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CBB4013 Plant Design I

Jan 2014 Semester (Three credit hours) Topic Ethylene is an important raw material for the manufacture of valuable chemical products. Therefore, an engineering firm needs a design proposal for the production of ethylene using any feedstock. Design a plant for manufacture of ethylene through green, sustainable and environmental friendly process. Furthermore, determine the following. 1. 2. 3. 4. 5. Plant capacity Raw materials for the process Innovative processing route Heat integrated process flow sheet, and Profitability of the design project

Summary of the project activities PDP I In PDP I, students must develop at least three alternative process flow sheets for the given design problem through heuristics. The material balance calculation must be carried out for all process flow sheets using spreadsheet/HYSYS/ICON software. The selection of feasible process flow sheet should be based oneconomic potential of the process. Energy balance calculation should be carried out for the selected process flow sheet. Finally, heat integration must be performed using any software for the economically viable process flow sheet. In addition, selection of plant location with proper justifications and HSE aspects of the proposed plant must be included in the design report. Thus, the steps involved in the first phase of plant design are given below. 1. 2. 3. 4. 5. 6. Market supply and demand analysis Technology Review Selection of Plant Location Reactor Synthesis Synthesis of Separation System Process Flow Sheet Synthesis

7. Material Calculation using Spreadsheet/HYSYS/ICON 8. Preliminary Economic Evaluation and Selection of Appropriate Process Flow Sheet 9. Energy Balance Calculation for the Feasible Process Flow sheet 10. Heat Integration PDP II In PDP II, students must include the P&ID for the heat integrated process flow sheet already developed in PDP I using the standards available in the literature. The design of major and minor equipment must be carried out using the procedure available in the plant design textbooks. Each student must design one major, and two minor equipment.The detailed cost estimation of the plant should be performed by including equipment cost. The economic feasibility of the proposed process plant must be evaluated by constructing cumulative cash flow diagram over the plant life span. The key economic indicators such as rate of return and payback period should be calculated. In addition, the design report should address the strategy for safety and loss prevention, effluent treatmentand water utility systems. Thus, the steps involved in the second phase of plant design are 11. Piping & Instrumentation Diagram 12. Safety and Loss Prevention Strategy 13. Process Design of Major Units 14. Mechanical Design of Major Units 15. Specification of Minor Units 16. Detailed Cost Estimation and Profitability Analysis 17. Concept for Waste Treatment 18. Concept for Plant Water Utility System POINTS TO NOTE The plant design should be as environmentally friendly as possible. Recover and recycle process materials to the maximum economic extent. Also, energy consumption should be minimized, to the extent economically justified. The plant design must also be safe to operate (for example, no flammable or explosive mixtures). Economic Information The prices of the feedstock and products should be based on year 2014 price. Similarly, the capital cost of hardware in the plant should also be based on year 2014. Interest rate for the project is 10% per year and the project life is 20 years. Assume that the plant will only operate for 330 days in a year.

Utilities Supply The price of utilities should be based on year 2014. This includes both saturated and superheated steam at appropriate levels, cooling water, utility water, fuel gas, plant and instrument air and electricity. Schedule All students must comply with the schedule requirement especially on oral presentation and report submission. Late submission will be penalized appropriately. The following textbooks may be useful for plant design project. Conceptual design 1. Robin Smith. Chemical Process Design and Integration. New York, USA: John Wiley & Sons, 2005. 2. Regina M. Murphy, Introduction to Chemical Processes: Principles, Analysis, Synthesis, McGraw Hill, 2007. 3. Richard Turton, Richard Bailie, Wallace Whiting, Joseph Shaeiwitz, Debangsu Bhattacharyya, Analysis, Synthesis and Design of Chemical Processes, 4th edition, Prentice Hall, 2012. Equipment design and Cost estimation 4. M. S. Peters, K. D. Timmerhaus, R. E. West. Plant Design and Economics for Chemical Engineers, Fifth edition, McGraw Hill, 2004. 5. Warren D. Seider, J. D. Seader, and Daniel R. Lewin. Product & Process Design Principles. 2nd edition, Wiley, 2004. 6. R. K. Sinnott. Chemical Engineering Design, Coulson & Richardsons Chemical Engineering, Volume 6, Fourth edition, Elsevier, 2005. Latest information 7. Chemical Engineering Progress magazine