CHEM-C7200
DESIGN PROJECT IN CHEMICAL ENGINEERING
Prof. Pekka Oinas, Dr. Sarwar Golam, Lecturer
A! Plant Design Research Group
AND
NN-Industrial clients
20.1. 2016
DESIGN PROJECT IN CHEMICAL ENGG.
 Introduction to course
 Work contents
 Work method
 Practical arrangements
 Total 10 cr (270 h/each student)
 all work phases
AIMS OF THE COURSE
• Making a feasibility study
• Process pre-design (with innovation)
• Project work
LEARNINGS
•
•
•
•
Information searching
Design methods
Presentation of results
Working procedure
GRADING OF THE COURSE
Grades: 1-5
Subjects to:
1. All reports (I-V)
2. Meetings
3. Seminar presentation
4. Learning log
Justification basis:
1. Contents of reports
2. Working approach
3. Presentation skills
4. Innovation in design
COURSE CONTENTS
1. MARKETS AND PROSESS ALTERNATIVES
 Application
 Costs /economic potential
 Quality
 Raw materials
 Properties
 Process alternatives, comparison and selection
2. PROCESS DESIGN OF THE SELECTED PROCESS
 Material balance
 Energy balance
 PFD
 Preliminary equipment sizing
3. DETAILED ENGINEERING
 Equipment sizing
 Selection of equipment
 P&I diagram of a particular process section
 Safety assessment
 Emissions & wastes
 Risks & permits
• Heat integration
4. ECONOMICS







Capital investment
Operating costs
Sales revenue
Profitability
Sensitivity analysis
Financing
Implementation timetable
5. SUMMARY
Summery of the factors which affacts the feasibility of your project.
COURSE STRUCTURE
1. The work is progress with agreed content (topic) and time schedule
2. Meetings:
- Weekly
- Report submission by due dates
- Project meetings (after submission of reports)
- Correction of report
3. Presentation in the seminar
APPROACH
Pre-feasibility study (= documents for investment decission)
REPORTING
Technical Report -> rather compact
• In general: (source.inform.) -> (equation) -> (results)
• Demanding tasks: (steps), (justification), (attachment)
• Corrections with next report
• Submission in due dates
• Return to: Professor, Lecturer, instructors and industy clients
WORK METHOD/HOW YOU SHOULD WORK?
Group decides the work distribution of the project
• each one (group member) has own part
• group meet several times to exchange findings
Project manager:
• in charge of work
• chair in the meetings
Project Secretary: writes minutes of meeting (MOM)
Project meeting:
• Project manager expalins shortly main findings of the report and lead
the speach
• Secretary writes the Minutes of meeting (MOM)
Duration (time) 1 – 1.5 h
Project Meeting Agenda
• Presences
• Previous MOM, if any
• Time schedule and hour estimation
• Corrections of previous report
• Presenting the new report (main results with justification)
• Comments and discussions
• Instruction to the next report
• Selecting new project manager and secretary
• Date and time for the next meeting
I REPORT
1. PROJECT STARTUP
• The technical goals
• Hour estimation
• Time schedule
2. MARKET REVIEW
1.
2.
3.
4.
5.
6.
uses
production
export, import
prices
grades
life cycle
For both the products & the raw materials
Market review is needed:
- Choosing the capacity
- Economic potential
- Choosing location
Producers & capacity : Finland, europe and world
Import & export : location (areas) & prices
Uses & grades
general physical & chemical properties
competitive products
demand forecasts
users in location
markets future trends
SOURCES OF INFORMATION
PRICES & PRODUCERS
Finnish customs statictics
Industrial statistics
Price table
ICIS journal (and its journal databases)
Importers catalog
www
(Avoid laboratory chemical manufacturer catalogs)
ECONOMIC POTENTIAL
Operating Margin = product price – raw material price
(note. yield)
CAPACITY
based on market study (kg/h)
operation time (h/a)
1/2/3-Shifts (discontinuous/continuous)
LOCATION
factors affecting
comparison table + reasons (justifications)
district levels
PROCESS ALTERNATIVES
Literature study:
- handbooks
- reference works
- journal
- process review
- patents
Specifically the modern processes and lists of sources
PRINCIPLE OF LITERATURE RESEARCH
• Start with:
Handbooks (Ullmann’s,… Kirk-Othmer,…Mcketta…)
Books; patents, www-pages
Referenceworks (Scifinder, Compendex, Scopus..knovel...)
Journals, Experts
PROCESS PRINCIPLE
1. Draw block/principle diagram for few alternatives
2. Process description
DRAWING PROGRAMS:
MS Visio (recommended)
Smartsketch
AutoCad
COMPARISON OF ALTERNATIVES
1.
2.
3.
4.
Main differences
Comparoson table with criteria and reasons
Proposal + Justification
Choose the bests alternative (Selection is confirmed in the 1st comment meeting)
FIRST ( AT THE BEGINING)
• Select project manager and secretary
• time schedule
• hour estimation
- DESIGN PROJECT ( 10 cr = 1350 h/(5 st. in a group)
- Reports:
1, 2, 3, 4, 5
15, 35, 25, 20, 5-% in hours
Work hours of each students are presented in the hour estimation table
SIMULATION PROGRAMS
1. Aspen Plus (in computer class)
2. PRO/II (in computer class)
3. SuperPro Designer (in computer class)
4. HSC Sim
5. Flowbat
INDUSTRIAL TOPICS FOR SPRING 2016
1. Feasibility study of bio-oil refining. Pöyry/Tuukka Sormunen
Kajaste
Leinonen
Nasiri
Tajuddin
2. Recovery of organic acids and solvent precursors from forest industry
biorefinery streams. Eastman/Jukka Hietala
Häkkinen
Montonen
Rostami
Veijalainen
3. Regenerated fibrecellulose carbamate CCA process. VTT/Ali Harlin
Hassinen
Henttonen
Kabugo
Perttula
ATTACHMENT 1. Hour estimate and follow-up form
DESIGN PROJECT HOUR ESTIMATION
Työvaihe
Estimate
Realized
Tot.
Pekka
Sarwar
Lotta
Maija
Päivi
TOTAL
Design the project
20
8
5
5
6
7
31
Market study
45
8
25
0
0
34
67
Process alternatives
45
4
0
30
20
0
54
Principle diagram
10
10
0
0
4
0
14
Comparison of Pros. alternative
20
12
0
7
0
0
19
I- raport correction
10
20
0
2
0
0
22
I- raport Total
150
62
30
44
30
41
207
24,5
Design and compilation
-
0
0
12
10,5
2
Selection of process
10
5
1
1
1
2,5
10,5
PFD
150
35
0
41,5
0
45
121,5
Balance calculation
90
7
40
44
51,5
24,5
167
Sizing
90
3
25,5
10,5
10
0
49
II- raport correction
30
23
3
21,5
15
0
62,5
II- raport Total
370
73
69,5
130,5
88
74
435
-
2,5
5
14
18
8
47,5
PI-diagram
50
0
0
0
0
38,5
38,5
Equipment sizing
60
0
4
40,5
14
4
62,5
Laitemääritt, luettelot
30
0
0
6,5
15
10
31,5
Lay-out
30
15
0
1
0
0
16
Energy inegration
10
1
0
0
10
0
11
Excursion
10
1,5
1,5
1,5
1,5
0
6
III raport correction
10
5
0
4,5
2
6,5
18
III raport Total
200
25
10,5
68
60,5
67
231
-
0
9
8,5
9
23
49,5
Invest. Kustannusarvio
50
0
10
25
20
22
77
Tarvittavat luvat
10
0
27
0
0
0
27
Päästöt
20
0
6
0
0
0
6
KäyttöKustannusarvio
50
16
5
5
1
20
47
Tuloslaskelma
30
10
0
0
0
0
10
Kannattavuus
30
14
0
0
10,5
0
24,5
Herkkyysanalyysi
20
0
11
0
0
0
11
Toteutuksen aikasuunn.
10
0
0
7
0
0
7
IV raportin korjaus
10
22
20
5
0
4
51
IV raportti yht.
230
62
88
50,5
40,5
69
310
Design and compilation
Suunnittelu ja kokoaminen
Loppuraportti
TOTAL PROJECT HOURS.
50
16
25
14
22,5
30
107,5
1350
238
223
307
241,5
281
1390,5
ATTACHMENT 2
BAR CHART
TASKS
Design the project
Markets
Process alternatives
Principle diagram
Comparison of alternatives
I raport correction
I raport Total
Prosessin valinta
Virtauskaavio
Taselaskenta
Mitoitukset
II raporin korjaus
II raportti yhteensä
PI-kaavio
Laitemitoitukset
Laitemäärittelyt, luettelot
Käyttöohje
Ei tehty
Sijoitussuunnittelu
Tarvittavat luvat
Päästöt
Energian säästö
kesken
Ekskursio
III raportin korjaus
III raportti yhteensä
Investointikustannusarvio
Käyttökustannusarvio
Tuloslaskelma
Kannattavuus
Herkkyysanalyysi
Toteutuksen aikasuunnitelma
ei tehty
IV raportin korjaus
IV raportti yhteensä
Loppuraportti
raporttien kokousajankohdat
YK1
3
P1
3
4
JAN
4
5
P2
5
6
6
7
FEB
7
P3
8
8
9
9
10
10
P4
11
MAR
11
12
12
13
13
P5
14
14
15
YK2
15
APR
16
16
VKO
NOTE: DESIGN PROJECT requires knowledge on various topics; e.g.
• equipment design
• reaction technology
• process chemistry,
• mass and energy balances
• process simulation
• heat integration
• process control, process safety
• costs and profitability estimation, etc.
These topics are not taught in this course but are considered as the
background knowledge of participating students.
Therefore, the design project course is recommended for senior students
(before you start the M.Sc. Thesis).