CBE 108A: PROCESS ECONOMICS AND ANALYSIS

Winter 2018

General Information

Lecture: MW 4-5.50 PM KNSY PN 1240B

Website: http://courseweb.seas.ucla.edu

Staff: Prof. K. Hing Pang

Office: Boelter Hall 5531K
Email: khpang@g.ucla.edu
Telephone 310 825 2206
Office Hours: Mon 2-4 pm
Wed 2-4 pm

Teaching Assistants: DING, YANGYAO dingyangyao1995@ucla.edu

GARCIA, CARLOS carlosagarcia91@gmail.com
TRAN, ANH anhtran6667@g.ucla.edu

Text: Gavin Towler, Ray Sinnott, Chemical Engineering Design, Second Edition 2012, Elsevier

References

(1) Max Peters and Klaus Timmerhaus “Plant Design & Economics for Chemical Engineer”, 5th edition, McGraw Hill
(2) King C. J., Separation Processes
(3) Douglas James M., Conceptual Design of Chemical Processes
(4) Turton Richard et al, Analysis, Synthesis, and Design of Chemical Processes
(5) Donald R Woods, Process Design and Engineering Practice
(6) Simsci-Esscor, PRO/II User’s Guide
(7) AspenTech, HYSYS User's Guide
(8) Brykowski F.J, Ammonia and Synthesis Gas: Recent and Energy Saving Developments, Park Ridge,
NJ, Noyes Data Corp., 1981
(9) Hydrocarbon Processing Refinery Handbook, 1988 or Later Edition
(10) Perry H., Chemical Engineers Handbook
(11) Nelson, W. L., Petroleum Refinery Engineering
(12) Leffler, W, Petroleum Refining for the Non-Technical Person
(13) Slack, A.V., James, G.R., Ammonia, New York, NY, Marcel Dekker, 1977.
(14) Crowl, Daniel A., Louvar Joseph F., Chemical Process Safety, Fundamental with Applications, second Edition, Prentice Hall.
(15) Ken Petrunik, Practical Project Management, Friesen Press

Computer software
Process simulation software PRO/II will be used in this class. The software is available in the UCLA computer lab.

Other Equipment
12-inch ruler, All Purpose Template AA27200, Engineering Calculation Pad

Course Overview

This course, the first of the design series is divided into two parts. In the first six weeks, the students will learn how to design major
equipment common to most chemical processes. The students will also learn how unit operations fit together and interact in these
processes and the basic procedure in process engineering design. The student will also learn to determine the economics viability of a
project. In the seventh week students will start performing a process design of a designated industrial plant. Students will learn project
management methodology commonly used in industry today. They will work in teams to define project scope, work plan, schedule and
how to effectively control and execute a project. Finally, they will learn the skills of effective communication through report writing
and oral presentation. The design project will continue for 15 weeks in CBE 108B till the end of the Spring Quarter. The scope of the
plant design project will be defined in a separate document “Statement of the Project”

In this course, two processes are selected to demonstrate the principles of process design. The ammonia process is a good candidate for
the students to gain their first design experience, because it involves simple, familiar and well-defined components yet it is comprised
of many important unit operations common to all chemical industries. As the operating temperature changes significantly throughout
the process, it provides an excellent example for the students to learn and appreciate energy optimization through the design of a tightly-
integrated heat exchanger network.

The oil refining process is important to the students, because it represents a major industry in California. Many of our graduates and
current students are working in the oil industry. From the technology standpoint, the refining process offers the students a totally different
perspective than the ammonia process. Unlike many processes, which have one or two products, the refinery produces multiple products
which have to satisfy many quality specifications. A refinery also has to meet seasonal demands, such as gasoline in the summer and
fuel oil and jet fuel in the winter. These characteristics make the refinery the best candidate for the students to learn how product pricing,
sales, specifications and demands influence design decisions. Through these two processes, the students will also learn basic engineering
economics including cost estimating and optimization techniques.

At the end of this course students are expected to be able to perform the following:

1. Synthesize a process plant using the onion diagram concept

2. Produce PFD and material and energy balances of a process
3. Design a heat integration network
4. Design a steam system
5. Design and size a distillation column
6. Cost-estimate a process plant
7. Conduct a cash flow analysis of an industrial plant
8. Plan a design project
9. Manage a design project

Homework: Due at the start of the Wednesday class one week after homework is assigned, unless stated otherwise

Grading: Quizzes 40%

Homework/Assignments 30%
Oral presentations 15%
Project execution 15%

Course Outline

Mondays Lectures
Wednesday Hands-on design experience

1M Jan 8, 2017 Process Synthesis (Ch 1; Ref 3); Process Flow Diagram & P & I diagrams
( Ch.
4)
2W Jan 10, 2017 Compressor systems (Chap 3,20) ; Heat Exchanger Networks ( Ch 3)
3M Jan 14, 2017 Martin Luther King Holiday
4W Jan 17, 2017 Oil Refining Processes ( Ref 11,12)
5M Jan 22, 2017 Heat Exchanger Design and Sizing (Ch 19)
6W Jan 24, 2017 Quiz, Heat Exchanger Sizing (Ch 19)
7M Jan 29, 2017 Steam systems ( Ch 7)
8W Jan 31, 2017 Cost Estimating and Project Evaluation (Chap. 7,8,9, Ref 1,4)
9M Feb 5, 2017 Design, size and cost estimate a C2-splitter (Ch 17)
10W Feb 7, 2017 Cost Estimating and Project Evaluation (Chap. 7,8,9,Ref 1, 4)
11M Feb 12, 2017 Kick-off meeting. Client discusses scope and organization
12W Feb 14, 2017 Project Planning, scope, work plan, schedule, milestones and team
organization; Task list and assignments (Ref 15)
13M Feb 18, 2017 Presidents’ Day Holiday
14W Feb 21, 2017 Quiz
15M Feb 26, 2017 Research on plant location
16W Feb 28, 2017 Client review rough draft PFD
 17M Mar 5, 2017 Oral Report,
18W Mar 7, 2017 Oral Report
19M Mar 12, 2017 Hazard and Safety (Chap 10, Ref 14)
20W Mar 14, 2017 Quiz

Final Exam: No final exam.

ABET Information

All CBE graduates are expected to acquire certain knowledge and skills by the time of graduation. These are called ABET
Program Outcomes and are listed on the departmental website, on CourseWeb, and on a poster in the hall outside 5531/5532
BH. Each required course addresses a subset of these 15 outcomes (a – o) to varying extent. A matrix of course topics and
program outcomes is published for each required class on CourseWeb (go to ABET/CSAB under Class Resources). An
entry of 0 in the matrix or for the course as a whole indicates that the particular outcome is not addressed at all, whereas an
entry of 3 indicates that the course addresses the particular outcome strongly. In addition, each required course is assigned
one or more highlighted outcomes. The instructor must make a detailed assessment of whether or not students in the class
achieved satisfactory performance relative to all highlighted outcomes for the course.

The highlighted outcomes for CBE 108A are:

(a) An ability to apply knowledge of mathematics, physics, chemistry, biology, and chemical and biological
engineering, especially for the integration of molecular- to micro-scale information into macro-scale analysis and
design of chemical and biological processes and products
(c) An ability to design a chemical or biological system, component, or process that meets technical and economical
design objectives with consideration of environmental, social, and ethical issues, as well as sustainable
development goals
(h) An understanding of the impact of engineering solutions in a global and societal context

In this class, certain designated problems on the homework and quizzes, reports and oral presentations, which will be noted
clearly on printed materials, may be used for ABET assessment purposes. A score of 80% or better on these particular
problems will provide evidence that the outcomes have been met.

Class Addendum to HSSEAS Academic Integrity Policy

The HSSEAS Academic Integrity Policy is available for download from CourseWeb. Go to Syllabus/Info under Class
Resources and scroll to the bottom of the page. The HSSEAS policy statement also will guide you to the Student Guide to
Academic Integrity available at the website of the Office of the Dean of Students. Please note the following additional
policy items for this class:

1. Sharing of information of any kind among students during an exam is prohibited.

2. All assignments must be reflective of individual student effort. A student must attempt all assignments
independently before discussing them with classmates. Students may discuss assignments and projects with
classmates to a limited extent. However, students absolutely must not dictate detailed solution procedures or
provide written copies of solutions for others to copy or paraphrase. If in doubt about this issue, ask yourself “If I
give this help, will I be destroying all, or nearly all, the educational benefit of this homework problem for my
classmate?” If the answer is “Yes”, please avoid putting yourself and your classmate in violation of academic
integrity policy.
3. Usage of homework, project or exam solutions from any source is prohibited, unless they are distributed to the class
by the instructors or the TA.

Students with Disabilities

If you wish to request an accommodation due to a suspected or documented disability, please inform your instructor and
contact the Office for Students with Disabilities as soon as possible at A255 Murphy Hall, (310) 825-1501, (310) 206-
6083(telephone device for the deaf). Website: www.osd.ucla.edu.