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Introduction to Process

Design
Don Robinson
September 2003

History of a Typical Plant


Design Project
And How the Course Relates
to This

Steps

(Don Robinson, Dave Mody, not

covered)

Need Identification
Data Gathering
Conceptual Design
Prelim Equip Design
& Cost Estimate
Profitability Analysis
Approval of
Development Funds

Introduction to Process Design

Detailed
Equipment Design
Accurate Cost
Estimate
Approval of
Construction Funds
Construction
Startup
Post Mortem
Don Robinson

Identification of a Need
Opportunity

Sales increasing
New process
technology
New product

Problem

Introduction to Process Design

Environmental
regulations
Costs not
competitive
Product Deficiencies
Obsolete equipment
Don Robinson

Data Gathering

Info from existing process


Literature data
Data from simulation program
Plant tests
Lab experiments

Introduction to Process Design

Don Robinson

Conceptual Design

Map out structure of process


Heat and mass balances
Evaluate alternatives
Primary tool is process simulation
program

Introduction to Process Design

Don Robinson

Preliminary Cost estimate

Not all that accurate (20-30%)


Based on shortcut methods
Some additional design work
needed
Required for the do we proceed
decision
Introduction to Process Design

Don Robinson

Profitability Analysis

Will the expected return justify the


expenditure?
A process to direct resources to
what is valued most by society

Introduction to Process Design

Don Robinson

Approval of Development
Funds

Get sufficient $ to do a proper


design
Perhaps order long delivery time
equipment

Introduction to Process Design

Don Robinson

Detailed Equipment
Design

Sufficient detail to pin down costs


Much of the work done by
suppliers

Introduction to Process Design

Don Robinson

Accurate Cost Estimate

Improved accuracy
Required for control of construction

Introduction to Process Design

Don Robinson

Approval of Construction
Funds

Confirm that the profitability


picture is still good
A chance to bail out if conditions
have changed

Introduction to Process Design

Don Robinson

Implementation

Construction
Startup
Postmortem (learnings for future
projects)

Introduction to Process Design

Don Robinson

Sections of the Course

Concepts & tools Barrie Jackson


& Geoff Whitfield
Process analysis & modeling Don
Robinson
Equipment design and costing
Dave Mody

Introduction to Process Design

Don Robinson

Concepts and Tools

Project management
Capital cost estimation
Engineering economics
Profitability analysis
Health & safety issues
Thermodynamics
Distillation
Introduction to Process Design

Don Robinson

Process Analysis &


Modeling

HYSYS tutorial and practice


session
Process Analysis

Digest the information


Partial mass balance
Catalyst research

Introduction to Process Design

Don Robinson

Process Analysis

Initial HYSYS model


Refined Model

(cont.)

Optimized distillation column


Detailed design of heat exchanger
Energy minimization

Profitability analysis

Introduction to Process Design

Don Robinson

Equipment Design &


Costing

P&IDs
Sizing & costing of specific
equipment
Hazard analysis
Materials of construction
Cost of overall project
Introduction to Process Design

Don Robinson

Computer Facilities

Accounts
CD
Software
Web Site
Information on Server

Introduction to Process Design

Don Robinson

Computer Software

HYSYS process simulation to build models


CapCost (comes with the text)

crude estimates of equipment costs


compiling overall capital costs
profitability analysis

Excel for various calculations


Word for writing reports
Internet Explorer for viewing material
Introduction to Process Design

Don Robinson

Computer Accounts

Security pass
Password
CD containing course documentation
Cost is $20
See Ann Tobin in room 201
Must be done by Wednesday
afternoon
Introduction to Process Design

Don Robinson

Web Site

info.chee.queensu.ca/CHEE470
Course description & schedule
Info about staff and facilities
Group lists
Message log
Documents added after start of
course
Introduction to Process Design

Don Robinson

Information on Server
Available in Computer Cluster only

home folder (Z:) for your private storage


group folder (R:) used by all group
members
course folder (P:\CHEE470\start.wsf)
course material (a copy of the CD)

Introduction to Process Design

Don Robinson

Work Groups

Groups of 4
At least two chemical engineers
At least one engineering chemist
At least one not attending CSChE conf.
Designated A1,A2 . . . B1,B2 . . .
For some work the class will be split
while the A groups do modeling, the B
groups will do workshops
Introduction to Process Design

Don Robinson