CME 455. Product and process design I. syllabus. 2/7/2016.
Chemical and Materials Engineering Department
University of Kentucky
CME/MSE 455. Product and Process Design I (3 credit hours)
Fall, 2015
Overview
Time:
Location:
Instructor:
Office:
Phone:
Email:
Texts:
TA:
Website:
Grading:
MWF 10:00 – 10:50, Office hours by appointment
208 White Hall Classroom Building
Eric A. Grulke
763H F Paul Anderson Building, 215 ASTeCC (lab)
7-6097
eric.grulke@uky.edu
on reserve in the Engineering library
Warren Seider, J. D. Seader, Daniel Lewin, and Soemantri Wadagdo,
Product and Process Design Principles – Synthesis, Analysis, and
Evaluation, 3rd Edition, John Wiley & Sons
Max S. Peters, Klaus Timmerhaus, and Ronald E. West, Plant Design and
Economics for Chemical Engineers, 5th Edition, ISBN-13: 0639785503897, ISBN-10: 0072392665
Matthew L. Hancock, matthew.hancock@uky.edu
http://courses.engr.uky.edu/CME/cme455-001
Project 1
Project 2
Project 3
Project 4
Project 5
Team assessment
total
10%
15%
20%
25%
25%
5%
100%
This course will be graded on the curve. There will be no final exam.
Overview
1
Problem-based learning
2
Computational Tools:
2
Types of design problems
2
Design elements
3
Course Objectives/Expected Outcomes:
4
CME 455 Course Schedule
5
Integration of product/process design elements
6
Course Prerequisites: CME 415, CME 420, CME 425, CME 330, CME 220, and Engineering
Standing.
CME 455. Product and Process Design I. syllabus. 2/7/2016.
Problem-based learning
This course will be taught via problem-based learning. A succession of design problems of
increasing complexity will be assigned; students will learn design by developing solutions to the
problems. Four design elements, reporting, engineering design calculations, economics, and
creativity, will be integrated within these problems. Design problems will increase in complexity
during the semester; the design elements will increase as well.
Learning Methods:
The textbook, your class notes, and the homework problems are key tools for learning product
and process design. Learning can only be done by hard work on your part, however, there are
many ways to accelerate the process and make it fun.
Some students find team problem solving is an efficient way to optimize their learning per unit
time. Group discussion is highly encouraged for this course.
You will need to go outside of the textbook and typical course materials to obtain the
information needed for the design basis, the appropriate and creative application of technologies,
their potential costs, and socio-economic issues, such as environment, health, and safety.
I use active learning techniques, and will modify the class material based on questions raised by
you. The text is a good reference aid for solving design problems and should be consulted often.
My objective for class discussions is to go into depth on specific issues; please come to class
prepared to discuss problems.
Computational Tools:
There are a number of computational tools which will help you solve problems accurately
and efficiently. These include process simulator (ChemCad), spreadsheets (Excel), and other
programs such as MatLab and Maple. You are encouraged to submit your solutions using
these tools. A description of the equations and assumptions should accompany these
calculations.
Note: prior to using ChemCad, you should have an approximate solution to the process
flow diagram with clear assumptions, equipment specs, and operating conditions. Process
simulators are complex and it is easy to overspecify a problem or to select inappropriate
equipment. Understanding how the problem should solve is often essential to correcting
simulator programming issues.
Types of design problems
There are a wide variety of product design and process design problems from which to choose.
Categories include: petrochemicals, petroleum products, gas manufacture, foods,
pharmaceuticals, biomedical, polymers, electronic materials, and environmental (air quality,
water treatment, soil treatment, renewable fuels and chemicals).
2
CME 455. Product and process design I. syllabus. 2/7/2016.
Design elements
In working these design problems, you will be building your skills in reporting, engineering
design calculations, economics, social issues, environmental considerations, and creativity. The
following four tables show elements that you will be using.
Table 1. Design report elements
Written report element
Learning objectives
Brief statement of the report, signature(s)
Letter of transmittal
Short, descriptive title
Title page
Complete, including any appendices
Table of contents
Design objectives, design basis (assumptions), methods, key
Abstract/executive
results/conclusions (technical, social, economic),
summary
recommendations
Background for the project; specific goals; project scope;
Introduction/project
deliverables; timeline followed
charter
Assessed using the DOE definitions
Technology readiness
Need; existing products or technologies; expected market size
Market/competitive
analysis
What is wanted; fitness-to-standard (FTS); new-unique-difficult
Customer requirements
(NUD)
Table 2. Engineering calculations and considerations
Product Design
Process Design
Prod 1. Product requirements (critical-toProc 1. Physico-chemical property database; lab
quality)
data
Prod 2. Product concepts
Proc 2. Preliminary process flowsheet; synthesis
tree
Prod 3. Superior product concept
Proc 3. Process description
Prod 4. Intellectual property landscape
Proc 4. Process flow diagram (PFD); material
balances; energy balances; utilities; materials list
Prod 5. Bill of materials; manufacturing
Proc 5. Equipment list; specification sheets
costs; scale-up issues
Proc 6. Cost estimates: equipment cost summary;
fixed capital investment (FCI); operating costs
Prod 6. Environmental issues
Proc 7. Environmental issues
Prod 7. Safety/health issues
Proc 8. Safety/health issues
Proc 9. Control and instrumentation (P&ID)
Prod 8. Supply chain; distribution
Proc 10. Start-up costs
Proc 11. Plant layout
Prod 9. Profitability (cash flow)
Proc 12. Profitability
Prod 10. Conclusions/recommendations;
Proc 13. Conclusions/recommendations;
acknowledgements; bibliography
acknowledgements; bibliography
Appendices
Appendices
3
CME 455. Product and process design I. syllabus. 2/7/2016.
Table 3. Economic analysis elements
Economic analysis element Learning objectives
Econ 1. Direct costs; fixed charges; plant overhead
Manufacturing costs
Econ 2. Elements to include
General expenses
Econ 3. Direct and approximate methods
Total product costs
Econ 4. Direct materials
Bill of materials
Econ 5. Scaling by equipment capacity; inflation adjustments
Purchased equipment
Econ 6. Direct; indirect; fixed capital; working capital; total
Capital investment
capital investment; other investment costs
Econ 7. Capital + operating costs; interest; depreciation;
Cash flow analysis
Econ 8. Return on investment (ROI); payback period (PP); net
Profitability analysis
present value (NPV); investor’s rate of return (IRR) or
discounted cash flow rate of return (DCFRR)
Table 4. Innovation elements
Innovation process
Evolutionary/revolutionary
Stage-gate product
development
House-of-quality
Product triage
Learning objectives
Innov 1. Differences in design approaches
Innov 2. Process that helps address creativity in consumer
product development
Innov 3. Process that helps identify customer needs directly
Innov 4. Process that addresses major hurdles to
commercialization
Course Objectives/Expected Outcomes:
Table 5. Responses to Criterion 3 requirements (ABET)
Requirement Description
Response of this course
A
apply knowledge of mathematics,
All problems will include this
science, and engineering
requirement
B
Design/conduct experiments; analyze Data analysis is part of the engineering
data
calculation process
Design for realistic constraints
Fundamental skills assessed for this
C
course
Work in multidisciplinary teams
Fundamental skills assessed for this
D
course
E
Identify, formulate, and solve
Each design problem requires these skills
problems
F
Ethics and responsible behavior
Team responsibilities will be important
G
Effective communications
Design reports are evaluated
Broad education
Fundamental skills assessed for this
H
course
I
Lifelong learning
Teams will assemble design, social,
economic, and environmental data
Contemporary issues
Fundamental skills assessed for this
J
course
K
Use of modern engineering tools
ChemCad, Excel, MatLab, other
4
CME 455. Product and process design I. syllabus. 2/7/2016.
Table 6. Responses to intellectual inquiry requirements
Intellectual inquiry element
Response of this course
Personal engagement in the
Problem-based learning will be used to teach process design;
creative process
superior process design requires creativity.
Outside resources to define
Item I, Table 5.
creativity
Logic, laws and constraint
Tables 1-4.
processes
Students analyze work by
Table 4; applicable to team design problems
others
Students analyze their own
Table 4; applicable to individual design problems
work
CME 455 Course Schedule
Table 7. Design problem schedule
Date Topic
8/31 Design problem 1 assigned
9/14 Design problem 1 due
9/14 Design problem 2 assigned
9/28 Design problem 2 due
Design problem 3 assigned
10/14 Design problem 3 due
Design problem 4 assigned
11/4 Design problem 4 due
Design problem 5 assigned
12/9 Design problem 5 due
Type
Team
Team
Team
Team
Team
Note: The course schedule is approximate, and can be modified depending on the class
progress.
5
Integration of product/process design elements
This table shows the integration of reporting, engineering design calculations/considerations, economic analysis, and creativity within
the problem-based learning of the course. Actual elements will vary with each problem. This table is in order of increasing complexity
(going downward as shown by the arrow on the right hand side).
hierarchy.
Table 8. Integration of product and process design elements
Reporting
Engineering design calculations
and considerations
Customer needs
Physico-chemical data
Product/process assumptions
Process concept report
Product/process requirements &
concepts
Economics
Creativity
Rapid cost estimation method
Evolutionary
Detailed cost estimation
Revolutionary
Cash flow analysis
Technology readiness level
Product/process description
Profitability analysis
Market analysis
Complete design report
IP
Environment
Safety
Socio-economic factors
Structured methods
-Stage-Gate™
-House-of-quality
-Product triage