Introduction to process design
The word 'Plant design' to a chemical engineer means various engineering activities undertaken for
the over-all design of either a new process plant or expansion or revamping of an existing plant.
These activities would include:
• evaluation of new processes and available alternatives at different design stages,
• designing of individual pieces of equipment and unit,
• evaluation of competitive bids for equipment and services or developing a plot plan .
A chemical engineer who is often referred to as a design engineer or a process engineer has to
examine the economic aspects of the design as well as to undertake the actual design of equipment
and facilities necessary for the production process. The term 'Process engineering', in many
instances, refers to economic evaluation and analysis of industrial processes . Baasel has termed
process engineering as 'the procedure whereby a means of producing a given substance is created or
modified' . Therefore, it encompasses different aspects of chemical process plants with emphasis on
the development, evaluation and design of a process.
A process engineer is expected to perform these routinely :
1. To study processes and options for manufacturing different products or improvements or
changes in operating plants.
2. To prepare techno-economic studies (engineering studies) associated with project.
3. To design and/or specify equipment or units required as per the process flow sheet.
4. prepare bid documents.
5. To evaluate competitive bids of equipment, services, etc.
6. To evaluate operating data of existing plant or test equipment/units.
7. To prepare or guide the preparation and compilation of engineering documents including
drawings.
8. To develop tests and to interpret data and information from pilot plant and research
laboratory.
"Process design, on the other hand, refers to aspects of engineering and design undertaken for
completing a process plant project. Process design is a well defined group responsibility in the
organization of an engineering contractor while a production company may or may not have such
group depending on how it gets involved in the engineering of a project.
Process design scopes includes the following
1. Mass and energy balances of the process
2. Development of processing strategy and compilation of design data and parameters
3. Mass and energy balances for auxiliary units and services
4. Basic engineering
5. Process calculations for individual equipment and unit to develop data sheets along with
mechanical design criteria
6. Development of P& ID to have a safe and operable process
7. Process interpretation for mechanical, structural, civil, electrical, and instrument design
8. Preparation of equipment specifications in line with engineering specification in sufficient
detail for use by the project team as well as for the procurement purpose
9. Evaluation of bids and selection of competent vendors and suppliers
10. Review and approval of all engineering documents for the project
Definition of a process plant
A plant design project begins with its definition. In its broadest meaning, the definition states the
scope of the project. Without the scope, the project remains unspecified. This is certainly necessary
for assessing the project cost right from the beginning.
Before initiating the detailed design, the need which has given rise to primitive and specific
problem has to be examined on the basis of technical and economic considerations. A feasibility
study or survey consisting of technical and economic aspects including potential market conditions
for the particular product and raw material will indicate the probable success of the project and also
establish what additional data and information are required to complete the evaluation.
A feasibility study is to include the following :
1. Raw materials. ( sources, quantity, quality, cost)
2. Process know-how and alternative production technologies
3. Facilities and equipment available
4. Facilities and equipment to be procured
5. Production costs and total investment
6. Profits and profitability analysis
7. Materials of construction
8. Safety considerations
9. Market (possible and potential, price trend of products and by-products, distribution of
customers)
10. Competition (overall, specifications of available products, equivalent products)
11. Product specification (chemical and physical specifications, impurities, shelf life)
12. Sales and sales services
13. Shipping restrictions and containers
14. Plant location
15. Process licensing and related legal matters
16. Environmental impact assessment (EIA)
Items 9 through 13 are to be considered for a complete market analysis. While undertaking the
feasibility study, it is essential that a detailed study is made on comparison of different processes,
plant location and process cycle.
Location of a plant can be a decisive factor in determining the economic success of a process
plant. The factors which usually influence the selection of a plant site include :
1. raw materials,
2. markets,
3. utilities availability,
4. climate,
5. transport facilities,
6. water supply,
7. waste disposal,
8. labor supply,
9. site characteristics,
10. flood and fire protection,
11. community factors,
12. taxation,
13. legal requirements and environmental considerations
