Higher Institute of Engineering and Technology, Menoufia

Chemical Engineering Department

Chemical Plant Design & Management (CHE452)
Lecture (1)

Lecture (1)
Chemical Plant Design & Management (CHE452)
Number of hours weekly :( 2 hours lecture and 1 hour section)

total degrees 100 degree

year work 20 quizes 20 Final Exame 60

class work Reports midterm 15 quiz 5 MCQ written questions

Course Description:

A. Process design development .

B. Optimum design and Design Strategy.
C. Optimum Economic Design .
D. Optimum operating design .
E. General and practical consideration in design .
F. The design approach .
G. Computer aided design.

References:
1. Max Peters, Klaus Timmermans, and Ronald West, Plant Design and Economics for
Chemical Engineers, McGraw- Hill Science/ Engineering/ Math, 5th ., 2002.
2. Frank Peter Helmus , Process Plant Design: Project Management from Inquiry to
Acceptance, Wiley VCH, 2008.
3. Stanley M. Walas , Chemical Process Equipment; Selection and Butterworth Heinemann,
a division of Reed Publishing (USA) Inc,1990.
4. Lecture notes.

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 Higher Institute of Engineering and Technology, Menoufia
Chemical Engineering Department
Chemical Plant Design & Management (CHE452)
Lecture (1)

Introduction to Chemical Plant Design & Management:

Chemical plant design and management is a multidisciplinary field that focuses on :

➢ the planning.
➢ Construction.
➢ Operation.
➢ optimization of chemical processing facilities.
It involves combining principles from :
➢ chemical engineering.
➢ mechanical engineering.
➢ process control.
➢ Economics.
➢ project management .
to create systems that efficiently convert raw materials into valuable products such as fuels,
chemicals, and materials.

1. Chemical Plant Design:

Chemical plant design refers to:
➢ the development of processes and systems to produce chemicals or materials on an
industrial scale.
➢ creation manufacturing process to fulfill public need or commercial opportunity
It includes:

A. Process Design:
1. This involves creating a flow diagram that outlines the sequence of chemical reactions
and unit operations such as:
➢ Distillation.
➢ Filtration.
➢ heat exchange.
2. Engineers select the appropriate technology and equipment to optimize :
➢ production efficiency.
➢ Safety.
➢ cost.

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 Higher Institute of Engineering and Technology, Menoufia
Chemical Engineering Department
Chemical Plant Design & Management (CHE452)
Lecture (1)

B. Equipment Design:

1. The critical work for engineering is Choosing the right type of :

➢ Reactors.
➢ Separators.
➢ heat exchangers.
➢ storage units.
2. Engineers must consider factors such as:
➢ Temperature.
➢ Pressure.
➢ corrosion resistance.
➢ material handling.

C. Layout and Infrastructure:

The most important aspect of engineering is designing the physical layout of the plant to ensure:
➢ smooth operations.
➢ accessibility for maintenance.
➢ Safety.
The layout must accommodate:
➢ Piping.
➢ electrical systems.
➢ emergency systems like fire suppression.

D. Safety and Environmental Considerations:

Designing a plant involves rigorous attention to :
➢ safety standards (e.g., hazardous materials, pressure management) .
➢ environmental impact (e.g., emissions control, waste treatment).

2. Chemical Plant Management:

Managing a chemical plant involves overseeing operations to ensure production targets are met
safely and efficiently. It includes:
A. Operations Management:
Ensuring that the plant operates smoothly, including :
➢ scheduling production runs.
➢ monitoring performance.
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 Higher Institute of Engineering and Technology, Menoufia
Chemical Engineering Department
Chemical Plant Design & Management (CHE452)
Lecture (1)

➢ troubleshooting equipment .
➢ process issues.

B. Maintenance and Reliability:

for plant longevity and operational efficiency we can do :
➢ Regular inspections.
➢ preventive maintenance.
➢ equipment repairs.
➢ Reliable operations minimize downtime and safety risks.

C. Health, Safety, and Environment (HSE):

Ensuring that the plant complies with:
➢ safety regulations.
➢ worker safety protocols.
➢ environmental regulations.
This includes:
➢ monitoring emissions.
➢ managing waste.
➢ maintaining emergency response plans.

E. Supply Chain and Logistics:

Managing the flow of :
➢ raw materials into the plant .
➢ the distribution of finished products.
This requires coordinating with :
➢ Suppliers.
➢ optimizing inventory.
➢ managing transportation logistics.

F. Cost and Budgeting:

Economic considerations are a major aspect of plant management.
Managers must control :
➢ operating costs.

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 Higher Institute of Engineering and Technology, Menoufia
Chemical Engineering Department
Chemical Plant Design & Management (CHE452)
Lecture (1)

➢ energy consumption.
➢ Labor.
➢ raw material expenses
Managers must maximizing :
➢ productivity and profitability.

3. Integration of Design and Management:

➢ Effective chemical plant management starts at the design phase.

➢ A well-designed plant is :
➢ easier to manage.
➢ more cost-effective to operate.
➢ safer for workers and the environment.
➢ Design decisions directly impact the plant’s :
➢ operational efficiency.
➢ safety protocols.
➢ environmental footprint.

The ultimate goal of chemical plant design and management is :

to create facilities that operate:
➢ efficiently.
➢ Safely.
➢ sustainably while meeting the production demands of the market.

Aim of Chemical Engineering Design:

The primary aim of chemical engineering design is to create processes and systems that transform
raw materials into valuable products in an efficient, safe, cost-effective, and environmentally
responsible manner. This involves the application of engineering principles, chemistry, physics,
and economics to design processes that can be scaled from laboratory experiments to industrial-
scale operations. The specific aims of chemical engineering design include:

1. Efficiency in Production:

➢ Maximizing output while minimizing the use of raw materials and energy.
➢ Designing processes that are optimized for throughput and yield.

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 Higher Institute of Engineering and Technology, Menoufia
Chemical Engineering Department
Chemical Plant Design & Management (CHE452)
Lecture (1)

2. Safety:

➢ Ensuring the safety of workers, the public, and the environment by designing
systems that handle chemicals, energy, and equipment in a controlled and
secure way.
➢ Mitigating risks related to hazardous materials, high pressures, and extreme
temperatures.

3. Cost-Effectiveness:

➢ Reducing capital and operational costs by selecting cost-efficient materials,

equipment, and processes.
➢ Designing plants that minimize downtime and maintenance costs while
maximizing profitability.

4. Scalability:

➢ Designing processes that can scale from laboratory research or pilot plants to full
industrial production without losing efficiency or quality.
➢ Ensuring that processes are flexible enough to adapt to changing production
volumes or market demands.

5. Environmental Responsibility:

➢ Designing sustainable processes that minimize waste, emissions, and

environmental impact.
➢ Incorporating energy-efficient technologies and waste recycling into process
designs.

6. Regulatory Compliance:

➢ Ensuring that the plant design complies with local and international regulations,
including environmental, safety, and health standards.
➢ Designing for easy maintenance, monitoring, and adherence to legal requirements.

7. Innovation and Optimization:

➢ Continuously improving existing processes and incorporating new technologies to

enhance performance.
➢ Innovating new methods for chemical synthesis, energy use, or raw material
conversion.

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 Higher Institute of Engineering and Technology, Menoufia
Chemical Engineering Department
Chemical Plant Design & Management (CHE452)
Lecture (1)

The overall aim is to balance technical, economic, safety, and environmental considerations to
produce high-quality products while maximizing profit and sustainability.

Summary of Aim of Chemical Engineering Design:

1. Efficiency in Production: Maximize output and minimize raw material and energy
usage.
2. Safety: Ensure safe handling of chemicals, energy, and equipment to protect workers and
the environment.
3. Cost-Effectiveness: Reduce capital and operational costs while maximizing profitability.
4. Scalability: Design processes that can scale from lab experiments to industrial
production.
5. Environmental Responsibility: Minimize waste and emissions while incorporating
sustainable practices.
6. Regulatory Compliance: Ensure adherence to safety, health, and environmental
regulations.
7. Innovation and Optimization: Continuously improve processes and incorporate new
technologies for better performance.

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 Higher Institute of Engineering and Technology, Menoufia
Chemical Engineering Department
Chemical Plant Design & Management (CHE452)
Lecture (1)

Questions on lecture (1)

Answer the following questions:
1. Defined the following:

A. Chemical plant design .

B. Process Design.

2. Write short notes about the following :

A. Equipment Design.
B. Layout and Infrastructure

C. Safety and Environmental Considerations.

D. Chemical Plant Management.

E. Integration of Design and Management.

F. Aim of Chemical Engineering Design

3. What is the ultimate goal of chemical plant design and management ?

Best wishes
Asso.Prof :Wafaa Ahmed