Department of Chemical Engineering

College of Engineering
University of the Philippines
Diliman, Quezon City

COURSE SYLLABUS
Chemical Engineering 141: Chemical Process Development and Plant Economics
Course Description Application of engineering economics to process flow synthesis and industrial plant design. General
chemical process design considerations. Optimization of plant processes. Economic feasibility study.
Credits 3 units (2 hours lecture + 3 hours computational laboratory)
Prerequisite ChE 140
Lecture Schedule ChE 141 SBC ChE 141 SDE
Saturdays, 0800H – 1000H Saturdays, 1000H – 1200H
Lecture Instructors (Process) Engr. Bemboy Niño Subosa, Engr. Michael Sean Deang, Engr. Marlon Mopon Jr.
(Economics) Engr. Antonio Rivera and Engr. Carmelita Villanueva
References 1. Towler, G. and Sinnott, R. Chemical Engineering Design: Principles, Practice and Economics of
Plant and Process Design (Elsevier).
2. Smith, R. Chemical Process Design and Integration (John Wiley & Sons, Ltd).
3. Douglas, J.M. Conceptual Design of Chemical Processes (McGraw-Hill).
4. Peters, M.S. and Timmerhaus, K.D. Plant Design and Economics for Chemical Engineers, 4 ed.
th

(McGraw-Hill).
5. Park, C.S. Fundamentals of Engineering Economics (Prentice Hall).

COURSE OUTCOMES
At the end of the course, the student should be able to:
1. Prepare a market study for a chemical product or commodity and its raw materials.
2. Translate the assessed opportunity (based on the market study) into a design basis.
3. Prepare a database of physico-chemical and other relevant material properties.
4. Conduct a survey of related literature on pertinent chemical processes.
5. Apply chemical engineering principles and heuristics in generating a process flow diagram that abides to typical
industry standards.
6. Develop a simulation model of the process using a commercial simulator.
7. Integrate health, safety and environmental considerations in the process design.
8. Estimate total capital investment, total product cost, gross and net profit, and cash flow.
9. Quantify the effect of interest, taxes, and other economic parameters that affect profit.
10. Apply economic evaluation principles and methods in making investment decisions.

PROGRAM EDUCATIONAL OBJECTIVES (BS ChE)

The UPD Chemical Engineering program is geared toward equipping our graduates such that 3 to 5 years from graduation, they:
1. take leadership roles in their respective fields and/or effectively work in or manage a team
2. are equipped with the extensive knowledge and relevant skills necessary to succeed in their chosen careers and to become
responsive citizens
3. are able to demonstrate strong research & innovative capability as they recognize and address opportunities & challenges in their
respective spheres influence
4. have strong commitment to the ethical practice of their profession; to health, safety and environment and; to service to society.

STUDENT OUTCOMES SATISFIED BY THE COURSE OUTCOMES

SO 1 Ability to apply knowledge of mathematics and science to solve engineering problems
SO 3 Ability to design a system, component, or process to meet desired needs within realistic constraints
SO 5 Ability to identify, formulate, and solve engineering problems
SO 7 Ability to communicate effectively
SO 8 Broad education necessary to understand the impact of engineering solutions
SO 9 Recognition of the need for, and an ability to engage in life-long learning
COURSE OUTLINE AND OBJECTIVES
 Date Lecture Laboratory

Introduction to the Design Process

01 The Design Basis Discussion of course outline, course requirements and class
Aug 4 Overview of execution of design projects in industry. Translation of policies. Overview of content of market study.
BFS customer needs into a more precise process statement in the form of a
design basis.

02 The Process Flow Diagram Presentation of potential plant design topics. (Each group
Aug 11 General and specific requirements on the content and
should have an approved topic by the end of this week.)
MSD formatting of process flow diagrams (PFD).

Presentation of market study (part 1). Should include:

• Global product supply and demand
General Design Considerations Heuristics for
03 • Local product supply and demand
Process Synthesis (Part 1)
Aug 18 General design considerations, particularly on health, safety, and • Product growth rate and price
MSD environmental aspects of the design. Decision on whether the process 1. Updating of design basis sheet with product
should be batch or continuous (level 1 decision). information. Presentation of hazards of product in
terms of health, safety (includes fire and explosion
hazards) and environment.

Heuristics for Process Synthesis (Part 2) Presentation of market study (part 2). Should include:
Decisions on the input-output structure of the process flow diagram • Global and local raw material supply
(level 2 decisions): • Raw material price
04 1. Purification of feeds • Plant location
Aug 25 2. Removal or recycling of reversible byproduct Updating of design basis sheet with raw material
MSD 3. Usage of a gas recycle and purge stream information. Establishment of plant capacity and mode of
operation (level 1 decision). Presentation of hazards of raw
4. Recovery and recycling of some reactants
material in terms of health, safety (includes fire and
5. Number of product streams explosion hazards) and environment.

05 Oral presentation of market study and block flow diagram

Sept 1 with due consideration on level 2 decisions. Submission of
CJV Fundamentals of Engineering Economics (Part 1) design basis sheet.
Fundamentals of Engineering Economics (Part 2)
Engineering economic decisions. Time value of money. Economic
equivalence between single payment (like capital costs) and annual
payment (like operating costs).
06
Submission of draft of Parts I to III of the feasibility
Sept 8 report.
CJV

Presentation of physico-chemical property database (density,

07 Estimation of Capital and Operating Costs (Part 1) heat capacity, viscosity, thermal conductivity, vapor pressure,
Sept 22 Estimation of purchasing and installation costs of process equipment liquid surface tension) of all chemicals involved in the
CJV based on preliminary sizing data. process. Presentation of reaction properties (heat of reaction,
equilibrium constant, kinetic data)

First Departmental Examination (September 29)

Date Lecture Laboratory

Heuristics for Process Synthesis (Part 3)

Decisions on the recycle structure of the process flow diagram (level 3
decisions):
08 1. Number of reactor systems Presentation of draft process flow diagram based on the
Oct 6 block flow diagram.
2. Number of recycle streams
BFS 3. Introduction of excess reactants
4. Heat effects and equilibrium limitations

Heuristics for Process Synthesis (Part 4)

Decisions on the separation system structure of the process flow diagram Determination of most economic recycle structure
09 (level 4 decisions): (methodology and presentation of results of reactor
Oct 13 1. General structure of the separation system optimization studies). Updating of process flow diagram
BFS 2. Vapor recovery system with due consideration on level 3 decisions.
3. Liquid separation system

10 Determination of most economic separation system

Heuristics for Process Synthesis (Part 5) structure (methodology and presentation of results).
Oct 20 Application of pinch technology in the design of heat exchanger network Updating of process flow diagram with due consideration
MLM (level 5 decisions). on level 4 decisions.

11 Determination of most economic heat exchanger network

Process Control structure (methodology and presentation of results).
Oct 27 Design of control schemes of common unit operations and whole Updating of process flow diagram with due consideration on
MLM processes. level 5 decisions.

12 Updating of process flow diagram with process control

Nov 3 schemes. Presentation of breakdown of total equipment cost
AYR Estimation of Capital and Operating Costs (Part 2) and utility cost.
Estimation of Capital and Operating Costs (Part 3)
Estimation of total capital investment and total product costs based on
the total equipment and utility costs. Development of cash flow with due
13 consideration on taxation and depreciation. Presentation of estimated total capital investment and total
Nov 10 product cost. Submission of draft of Parts IV and V of the
AYR feasibility report.

14
Nov 24 Presentation of project cash flow.
AYR
Profitability Analysis (Part 1)
Profitability Analysis (Part 2)
Estimation of profitability of the project via various techniques.
15
Presentation of results of profitability analysis. Submission
Dec 1 of draft of Parts VI to VII of the feasibility report.
AYR

Second Departmental Examination (TBA)

Feasibility Study Presentation and Submission of Feasibility Study Report

COURSE
REQUIREMENTS
Feasibility Study Report 50%
Feasibility Study Presentation 10%
LABORATORY
Market Study Presentation 10%
(60% of final grade)
Group Evaluation 10%
Individual Evaluation 20%

LECTURE First Examination 50%

(40% of final grade) Second Examination 50%

IMPORTANT: A failing grade (less than 60%) in the laboratory part of this course will result in A FINAL GRADE OF 5.00.
 CLASS POLICIES AND OTHER COURSE REQUIREMENTS
Grading System. The general average will be rounded up to the first decimal place and converted as follows. This is a pass-
or-fail course. In addition, no curving of any form will be done on the final grades.
General Average Corresponding Grade General Average Corresponding Grade
92.0 – 100.0 1.00 72.0 – 75.9 2.25
88.0 – 91.9 1.25 68.0 – 71.9 2.50
84.0 – 87.9 1.50 64.0 – 67.9 2.75
80.0 – 83.9 1.75 60.0 – 63.9 3.00
76.0 – 79.9 2.00 0.0 – 59.9 5.00
Tardiness and Absences. Attendance will be checked every meeting. Tardiness is logged 15 minutes after the start of each class
session. Coming in late thrice is equivalent to one absence. Absence in more than 20% of total lecture class meetings is equivalent
to a 10-point deduction from the final grade. On the other hand, absence in more than 20% of total consultation sessions will mean
a failing grade irrespective of grade in other requirements.

Long Examinations. Two long examinations will be administered for this course. The first and second examinations are to be
answered by individual and by group respectively. Each student should submit around ten short bond papers as answer sheets (with
only the student number and page number written on the upper right corner of each paper) a week before the examination.

Use of notes, books, and references for the entire duration of the examination will not be allowed. Cheating is strictly prohibited
and those caught will be subjected to existing rules and regulations, one of which is expulsion from the university. Grievances will
only be entertained a week after the release of results.

Homeworks and Seatworks. Homeworks and seatworks are to be done individually unless otherwise specified by the lecturer.
No make-up is allowed for missed homeworks and seatworks. The plant design lecturers reserve the right to incorporate the
average scores of the homeworks and seatworks on the long examination scores, if deemed to be necessary.

Groupings. Each group shall consist of three to four members only. There is no exemption on this rule to maintain fairness.
Each group will submit the list of members, the name of the chosen group leader, and the contact numbers and email addresses
of every member on a short bond paper on the second laboratory session.

Plant Design Topics. A good plant design topic will satisfy the following descriptions, but consult with your plant design adviser
regarding his/her preferences and restrictions during the first laboratory session:
 Proposed process with distinct advantage over the conventional process. Possible explanations include: locally abundant raw
material, cheaper catalyst, absence of hazardous raw materials or by- products, better atom economy, less greenhouse
emissions.
 Proposed process requires relatively simple reactors. The laboratory-scale reactor used to generate the kinetic data is CSTR
or PFR, instead of complicated ones like fluidized bed and reactive distillation.
 Proposed process involves relatively simple chemicals. The physico-chemical properties of all compounds present in the process
can be readily found in Perry’s Chemical Engineers’ Handbook or calculated using group contribution method.

Each group will submit at most five plant design topics at the start of the second laboratory session. Each topic should be presented
with the following information:
 Description of the proposed process and its advantage over the conventional process.
 Journal, theses, dissertation, or patent discussing the kinetics of the reaction. Each group shall have at least one reactor. Since
the process becomes more complex as the number of reactors increases, it is recommended to set the maximum number of
reactors at two/three for groups with three/four members respectively. The references should have the rate equations of main
and side reactions and the temperature dependence of the rate constants.
 List of chemicals involved in the proposed process.

Consultations. The group must fill up the attached consultation report before every consultation. Every team member will report his/her
progress on specified sections of the feasibility report.

Teamwork. Aside from the tangible deliverables, groups will also be graded on their teamwork. Team leaders will be graded on how
well he leads his group (e.g., agenda during consultation time, readiness and completeness of updates and reports, ability to motivate and
drive his/her group to progress). Group members are graded according to their contributions, willingness to cooperate and to be involved,
punctuality and attendance in consultation meetings.

Division of Labor. The work of plant design is to be equally divided among the group members. In particular, design calculations must
be divided equally. No student may have as his/her contribution merely the writing of some section/chapter (e.g. literature review,
introduction). The work distribution must be such that each member must show proficiency in mass and energy balance, application of
chemical engineering principles and heuristics, and process equipment design. Feasibility report grades may reflect individual
contributions, as deemed necessary by the plant design adviser.

MARKET STUDY AND FEASIBILITY STUDY PRESENTATIONS

Time Limits. Each group will be given at least 15-20 minutes to present the results of their study and at least 10-15 minutes to address the
questions raised by the panel and the audience. The plant design advisers reserve the rights to increase these time limits if deemed
necessary.
Presenters and Panel Members. The plant design advisers reserve the rights to set the rules that each group must follow as presenters
(number of presenters, selection of presenter(s), etc) and panel members (group pairings, number of questions per group, etc) during
the presentation.

Market Study Presentation. It is recommended to report the following items during the presentation:
 Introduction. Describe your product and the significance of its large-scale production in today’s world. Discuss the conventional
processes of producing your product and the problems associated with it, Describe the proposed process and how it addresses the
drawbacks of the conventional process. What are the objectives of your feasibility study?
 The Main Product. The product will be sold at what grade/purity? Who will be the target consumers of your main product and
where are they located? Who are the current producers of your main product and how much do they supply? Based on the demand
growth rate, what is the projected demand by your target consumers by the time your plant is built?
 The Raw Materials. The raw materials will be available at what grade/purity? Who will be the source/s of your raw materials and
where are they located? Who are the current users of your raw materials (i.e., competing users) and how much do they demand? Is
the amount of available raw materials sufficient to meet the projected demand of your target consumers?
 Conclusions. Present a supply and demand analysis. What capacity will you set for your plant and where will you build your plant?
How did you come up with such decisions? Present the block flow diagram and economic potential. Will the plant be profitable
based on the raw material and product prices?

Feasibility Study Presentation. It is recommended to report the following items during the presentation:
 Introduction. Describe your product and the significance of its large-scale production in today’s world. Discuss the conventional
processes of producing your product and the problems associated with it, Describe the proposed process and how it addresses the
drawbacks of the conventional process. What are the objectives of your feasibility study?
 The Plant. Discuss the sources and estimated prices of your raw materials, the destination and estimated price of your main product,
and the plant capacity and location.
 The Process. Show your process flow diagram in describing the process. Mention important operating conditions (temperature,
pressure, composition) along the course of the presentation. Mention the results of optimization studies obtained and important
decisions made during process synthesis, if time permits.
 Economic Analysis and Profitability Study. Discuss the breakdown of the total capital and operating costs, with focus on the equipment
cost, raw material and utility cost, and product revenue. Show the after tax cash flow diagram and discuss the profitability of the plant
(NPV, IRR, and payback).
 Conclusions and Recommendations. Answer the objectives of the study. What modifications on the process does your group
recommend to improve the economic feasibility of the plant?

Grading. Each oral presentation contributes to 10% of the final laboratory grade. The group will be graded on their performance as
presenters (7%) and as panel members (3%). The presenters are judged according to the effectiveness of their presentation, the depth of
understanding they demonstrate in addressing the panel and audience’s questions, comments, and suggestions. On the other hand, the panel
members are judged according to the level of discussion that ensues.
 FEASIBILITY STUDY REPORT
At the end of the semester, each group is required to submit (1) a ring-bound copy of the feasibility study report and (2) a CD containing the
soft copies of the feasibility study report and associated calculation sheets. Instead of a CD, plant design advisers might opt for uploads to their
Google drives. A soft copy of the feasibility study report template will be issued for use.

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Project Title : ___________________________________ Date : ____________________
Group LEADER : ___________________________________ Week# : ____________________

Deliverables as 1. 4.
scheduled in the 2. 5.
Syllabus 3. 6.
1. 4.
Pending Deliverables 2. 5.
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Name and Signature of

Delivered Adviser’s Comments & Rating
Leader/Member

LEADER

Adviser’s Overall Comments

Adviser’s Signature