IChEC 2015

INDONESIA CHEMICAL ENGINEERING CHALLENGE

2015

PLANT DESIGN
2 nd PHASE COMPETITION

GUIDEBOOK
GUIDELINES BOOK

SUBMISSION RULES
1.

ONLY teams that have passed the 1st phase abstract selection may continue to the 2nd phase
of Plant Design Competition

2.

Participating teams must submit the required 2nd phase documents via e-mail to
ichec.2015@gmail.com before the deadline at 11.59 pm (GMT+7) on 14 February 2015. Late
submission up to 12 hours after the time stamp will be accepted but heavy penalties will be
given (5 pts deduction for every hour of lateness). No submission is accepted after that and
will result in immediate disqualification

3.

The 2nd phase document consists of:

FINAL REPORT
(Details regarding the content and the format are explained in the next chapter)

4.

The document must be compressed into a single file (*.zip or *.rar) with the file name and
subject:
IChEC2015_PD2_XXXXX
XXXXX is your team number

5.

Participating teams will receive an e-mail confirmation within 2 x 24 hours after sending the email

6.

Selection process results of the 2nd phase can be accessed on: http://www.ichec-itb.com

7.

Participating teams that have successfully passed the 2nd phase selection process will be
further competing in the Grand Final on 27 March 2015. Further details regarding the Grand
Final will be notified via e-mail.

INDONESIA CHEMICAL ENGINEERING CHALLENGE 2015

PLANT DESIGN REPORT CONTENT AND

ASSESSMENT CRITERIA
The final report must contain three following main sections, explained in sub-chapter
A, B and C, as well as several supporting documents and references.
A.

Executive Summary

Executive summary (2 page maximum) should contain a summary or brief description

of the proposed plant design. The executive summary must also deliver arguments that
explain and answer these questions below in the executive summary:
-

Why does the proposed plant deserve to be implemented?

Is the proposed plant a new design or an improvement of an existing plant?

Can the new plant design produce more efficiently in terms of energy, chemical
reactions, by-products generation, etc.? Make a comparison with similar existing
plants (if any)

Is the technology used can be categorized as hybrid or part of the green

(sustainable) technologies development?

How can you guarantee that the plant is designed safely for both humanity and
the environment?

Arguments should correspond to the proposed plant design and are to be written into
paragraphs form, NOT into bullet points. Those questions above are only cues of the
arguments. Headings, relevant figures, equations and/or any other relevant items in
strengthening the arguments are allowed.
Please display your arguments sharply to show that your plant is better than others.
Clearly explain and specify your arguments to avoid overgeneralizing.
B.

Plant Performance and Economic Summary Sheet

The Plant Performance and Economic Summary Sheet template can be downloaded
on our official website (along with this guidebook). Both sheets must be attached to the
front of the report after executive summary. Note that the provided template only
serves as the general guidance of the sheet; participants are highly encouraged to
customize the sheet to suit their own proposed plant design, as the details are
dependent on each own design.

PLANT DESIGN 2ND PHASE COMPETITION GUIDEBOOK

C.

Plant Design Main Report

This section is the most comprehensive aspect of the final report and should consist of
several chapters. The chapter structure and its corresponding score weight factors are
as follows: (Please note that adherence to chapter structure is mandatory, however participants
may add more sub-chapters, as well as the points included in each of it)

ASSESSMENT
CRITERIA
CHAPTER
A

Chapter I Introduction

W E I G H T FAC TO R
10

Sub-chapters:
1.1 Background
Objectives
Sharpness in seeing opportunities
Impact to industrial regional sector
1.2 Raw Materials
Selection of raw materials, availability, supplies
continuity, etc.
1.3 Market Analysis
Market research
Product competiveness in the market (competitors,
commodity complementary and substitute)
Product off taker: local, regional, or international
market? Other companies or direct off taker?
1.4 Site Selection
Supply plan and access to raw material and utility
Product marketing plans
Supporting facilities (facilities and infrastructures,
telecommunications, ports, etc.)
Other related conditions (geographical, social, political,
labor, etc.)
B

Chapter II Plant Design Methodology

Sub-chapters:
2.1 Theoretical Background
Detailed description to support process selection basis
used in the plant
The whole description must be taken from reliable
references or thorough personal analysis
2.2 Methodology
Step-by-step explanation of plant design
Approaches and assumptions used in designing the plant

INDONESIA CHEMICAL ENGINEERING CHALLENGE 2015

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Chapter III Comprehensive Process Description

23

Sub-chapters:
3.1 Plant Design Basis
Plant Capacity
Specification of feed and product
Ambient environmental conditions (air temperature,
water, wind speed and direction, etc.)
Mode of the operation (continuous, batch, semi-batch,
or semi-continuous)
3.2 Process Flow Diagram (PFD)
Refer to Turton et al (2009) for standard use in this competition
(see the Appendix of this guidebook)
Operating units and operating conditions of main
equipments and streams
Detailed sequence of processes of raw materials into
products
Mass and energy balances for every stream process
Energy consumption and release for every unit operation
and total energy consumption per production unit
Process control instrumentation (emphasis on
philosophy of the control itself; complex and specific
code number is not necessary)
3.3 Utility Flow Diagram
Utilities involved in the process
Equipments and streams of utilities

Chapter IV Process Safety and Environmental

Considerations

12

Sub-chapters:
4.1 Process Safety
Hazards that may arise from the plant operation
Prevention and mitigation to avoid and/or overcome
potential hazards
Safety-related equipments for hazardous materials
handling process
Hazardous materials/chemicals that are used or
contained in PFD (MSDS can be attached if necessary)
4.2 Environmental Impact and Waste Management
Government regulations (local and international) of the
environmental impact of waste generated from process
operations
Types of waste and pollution generated, including the
way to handle them
E

Chapter V Equipment Specifications

15

Sub-chapters:
5.1 Consideration in Equipments Selection
Personal consideration and explanation of selection
depending on several factors
5.2 List of Equipments
Specification of primary equipments, including type,

PLANT DESIGN 2ND PHASE COMPETITION GUIDEBOOK

size, material, number, and others

5.3 List of Piping
Type of pipe, diameter, and total length of the apropriate
diameter
5.4 Material Selection and Specifications for Pipe and
Primary Equipments
Operating conditions (pressure and temperature)
Durability of the materials compared to physical
properties of the process fluid
Analysis of materials selection
F

Chapter VI Layout

Sub-chapters:
6.1 Plot Plan
Schematic layout of various areas in plant consists of:
Primary infrastructures in process inside plant
Utilities
Raw materials and products storage
Office
Road plan
Personal additional objects
6.2 Plant Layout
Detailed equipment layout in the plant (consider factors
of safety, traffic, accessibility of operation and
maintenance)
6.3 Pipe Rack
Management and placement of pipes across the plant
G

Chapter VII Economic Investment and Calculations

Sub-chapters:
7.1 Capital Cost Estimation
Refer to Turton et al (2009) on chapter 7 for standard use in
this competition
Engineering cost
Procurement cost
Construction cost
Commisioning cost
Start-up cost
Others
7.2 Manufacturing Cost Estimation
Refer to Turton et al (2009) on chapter 8 for standard use in
this competition
Variable cost
Raw materials, utilities, labour, fringe, benefits,
maintenance, distribution, packaging, storage, sales
expense, R&D, promotion, etc.
Fixed cost: depreciation, taxes, insurance, patents,
royalties, etc.
7.3 Profitability Analysis
Refer to Turton et al (2009) on chapter 9 and 10 for standard

INDONESIA CHEMICAL ENGINEERING CHALLENGE 2015

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use in this competition

Cash flow from designing to finishing
Detailed cash flow can be inserted in Appendix
Profitability criteria from discounted method
NPV, DPBP, ROI, DCFROR (IRR)
IDC (interest during construction), taxes, O&M cost,
amortization, and depreciation (Use straight line method
for depreciation)
7.4 Sensitivity Analysis
Spider web diagram, impact of changes in product prices,
sales volume, raw materials, and investment to the value
of IRR
Chapter VIII Final

Conclusion of the plant design proposal

APPENDIX
1.

2.
3.

Specification Sheet: covering the calculation and major

equipement specifications with clear assumptions and
references (computer typing or manual writing is allowed)
Cash Flow Sheet, Economic Summary Sheet, etc.
Bibliography and Other References

PLANT DESIGN 2ND PHASE COMPETITION GUIDEBOOK

COMPETITION TERMS
A.

Plant Design Regulations

Regulations are given with the intention to meet minimum reporting standards,
uniformity and to facilitate assessment. The regulations are:

1.

The drawing of Process Flow Diagram, Plant Layout, etc., must be equipped with
plant name and its capacity (in tons of products/year). It is recommended that the
drawing is made by using a drawing software (i.e. AutoCAD) on A3 paper size and
follows our stated reference for the standard (Turton et al., 2009)

2.

Use metric units for the whole calculation, especially in the summary and the
conclusion. Imperial units are only allowed, as long as it is followed by a
conversion to metric unit

3.

Do not use scientific number on the Investment and Economic Calculation (use
1341 instead of 1,34 x 103)

4.

Use number rounding up to two decimal points

5.

Numbering format must be the following: comma for digit separator (,) and dot for
decimal separator (.) e.g. 34,500.23 or 14,225,821.53

6.

The economic estimation, if present, must be calculated based in USD. If currency

exchanges are needed, provide the currency rates and its date along

7.

Process Flow Diagram must be drawn on A3 size paper

8.

Plot Plan and Plant Layout must be drawn on A4 size paper with appropriate scale

9.

Include the estimation of revenue (i.e. USD XX,X00,000,000 per year)

10.

Include the percentage of corporate tax that follows the standard set by the
government based on revenue per year

11.

Include detailed data of total investment (total equipment cost, manufacturing cost,
etc.)

12.

Use assumption of 10-year plant life

13.

The construction period is standardized to 2 years

14.

The inflation and interest rate value depend on the country where the plant is
located (also attach the basis of assumptions or facts)

INDONESIA CHEMICAL ENGINEERING CHALLENGE 2015

15.

The value of IDC (Interest During Construction) is approximately 10% per annum

16.

All relevant references must be inserted in Appendix section of the report

17.

Violation of the provisions above will result in score deduction of the report

B.

Report Writing Technical Regulations

The plant design report must be written by using proper UK or US English on A4
size paper with a left and upper margin of 3 cm and 2.5 cm for the lower and right
margins. The report should be written using Times New Roman or Calibri
typeface, 11 pt font size, and a minimum spacing of 1.15. Page numbers are to be
given at the bottom right corner on every pages, including the flow sheet. The
content of the report should be no more than 150 pages (Chapter I until VIII,
excluding appendix, executive summary and table of contents/figures/tables). For
each excess page, there will be 1 point deduction.

C.

Competition Rules
Participants are allowed to design the equipments required in the process or
incorporate either standard or non-standard existing design. Equipment designs
must include the design, working principles, and the calculations used for the
design.

1.

2.

3.

Design Report Format and Requirements

a.

The plant design included in the competition must be original

b.

The design must follow all the requirements stated in this guidebook

Assessment
a.

Assessment will be carried out by international judges drawn from college

academician, industrial practitioners, and others who are determined by
organizing committee

b.

Assessment will be carried out based on the reports submitted by the

participants and the decision of the judges is final and cannot be changed

Final Presentation
a.

Participating teams that are chosen as grand finalists are the top six teams
with the highest overall score

b.

Finalists will be immediately informed by e-mail and phone for further

participation in the Grand Final

PLANT DESIGN 2ND PHASE COMPETITION GUIDEBOOK

c.

4.

10

Regulations regarding the final presentation will be announced in conjunction

with the announcement of the finalists

Miscellaneous
a.

All submitted plant design reports will become the property of IChEC 2015
organizing committee

b.

Only accommodation and transportation of the finalists during the Grand

Final in Bandung will be provided by the organizing committee. Finalists
should provide tickets to and from Indonesia themselves

c.

Further information regarding the Grand Final will be delivered later along
with the finalists announcement.

INDONESIA CHEMICAL ENGINEERING CHALLENGE 2015

APPENDIX
Main Reference:
Turton, R.; Bailie, R.C.; Whiting, W.B.; Shaewitz, J.A. Analysis, Synthesis, and Design of
Chemical Processes 3rd Edition. Boston: Pearson Education, Inc., 2009.
Process flow diagram example of a certain plant section (Turton et al., 2009):

Flow table which shows mass and energy balance from the process flow diagram (Turton et al.,
2009):

PLANT DESIGN 2ND PHASE COMPETITION GUIDEBOOK

11

Preliminary equipment summary table from the process flow diagram (Turton et al., 2009):

Utility flow table from the process flow diagram (Turton et al., 2009):

12

INDONESIA CHEMICAL ENGINEERING CHALLENGE 2015

CP: Kevin (+6281299069168)

ichec.2015@gmailcom
www.ichec-itb.com
@IChEC2015
https://www.facebook.com/IChEC2015

GUIDELINES BOOK

13

IChEC 2015
INDONESIA CHEMICAL ENGINEERING CHALLENGE

Organized by:

14

INDONESIA CHEMICAL ENGINEERING CHALLENGE 2015

Supported by:

2015