Process Design 01 Introduction

ASEE ChE SUMMER SCHOOL W5 - PROCESS DESIGN LECTURE 1 - INTRODUCTION
Daniel R. Lewin, Technion 1

1 - Introduction PROCESS DESIGN - (c) Daniel R. Lewin
1
ASEE ASEE ChE ChE SUMMER SCHOOL SUMMER SCHOOL
Workshop 5 Workshop 5 - - Process Design Process Design
LECTURE 01: LECTURE 01:
INTRODUCTION INTRODUCTION
Daniel R. Lewin, Technion IIT
Warren D. Seider, University of Pennsylvania
J. D. Seader, University of Utah
Soemantri Widagdo, 3M
2
Some of the capabilities expected from chemical
engineers that we graduate:
Our products should meet these
challenges, instructed by an appropriate curriculum,
that is also mindful of the limited time available.
Product Specifications
E to react flexibly to shorter production
cycles and strict quality requirements
E to assimilate new and emerging
technologies as required
E to improve product quality, reduce costs,
and limit environmental impact
3
The heart of chemical engineering
is the process and not the product
Process analysis/synthesis skills
are the reason why our graduates
are sought after, even those who
will join interdisciplinary product
design teams
Our main concern should be to
make sure that these skills are
strengthened
System Capabilities
We need to ensure the development of an appropriate
curriculum, mindful of the limited time available.
4
+ Process design involves:
O systematic decomposition of the overall design problem
into sub-systems
O synthesis of feasible alternative solutions for each
process subsystem
O testing of and selection between alternative
subsystems
O integration of subsystems
O fine-tuning (optimization) of overall design
+ Instruction in the higher-level cognitive skills of
engineering synthesis and evaluation mandatory
+ Efficient instruction in the use of process simulators
is mandatory
Interactive Nature of Design
5
Positioned to seed
the best designs
for detailed engng
Focuses on large-
scale, integrated
process design.
The Design Sequence @ Technion
Positioned just-in-
time
in parallel with
Separations
(& reactor) courses
in parallel with a
plant economics
course.
6
09:30-10:00 Introduction
10:00-11:00 Technion Process Design Sequence
11:00-11:10 Coffee Break
11:10-12:00 Introduction to Product Design and
Manufacturing (actual lesson slides)
Schedule Schedule
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Stage Gate Product Design Process
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Initial Project Charter
Feasible process package within 6 months. Timeline
Business opportunity assessment
Technical feasibility assessment
Product life-cycle assessment
Deliverables
In-scope:
H
2
from natural gas, N
2
from air
Joint project with Jordan
Purchase NH
3
from Egypt
Out-of-scope:
Production and storage in port cities with large
populations
Project Scope
Produce and store NH
3
from synthesis gas beginning with
natural gas. Minimize cost. Minimize risk to population
centers. Consider the initial design proposed by Emek
Project Ltd (EPL), as a possible starting point. Consider a
joint facility with the State of Jordan and the purchase
of natural gas from Egypt and/or the Palestinian
Authority.
Specific Goals
Speedy and Ploni Gonzales Project Leaders
Business Director of Haifa Chemicals, Inc. Project Champions
Ammonia Production in Israel Project Name
9
Development Stage
Concept Stage
Concept Stage
Gate Review
Yes
Fail
Pass
Position reaction, separation, T-P change operations
Task integrate - select equipment
Bench-scale laboratory work
Preliminary process synthesis
Opportunity assessments, customer &tech. reqts.
Database creation
Feasibility Stage
Use algorithmic methods for:
Synthesis of chemical reactor networks
Separation train synthesis
Synthesis of heat exchanger networks
Develop base case design
Use process simulation andpilot-plant testing
Plantwide controllability assessment
Detaileddesign, equipment sizing,
profitability analysis, andoptimization
Safety analysis
Develop startup strategies
Pass
Development Stage
Gate Review
Fail
Fail
Pass
Feasibility Stage
Gate Review
Initiate SGPDP ?
No
10
SGPDP Concept Stage
11
EPL Design for SynGas Section
12
EPL Design for NH
3
Syn Section
13
Features of the EPL Design Features of the EPL Design
Improperly selected reactor operating conditions
Synthesis gas produced at the wrong H
2
:N
2
ratio
Poor usage of heat integration
The EPL design loses money!!
Pedagogical advantages of providing a working solution
of the design problem:
Students have less difficulty with the UNISIM
coding
Can ensure correct modelling of complex kinetic
formula, and the same costing equations.
However, the EPL design is still a very poor design very poor design and
requires considerable sound engineering judgement to
make it work:
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Innovation Map for NH
3
Process
Customer
Value
Proposition
Products
NH3
Process/
Manufacturing
Technology
Improved heat
integration
Technical
Differentiation
Efficient
recovery of
valuable H2
HME technology to
enhance conversion
in NH3 synthesis loop
- enhanced heat
recovery
Reduced separation and
circulation costs
Lower Cost NH3
<$0.25/kg
Membrane separation
to recover H2 from
purge stream
Higher
thermodynamic
efficiency
Produce and store
NH3 in a secure
environment - secure
fromrocket fire
15
SGPDP Feasibility Stage
16
Improved Design for SynGas Section
17
Example Improvement Example Improvement Shift Reactors Shift Reactors
The two shift
reactors are
adiabatic PFRs
designed to
eliminate as much as
possiple of the CO.
The feed
temperatures need
to be selected
carefully

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18
Improved Design for NH
3
Syn Section
19
Example Improvement Example Improvement Use of GCC Use of GCC
20
SGPDP Development Stage
21
SGPDP Development Stage
Preparation of complete process package
including:
PFDs for complete process
Plantwide control system design
Section-by-section detailed equipment design
Prepartion of P&IDs
Start-up policy
HAZOP
Profittability Analysis
22
Introduction Summary Introduction Summary
+ Provided an overview of proposed approach
+ Shown how the systematic SGPDP can be applied
also to the design of chemical processes
This provides a universal vehicle to teach
both product and process design
+ Next we review the Technion Design Technion Design
Sequence Sequence in more detail

Process Design 01 Introduction

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ASEE ChE SUMMER SCHOOL W5 - PROCESS DESIGN LECTURE 1 - INTRODUCTION

Daniel R. Lewin, Technion 1

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