concept of a separation factor and be able to select appropriate separation methods for liquid mixtures. 11. Be able to sequence distillation columns by using heuristics and algorithmic methods. 12. Be familiar with techniques for separating azeotropic mixtures, including the use of residue/distillation curve maps.

3.2.2 Study units Product and Process Design Principles, WD Seider, JD Seader and DR Lewin: Chap 1, 3, 4, 5, 7, 10, 12.