Introduction to Process Design

1
Introduction to Process Design

• Don Robinson
• September 2003

2
History of a Typical Plant Design Project

• And How the Course Relates to This

3
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

4
Identification of a Need
Opportunity
Problem

• Sales increasing
• New process technology
• New product

• Environmental regulations
• Costs not competitive
• Product Deficiencies
• Obsolete equipment

5
Data Gathering

• Info from existing process
• Literature data
• Data from simulation program
• Plant tests
• Lab experiments

6
Conceptual Design

• Map out structure of process
• Heat and mass balances
• Evaluate alternatives
• Primary tool is process simulation program

7
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

8
Profitability Analysis

• Will the expected return justify the expenditure?
• A process to direct resources to what is valued
  most by society

9
Approval of Development Funds

• Get sufficient to do a proper design
• Perhaps order long delivery time equipment

10
Detailed Equipment Design

• Sufficient detail to pin down costs
• Much of the work done by suppliers

11
Accurate Cost Estimate

• Improved accuracy
• Required for control of construction

12
Approval of Construction Funds

• Confirm that the profitability picture is still
  good
• A chance to bail out if conditions have changed

13
Implementation

• Construction
• Startup
• Postmortem (learnings for future projects)

14
Sections of the Course

• Concepts tools Barrie Jackson Geoff
  Whitfield
• Process analysis modeling Don Robinson
• Equipment design and costing Dave Mody

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Concepts and Tools

• Project management
• Capital cost estimation
• Engineering economics
• Profitability analysis
• Health safety issues
• Thermodynamics
• Distillation

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Process Analysis Modeling

• HYSYS tutorial and practice session
• Process Analysis
• Digest the information
• Partial mass balance
• Catalyst research

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Process Analysis (cont.)

• Initial HYSYS model
• Refined Model
• Optimized distillation column
• Detailed design of heat exchanger
• Energy minimization
• Profitability analysis

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Equipment Design Costing

• PIDs
• Sizing costing of specific equipment
• Hazard analysis
• Materials of construction
• Cost of overall project

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Computer Facilities

• Accounts
• CD
• Software
• Web Site
• Information on Server

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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

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Computer Accounts

• Security pass
• Password
• CD containing course documentation
• Cost is 20
• See Ann Tobin in room 201
• Must be done by Wednesday afternoon

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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

23
Information on Server
Available in Computer Cluster only

• 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)

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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