CBB 3024 PROCESS PLANT DESIGN

4 Credit-Hour Core Course Semester May 2011

Lecturer :
Lecture Time Location

Assoc. Prof. Dr. Mohamed Ibrahim Abdul Mutalib Dr Balasubramanian Periyasamy

: Mon 10 am 12 noon ; Tues 10 am 12 noon : Thurs 10 am 12 noon ; Fri 8 10 am : 21-01-04 ; 01-02-02 LT C6 21-02-07

PROGRAMME OUTCOMES UTP CHEMICAL ENGINEERING

1 2 3

Acquire and apply knowledge of basic sciences and engineering fundamentals

Acquire and apply Chemical Engineering principles and in-depth technical knowledge
Ability to design, optimize and operate processes Undertake problem identification, formulation and solution by considering the concept of sustainable development Comprehend social, cultural, global and environmental responsibilities of a professional engineer, and the need for sustainable development Communicate effectively in a professional context Exhibit professional and ethical responsibilities Demonstrate leadership, business acumen and entrepreneurship Demonstrate the capability to undertake lifelong learning

4
5 6 7 8 9

COURSE OUTCOMES CHEMICAL PLANT DESIGN

K 3 CO1 Integrate knowledge from previous chemical engineering courses in designing a chemical process system Apply conceptual process design and synthesis tools in designing a chemical process system Apply a systematic approach or method to design a chemical process system S A

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO3 PO9 PO7 x x x

CO2

CO3

K Knowledge S Skill A Attitude

Course Content, Delivery & Assessment

Lec. No. 1-2 Topic Introduction to Plant Design and Economics (Approaches and Stages of Process Design)
Quiz 1 3-4 5-8 General Plant Consideration (Plant Layout/Utility System) Synthesis of Reactor Separation System (Fundamentals and Selection of Reaction System & Separation System) Synthesis of Reactor Separation System (Fundamentals and Selection of Reaction System & Separation System) Assign 1 Test 1 Assign 1 Quiz 2 Test 1 Dr Ibrahim Dr Ibrahim

Assessment

Lecturer Dr Ibrahim

9-12

Dr Ibrahim

13-16 17-20 21-24 25-28

Synthesis of Reactor Separation System (Process Recycle and Distillation Sequencing) Heat Integration (Composite Curve & Heat Recovery Pinch, Problem Table Algorithm) Heat Integration (Grand Composite Curve & Multiple Utilities) Heat Integration (HEN Design)

Assign 1 Test 1 Assign 2 Test 1 Assign 2 Test 1 Assign 2 Test 1

Dr Ibrahim Dr Ibrahim Dr Ibrahim Dr Ibrahim

Lec. No. 29-32 33-36 37-40 41-44

Topic Process Flowsheeting (Flowsheet Synthesis & Simulation, Model Formulation, Solution Strategies) Economics of Chemical Plants Equipment Design & Specification (Material Transfer & Handling, Mass Transfer Equipment) Equipment Design & Specification (Mass Transfer & Reactor Equipment)

Assessment Test 2 Quiz 3 Assign 3 Test 2 Assign 3 Test 2

Lecturer Dr Bala Dr Bala Dr Bala Dr Bala

45-48 49-52 53-56

Equipment Design & Specification (Pressure Vessel Design) Environmental Studies & Consideration Effluent Treatment, Waste Minimisation and Life Cycle Analysis Plant Wide Control (Material & Quality Control, Pairing of Variables in MIMOS, Typical Unit Operation and Control Strategies)

Assign 3 Test 2 Quiz 4 Quiz 4

Dr Bala Dr Bala Dr Bala

Assessment :

Quizzes 4 (5 %) Tests - 2 (20%)

Assignments - 3 (5%) Final Exam - 1 (60%)

Project - 1 (10%)

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 Process Design 1995)

Raw Materials + Other Feeds

CHEMICAL PROCESS

Products + Wastes

Energy

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

Products + Wastes

Energy

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. (Douglas, Conceptual Design of Chemical Processes 1988)

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 No. of stages for contact Heat Transfer Area Needed

2. Vessel Mechanical Design

Internal Design Wall thickness

Support Design

Pipe fittings & Reinforcement

The 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

Risk Assessment Matrix

Overall Plant and Equipment .

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

FEED

REACTOR
PRODUCT 1

CW Str1 F T P x H Str2 Str3 Str4 Str5 Str6 Str7 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)

Now, what criteria should be adopted besides economics during the design activities?

1. ADDRESS THE INDIVIDUAL PROCESS/TRANSFORMATION STEP

RECYCLE

STEAM
FEED

REACTOR
PRODUCT 1

CW

FLOWSHEET

PRODUCT 2

2. ADDRESS THE REQUIRED INTERCONNECTION BETWEEN THE STEPS

QUANTIFIABLE FACTOR ! MINIMISE COST

VERSUS

NON - QUANTIFIABLE FACTOR ! HIGH SAFETY & INTEGRITY GOOD OPERATIONAL ASPECTS

MINIMISE WASTES GENERATION

MINIMISE ENERGY CONSUMPTION

..... BUT HOW TO OPTIMISE ?

Consider back the flowsheet !

RECYCLE

STEAM

FEED

REACTOR
PRODUCT 1

CW

PRODUCT 2

OPTIMISING A SINGLE UNIT/STEP IN THE PROCESS EG. DISTILLATION COLUMN

TOTAL COST

OPTIMISING THE INTERCONNECTIONS BETWEEN THE UNITS/STEPS IN THE PROCESS

MANY POSSIBLE CONNECTIONS WHICH LEAD TO DIFFERENT STRUCTURES OF FLOWSHEET THUS DIFFERENT ECONOMIC IMPACT EVEN TO THE EXTENT OF THE INDIVIDUAL UNIT ITSELF!

RR --> ENERGY

RR

RR --> CAPITAL

CONTINUOUS FUNCTION

DIS-CONTINUOUS FUNCTION

PARAMETER OPTIMISATION

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"

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"

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

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

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
Disadvantages

HEAT EXCHANGER NETWORK

UTILITIES

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

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.

UTILITIES

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 Disadvantages

other process alternatives

Semester July 2004

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 Reactor Distillation

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

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

Remove or attenuate conditions that could lead to the 3 incidents such as high P and T ..

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

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)

Reactor Increase conversion if selectivity is not an issue Product removal for reversible reaction favoring product Set T & P to improve selectivity Distillation Recycling waste stream to suppress by product reaction Feed purification Eliminate use of extraneous material for separation (entrainer) Waste stream recovery Improve heat recovery

Waste Treatment
Air Effluent Particulate, CO2, CO, SOx, Nox Gravity Settlers, Inertial Collectors, Scribbers, Filters, Electrostatic precipitators, catalytic reaction etc. Water Effluent Membrane, Adsorption, Absorption, thermal oxidation, biological treatment, membrane separation etc.

Finally ..

You will develop the construction details for a process plant .