CBB 3024

PROCESS PLANT DESIGN

4 Credit-Hour Core Course
Semester May 2011

Lecturer : Assoc. Prof. Dr. Mohamed Ibrahim Abdul Mutalib

Dr Mohanad El-Harbawi
Lecture Time : Mon 10 am – 12 noon ; Mon 1 – 3 pm
: Thurs 11 am – 1 pm ; Fri 8 – 10 am
Location : LT D2 ; 21-01-04
17-02-06 21-02-07
PROGRAMME OUTCOMES – UTP CHEMICAL ENGINEERING

1 Acquire and apply knowledge of basic sciences and engineering fundamentals

Acquire and apply Chemical Engineering principles and in-depth technical

2
knowledge
3 Ability to design, optimize and operate processes
Undertake problem identification, formulation and solution by considering the
4
concept of sustainable development
Comprehend social, cultural, global and environmental responsibilities of a
5
professional engineer, and the need for sustainable development
6 Communicate effectively in a professional context

7 Exhibit professional and ethical responsibilities

8 Demonstrate leadership, business acumen and entrepreneurship

9 Demonstrate the capability to undertake lifelong learning

COURSE OUTCOMES – CHEMICAL PLANT DESIGN

K S A
3 PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO3 PO9 PO7

Integrate knowledge from previous

CO1 chemical engineering courses in designing x x x x
a chemical process system

Apply conceptual process design and

CO2 synthesis tools in designing a chemical x x x x x
process system

Apply a systematic approach or method to

CO3 x x x x x x
design a chemical process system

K – Knowledge
S – Skill
A – Attitude
Course Content, Delivery & Assessment

Lec. Topic Assessment Lecturer

No.
1-2 Introduction to Plant Design and Economics (Approaches and Dr Ibrahim
Stages of Process Design)
Quiz 1
3-4 General Plant Consideration (Plant Layout/Utility System) Dr Ibrahim
5-8 Synthesis of Reactor Separation System Assign 1 Dr Ibrahim
(Fundamentals and Selection of Reaction System & Test 1
Separation System)
9-12 Synthesis of Reactor Separation System Assign 1 Dr Ibrahim
(Fundamentals and Selection of Reaction System & Test 1
Separation System)
13-16 Synthesis of Reactor Separation System Assign 1 Dr Ibrahim
(Process Recycle and Distillation Sequencing) Test 1
17-20 Heat Integration (Composite Curve & Heat Recovery Pinch, Assign 2 Dr Ibrahim
Problem Table Algorithm) Test 1
21-24 Heat Integration (Grand Composite Curve & Multiple Utilities) Assign 2 Dr Ibrahim
Test 1
25-28 Heat Integration (HEN Design) Assign 2 Dr Ibrahim
Test 1
Lec. Topic Assessment Lecturer
No.
29-32 Process Flowsheeting (Flowsheet Synthesis & Simulation, Test 2 Dr Mohanad
Model Formulation, Solution Strategies)
33-36 Economics of Chemical Plants Quiz 2 Dr Ibrahim

37-40 Equipment Design & Specification (Material Transfer & Assign 3 Dr Mohanad
Handling, Mass Transfer Equipment) Test 2
41-44 Equipment Design & Specification (Mass Transfer & Reactor Assign 3 Dr Mohanad
Equipment) Test 2
45-48 Equipment Design & Specification (Pressure Vessel Design) Assign 3 Dr Mohanad
Test 2
49-52 Environmental Studies & Consideration – Effluent Treatment, Quiz 3 Dr Mohanad
Waste Minimisation and Life Cycle Analysis
53-56 Plant Wide Control (Material & Quality Control, Pairing of Quiz 4 Dr Ibrahim
Variables in MIMOS, Typical Unit Operation and Control
Strategies)

Assessment : Quizzes – 4 (5 %) Assignments - 3 (5%) Projects - 1 (10%)

Tests - 2 (20%) Final Exam - 1 (60%)
Lecture 1. Introduction to Plant Design and Economics
The purpose of engineering is to create material wealth – Douglas, Conceptual Design of Chemical
Processes 1988.
The goal of the engineer is to design and produce artifacts and systems that are beneficial to mankind
– Biegler, Grossman & Westerberg, Systematic Methods of Chemical Process Design 1997.

How to do so ?
Energy
In

CHEMICAL
Raw Materials Products + Wastes
PROCESS
+ Other Feeds

Energy
Out

WHAT CAN YOU SAY ABOUT THE CHEMICAL PROCESS ?

In a chemical process, the transformation of raw materials into desired products usually cannot be
achieved in a single step. Instead, the overall transformation is broken down into a number of steps
that provide intermediate transformations. (Robin Smith, Chemical Process Design 1995)
 Raw Materials CHEMICAL Products + Wastes
+ Other Feeds
PROCESS

Energy Energy

SO, A NUMBER OF PROCESSING STEPS MADE UP THE CHEMICAL PROCESS.

QUESTIONS?

- WHAT SORT OF PROCESSINGS ARE LOCATED IN THE CHEMICAL PROCESS?

- HOW DO WE SEQUENCE THE PROCESSING STEPS?
- TO WHAT EXTEND CAN WE EXPECT EACH OF THE PROCESSING STEP TO
PERFORM AND WHAT FEATURES ARE REQUIRED?
- HOW MUCH ENERGY IS REQUIRED AND HOW MUCH IS PRODUCED?
- HOW MUCH FEEDS DO WE NEED AND HOW MUCH PRODUCTS ARE PRODUCED?
- HOW MUCH WASTES ARE GENERATED?
- HOW MUCH PROFIT COULD BE DERIVED?

HOW DO WE ADDRESS
THIS?
Concept Design for Chemical Process
 Raw Materials CHEMICAL Products + Wastes
+ Other Feeds
PROCESS

Energy Energy

PROCESS PLANT DESIGN IS THE NAME OF THE GAME HERE !

LITTLE OR LIMITED
BEFORE COMING UP WITH A
INFORMATIONS ARE
COMPLETE PROCESS
AVAILABLE

But so many possibilities

or solutions !

Perhaps, the major features that distinguishes design problems from other types of engineering
problems is that they are under defined; i.e., only a very small fraction of the information needed
to define a design problem is available from the problem statement.
(Douglas, Conceptual Design of Chemical Processes 1988)
Once the process concept has been designed which produces process flowsheet,

the equipment design then has to be performed…..

Distillation
The equipment design comprises of ;

1. Performance/Capacity Rating or Sizing

Equipments’ Dimensions
– diameter & height

No. of stages Heat Transfer

for contact Area Needed

2. Vessel Mechanical Design

Internal Design
Wall thickness

Pipe fittings &

Support Design Reinforcement
The process safety and control strategy has to be devised;

1. Process Safety
- Hazard and Operability Study (HAZOP)

- Risk Assessment
HAZOP study

2. Process Control Strategy Risk Assessment

Matrix
- Material Control

- Product Control

Overall Plant and Equipment ….

And Waste Treatment/Minimisation need to also be addressed…

1. Waste Treatment (conventional)

- Suitable ‘end of pipe’ treatment on the effluent (gases & liquids)

2. Waste Minimisation (sustainability)

- Adjusting processes to minimise the generation of waste
REACTOR

SEPARATION
& RECYCLE
SYSTEM

HEAT EXCHANGER
NETWORK

UTILITIES
In finalising the process and equipment design, several stages of economic analysis
could be conducted …

First step;
EP 1 = Revenue – Cost of Raw Material

Second Step (after mass balance developed)

EP 2 = Revenue – Cost of Raw Material - Utility

Third Step (after equipments designed)

EP 3 = Revenue – Cost of Raw Material – Utility – Annualised Cost of Equipment

The economics analysis continues with other costs (manpower, insurance etc) ….

Pay back time,

Return on Investment
Internal Rate of Return

with profitability analysis conducted at the end to assess project viability ……

Finally …..
Lecture 2. Approaches and Stages of Process Plant Design
In the first stage, conceptual process design has to be conducted.
In general conceptual process design has to address two major activities ….

1. ADDRESS THE INDIVIDUAL

PROCESS/TRANSFORMATION STEP

RECYCLE

STEAM

FEED REACTOR

PRODUCT 1
CW

PRODUCT 2

2. ADDRESS THE REQUIRED

INTERCONNECTION BETWEEN THE STEPS
……….and the target is to create the best possible feasible flowsheet for the process.

DEFINITION OF A FLOWSHEET.
FLOWSHEET IS A DIAGRAMMATIC REPRESENTATION OF THE PROCESS
STEPS AND ITS INTERCONNECTIONS.

RECYCLE

STEAM

FEED REACTOR

PRODUCT 1
CW

Str1 Str2 Str3 Str4 Str5 Str6 Str7 Str8 Str9

F
T
P
x PRODUCT 2

WHAT OTHER INFORMATIONS SHOULD BE THIS IS WHAT YOU WANT

AVAILABLE IN A FLOWSHEET ?
AT THE END OF THE STAGE !
AND HOW DO YOU GET SUCH INFORMATION ?
 A SYSTEMATIC APPROACH OR METHOD IS REQUIRED

The approach or method should be able to help in addressing these questions …

Why is the unit operation selected ?

How are the unit operations connected ?

What are the utilities required and approximate amount ?

How will it be supplied to the process unit operations ?

What wastes will be generated?

However, as much as we would like to have a systematic approach or method, we must also
recognised that process design is an art !

If we reflect on the nature of process synthesis and analysis, …. , we recognize that process design
actually is an art, i.e., creative process. (Douglas, Conceptual Design of Chemical Processes 1988)
Now, what criteria should be adopted besides economics during the design activities?

1. ADDRESS THE INDIVIDUAL

PROCESS/TRANSFORMATION STEP

RECYCLE

STEAM

REACTOR

FLOWSHEET
FEED

PRODUCT 1
CW

PRODUCT 2

2. ADDRESS THE REQUIRED

INTERCONNECTION BETWEEN THE STEPS

QUANTIFIABLE NON - QUANTIFIABLE

VERSUS
FACTOR ! FACTOR !

MINIMISE COST HIGH SAFETY & INTEGRITY

MINIMISE WASTES GENERATION GOOD OPERATIONAL ASPECTS

MINIMISE ENERGY CONSUMPTION

..... BUT HOW TO OPTIMISE ?

Consider back the flowsheet !

RECYCLE

STEAM

FEED REACTOR
PRODUCT 1
CW

PRODUCT 2

OPTIMISING A SINGLE UNIT/STEP

IN THE PROCESS OPTIMISING THE INTERCONNECTIONS
BETWEEN THE UNITS/STEPS IN THE PROCESS
EG. DISTILLATION COLUMN
MANY POSSIBLE CONNECTIONS WHICH LEAD
TOTAL RR --> ENERGY TO DIFFERENT STRUCTURES OF FLOWSHEET
COST
THUS DIFFERENT ECONOMIC IMPACT EVEN TO THE
EXTENT OF THE INDIVIDUAL UNIT ITSELF!

RR

CONTINUOUS FUNCTION
RR --> CAPITAL ?
DIS-CONTINUOUS FUNCTION

PARAMETER OPTIMISATION STRUCTURAL OPTIMISATION

How do we tackle them ?

Consider the approaches/methods which have been introduced to deal with such complex optimisation ?

HEURISTIC METHOD MATHEMATICAL METHOD

ONION MODEL MIXED INTEGER LINEAR/

USE A SEQUENTIAL/HIERARCHICAL METHOD
ACCORDING TO FOLLOWING SEQUENCE ;
1. REACTOR
2. SEPARATION AND RECYCLE SYSTEM
3. HEAT EXCHANGER NETWORK
4. UTILITIES
DECISION ARE BASED ON ENGINEERING GUIDELINES
ESTABLISHED AND MATHEMATICAL OPTIMISATION
CONCEPT IS BASED ON
"BUILDING AN IRREDUCIBLE STRUCTURE"
NON-LINEAR PROGRAMMING
USE A MATHEMATICAL PROGRAMMING METHOD TO
SOLVE AND GIVE SOLUTION FOR THE PROCESS.
SIMULTANEOUS SOLUTION OF ALL THE SYSTEM.
DECISION ARE BASED ON SOLELY MATHEMATICAL
OPTIMISATION CRITERIA
CONCEPT IS BASED ON
"CREATING AND OPTIMISING A REDUCIBLE
STRUCTURE"

Smith R.,Chemical Process Design 1995 Grossman I. E, Comp. Chem. Eng., 9: 463, 1985
Biegler, Grossman & Westerberg, Systematic
HIERARCHICAL APPROACH Method of Chemical Process Design 1997
USE A SEQUENTIAL/HIERARCHICAL METHOD
ACCORDING TO FOLLOWING SEQUENCE ;
1. BATCH VS CONTINUOUS
2. INPUT-OUTPUT STRUCTURE OF THE FLOWSHEET
3. RECYCLE STRUCTURE OF THE FLOWSHEET
4. GENERAL STRUCTURE OF SEPARATION SYSTEM
5. HEAT EXCHANGER NETWORK Douglas.,Conceptual Design of Chemical Process 1988
HEURISTIC METHOD – The Onion Model

- FOLLOWS ONION LOGIC

Design starts from the centre ( heart of process ) which is the reactor.
REACTOR
At each layer, decision has to be made to complete the design
requirement for the stage. As such, many best local optimal decisions
are made since the whole picture is incomplete. Unit/Equipment is
SEPARATION added only if it is economically justified based on the current available
& RECYCLE
SYSTEM information. This keeps the process (structure) irreducible and features
which are technically/economically redundant are not included.

HEAT EXCHANGER
NETWORK What do you see are the advantages and disadvantages of this method ?

Advantages Disadvantages

UTILITIES
HEURISTIC METHOD – The Hierarchical Approach

The conceptual design is performed based on 5 different stages. The approach is somewhat
different by tackling the 5 different level that are classified differently. The 5 levels are ;
Level 1 Decision : Batch vs Continuous
Level 2 Decision : Fixing the Input-Output Structure
Level 3 Decision : Determining the Recycle Structure for the Process
Level 4 Decision : Determining the Separation System
Level 5 Decision : Determining the Heat Exchanger Network

WHAT DO YOU NOTICE ON

THE STATEMENT CONTAIN WITHIN
THE SHADED BOX ? At each level except level 1, alternatives have to
REACTOR
be generated and assessed to see its economic
SEPARATION and operational potential. Some level of process
& RECYCLE
Compare these statements
design has to be conducted on the
SYSTEM

HEAT EXCHANGER
to the onion model !
NETWORK
units/process placed at every stages.
UTILITIES
 MATHEMATICAL METHOD – The Mixed Integer Linear/Nonlinear Programming

- CREATION OF SUPERSTRUCTURE/HYPERSTRUCTURE
A major (super) structure is created which embedded within it all feasible
process (including its operations) and all feasible interconnections that
are candidates for an optimal design. The method is completely automated
and depends only on the computer programming to solve it. The design
problem is formulated into sets of mathematical equations which has to be
solved by the mathematical programming. Started off with many redundant
features, the programming optimise and reduce the process (structure)
to an optimal solution.

What are the advantages and disadvantages of this method ?

Advantages Disadvantages

other process
alternatives

Semester July 2004

From the conceptual process design, a flowsheet is generated for the process. The next stage
would then be to address the equipment design …

RECYCLE

STEAM

FEED REACTOR
PRODUCT 1
CW

PRODUCT 2

Heat Exchanger
Reactor
Distillation

No of stages
Reflux Ratio
Feed Location
Type of Exchanger (Plate / Shell & Tube)
Vapour/Liquid Loading
Heat Transfer Coefficient
Column Sizing
Heat Transfer Area Type of Reactor Internals
Pressure Drop Reaction Kinetics Column Temperature &
Exchanger Configuration Reaction Selectivity Pressure
Reactor Sizing
Reactor Temperature & Pressure
There are established methods for performing the design of these equipments ….
Heat Exchanger
Kern’s method
Rating calculation that will
enable the sizing of the heat
exchanger to be done
Reactor
Reactor
From the kinetics obtained
from experiment, sizing of
reactor could be done based
on residence time.
Distillation
Fenske, Gilliland & Underwood
No of stages calculation versus reflux ratio
could be made and the feed location
determined.
Results are then simulated in rigorous
simulation model for actual design involving
capacity calculation for internals.
Given that each of the equipment will normally involved vessel operated at various pressure and
temperature, the design of the pressure vessel has to be conducted. The design is to be done
according to standards…..

Heat Exchanger

Reactor

Pressure Vessel Dimension

Distillation Shell Thickness
Flanges Connection &
Reinforcement
Support type and Design
Corrosion Allowance
Welding specification

American Society of Mechanical Engineers (ASME)

Boiler and Pressure Vessel Code.
ASME Boiler and Pressure Vessel Code (BPVC) is a standard that
provides rules for the design, fabrication, and inspection of boilers and
pressure vessels. It is reviewed every three years.
Health, Safety and Environment aspects are increasingly gaining attention in view of their importance.
Therefore the design of process plant has to take into account of the HSE particularly the safety and
environment aspects where it has to be integrated with the design activities ….

Inherent Safety
Remove or attenuate conditions that
Hazard Analysis
could lead to the 3 incidents such as
high P and T …..

FIRE EXPLOSION TOXIC RELEASE HAZOP

Auto Ignition temp. Chemical Energy vs Time weighed exposure Hazard and
Flammability Limits Physical Energy Short term Exposure Operability
Flash Points Deflagration vs detonation Ceiling Exposure Study.
Minimum Oxygen concentration Confined vs Unconfined LC50 & LD50
Explosions (VCE) DOW Index
Flammable liquids are more
dangerous than flammable gas
Health, Safety and Environment aspects are increasingly gaining attention in view of their importance.
Therefore the design of process plant has to take into account of the HSE particularly the safety and
environment aspects where it has to be integrated with the design activities ….
Environment
Environment

Waste Minimisation Waste Treatment

(Clean Process Technology)
Reactor
Increase conversion if selectivity is not an issue
Product removal for reversible reaction favoring product
Set T & P to improve selectivity
Air Effluent
Particulate, CO2, CO, SOx, Nox
Gravity Settlers, Inertial Collectors, Scribbers, Filters,
Electrostatic precipitators, catalytic reaction etc.

Distillation Water Effluent

Recycling waste stream to suppress by product reaction Membrane, Adsorption, Absorption, thermal oxidation,
Feed purification biological treatment, membrane separation etc.
Eliminate use of extraneous material for separation
(entrainer)

Waste stream recovery

Improve heat recovery
Finally …..

You will develop the construction

details for a process plant ….