Analysis & Design of

Common Chemical
Engineering Systems
 What is Analysis?
? Analysis is the process of identifying a question
or issue to be addressed, modeling the issue,
investigating model results, interpreting the
results, and possibly making a recommendation.
 Typical analysis for process
design may include:
? Market and Technical Feasibility
? Choice of Technology (Proven, Innovative,
path/ rating)
? Identification Process Equipment in the Plant
? Choice of Design theme and mode
? Availability of raw materials, utilities, human
resource and process constraints
? Costs of providing the services, skills, materials,
equipment, taxes and other economic issues.
 Invention and Design
? INVENTION
An invention is something produced for the first
time through the use of imagination or
ingenious thinking and experimentation. A
famous quote is: "Necessity is the mother of
invention
? DESIGN
Engineering Design is like an invention to
suit the unique demand of the customer
(customized solutions).
 What is Design?
? Design is the human power to conceive,
plan, and realize products that serve
human beings in the accomplishment of
any individual or collective purpose."

? Process Design is the sizing of equipment

and facilities necessary to carry out the
process.
Engineering Design may require

(A). Design for new process

(B). Process design

(C). Mechanical design

(D). 3D design

(E). Fabrication
 (A). Design for New Processes

– What is the Design Process?

Typical five steps through which scientific
principles are applied for the solution of
Engineering problems are:

1. Define the Problem

2. Finding solutions and ideas
3. Documentation of ideas
4. Testing and Refining
5. Production
Defining the Problem

? The design process is undertaken after a specific

problem or need has been identified. The
identification of the problem occurs in the
research and development stage of
manufacturing.
? Once scientists and engineers working in R&D
have identified the need for a product or
discovered a problem, the design process is used
to make the new product or solve the problem
 The design process

The wagon... ...broke

Either fix the wheel Or add tires so it doesn't brake again

Finding solutions and Ideas

? In this phase, ideas are

examined and a concept
of the overall design is
developed. One can document by hand or...

? Preliminary sketches are

used to document the
design and/ or computer
software used for it.
... use a CAD system
Documentation of Ideas

? In this phase, all preliminary drawings

or sketches from the previous phase are
transformed into a finished package.
? Today, this is accomplished using
Computer Aided Drafting and Design
(CADD) systems.
To test, a computer simulation can be made ... and examined using virtual reality ....

... and a SLA/ CNC machine can be used to make a physical prototype.
Testing and Refining

? In this phase, the design is tested in more

realistic modes. This usually involves pilot plants
and computer simulations for better
visualization.

Machining equipment is used to mass produce the final product.

Production

? In the production phase, the

design is sent off to be produced.
With the use of a CADD system,
the data from the design is
translated into a form that a
Computer Aided Manufacturing
(CAM) system can understand.
? Typical examples are CNC and
CIM. Some productions processes
involve Robotics as well.
 (B). Process Design

? Process design is the design of processes for desired

physical and/or chemical transformation of materials.
? The deep understanding of physical, chemical,
thermodynamic properties in relation with working
conditions, separation phenomena, rates of reactions,
laws of transfer, transformation etc is desired.
? The availability of technology and kind of machinery
and it’s range of applicability should be well
understood.
? The overlapping areas of mechanical, electrical,
chemical, metallurgical and civil engineering need to
be well understood.
 (C). Mechanical Design
? Using Drawing boards/CAD
(Horizontal Cylindrical Tank supported on compression load cell)
Conical Hopper
(D). 3D design
Drawing and Model
 (E). Fabrication
? Fabrication is a specialized job jointly done by the
collaboration of Chemical, Mechanical and
Instrumentation engineers.
 How to design

1). Mathematical
2). Software 3). By Analogy
Model/Equations
1). Using Mathematical
Model/Equations

(The continuity equation)

(Heat conduction equation)

(Bernoulli equation)
 2). Using Software
Design software can be categorized as :

1. Design and Draft

(e.g AutoCAD)
2. Modeling and Simulation
(Solid Edge, Hysys, AspinPlus, AspinDyn,PRO-II,
SuperChem)
3. Analysis Software
(Hysys, Asys, PRO-II)

Right software for right job !

Software Tools for Design

ASPIN PLUS

HYSIS PIPECAD

CONSYD SOLID EDGE

SOFTWARE
TOOLS

TUTSIM AUTOCAD

AUTOPLANT MATLAB

MATRIX--X
MATRIX
 Characteristics of Drafting Softwares
? Main capability is Drafting
(Generate Drawings, Fabrication & Assembly Diagrams)
? Low 3-D capabilities
? Different Environments available in Software to
suit Mechanical, Civil, Architecture etc.
? Fabrication details can be provided such as
( Materials, welding, grinding, Tolerances and Surface Finish
information)
 Characteristics of Modeling Software
? Can generate drawings
? Can model a process for better
visualization
? Models can be used with other softwares
for further processing
? Can Generate machine code for fabrication
Model Visualization
Gasifier
 Characteristics of Analysis Softwares
? Requires most input from other software e. g.
Drawing/Model, Material Properties, Boundary Conditions
and other Computational constraints
? Elementary Analysis e.g. Assembly, Fixing and
Alignment, Collision, Force
? Working in layers
? Integration with other software
? Standard procedures need to be followed in the design

(Hysys, Fluent, Asys, Aspin etc)

 3). By Analogy

Scale up
Common Chemical Engineering Systems

Furnace
Furnace
Auxiliaries
Auxiliaries Heat
Heat
Ancillaries
Ancillaries Exchanger
Exchanger

Distillation
Distillation
Crystallizer
Crystallizer Column
Column
COMMON
COMMON
Chemical
Chemical
Engg.
Engg.
systems
systems
Filters
Filters Boiler
Boiler

Tanks
Tanks
Centrifuges
Centrifuges Vessels
Vessels
Reactor
Reactor
 Case Study

Design & Fabrication of a

Down Draft Gasifier Rig
 Facility Developed at Chemical Engineering, UET

Downdraft
Gasifier

Wet Blower
Scrubber

Water Recycle
Recirculation Pump
Tank