CHEMICAL PLANT DESIGN
Chapter 1
Dr. Muhammad Rizwan
Assistant Professor
NFC-IET
PLANT DESIGN PROJECT: STAGES OF COMPLETION:
Development of a new plant or process from concept evaluation to profitable
reality is often an enormously complex problem.
A plant design project moves to completion through a series of stages as listed
below:
1. Inception
2. Preliminary evaluation of economics and market
3. Development of data necessary for final design
4. Final economic evaluation
5. Detailed engineering design
6. Procurement
7. Plant Erection
8. Startup and trial runs
9. production
BASIC ANATOMY OF A CHEMICAL PROCESS:
Unreacted By-
reactants Products
Raw Feed Products
material preparatio Reactor separation Main
storage n unit Products
Product
Sales Purification
storage
Chemical process design is about selection and arrangement of various stages in
process, and selection, specification and design of equipment in that stage.
PROCESS INFORMATION REQUIRED FOR PROCESS DESIGN:
Special safety precautions/notes
Knowledge of all raw materials, products and intermediate process quantities in
convenient units
Knowledge of physical and chemical characteristics
Compositions and also properties of raw materials under operating conditions
Material and energy balances on all significant operations or equipments.
A complete diagrammatic process flow sheet, which shows the flow of the process
streams at suitable points on the process streamlines and equipment sketches where
convenient.
PROCESS DESIGN DEVELOPMENT:
Inception:
Idea may generate from sales department
As a result of customer request
To meet competing product
An off-shoot of a research program
Operating department result
Engg. Dept may originate a new process
Preliminary Research:
General survey of success possibilities
Physical and chemical operations involved considered
PROCESS DESIGN DEVELOPMENT:
Process Research phase:
Preliminary market surveys
Laboratory scale requirements
Production of research samples
Development Phase:
Pilot plant constructed
Design data obtained (used as basis)
Complete market analysis made
Final product sent to customers
Cost-Profit analysis are made
HIERARCHY OF A CHEMICAL PROCESS DESIGN:
The hierarchy is the systematic gradation of the
process.
It is an attempt to develop a methodology which
shows the clear picture of the structure and
problems in the process.
Hierarchy can be represented symbolically by the
layers of onion diagram (Onion model)
The onion diagram stresses the sequential
hierarchical nature of process design.
Some processes like oil refinery processes do not
require a reactor, there the design starts from 2nd
layer and so on.
HIERARCHY OF A CHEMICAL PROCESS DESIGN:
HIERARCHY OF A CHEMICAL PROCESS DESIGN:
HIERARCHY OF A CHEMICAL PROCESS DESIGN:
HIERARCHY OF A CHEMICAL PROCESS DESIGN:
SUSTAINABLE INDUSTRIAL DEVELOPMENT/PROCESSES:
Minimum wastage
Minimum energy consumption
Safety and health
Start up and shut down
Availability (No. of operating hrs/yr)
Flexibility
SIMULATION:
“Attempt which predicts the behavior of process”
It is carried out by math models/methods
It gives all the parameters i.e., temp, pressure etc
Simulation also predicts, how much raw material is being used, how much energy is
being consumed in the process.
Importance:
It is a powerful tool to:
Develop capacity planning
Optimize product scheduling
Evaluate design facility layout
Improve product quality
SIMULATION:
CHEMICAL ENGINEERING PLANT DESIGN:
The Key Terms
Plant Design
It includes all engineering aspects involved in the development of either a new, modified or
expanded industrial plant.
Design Engineer
In the development, the chemical engineering will be making economic evaluation of new
processes, designing individual pieces of equipment for the proposed new venture, or developing
a plant layout for coordination of the overall operation. Because of these many duties, the
chemical engineer is many times referred to as a Design Engineer.
Cost Engineer
Chemical engineer specializing in the economic aspects of the design is often referred to as Cost
Engineer.
CHEMICAL ENGINEERING PLANT DESIGN:
The Key Terms
Process Engineering
The term is used in connection with economic evaluation and general economic analysis of
industrial processes.
Capitalized Engineering
When management has made a firm decision to proceed with provision of significant capital funds
for a project, the engineering then involved in further work on the project is known a Capitalized
Engineering.
Expensed Engineering
Engineering which has gone on before while the consideration of project was in the development
stage is referred as Expensed Engineering.