CH4034 Comprehensive
Design Project II
General Introduction to Batch 21
Prof Shantha Amarasinghe
Intended Learning Outcomes:
After completing this module, the students should be able to,
LO1– Appraise key decisions to be made and relevant assessment criteria for equipment
selection
LO2 – Design a selected process equipment in detail, including chemical, mechanical and
operational aspects
LO3 – Identify the type of material and method of fabrication suitable for the equipment
LO4 – Select control schemes and instrumentation
LO5 – Describe the startup, shut down, operational, and maintenance procedure
LO6 – Analyze safety and economic aspects of the equipment
LO7 – Develop technical report writing and drawing skills
What must you gain ?
Design skills
For any other type of
process plant equipment?
• Ability to apply theoretical knowledge and skills to solve a real-world problem
• Comprehensive report, presentation, and showcasing skills in design thinking
• Problem-solving, technical proficiency
• Communication, and project management
• Readiness for professional practice in their chosen field
Before you start
Stress Management through time management
Do not overstretch
Where to start ? 210106T Ammonia absorber
210225G Carbonating Tower
210455K Distillation column 210084V Evaporator
210742M Cyclone Separator 210132T Chlorine Dryer
210020A Slaker (Reactor) 210148X Crystallizer 210256C Scrubber
210082M Electrolyzer Cell 210211K Cyclone Separator 210046H dryer
210441N Catalytic De-Oxo Bed 210032L Distillation column 210073L Evaporator
210260H Primary Dechlorination Tower 210590T Distillation column 210147T Fluidized bed cooler
R 210480G Intermediate Absorption Tower 210677R Extraction Column 210532U Fluidized Bed Dryer
210644N Converter Tower (reactor) 210704B Cyclone Separator 210514R Cooling Tower
210033P Final Absorption Tower 210118G Vaccum Distillation Column 210288B Heat Exchanger
210093X Reactor 210105N HCl Distillation column 210550X Drying Tower
S 210240X Reactor 210635M Scrubber
210050N VCM Distillation column
210582V Acetylation Reactor 210727X Multi-Comp Distillation Column 210673C Scrubber
210519L Reactor 210430F Flash Vessel 210717R Cooling Tower
H 210431J Reactor 2 210411A Gas Liquid Seperator 210328B Heat Exchanger
210137M Absorption column 210457T Vacuum Distillation Column 210702R Evaporator 1
210561G Absorber 210423L Extraction Column 210154L Evaporator 2
210643K Reactor 210228T Gas Liquid Separator 210117D Evaporator
210747H Reactor 210231V Liquid - Liquid Separator 210399P Scrubber
210380B Oxidation Reactor 210475V Distillation column 210384P Heat exchanger
210283F Reactor 210188T Flash Separation Column 210440K Vaporizor
210026X Absorption Column 210208H Distillation column 210255X Heat Exchanger
210715J Depolymerization Reactor 210251G Stripping Column 210659N Scrubber
CDP I CDP II 210738G Reactor 02 210667L Evaporater
210304A LP Decomposer 210524X Flash Cooler
R group H group
- Reactors S group
Heat exchangers
– Separators
Follow the design Guide
Part 1 is the main section of the CDP II – Chemical
Process Equipment Design. Students will be grouped
into 3 subgroups namely, Reactor Design (R),
Separator Design (S) and Heat exchanger Design (H).
Each subgroup will be supervised by at least 3
lecturers, either individually or as a group.
Part 2 is divided into 4 subsections namely:
Mechanical design (M&D); Process control and
Instrumentation (P&I); Safety and operation (S&O);
Cost estimation and analysis (C&A). Each subsection
will be separately supervised by experts in those
areas, either individually or as a group.
Schedule of Lectures
Week Lecture Date Time Coordinator
Introduction 15.15 - 17.15 Prof. Shantha A
Chemical Design – S group 09.15 - 10.15 Dr. Tharushi
1 26-01-2026
Chemical Design – R group 10.15 - 11.15 Prof. Rathnasiri
Chemical Design – HA group 11.15 - 12.15 Dr. Duleeka
Mechanical design Lecture 09.15 - 12.15
2 02-02-2026 Dr. Mahinsasa
Guest lecture on mechanical design 15.15 - 17.15
Process control & Instrumentation 09.15 - 10.15 Dr. Dilhara
Process Safety and Operation 10.15 - 11.15 Dr. Hiran
8 23-03-2026
Costing and Analysis 11.15 - 12.15
Prof. Shantha A
Guest Lectures on Industrial Practice 15.15 - 17.15
Lectures will be conducted in the DCPE Computer Lab
Report Submission
Submission Description Due Date for Method of Marks*
(Maximum Number of pages) submission submission (Evaluated by)
Part 1 -Chemical Design (pdf only) (maximum 30
Interim pages)
End of Week 5
Report I and Simulation algorithm (Excel sheet/MATLAB-M-
file) Submit written report 40**
to Moodle (Panel S/R/HA)
Corrected Corrected Chemical Design (pdf only)
End of Week 8
Interim Report I (maximum 30 pages)
Interim
Mechanical Design Calculations (pdf only) End of Week 9
Report II
40**
Part 2 -Mechanical Design; Process Control and Submit written report
(Panel M & D, P & I, S
Interim Instrumentation; Process safety and operation; Cost to Moodle
End of Week 12 & O, C & A)
Report III estimation and analysis (pdf only)
(maximum 30 pages)
Final report with drawings (pdf only)
(60 pages excluding Appendices, Contents, Submit written
1 Week after
Abstract etc.) report with
Semester 8 20
Final report Corrections for Interim Reports must be corrections of
written (All the above panels)
highlighted with yellow color and a separate Interim reports to
examination
report on corrections must be uploaded (see Moodle
Appendix I)
Late Submissions
• Late submissions of interim reports and final report are strongly discouraged, and
a penalty of “5% of total marks earned for the relevant section no of days” up to
a maximum of 10 days will be imposed. Late submissions for more than 10 days
are not accepted.
• By Law 15 Regulation 15.1 will be followed for the “Procedure for Academic
Concessions”
Expected outcomes
Submission Contents Subsections Assessment of learning outcomes Marks
Interim Introduction of design problem A. Design problem Students should be able to demonstrate the ability to: 10
Report I including the design and Equipment
1. Explain the design problem.
requirement (capacity, purity selection
(Maximum 2. Critically review the alternative options on equipment
etc..) and constraints;
30 pages) selection.
Review of alternative options 3. Use decision diagrams in support of equipment
for selecting the suitable selection procedure.
process equipment;
B. Size calculations 1. Develop a flowchart to explain the design procedure 20
Chemical design calculations 2. Perform design calculations
and Design specifications 3. Prepare the Process Equipment Design Specifications
required for latter parts of the
design. C. Simulation and 1. Identify the key design parameters affecting the design 10
Sensitivity Analysis with a tailormade program using computational
software (E.g. Excel, MATLAB)
2. Perform a sensitivity analysis
Interim Mechanical design D. Mechanical 1. Identify the mechanical design specifications (i.e. material of 12
Reports II & calculations of major unit, design and construction, methods of fabrication, assembly / fixtures /
III accessories and supports; Drawings installation, etc.) suitable for the process equipment
Mechanical drawings of major 2. Calculate and analyze for a mechanically safe design with
(Maximum
unit and components; dimensions according to the appropriate mechanical design
30 pages)
standards for the process equipment (E.g. ASME Boiler & Pressure
Design of the control
Vessel Code (BPVC), TEMA Standard for Heat Exchanger design)
structure for the process unit;
3. Develop detailed engineering drawings with required dimensions
P & I diagram and
of all sections for fabrication of the process equipment using CAD
Specifications of required
software tools (E.g. AutoCAD, SolidWorks).
instruments;
4. Prepare an inventory including all the accessories and
Conduct hazard and specifications
operability study (HAZOP) and E. Process 1. Apply process control techniques to the unit design 12
identify and analyze problems Control and 2. Design control structures to the system
that may represent hazards to Instrumentation 3. Prepare an inventory including all the accessories and
personnel or equipment; specifications
Devise start up – shut down F. Process 1. Conduct HAZOP study. Identify and analyze potential hazards. 8
procedure; Safety and 2. Explain procedures of Startup/shutdown
Operation
Costing of the complete unit
G. Cost 1. Calculate the overall costing based on inventories prepared in 8
including accessories and
estimation and sections D and E.
instrumentation.
Analysis 2. Justify the costing for overall and individual units against actual
pricing
Final report Abstract/Executive summary, A. Corrections of Interim 1. Address all the corrections given by the 14
Acknowledgement, Content, reports examiners. Provide a report on how
List of Figures, List of Tables, you addressed the comments given by
Nomenclature, Main body of the examiners.
the text, References and A. Overall quality of the report 1. Organize the report with logical 6
Appendix*. sequence.
2. Concise writing with proper referencing.
A separate report on
3. Minimize Syntax errors, typos, and
“Corrections done” must be
grammatical mistakes.
attached. Refer section 4
Report
50%
Dependent on each other
Evaluations
Viva
50%
APPENDIX VII – Assessment Rubrics for Process Safety and Operation
Exemplary (A+, A, A- > 70) Competent (70 > B+, B, B- > 55) Developing (55 > C+, C, C-, D > 35) Beginning (35 > F)
Hazards and The design intent related to all The design intent related to The design intent related to Fail to identify the design
operability study the design parameters are salient design parameters are salient design parameters are intent related to design
(HAZOP) identified with sound scientific identified with reasoning. identified but without reasoning. parameters and to conduct
reasoning. a systematic HAZOP study.
[6 % of overall A systematic HAZOP study is A HAZOP study is conducted but
marks] A systematic HAZOP study is conducted addressing all the limited to addressing only the
conducted addressing all the important design parameters important design parameters.
design parameters and and identifying safety actions/ Safety actions/ measures for the
identifying alternate safety measures with causes and identified hazards are given but
actions/measures for each hazard consequences. without causes and
with causes and consequences. consequences.
The identified safety
The identified safety actions/measures are Attempted to implement the
actions/measures are accurately implemented in the design but safety actions/measures
implemented in the design. with some mistakes. identified in the design.
Startup and Give a clear and comprehensive Give a clear description of the Give a clear description of only Fail to give an acceptable
shutdown description of all the steps necessary steps required for the main steps required for description of the
procedure required for smooth startup and startup and shutdown. startup and shutdown. But the necessary steps required
shutdown with logical sequence. Sequencing is logical but with sequence is not logical. for startup and shutdown.
[2 % of overall
minor mistakes
marks]
Note that each section is evaluated by two methods namely, Report evaluation and viva evaluation
APPENDIX VII – Assessment Rubrics for Process Safety and Operation
Exemplary (A+, A, A- > 70) Competent (70 > B+, B, B- > Developing (55 > C+, C, C-, D Beginning (35 > F)
55) > 35)
Report Excellent organization at the Good organization at the Basic organization at the Poorly organized
Evaluation level of each point and level of main points and overview level and sentence without logical
sentence with logical sentence with logical with logical sequence. sequencing. Difficult to
(50 % of
sequence. Easy to follow sequence. Easy to follow Comprehensive with proper follow, Syntax errors,
allocated
with clarity. Comprehensive with clarity. Comprehensive referencing but with poor typos and grammatical
marks for
with proper referencing. with proper referencing but clarity, some syntax errors, mistakes exceed
above sections)
Syntax errors, typos and with some syntax errors, typos and grammatical acceptable level.
grammatical mistakes are at typos and grammatical mistakes.
a minimum level. mistakes.
Viva Excellent command of the Good command of the Provide incomplete, dead- Fail to comprehend or
Examination discussion demonstrating the discussion demonstrating ended, and sometimes respond to most
subject knowledge, design the subject knowledge, irrelevant answers. Appear questions.
(50 % of
skills, and analytical skills. design skills, and analytical defensive or diffident.
allocated
Graceful response to difficult skills. But do not know how
marks for
questions. to handle difficult
above sections)
questions.
Case study
End