EPF 4802 PROCESS PLANT DESIGN PROJECT (SEM 2 12/13) 1

TITLE : An investor would like to develop a processing plant that refines crude palm oil to become acceptable for human consumption. Your company has been selected to develop the processing plant. You, as project manager (process engineer) need to prepare a report for the most suitable and economical processing plant design. You have the freedom to choose the processes involved and the byproducts, the production rate and the product specification. However, justifications are needed for all decisions. Include supporting evidence in the appendix. Assume that the plant has the processing capacity of 4000 MT per day.

The report needs to be submitted before 12.00 pm, Friday, 24th May 2013. The report must contains maximum 20 000 words only. It should be sent in both hardcopy and softcopy that contains all information such as appendix, excel files, drawings, etc. Presentation will take 20 25 minutes with 5 minutes question and answer. A panel of judges will evaluate the presentation. Please follow the steps in designing a plant as described in Chapter One. This project will contribute 30% of the final marks for EPF 4802. You will be assessed based on the report and presentation given. Imagine you are a process engineer and are preparing a report to important investors and the company managements. In your design or report, please ensure that you use the principles of sustainable design and development. You may present different alternatives for your process design and make justification on the selected design based on your constraints. You may produce different byproducts based on your creativity. Design Documentation: The design documentation for a process usually includes a minimum of: 1. The design basis 2. A written description of the process 3. A process flow diagram 4. At least one mass & energy balance 5. Product specifications and properties 6. A list of major plant equipment 7. A detailed drawing and specification for major equipments 8. A piping and instrumentation diagram 9. A drawing of the plant layout and site 10. A cost estimate 11. HS&E information (e.g., HAZAN, HAZOP, MSDS forms) 12. Water and waste treatment physical, chemical or biological The approach generally used for undergraduate design project is to use the combination of Techno-Economic Analysis type report and Basic Engineering Design

EPF 4802 PROCESS PLANT DESIGN PROJECT (SEM 2 12/13)

type report. Kindly refer to the handout that entitled Design Report Types for more description.

Organization of a Design Report I. Title page A. Includes title of report, name of person to whom report is submitted, writers name and date of submission II. Table of contents A. Indicates location and title of figures, tables, and all major sections with page numbers III. Executive Summary A. Briefly presents essential results and conclusions in a clear and precise manner IV. Body of report A. Introduction 1. Presents a brief discussion to explain what the report is about and the reason for the report; no results are included B. Feasibility studies that includes: 1. The use of the product 2. Current demand and production of the product 3. Effect of the plant on the environment and to the local community C. Discussion 1. Outlines method and gives design basis 2. Includes graphs, tables, and figures that are essential for understanding the discussion 3. Discusses technical matters of importance 4. Indicates assumptions made and their justification 5. Indicates possible sources of error 6. Gives a general discussion of results and proposed design 7. In general, include outline of the process, the product, its uses, properties, alternative routes for production 8. Describe briefly the conceptual design which should cover briefly the financial case. Outline briefly things such as where the plant will be sited and why. You should also indicate safety and environmental issues. Hint: Describe the procedures you adopted in order to arrive at the initial PFD. In other words, the initial block diagram of the proposed process, hand heat and mass balance, development into the PFD and the reasons for the choices you made. Outline any technical calculations you made. If necessary refer to an Appendix for details and especially for any lengthy example calculations (which you should include to demonstrate your understanding) Describe the model, choices and assumptions made. D. Final recommended design with appropriate data

EPF 4802 PROCESS PLANT DESIGN PROJECT (SEM 2 12/13)

1. Drawings of proposed design a. Block Diagram b. PFD c. P and ID 2. Tables listing equipment and specifications 3. Tables giving material and energy balances 4. Plant layout 5. Process economics including costs, profits, and return on investment Conclusions and recommendations 1. Presented in more detail than a summary Acknowledge 1. Acknowledges important assistance of others who are not listed a preparing the report Table of nomenclature 1. Sample units should be known References to literature (bibliography) 1. Gives complete identification of literature sources referred to in the report Appendix Sample calculations 1. One example should be presented and explained clearly for each type of calculation Derivation of equations essential to understanding the report but not presented in detailed in the main body of the report Tables of data employed with reference to source All standards and codes used List of symbols Price for the raw materials, products, equipments, utilities, site, etc Properties of raw materials, product

E. F.

G. H.

V. A.

B. C. D. E. F. G.

Guidelines: The intention of the report is to get your ideas and proposals over to the reader in a form that is understandable by someone with a reasonable grasp of technology. It should also aim to convince. The added problem that you have as a student is that it also needs to be a showcase for your abilities in process design. The report must, however, be clearly and logically structured. You should aim to tell a story. Material in the Appendices should be tidy (no scraps of paper) and logically organised. Appendices must be listed on the CONTENTS page, and referenced in the main text where necessary. Put great emphasis in developing the PFD and P and ID. This is where everything comes together and you can discuss the features that need to be added to make the

EPF 4802 PROCESS PLANT DESIGN PROJECT (SEM 2 12/13)

plant operable and safe. Here is where you talk about pumps, compressors, valves, piping, instrumentation, control, utility requirements and all the design calculations. Remember to be logical in your description - tell the story of the development. Always justify decisions, and assumptions. This is likely to be qualitative, but develop sensible arguments based on a knowledge of what is likely to happen given the plant you have designed. Reactor vessel V101 operates at 5 bar and is required to have a relief valve fitted of type XXX. The valve has been sized using procedure XXXX and a specification can be found in XXX. Briefly review what has gone before and summarise it so that you can make a concise statement about the main points of the plant you have designed, its safety and environmental impact and its financial viability.

Remember - your ability to make judgements and decisions, and to justify every step and result is what is being tested here.