Chemical Engineering Plant

Design

Dr. M. Azam Saeed

Course Title Chemical Engineering Plant Design

Course Number Ch.E-403

Semester Fall 2019

Instructor (Theory) Dr. M. Azam Saeed

Designation Assistant Professor

Email [email protected]

Credit Hours 3

Contact Hours 3

Compulsory/Elective Compulsory
What do you understand about

OBE
 Class Learning Outcomes (CLOs)
• CLOs are the skills learnt by the students at
the end of each course in the program.
• The three (3) learning domains characterize by
Bloom’s Taxonomy and their respective levels
of learning are
1. Cognitive (Knowledge) (6 levels)
2. Psychomotor (Skill) (7 levels)
3. Affective (Attitude) (5 levels)
Program learning outcomes (Total=12)

1) Engineering Knowledge
2) Problem Analysis 
3) Design/Development of Solutions
4) Investigation 
5) Modern Tool Usage 
6) The Engineer and Society 
7) Environment and Sustainability 
8) Ethics
9) Individual and Team Work 
10) Communication
11) Project Management 
12) Lifelong Learning
PRE-REQUISITE COURSES

1. Process Heat Transfer

2. Separation Processes
MEASURABLE STUDENT LEARNING OUTCOMES
Domain
CLOs Description PLOs Domain
Level
Create, design and evaluate alternate processes
and equipment for a chemical process and
CLO-1 PLO-4 Cognitive 6. Create
assess various societal, environmental, and
safety issues associated with such design

Apply knowledge acquired in core Chemical

Engineering courses (e.g., Stoichiometry,
Reaction Engineering, Thermodynamics, and
CLO-2 PLO-3 Cognitive 3. Apply
Unit Operations) for selection and design of
materials handling, heat transfer, and
separation process equipment.

Understand the concept of heat integration for

CLO-3 minimization of overall energy footprint of a PLO-6 Cognitive 6. Create
chemical process
Use process simulation software for process
CLO-4 creation and simulation, equipment sizing and PLO-5 Cognitive 3. Apply
costing, and process optimization
EXAMINATION DETAIL

Mid-Term Minimum Duration: 60 Minutes

Exam Specifications: Closed books/Closed notes

Final Term Minimum Duration: 90 Minutes

Exam Specifications: Closed books/Closed notes
Final exam will include 20-30 % course from pre-
midterm lectures.
 Semester Schedule
S. No. Activity Date

1 Start of Semester 02-09-2019

2 Quiz-1 10-10-2019

3 Mid Term 28-10-2019 to 01-11-2019

4 Quiz-2 05-12-2019

5 Final Term 23-12-2019 to 03-01-2020

 Grading backup
Grading Breakup (Theory) Grading Breakup (Laboratory)

SESSIONAL: 30% [(Quiz = 20 %), (Class

attendance and assignments = 10 %)]
MIDTERM: 30 %
--------
FINAL TERM: 40 %
NOTE:
An attendance of 75% is mandatory to sit
in the final examination.
 Time Table
Time Mon Tue Wed Thu Fri

8:00-9:00   Lecture  Lecture    

9:00-10:00     Lecture  

10:00-11:00      

11:00-12:00

12:00-13:00

13:00-14:00

14:00-15:00  

15:00-16:00          
 Course description
(1) Introduction to process design and development
(2) General design considerations
(3) Optimal design
(4) Materials of fabrication and their selection
(5) Material transfer handling and equipment design
(6) Heat transfer equipment design
(7) Mass transfer equipment design
(8) Application of computer aided design software
WEEK-WISE LECTURE PLAN
Week Topics CLO’s
Introduction: General overall design considerations: Process design and flowsheet development, optimum design; practical consideration
Week 1 CLO-1
and engineering ethics in design

General design considerations: Health and safety hazards, importance and objectives of safety, safety measures in equipment design:
Week 2 Fire and explosion hazards and prevention, Chemical, toxic, electrical hazards, control, precautions and prevention, personnel safety, loss CLO-1
prevention and safety audit.

Environmental protection and development of pollution control systems. Thermal pollution control, toxicological studies, industrial
Week 3 CLO-1
hygiene, radiation hazards.

Week 4 Plant site location and layout of chemical plant, piping layout, plant operation and control, plant considerations and exercise problems. CLO-1

Process design development: Process selection/creation, synthesis and design: equipment design and specifications. Preliminary process
Week 5 CLO-1
design: screening of process alternatives; economic decision making.
Flow sheet synthesis and development: Process information, input-output structure; function and operation diagrams; analysis and
Week 6 CLO-2
development of process flow sheet.
Optimum design and design strategy: defining the optimum problems, programming optimization problems; optimization solution
Week 7 CLO-2
methodologies; optimization applications and cost analysis.

Pinch technology an overview, key steps of pinch technology: Targeting of heat exchanger network: Designing of HEN: Pinch design
Week 8 CLO-3
methods, Heuristic rules, stream splitting, design of maximum energy recovery (MER)

MID TERM EXAMINATION

Materials selection and fabrication: Corrosion and factors contributing to corrosion; corrosion prevention; material properties;
Week 10 CLO-2
economics involved in materials selection.
Materials handling equipment design and cost: Basic concept of fluid transport, frictional losses, selection of piping material, design of
Week 11 CLO-2
piping system.

Computer aided design, cost estimation and profitability analysis of investments, Transport of fluids: selection, design and cost analysis
Week 12 CLO-4
for pumping, compression, expansion, agitation and mixing of fluids, flow measurement and storage of fluids.

Week 13 Heat transfer equipment design and cost: Basic theory of heat transfer in exchanger, heat exchanger selection criterion. CLO-2

Week 14 General methods for the design of heat exchangers: Design of key heat exchangers CLO-1

Week 15 Separation equipment design and costs: Introduction, selection, general design and cost of equipment for separation process. CLO-1

Design and cost for multi-component distillation: Absorption, adsorption membrane separation. Selection and design of filtration
Week 16 CLO-1
equipment.
FINAL TERM EXAMINATION
 Text book and other sources
Textbook

1. “Plant Design and Economics for Chemical Engineers” by M. S. Peters, K. D. Timmerhaus,

and R. E. West

Reference books

1. “Ludwig’s Applied Process Design for Chemical and Petrochemical Plants” by A. K. Coker
2. “Chemical Engineering Desgin-Volume 6” by R. Sinnott & Cavin Towler
3. “Chemical Process Equipment: Selection and Design” by J. R. Couper, W. R. Penney, J. R.
Fair, and S. M. Walas
4. “Equipment Design Handbook: For Refineries and Chemical Engineers” by F. L. Evans
5. “Chemical Process: Design and Integration” by R. Smith
6. “The Art of Chemical Process Design” by G. L. Wells, and L. M. Rose
7. “Coulson and Richardson’s Chemical Engineering — Volume 6: Chemical Engineering
Design” by R. K. Sinnott
 What does design mean?
Design is a creative process whereby an
innovative solution for a problem is conceived.
 What does design mean?
e.g.
A fashion designer creates clothes
that will enhance the appeal of an
individual.

An automobile designer creates a

car model that will provide
transportation and a certain appeal
to the consumer.
Design occurs when a possible answer for a
present or projected need or desire by people or
industry has been found. If a product were not
expected to meet a need or desire, there would
be no reason to produce it and hence no reason
for design.
Design Process
Design Constraints
 Skills needed for Plant design project

• Research
• Market analysis
• Design of individual pieces of equipment
• Cost estimation
• Computer programming
• Plant-location surveys
 Common abbreviations used in plant layout and piping design

• N,S,E,W: North, South, East and AG: Above Ground

West UG: Underground
• CL: Centerline f: Diameter
• El: Elevation OD: Outside Diameter of pipe
ID: Inside Diameter of pipe
• TOS: Top of Steel
TL: Tangent Line
• BOP: Bottom of Pipe TYP: Typical
• POS: Point of Support PFD: Process Flow Diagram
• BBP: Bottom of Baseplate P&ID: Piping and Instrumentation
• ISBL: Inside Battery Limits Diagram
• OSBL: Outside Battery Limits
 Organizations involved in providing standards
and guidelines for plant layout and piping design
• American Society for Mechanical Engineers (ASME): Publishes and updates codes for piping
design. The code relevant to the design of piping systems is ASME B31.3 – 2016 Process Piping.
(www.asme.org)
• Center for Chemical Process Safety (CCPS): Publishes documents and guidelines related to
process safety. The focus is on preventing or mitigating catastrophic releases of chemicals,
hydrocarbons, and other hazardous materials. CCPS has published guidelines for “Facility Siting
and Layout”. (www.aiche.org/ccps)
• Construction Industry Institute (CII): Provides guidelines for cost effective and safe construction
methods and has several publications on constructability. (www.construction-institute.org)
• Society of Piping Engineers and Designers (SPED): Promotes excellence and quality in the
practice of piping engineering and design. SPED emphasizes education and training and has
certification programs for piping designers. (www.spedweb.org)
• Occupational Safety and Health Administration (OSHA): Provides regulations and safety
standards for the operation of process plants. (www.osha.gov)
• National Fire Protection Association (NFPA): Provides fire protection standards for process
plants and for gas storage and handling. (www.nfpa.org)