A New Ebook - Chemical Engineering Plant Design Project, How To

Reflections on how to excel in doing a chemical plant design project
Contents
1
Why this short book?............................................................................................3
Chapter One.........................................................................................................5
The literature survey............................................................................................5
Chapter Two.........................................................................................................9
Process and Raw Material Selection.....................................................................9
Chapter Three.....................................................................................................12
Material and Energy Balances............................................................................12
Chapter Four ......................................................................................................17
Equipment Sizing and Selection.........................................................................17
Chapter Five ......................................................................................................19
Detail Design of Equipment................................................................................19
Chapter Six.........................................................................................................21
Financial and Economic Analyses.......................................................................22
Chapter Seven....................................................................................................25
Site Selection and Plant Layout..........................................................................25
Chapter Eight .....................................................................................................26
Environmental Impact Analysis..........................................................................26
Chapter Nine .....................................................................................................27
Writing the References.......................................................................................27
Chapter Ten .......................................................................................................28
Presentation and Defense..................................................................................28
Appendices.........................................................................................................30
Writing and grammar..............................................................................................................30
Format of Project ....................................................................................................................31

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Writing the Abstract.................................................................................................................32
Work plan and habit................................................................................................................33
Planning Experiments..............................................................................................................34
Project ideas............................................................................................................................35
Searching the internet.............................................................................................................36
Similar ebooks and undergrad/Grad thesis Library at

https://sites.google.com/site/ethiograd123/
Ethiograd123 Services
• SCHOLARSHIP resources
• Project / Thesis ideas
• Sample projects and formats
• Process flow sheets and description
• Hints on successful project writing
• Questions and Answers
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• Access to Publication sites
• Grad/Undergrad thesis library
• Some projects explained
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https://sites.google.com/site/projectethio/
Why this short book?
3
The main reason behind writing this short book is to share some vital insights I
have developed over the four years as a final project advisor, evaluator and
lecturer. It is not intended to repeat what you have been taught but to
reflect on them. During the last three years I have advised at least three
projects a year in total 9 projects not to mention 10 projects I have co-advised.
Also I have evaluated at least nine projects for last three year. I have advised
students from top five students to bottom five students.
Final year project grade plays a key role in someone’s professional life may be
much more than the theme of the project itself. Plant design projects are unique
in this way as they require sound understanding of major courses like mass and
energy balance, mass transfer concepts, economic analysis etc. Excellent
project grade shows very good understanding of the subject matter
and even more her problem solving ability and research potential.
Over the years, unlike other departments, project grades of the chemical
engineering department (BDU) have changed. They are not like 90-95% 'A'. I
have seen them evolve to more like regular course grades. Therefore,
projects needs much more understanding and smart effort. This short
book gives proven ideas in each section of the project. Note that application of
them leads to much more success.
Each chapter ends with useful books, software tools and web pages that can
assist you in doing your projects. This avoids running around looking for data.
Furthermore, various insights into each section of plant desing are presented.
Putting the insights into action is the vital step. Enjoy reading the rest of
the chapters which give you ideas from project ideas, writing the introduction to
presentation and defence.
4
Chapter One
The literature survey
The literature survey is best written if it is designed to contain the atleast the
following information; history and background, problem statement,
methodology and objectives. More contents are listed on the ´´format of a
project`` section.
History and background: It reviews previous literature on related topics of

the main research idea. Note that you should write only relevant information.
Don´t fall in the trap of stating every trivial but non impotant texts just because
you like them or want to increase your thesis volume.
For a plant design project, the best contents are short description or
introduction, chemical formula, chemical and physical properties, application
and uses, source of raw materials and the current and future demand and
prices. (Market study)
Market study is the crucial part of the literature survey as it later determines
the proper size of the plant and the selling price of the product. It contains
present demand and supply, priccing and distribution and projected demand.
The later could be made based on the past and current price trends if figures
are availble. Also, it can be estimated from expected future scenarios (e.g
economic growth, growth or reduction of a sector etc). If figures are available,
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the average growth percent or the expected growth rate could be used. The
estimate should be conservative. Always present a table showing the 3-5
years of annual production or import of the product.
Below is a list of recommendations where useful information for the literature

survey can be found.
Useful references
1. Central statistics agency, CSA publications, Money and economy biro

library, Bahir-dar, hospital road.
2. CSA website, http://www.csa.gov.et/Census.htm
Or http://www.csa.gov.et/
3. Encyclopedias and Handbooks
4. Ethiopian foregn trade statistics, Ethiopian customs authority,

Megenagna, close to the office of Bole Sub City, http://www.erca.gov.et/
Problem statement: This section develops the main motivation for the study
explaining real life problems to be dealt with. It is also called the rationale. In
stating the problem it is best to specifically describe what the project intends
to solve. For example, the possible real life problems may be shortage or
even absence of the product in the local market, or to reduce the foreign import
or to introduce a new and innovative product. The problem statement should
specifically mention these reasons.
6
The justifications of the project, reasons for studying the problem, should also
be included in this section. For instance, the fact that Brewery industries in
Amhara region mainly import malt while it was possible to produce the barely in
highlands of the region could justify the malt production project.
This part is best written if specific numbers are mentioned. For instance, if
reduction in foreign import is the main problem, the average import in 3-5 years
and its implications should be mentioned. This will transform the problem
statement part to evidence based argument than a mere general
problem.
Objectives: This is the most crucial part of the project. It is the first seen by
project evaluators hence leading to many critical questions. If the student came
up with an the project idea, the best step is to have the preliminary objectives
and discuss with the advisor to come up with the final clear objectives. In
writing the objective part the best format is to divide them into
general objective and specific objectives and write at least three
objectives in each category.
The general objective is derived from the statement of the problem. It

restates how this project solves the problems and the overall uses thereof. For
instance, for plant design project, the general objectives could be to satisfy
local demand, reduce foreign import and save foreign currency, introducing new
product that has market potential, create jobs and contribute to economy etc.
Please note that writing bulleted one line statements as objectives is
the worest way to describe them. So always write an elaborated objectives
to make it clear to even the project evaluator who has little knowledge about
your objectives.
7
The specific objective should state what specific tasks are planned in
the study. For instance, the literature survey leads to identification of the state
of the art in the production and review of current researches related to the
topic. These results are one specific objective.
Another specific objective could be derived from the mass balance, energy
balance and sizing chapters. This could be generalized as one specific objective
i.e. to determine the exact size of the plant that can balance supply and
demand or at least reduce the shortage.
The market and demand study is another source of specific objectives.

The outcome of this study is to determine the demand of the product and the
selling price that affect the financial success of the plant. This could be
generalized as one specific objective.
Financial and economic analysis gives a specific objective to determine the

financial feasibility of the process plant. The outcome of the environmental
impact analysis section is summarized as one specific objective.
Methodology
The methodolgy of a project is details the principles, procedures or rules to

be used. Plant design procedures are usually clear. It starts with literature
survey, market survey, design calculations, may include laboratory experiments
and ends with financial analysis and environmental impact analysis. These
processes should be elaborated in the project methodology section.
8
Useful references
1. Shafiur Rahman, 1995, Food properties handbook,1st ed, CRC press,

Important for properties of food and related items.
2. Inroductory texts at FAO library http://www4.fao.org/faobib/
3. Cheresources, Chemical engineerind resources , www.cheresources.com
4. Perry et al, chemical engineers handbook, 8th ed, McGraw Hill, also
available online
5. 400 project ideas discussion , https://sites.google.com/site/projectethio/
6. Publication sites, get acess to them at ,

http://sites.google.com/site/ethiograd123/
Chapter Two
Process and Raw Material Selection
The state of the art and status of the research in the project idea is studied in
the literature survey. Competitive and possible production routes and raw
materials are discussed in this chapter. This section is written best when a
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well supported and balanced argument is presented in the selection of process

alternatives and raw materials.
The common mistake is to present more advantages for the process to be and
discuss more disadvantages of the other competitive ways. Most students reject
alternative process entirely based on one or few reasons. The best way to
compare alternative processes is to rate them on comparative criteria. The
main point to remember is that it is your ability to make reseonalble
arguments (as an engineer) that is being evaluated. It is not expected
that you might make wrong choices.
In some cases process selection could be obvious. The state of the art is the
only process available. In these cases, the alternative processes should be
mentioned to comply with the plant design procedure. These processes are
predecessors of the current process and it is your jos to discrbibe how the
process evolved to it.
Raw material selection is done once the process is known in process selection.
Some processes have many alternative raw materials. Ethanol production and
biodiesel are typical examples. From process point of view, trans-esterification
and estirification are possible pathways with the previous one being the most
common. If raw material sources are considered, numerous options could be
sited. For ethanol it could be cereals like corn or cheap alternatives like
molases. In this case you can compare the price per liter of the ethanol from the
alternatives, potentital of raw material and price, process technology and
related utilities can be used to select the appropriate raw material. Therefore,
each alternative should be scrutinized to come up with convincing
argument.
10
It is true that the selected process requires specific raw materials making it
unnecessary or challenging to try another. This step is only desired when it is
possible to substitute one raw material by another less cheap, more
environmentally safe or available locally. But the basic requirement is that it
should give comparable process performance without substantial increase in
process steps or costs. Common example is the methanol versus ethanol as a
catalyst for bio diesel. It would seem feasible to select ethanol because
currently methanol is not widely availble. But this should be weighted with the
cost of additional azeotropic distillation coloumn .
Finding flow sheets is challenging in most cases. The reference one below is the
most common source of flow sheet for common processes. Mostly it is not easy
to find flowseets. Students should, however, understand that once the
process description is understood, flow sheets could be developed
from it.
The best way to prepare flow sheet is using CHEMCAD since actual unit
diagrams are used than simple boxes (prefered in the introduction section for
briefe discription). Another disadvantage with boxes is that they don’t show
auxiliary units leading to over simplifications. If you are determiined to make a
project sucessful, learning how to draw in CHEMCAD takes not more than
a day.
See reference 11 on flow sheet preparation and discription.
Useful references
1. Shrives,1995, chemical process industries, McGraw Hill
2. Encyclopedia of science and technology, 10th ed McGraw Hill

11
3. Free resources at national academy of science, www.nasonline.org/ and

issues http://www.issues.org/
4. Design thesis, collection of plant desing projects,

http://www.sbioinformatics.com/design_thesis/design-2520thesis.htm
5. Cheresources plant design library

http://www.cheresources.com/process_design.shtml
6. Publication sites, get acess to them at ,

http://sites.google.com/site/ethiograd123/
7. Free publications of chresources, http://cheresources.tradepub.com/
8. CHEMCAD, www.chemstations.com
9. Or http://www.chemstations.com/Downloads/
10. Guides on process and raw material selection, Klaus D. Timmerhaus Plant
Design and Economics for Chemical Engineers, Mcgraw Hill
11. Stanely Waalas, Chemical process equipment selection and design, 2nd
ed, Elsevier
Chapter Three
Material and Energy Balances
The market demand study and raw material availability studies give us the
proper size of the manufacturing plant. The size of the plant should balance the
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raw material availability and the market demand. Based on this, the material
and energy balances are done.
Using the information form demand study determine the capacity of the plant
interms of total annual production or total raw material requirement. This leads
to the following ways of making balances.
There are two approaches for performing material and energy balances;
upstream and downstream ways as known informally. In the upstream the
balance is started from the last unit in the process. Final product amount,
quality, yield and equipement efficiency are mainly used to do the balance. In
the downstream way, the initial raw material amount is determined to arrive
at desired production capacity. This could be possible if the overall yield of the
process in tons of product per tons of raw materials is known.
While writing material balance, the best format is to first present the overall
or general material balance and second the component balance. Show clearly
the total flow rate and composition of the known streams and represent the
unkown stream with appropriate labels. At the end of each section prepare
summary tables with columns input, output and remark. In the remark write
balanced, or state the accumulated, generated or lost amount.
The common mistake students make is failing to mention the assumptions in

the calculation and yet worse not to show how the assumptions are justified.
Therefore always mention the assumptions at the beginning of the material and
energy balance chapters with good justifications or references.
13
Balances for units with no change in mass like storage tanks are not done and it
is acceptable. Electrical energy required for running units are not usually
included in the balances. This is partly because their rating in only known in the
sizing and at the end it is included in calculation of utility costs as fraction of
total costs.
Choose the reference temperature to be the ambient conditions for energy

balances. Always study the detail process steps before calculating the total
energy requirement. Spray driers, kilns, coolers and combustion devices are
included in this catagory and are always challenging. The common mistake is
considering only sensible heat changes. The above units combine sensible,
latent heat and superheating. Besides the processes are of simultaneous mass
and heat transfer.
If you are dealing with mixtures in energy balance stream the overall physical
properites like density, specific heat capacity and so on may be not found in
tables. In this case they should be calculated based on the methods discussed
in coluson and Richardson, chemical engineering, Vol 6.
Balances of size reduction machines
Crushers, grinders and milling machines need mass balances in principle.

Ususally the dust loss and the recycled coarse fraction are ignored. This is not
accurate and the best way to do this balance is to consider the grinder alone
then balances for dust recovery cyclones (high efficiency or high throughput). If
the control volume include the dust recovery system, it is possible to neglect
the dust loss lost but still there is some loss. Wet grinding aviods the need for
14
dust recovery systems. Since water is added during the crushing process the
material balance should include this amount.
Energy balance for this units determines the energy required for crushing( Bond
´s Law). But this is not relevant from energy balance point of view and is
needed if it is designed in detail. This is because the energy required is usually
calculated indirectly as utility cost. For more details see references 1 and 3.
Balances on filters
The filteration objective, whether the cake or the liquid is the final product,
determines the type of filteration to be used and operating pressure. Overall
balance on filtes requires the calculation of the accululated cake amount. This
calculation inturn requires prehand determination of the filter area, cake
properties and operating pressures. Further complexity arises when the rate of
filterate flow should be detemined for subsequent balances. This means the
filter design and operation should be known prehand.
The best way to approach this problem is first to seek for general guides on
operations of filteration units. See reference 11, which contains design guides
such as cake properties of some common materails and performance data of
filters. availble.
Balances on spray diers
In spray diers hot air at given humidity and temerpature absorbs mosture from
wet substabce and at the same time the heat is transfered. Hence both mass
balance and energy balance equations should be used. The heat transfered
15
raised the temperature of the dry air and the moisture. One typical problem is
the final humidity of the exit air. It should be assumed to calculate the outlet air
mass flow and solve the energy balance equations. Therefore some iteration is
required to arrive at final values. For more details see refernce 7.
Balances on kilns
Cement kilns balances are complex. The feed materials contain surface water
and inherent water. The surface water undergoes sensible heat change and
latent heat change at lower temperature. The inherent water in clay for
instance, is evaporated in the kiln zone where temperature around 600C.
Sensible heat change of every feed material shoud be considered. Besides
separate balances of the primary and secondary kiln air should be done.
Reaction energy of clinker formation reactions should be calculated. This
calculation requires the knowledge of heat of formation of the kiln reactions at
standard temperature and then at the kiln temperature. There is alos
considerable kiln gasses released as loss.
Useful references
1. Nicolas et al,2003, Hand book of chemical engineering calculations,

McGraw Hill
2. Reynolds et al, 2002, Handbook of chemical and environmental

engineering calculations,
3. Mc Cabe, Unit operation of chemical engineering, 3rd ed, Mc Graw Hill
4. Fundamentals of chemical engineering text book
5. Seader et al, 2nd ed, Separation process principles, Willey

16
6. Chrome balance in leather processing

http://www.4shared.com/document/2CzAlvHr/Chrome_balance_in_Leather
_Proc.htm
7. Spray drier balances, G V Barbosa et al, 1997, Food engineering lab

manual,
8. Mass balances in leather processing
http://preresi.ineti.pt/documentacao/guias/doc_tec/Curtumes/UNIDO/Mass
Balance inLeatherProcessing.pdf
9. Online steam tables and unit converters www.cheresources.com
Online steam tables calculator, http://www.dofmaster.com/steam.html
Chapter Four
Equipment Sizing and Selection
Once accurate results of the material and energy flow are determined, sizing
determines the volume of storage tanks. The common mistake I have seen
over the years is to size reactors and distillation columns as a storage
17
tank. For these units the mass and heat transfer inside leads to different mass
and energy balance and hence size.
Input flow rate and residence time are used to calculate the volumes of units
involving no reaction or accumulation. For reactors, the appropriate rate
equation should be used to determine the volume of the reactor. Common
mistake is usually to assume first order kinetics. Reaction engineering
laboratory equipment such as batch reactors should be used to determine the
order of the reaction.
The equipment sizes should not be unusually large. This is partly because of the
selected capacity for design. In this case using two or more identical units
avoids the need for one very large volume. Length to width ratios are used to
determine the dimensions once the volume is known. Refernce 1 below is a
good guide for sizing units as it gives standard dimensions and proper rules.
The common mistakes is sizing is to simply calculate the size without
‘feeling’ the numbers, for instance, a CSTR with 15m diameter.
Selection is done to determine the type of equipment to be used, for example,

reactor types or heat exchanger types. Unless a new process is developed,
there is not much need for rigorous equipment selection with a scope of plant
design projects. In real cases, the different manufacturers with different
specialty for one unit may exist. Only in this case thorough analysis of
competitive suppliers should be done.
Design of Mixers
18
It requires the parameters like specific gravity , solid content and settling
velocity (Stoke´s law) and the nature of mixing (uniform of off bottom). The
blend tim, superficial velocity, power requirement should be determined besides
the detail geometery and orientation of the tank, baffles and impeller. See
reference 1 for complete discussion.
Useful references
1. Stanley M Walas, 1990, chemical process equipment selection and design,

3rd ed
2. J M Coulsen and Richardson, chemical engineering vol 6, 6th ed
3. Chemical engineering resources, design software library

http://www.cheresources.com/invision/files/
4. Comprehensive guide on spray diers design,

http://www.spraydrysys.com/spray-dryers/spray-dryers.htm
5. Kern, process heat transfer, chapters 10 onwards, furnace and kiln design
Chapter Five
Detail Design of Equipment
19
This chapter is always included in plant design projects to test the students'
capability in detail design of equipment. Sizing provides only simple details like
size, length, width or volume. This section selects one major unit and deals in
detail about it starting from thermodynamics to theoretical explanation on
opertaion, proper dimensions and to selecting the material of construction.
Distillation columns designs for instance included detail mass and heat transfer
equations, determining the parameters like number of trays, column
dimensions, tray spacing and so on. But this is not the whole story, also
included mechanical design (pressure vessel desing) of the distillation column
besides checking for entrainement and weeping. Please donot forget the heat
exchanger design of the condenser.
The heat loss assumption is one of the most challenging and controversial.
Normally, energy balances are made assuming no heat loss. Even the
assumption of 10 percent loss of the input energy can lead to misleading figures
based the energy amount considered. Assuming there is loss of energy is more
accurate that the no loss assumption and should be used if proper guides on the
loss available. Always use justified or referenced assumptions on detail
design.
If you do detail design very well, I assure you that you have multiple best
outcomes. First, you get most of the mark by the advisor. Second, you get high
marks by the document evaluator in the content criteria. Third, you will get high
marks while presenting and defending it. Fourth, you will have unforgettable
knowledge. Invest quite a good time in this part it pays off high.
20
The best way to end this chapter is to summarize the results in scaled
drawing showing every detail dimension and key results. Challenging designs
include boiler design, filtration unit design, kiln design, furnace design, and
cooler design and spray dryer design. The following materials are highly
useful.
Useful references
1. Stanley Walaas, chemical equipment sizing and design
2. Process equipement design handbook,

http://www.4shared.com/document/ObRSRAHN/Process_Equipment_Desig
n_Handb.htm
3. Coulsen and Richardson, chemical engineering vol 1, 2 and 6
4. Kern, process heat transfer, chapters 10 onwards, furnace and kiln design
5. Detail design of sulfuric acid absorber desing,

http://www.sbioinformatics.com/design_thesis/Sulphuric_acid/Sulfuric-
2520Acid_Design-2520of-2520Equipments.pdf
6. Distillation column design,

www.sbioinformatics.com/design_thesis/Ethylene_Glycol/Ethyleneglycol_D
esign-2520of-2520Equipments.pdf
7. Ammonia absorber design,

www.sbioinformatics.com/design_thesis/Soda_ash/Soda-2520ash_Design-
2520of-2520Equipments.pdf
Chapter Six
21
Financial and Economic Analyses
Using the specifications obtained in the sizing and detail design chapters,
approximate costs of equipments are obtained. Using the results from the
material and energy balance sections, annual raw material and utility cost could
be determined. The most common mistake students make in this chapter is
to use the fraction of capital investment cost as raw material cost and process
and utility cost. The purpose of material and energy balances is to determine
the annual raw material and utility cost directly.
Steam cost is the less known though it is used largely in the industry. It is the
price of energy used to generate steam per ton of steam produced. It is
dependent on the efficiency of the equipment. Comparable prices could be
obtained from similar plants and equipments. It is essential tool in calculating
the utility cost.
The selling price is always the controversial part in most cases. It is usually
made higher if the plant is found unprofitable and this happens at the last hour.
This problem arises from many sources; larger plant capacity, errors in balances
leading to oversized and costly units or errors in sizing. Always try to know the
selling price before hand to help you determine the plant capacity. If the
selling price is cheap, going for larger size improves the feasibility.
Payback time, ROR, IRO and NPV/W are main methods used in financial
analysis. A common mistake is failing not to use NPV/W. The main point one
should remember is NPV/W is the best method for evaluation of projects and it
22
should be large and positive. In payback analysis it is assumed that the plant
will give revenue similar to first year revenue through 20yrs life time making it
obviously a poor method.
The useful life of plants is usually taken as 20-25yrs. This is the financial life
time not the actual life time. It is to mean the cash flow after 20-25yrs
discounted to present time is worth insignificant. Actually plants last
longer than 25 years. Depreciation is usually calculated using straight line
method which is a handy method.
The average values of fractions should be used to calculate various costs. For
instance, the raw material cost may be 10-20% of the total capital investment.
In this case, the average 15% should be used. Do not fall in to assuming
that since fewer raw materials are used, 10% should be used.
The other most common mistake is to use costs directly from the internet. This
is wrong for many reasons. Firstly, the price stated may be out dated, second
hand price or wrong totally. Usually truseted suppliers don´t provide costs
directly on the web page. You have to ask for quotations. Refence 1 is unque in
such a way that it is mainky designed for equipement costs. You can opt for
various dimensions of the equipement to get the cost and they are very recent
costs. Reference 4 is also a good resource but values available for most
equipements are old and Marshall and Swift cost index must be used to get
current costs.
What is the plant is not profitable? There many questions after this. Is the plant
known to be non profitable? If yes, you are more justified. If no you have done
the following mistakes and here are some tips. Is the selling price so cheap? If
23
yes try alternative justified prices since you have to change only small pages of
the paper. Or show the minimum price required for profitability. Have you made
silly mistakes in cost estimation? Check back and change only few pages of the
project. Have you made mistakes in material and energy balance?( Which
affects the sizing, costing and profitability) This type of problem is hard to solve.
Sometimes, provisions are made so that you will submit the corrected version
after the presentation date. Hence discuss with the advisor. Have you designed
a small scale capacity plant ? If yes then you have to confess this in the paper
and state how going for large scale improves profitabilty.
Useful references
1. www.matche.com , Updated equipement prices
2. Complete financial analysis in excel, at,

http://sites.google.com/site/ethiograd123/moges
3. Guides economic anamysis , Klaus D. Timmerhaus Plant Design and

Economics for Chemical Engineers, Mcgraw Hill
4. Equipement costs and cost index, D E Garette, 1989, Chemical

engineering economics, Springer
24
Chapter Seven
Site Selection and Plant Layout
Site selection determines the location where the plant could operate profitably.
Almost 85% of the projects studied so far located their plant around Addis
Ababa in my estimations. It may be right, but the common mistake is
choosing Addis Ababa without showing at least another competitive
town.
The best arguments in sitel selection are done using the data of site´s raw
material potential along with near ness to the potential market. Remember it
may be obvious to located the plant arround Addis Ababa. BUT you have to
show how justified the are criterea such as availabilty of labor, infrastructure,
the demand and supply market (in numbers) even for the selected location.
Plant layouts show the top view of the equipement positioning, offices and other
accessories in the industry. This is the test of you industry experience, if you
haven´t any i advise you to use help. The best way to do this section is also to
prepare physical model out of paper. I challange you to do this if you would like
to have nice very good presentation and much better marks.
[1] Guides site selection, Klaus D. Timmerhaus Plant Design and Economics for
Chemical Engineers, Mcgraw Hill
25
Chapter Eight
Environmental Impact Analysis
Environmental performance of the process is discussed in this section to prove

that the process is safe environmentally. Some advisors disagree on the
naming. This is true environmental impact analysis is a wide subject by itself. It
is better renamed as environmental effects for the purpose of plant design
projects. Always express the detail environmental impacts of the
product, raw materials and waste streams both liquid and gaseous.
Make sure all the hazardous wastes are treated or recyled and even those
released has negligible impact. Use environmental protection agency (EPA)
regulations and rules as a standard for the evaluation of your project. EPA USA
[1], hosts such information and the best way to end your project is to use it
well.
[1] http://www.epa.gov/lawsregs/topics/
26
Chapter Nine
Writing the References
References state the sources of information implying credibility. Looking at the

back of most of the final year projects, one could notice that references are
poorly mentioned. In a text of about 120 pages, the reference is not
more than a page.
Another common mistake in referencing is not mentioning the sources

inside the main text. From my experience, this is done deliberately to hide
plagiarism. Well turn on the light, we can see you. You should always have time
to read and reread the text and write it in your own words. It has double
advantages; avoiding the plagiarism and that the knowledge is yours.
The best ways to write your project is to mention the references inside the
main text is one of the two ways; giving references a number like, the yield of
the process is 40%[1] and at the end write [1] name of the reference in the
proper format. The other way goes like this; the yield of the process is 40 %.
(Name, year)
This is the format in writing the references; Authors, year, Title, publisher, city.
Always use the proper format for references. Mention the references in
appropriate places in the text. These are 100% the advice you need in
writing the references.
27
Useful references
1. Online bibliography maker, www.easybib.com
2. Very good guide on how to write references,

http://www.aresearchguide.com/12biblio.html
Chapter Ten
Presentation and Defense
Chemical engineering department has a good name in having two presentations

until the completion. This gives a chance to shape the projects to much better
outcome. Being aware of this fact is vital for the students as 10-15% of its mark
is decided on the progress presentation. The best advice is the project
should be done by reading very well so that you have understood it.
Don’t copy paste related texts from everywhere. If this is not the case, you can
defend your project. This is 90% of the advice you need to score well in
oral presentation. But it is not all. One trick I have seen it work magic for me
is to present to yourself at least once after you have prepared the
power point.
There are some helpful tools online you can download for free. The first is “my
screen recorder”. With a head phone and microphone, the software can make a
video of your presentation with a voice. You can replay this and listen to it so
that correct you mistakes. The other magic trick is to deliberately write
sentences to say at the presentation and study them by heart. This is
nice because it can dramatically improve you score on the confident speaking
and grammar. Because of poor general English speaking ability, students find it
28
hard to speak well constructed and grammatically correct sentences.

Deliberate writing of key sentences improves the grammar and
presentation. Important notice here is that do not write all you will say, that
will make it clear during the presentation that you are merely reading.
One silly mistake students make in power point presentation is to copy paste
texts from project to the power point. This will one make them loose mark in
slide preparation, two, force them read it adding to lose of mark in presentation
skills. The key is to put key words that will remind you what to say.
Remember this is very useful if coupled with the idea of presenting for yourself
before defense since you become very familiar with the key words.
Using key words in power point is useful for the literature survey, process
description, and environmental impact analysis. For presenting material and
energy balances, here are few ideas. Usually you can prepare series of
boxes representing each unit and show balances there with summary of
calculations steps and results for each. This has advantages and disadvantages.
The clear presentation in this way gives you more marks but exposing some of
the errors you have made hence stealing you marks. Sometimes the latter
makes you lose more marks.
Optionally also, summary of key material and energy balance results could be
put on the process flow sheet and the process description can be made with
numbers from balance results. This makes it less necessary to put so many
boxes in the power point and focus the presentation to very important parts like
detail design. Another alternative is to show detail balance for selected major
processes like reaction or separation units and show summary of other in table.
This can earn you points by making the presentation focused and
hence interesting.
One important advice is to prepare well and discuss the detail design part. This
really earns you more points as it makes the presentation very lively.
29
But remember prepare well not to make yourself vulnerable for many questions.
You must be sure that you have done the detail design well.
Defense is answering questions raised by the judge and guests. The project
evaluator raises the most critical questions. Try your best to answer this
question. This doesn’t mean argue with him. Mostly he/she has identified a
weakness you haven’t seen. If this is obvious, accept it.
Don’t argue one sided. Acknowledge the comment first and present your view.
Arguing is preferred if only you are so sure that you can answer it. Otherwise it
is running against the persons’ ego which will be defended at whatever cost.
The best step whether you know the answer or not is to first
acknowledge the comment before defending it. You have already lost if
you begin by saying no!
Appendices
Writing and grammar
Final projects must be well organized and written with very good grammar.
Almost every student struggles with grammar and composition. It is always
easy to identify when paragraphs are copy paste because uneven writing and
grammar skill throughout.
The best solution is first to edit before the advisor reads it. Secondly, use
several online grammar editors and software tools. It is not up to the advisor to
correct grammars for you.
These are tools you can use;
30
1. Whitesmoke: www.shitesmoke.com this is one my favorite software. It

gives suggestions on grammar, spelling, style, vocabulary suggestions
and enrichment. You can download for 9 days trials hence use it to edit
the final text. It requires internet connection to do the tasks. It integrates
with word putting the corrections in the main text. No need for you to
copy the text or corrections. Just press F2 inside any text and press apply
and then the software copies the corrections in the main text.
2. Style writer: www.stylewriter-usa.com this software is more focused on

style of your writing. It is very powerful tool. You can use this software for
10 runs only. Hence, you can run this software more than enough for your
progress and final report since the runs are counted when you close the
software. You need to copy paste the main text and the corrections.
3. Grammar expert: www.wintertree-software.com/app/gramxp/index.html

this is also good software with 30 days trial. But it can work even after 30
days, only you have to wait 10sec between each run. You need to copy
paste the text and the corrections.
4. Online grammar checker. www.spellchecker.net/grammar/ copy paste

the main text and click on check to use this online tool. It is handy if you
use it daily checking small texts.
Format of Project
Plant design projects have the following format.

Chapter one: Literature survey
● History and backgrounds
31
● Short process description

● Demand study
1. Current and future prices
2. Prices and distributions
● Objectives
● Methodology
Chapter two: Processes and raw material selection
Detailed process description
Chapter three: Material and energy balance
Chapter four: Detail design of equipment
Chapter five: Financial analysis
Chapter six: Environmental analysis
Chapter seven: Site selection and plant layout
References
Writing the Abstract
The abstract summarizes what has been done in the study. The format of the
thesis is IMRAD. The letter ‘I’ stand for introduction, M is for materials and
32
methods and RAD is for results and discussion. Therefore, writing the abstract
should follow this format. The first part should summarize the introduction and
then the method is expressed. The result summarizes key results of the study.
The discussion part tells the interpretations of the result.
More on http://www.unc.edu/depts/wcweb/handouts/abstracts.html
Work plan and habit
For successful completion of plant design project four months effort is required.
The real question is not time management, it is energy management. It is
choosing what to focus on.
Time plan depends on the nature of the project. The usual plan is to give one
month for literature survey, process and raw material selection and process
description. Give two and half months for material and energy balance and
sizing and detail design. The rest 15days is used for financial analysis.
This is a tight schedule because it is interrupted by exams and time is lost in

waiting for advisor comments or making the corrections. No time is available to
correct mistakes and rework the financial analysis making students fall in to the
trap of manipulating the financial part.
The best schedule in my view is to give a maximum of two weeks for

everything before the balances. While waiting for comments, start reading and
33
collecting data for balances. Give one month for the balances and have
comments from advisor. While waiting for comments read a lot about the detail
design. Once you make the correction give about a month for detail design
including comments. Give only two weeks in the extreme case for financial
analysis and have time for grammar editing at the rest of the time. If
experiments are planned, always the best projects do, plan the night time
for it. You have to work in balances and experiments at the same time.
The work habit in plant design projects that leads to best result is work every
day. Here is one trick for avoiding procrastination. Work only for ten minutes
on the important task every day. You will find it impossible to stop after the
end of ten minutes.
Don’t count on the internet as best source of data. It is intended for

advertising most of the time not as a genuine source of data. Realizing this
saves you a lot of time otherwise wasted for nothing. At least ask for advice on
the search and specific websites before Googling directly.
Planning Experiments
It is always best if projects include demonstration experiment. You can give the
night time for making experiments. But make sure that accuracy will not be
harmed.
Here are some advices for making plans.
1. Give enough time for collection relevant chemical and equipments to be

used. Without these don’t start it.
2. Know the procedures well first at least by making trial experiment to

know sources of error.
34
3. Consult with your advisor so that he is aware of the procedures and invite
him to see crucial step results, not the final result. This contributes a
lot to openness of your work and the trust of the advisor.
4. Consult other lecturers you know has research experiences for valuable
insights on setup and execution of experiments.
Project ideas
Using internship experiences to come up with a project idea is the best way.
The next best step is to contact local institutes like Amhara investment
office, Tiret, GTZ and Minstry of mines and energy in Bahirdar or similar offices
where ever near and Ethiopian science and technology commission for patents.
The unique advantage of doing such a search is usually you will find real life
problems whose accomplishment presents very good opportunities.
The other ways is to use the publication and professional websites in related
fields. The following sites are useful.
1. Ethiograd123, http://sites.google.com/site/ethiograd123/ project ideas in

chemical and energy engineering. Graduate and undergraduate project
library and access to publications (most of them accessed on Bahir-dar
University server )
2. Project ethio, https://sites.google.com/site/projectethio/ collection 400

project ideas in every major sector in Ethiopia.
3. This site is my favorite. www.cheresources.com is the best site in my view

in the fields of chemical engineering.
35
4. Chemical engineering societies have numerous discussion topics,

newsletters and journals you can follow to get ideas. For instance,
Ethiopian society of chemical engineers, ESCHE, www.esche.org.et/
American institute of chemical engineers, www.aiche.org/
5. Visit websites of excellent universities in the related field and see their
research activities. Usually, their research is top level, but reading I could
spark ideas.
6. The following sites, free patents online, www.freepatentsonline.com

national academy of science, www.nasonline.org/ are useful. The later
has interesting reports and reviews.
Follow publications and take time to read and understand them to come up
with a project idea. Knowing the hot topic at the time through reading a lot
leads you to best project title. Also discuss with instructors to get suggestions
which can be developed to projects or share your ideas.
Searching the internet
One of the major difficulties searching the internt for infomation about projects.
The initial assumption that there is everything on the internet is wrong. There is
not everything about your projects on the internet. However; this doesnt mean
to underestimate the power of the internet. It can help you a lot if you know
how to search it.
Here is short guide for internet searching,
1. Use nouns as query keywords. Never use articles ("a," "the"), pronouns
("he," "it"), conjunctions ("and," "or") or prepositions ("to," "from") in your
queries
36
2. Use 6 to 8 keywords per query
3. Where possible, combine keywords into phrases by using quotation

marks, as in "solar system"
4. Spell carefully, and consider alternate spellings
5. Avoid redundant terms
6. Insert a plus or minus sign: Put a plus sign (+) in front of a word that must
be found in the search window. For example, city guides + New York will
help you narrow the search for city guides for New York only.
More http://www.virtualsalt.com/howlook.htm
37

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Reflections on how to excel in doing a chemical plant design project

Why this short book?............................................................................................3

The literature survey............................................................................................5

Process and Raw Material Selection.....................................................................9

Material and Energy Balances............................................................................12

Chapter Four ......................................................................................................17

Equipment Sizing and Selection.........................................................................17

Chapter Five ......................................................................................................19

Detail Design of Equipment................................................................................19

Financial and Economic Analyses.......................................................................22

Site Selection and Plant Layout..........................................................................25

Chapter Eight .....................................................................................................26

Environmental Impact Analysis..........................................................................26

Chapter Nine .....................................................................................................27

Writing the References.......................................................................................27

Chapter Ten .......................................................................................................28

Presentation and Defense..................................................................................28

Writing and grammar..............................................................................................................30

Format of Project ....................................................................................................................31

Writing the Abstract.................................................................................................................32

Work plan and habit................................................................................................................33

Searching the internet.............................................................................................................36

Similar ebooks and undergrad/Grad thesis Library at

400 Project/ Business ideas in Ethiopia

Why this short book?

The literature survey

History and background: It reviews previous literature on related topics of

Below is a list of recommendations where useful information for the literature

1. Central statistics agency, CSA publications, Money and economy biro

2. CSA website, http://www.csa.gov.et/Census.htm

3. Encyclopedias and Handbooks

4. Ethiopian foregn trade statistics, Ethiopian customs authority,

The general objective is derived from the statement of the problem. It

The market and demand study is another source of specific objectives.

Financial and economic analysis gives a specific objective to determine the

The methodolgy of a project is details the principles, procedures or rules to

1. Shafiur Rahman, 1995, Food properties handbook,1st ed, CRC press,

2. Inroductory texts at FAO library http://www4.fao.org/faobib/

3. Cheresources, Chemical engineerind resources , www.cheresources.com

5. 400 project ideas discussion , https://sites.google.com/site/projectethio/

6. Publication sites, get acess to them at ,

Process and Raw Material Selection

well supported and balanced argument is presented in the selection of process

See reference 11 on flow sheet preparation and discription.

1. Shrives,1995, chemical process industries, McGraw Hill

2. Encyclopedia of science and technology, 10th ed McGraw Hill

3. Free resources at national academy of science, www.nasonline.org/ and

4. Design thesis, collection of plant desing projects,

5. Cheresources plant design library

6. Publication sites, get acess to them at ,

7. Free publications of chresources, http://cheresources.tradepub.com/

Material and Energy Balances

The common mistake students make is failing to mention the assumptions in

Choose the reference temperature to be the ambient conditions for energy

Balances of size reduction machines

Crushers, grinders and milling machines need mass balances in principle.

Balances on spray diers

1. Nicolas et al,2003, Hand book of chemical engineering calculations,

2. Reynolds et al, 2002, Handbook of chemical and environmental

3. Mc Cabe, Unit operation of chemical engineering, 3rd ed, Mc Graw Hill

4. Fundamentals of chemical engineering text book

5. Seader et al, 2nd ed, Separation process principles, Willey

6. Chrome balance in leather processing