Harare Institute of Technology Bachelor of Technology Honours Degree in Chemical and Process System Engineering Project outline

Project Title: Project Code: Duration: Weighting: Lecturers: 1.0 Preamble HIT400 is a capstone design project intended to demonstrate the students ability to solve a problem of a technical nature. It involves the conceptualization, analysis, synthesis, design and construction of a model of a real plant. The student works individually under the supervision of a senior member of the academic staff in the department. On completion of the project, the student is expected to produce a model and a project design report. The project should show innovation and demonstrate an apparent improvement from HIT 300 in terms of the degree of difficulty of the problem being solved and the extent to which Chemical and Process Systems Engineering concepts are applied. The practical exposure at HIT 301 must also be demonstrated and enable the student to solve real life challenges. Students should be able to demonstrate all chemical and process engineering concepts they assimilated in the previous years. The project must encompass the design of major pieces of equipment such as distillation columns, heat exchangers, chemical reactors evaporators and the sizing of other common equipment like pumps, valves storage tanks, and pipes. Capstone Design Project HIT 400 144 hrs 8 credits All Academic members of Department

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2.0 Aims The broad aims of the capstone project are to demonstrate competence in technical problem solving by testing the ability of the student to design and conduct experiments; ability to analyse, interpret and use data; ability to design a system and its components;and an understanding of the economic, social and environmental impact of projects. 3.0 Objectives By the end of the course students should be able to: Apply principles and techniques learnt to the chemical and mechanical design, construction, process control and improvement of machines and equipment of processing plants. Apply skills to rehabilitate and show innovativeness in existing process manufacturing facilities. Be able to scale up and commercialise chemical engineering processes Solve real life technical problems Start their own high tech business enterprises

4.0 Project Content 4.1 Project Document Chapters 4.1.1 Chapter 1: INTRODUCTION The chapter should spell out clearly the problem the project is intended to address, the product to be manufactured, its role in in industry, consumption levels and choice of production level and an overview of the environmental issues including safety and toxicity of the product.

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4.1.2 Chapter 2: LITERATURE REVIEW The chapter should contain literature review of the project. This is done to give a theoretical background to the chemical processes involved.as well as to collect physical data for design purposes. A comparison of the technologies available on the subject is undertaken and the best process option selected. 4.1.3 Chapter 3: RESEARCH METHODOLOGY The chapter includes the research methodology and design of experiments. It encompasses all the approaches to be employed to enable the student to design the process and the equipment. Algorithms to be followed are part of this chapter. Included are all the means of data gathering and processing to be done. Each experiment to be done should be for data required in the design of the capstone project. All the experiments to be undertaken are to be formulated and designed in this chapter. 4.1.4 Chapter 4: EXPERIMENTAL RESULTS AND ANALYSIS The chapter should contain results of experiments undertaken and the analysis of the results. All results are to be clearly tabulated in this chapter. A proper statistical analysis of the collected data using statistical packages where possible .should be undertaken. The student should use this data in designing pieces of equipment in the project. 4.1.5 Chapter 5: PROCESS DESIGN This chapter includes design assumptions, block flow diagram (BFD), material and energy balances for the entire process, process flow diagram (PFD) showing all major equipment and streams and their composition and process conditions; pipe and instrumentation diagrams, (PID) and process description 4.1.6 Chapter 6: EQUIPMENT DESIGN Students are expected to demonstrate an in-depth understanding of chemical engineering design principles and mechanical design of the equipment. The students should select at
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least two major equipment and carry out a detailed design of each. They should demonstrate understanding of equipment architecture, choice of material of construction, stress calculations and pressure vessels fabrication. An equipment specification sheet should be prepared for each piece of major equipment designed. 4.1.6 Chapter 7: PROCESS CONTROL AND HAZOP ANALYSIS Process control strategy for temperature, pressure, level and flow should be done and process instrumentation should be recommended Students should come up with HAZOP analysis of the chosen equipment. 4.1.8 Chapter 8: SITE SELECTION AND PLANT LAYOUT The chapter deals with factors affecting site selection, decision matrix for site selection, equipment spacing assumptions made in deciding the plant layout and the plant layout diagram. 4.1.9 Chapter 9: ENVIRONMENT IMPACT ASSESSMENT The student should prepare a preliminary environment impact assessment as a result of the products and waste material produced by the project. The assessment should cover the impact of gaseous, liquid and solid pollutants on air, water, soil; and human and animal life 4.1.10 Chapter 10: ECONOMIC ANALYSIS The purpose of this chapter is to demonstrate the economic and financial viability of the project using profitability indicators such as return on investment (ROI), payback period (PP), break-even (BE) point analysis, net present value (NPV) and internal rate of return (IRR). The chapter will cover assumptions on financing (gearing ratio used, interest rate on any loan amount borrowed, and grace period) estimation of project cost (fixed cost and working capital), estimation of manufacturing unit cost, and calculation of annual net cash flows.

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4.1.11 Chapter 10: CONCLUSION AND RECOMMENDATIONS This chapter should cover design results discussion, conclusion and recommendations 4.1.12REFERENCES All sources of information used should be listed in the references. Students must use the Harvard reference system. 4.2 MODEL OR PROTOTYPE PRODUCTION A HIT 400 project must be backed up with the production of either a model or a prototype for the production processor of the designed equipment. 4.3 REPORT WRITING The report should: Have a minimum of 80 pages and maximum of 100 Have a font size 12, Times New Roman Be presented in one and half spacing

In the preliminary pages or front pages of the Design Project, the following materials are presented: The title page Abstract Declaration Copyright Dedication Acknowledgments Abbreviation Table of contents List of tables

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List of figures

4.3.1 The title page It is considered as page (i) but is left unnumbered. Titles are single spaced and are written in upper case. If the title is more than one line it should break in a logical place for easy reading. The title page shows: Title of project Name of writer Purpose of the project Name of the Institute & Department Year

4.3.2 Copyright This is a form that grants the Harare Institute of Technology permission to produce copies of the Research and Development Project and also reserves the authors publication rights. 4.3.3 Declaration This serves as official acknowledgment and acceptance of the research project as satisfactory. It is signed by your supervisor(s) 4.3.4 Dedication This serves as a tribute or recognition to a specific individual or individuals. 4.3.5 The Abstract The abstract is used by potential readers to determine at a glance, the contents of the capstone design project. You should present it as a precise and well written summary. Your abstract should contain: A clear statement of the problem/ problems being solved. The purpose of the project. A summary of the methods used in the design of major equipment such as heat exchangers, distillation columns etc.
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A statement of source and type of physical data collected and its use. A summary of experimental work undertaken and the type of data collected and its use in the design.

A summary of the findings, conclusions, recommendations and suggestions for further research. Your abstract should not be more than a page in length.

4.3.6 Acknowledgements In this section you thank persons to whom you are indebted for guidance and assistance in making your study successful. You must present this section on a separate page. 4.3.7 Table of Contents You present an outline of the components of your design project. These components include, the preliminaries and these are typed in lower case. They are arranged as follows: Title Page (i) Abstract (ii) Declaration (iii) Copyright (iv) Dedication (v) Acknowledgements (vi) Table of Contents (vii) List of Tables (viii) List of Figures (ix) List of Appendices (x) Abbreviations

After the preliminaries you then list chapters and chapter headings and sub-headings giving the page(s) where these are located in your design project. Lastly you present the back pages materials, which are references and appendices. For typing you should ensure that:

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Chapter numbers and preliminaries pages are typed in Roman numerals. Chapter titles and chapter numbers are typed in upper case. Sub-headings of each chapter are typed in lower case and are single spaced. Margins are 4.0cm on the left, 1.0 on the right hand side, 2.5cm at the top and 4.0cm at the bottom of the page. Numbering of the pages should be at the centre bottom edge. Appendices are presented in Arabic numerals and typed in upper case.

4.3.8 List of Figures Anything other than tables should be considered as a figure. You should write the figure number, title and reference page. Type these in lower case. 4.3.9 List of Tables You should show the table number, its title and reference page. This should be done in lower case. Abbreviations All terms abbreviated in the project document should be specified in this category 5.0 Project assessment The course will be taken over a two semesters and will be examined by oral and written presentation of the project. 5.1 Oral presentations The presentation will be evaluated on the following basis: Organization systematic, logical and integrate Clarity easy to follow and understand Presentation skills good voice, projection, eye contact, confident and good results. Visual aids- readable, understandable and pertinent
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Content Relevance of the information presented to the solution of the problem Conclusions defensible and rationale provided

Ability to answer questions effectively

5.2 Written report Report writing is a key skill in presentation of information. As such students should show a mastery of this. Assessment of the written report will be upon the following basis Typography spelling and grammar Information flow coherence and cohesion of information Referencing knowledge of referencing skills, (the Harvard System) Content relevance of information in the document toward solving the problem Adherence to set rules - following the prescribed procedure

Final report assessment is based on the guidance given in Table 1.0: The oral presentations will be assessed as shown in appendix I III. Table 1.0: Final Written Report Assessment

Performance Task

Performance Criteria

Score Total 100

Abstract

Cover all elements Coherence Concise

Problem Identification

Wealth creation Political needs Problem solving

Literature Survey

Journal Internet Textbooks

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Questionnaire Research Methodology Laboratory work Pilot plant study Modelling Experimental Results and Analysis Reaction kinetics Scaling up 15 15

Process Design

Mass balance Energy balance Technical composition

10

Equipment design

Chemical engineering design aspects Mechanical engineering design aspects Material selection Stress, strain calculations

15

Process Control and HAZOP analysis

Selection of sensors Monitoring devices HAZOP studies Environment Safety

Site Selection and Plant Layout

Decision matrix for site selection Plant layout

Environment Impact Assessment

Impact of product and by products on the

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environment Economic Analysis Payback period Engineering cost factors Cost indices Conclusion and Recommendations Design results discussion Innovativeness Value creation Problem solving References 5 5 5

5.3 Overall assessment The project will be evaluated in reference to Table 2.0: Table 2.0: Assessments components Work Component First presentation Second presentation Final presentation Model or prototype development Final written project report Total % of Final Course mark 10% 10% 30% 20% 30% 100%

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Students must submit 1 soft copy of the project, 1 spiral bound copy (for marking and corrections) and two leather bound copies.
Title page Sample

HARARE INSTITUTE OF TECHNOLOGY LOGO

DESIGN OF A 5000 TONS PER ANNUM HIGH DENSITY POLY-ETHYLENE PLANT FROM BIO-ETHANOL

BY JOUSHUA J DUBE H2020067S SUPERVISED BY

PROFESSOR P. MOYO PROFESSOR M. ERIC

THIS DESIGN AND INNOVATION PROJECT WAS SUBMITTED TO HARARE INSTITUTE OF TECHNOLOGY IN PARTIAL FULFILMENT OF THE BACHELOR OF TECHNOLOGY (HONOURS) DEGREE IN CHEMICAL AND PROCESS SYSTEMS ENGINEERING

2013 Copyright Sample page

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All rights reserved. No part of this design and innovation project may be reproduced, stored in any retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise from scholarly purpose, without the prior written permission of the author or of Harare Institute of Technology on behalf of the author.

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Declaration Page Sample DECLARATION I, Joushua J Dube hereby do declare that this work has not previously been accepted in substance for any degree and is not being concurrently submitted in candidature for any degree.

Students Signature: . Date . (Joushua J Dube)

Supervisors Signature: . Date . (Professor P. Eric)

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Dedication Sample DEDICATION Firstly I would like to dedicate this piece of work to my mum and dad (Mr. and Mrs.

Dube) for the love and care they have given to me. Abstract Sample Page

ABSTRACT This report aims at documenting the design of a fractional distillation column to separate crude oil into its various fractions. It covers the process design, mechanical design and equipment costing. Chapter 1 introduces the project, stressing out the design problem, its significance and the methodologies used in going about with the project. Chapter 2 covers the literature aspect of a fractional distillation column. It presents a brief summary of what a fractional distillation is, the type of trays, reflux and reflux considerations. Chapter 3 contains the process calculations and design aspects of the project, with

equations, tables and graphs and enhances understanding of the design. A bit of extra literature is provided for some parts designed such that readers will appreciate the way the equipment should function.

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The process economics and estimated costing of the plant are given in chapter 4, whilst chapter 5 discusses the design results, and chapter 6 the recommendations and the conclusion which are therein presented. Acknowledgements Sample ACKNOWLEDGEMENTS Firstly I would like to thank the Lord God almighty for his mercies, for seeing me through this design and innovation project and throughout my life. Secondary I would like to thank my supervisor Eng. Moyo for his guidance through which I managed to come up with the dissertation and his time he set aside to supervise me. Thirdly I would like to thank mum and dad for their encouragement and support. Special appreciation goes to all my friends for the encouragement and technical support. Lastly my sincere gratitude goes to all lecturers in the Chemical and Process Systems Engineering Department, without them it would have been impossible for me to acquire the knowledge and be able to undertake this project. TABLE OF CONTENTS Copyright...i Declaration.................................................................................................................... ii Dedication.....................................................................................................................iii Abstract ....................................................................................................................iv Acknowledgements.......................................................................................................v Table of contents ..vi List of tables vii List of figures ...viii List of appendices..........................................................................................................ix

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5.1.1 Sorting ............................................................................................................. 21 5.1.3 Shredding......................................................................................................... 21 5.1.4 First Washing Phase (pre-grinding washing) ................................................. 21 5.1.5 Grinding .......................................................................................................... 21 Valve plate........ 11

Simple Valve Plate.................................................................................................... 12 Bubble Trays used in fractional distillation.............................................................. 13 TBP Crude oil plot.................................................................................................... 19 Comparison of computed stage temperature with plant data.................................... 22 Atmospheric Distillation Column............................................................................. 27 Process control of the Fractionating Column............................................................ 32

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List of Appendices Appendix 1 Table of Average enthalpies 33 Appendix 2 Average particle sizes 37

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References Levenspeil O (1999), Chemical Reaction Engineering, 3rd edition, Jon Wiley and sons, New York. Neumann E. B. (1990), Chemical Reactor Design Optimization and Scale up, New York. Perry R.H, Sheby M.G. (1984), Chemical Engineers Handbook, 6th edition, McGraw-Hill. Quaik S.T, Embrandiri T.Z , RupaniP. F., SinghR. P., Ibrahim M. H. (2012), Effect of Vermiwash and Vermicomposting Leachate in Hydroponics Culture of Indian Borage (Plectranthus ambionicus) Plantlets, UMT 11th International Annual Symposium on Sustainability Science and Management, pp.210-214

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APPENDIX I HARARE INSTITUTE OF TECHNOLOGY

CHEMICAL & PROCESS SYSTEMS ENGINEERING DEPARTMENT
HIT 400 PROPOSAL PRESENTATION ASSESSMENT FORM Project Title: _____________________________________________________________ Students Name: _________________________ Student Number:___________________ Panelist: __________________________________ Criterion Organization Clarity Presentation skills Problem Definition Objectives Innovation aspects Project feasibility Research design Visual aids Conclusions Answering questions Total marks awarded Total possible score 5 5 5 5 5 15 5 15 5 10 25 100 Mark awarded

NB: Maximum marks are awarded for the following: 1. Organization-systematic, logical and integrate 2. Clarity-easy to follow and understand 3. Presentation skills-good voice projection and eye contact, comfortable and confident 4. Visual aids-readable, understandable and pertinent 5. Conclusions-defensible and rationale provided 6. Answering questions-ability to answer questions effectively Panelists Signature: ______________________ Date:_______________________ Chairmans signature: ______________________ Date: _______________

APPENDIX 11
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HARARE INSTITUTE OF TECHNOLOGY

CHEMICAL & PROCESS SYSTEMS ENGINEERING DEPARTMENT
HIT 400 PROGRESS PRESENTATION ASSESSMENT FORM Project Title: _____________________________________________________________ Students Name: _______________________Student Number: ___________________ Panelist: __________________________________ Criterion Organization Clarity Presentation skills Experimental results analysis Process design Visual aids Conclusions Answering questions Total marks awarded Total possible score 5 5 5 25 20 5 10 25 100 Mark awarded

NB: Maximum marks are awarded for the following: 1. 2. 3. 4. 5. 6. Organization-systematic, logical and integrate Clarity-easy to follow and understand Presentation skills-good voice projection and eye contact, comfortable and confident Visual aids-readable, understandable and pertinent Conclusions-defensible and rationale provided Answering questions-ability to answer questions effectively ______________________ Date: _______________________

Panelists Signature:

Chairmans signature: ______________________ Date: _______________________

APPENDIX III

HARARE INSTITUTE OF TECHNOLOGY

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CHEMICAL & PROCESS SYSTEMS ENGINEERING DEPARTMENT

HIT 400 FINAL PRESENTATION ASSESSMENT FORM Project Title:_____________________________________________________________ Students Name:_________________________ Student Number:___________________ Panelist:__________________________________ Criterion Organization Clarity Presentation skills Chemical engineering design Mechanical engineering design Process control Environmental Impact Assessment Economic analysis Visual aids Conclusions Answering questions Prototype or Model Total marks awarded Total possible score 5 5 5 15 5 Mark awarded

5 5

5 5 5 20 20 100

Panelists Signature:______________________ Date:_______________________ Chairmans signature______________________ Date:_______________________

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