CE2002: Process Design 2018/19

Design of a Process Equipment and HAZOP

1.0 Assignment Brief
Working in your groups from TP1, you will produce a comprehensive group report on the
design of a process equipment assigned to you. The process equipment is part of the PF
Resin process, which you have been working on from TP1.
1.1 Main tasks
i. Selection of process equipment
ii. Chemical engineering design of process equipment
iii. Mechanical engineering design of process equipment
iv. HAZOP study on a line around the process equipment
v. Selection of suitable pump to transporting heat transfer fluid
2.0 Structure and Requirements of Equipment Design Coursework

2.1. Presentation (5 marks)

Logic and accuracy of contents, format and professional appearance

2.2. Title Page (1 mark)

This should give the Project Title, group number, names of group members, submission
date, module code, names of module instructors, appropriate logo (Aston), image, etc.

2.3. Executive Summary (5 marks)

The Executive Summary should objectively state the basis of the design task and how they
align with the coursework brief. It should some provide quantitative data on the final design
achieved by your group as well as any suggestions for improvements. The language used
here should be suitable for a general audience, providing the reader with an overview of the
content of the entire report. It should be no more than 350 words.

2.4. Table of Contents (2 marks)

Following the executive summary, you should provide a table of contents identifying the titles
of the chapters of your report and the page they begin on. This should be a maximum of 2
pages.

2.5. Introduction (7 marks)

Provide a technical introduction into PF Resin production process routes, the global annual
production capacity of PF Resin as well as its uses and applications. Thereafter, introduce
the tasks for this coursework.

2.6. Plan and Objectives (5 marks)

Provide your groups’ plans and objectives in delivering the tasks. Use Gantt Chart to present
information about how the task was carried out by group members.
2.7. Selection of PF Resin Reactor (10 marks)
From TP1, we learned that PF Resin production requires the use of an Isothermal Batch
Reactor (IBR) and each group has been assigned to design this. However, you should
provide a concise review of chemical reactors and their applications. Moreover, you will
specifically need to carry out background research on 3 different reactors that could be used
for PF Resin production to justify the use of IBR in industry. Use this section to research
about the kinetics and thermodynamics of the main reactions occurring in the process,
providing sufficient data that will help you to discuss the reasons for using an IBR.

2.8. Chemical Engineering Design of IBR (30 marks)

Chemical engineering design entails the selection of methodology, followed by relevant
calculations that you will perform in order to size your process equipment. For reactor
designs, you will need the relevant kinetic data for your reaction as well as the appropriate
performance equation for the type of reactor. You should normally begin your design
calculations by reviewing the mass and/or energy balances related to the process equipment
as your design calculations depend on these data. You should clearly explain your design
methodology and include the production capacity, specifications, assumptions for sizing your
reactor. You will then proceed to perform relevant calculations to obtain the size of your
reactor. Thereafter, you will include the design of other reactor accessories such as
agitators, cooling/heating jackets, insulation, etc. You are required to carry out a sensitivity
analysis & optimisation of your design (e.g. change in temperature, pressure, viscosity, etc.).

2.9. Mechanical Engineering Design of IBR (15 marks)

You should make considerations for the selection of materials for construction of your
process equipment based on your chemical engineering design. It should also include
calculations of vessel wall thickness, selection and justification of vessel heads and their
thicknesses (where applicable), considerations for vessel supports, etc. You should clearly
specify your reasoning for your choices. A concept 2D drawing of your equipment is
required.

2.10. HAZOP Study (20 marks)

Using the P&ID that you have submitted for your CE2009 coursework (or a revised form of
it), you will carry out a HAZOP study on one of the lines relating to your process equipment.
You will be required to submit both a pre-HAZOP and a post-HAZOP P&ID with this
coursework. Groups assigned to Task A will carry HAZOP on the line that delivers heat
transfer fluid to the reactor for cooling. Groups assigned to Task B will perform HAZOP on
the line that delivers heat transfer fluid for heating the reactor.

2.11. Selection of Pump for Heat Transfer Fluid (10 marks)

Heat transfer fluid for cooling or heating the reactor at different stages of PF Resin
production would require a pump for its transport through pipe lines to the IBR. You will need
to carry out relevant calculations that would enable your group to select the appropriate type
of pump for this duty. Groups assigned to Task A will select a pump that delivers heat
transfer fluid to the reactor for cooling. Groups assigned to Task B will select a pump that
delivers heat transfer fluid for heating the reactor.
2.12. Concluding Remarks (5 marks)
Provide a concise section on your concluding remarks to the report. It should focus on your
general achievements as a group, particularly on how you achieved your group’s plans and
objectives for this task. Also include a brief reflection on what you could do differently with
this sort of tasks in future. This should no more than 300 words.

2.13. References (5 marks)

Citing and listing of references must follow the Harvard style. You must provide a list of
references detailing the literature you used as sources of information for your project.
References must clearly identify the source material and should be in the form of a
numbered list. At the appropriate location in the main body of your document, identify the
cited reference by its number in the list of references.

3.0. Other Assessments

3.1 Peer-Assessment (10 marks)
You should submit an independent and anonymous peer-assessed mark for other members
of your group that indicates their contribution to the group task. Use the template provided on
Blackboard for this. Do not assess yourself.

3.2. Industry and Initiative (20 marks)

You will be assessed on your instructors’ perception of your participation and contributions to
this group project.

4.0 Submission
Due date: Friday March 29, 2019 by 2.00pm
Submission mode: Blackboard (online) and Hardcopy (EAS Reception)
Late submission penalty: 10% of mark deducted per day as per University Regulations

5.0 Report Format

Title Page
Executive summary
Table of content
Main Report (arrange in order from Section 2.2 to Section 2.13). Word limit: 12500 words
(excluding references)
Page numbering: Bottom or top of page
Page Margins: At least 2.0 cm
References: Harvard style recommended
Font type/size: Arial size 12
Line Spacing: 1½

Total 150 marks