Date post: | 09-Jan-2016 |
Category: |
Documents |
Upload: | aleep-youngbae |
View: | 11 times |
Download: | 0 times |
of 23
BTE 4417
PROCESS PLANT DESIGN AND SAFETY
Lecturer : Dr Azlin Suhaida Azmi
Dr Sarina Sulaiman
3 Credit-Hour Course
Lecture Time : MONDAY & WEDNESDAY 11.30 to 12.50pm
Venue : E0-01-16 (1 section)
1Semester 1 2014/15
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
2
Dress Code in IIUM
http://www.iium.edu.my/legaladviser/articles-4
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
Course Content & Delivery
Content outline of the course / module and the SLT per topic
Weeks TopicsLearning
HoursTask/Reading
1 Integrated process design9
Chapter 1
2 Process synthesis by hierarchical approach9
Chapter 2
3 Synthesis of separation system9
Chapter 3
4 Reactor/separation/recycle systems9
Chapter 4
5 Cost analysis of process plant design and operations
*MIDTERM*
9
Hands out
6-7 Safety of integrated process plant design 25
Hands out
8-10 Case study: Biochemical processes, biodiesel and bioethanol
manufacturer 20Chapter 12, 14, 15
11-14 Preparation and presentation of complete conceptual plant design with
process flow sheet, layout considering the fundamental engineering
principles such as biological systems, thermodynamics, transport
processes, individual design of bioreactor and separator etc 33.5
Hands out (design
hand book, journal
papers)
3
Semester 2 2013/14
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
Course Content & Delivery
Weeks Topics Task/Reading
1 Overview/ Introduction Chapter 1
2 Process Design Development Chapter 3
3 Flowsheet Synthesis and Development Chapter 4
4 Software Use in Process Design Chapter 5
5 General Design Consideration
*MIDTERM*
Chapter 2
6-7 Optimum Design and Design Strategy Chapter 9
8 Costing and Project Evaluation
9 Material and Fabrication Selection Chapter 10
10 Material-Handling Equipment Design and Cost Chapter 12
11 Reactor Equipment Design and Costs Chapter 13
12 Heat-Transfer Equipment Design and Costs Chapter 14
13 Separation Equipment Design and Costs Chapter 15
14 Written and Oral Design Reports Chapter 11
(Self-Reading)
4
Semester 2 2013/14
Quiz 10%
Assignment 10%
Midterm 30%
Final Exam 50%
Overall Assessment
Assessment
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
5
Semester 2 2013/14
Pre-requisites
BTE 4481 Separation Process II
BTE 4412 - Biological Reactor Design and Analysis
1. Dimian, A. C. Bildea, C. S. (2008), Chemical Process Design, Wiley-VCH Verlag GmbH &
Co.
2. Smith, R. (1995), Chemical Process Design, McGraw Hill Inc.
3. Seider, W. D., Seader, J. D., Lewin, D. R. (1999). Process Design Principles: Synthesis,
Analysis and Evaluation. Wiley, New York.
4. Chemical Engineering Design Vol. 6 by Sinnot R.K.
Peters M.S., Timmerhaous K.D., West R.E. (2003). Plant Design and Economic for
Chemical Engineers (5 ed.)
The purpose of engineering is to create material wealth Douglas, Conceptual Design of Chemical Processes 1988.
How to do so ?
Raw Materials
+ Other Feeds
Energy
In
CHEMICAL
PROCESS Products + Wastes
Energy
Out
WHAT CAN YOU SAY ABOUT THIS CHEMICAL PROCESS ?
1. OVERVIEW PROCESS PLANT DESIGN AND SAFETY
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)
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.
6
Semester 2 2013/14
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
Raw Materials
+ Other Feeds
Energy
BIOCHEMICAL
PROCESSProducts + Wastes
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 DO WE ADDRESS
THIS?
Concept Design for Chemical Process
1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS
7Semester 2 2013/14
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
IS THE CONCEPTUAL DESIGN OF CHEMICAL PROCESSES IS AN OPEN-ENDED OR CLOSED PROBLEM. WHY ?
Raw Materials
+ Other Feeds
Energy
CHEMICAL
PROCESSProducts + Wastes
Energy
DESIGN IS THE NAME OF THE GAME !
LITTLE OR LIMITED
INFORMATIONS ARE
AVAILABLE
BEFORE COMING UP WITH A
COMPLETE PLANT
But so many possibilities
or solutions !
1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS
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)
8
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
THUS,
A SYSTEMATIC APPROACH OR METHOD IS REQUIRED
1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS
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)
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?
9
Semester 2 2013/14
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
1. ADDRESS THE INDIVIDUAL
PROCESS/TRANSFORMATION STEP
2. ADDRESS THE REQUIRED
INTERCONNECTION BETWEEN THE STEPS
FEED REACTOR
CW
STEAM
PRODUCT 1
PRODUCT 2
RECYCLE
1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS
In general, any systematic approach/method used for process design have to consider two major activities,
10Semester 2 2013/14
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
.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.
THIS IS WHAT YOU WANT
AT THE END OF THE DAY!
FEED REACTOR
CW
STEAM
PRODUCT 1
PRODUCT 2
RECYCLE
WHAT OTHER INFORMATIONS SHOULD BE
AVAILABLE IN A FLOWSHEET ?
AND HOW DO YOU GET SUCH INFORMATION ?
Str1 Str2 Str3 Str4 Str5 Str6 Str7 Str8 Str9
F
T
P
x
H
1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS
11Semester 2 2013/14
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
1. ADDRESS THE INDIVIDUAL
PROCESS/TRANSFORMATION STEP
2. ADDRESS THE REQUIRED
INTERCONNECTION BETWEEN THE STEPS
FEED REACTOR
CW
STEAM
PRODUCT 1
PRODUCT 2
RECYCLE
FLOWSHEET
What criteria should be adopted during the activities?
MINIMISE COST HIGH SAFETY & INTEGRITY
MINIMISE ENERGY CONSUMPTION
MINIMISE WASTES GENERATION
..... BUT HOW TO OPTIMISE ?
QUANTIFIABLE
FACTOR !
GOOD OPERATIONAL ASPECTS
NON - QUANTIFIABLE
FACTOR !VERSUS
1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS
12Semester 2 2013/14
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
FEED REACTOR
CW
STEAM
PRODUCT 1
PRODUCT 2
RECYCLE
Consider back the flowsheet !
OPTIMISING A SINGLE UNIT/STEP
IN THE PROCESS
EG. PIPE DIAMETER
OPTIMISING THE INTERCONNECTIONS
BETWEEN THE UNITS/STEPS IN THE PROCESS
TOTAL
COST
Fixed charges based
on capital investment
for installed pipe
Cost for pumping
power
PIPE DIAMETER
?
MANY POSSIBLE CONNECTIONS WHICH LEAD
TO DIFFERENT IN STRUCTURE OF FLOWSHEET
THUS DIFFERENT ECONOMIC IMPACT EVEN TO THE
EXTENT OF THE INDIVIDUAL UNIT ITSELF!
DIS-CONTINUOUS FUNCTION
STRUCTURAL OPTIMISATION
PARAMETER OPTIMISATION
1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS
And how do we tackle this ? 13Semester 2 2013/14
CONTINUOUS FUNCTION
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
What approaches/methods have been introduced to deal with such complex optimisation?
ONION MODEL
HEURISTIC METHOD
MIXED INTEGER LINEAR/
NON-LINEAR PROGRAMMING
MATHEMATICAL METHOD
USE A SEQUENTIAL/HIERARCHICAL METHOD
ACCORDING TO FOLLOWING SEQUENCE ;
1. REACTOR
2. SEPARATION AND RECYCLE SYSTEM
3. HEAT EXCHANGER NETWORK
4. UTILITIES
CONCEPT IS BASED ON
"BUILDING AN IRREDUCIBLE STRUCTURE"
DECISION ARE BASED ON ENGINEERING GUIDELINES
ESTABLISHED AND MATHEMATICAL OPTIMISATION
USE A MATHEMATICAL PROGRAMMING METHOD TO
SOLVE AND GIVE SOLUTION FOR THE PROCESS.
SIMULTANEOUS SOLUTION OF ALL THE SYSTEM.
CONCEPT IS BASED ON
"CREATING AND OPTIMISING A REDUCIBLE
STRUCTURE"
DECISION ARE BASED ON SOLELY MATHEMATICAL
OPTIMISATION CRITERIA
1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS
Grossman I. E, Comp. Chem. Eng., 9: 463, 1985Smith R.,Chemical Process Design 1995
Biegler, Grossman & Westerberg, Systematic
Method of Chemical Process Design 1997HIERARCHICAL APPROACH
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 198814
Semester 2 2013/14
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
HEURISTIC METHOD The Onion Model
REACTOR
SEPARATION
& RECYCLE
SYSTEM
HEAT EXCHANGER
NETWORK
UTILITIES
- FOLLOWS ONION LOGIC
Design starts from the centre ( heart of process ) which is the 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
added only if it is economically justified based on the current available
information. This keeps the process (structure) irreducible and features
which are technically/economically redundant are not included.
What do you see are the advantages and disadvantages of this method ?
Advantages Disadvantages
1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS
15
Semester 2 2013/14
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
ENVIRONMENTAL
PROTECTION
SAFETY &
OPERABILITY
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
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
At each level except level 1, alternatives have to
be generated and assessed to see its economic
and operational potential. Some level of process
design has to be conducted on the units/process
placed at every stages.
WHAT DO YOU NOTICE ON
THE STATEMENT CONTAIN WITHIN
THE SHADED BOX ?
REACTOR
SEPARATION
& RECYCLE
SYSTEM
HEAT EXCHANGER
NETWORK
UTILITIES
Compare these statements
to the onion model !
1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS
16Semester 2 2013/14
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
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
1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS
17Semester 2 2013/14
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
Generalized block diagram of downstream processing
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
Design Database
Literature Survey
Patent Search
Semester 2 2013/14 19
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
QUESTIONS TO PONDER......
WHAT ARE THE BASIC PROBLEMS THAT YOU HAVE TO FACE DURING THE
CONCEPTUAL DESIGN OF ANY CHEMICAL PROCESSES ?
STRUCTURE & OPTIMISATION
WHAT ARE THE MAJOR APPROACHES INTRODUCED TO TACKLE THE
CONCEPTUAL DESIGN OF ANY CHEMICAL PROCESSES ?
1. OVERVIEW FOR CONCEPTUAL DESIGN OF CHEMICAL PROCESS
Semester 2 2013/14 20
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
General Overall Design Consideration
Process Design Development
Flowsheet Development
Computer-Aided Design
Cost Estimation
Profitability Analysis of Investments
Optimum Design
Safety & Loss Prevention (Chapter 2)
Plant Location and Layout (Chapter 2)
Semester 2 2013/14 21
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
Semester 2 2013/14 22
BTE 4417 PROCESS PLANT DESIGN AND SAFETY
Semester 2 2013/14 23