Review for Design I Exam

CHEN 4253
Terry A. Ring
 Materials Covered
Week 1-22 August
Chapt 1 (p.1 -25), Chapt 2, Chapt 3 Product Design-
Introduction to course – Product and Process Design
Product Design-1 Overview
Product Design-2 Property Estimation
Week 2-29 August
Chapters 16 and 17
Product Design-3 Innovation Maps
Product Design-4 Six Sigma in Product Design
Product Design-5 Engineering Ethics
Week 3–5 September (Holiday Monday)
Chapt 1 (p25-31) Chapter 4 Process Creation-
Ethics in Chemical Engineering
Process Safety
Process Design Overview
Process Creation
 Materials Covered-con’t
Week 4–12 September (Celanese in Class Monday)
Chapt 4&5&6 Aspen for Process Creation–
Use of Aspen for Process Creation-1
Use of Aspen for Process Creation-2
Heuristics for Process Simulation
Week 5 – 19 September
Chapt 4&5 Aspen Tutorials and Problems Solved in Class (Reserve the ICC) -
Week 6 - 26 September (Away Wednesday and Friday)
Chapt 5&6 ProMax Tutorials and Problems Solved in Class (Reserve the ICC) -
Week 7–3 October
Chapter 22-22 (p543-558) &23 Profitability Analyses -
Annual Costs
Earnings
Profitability Analysis
Week 8- 11 October FALL BREAK
 What have we really covered?
• Product Design (Ethics) Chapt. 1,2&3
• Process Creation Chapt 4
– Heuristics for Process Synthesis Chapt 6
• Process Simulators Chapt 5
– Aspen
– Promax
• Capital Cost Estimates Chapt 22
• Profitability Analyses Chapt 23
 Chapters 1, 2,3 & 4
• Chpt. 1 - The Design Process
– Ethics in Chemical Engineering
– Product design
• Chpt. 2 – Product Development
• Chpt. 3 - Molecular Structure Design
– Property estimation
• Chpt. 4 – Process Creation
– Gross Profitability Analysis
– Process Synthesis
• Start with the reactor (differences in molecular type)
• Separation (differences in composition)
• Heat transfer, pumping, compression, flash tanks
(differences in temperature, pressure, and phase)
• Integraton
 Chemical
Product
Design
Pyramid

Figure of Merit
 Physical Property Estimation
• Hansen Solubility Parameters
• Group Contribution Methods
– Polymer properties
– Surface tension
– HLB
– Heat of Mixing
• Drago E and C
– Work of Adhesion
• Wetting
• Bio-concentration factor
• Oil-water distribution Coefficient
• Lethal Dose
• Flash Point Temp.
 Chapters 5 and 6
• Chapter 5 – Simulation to Assist in
Process Creation
– Steady-state flow sheet simulation
• Table 5.1 – Unit Subroutines
• Recycle (tear streams)
– Recycle convergence
• Chapter 6 – Heuristics for Process
Synthesis
– Summary on page 174, Table 6.2
– Using these as a start in design/simulation
 Process Creation
• Process Economics – Gross Profitability
Analysis
• Focus on Reactor
– Equilibrium
– Kinetics or Conversion
• Focus on Separation System

• Heuristics in Process Design

 Chapter 22 - Costing
• Accounting
– Debits/credits; annual report; balance sheet
• Cost Indexes
• Capital investment costs (Table 22.9,pg. 547)
– Bare model costs
– Total depreciable capital
– Total permanent investment
– Total capital investment
• Estimation of Total Capital Investment
– Order-of-magnitude
– Study estimate
– Preliminary estimate
– Definitive estimate
 Investment Chapter 23 - Costing
• Estimation of total capital
– Order-of-magnitude (method of Hill)
• See page 498
• +/- 50%
– Study estimate (Method of Lang)
• See page 500
• +/- 35%
– Preliminary estimate (method of Guthrie)
• See page 503
• +/- 20%
• Most likely used
• Need fob equipment purchase cost
– More definitive
• Aspen Icarus (but we do not have this license)
 Process Economics
• Capital Cost Estimation
– Cost Indexes
– Three types
• Scaleup of Capital Investments - 6/10th rule
• Order of Magnitude Estimate (±50%) - Hill
• Study Estimate (±35%) - Lang
• Profitability Analysis
– ROI, PBP, IRR, VP, Cash Flow Calcs.
• Accounting
 Format for Exam
• Exam in 2 parts
– Wednesday, 20 October 2009
• In class written exam
• Open book, open notes
• Last Year’s Exam
– Friday, 22 October 2009
• In class, open book, open notes
– 1- Aspen Problem
– 1- ProMax Problem
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