UNIVERSITY OF CAPE TOWN DEPARTMENT OF CHEMICAL ENGINEERING CHE4049F PROCESS SYNTHESIS AND EQUIPMENT DESIGN 2012 PROJECT 3: ECONOMIC

C ANALYSIS, CONTROL PHILOSOPHY AND PLANT LAYOUT

This project will be done in groups of four as specified in the attached group allocation handout.

Introduction This project is a continuation of the theme that was presented in Projects 1 and 2. From those projects, you should now be familiar with the acrylic acid production process, and with the various factors affecting the reaction and separation stages of the process. For this project, the flow sheet, flow rates and stream conditions have been fixed. The process flow diagram (PFD) is attached in a separate file, while the flow rates and stream conditions can be ascertained from the attached Aspen file. The focus of this project will be on: the economic and environmental analyses of the process. the control strategy for the system. Site/plant layout. Project brief You are required to prepare a preliminary cost estimate (along with preliminary control and plant layout strategies) for senior management, which will enable them to evaluate whether or not this project should proceed to the next stage of the companys engineering design procedure detailed design. The report should include the following. 1. An executive summary of the work carried out in this phase, the recommendations arising from the work, and the key issues that should be given priority in the following phase [max. 1 pages]. A process description [max. 1 page], PFD and stream table (showing flow rates in kg/h and stream conditions e.g. temperature, pressure, phase, etc.). Most of the information for this section can be taken directly from previous projects and the attached PFD and Aspen file, and merely presented in an appropriate format. Note, however, that the PFD should be expanded to include storage tanks, as well as the equipment associated with the two vacuum systems. An equipment list showing all major equipment in the process, along with the relevant parameters for determining the cost of each item (e.g. characteristic size parameter(s), design temperature/pressure, material of construction, etc.). In an appendix, for each equipment item, there should be an equipment specification/calculation sheet, which should include: (i) the design basis, i.e. flow rate, energy, temperature and other information used in the specification/calculation of the item (all of which should be consistent with the PFD/stream table). (ii) any additional assumptions that were made (including those derived from heuristics, or from information given in this handout). (iii) all relevant calculations.

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A utility summary table. This should include a list of all the utility-types that will be required in the process. For the utilities where usage can be determined (e.g. steam, cooling water, chilled water, electricity, etc.), the list should be expanded to include the details of user and usage. All usage amounts should be consistent with the energy balance and/or equipment calculations. An economic analysis of the process, as depicted on the PFD generated in step 2. This should include: (i) a summary of the methods and assumptions used to estimate the profitability of the process [max. 1 page]. All details of the costing calculations (e.g. costing parameters used for individual equipment; installation factors used; etc.) should be included in an appendix. (ii) a summary of the standard profitability indicators for the process [max. page]. (iii) a discussion [max. 2 pages] of the five parameters that will most effect the profitability of the process (e.g. cost of installing or operating a particular equipment item or section of the process; price of particular utility, raw material, or product; etc.). This section should include a discussion on: (a) why you chose those particular parameters; and (b) changes that could be made to the process (with regard to the parameters) to improve profitability. All calculations should be included in an appendix. An environmental analysis of the process [max. 1 page]. This should include: (a) an analysis of the carbon footprint that results from both the process itself, and from the energy/utility requirements of the process, including a discussion on which aspects of the flow sheet should be targeted to reduce this footprint; (b) an analysis of the other emissions of the process, with reference to any legal requirements/limitations, including a discussion of any changes that will have to be made to the process and potential impacts on profitability. All calculations should be included in an appendix. A summary discussion on the profitability and environmental impact of the process, including recommendations on whether or not to proceed to the next phase and, if so, which issues should be given particular focus in the next phase [max. page] A process control strategy. This should consist of: (i) a process control diagram, similar to the PFD but showing all necessary control loops. At a minimum, the control loops should include the measurement element (in the case of flow), the transducer, and the indicator/controller. (ii) a discussion of the overall steady-state control scheme (i.e. why flow control was used in certain cases, and level control in others, etc.) as well as of the startup/shutdown strategy and how this impacts on the instrumentation [max. 2 pages]. A control valve specification list giving the minimum, normal and maximum flow rates for all control valves in the flow sheet. In addition, for ONE control valve (of your choice) in a pumped liquid line, the minimum, normal and maximum Cvs should be calculated in an appendix, and shown on the specification sheet. A site/plant layout strategy. This should consist of: (i) a site layout diagram (plan view). (ii) a plant layout diagram (plan view). (iii) a plant side-elevation diagram. (iv) a discussion of the site/plant layout, including reasons for the chosen location/elevation of key equipment [max. 1 page]

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All appendices should be appropriately labelled/titled (e.g. Appendix A: Equipment calculation sheets), and clearly referred to in the main text.

Report Format The report should be typed in 12 point Arial font with 1 line spacing using the standard MSWord template, and should be ring-bound. It should include: a cover page giving the title of the report, and the names and student numbers of all group members. a standard UCT plagiarism declaration (i.e. that the submission reflects the groups own, unaided work), signed by each group member. a table of contents, with page numbers. sections 1-10 of the report, as defined in the project brief. appendices, as defined in the project brief references, using the Harvard system format. All diagrams and flow sheets should be computer-generated. The PFD/stream table, process control diagram, and site/plant layout diagrams may optionally be printed on A3 paper in landscape format and folded to fit within the A4 report. Engineers are expected to present their work professionally, and this will be taken into account in the marking of the project. As in Projects 1 and 2, marks will be deducted for: Typographical errors and /or inappropriate numbers of significant figures. Incorrect fonts and line spacings. No/inconsistent page numbering. User-unfriendly or inaccurate contents list. Poor quality diagrams and tables. Drawings without border, name block, project title, process area name, drafters name, date drawn. Lack of attention to detail in Harvard referencing format. Incorrect English grammar, or sentence construction that makes the document difficult to read. Information presented in an illogical sequence jumping between points and concepts. Incorrect title page or plagiarism declaration. Exceeding maximum length restrictions given in the different sections of the project brief. [Note: page limits apply only to text, i.e. diagrams, charts, etc. are in addition.] Appendices not labelled/titled and/or not referred to in the main text. Report not ring-bound.

Report Deadline The report should be submitted to the submission box outside the Design Studio by 17h00 (5 pm) on Saturday 5 May 2012. Penalty for late submission will be 2[(n+1)!] percentage points, where n is the number of days (or part thereof) that your project is late. Please note that n is cumulative over all projects, e.g. if you were one day late for both of Projects 1 and 2, n will start at 3 for Project 3. This rule will be applied to individuals.

Assessment/Mark Allocation Description 1. 2. 3. Executive summary Process description/PFD/stream table (a) Equipment list: table (b) Equipment list: appendix/calculations 4. Utility table 5. (a) Profitability: methodology (b) Profitability: summary of indicators (c) Profitability: appendix/calculations (d) Profitability: parameter discussion 6. (a) Environmental analysis: carbon footprint analysis/discussion (b) Environmental analysis: carbon footprint appendix/calculations (c) Environmental analysis: emissions analysis discussion 7. Summary discussion of profitability and environmental impact 8. (a) Control strategy: diagram (b) Control strategy: discussion 9. Control valve specification list (including calculation) 10. (a) Site/plant layout: diagrams (b) Site/plant layout: discussion 11. General document presentation TOTAL Notes: 1. 2. Although the above table gives a mark allocation for each section, the final overall mark may be adjusted to take into account the total quality of the work. Each student will have to submit a peer assessment sheet (see attached template), evaluating the contribution of the other members of the group. Only the lecturer will see these sheets. The peer assessments will be taken into consideration when deciding on final individual marks for the project (i.e. not every individual in the group will necessarily receive the same mark). Any student that does not submit a peer assessment sheet will lose 5 marks (out of 200). Maximum mark 10 5 10 20 5 5 10 25 5 10 5 15 20 10 10 30 5 45

20 5 35 5 20 20 200

Assumptions and Supplementary information Economic data Propylene price: Acrylic acid price: Acetic acid price: Depreciation: Utility data Electricity Low Pressure Steam Cooling Water Chilled Water R 1.10/kWh 3.5 barg (saturated) @ R 0.12/kg Supply temp 30C, return temp. max 45C @ R 3/GJ Supply temp 5C, return temp. max 20C @ R 30/GJ R 11/kg of C3H6 R 21/kg of C2H3COOH R 4.30/kg of CH3COOH Straight line over 10 years

Equipment specifications/costing Since the reactor is a vessel with cooling tubes inside it, it should be sized/costed as a combination of both, i.e. the cost of the vessel plus the cost of a shell-and-tube heat exchanger with the equivalent heat transfer area. For pump sizing, vessel pressures from the Aspen file can be used, but not stream pressures, since the Aspen simulation does not take into account line-loss, control valve pressure drop, etc. For column sizing, number of theoretical stages and internal vapour and liquid flow rates from the Aspen simulation can be used, but the actual dimensions should be calculated using other methods, with Aspens automated sizing used only as a check.

Attachments (For electronic attachments, see course Vula site: Resources/Project 3) 1. 2. 3. 4. Project group allocation (electronic) Process flow diagram (electronic) Aspen file: basis for mass and energy balance (electronic) Peer assessment sheet (hard-copy)

A final hint The main aim of the sizing/costing exercise (in this phase of the project) is to get an estimate of profitability. Thus, if you are faced with a decision but the particular choice you make will have a negligible impact on profitability, spend less time on it. On the other hand, a decision that will have a big effect on profitability warrants more time [and such a situation also indicates that the parameter might be a candidate for point 5 (iii)].