Introduction to Process Design
Don Robinson
September 2003
History of a Typical Plant
Design Project
And How the Course Relates to
This
Steps
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(Don Robinson, Dave Mody, not covered)
Need Identification
Data Gathering
Conceptual Design
Prelim Equip Design
& Cost Estimate
Profitability Analysis
Approval of
Development Funds
Introduction to Process Design Course
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Detailed Equipment
Design
Accurate Cost
Estimate
Approval of
Construction Funds
Construction
Startup
Post Mortem
Don Robinson
Identification of a Need
Opportunity
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Sales increasing
New process technology
New product
Problem
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Introduction to Process Design Course
Environmental
regulations
Costs not
competitive
Product Deficiencies
Obsolete equipment
Don Robinson
Data Gathering
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Info from existing process
Literature data
Data from simulation program
Plant tests
Lab experiments
Introduction to Process Design Course
Don Robinson
Conceptual Design
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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
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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
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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
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Get sufficient $ to do a proper design
Perhaps order long delivery time
equipment
Introduction to Process Design Course
Don Robinson
Detailed Equipment Design
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Sufficient detail to pin down costs
Much of the work done by suppliers
Introduction to Process Design Course
Don Robinson
Accurate Cost Estimate
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Improved accuracy
Required for control of construction
Introduction to Process Design Course
Don Robinson
Approval of Construction
Funds
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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
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Construction
Startup
Postmortem (learnings for future
projects)
Introduction to Process Design Course
Don Robinson
Sections of the Course
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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
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Project management
Capital cost estimation
Engineering economics
Profitability analysis
Health & safety issues
Thermodynamics
Distillation
Introduction to Process Design Course
Don Robinson
Process Analysis & Modeling
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HYSYS® tutorial and practice session
Process Analysis
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Digest the information
Partial mass balance
Catalyst research
Introduction to Process Design Course
Don Robinson
Process Analysis
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Initial HYSYS model
Refined Model
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(cont.)
Optimized distillation column
Detailed design of heat exchanger
Energy minimization
Profitability analysis
Introduction to Process Design Course
Don Robinson
Equipment Design & Costing
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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
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Accounts
CD
Software
Web Site
Information on Server
Introduction to Process Design Course
Don Robinson
Computer Software
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HYSYS process simulation to build models
CapCost (comes with the text)
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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
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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
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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
Available in Computer Cluster only
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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)
Introduction to Process Design Course
Don Robinson
Work Groups
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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
Introduction to Process Design Course
Don Robinson