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Course Content Learning Outcomes Method of Instruction List of Books List of Chemical Engineering Journals List of Chemical/Process Design Softwares Class Grouping for Process Design
Course Content
Scope of Design Project Sources of Design Data Equipment Design and Specification Mechanical Design of Process Vessels and piping Site Location and Layout Process Services Environmental Consideration Design Report Elements of Modular Simulation Use of Computer Software in Design of Process Plants(Hysys, ChemCAD, Pro II, Prosim etc)
Learning Outcomes
Scope a design project Collect and collate design data Design and Specify any process equipment Work effectively in a design team Establish passion for the use of computer software in the design of a chemical plant Familiarity with Hysys and other computer softwares
Method of Instruction
Lectures Class Exercises Home Assignments Assessments Video Presentation Industrial Visits Invited Guest Speakers
Class Discussion
Students Expectations How to realise these expectations Appointment of Class Industrial liaison officer Listing of Potential Industries to visit
List of Books
R.H. Perry and D.W. Green (Editors), The Chemical Engineers Handbook, McGraw Hill Book Company, 7th Edition, (1997) M.S. Peters and K.D. Timmerhaus, Plant Design and Economics for Chemical Engineers, McGraw Hill Book Company, 5th Edition, (2003) D.M. Himmelbau, Basic Principles and Calculations in Chemical Engineering, PrenticeHall International, 6th Edition, (1999) J.M. Coulson and J. F. Richardson, Chemical Engineering, Volume 6, Pergamon Press, ( 1999 )
Design Scope
Definitions Parts of Project Design Scope Emphasis on safety during the design stage Scoping a chemical Engineering Project Assignment ONE
Definition of Scope
A clear definition of the project is the first stage of plant design. A clear definition of the project makes preliminary process design easy, which in turn provides a reasonably accurate cost estimates.
Product(s)
Size of container Size of expected orders How much material must be sold (predicted by marketing expert) Technical and economic questions Board of Directors make final decision on size of plant Plant can be large, small, multipurpose Containers (steel drums, filler drums, Polyethylene drum/bags, boxes, car bays, pails, cans)
Quality
Number and types of processing steps determine purity of products Use very expensive raw material when small quantity is required Purify raw material of low quality when large quantities are processed Set product specification at the time of deciding the capacity
Product Storage
Product storage must be large enough that it does not impede production Consider whether product has a steady market or vary with season of the year
Hours of Operation
There are 8,760 hours in a year For a small plant involving new technology, allow 90 percent of total time (7900 hours) For a large plant using well documented processes, use 95 percent Consider shift arrangements In general design for 300 days in the year
Completion Date
Completion date has effect on cost and profitability Prices change with time However rushing can cause increase in prices(You speed up equipment delivery and do things in more expensive ways to save time) It takes two to three years after the scope is written before the plant is ready for start up
Safety
A major design consideration Bury tanks, provide fire walls, separate parts of the plant Provide a sprinkler system Storage facilities should be at least 500m form processing equipment Record all dangerous aspects of chemicals and processes Safety consideration will reduce the probability that some safety features will be omitted Such omission can cause injury to man, equipment and environment Prepare hazard sheets for all chemicals
Class Exercise
Think of a process plant Develop a design scope for the process plant Draw up a hazard sheet for one of the hazardous chemicals. (20 minutes)
Home Assignment
Get a recent copy of one of the national dailies and find a scope of a project. Write out the important sub-heads of the scope. Get a copy of the article stated below and read and do a summary write up on it. Glen Rosentrater, Preliminary and Final Engineering Scope of Work, Chemical Engineering Progress, vol.97, no.12, Dec. 2001
Internet Sources
Key words Chemical Engineering Information www.hw.ac.uk/lib www.che.ufl.edu/ www.ciw.uni-karlsruhe.de/chem-eng Many of the important sources of engineering information are subscription services Knovel organisation: Provides on line access to most standard reference books. Although subscriptive, it can be accessed through many libraries including professional engineering ihstitutions and some universities
Subscription
http://www.che.com http://www.cepmagazine.org http://www.aiche.org http://www.ualberta.ca/cmeng www.sciencedirect http://www.blueskythinker.co.uk (geniusDirector of information), (Exploitation of Science, technology, innovation and technology transfer)
Estimation of Properties
Specific heat capacity, latent heat of vapourisation Vapour Pressures, use the equation
B InP A T C
A, B, C are called Antoine Constants compiled by Ohe (1976, 1989,1990) Enthalpy of Reaction/Formation Phase Equilibria Data Diffusion Coefficients needed in the design of mass transfer processes of gas absorption, liquid-liquid extraction
Lecture Number 3
Equipment Design and Specification Classification of Processing Equipment Design Equations Codes and Standards Equipment Specification Sheet
Equipment Specification
Standard equipment should be selected. If equipment is standard, manufacturer may have desire size in stock. Manufacturer will quote a lower price and give better guarantees than for special equipment. A lot of valuable information can be obtained from equipment manufacturers who specialise in particular types of equipment. Before contacting a manufacturer, the engineer evaluates the design needs and prepare a preliminary specification sheet for the equipment.
Heat Exchanger
Date : 30/05/2010 By : Dr. S. E. OGBEIDE
outside area: 470 sq ft Tubes: 1in. Dia. 14 BWG 1.25 centimetre Pattern 225 tubes each 8ft long 2 passes Tube material Carbon Steel Shell: 22 in dia. 1 pass Transverse baffles , Tube support required Longitudinal baffles 0 required Shell material Carbon Steel
Utilities : Untreated cooling water . Controls : cooling water rate controlled by vapour temperature in vent line. Insulation: 2 in rock cork or equivalent weather proof. Tolerances: TEMA Standards. Comments on Drawing: Location and sizes of inlets and outlets as shown in drawing.
Function : separation of a mixture Operation: Continuous Materials Handled: Quantity: Composition: Temperature: Design data: Feed ------------------------------------Overhead ---------------------------------------------Reflux --------------------------------------Bottoms -------------------------------------------------------
No of trays: ---------------Pressure: ----------------Functional height: ---------------Material of construction: -------Diameter: -----------------Max. Allowable vapour velocity: ft/s ----------------Max. vapour flow rate: ft3/s ---------------Recommended inside diameter: --------------Hole sizes and arrangement: ------Tray thickness: ----------------------
Design Methodology
Design Steps/Procedure Design Equations Standards and Codes Interaction with Manufacturers Final Design Specification Sheets on all equipment Engage a fabricator
Write a technical essay on computer aided design of a process equipment of your choice. Submission date is on or before 17/05/2011
Course Assignment
Divide the class further into group of 4 students to carry out assignment a) Design of air cooled condenser b) of vertical thermo-siphon reboiler c) of kettle type evaporator d) ,, of finned tube heat exchanger e) of reciprocating compressor f) of centrifugal compressor g) of blowers/vacuum pump h) of steam turbines i) of surge drums/tanks j) of gas turbines
Lecture N. 4
Classification of Pressure Vessels Pressure Vessels Codes and Standards Fundamental Principles and equations
Vessel Supports
Saddle Supports Skirt Supports Bracket Supports
Pressure Vessel
Any closed vessel over 150mm diameter subject to a pressure difference of more than 0.5 bar They are divided into two groups depending on the ratio of wall thickness to wall diameter thin walled vessels (thickness ratio less than 1:10) Thick walled vessels (thickness ration more than 1:10)
Group Assignment
Text Book (Chemical Engineering Vol.6 p. 890) Problem 13.5 Groups 1&2 Problem 13.4 Groups 3&4 Problem 13.6 Groups 5&6 Problem 13.7 Groups 7&8 Problem 13.9 Groups 9&10
References
Mukherjee, R. , Effectively Design Shell and Tube Heat Exchangers, Chemical Engineering Progress, vol.94, No. 2, pp.21 37, (Feb. 1998) Mukherjee, R. , Broaden your heat exchanger design Skills, Chemical Engineering Progress, vol.94, no. 3, pp.35-43, (March 1998) Aurioles, G. Comply with ASME Codes during early design stages, Chemical Engineering Progress, vol.943, no.6, pp.45-50, (1998) M. Sloan, Designing and trouble shooting plate heat exchanger, Chemical Engineering, vol.105, no.5, pp.78-83, (May 1998)
Questions addressed before starting, while writing and after finishing a report
What is the purpose of report? Who will read the report? Why will they read it? What are their functions? What technical level will they understand? What background information do they have?
1. Letter of Transmittal
Indicates why report has been prepared. Gives essential results that has been specifically requested.
2. Title Page
Includes title of report name of person to whom the report is submitted Includes writers name and organisation and date
3.Table of Content
Includes location and title of figures, tables and all major sections
4. Summary
Briefly presents essential results and conclusions in clear and precise manner
5. Body of Report
Introduction Presents a brief discussion to explain what the report is about and the reason for the report. Previous work (discuses important results obtained from literature surveys, and other previous work) Discussion
5. Body of Report
Outlines the method of attack on the project and gives the design basis. Includes graphs, tables, figures that are essential for understanding the discussion Discuss technical matters of importance Indicates assumptions made and their justification Gives a general discussion of results and proposed design
8. Acknowledgements
acknowledge important assistance of others who are not listed as preparing report
11. Appendix
Sample calculations Derivation of equations essential to understanding the report but not given in the main body Tables of data employed with reference to some part Results of laboratory tests (to obtain design data)