Scope for the Individual Parts

of the Team Report

Design Coordinators

1
 Process Development & Simulation
(2250 ± 250 words)
 Process Development: Complete PFD.

 Select and justify alternatives with any simulations or calculations.

 Include all equipment items including pumps, compressors, major

valves, and vacuum generation units with correct utilities.

 Use proper symbols and labels, and legend. NO COMPONENT

SPLITTERS or TEES or MIXERS (unless using special devices).

 Simulation: Hysys model and stream table

 Briefly justify FP.

 Converge Hysys model fully.

 Full stream table. NO DIGIT DUMPING.

 Make all readable and concise.

2
Process Optimization and Heat Integration
(2250 ± 250 words)
 Optimization:

 Summary of optimization strategy

 Choice of design variables

 Sensitivity analysis and dominant vs local design variables

 Trade-off analysis with key plots/tables

 Optimization results summary for all runs

 Summary of final optimized parameters

 Heat integration:

 Rationale for basic heat integration network for the plant

 Stream table and summary of heat exchangers

 Comparison with and without heat integration

3
Cost Estimation and Economic Analysis
(2250 ± 250 words)
 Cost estimation:
 Perform complete cost estimation (capital and manufacturing costs)
for the whole optimized process

 Use any one program (e.g., CAPCOST, CCEP, DCP)

 Use the average CEPCI for the most recent year (that you can find)

 Feed and product prices from reliable sources

 Utilities and waste treatment cost factors from design textbooks

 Singapore land cost? How will you handle grass roots cost?

 Singapore operator salary?

Do not mix-and-match costing methods

except for vacuum system costs
4
 Economic analysis:

 Discuss the profitability of the proposed plant using discounted

criteria for internal rate of return on investment of 15%

 Assume the following:

 Project life of 20 years

 MACRS depreciation (what depreciates and what does not?)

 Assume WC = 15% of FCI

 Salvage value = 2% of FCI

 Other info:

 Singapore corporate taxation rate?

 Anything else?

5
 Equipment Schedule

 Prepare an equipment schedule listing all major equipment including

tanks and pumps

 A table listing all equipment in the process

 Equipment number/label

 Item name/type

 Capacity, i.e., dimensions necessary for costing (e.g., area for heat
exchanger; volume, height, diameter for distillation column; power
for pump/compressor, etc.)

 Design conditions (T and P)

 MOC

 Purchase cost, Bare module cost

6
 Reactor Design for Optimized Plant
(6000 ± 250 words)
 Fermentation Reactor:
 Number and configuration of reactor(s)
 Operating temperatures and pressures of the reactor(s)
 Operating cycle, including fermentation time, cleaning time, etc.
 Kinetic models for substrate consumption, cell growth and product
formation
 Simulated concentration profiles of substrate, biomass and product
 Flow rates and compositions of all streams entering and exiting the
reactor(s) during each part of operating cycle
 Sizes of inventory tanks
 Reactor dimensions and MOC
 Impeller design
 Design of oxygen supply system
 Design of heat removal system
 Sterilisation procedures

7
 6-APA Synthesis Reactor:

 Number and configuration of reactor(s)

 Operating temperatures and pressures of the reactor(s)

 Flow rates and compositions of all streams entering and exiting the
reactor(s)

 Catalyst(s) and reaction kinetics

 Reactor dimensions and MOC

 Design of heat removal

 Operating cycle, including reaction time, cleaning time, etc.

 Mass transfer consideration - estimate of internal effectiveness factor

 You should justify your decisions using Chemical Engineering

principles, heuristics and/or relevant literature, where possible.

8
 AMOX Synthesis Reactor:
 Number and configuration of reactor(s)
 Operating temperatures and pressures of the reactor(s)
 Operating cycle, including reaction time, cleaning time, etc.
 Choice of enzyme and kinetic model
 Simulated concentration profiles of all participating species
 Flow rates and compositions of all streams entering and exiting the
reactor(s) during each part of operating cycle
 Sizes of inventory tanks
 Reactor dimensions and MOC
 Enzyme immobilisation technique
 Mass transfer consideration - estimate of internal effectiveness factor
(CN2105 Part II)

9
Separator Design for Optimized Plant
(2250 ± 250 words)
 Justification of separation technology
 Specification of separator inlet conditions and targets
 Extractor unit
 Summary of optimized operating conditions (example temperature,
choice of solvent, etc)
 Type of extractor
 Distillation unit
 Summary of optimized operating conditions (example feed condition,
pressure/temperature, etc)
 Choice of auxiliaries and utilities
 Operability limits (Turn-up/down)
 Note: Extra 1000 words for additional separation units
design (e.g., centrifuge, crystallization, filtration, drying,
etc.)
10
 Safety and Sustainability Analysis
(2250 ± 250 words)
 Safety & Sustainability Analysis:

 Overview of how safety & sustainability are considered at various stages of the plant design
process, covering

 Design for Safety (DfS) considerations, Design for Maintainability (DfM) considerations, Design
for Sustainable Development (DfSD) considerations

 Conceptual Research & Design Stage:

 Evaluation of Reaction Pathways & Safety Hazards

• Analyze the Safety Hazards associated with the various reaction pathways using the
Safety Data Sheet (SDS), Preliminary Hazard Analysis, Process-FMEA, Determine Most
Hazardous Unit

 Green Chemistry & Engineering, Energy-efficiency Analysis, Environment Protection Analysis

• Analyze the Sustainability Metrics associated with the various reaction pathways using
Process Data on carbon emissions, fossil fuel usage, NOx/SOx emissions, energy efficiency,
water use, wastewater generation, hazardous wastes, environmental impacts, etc.

 Justify for your recommended and selected process reaction pathway

11
 Safety & Sustainability Analysis:
 Preliminary Design Stage:

 Evaluation of Preliminary Layout, Preliminary Piping & Instrumentation Diagrams (PrPID),

Design-HAZOP, Identified Hazard-scenarios, Determination of Most Hazardous Equipment,
Hazardous Area & Equipment Classification, Emergency Procedures, Safety Indices.

 Detailed Design Engineering Stage:

 Evaluation of Fault Tree Analysis (FTA) for one of Hazard-scenarios

 Construct the Layer of Protection Analysis (LOPA) for the Plant

 Summary of How Safe & Sustainable by Design (SSbD) are undertaken by the design team

 Sum-up with the key SSbD measures adopted

12