ENCH 511 / 531 - Introduction

Hector De la Hoz Siegler

Slides originally prepared by: Marco A. Satyro and Michael W. Foley
1
 ENCH 511/531 – In a nutshell

 You will be doing lots of learning

 But this is not a traditional lecture-based course!

 This is your chance to show what you are made of.

 In another words…

—This is a dress rehearsal for the real world…

… where you have to perform on your own.

 Course Objectives

In these courses you will exercise your:

 skills and knowledge on basic areas of Chemical Engineering –

Momentum, Heat, Mass Transfer, Reactor Engineering, Applied
Mathematics and Common Sense.

 skills on basic project management – problem definition, solution

strategy, solution implementation and Time Management

 social skills – working in groups, interacting with senior engineers

and Professional Presentations – Individual & Group plus Reports
 Learning Outcomes

 Identify and characterize chemical process engineering

problems, and formulate and execute a solution for such
problems.
 Generate alternative design solutions and rank them
according to multiple evaluation criteria, including technical,
economic, and environmental metrics.
 Use proper research databases; independently summarize,
analyze, synthesize, and evaluate information from a wide
variety of sources; and develop strategies to identify and
address gaps in own knowledge.
 Use process simulators to develop process flow sheets and
solve steady state mass and energy balances involving
multiple unit operations.
 Learning Outcomes

 Estimate capital and operating costs, and calculate financial

indicators to assess project feasibility.
 Plan and manage engineering activities within time and
resource constraints.
 Understand the impact of engineering solutions, including
environmental and economic impacts, in a global and in a
societal context.
 Communicate engineering knowledge in the form of written
documentation (i.e. PFDs, block diagrams, DBM) and oral
presentations.
 Establish and monitor team’s organizational structure and
promote team effectiveness through individual action.
 Expectations

 You will be treated as Engineers

 As such We expect:
— Honesty

— Hard Work

— Creativity

— Ingenuity

— Competence

— Endurance
 The Facts

 This Will Be the Hardest Course You Have Ever Taken

— You will have to devise your own solutions to open ended
problems.
— You will have to integrate vast amounts of information
received over last 3 years.
— You will have to speak in public.

— You will have to present your solutions.

— Your solutions will be examined by an outstanding group of
senior engineers.
 Course Mechanics

 Open-Ended Design Project

— Literature studies
— Flowsheet synthesis
— Process simulation
— Economic, environmental, health & safety evaluations
— Not one single correct solution
— Identify possibilities and argue for choices
— Optimization of suggested process
 Team Work
— Performed as consulting company
— Emphasis on capability to delegate and structure efforts
— Focus on presentation skills (oral & written)
— Manage relationship with your client (supervisor)
 Course Mechanics

 Lectures
— Professional development

— Expose you to different industrial techniques

— Tuesdays and Thursdays from 09:30 to 10:50

— ASK QUESTIONS – we have outstanding guest lecturers.

— THERE ARE NO STUPID QUESTIONS – only unasked

questions.
 Marking Structure

Component Weight
Conflict Resolution Exercise 4 %
Mid-term progress report 15 %
Mid-term oral examination 10 %
Peer Evaluation Exercise 4 %
Individual presentation 15 %
Design Basis Memorandum (DBM) 50 %
Quizzes 2 %
TOTAL 100 %
 Grade scale conversion chart

Letter Total Mark (T)

Grade
A+ T ≥ 95%
A 90% ≤ T < 95%
A- 85% ≤ T < 90%
B+ 80% ≤ T < 85%
B 75% ≤ T < 80%
B- 70% ≤ T < 75%
C+ 65% ≤ T < 70%
C 60% ≤ T < 65%
C- 55% ≤ T < 60%
D+ 50% ≤ T < 55%
D 45% ≤ T < 50%
F T < 45%
 Midterm Evaluation

 Mid Term evaluation: ORAL (10%) / Report (15%)

 OCTOBER 16th – Hand in your short progress report.

 OCTOBER 20th – Oral Examination

9:00 to 16:30 in Room ENB 206

 15 Minutes per group

— 5 Minutes – Presentation

— 10 Minutes – Questions from Examiners

 Do not miss your presentation. No retakes and dates are firm.

 Give yourself time to proof read report and practice presentation!

 Midterm Report Structure

 At a minimum, your progress report should contain the

following elements:
 Letter of transmittal
 Executive summary
 Introduction/literature survey
 Market survey
 Process selection
 BFD & PFD (without control strategies) & Gantt chart
 Preliminary material and energy balances
 Conclusions and Recommendations
 Length of report not to exceed six pages, excluding Cover
page, Letter of Transmittal, Executive Summary, References
and Appendix
 BFD, PFD, Gantt chart and Material Balances can be in the
appendix (No more than 5 pages, 3 is better)
 Individual Presentations

• Oral examination: 15%

• 5 minutes individual presentation
• Showcase your work
• 5 minutes for questions from me
• Be punctual and use presentation time wisely
• Do not exceed allotted time. You will be interrupted
if time limit is exceeded.
• Do not miss your presentation. there are no retakes
and dates are firm.
 Individual Presentations

 Individual Presentations dates:

—November 20th: 13:00 – 16:00
—November 21st: 9:00 – 12:00
—November 22nd: 13:00 – 16:00
—November 23th: 9:00 – 12:00
—November 24th: 13:00 – 16:00
 Signup forms will open on November 1st
 Design Basis Memorandum

 Final Report - 50%

 By 16:30, December 8th, 2017:

— Submit one (1) printed copy to your supervisor

— Upload a PDF copy of your report to D2L dropbox

 Busy people will read your report. Be precise and objective and
write clearly.

 Report will be graded by both your supervisor and either me or a TA

 Do not miss the deadline – Late reports will be heavily penalized

 Design Basis Memorandum

 Suggested report structure

— Letter of transmittal
— Executive summary
— Problem description / introduction
— Market survey
— Process selection
— Process description
— Material and energy balances (put sample calculations in Appendix)
— Pre-design equipment sizing
— Pre-design economic evaluation (ROI, POP, DCCFRR, etc. with
sensitivity analyses)
— Safety and environmental impact analyses
— Conclusions and recommendations

— BFD & PFD (with control strategies) & Gantt chart

 Let’s Get Busy!

 Groups structure
— 3 groups of 3 Engineers
— All other groups – 4 Engineers
— If you don’t have a group or your group only have 2 or 3 members
come forward and introduce each other!
— Complete group enrollment by the end of TODAY
— Name your group: Catchy is always Nice!

 Project topics posted on D2L

 Submit your preference starting tomorrow at noon
 Projects are first come, first served basis
 Schedule weekly meetings with your supervisor
 Start literature survey and process selection
 Competitions

 Schulich Capstone Design Fair

— April 2018
— Industrial judges
— This is your chance to sell yourself as an engineer!

 Hatch Plant Design Competition

— Open to all Canadian chemical engineering programs
— 1 submission per university
— Top 3 are invited to final in Toronto (October 2018)
— Last year (2016), U. Calgary placed second overall
ENCH 511 / 531 – Process Design
Hector De la Hoz Siegler
Slides originally prepared by: Marco A. Satyro and Michael W. Foley
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 Nature of design

Starting from a vaguely defined problem statement

such as a customer need or a set of experimental
results, chemical engineers can develop an
understanding of the important underlying physical
science relevant to the problem and use this
understanding to create a plan of action and set of
detailed specifications which, if implemented, will
lead to a predicted financial outcome.
 Design constraints

All designs

Plausible designs

Personnel

Modified from Towler and Sinnott (2012)

 The Process of Process Design
Customer Needs

Model Building
Generate
Design Specs
Design Concepts R&D

Performance
Estimates

Evaluate Economics,
Optimize and select
design

Customer
Approval
Procurement
Detailed Design and
Construction Operation
Equipment Selection
Commissioning

Modified from Towler and Sinnott (2012)

 Process design implementation: The Design Team

Project Business
Sponsor Input

Project
Manager

Process Technical Control

Cost Engineer Consultants
Engineer(s) Specialists Engineer

R&D Mechanical Civil

Contractors
Specialists Engineer(s) Engineers

Modified from Towler and Sinnott (2012)

 The Design Team

Project Business
Operating Sponsor Input
Company

Project
Manager

Process Technical Control

Cost Engineer Consultants
Engineer(s) Specialists Engineer

R&D Mechanical Civil

Contractors
Specialists Engineer(s) Engineers

Technology EPC
Vendor Company

Modified from Towler and Sinnott (2012)

 Project Plan

Resource
allocation

List of tasks Gantt Chart

Duration, start
and end dates

Predecessor
tasks
 Design Documentation

Design information must be clearly documented to enable:

 Fair comparison between competing design alternatives
 Transfer of information to E&C company for detailed design
 Development of plant manuals
 Design documentation
The design documentation for a process usually includes a minimum of:

1. The design basis (specifications from client)

2. Description of the process
3. Block flow diagram
4. Process flow diagram
5. Mass & energy balance
6. Product specifications and properties
7. List of major plant equipment
8. Equipment specification sheets
9. Piping and instrumentation diagrams
10. Cost estimate
11. HS&E information (e.g., HAZAN, HAZOP, MSDS forms)

Additional information such as techno-economic analysis, market information,

analysis of competing technologies or alternative design options may also be
included if within the scope of the project
Block Flow Diagram
Process Flow Diagram
Piping and Instrumentation Diagram