Chemical Plant Design and Operation

Overview

Dr. J. Abu-Dahrieh j.abudahrieh@qub.ac.uk
2. Computer Lab Classes; Section 1. Review and Analysis of Production Process
Dr. M. Blesic - m.blesic@qub.ac.uk
Section 3. Chemical Design; Section 4. Process Control and Operation
Dr. N. Gui Email: m.gui@qub.ac.uk
Section 2. Heat and Mass Balances
Dr. C. Mangwandi
c.mangwandi@qub.ac.uk
1. Mathematics and numerical methods; 2. Computer Lab Classes and assessment;
Dr. E. Themistou –e.themistou@qub.ac.uk 3. Process Economics
Dr. Chunfei Wu c.wu@qub.ac.uk
2. Computer Lab Classes and assessment; Section 2. Heat and Mass Balances

Course content
1. Mathematics and numerical methods (6 hours, 3 tutorials):
 Revision of ordinary differential equations (ODEs) and initial value problems. Application to first order reactions. Solution by quadrature;
 System of first order ODEs and initial value problems. Application to chemical kinetics. Solution by Laplace transform and associated linear system. Revision of Cramer's rule. Gaussian elimination;
 Reduction of a higher order ODE to a system of first order ODEs. Nonlinear ODEs and numerical solution by the Euler method. Local and global error. Runge-Kutta methods. Application to chemical kinetics;
 Matlab revision Class.

2. Computer Lab Classes and assessment:
 Students are provided with online tutorials. Students will also have the opportunity to be offered summary computer lab class in each of the core areas.

 Aspen
 AutoCAD (self-learning)
 Excel
 Matlab
 Class tests on Aspen and Matlab

3.Process Economics (9 hours)
 Basics of process economics including financial statements, depreciation, interest, IRR, NPV
 
4. Chemical Plant Design
Section 1. Review & Analysis of Production Method (6 hours):
 Review and analyse the production process.
 Source and use key physical property data for design purposes.
 Provide detail process description and refine the PFD of the production process.
 Produce an initial report including a preliminary mass balance.

Section 2. Heat and Mass Balances (16 hours):
 Conduct detailed heat and mass balances on all unit operations in the plant including use of Excel models.
 Develop an Aspen simulation model of the process.
 Report the heat and mass balances.

Section 3. Chemical Design (10 hours):
 Provide a detailed chemical engineering design for a main unit (multistage gas compressor, heat exchanger, distillation column):
 Equipment type.
 Major vessel dimensions (size, shape).
 Internals (trays, packing, agitator, baffles, etc.).
 Using AutoCAD, generate a drawing detailing the results obtained from above considerations.

Section 4.Process Control and Operation (6 hours)
 Develop and report a control strategy for a specific unit.
 Identify and report operational and health & safety issues.
 Using AutoCAD generate a drawing detailing the control system
 Prepare start-up and shut-down procedures for a specific unit.
 Prepare a complete HAZOP report for a specific unit.

Learning Objectives

Students will obtain a foundation in chemical engineering design using a given process example. By the end of the course, the students will be able to:

• effectively use computer software including Excel, Matlab, Aspen and AutoCad as tools for solving chemical engineering design problems and presenting flow-sheets and equipment
• identify appropriate mathematical equations and tools needed to support other core modules at stage 2 and beyond
• apply numerical methods for solving complex engineering design problems
• source and evaluate key physical property data from the literature, or computer databanks for design calculations
• use a computational language (e.g., Matlab) for the development of computer code needed to solve chemical engineering problems
• apply the overall heat and mass balances and conceptual process flow diagrams (PFD) in solving chemical engineering problems.
• explore design and operational considerations for a chemical plant
• produce a suitable plant layout
• develop appropriate health, safety and environmental guidelines
• produce a final design report
• develop and apply knowledge of financial costing and accounting systems to evaluate process economics.

Skills

Students will develop skill in the use of specific computer software to solve chemical engineering problems and sketch flow-sheets or equipment Moreover, the module will develop skills in plant operation and in the design and development of a chemical engineering production process including skills in identifying and articulating environmental impacts and operational protocols. Specific skills include:

• improved mathematical and problem solving skills
• computational skills will be developed through use of specific and general computer packages for solving chemical engineering design problems
• P&ID reading
• literature reviews and data selection
• analytical and computational
• communication and reporting
• team and individual working
• time management
• costing and financial analysis skills.

Assessment

The module is assessed by class tests and continuous assessments. Details on all coursework will be given out in the form of a coursework brief during the semester. All reports must be submitted electronically via Canvas in the format specified in the brief.

Assessment Profile:
Element type Element weight (%)

1. Mathematical and Numerical Methods Assignment 10
2. Aspen Test 10
3. Matlab Test 10
4. Process Economics Test 10
5. Plant design project: Section 1- Review and Analysis of Production Process 10
6. Plant design project: Section 2- Heat and Mass Balances 20
7. Plant design project: Section 3- Chemical Design 10
8. Plant design project: Section 4- Process Control and Operation Strategy 10
10. Plant design project: Student Peer Evaluation and Supervisor Evaluation 10

Course Requirements:

 Attendance 80 %
 Process Economics Test Pass Mark Veto 40 %
 Matlab test Pass Mark Veto 40 %
 Aspen Test Pass Mark Veto 40%
 Mathematical and Numerical Methods Assignment 40 %
 Design Project assignment submission 100 %
 Module Pass Mark Veto 40 %