Introduction to Process Design
Don RobinsonSeptember 2003
History of a Typical Plant Design Project
And How the Course Relates to This
Introduction to Process Design Course Don Robinson
Steps (Don Robinson, Dave Mody, not covered)
Need Identification Data Gathering Conceptual Design Prelim Equip Design
& Cost Estimate Profitability
Analysis Approval of
Development Funds
Detailed Equipment Design
Accurate Cost Estimate
Approval of Construction Funds
Construction Startup Post Mortem
Introduction to Process Design Course Don Robinson
Identification of a Need
Sales increasing New process
technology New product
Environmental regulations
Costs not competitive
Product Deficiencies Obsolete equipment
Opportunity Problem
Introduction to Process Design Course Don Robinson
Data Gathering Info from existing process Literature data Data from simulation program Plant tests Lab experiments
Introduction to Process Design Course Don Robinson
Conceptual Design Map out structure of process Heat and mass balances Evaluate alternatives Primary tool is process simulation
program
Introduction to Process Design Course Don Robinson
Preliminary Cost estimate Not all that accurate (20-30%) Based on shortcut methods Some additional design work
needed Required for the “do we proceed”
decision
Introduction to Process Design Course Don Robinson
Profitability Analysis Will the expected return justify the
expenditure? A process to direct resources to
what is valued most by society
Introduction to Process Design Course Don Robinson
Approval of Development Funds Get sufficient $ to do a proper
design Perhaps order long delivery time
equipment
Introduction to Process Design Course Don Robinson
Detailed Equipment Design Sufficient detail to pin down costs Much of the work done by
suppliers
Introduction to Process Design Course Don Robinson
Accurate Cost Estimate Improved accuracy Required for control of
construction
Introduction to Process Design Course Don Robinson
Approval of Construction Funds Confirm that the profitability
picture is still good A chance to bail out if conditions
have changed
Introduction to Process Design Course Don Robinson
Implementation Construction Startup Postmortem (learnings for future
projects)
Introduction to Process Design Course Don Robinson
Sections of the Course Concepts & tools – Barrie Jackson
& Geoff Whitfield Process analysis & modeling – Don
Robinson Equipment design and costing –
Dave Mody
Introduction to Process Design Course Don Robinson
Concepts and Tools Project management Capital cost estimation Engineering economics Profitability analysis Health & safety issues Thermodynamics Distillation
Introduction to Process Design Course Don Robinson
Process Analysis & Modeling HYSYS® tutorial and practice
session Process Analysis
Digest the information Partial mass balance Catalyst research
Introduction to Process Design Course Don Robinson
Process Analysis (cont.)
Initial HYSYS model Refined Model
Optimized distillation column Detailed design of heat exchanger Energy minimization
Profitability analysis
Introduction to Process Design Course Don Robinson
Equipment Design & Costing P&ID’s Sizing & costing of specific
equipment Hazard analysis Materials of construction Cost of overall project
Introduction to Process Design Course Don Robinson
Computer Facilities Accounts CD Software Web Site Information on Server
Introduction to Process Design Course Don Robinson
Computer Software HYSYS process simulation to build
models CapCost (comes with the text)
crude estimates of equipment costs compiling overall capital costs profitability analysis
Excel for various calculations Word for writing reports Internet Explorer for viewing material
Introduction to Process Design Course Don Robinson
Computer Accounts Security pass Password CD containing course documentation Cost is $20 See Ann Tobin in room 201 Must be done by Wednesday
afternoon
Introduction to Process Design Course Don Robinson
Web Site info.chee.queensu.ca/CHEE470 Course description & schedule Info about staff and facilities Group lists Message log Documents added after start of
course
Introduction to Process Design Course Don Robinson
Information on Server
home folder (Z:) for your private storage group folder (R:) used by all group
members course folder (P:\CHEE470\start.wsf)
course material (a copy of the CD)
Available in Computer Cluster only
Introduction to Process Design Course Don Robinson
Work Groups Groups of 4 At least two chemical engineers At least one engineering chemist At least one not attending CSChE
conf. Designated A1,A2 . . . B1,B2 . . . For some work the class will be split –
while the A groups do modeling, the B groups will do workshops