School of Chemical and Process Engineering

2023-24

MODULE CODE and TITLE: CAPE1010 Introduction to Process Engineering

ASSIGNMENT TITLE: Design Project I
DEADLINE: 3rd May 2024 @ 2pm
FEEDBACK METHOD(S) and TIMELINE: Feedback on Minerva
ASSIGNMENT VALUE WITHIN THE MODULE: 20%
Set for each section (excluding appendix,
WORD LIMIT:
references and figure captions)

Assignment Learning Outcomes:

a) Demonstrate an ability to define a problem, identify constraints, and defend chosen
design options and decisions taken;
b) Identifying the objectives and context of the design in terms of: the business
requirements and the technical requirements;
c) Evaluate the effectiveness of the design, including its environmental impacts and
process sustainability;
d) Be able to communicate effectively to acquire input information; present the
outcomes of the design clearly, concisely and with the appropriate amount of detail,
including flowsheets and stream data;
e) Be able to work in a team and understand and manage the processes of: peer
challenge; planning, prioritising and organising team activity; the discipline of mutual
dependency.

Description of the assignment:

The design of chemical processes to convert raw materials (feed) into valuable products
(output) is a core skill of a chemical engineer. Chemical engineers must be comfortable
working with limited initial data to work through a problem to propose an optimized design.
The method of design begins by gathering data and information to familiarize yourself with
the process and the process options, before critically assessing the gathered information, and
making informed engineering assumptions to decide on the most appropriate design route.
The process must then by conceptualized as a block flow diagram, highlighting the sequence
of unit operations to transform the feed into a product. With the basic structure of the
process determined, the next phase of the design is to develop a process flow diagram so
that the process streams, major equipment, recycle or bypass lines, waste streams and
process conditions are all identified. The sustainability and environmental impact of the
process must also be considered, and areas of concern mitigated using appropriate
abatement methods in the final engineering design.

Design objective: Propose a suitable chemical process and undertake an initial chemical plant
design for one process selected from the list of nine.

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 # Chemical process /
product manufacture
1 Biodiesel https://www.thechemicalengineer.com/search/?q=biod
iesel
2 Methanol https://www.thechemicalengineer.com/search/?q=met
hanol
3 Citric acid https://www.sciencedirect.com/topics/agricultural-and-
biological-sciences/citric-acid
4 Paracetamol https://www.chemistryworld.com/podcasts/paracetam
ol/6976.article
5 Desalination https://www.thechemicalengineer.com/search/?q=des
alination
6 Titania (paint pigment) https://www.chemengevolution.org/search?q=paint
7 Green ammonia https://www.thechemicalengineer.com/search/?q=gree
n+ammonia
8 PET plastic bottle-to- https://www.thechemicalengineer.com/search/?q=PET
bottle recycling +recycle
9 Paper https://new.abb.com/pulp-paper

Report structure:
1. Title Page
2. Executive Summary
3. Table of Contents
4. Nomenclature
5. Background
6. Process Optioneering and Selection
7. Block Flow Diagram
8. Process Flow Diagram
9. Design Basis and Stream Table
10. Unit Operations
11. Environment and Process Sustainability
12. Conclusion
13. References
14. Appendix

Each section has a word limit: provide a word count at the end of each section and do not
write more than the prescribed word limit. However, please note that the number of words
specified is a maximum but fewer words are also fine, provided that the corresponding
section is complete, clear and coherent. The word limit does not include any graphics or
tables that you will need to add to illustrate the report.

Section (mark) Guidance Word Count /

Page limit
Title Page Project title; group number; names of group members; 1-page
(presentation*) module code; name of project consultant; word count.
Executive Provide a concise summary and a specific statement of 200
Summary (2.5%) your findings for a general audience. Restate the

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 purpose of the design problem, the major findings and
the recommendations from the study.
Table of Contents List the titles and subtitles of the chapters of your 1-page
(presentation*) report and the page they begin on.
Nomenclature and List the symbols used and associated SI units. Provide a 1-page
Abbreviations list of all abbreviations used in the report.
(presentation*)
Background (10%) Provide background information to the design problem. 400
Clearly state the process objective; the materials used
and/or generated in the process (including by-
products); why the process is needed – environmental,
societal, economic; plant location and market served
(size/location); who are the commercial operators of
such processes.
Process Research the various processing routes (up to 3 routes) 1200
Optioneering and for the chemical process. Provide a brief description of
Selection (15%) each process and select the preferred option. Your
choice must be justified based on: the process
conditions (process category [batch, continuous, semi-
batch], T, P); process yields and efficiency; process
chemistry (reactions [list all reactions and associated
conditions], use of secondary materials [catalysts,
solvents etc.]); number and type of unit operations and
the process costs (estimated).
Block Flow Draw a block flow diagram for the selected process. The 1-page
Diagram (5%) diagram must identify the sequence of unit operations,
(all group process flows (feed, product, by-pass, recycle), and
members must process conditions (T, P).
contribute)
Process Flow Draw a process flow diagram for the selected process 1-page
Diagram (15%) using ConceptDraw. The PFD should show the
(all group arrangement and interconnection of all the major
members must pieces of equipment and all flow streams (streams must
contribute) be numbered), and the process units must be
represented using appropriate symbols. The PFD must
also identify the equipment needed to move fluids
(pump, fan, conveyors); heat or cool process streams
(heat exchangers, utilities – steam, cooling water), and
increase/decrease stream pressures (compressor, by-
pass).
Design Basis and The design basis for the material balance of your 2-page
Stream Table process should state the i) production capacity
(15%) (remember the units), and ii) any efficiencies associated
(all group with unit operations and process streams (recycle,
members must purge). These assumptions should be clearly presented.
contribute) Construct a stream table which corresponds to the PFD.
The stream table should include: i) temperatures; ii)
pressures; iii) phases (gas, liquid, solid); iv) stream
compositions and v) flowrates. Remember to include SI
units.

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 Unit Operations For the unit operations identified in the block diagram 1200
(20%) (3 unit operations), briefly describe the action and
chemical engineering science (underpinning principles)
of each unit operation. For the selected process unit
you are required to include a schematic showing its
configuration identifying process streams in and out,
and exterior/interior ancillaries.
Environment and Discuss the environmental impact of your process. 800
Process Consider the chemicals used (amounts and availability),
Sustainability the products and wastes generated (amount and
(10%) potential abatement technologies), and the sources for
carbon emissions. Undertake a preliminary costing of
your process, which should consider plant capacity and
the type of processing facility.
Conclusion (2.5%) The conclusion should be a summary of the main 300
design outcomes. Plant location, capacity and
attainment; rationale behind process selection; any
requirements for waste management and abatement
technologies; main process units needed to produce
the product; the market served (regional, size); and an
estimate of the process cost should all be discussed.
References You must provide a list of references detailing the
(presentation*) literature you used as sources of information for your
project. References must clearly identify the source
material and should be appended to the text of the
report using numerical style. At the appropriate
location in the text, identify the cited reference by its
number in the list of references. Be sure to follow the
guidance you have received throughout the semester on
avoiding plagiarism!
* General presentation = 5%

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Further information:

i) Report formatting:
Report MS Word
Page layout Normal margins (2.54 cm), portrait
Block flow diagram and process flow diagram
can be in landscape page layout.
Text Times New Roman or Calibri (not both)
Text size 12 main text; 14 + bold titles; 12 + bold sub-
titles
Line spacing 1.5 for main text
Line spacing (figures and 1.0
tables)
Figure and table numbers Bold text
References Numerical style
Paragraphs Leave one space between paragraphs
Units SI

ii) Project milestones: In order to work efficiently and to complete the project
successfully, you will have to work as a group and take up individual
responsibilities as appropriate for the project.

It is important that you keep track of your work and the work of your colleagues in
the group. This is best done through weekly project meetings. The group should
initially elect a meeting chair and keep this post rotating round group members
during the course of the project. You should discuss the aims and progress made
in the project at weekly meetings. Furthermore, the discussions at these meetings
should be documented by recording meeting minutes. A template for meeting
minutes is attached in the Appendix. All the meeting minutes must be placed in
the Appendix of the final group report submission. In the group meetings, you
should also discuss how to split the work between you. These are the list of
suggested milestones to ensure your project is on track:

• Week 6/7 – Make contact with your group, discuss the design project
assessment brief, establish a team working culture (dates of group meetings,
channels of communication, data sharing methods within the group).
• Week 8/9 – Research different process routes and alternatives (optioneering),
for the process you have been asked to design. Identify the process route you
want to design with justification and draw the block diagram of the selected
process.
• Week 10 – Present your BFD for formative feedback. This needs approval by
the consultant to continue the project.
• Week 14/15 – Draw the PFD and complete the material balance calculations
for the process. Your calculations should be presented in the stream table.
• Week 16 – Present the PFD and stream table for formative feedback from the
consultant.

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 • Week 17/18/19 – Complete ‘Background’, ‘Process Optioneering and
Selection’ and ‘Unit Operations’ chapters of the report.
• Week 20 – Discuss progress with the consultant and present your initial ideas
for completing the ‘Environment and Process Sustainability’ chapter.
• Week 21/22 – Complete all remaining chapters of the report.
• Week 23 – Assemble final report with final edits made, and complete your
individual reflective summary using the provided template.
• Week 23 Friday 3rd May 2 pm – Submission of final report.

iii) Group consultancy and mentoring: Based on the specific chemical process being
designed, your group will be assigned a consultant. The consultant will be a
member of the module teaching staff and will guide you through the technical
aspects of your process design. The consultant will advise on how to approach
problems you will encounter in the process.

There are three 1-hour long consultancy sessions scheduled during the course of
the design project (tentatively scheduled in Weeks 10, 16 and 20). Outside of the
support provided during these consultancy sessions, you are expected to work
individually and as a group to address any challenges that arise during the project.
However, should you require further support, you will need to have one member
of your group contact your consultant to arrange a mutually acceptable meeting
time. You should meet as a group prior to a meeting with the consultant and
prepare the questions you would like to ask them – this will ensure best use of
your time with your consultant.

iv) Assessment and submission: One student must upload the final report on behalf
of the group to the Minerva Turnitin submission box. No hard copy is required. A
penalty for going over the word limit will also apply as follows – 10% of the total
marks if the word count is over 10% and up to 20% of the limit set. If the word
count is over 20% of the limit set, a mark of 0 will be awarded.

Late submissions: The Faculty’s standard late penalties apply: for every period of
24 hours or part thereof that your assessment is overdue, you will lose 5% of the
total marks available for the assessment component.

v) Academic integrity and plagiarism: As this is an online submission, there is

confirmation that when you submit you are completing a Statement of Academic
Integrity. The statement reminds you of the University’s definition of plagiarism
and in signing the form (in this case, clicking the check box to confirm acceptance)
you are confirming the work you have submitted is entirely that of your group.

vi) Assessment criteria: For the design report to be marked, every group member
must submit their reflective summary. Although you will submit a group report,
you will receive an individual mark for the project.
Your individual mark will be calculated from:
• The author contributions declaration (use template provided in Appendix)
signed by all group members and submitted as part of the group report

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 • Individual mark modulation based on peer assessment done using Buddycheck
on Minerva (see point viii).

The assessment rubric that will inform the marking of these report sections in
provided below. For the general presentation of the report, the following points
will be assessed:

• Title page contains all requested information.

• List of contents fits on one page and gives accurate information.
• Free of grammatical/spelling errors.
• Structure of the report follows guidelines.
• SI units are used and always shown in the data.
• Titles and legends of figures always given and appropriately positioned.
• References are well balanced (between websites, textbooks and journal
articles) and appropriately expressed.
• Word Count is indicated for all sections and follows the guidelines.
• Writing style is suitable for an academic report.
• All minutes of the meetings and author contributions declaration present in
the appendices.

vii) Marks rubric: All written work will be considered for English competency:
• Paragraphs are used;
• There are links between and within paragraphs although these may be
ineffective at times;
• There are attempts at referencing;
• Word choice and grammar do not seriously undermine the meaning and
comprehensibility of the argument;
• Word choice and grammar are generally appropriate to an academic text.
This is a pass/fail aspect of the report.

Sections Level of Achievement

and Fail III II/2 II/1 I
weightage (0-39) (40-49) (50-59) (60-69) (70+)
Background Poorly organized with Acceptable Reasonable Mostly well organized Exceptional and orderly
(10%) content lacking detail, organisation and organisation and and an appropriate presentation and well-
incorrect information covers most of the structure. Project structure. Mostly referenced. Project
and displaying little to required content but background is appropriate content background is presented in
no understanding of displaying only a explained but with
with references used. a logical manner,
the project limited many minor Project background is demonstrating extensive
background understanding of the inaccuracies explained but background reading and
subject matter without a thorough understanding of the
understanding of the subject matter
subject matter
Process Process route options Process route Process route Well-written Exceptional orderly
Optioneering are not or options are options are presentation and presentation and analysis
and Selection incompletely presented but presented with few analysis of process of process route options
(15%) presented. Process content lacks inaccuracies and route options collated from diverse
selection and rigor. Process collated from few collated from diverse references. Process
justification is not selection and resources. Process references. Process selection is justified with
presented or if justification selection and selection is presented technically sound
presented, presented on the justification and justified by arguments and presented
demonstrates

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 represents poor basis of limited evidence of some writing of a good by writing of a very high
understanding. understanding. misunderstanding. academic standard. academic standard.
Block flow No diagram or a Diagram only meets Diagram is missing Well-drawn diagram Accurate and thorough
diagram diagram with many the basic some of the required containing all the diagram of a very high
(5%) major errors requirements and information and has required information standard containing all the
representing poor represents limited minor inaccuracies but with few minor required information
understanding understanding inaccuracies
Process flow No diagram or a Diagram only meets Diagram is missing Well-drawn diagram Accurate and thorough
diagram diagram with many the basic some of the required containing all the diagram of a very high
(15%) major errors requirements and information and has required information standard containing all the
representing poor represents limited minor inaccuracies but with few minor required information
understanding understanding inaccuracies
Stream Table No stream table or a A stream table A stream table A comprehensive A comprehensive stream
(15%) stream table that missing several displaying streams stream table table displaying all streams
misses most of the streams and/or labelled displaying all streams labelled appropriately with
necessary labelled incorrectly appropriately but labelled appropriately accurately calculated
information or a and many major with many minor or but with few minor stream compositions based
stream table that inaccuracies in some major inaccuracies in on mass balances,
demonstrates very calculated stream inaccuracies in calculated stream temperature, pressure and
poor understanding compositions based calculated stream compositions based phase information
of material balance on mass balances, compositions based on mass balances,
calculations, inappropriate on mass balances, temperature,
temperature, temperature, temperature, pressure and phase
pressure and phase pressure and phase pressure and phase information
information information information
Unit Poorly written The presentation of The action, options The action, options The action, options and
Operations incomplete action, options and and selection of each and selection of each selection of each unit
(20%) presentation of selection of each unit operation is not unit operation is operation is articulated by
action, options and unit operation is presented articulated by writing writing of a very high
selection of unit incomplete or coherently and of a good academic academic standard. The
operations. No or contains many contains standard. The presentation is well-
poorly drawn inaccuracies. The inaccuracies. The presentation is well- referenced and
schematics. accompanying accompanying referenced and complemented by
schematics are schematics do not complemented by comprehensive and well-
incomplete and contain all the good schematics drawn schematics.
contain many required information containing most of
inaccuracies. / has inaccuracies. the required
information.
Life Cycle No system identified System identified but System identified System identified and System identified and the
Assessment and limited limited and the the environmental environmental impacts of
and understanding of the understanding of the environmental impacts of the the proposed process are
Sustainability environmental environmental impacts of the proposed process are identified and discussed,
(10%) impacts of the impacts of the proposed process identified and with the pseudo-
proposed process. proposed process. are identified and discussed, with an quantitative assessment
discussed, but the attempt to provide being accurate and to a
assessment remains pseudo-quantitative professional engineering
qualitative. assessment. standard.
Executive Executive summary Executive summary Executive summary Well-written Concisely written executive
summary and and conclusions and conclusions and conclusions executive summary summary and conclusions
conclusions sections are missing sections contain sections contain and conclusions sections that are of a very
(2.5% each) or are presented with factually inaccurate factually accurate sections that are of a high academic standard
very poor statements and the statements but an good academic highlighting the project
understanding. project aims, incoherent standard highlighting aims, approach, findings
approach, findings presentation of the the project aims, and conclusions with each
and conclusions are project aims, approach, findings of these
superficial or approach, findings and conclusions but
presented in a and conclusions, with excessive
manner suggesting lacking clarity and numerical details
knowledge gaps consistency. and/or minimal focus
on points of
importance

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General Extremely messy Writing style that has Writing style of a Writing style of a Writing style of a very high
presentation presentation lacking a basic structure but reasonable academic good academic academic standard
including title in basic structure many standard and minor standard, Chapter demonstrating
page, table of with an inarticulate grammatical/spelling grammatical/spelling sections of professional
contents, writing style, several errors, Chapter errors , Chapter appropriate communication skills,
nomenclature missing chapters or sections are not of sections of length, Title page Chapter sections of
and references chapter of very appropriate acceptable containing all appropriate length, Title
and appendix inappropriate lengths, Title page lengths, Title page requested page containing all
(5%) lengths, Missing or containing all containing all information, Table of requested information,
inappropriate title requested requested contents listing Table of contents listing
page, Table of information, Table of information, Table of accurate information, accurate information, a
contents, and contents listing contents listing a comprehensive comprehensive
nomenclature inaccurate accurate nomenclature nomenclature section,
sections, no information, a information, a section, references references are well-
references and nomenclature comprehensive are appropriately balanced and appropriately
appendix section, only few nomenclature expressed, all expressed, comprehensive
references are section, references meeting minutes and meeting minutes and
expressed / are appropriately individual author individual author
references expressed, meeting contributions contributions declaration
expressed with minutes and declaration present present in the appendix
inconsistencies, individual author in the appendix
incomplete contributions
appendix declaration present
in the appendix

viii) Peer assessment: It is important for engineers to work well in groups and teams.
The peer assessment is an opportunity to reflect on the contributions to the group
research project by your group members and yourself. Peer assessment will be
done using the ‘Buddycheck Pilot’ feature available on the Minerva page for this
module.

Two rounds of peer assessment will take place: the first peer assessment will take
place after the consultancy in Week 10. The second will take place in Week 23
after the report and reflective summaries are submitted.

In each round of peer assessment you will be asked to rate the contribution of
your group members and yourself in the relevant working period. You have to rate
each individual’s contribution on a scale of 1 (lowest) to 5 (highest). Please note,
that if you do not submit your peer assessment, you will lose 1 mark from your
peer assessment score, however you cannot score less than 0. Please see the
details below for how you are expected to rate contributions.

Criteria Rating
1 2 3 4 5
Score the Minimal Some Has appropriately Very good Excellent contribution
contribution contribution, has contribution, has contributed to the contribution to to the group. This
of the group responded to responded to group, however the group. group member not
member over some some either only is excellent with
communication communication, communication, their communication,
the relevant
but not attended however had attendance or attendance and quality
period of meetings or met unexplained quality of work of work, but also
time internal group absences or poor- could be improved. supports other group
deadlines. quality work. members / encourages
all to contribute.

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Appendix: Minutes of Group Meetings

(A similar style can be used and all meetings minutes have to be placed in the Appendix of the group
report submitted)

Group Number:

Names of Students:

Title of Project:

Date of Last Meeting: Date of Current Meeting:

Progress:

Aims for next meeting:

Name of person recording minutes: Date:

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Appendix: Author Contributions Declaration

All members of the group are expected to contribute equally to the project. The table below needs to
be used to evidence the contribution of each individual in the group project. For each ‘Report section’
in the table below, the sum of individual contributions % must equal 100%. By signing off this
declaration, you testify that the specified contribution% is a fair reflection of the work done by every
individual in your group.

Report section Student names Individual Signatures

Contribution %
Background

Sum total: 100%

Process Optioneering and
Selection
Sum total: 100%
Block Flow Diagram
(all group members must
contribute) Sum total: 100%
Process Flow Diagram
(all group members must
contribute) Sum total: 100%
Design Basis and Stream
Table
(all group members must Sum total: 100%
contribute)
Unit Operations

Sum total: 100%

Environment and Process
Sustainability
Sum total: 100%
General presentation and
other parts of the report
(title page, executive
summary, table of
contents, nomenclature,
conclusion, references and
appendix) Sum total: 100%
General presentation and
other parts of the report
(title page, executive
summary, table of
contents, nomenclature,
conclusion, references and
appendix) Sum total: 100%

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