Chemical Plant

Design
B.SC. (Engg.) Chemical Engineering
7th Semester
2011

Dr. Mahmood Saleem ICET Digitally signed by ICET Students

DN: cn=ICET Students, o=ICET
Students, ou=Administrator,

Students
[email protected],
c=PK
Date: 2011.06.12 18:16:52 +05'00'

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Recommended Books
 Coulson & Richardson’s Chemical Engineering by R. K.
Sinnot, Vol. 6 (Chemical Engineering Design) 3rd Edition,
1999.
 Peters Max S, Timmerhaus Klaus D. “Plant Design and
Economics for Chemical Engineers” 4th Ed. McGrawHill
Inc., 1991
 PROCESS HEAT TRANSFER BY D.Q.KERN
 Ludwig Ernest R. “Applied Process Design for Chemical
and Petrochemical Plants” Vol,2,3 3rd Ed.
 Wells G.L. Rose L.M. “ The Art of Chemical Process
Design” Published by The Elsevier.
 Smith Robin “ Chemical Process Design” McGrawHill Inc.

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 Course Contents/Lesson plan

1. Introduction to design  3 hours

2. Overview of material balance,  1 hour
energy balance, & Flow sheeting
(only flow sheeting will be
discussed)
3. Design information and Data  2 hours
4. Design of Heat Transfer equipments  9 hours
5. Design of Separation Columns  9 hours
6. Miscellaneous Equipment selection,  9 hours
specification and design
7. Mechanical Design of Process  3 hours
Vessels
8. Costing and Project evaluation
9. Optimization
 3 hours
 6 hours
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Assessment

Mid Term Assignments Final Term

Marks 35 5 5 5 5 5 40

Mode Written Home assignments Written

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Chemical Engineer-----You

 The work of a chemical engineer is typically on a much

larger scale , for instance:
 Chemical engineers tend to deal with problems in
huge facilities such as industrial plants,
 Chemical engineers are involved at all stages of
manufacturing from the
 design and construction of processes and equipment
 to the daily production of products,
 the maintenance of facilities,
 research on new products and
 perfecting or enhancement of processes.

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As a Design Engineers

 You have to combine basic technical

principles learned in other courses in
the general curriculum with practical
elements of economics, business
practices and organization along with
principles of safety, environmental
and sociological issues to design an
integrated chemical process plant.

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 Learning Objectives
 Demonstrate proficiency in all major elements of chemical engineering
including:
 Mass and Energy Balances
 Unit Operations
 Hierarchy of Chemical Process Design
 Process Integration
 Basic Equipment Sizing & Design
 Optimization Methods
 Economic Analysis (Estimations of Costs and Return on Investment)
 A strong emphasis on written and oral communication including the following:
 Plant Safety and Hazards Analyses
 Engineering ethics
 Local Global Impact Analysis
 Project Scheduling
 Problem Solving in a Team Environment
 Engineering/Business Report Writing and Oral Presentation

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 Nature of Design

 Success < 1% become

commercial
 Constraints
 External
 Internal
 Design Process

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 Design Constraints

 External  Internal
1. Resources 1. Process
2. Physical laws conditions
3. Standards and 2. Materials
codes 3. Personnel
4. Government controls 4. Time
5. Economic 5. Methods
constraints 6. Choice of
6. Safety regulations process

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 Design Process
Design Collection of data:
Objective physical properties,
design methods

Generation of
possible designs

Selection &
Final Design
Evaluation
(Optimization)

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Design Objective

 Before you start design of a

process/equipment, establish:
As complete as possible and
unambiguous statement of
requirements
 This will save you a lot of time and
money during rest of the design

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Data Collection

 For process design you must first collect

information like:
 Possible process
 Equipment performance
 Physical property data
 You will find data in:
 Company maintained manuals
 National or International standards
 Handbooks/Encyclopedia

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Generation/Selection of
designs
 Step1: Possible solutions bounded by
external constraints
 Step 2: Plausible designs bounded by
internal constraints
 Step 3: Probable designs or likely
candidates
 Step 4: Best design (Optimum)-judged
best solution to the problem
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 Anatomy of a chemical
manufacturing process
By-products
Recycle of recovered reactants
wastes

Raw material Feed Reaction Product

storage preparation separation
Stage 1 Stage 2 Stage 3
Stage 4

Sales Product Product

storage purification
Stage 7 Stage 5
Stage 6

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Choice of continuous or
batch process-rough guide
 Continuous  Batch
 Production > 5 million  Production < 5 million
kg/h kg/h
 Single product  A range of product
 No severe fouling and product
 Good catalyst life specification
 Proven process  Severe fouling
design  Short catalyst life
 Established market  New product
 Uncertain design

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Organization of a Chemical
Engineering Project
 Phase 1:Process design
 Selection, specification and chemical
engineering design of equipments mostly
done by chemical engineers
 Phase 2:
 Detailed mechanical design
 Civil and electrical design
 Specification and design of ancillary facilities
done by specialist design groups.

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 Project
organization/coordination
Process section Construction section

Process evaluation Construction

Flow sheeting Start-up

Equipment specification
Procurement section
Project Estimating
Manager
Inspection
?
Scheduling

Specialist design sections

Vessels Layout Piping & valves Heat exchangers
Control & Instr. Civil work Electrical
Compressors,
17 turbines, pumps Utilities
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Project documentation
 General correspondence
 Within groups and with government departments,
vendors, site personnel and client
 Calculation sheets
 Design calculations, costing, computer print out
 Drawings
 Flow sheets, PID’s, layout, site plan, equipment
details, piping, architectural, design sketches
 Specification sheets
 For equipments like heat exchanger, pumps,
compressors etc.
 Purchase orders
 Quotations, invoices

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 Codes & Standards
 in engineering practices cover :
 Materials, properties, and composition
 Testing procedures for performance,
compositions, quality
 Preferred sizes; for example tubes, plates,
sections
 Design methods, inspection, fabrication
 Codes of practice, for plant operation and safety
 Pakistan Standards,
 British Standards in UK
 In US: Standards issued by API, ANSI,ASTM,ASME
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Safety factor/Design
allowance
 Uncertainty in
 Material properties
 Design methods
 Fabrication
 Operating loads
 Design factors depends on level of
uncertainties and vary over wide range
 In process design capacity is normally
increased by 10% to provide some
tolerance

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Design variables
A processing unit

 Nd=Nv-Nr Input Output

streams streams
 Nd=0: uniqe Unit
solution, no
optimization Input
information Calculation
 Nd<0: overdefined,
method
only trivial solution Output
is possible information

 Nd>0: infinite A design unit

number of solutions

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Degree of Freedom: example
1- a single process stream
A single phase stream with C components
Variable name Counts
Flow rate 1
Composition (concentration of each component) C
Temperature 1
Pressure 1
Enthalpy of stream 1
Total variables, Nv=C+4
Relationships between variables Counts
Composition 1
Enthalpy 1
Total relations, Nr= 2
Degree of Freedom Nd=Nv-Nr=C+4-2=C+2

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Example 2: Flash distillation-
Description of the system F 2

P2
 A Feed stream (1) is T2
heated and flashed to F1 (Xi)2
separate into liquid (3)
P1
and vapour(2) streams.
Latent heat is provided T1
(Xi)1 F3
 F is flow rate
P3
 T is temperature
 P is pressure T3
 Xi is concentration of (Xi)3
component I
 Q is heat input

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Analysis
Variable Number
Free stream variables 3(C+2)
Still Pressure 1
Still Temperature 1
Heat input 1
Nv= 3C+ 9
Relationships Number
Material balance C
Heat balance (Overall) 1
V-l-e relations C
Equilibrium still relations 4
Nr = 2C+ 5
Nd= C+ 4
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 Selection of design variables
Flash distillation 2 components
F1
X1
X2 (or x3) F3 (or F2)
Feed P1
X2
T1
X3
P T
Select
F2(or F3)

Direction of calculation

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Developing information flow
of a design problem
 Write the problem in fi(vj)=0 form,
where :
 j=1,2,3,…………,Nv
 i= 1,2,3,………..,Nr
 Compute DOF Nd=Nv-Nr
 Decide Nd variables as design
variables among many choices
 Solve equations to get design solution

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Developing information flow of
a design problem-Illustration
problem
 Consider the following set of equations:
 F1(v1,v2)=0
 F2(v1,v2,v3,v5)=0
 F3(v1,v3,v4)=0
 F4(v2,v4,v5,v6)=0
 F5(v5,v6,v7)=0
 Nr=5, Nv=7 ; Nd=7-5=2
 Choice of design variables is 2
 There are 21 ways of selecting design
variables nCr=7!/2!5!

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Developing information flow of
a design problem-Illustration
problem
 The method proposed by Lee at
al.(1966) will be used which is a form
of directed graph called a biparte
graph
 Each equation is represented by
nodes connected by lines showing
relation between function and
variables

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Developing information flow of
a design problem-Illustration
problem
 For example the first relation in nodes
notation is
f1 f node

v1 v2 v node

f1(v1,v2)=0

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 Developing information flow of
a design problem-Illustration
problem
 The problem in this notation looks like

f1 f2 f3 f4 f5

v2 v3 v4 v5 v6 v7
v1

Complete set of equations in graphical notation

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 Developing information flow of
a design problem-Illustration
problem
 Let us select v3 and v4 as design
variables and assign certain values to
them the remaining unknowns are 5
f1 f2 f3 f4 f5

v2 v3 v4 v5 v6 v7
v1

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 Developing information flow of
a design problem-Illustration
problem
v4
v3

f1 f2 f3 f4 f5

v2 v5 v6 v7
v1

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 Developing information flow of
a design problem-Illustration
problem
v4 Arrows show flow of
v3
information

f1 f2 f3 f4 f5

v2 v5 v6 v7
v1

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 Developing information flow of
a design problem-Illustration
problem
v4 F3 can be solved for
v3
v1

f1 f2 f3 f4 f5

v2 v5 v6 v7
v1

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 Developing information flow of
a design problem-Illustration
problem
v4 V1 is known and input
v3
to f1 and f2

f1 f2 f3 f4 f5

v2 v5 v6 v7
v1

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 Developing information flow of
a design problem-Illustration
problem
v4 F1 can be solved for
v3
v2 which is input for
f2 and f4

f1 f2 f3 f4 f5

v2 v5 v6 v7
v1

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 Developing information flow of
a design problem-Illustration
problem
v4 F2 can be solved for
v3
v5 which is input for
f4 and f5

f1 f2 f3 f4 f5

v2 v5 v6 v7
v1

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 Developing information flow of
a design problem-Illustration
problem
v4 F4 can be solved for
v3
v6 which is input for
f5

f1 f2 f3 f4 f5

v2 v5 v6 v7
v1

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 Developing information flow of
a design problem-Illustration
problem
v4 solution is completed
v3
by solving F5 for v7

f1 f2 f3 f4 f5

v2 v5 v6 v7
v1

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Developing information flow of
a design problem-Illustration
problem-Summary
 Assigning values to design variables v3 and
v4 enables solving f3 for v1 which is input to
f1 and f2
 Then f1 can be solved for v2; v2 is input to
f2 and f4
 Then f2 can be solved for v5; v5 is input to
f4 and f5
 Then f4 can be solved for v6; v6 is an input
to f5
 Then f5 can be solved for v7 which
completes the solution.

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Developing information flow of
a design problem-Illustration
problem-Summary
 There are graphical methods to represent summary as
well. Refer to Coulson’s Vol.6 Chapter 1 for further
details.
 Some time choice of design variables will not produce
a simple solution. An example is discussed in
Coulson’s Vol.6 Chapter 1.
 Your judgment is very important for the choice of
design variables which improves with experience.
 This methodology is very useful when dealing with
complex problems where the designer likes to write a
computer code for solving the set of equations.
 For simple problems intuitive solution is faster and
sufficient.

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Optimization

 A best design will not be accepted by

the management if it is not
economical
 Engineer must be familiar with the
methods and tools for optimization of
design problems
 You will learn more details later in this
course

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Exercise questions

 A problem sheet will be distributed for

student’s practice

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