COURSE OUTLINE

Department & Faculty: Department of Chemical Engineering

Faculty of Chemical Engineering, UTM

Course & Code: Plant Design Project (SKKK 4824)

Page 1 of 7

Semester: 2
Academic Session: 2014/2015

BASIC COURSE INFORMATION

Coordinators
Room No.
Tel. No.
E-mail

Dr. Azizul Azri Bin Mustaffa

: Dr. Zarina Ab. Muis
Dr. Aziatul Niza Sadikin
: N01 209 / N01 210 / N01 212
: 07-5535523 / 07-5535524 / 07-5535526
: azizul@cheme.utm.my / zarinamuis@cheme.utm.my / aziatulniza@cheme.utm.my

Section
Prerequisites

: 01
:
SKKK 4153 (Plant Design)

SKKK 4163 (Safety and Health in Chemical Industry)

SKKK 3323 (Separation Processes I)

SKKK 3333 (Separation Processes II)

SKKK 3223 (Chemical Reaction Engineering)

SKKK 4173 (Engineering Economics and Project Management)

SKKK 2213 (Chemical Engineering Thermodynamics)

SKKK 2313 (Transport Processes)

SKKK 1113 (Principles of Chemical Process I)

SKKK 2123 (Principles of Chemical Process II)

Synopsis

: This project is aimed at equipping the students with the skills and creativity in designing
a process plant in the absence of complete data. In particular, it emphasizes on the key
elements of process design which include process creation/synthesis, process
analysis, process evaluation and process optimization in generating inherently safe,
economic and environmentally friendly processes. Students will acquire the skill for
hands on application and integration of the principles of chemical engineering required
to design a process plant. Students will also learn the technique of writing a
comprehensive technical plant design report.

Learning Outcomes

: By the end of the course, students should be able to:

i)
ii)

iii)
iv)
v)
vi)

Formulate desired process design objectives and requirement including project

background, market survey and site location and as well as possible constraints
for a complex chemical process design problem.
Evaluate process routes for synthesizing a preliminary chemical process flow
sheet by employing conventional as well as current practices of process
synthesis and design strategies.
Seek the engineering and scientific data required for process design from
various related sources.
Conduct mass and energy balance calculations for constructing process flow
diagram (PFD) by employing chemical engineering principles.
Simulate a process flow sheet and optimize process parameters using
commercially available software packages.
Propose energy conservation measures, waste treatment methods and
pollution control of a process design to comply with
governmental/environmental regulations.

COURSE OUTLINE

Page 2 of 7

Department & Faculty: Department of Chemical Engineering

Faculty of Chemical Engineering, UTM

Semester: 2
Academic Session: 2014/2015

Course & Code: Plant Design Project (SKKK 4824)

BASIC COURSE INFORMATION (Continued)

Learning Outcomes
(Continued)

vii)
viii)

Produce mechanical design and equipment sizing based on ASME standard.

Conduct profitability analysis to achieve desired payback period or return of
investment (ROI).
Perform safety assessment of the chemical process using HAZOP analysis.
Develop control systems of a process plant to produce piping and
instrumentation diagrams (P&ID).
Work as a team for solving a complex design project and lead a specific task.
Produce well written project reports and deliver an effective oral presentation
on design project with appropriate visual aids.
Adopt academic honesty and professional integrity.
Manage project effectively

ix)
x)
xi)
xii)
xiii)
xiv)
Generic Skills
Assessed

1)
2)
3)
4)
5)
6)
7)

Communication Skills (CS1-4 PO8)

Teamworking (TW1-5 PO9)
Critical Thinking & Problem Solving (CTPS1-4 PO7)
Ethics & Professionalism (ET1-3 PO5)
Lifelong Learning (LL1-2 PO11)
Entrepreneurship Skills (ES1 PO12)
Leadership Skills (LS1-3 PO9)

COURSE MAPPING ON BLOOM TAXONOMY AND

KEY PERFORMANCE INDEX (KPI) OF COURSE OUTCOME
CO

CO1

CO2

CO3

CO4

Course Outcome
Formulate desired process design objectives and
requirement including project background, market
survey and site location and as well as possible
constraints for a complex chemical process design
problem.
Evaluate process routes for synthesizing a
preliminary chemical process flow sheet by
employing conventional as well as current practices
of process synthesis and design strategies.
Seek the engineering and scientific data required for
process design from various related sources.
Conduct mass and energy balance calculations for
constructing process flow diagram (PFD) by
employing chemical engineering principles.

Program
Outcome

Bloom
Taxonomy

PO1

C5

PO3

C6

PO11

A3

PO7

P4

Assessment

KPI

0.65
Interim &
Overall Project
Report, Interim
& Final
Presentation

0.65

0.65
Interim &
Overall Project
Report, Interim
& Final
Presentation,
Supervision

0.65

COURSE OUTLINE

Department & Faculty: Department of Chemical Engineering

Faculty of Chemical Engineering, UTM

Page 3 of 7
Semester: 2
Academic Session: 2014/2015

Course & Code: Plant Design Project (SKKK 4824)

COURSE MAPPING ON BLOOM TAXONOMY AND

KEY PERFORMANCE INDEX (KPI) OF COURSE OUTCOME (Continued)
CO

Course Outcome

CO5

Simulate a process flow sheet and optimize process

parameters using commercially available software
packages.

CO6

CO7
CO8
CO9
CO10
CO11

Propose energy conservation measures, waste

treatment methods and pollution control of a process
design to comply with governmental / environmental
regulations.
Produce mechanical design and equipment sizing
based on ASME standard.
Conduct profitability analysis to achieve desired
payback period or return of investment (ROI).
Perform safety assessment of the chemical process
using HAZOP analysis.
Develop control systems of a process plant to
produce piping and instrumentation diagrams (P&ID).
Work as a team for solving a complex design project
and lead a specific task.

Program
Outcome

Bloom
Taxonomy

Assessment

KPI

PO4

C3, C6

Interim & Overall

Project Report,
Interim & Final
Presentation

0.65

PO6

C5

PO3

C5

PO12

P4

PO5

C4

PO1

C5

PO9

A3, A3

CO12

Produce well written project reports and deliver an

effective oral presentation on design project with
appropriate visual aids.

PO8

C4, P4

CO13

Adopt academic honesty and professional integrity.

PO10

A3

CO14

Manage project effectively

PO12

C3

Overall Project
Report, Final
Presentation

0.65

0.65
Overall Project
Report, Final
Presentation,
Supervision
Overall Project
Report, Final
Presentation
Peer Rating,
Supervision
Interim & Overall
Project Report,
Interim & Final
Presentation
Log Book,
Industrial Visit &
Report,
Supervision
Log book

0.65
0.65
0.65
0.65
0.65

0.65
0.65

Program Outcomes (PO) Related to the Course:

PO1
PO3

PO4
PO5
PO6
PO7

Apply general knowledge, sciences, engineering fundamentals and chemical engineering principles to solve
complex chemical engineering problems
Design a system or process for solving complex engineering problems to meet specified needs with
appropriate consideration for public health and safety, cultural, societal, and environmental considerations
consideration
Ability to inculcate modern computational techniques and skills to solve complex chemical engineering
activities
Ability to responsibly act as well as response to the societal health, safety, environment, legal and cultural
issues that are relevant to the professional chemical engineering practice.
Ability to practice professional chemical engineering knowledge for sustainable development
Ability to integrate the first principles of mathematics, natural sciences and chemical engineering for solving
complex engineering problems through creative, innovative, lateral and critical thinking skills.

COURSE OUTLINE

Department & Faculty: Department of Chemical Engineering

Faculty of Chemical Engineering, UTM

Page 4 of 7
Semester: 2
Academic Session: 2014/2015

Course & Code: Plant Design Project (SKKK 4824)

Program Outcomes (PO) Related to the Course (Continued):

PO8
PO9

Ability to communicate effectively through written and oral modes to all levels of society
Ability to work independently, and as a member or a leader in a team to manage project in multi-disciplinary
environment
PO10 Ability to work ethically according to the norms of chemical - engineering practice.
PO11 Ability to acquire knowledge and engage in life-long learning
PO12 Ability to acquire entrepreneurship skills and business insights

STUDENT LEARNING TIME (SLT)

Teaching and Learning Activities
1. Project Briefing
2. Final Presentation Briefing
3. Discussion with Supervisor
4. Seminars
5. Industrial Visit
6. Interim Presentation
7. Independent Study and Group Discussion
8. Presentation Preparation & Report Writing
7. Final Presentation
Total

Student Learning Time (hours)

1
1
28
5
4
1
90
28
2
160

TEACHING METHODOLOGY
At the beginning of the semester, a project briefing will be given by the coordinator and students will be divided into
teams (minimum 4, maximum 5). A supervisor or a pair of supervisors will be assigned to each group. The project
topics will be given by the coordinators or suggested by the supervisors. Approximately 4 groups will be given the
same topic (chemicals) but the capacity of the production can be different. This is to create competitiveness between
groups and to avoid too many different topics.
The progress of each of the project design teams will be supervised continuously by the supervisors and must be
according to the project schedule. In Week 9 of the schedule, all teams need to prepare for interim evaluation where
they need to write reports and also give presentations. During the interim presentation session, a group of panels will
be evaluating the progress of the team and provide any positive feedback in order to improve further. All teams need
to consider the comments given and improve accordingly.
After the interim evaluation, all project design team will continue with the remaining parts of the project. Throughout
the duration of the project, whenever suitable, a series of seminars will be conducted covering topics which are not
extensively covered in the syllabus of the program. In this seminars, the students can gain a lot of information which
can be useful for their project. Besides that, the students also need to prepare log book containing the information on
the progress of their project and also conduct industrial visit to relevent industries.
In terms of the generic skills, oral communication skills will be assessed by panels during the interim and final
presentation session while teamworking and leadership skills will be assessed through peer rating and observation
from supervisor. Besides that, ethics, entreprenuership and problem solving skills will also be assesed by the
supervisors through observation during supervision.

COURSE OUTLINE
Department & Faculty: Department of Chemical Engineering
Faculty of Chemical Engineering, UTM

Page 5 of 7
Semester: 2
Academic Session: 2014/2015

Course & Code: Plant Design Project (SKKK 4824)

WEEKLY PROJECT SCHEDULE
Week
Week 1-3

Topic
:

1.0
1.1
1.2
1.3

Week 4-5

2.0
2.1
2.2
2.3
2.4

Week 6 and 8

3.0
3.1
3.2

Topic Outcomes

Literature Review and

Project Conception
Process Background
Market Survey and Site Study
Process Selection

It is expected that students will be able to:

Study the process background and project
feasibility
Conduct product market survey and site
study
Perform physical and chemical property
data search
Review and screen alternative processes
and chemical reactions by calculating the
economic potential of different reaction
routes

Process Synthesis of
Process Flow Diagram (PFD)
Process Database
Process Synthesis Approaches
and Heuristics
Preliminary Process Screening
Development of Base Case
Flow Sheet and Plant Layout

It is expected that students will be able to:

Create physical and chemical property
database
Synthesis a process selection decision
using heuristics approach
Construct a process flow diagram using
commercial software

Material and Energy

Balances
Manual Material and Energy
Balances for Selected
Chemical Process
Simulation using Available
Software for Selected
Chemical Process

It is expected that students will be able to:

Calculate base case material and energy
balances manually
Simulate a chemical process to generate
material and energy balance data using
commercial software such as ASPEN Plus,
APSEN Hysis etc.

Week 7

Mid-Semester Break

Week 9

Preparation for Interim Presentation

Week 10-11

4.0

4.1
4.2
4.3

Process Integration,
Optimization and Waste
Treatment
Heat Exchanger Network
Design to Achieve Maximum
Heat Recovery
Optimization using Linear
Programming Method
Design of Waste Treatment
Process

It is expected that students has the ability to:

Apply the 1st and 2nd law of thermodynamics
in designing heat recovery systems
Design a heat exchanger network to meet
the MER targets using grid diagram
Apply linear programming model to solve an
optimisation problem using graphical method
or using commercial solver such as EXCEL
Solver, GAMS or MATLAB.
Design a process to treat waste produced
from the process plant

COURSE OUTLINE
Department & Faculty: Department of Chemical Engineering
Faculty of Chemical Engineering, UTM
Course & Code: Plant Design Project (SKF 4824)

Page 6 of 7
Semester: 2
Academic Session: 2013/2014

WEEKLY PROJECT SCHEDULE (Continued)

Week
Week 12

Topic
:

5.0

Equipment Sizing and Cost

Estimation
Design Specification
Plant Cost Components
Cost Estimation for Auxiliary
Equipment (Pump,
Compressor, Heat Exchanger
etc.)
Cost Estimation for Major
Equipment (Distillation
Column, Absorber etc.)

It is expected that students has the ability to:

Select design specification based on
available standard
Calculate the equipment bare module cost
based on various cost estimation method

6.3

Process Control and Safety

Control Systems
Piping and Instrumentation
Diagram (P&ID)
HAZOP Study

It is expected that students has the ability to:

Design control systems
Draw Piping and Instrumentation Diagram
(P&ID)
Perform general process safety procedures
including HAZOP studies
Design a procedure for plant start-up and
shut-down

5.1
5.2
5.3

5.4

Week 13

Topic Outcomes

6.0
6.1
6.2

Week 14

7.0
7.1
7.2

Mechanical Design
Detailed Engineering Drawings
Equipment Specifications

It is expected that students has the ability to:

Design detailed engineering drawings and
equipment specification sheets for major and
auxiliary equipment (include equipment cost)

Week 15

8.0
8.1
8.2

Profitability Analysis
Total Capital Investments
Payback Period or Return of
Investment (ROI)

It is expected that students has the ability to:

Estimate the total capital investment of the
process plant
Perform economic analysis using the
discounted cash flow analysis to achieve the
desired payback period or return of
investment (ROI)

Week 16

Revision Week and Final Presentation

COURSE OUTLINE

Department & Faculty: Department of Chemical Engineering

Faculty of Chemical Engineering, UTM

Page 7 of 7
Semester: 2
Academic Session: 2013/2014

Course & Code: Plant Design Project (SKF 4824)

REFERENCES

Essential Text

Other Texts:

Warren D. Seider, J. D. Seider and Daniel R. Lewin, Soemantri Widagdo, Product and
Process Design Principles: Synthesis, Analysis and Evaluation, Third Edition, John
Wiley and Sons, Inc., 2010.
1. Biegler, Lorenz T., Grossman, Ignacio E., Westerberg, Authur W., Systematic
Methods of Chemical Process Design, Prentice Hall Itl., 1997.
2. Douglas, J. M., Conceptual Design of Chemical Processes, McGraw Hill, 1998.
3. Ulrich, G. D., Process Plant Design and Economics, John Wiley, 1984.
4. Smith, R., Chemical Process Design, McGraw Hill, 1995.
5. Coulson, J. M., Richardson, J. F. & Sinnot, R. K., Chemical Engineering Vol. 6,
Pergamon Press, 1985.
ASSESSMENT

Evaluation Items
Interim Report
Interim Presentation
Final Presentation
Final Report
Log Book
Leadership
Teamworking
Ethics
Enterprenuership
Critical Thinking and Problem Solving
Industrial Visit and Report

:
:
:
:
:
:
:
:
:
:
:

Tools
Written Report
Oral Presentation
Oral Presentation
Written Report
Log Book
Peer Rating
Peer Rating
Observation
Observation
Observation
Industrial Visit Report

Evaluator
Supervisor
Panel
Panel
Supervisor
Coordinator
Coordinator
Coordinator
Supervisor
Supervisor
Supervisor
Coordinator
TOTAL

Percentage (%)
15
15
20
15
5
5
5
5
5
5
5
100

Breakdown of Evaluators Asssesment

Coordinator 20 %
Supervisor 45 %
Panels 35 %
ACADEMIC INTEGRITY

The University has a strict policy on academic integrity. Any form of plagiarism or academic dishonesty will not be
tolerated in this project. If you have any questions, please consult the coordinators.

Prepared by: Dr. Azizul Azri Mustaffa February 2015