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ChE–470: Process Design

Syllabus
Instructor Robert Nedwick
132A Fenske
863-6229
nedwick@psu.edu

Office Hours Open

Lectures MWF 9:05-9:55 in 110 Wartik

Recitations Wednesday 4:30-6:00 (about 6 times during


semester)

Text Book ChE 470 (Blue Book)


Class Notes: Rev 14.0

Teaching Assistant NONE

Objective
This course integrates the basic material learned previously in the Chemical Engineering
curriculum, including material and energy balances, fluid mechanics, heat transfer,
thermodynamics and reactor design, in order to develop the critical design logic needed to
design and evaluate a process. Specific topics include Process Synthesis, Process
Simulation, Unit Operations Design, Equipment Sizing and Economic Evaluation of
Projects. Students will develop various aspects of a plant design through various
assignments while working closely in a team environment. A formal report and
presentation of the design will be required.

Grading System (Tentative (subject to change) Grade Matrix)


Assignments
1 (MatBal) 15%
2 (Reactor) 15%
3 (HYSYS) 15%
4 (PFD) 5%
5 (Equip) 15%
6 (Final Report) 15%

Pre-Test 4%
Team Meetings 4%
Status Reports 3%
Teammate Evaluation 5%
Attendance Quizzes 4%

Prerequisites
ChE410 & ChE430

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ChE465 Grade History
Average GPA: 3.29
1393 Students

The grade distribution is based roughly on


A/A- 88-100
B+/B- 77-88
C+/C 65-77
D 55-65
F Less than 55

Final Grade Distribution is at the discretion of the Instructor.

Not all teammates will get the same grade.

Effort counts, BUT so do results. Just putting in time with mediocre results will probably
result in a mediocre grade.

Effort is a determining factor for those students near a transition point.

WARNING: Grading for this course is very subjective. Please understand that with the volume of
material that you will be generating, that every single word and calculation cannot be reviewed in
detail. Mistakes will be made in grading but you will be given an opportunity to get re-graded.
However, please also understand that the grading in this course is very similar to the seemingly
arbitrary way you will be evaluated in the “Real World.”

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Team Rules
Picking Teams
Each design team will consist of up to five students. Students are allowed and encouraged to
chose their teammates but at the same time bear the responsibility for their selections. It is strongly
suggested that you pick your teammates based on compatible schedules and common expectations
for the course. Someone who desperately wants (needs) an A can get very frustrated being on a
team with people who already have jobs and want to get by with a simple C and a lot less effort.
There is a sign-up sheet in room 158 Fenske. Students who fail to join a design team by Friday (1 st
week) Noon will randomly be assigned to the remaining design teams. After that date, no team
changes will be allowed.

What’s Expected?
Every team member is expected to contribute to the overall project. All team members are also
expected to be proficient with every aspect of the design, even if you were assigned something
else. If you have a problem with a teammate, it should be addressed immediately. A good
teammate is one who includes everyone in the planning and execution of the project. The grades
will not necessarily be the same for all members of a team.

Assignment Task Allocation Sheet


A signed, Assignment Task Allocation Sheet is expected in the appendix of every assignment. The
one page table should list what each member worked on and a score indicating the effort put into
the work. A score of 20% for each of 5-team members indicates a perfectly performing team (25%
for 4-person teams). While some team members may contribute more of the technical ideas or be
more involved in the planning and execution of the project, ALL team members (even those who
find themselves in a secondary role), are expected to give EQUAL EFFORT. In the event that the
team feels that a member is not contributing and/or is hindering the team's effort, then that should
be reflected in the signed, contribution sheet. If you cannot come to agreement on the percent
contribution, then a minority report can be added explaining why you feel there is a discrepancy.
Sign it and live with it.

Assignment Leaders
There are 5 Assignments plus a Final Report. An ASSIGNMENT LEADER should be designated for
each assignment. That person is responsible to see that the assignment is properly scheduled,
meetings called, work assignments made, and the work completed in a timely manner. The
ASSIGNMENT LEADER is NOT the one responsible for doing all of the work, but that person must
make sure the work is properly distributed among the team members.

Team Problems
It is the responsibility of the team to notify me if there is a serious problem with Team Chemistry. In
the event that a TEAMWORK problem arises, it should be reflected in the Assignment Team
Allocation Sheet. I will note any discrepancies and if there is not a satisfactory explanation, I will
start deducting points from that person’s grade. If the problem continues, there will be a resolution
meeting between myself and the team where I will mediate first and, if necessary, arbitrate a
solution. Please understand that there are legitimate reasons why a person may not fully contribute
--- illness, death in family, etc --- in which case the team should pick up the slack and expect that
person to makeup some of the work in subsequent assignments. This is how a “good team”
operates. However, there are also good, but less compelling reasons --- THON, job interviews, etc
--- which while legitimate, does not absolve the person from making a solid contribution.
Remember that your first priority is to graduate and these extracurricular activities must take proper
priority. Probably, the only way you can fail this course is to screw your teammates.

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ChE470 Process Design
Tentative Schedule

Team
Week Lectures Meetings Assignments

Jan13 Intro/Set-Up
Project Scope

Jan 20 Process Synthesis Pre-Test (Wed)

Jan 27* Process Synthesis 1


Reactor

Feb 3 Reactor 1-BFD/MatBal (Fri)


Utility Systems

Feb 10* Separations

Feb 17 Separations 2-Reactor Design (Fri)

Feb 24 Heat Exchangers

Mar 3* Rotating Equipment 3-HYSYS (Fri)

Mar10 Spring Break

Mar 17 Drums/Tanks 4-PFD/Description (Mon – 3/24)


Capital Estimating

Mar 24* Economics

Mar 31 Economics 2

Apr 7* Safety 5-Equip/CapEst (Fri)

Apr 14 Safety

Apr 21* Process Control 6-Final Report (Mon – 4/28)

* Status Reports due the Friday of that week

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Course Format

Lectures/Recitations
There are three lectures a week at which time new information will be presented. There
will also be non-mandatory recitations sessions where supplemental and review material
will be discussed on an as needed basis. You can request a review session on any
subject and I will try and accommodate you. Some subjects that have been helpful to
students in the past include HYSYS, Excel for Material Balances, Utility Systems, Career,
etc.

Pre-Test
You are expected to come to this course with a certain level of proficiency in key chemical
engineering principles. Instead of spending valuable class lecture time reviewing these
principles, you will be given a test very early in the semester to test your knowledge of this
material. It’s worth 5% of your grade and should be taken seriously. The pre-test is a good
indicator of the calculations you will be expected to perform for this course.

Assignments
There are five assignments plus your final report. The requirements will be posted on
ANGEL and may be modified somewhat depending on the lecture schedule. The
assignments should have TABS and/or a Table of Contents for the grader to easily find the
material. A signed Assignment Task Allocation Sheet must be provided documenting who
did what along with the percent contribution of each member. Please use a 1” or smaller
binder. Appendix C in the Blue Book contains a sample of what is expected.

Final Report (Assignment 6)


Much of the material developed in the first five assignments will end up in your final report.
Based on previous experience, a large amount of time is spent recreating lost material
and reorganizing information for the Final Report. If you are smart, you will correct and
then compile this material, either electronically in a Master File, or in a 2” binder as you
develop it. The Report Format is given in ANGEL. Please adhere to it as closely as
possible. The key item in the Final Report is the Executive Summary. You will need to
condense all of the work required to produce a 3-400 page report into a page or two.

Team Status Meetings


There will be one to three 30-60 minute Project Meetings with individual teams at key
points in the semester to monitor your progress, to see individual performance (or lack)
first hand, and to answer any questions that you may have about the assignment. If there
are no questions or issues, then a simple update is sufficient. Your individual grades will
depend on you ATTENDING AND CONTRIBUTING to the meeting. It is strongly
suggested that some time be allotted for each team member to speak. The team is
responsible for the agenda.

Teammate Evaluation
Each student will confidentially submit a grade for his teammates. It should be based on
effort and accomplishment. I also contribute to the grade based on my observations. My
impressions count if you are near a transition point in the grading. If you fail to turn in an
evaluation of your teammates, you will be penalized.

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Grades
You have ONE WEEK from the time I give back the graded assignments to petition for
more credit. You need to attach an explanation sheet detailing what I may have missed.
I will then re-grade the ENTIRE assignment in the privacy of my office. Therefore, make
sure your explanation sheet is detailed enough for me to understand.

Communications
ANGEL will be used as the main communication system for the class. It will be used to
introduce new or revised information on the project and to communicate schedule
changes. ANGEL will contain the course Syllabus, Report Format, Assignments, and
Project Statement and associated data.

Other Requirements
 Hand in only the assignment that’s due in a ONE inch binder (or smaller). That
should be big enough for all of the assignments. If you need to refer to previous
work, put that work into an appendix. Do NOT put everything you’ve generated to
date into each assignment.
 Assignments should be organized with a Table of Contents and page numbers
(can be hand written).
 Always include your computer disk or memory stick with the assignments.
Attach it securely to your report.
 English Units (lbs, BTU, psi, F, horsepower or kw, hr, etc)

E-mail Consultant (EMC)


Each team will be assigned an e-mail consultant. He is your "Stupid Question Buddy." He
will not be asked to grade you, so feel free to take advantage of his wisdom. He will have
instructions to HELP you with key technical questions, NOT TO DO THE DESIGN FOR
YOU. In most cases, he is not familiar with the specific project design, but he should be
able to offer suggestions as to how to proceed or provide references for you to follow. If
the EMC is willing, get the phone number so you can discuss with him the more detailed,
complicated questions. All EMC correspondence should be included in your final report.
Try and use him on a weekly basis, minimum --- not just as a Status Report requirement. I
would suggest you email him every time you have a question and not wait until the Status
Report to fill him in on your needs. This is a resource --- USE IT!!!!!!

References
You MUST reference any source of information for your report. Please have a page in
your binder that keeps a running track of these. You only need reference recurring
sources (like the EMC) once.

Helpful Hint:
Every year I get comments about the INSANE amount of work required for the
course. I’m sure that this year will be no exception. However, you can do
yourselves a big favor by spreading out the work over the allotted time
(approximately 2-3 weeks). If you wait until the week that the project is due to start
working on the assignment, you can be assured that you will be in Fenske at 3:00 in
the morning. If you start the next assignment immediately after the previous one is
handed in, then you will find the semester much more pleasant. This course is, and
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always has been, time consuming. Some work is mundane, but quite necessary if
you are to properly evaluate the project. All Team Members must buy-in to this
concept or there will be a lot of team friction.

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Status Reports
In addition to periodically asking your EMC specific questions, it is important to keep him
updated on your progress so he doesn’t have to answer questions without knowing the full
context of your problem. Therefore, you will be required to keep your EMC informed by
writing a 2-4 page Status Report roughly every two weeks (see schedule), with a copy to
me. Make sure that both the EMC and I can read your attachments (e.g. you can’t read a
VISIO file if you don’t have VISIO on your computer). The report should always include a
BFD sketch and must be in the format given below:
-----------------------------------------------------------------------------------------------------------------------------------
Date: September 20, 2007

To: EMC

From: James T. Kirk, M.R. Spock, D.R. McCoy, Uhura, Montgomery Scott
Team 16

Subject: Status Report


September 6-20

cc R. Nedwick (DON’T Forget to cc me)

Status
What was accomplished over the last two weeks? NOT IN EXCRUCIATING DETAIL. Just an
overview. e.g. Designed the Deethanizer, NOT “……….ran a HYSYS run to get the RR and then
changed the number of stages and ran it again, and then increased the pressure ……….”

Major Issues
that’s MAJOR ISSUES…….don’t just give the EMC every random thought you’ve had in the last
two weeks. Try and focus on not more than 5-issues that you’re asking his assistance. You can
mention future issues or minor issues, but be clear what your priority issues are. Also, I recommend
the
 Use the BULLET format to writing your issues, rather than page after page of unbroken
text.
 A brief (2-4 sentences) of explanation as to the technical details. Don’t just say the
tower is large without some discussion as to why and some quantitative details.
 An explanation as to why you feel this is a key issue (e.g. the tower is very large and
expensive and an alternate separation technique can be more economical).

Technical Info
The stuff you just calculated to support major decisions or to give the EMC some insight as to why
you asked the question (e.g. giving your graphs of C3 Selectivity vs C2/C4 ratio to show why you
picked a design point).

Attachments
BFD --- always, to refresh EMC memory
MatBal --- always
Whatever else you feel is important

The status report is one way of communicating with your EMC. It doesn’t have to be the only time
you contact him/her. Successful teams make full use of their resources. I would suggest you email
him every time you have a question and not just wait until the Status Report to fill him in on your
needs. Try and get the EMC to take your phone calls.

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Please Note

“Penn State welcomes students with disabilities into the University's


educational programs. If you have a disability-related need for reasonable
academic adjustments in this course, contact the Office for Disability
Services (ODS) at 814-863-1807 (V/TTY). For further information regarding
ODS, please visit the Office for Disability Services Web site at
http://equity.psu.edu/ods/.

In order to receive consideration for course accommodations, you must contact


ODS and provide documentation (see the documentation guidelines at
http://equity.psu.edu/ods/guidelines/documentation-guidelines). If the
documentation supports the need for academic adjustments, ODS will provide a
letter identifying appropriate academic adjustments. Please share this letter
and discuss the adjustments with your instructor as early in the course as
possible. You must contact ODS and request academic adjustment letters at the
beginning of each semester.”

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Real World Lessons
Keep a Sense of Humor
Take your work seriously, but don’t take yourself seriously. Learn from your mistakes, but
don’t dwell on them. The Real World is full of comedians that will look for ways to “yank
your chain.” You need to be ready for that banter --- be able to give as well as receive and
not have any lingering hurt feelings. In most instances, this activity is conducted in good
faith, so roll with it. At the same time, learn to recognize the mean ones in your midst, and
avoid becoming one of them. Remember that everyone makes mistakes, including your
boss with 30-years experience.

Life is (Often) Unfair


Hate to say it, but you will be judged on many things in your work (life) and technical
competence is only one of them. You may be the best engineer in your group and still find
yourself losing out on promotions to your roommate who gets his answers from you. Just
being a good engineer, while critical, isn’t sufficient. Management values a lot of things,
such as, presentation skills, lunch table banter, teamwork, leadership skills, marrying the
boss’s daughter (son), etc. Most of these intangibles are also very hard to grade
objectively --- you may think you’ve got them, but your boss may think otherwise. You’ll
get a taste of “Life is Unfair” in this class since so much of the grading is subjective.

Get a "Stupid Question Buddy"


Find someone you trust to ask really stupid questions. Even the simplest concepts
sometime get muddled in very complex problems and talking it out with someone who isn't
going to laugh (well maybe he will laugh, but so what) really helps. Asking your boss or
client or stranger may come back to bite you come raise and promotion time. Your Stupid
Question Buddy is also a good place to go for a reality check when you feel Life is Unfair.
It really helps if you become your Stupid Question Buddy's Stupid Question Buddy. A peer
(friend) that started the same time you did is the likely candidate.

Meet People
The more people you know, the more chances for you to impress. Go out of your way to
knock on doors of people you don’t know and find out what they do. You’ll be surprised
how many (not all) older, more experienced people are eager to become a mentor. They
can help you understand the company better which makes your job more interesting and
gives you an extra intangible. They can also be a job networking contact should an
opportunity arise in their area. Finally, getting to meet your Second Level Supervisor in a
non-confrontational situation (just knock on his door at 5:00PM to say hello) gives you
some measure of protection if you find yourself in a personality conflict with your direct
supervisor.

Don’t be afraid to fail


Some very successful people have failures on their resume. They learn from it. They pick
themselves up and start all over again. Extend yourselves. Take chances. Companies
often “fast track” individuals that they see as eventually leading the company. Those
assignments are often destined to fail, but can be full of interesting experiences. Don’t
always take the comfortable route.

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