University of Western Ontario Department of Chemical and Biochemical Engineering CBE/GPE 4497/8 Chemical Process and Plant Design Lecture 1 S. Barghi, PhD, PEng Email: sbarghi2@uwo.ca Sept. 2020 A. Prakash, PhD, PEng Email: aprakas2@uwo.ca Welcome • Hopefully you all had a relaxing summer, despite COVID-19 issues, and ready for the Capstone Design course, a finishing full year course. • As you may know, we all have experienced many changes in life including classrooms/labs https://www.schulich.uwo.ca/facilities/classrooms .html https://www.techspot.com/news/85051-zoom-stockslips-company-comes-clean-about-misleading.html Instructors • I (Shahzad Barghi), am the course instructor and coordinator and have been involved in the course as instructor and projects’ supervisor for over 15 years sbarghi2@uwo.ca • Dr. Anand Prakash will be also available as instructor and project supervisor aprakas2@uwo.ca Instructors, (communication tools) • The course is offered in hybrid format, where class teaching and virtual lectures will be available (depending on the conditions related to COVID-19). • Our first line of communication is the course website in OWL, where you can have access to announcements, lectures, notes, examples, … . • You can also contact us by email (please use your UWO email address) or other available means of communication. Instructors, (communication tools) • Due to the nature if the course, we must have weekly meetings to review your accomplishments and discuss the objectives • The meetings will be carried out using Zoom, where the teaching assistant and supervisor will connect remotely • We may need to have face to face meetings (to be determined as we go on) following the social distancing and other rules as directed by the University Introduction • Design is an engineering practice, providing practicable engineered solutions which are ready for implementation. • Design derives from engineering principles, influenced by: customer requirements, market, legislation (legal and environmental) , standards, etc. • There are components of art to design, leaving room for individual expression and innovation. Introduction • Design demands professional responsibility. • Flaws in design are all too common. Failures in design may result in loss of performance, assets and sometimes life. • High level of design capability is what makes a good chemical engineer. https://www.thehindu.com Application of the knowledge acquired in different chemical engineering related courses in chemical industry is complicated and challenging. The capstone design course (CBE/GPE 4497/8) is an introductory course revealing main features of chemical engineers‘ role in chemical industry. • Design principles are common regardless of the field of study. Chemical Engineering Biochemical Engineering Green Process Engineering • There are minor differences, no effect on design methodology, but some concerns about safety, cross contamination, etc. Chemical Engineering Green Process Engineering Biochemical Engineering DEVELOP YOUR PROFESSIONAL AND ENGINEERING JUDGEMENT SKILLS THROUGH TEAM BASED CHEMICAL PROCESS DEVELOPMENT AND DESIGN EXERCISE General Objectives • Providing a real-world perspective on process development and design in chemical industry • Giving insight into constraints (practical, Scientific, environmental, social and economical) governing design decisions • Translating knowledge into development and design of commercial chemical plants • Providing criteria for selection and design of equipment Specific Objectives • Problem Formulation & Decision Making for Open-ended Design Problems • Exposure to Wide Spectrum of Learning Situations • Enhance Engineering Judgment • Account for Safety, Environmental, Social, Legal & Economic Issues Specific Objectives (Cont’d) • Share Know-How, Insights and Perceptions • Develop Strong Technical Communication Skills – Both Oral & Written • Prepare You for Life-Long Learning SKILLS TO BEDEVELOPED/ENHANCED • TEAM WORK & TIME MANAGEMENT • ENGINEERING JUDGMENT • INFORMATION GATHERING AND PROCESSING • CRITICAL THINKING & DECISION MAKING • COMMUNICATION • NETWORKING https://laurelplace.ca/delta-chamber-networking-evening/ WORK STATEMENT DESIGN A COMMERCIAL SIZE CHEMICAL/BIOCHEMICAL PROCESS TO: MANUFACTURE A SELECTED PRODUCT TREAT WASTE STREAMS MODIFY AND/OR IMPROVE AN EXISTING PRODUCTION PLANT WHAT IS DESIGN? A Process that Creates a Solution to a: - Problem or Need with the most desirable attributes The Solution Must Satisfy the Demands and Constraints of: - Regulatory Agencies, - Investors, Customers, Employees etc. MAIN STEPS IN CBE 4497 1. Problem Definition CBE 3319 Report (need analysis; concept design; selection of options) 2. Process synthesis & base case design (flow plan, M&E balances, simulation) First Term Report 3.Process design Final Report (equipment design, analysis of safety, environmental and financial issues) 4. Process analysis and optimization Equipment Design • It may be challenging to learn design methods from books/handbooks and lecture notes. • It usually requires lots of iteration, and you may need to: – be creative – follow lots of rules – consider the constraints – have experience Design • Design is inherently open ended and multidisciplinary in nature, however it is always challenging often frustrating usually very satisfying https://www.bilfinger.com/en/industries/chemical-petrochemical/ HOW DOES IT WORK? • Within the framework of a workshop • Groups of up to 5 engineers assigned to a section head and an advisor • Regular meetings among group members, with section head and advisor HOW DOES IT WORK? Process Simulator Internet Consultants Faculty Advisor STUDENT Teaching Asst. Team Members Classmates Design Simulation Packages • HYSYS • Aspen Plus • VMGSim Academic: All Faculty members in CBE and other departments at Western (or any other university). Industry: Engineers from chemical industry across Canada/overseas. https://students.tufts.edu/academic-advice-and-support Get Organized! • Use of available digital notebooks is highly recommended (use OneNote in office365, or create accounts in Google, use Dropbox, etc.). • You may share the notebook, with your design team members, TA and supervisor on a weekly basis. • You may also use a design notebook (hard copy) for: – rough calculations, sketches etc. – weekly planning and progress reports • Project Scheduling First Term Tasks • • • • • • Project Definition and Scope ($) Detailed Process Flow Plan ($) Material and Energy Balances Sizing of Standard Equipment First Oral Presentation ($) First Design Report ($) Project Scheduling Second Term Tasks • Short-cut Equipment Design ($) • Detailed Equipment Design • Safety and Environmental Analysis • Process Economics • Final Oral Presentation ($) • Final Design Report ($) First Term Tasks - Progression First Formal Report First Oral Pres. Design Calc. Flow Plan Project Scope Basis For Final Grade • Project Definition and Scope • Detailed Flow Plan and • • • • • process description First Oral Presentation First Design Report Short-cut Equipment Design Final Oral Presentation (Sarnia) Final Design Report * To be determined, most probably to be carried out remotely 5% 12% 10% 16% 15% 12%* 30% A FINISHING COURSE Requires Integration of Knowledge Acquired in Several Pre- and Co-requisites and More ……. Remember: You are at the Center of All Activities A FINISHING COURSE You Need to Demonstrate Sound Design and Professional Capabilities Before You Can Graduate http://www.cartoonbrew.com A FINISHING COURSE University 5 km Industry A FINISHING COURSE University 2 km Industry 5 km A FINISHING COURSE University CBE 497 Industry CBE/GPE 4497/8 5 km Lecture Topics (First Term) • Course Overview and Planning • Project Definition and Scope, plant location and capacity • Review of Piping, Valve, Pump and Compressor Design • Mixing tank reactor design • Heat transfer in jacketed vessels (design issues) Lecture Topics (Cont’d) (First Term) • Design of knock out drums (Design Practice) • Life cycle assessment/Analysis • Design of heat exchangers • First Formal Report Lecture Topics (Second Term) • Overview and planning • Short-cut Design and scale up (I) • Short-cut Design and scale up (II) • Safety in design • Risk assessment/management Lecture Topics (Second Term) • Process Economics (I) • Process Economics (II) • Optimization in process design • Final Formal report Questions?
