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PDP3702 Report Note

Design Principles

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PDP3702 Report Note

Design Principles

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unisamodules5
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Chemical Process Design Project

Conceptual Design

Taile Leswifi

Chemical Engineering
Introduction

• Plant design
– Design basis
– Literature survey/review
– Process Description
– Process Simulation
– Process Flow Diagram
– Equipment list
– Environmental Aspects
– Cost Analysis
Introduction

• Equipment design
– P&ID (MFD)
– Control philosophy
– HAZOP study
– Instrument list
– Reactor design
– Equipment design (heat exchange or separator)
– Pump datasheet
– Utility requirement schedule
Introduction

Design is generally divided in 5 primary sections

• Conceptual design

• Basic Engineering Package (BEP)

• Detailed Design Package

• Construction and Commissioning

• Operation
Conceptual Design

• Includes pre-feasibility, feasibility, technical feasibility,


etc.
• Comprised of Block Flow Diagram (BFDs) with some
idealised mass and energy balances.
Basic Engineering Package (BEP)

• More detailed than the conceptual design.


• Includes:
– Full process flow diagram
– Mass and energy balances
– Sizing of all process units
– All process P&ID
– Hazop on all units
– Full profitability and cost anaylysis
Basic Engineering Package (BEP)
Assignment 1 Report Structure
➢ Cover page: Title page
➢ Declaration
➢ Acknowledgment
➢ Executive summary
➢ Table of Contents
➢ Design Basis
➢ Literature review
➢ Process Description
➢ Process Flow Diagram
➢ Process Simulation
➢ Equipment list
➢ Conclusions
➢ References
➢ Appendices (if any)
Report Structure

• Title page
Module name & code, project title, your name, student
number and submission date.
• Declaration
A signed statement stating that the project is your own
work.
• Acknowledgement
This is where you than all contributors who have
assisted you while working on the project.
Executive Summary/
Abstract
• Abstract provide a brief summary of the report.
• Short review of the essential contents of the report.
• It should not review the report, by should rather act
as a sampler of the contents of the report.
• Focuses attention on the important aspects of the
report:
➢ Purpose
➢ Objectives
➢ Methods
➢ Findings/results
➢ Conclusions and recommendations
Report Structure
• Table of Content
Contains a list of divisions and subdivisions in the report
with their page number.
• Design Basis
The Design Basis is a statement of how a design will be
performed.
State what your plant will be able to produce and the
expected purities.
➢ Mass basis
➢ Energy basis
➢ Over design allowance
Design Basis
Mass balance basis
• Plant capacity
– How much product are you going to make?
– It could also be how much feed needs to be used
up.

• What are you going to use to make the


product?
– Is your feed Natural Gas? What is Natural Gas,
what is its composition.
– Do you require other feeds? E.g. water, air, etc?
Design Basis

• Energy basis
– Are you using a simulation program? What is its
basis temperature?

– What is ambient temperature? If you are using nay


kind of air cooling.
Design Basis

• Design Philosophy
– This is a statement of the overall goal and approach of the
design

– For example
• The design philosophy may be to only use well established
technologies to ensure the technical feasibility of the project.

• Another philosophy may be to investigate new and untested


technologies to meet other challenges (like environmental)
– For instance, the design philosophy might be to design a process that
emits no/minimal CO2. Another might be to design a process that does
not use water.
Design Basis

• Overdesign Allowance/Safety Factor


– It is not possible to design with 100% accuracy.
– Processes are designed a little bit bigger (just in
case)
– It is better for a unit to be a little bigger and more
expensive but works than to be too small and
cheap and not work at all.
– How much bigger will you design? 10%, 30% or
100%?
Literature Review

• Give a background of the project, what is currently


being done, what are the different technologies being
used, advantages, disadvantages, etc.
• Expected to cover the following important aspects:
➢ What are you doing and why are you doing it?
➢ How is it done?
• Try to make critical evaluation of what you read (is it
good, is it bad? Give reasons).
• Important to reference (Avoid plagiarism by all
means).
Process Description

• Describe in words how your intended design is


meant to function.
• It should be read in conjunction with the PFD.
• It should describe the functions of the different
equipment as well as how they interact.
Process Description
Example of Process description (Turton et al.,1998)
Fresh toluene, Stream 1, is combined with recycled toluene, Stream 11, in the storage tank, V-101. Toluene from the storage
tank is pumped, via P-101, up to a pressure of 25.8 bar and combined with the recycled and fresh hydrogen streams, Streams
3 and 5. This two-phase mixture is then fed through the feed preheater exchanger, E-101, where its temperature is raised to
225°C, and the toluene is completely vaporized. Further heating is accomplished in the heater, H-101, where the temperature
of the stream is raised to 600°C. The stream leaving the heater, Stream 6, enters the reactor, R-101, at 600°C and 25.0bar. The
reactor consists of a vertical packed bed of catalyst, down through which the hot gas stream flows. The hydrogen and toluene
react catalytically to produce benzene and methane according to the following exothermic reaction:

(NB: I have put the PFD here so that you can easily follow the description, In your case it will be in the PFD section)
Process Flow Diagram
(PFD)
• The process flow diagram is intended to display
and explain the basic material and energy
balance of the process.
• Concisely, it has to illustrate the principal steps,
flows and equipment employed to bring about the
design together with the table detailing the flow
streams, their properties and compositions
Process Flow Diagram (PFD)
• The basic information provided by a PFD can be categorized into one
of the following:
• Process topology - diagram illustrates the location of the major pieces of
equipment and the connections that the process streams make between
equipment (can draw using Microsoft Visio, COCO output PFD is
acceptable or software you comfortable using, even a neat sketch by hand
will be acceptable but not encouraged).
• Stream information - each of the process streams is identified by a
number. One or more arrowheads identify the direction of the stream.
• Equipment information - each major piece of process equipment is
identified by a number on the diagram. A list of the equipment numbers
along with a brief descriptive name for the equipment is printed along the
top of the diagram.
Process Flow Diagram (PFD)

• Example of PFD (Turton et al.,1998)


PDF: Mass and Energy Balances

• Mass balances/Material balances show the


composition and flow rates of your streams

• Energy balance give information on the quantity of heat


in streams in a chemical plant and their temperatures.
Energy balance are also made over individual items of
equipment (e.g., reactor, heat exchanger)

• Important: both mass and energy must be conserved


Mass and Energy Balances
• Example of mass and energy balance.

Equipment
Equipment Description Heat Requirements (kJ/hr) Work Requirements (kJ/hr)
Number

P-101 Toluene Feed Pump

E-101 Feed Preheater


H101 Feed Heater
R101 Reactor
Process Simulation
It is very important in this module that you demonstrate that you are
able to use a simulation software.
• In our case simulation simply means running a computer software
in an effort to mimic how your plant would perform in a ‘real life
situation’
• At this point you should have read your literature and understood
clearly your design (meaning understood the conditions under
which your different units will be operating, you must have an idea
of your preliminary PFD)
• Need to specify which thermodynamic model used, need to show
how variables like temperature, pressure, conversion, recycles etc.
affect your process.
• Need to justify decisions made
Process Simulation

There are two important and interrelated


elements in chemical process design
• Process simulation
➢For this process, the process flowsheet and inputs
are given. The aim is to predict the outputs of the
process.
• Process synthesis
➢Process input and output are given. Process
flowsheet to be created.
Process Simulation

(Dominic et al., 2017)


Equipment List

• Compilation of all the equipment


• List is developed directly from the detailed flow sheet. Each
equipment shown on the flow sheet should appear on the
equipment list. The symbols assigned to each piece of
equipment are included on the equipment list to provide cross
referencing between the list and the detailed flowsheet.
• Normally the equipment list contains parameters that will
make it easy for costing the equipment.
• At this point your list must contain, equipment, material of
construction and energy requirements
Equipment List: Example

Mulaudzi N., 2020


Report Structure
Conclusion
• Summary of what you have done.
References
• List all your references, use Harvard
referencing style
Appendix
• Have all calculations and information needed
to clarify anything in the main report.
Harvard Referencing Style
Mark Allocation
All assignments must first be submitted on Turnitin and
then be submitted online (myUnisa).

• Design basis 5
• Literature review/survey 15
• Process Description 15
• Process Simulation 25
• Process Flow Diagram 25
• Equipment list 5
• Overall Presentation 10
TOTAL 100
Very Important
• Please let us know when you encounter any difficulties.
• Use myUnisa (discussion platform) to ask anything
related to the module/project.
• DO NOT USE EMAILS AS A DISCUSSION
PLATFORM. Make use of myUnisa.
• Remember myUnisa is our classroom. Questions and
answers on myUnisa discussion platform will help
other students who might be having the same problem
as you.
Recommended textbooks

• Chemical Engineering Design: Principles,


practice and economics of plant and process
design.
– By: Gavin Towler & Ray Sinnott

• Coulson and Richardson’s Chemical


Engineering Design: Volume 6
– By: R K Sinnott
Recommended textbooks

• Basic Principles & Calculations in Chemical


Engineering
– By: David M. Himmelblou & James B. Riggs

• Analysis, Synthesis, and Design of Chemical


Processes
– By: Richard Turton, Richard C. Bailie, Wallace B.
Whiting & Joseph A. Shaeiwitz
Recommended textbooks

• Elementary Principles of Chemical Processes


– By: Richard M. Felder & Ronald W. Rousseau

• Element of Chemical Reaction Engineering


– By: H Scott Fogler

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