Product, Process
Design &
Process Creation
Dr Zarina Ab Muis
Design od Chemical Products Begin By…
• Identification of potential opportunities and Creation
of potential opportunities,
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New chemical product
Product with new properties
Using different raw material
Satisfy societal needs
Generate profit
Keyword: Desired properties & performance!
For Commodity Chemicals
• Here, the focus is more on the design of
manufacturing facilities…………
This is what most of us have in mind when we mention
plant design………..
Source of Opportunities
• Research
• By accident…….
• New market
• Existing customers (complaint of current prod…)
• Inexpensive raw material
• New synthesis routes
Create & Access Primitive Problem
• Product design team identifies needs and generate ideas for new
product that meets customer requirement.
• Brainstorming sessions for alternatives
• Select promising alternatives for further research and development
Base on the principles of thermodynamics, chemical kinetics, heat &
mass transfer etc
Search for information
Technical information (process), Market supply/demand/plant capacity, Price
histories, Regulatory restriction, Competitors, Chemical Properties etc
• Company library /Archive
• SRI Design Reports
• Encyclopedia
• Handbooks and Reference Books
• Indexes for Journal (mostly through internet access)
• Patents
Steps in Product & Process Design…
Once chemical product is identified…(could be the
solution of primitive problem statement?)
• Process creation…………more than one processes?
• Check gross profit (economic potential)
Steps in Product & Process
Design…
• Base-case design
PF Diagram (Major equipments)
M&E Balance
Simulation
Heat and Power Integration
Mass Integration
Pilot-Plant Testing?
Steps in Product & Process
Design…
Calculations:
1. Manual
2. Spreadsheet (Excel, Lotus, Quattro Pro, Numbers (Apple
iWork))
3. Mathematical Packages (Mathematica, Matlab, Mathcad,
Maple)
4. Process Simulators (Aspen Plus, Hysys.Plant, PRO/II,
CHEMCAD, SUPERPRO DESIGNER)
5. Write your owm program (FORTRAN, C, C++, Visual Basic,
Java).
Steps in Product & Process
Design…
• Plantwide controllability assessment
Process control structure
• If everything is still promising…
• Detailed design, equipment sizing and optimization
• Profitability analysis
• Written report and presentation
Copyright@FKKKSA, UTM
Computer-Aided Process Simulation Project
Intro to PD - 10
Steps in Product & Process
Design…
• Detailed mechanical/civil design & ConstructionMostly done by contractors
• Startup and Operation
• All these MUST to be carried out in compliance with
safety and environmental regulations and concerns.