Chemical Engineering Design walk-through - Elsevier · PDF filechapter • ASME boiler and ... Sinnott & Towler Chemical Engineering Design only. ... Return on investment (10 yrs)

© 2007 G.P. Towler / UOP. For educational use in conjunction with Sinnott & Towler Chemical Engineering Design only. Do not copy Chemical Engineering Design

Chemical Engineering DesignChemical Engineering DesignPrinciples, Practice and Economics of Plant and Process DesignPrinciples, Practice and Economics of Plant and Process Design

TowlerTowler & & SinnottSinnott, Elsevier, 2008, ISBN: 978, Elsevier, 2008, ISBN: 978--00--75067506--8423184231

•• A practical design text for the Senior A practical design text for the Senior Design Course plus introduction to Design Course plus introduction to chemical engineering courseschemical engineering courses

•• Teaches commercial engineering tools Teaches commercial engineering tools for simulation and costingfor simulation and costing

•• Strong emphasis on HS&E issues, Strong emphasis on HS&E issues, codes and standardscodes and standards

•• 108 realistic commercial design 108 realistic commercial design projects from diverse industriesprojects from diverse industries

•• 1170 lecture slides on CD, solutions 1170 lecture slides on CD, solutions manual, Excel spreadsheetsmanual, Excel spreadsheets

•• For more information and to register For more information and to register for an examination copy visit for an examination copy visit http://http://textbooks.elsevier.comtextbooks.elsevier.com

© 2009 Elsevier Ltd. All rights reserved


ChEChE’’s Are Paid Well to Work in Diverse s Are Paid Well to Work in Diverse Industries Because Industries Because ……

•• They can start from a They can start from a vaguely defined vaguely defined problemproblem statement such as a customer statement such as a customer need or a set of experimental resultsneed or a set of experimental results

•• From the problem statement they From the problem statement they develop an understanding of the develop an understanding of the important underlying physical science important underlying physical science relevant to the problemrelevant to the problem

•• Using this understanding they can Using this understanding they can develop a develop a plan of actionplan of action and set of and set of detailed specifications, which if followed detailed specifications, which if followed will lead to a will lead to a predicted financial predicted financial outcomeoutcome

This is all the other ChE classes

The design course teaches these key skills



The Design ProcessThe Design ProcessProblem statement

Implementation

PlanFinancialoutcome

XYZ Co.



Key Features of Towler & SinnottKey Features of Towler & Sinnott•• Practical emphasis, based on authorsPractical emphasis, based on authors’’ industrial industrial

experienceexperience•• Towler Towler –– ICI, UOPICI, UOP•• Sinnott Sinnott –– DuPont, DavyDuPont, Davy

•• Teaches realTeaches real--world engineering tools & methodsworld engineering tools & methods•• Process simulators: Process simulators: AspenPlusAspenPlus, UniSim, UniSim•• Costing software: Aspen ICARUSCosting software: Aspen ICARUS•• Heat exchangers: HTFS TASC, AspenPinchHeat exchangers: HTFS TASC, AspenPinch•• Lots of spreadsheet examples & problemsLots of spreadsheet examples & problems



Key Features of Towler & SinnottKey Features of Towler & Sinnott

•• Emphasis on safety, environment, industry Emphasis on safety, environment, industry codes and standardscodes and standards

•• Ch 9: safety issues in designCh 9: safety issues in design•• Ch 14: environmental issues in designCh 14: environmental issues in design

•• Relevant industry codes introduced in every Relevant industry codes introduced in every chapterchapter

•• ASME boiler and pressure vessel code (Ch 13) pipe codes (Ch 5)ASME boiler and pressure vessel code (Ch 13) pipe codes (Ch 5)•• API codes for safety, relief valve design (Ch 9)API codes for safety, relief valve design (Ch 9)•• NFPA codes for electrical installations and fire safety (Ch 9)NFPA codes for electrical installations and fire safety (Ch 9)•• OSHA standards for safety (Ch 9)OSHA standards for safety (Ch 9)•• ISA codes for ISA codes for P&IDsP&IDs (Ch 5)(Ch 5)•• TEMA codes for exchangers (Ch 12)TEMA codes for exchangers (Ch 12)•• ISO codes for lifeISO codes for life--cycle analysis (Ch 13)cycle analysis (Ch 13) W (if arc or gas welded)

RT (if Radio graphed)HT (if Postweld heat treated)

Name of Manufacturer

psi at °FMax. Allowable Working Pressure

Min. Design Metal Temperature

Manufacturer’s Serial Number

Year Built

°F at psiW (if arc or gas welded)RT (if Radio graphed)

HT (if Postweld heat treated)





Year Built

°F at psi





Year Built

°F at psi



Extensive Support MaterialsExtensive Support Materials

•• Over 100 realistic industrial design projects from diverse Over 100 realistic industrial design projects from diverse industriesindustries

•• Commodity chemicals (25)Commodity chemicals (25)•• Devices (2)Devices (2)•• Electronics and electrochemical processes (3)Electronics and electrochemical processes (3)•• Foods and formulated products (14)Foods and formulated products (14)•• Fuels (5)Fuels (5)•• Gas processing (7)Gas processing (7)•• Inorganic chemicals (8)Inorganic chemicals (8)•• Pharmaceuticals (29)Pharmaceuticals (29)•• Pulp and paper (5)Pulp and paper (5)•• Specialty chemicals (7)Specialty chemicals (7)•• Waste treatment and recovery (4)Waste treatment and recovery (4)

•• 14 of the projects involve biological processing (across 14 of the projects involve biological processing (across almost all the industry sectors)almost all the industry sectors)



Supporting Lectures in MS PowerPointSupporting Lectures in MS PowerPoint

•• 22 presentations with 1170 22 presentations with 1170 slidesslides

•• Lots of industrial pictures and Lots of industrial pictures and diagrams (with copyright diagrams (with copyright approval!)approval!)

•• StepStep--byby--step guides to problem step guides to problem solving using commercial solving using commercial softwaresoftware




1.1. Introduction (Ch 1)Introduction (Ch 1)1.1. OverviewOverview2.2. Industrial process designIndustrial process design3.3. Product designProduct design4.4. Optimization in ChE designOptimization in ChE design

2.2. Process flowsheet development Process flowsheet development (Ch 2, 3, 4)(Ch 2, 3, 4)

1.1. Flowsheet overviewFlowsheet overview2.2. Process simulation Process simulation 3.3. Pinch analysisPinch analysis



Supporting Lectures in MS PowerPointSupporting Lectures in MS PowerPoint5.5. The P&ID (Ch5)The P&ID (Ch5)

1.1. Process hydraulicsProcess hydraulics2.2. Instrumentation & controlInstrumentation & control

6.6. Process Economics (Ch6)Process Economics (Ch6)1.1. Capital costsCapital costs2.2. Operating costsOperating costs3.3. Economic analysisEconomic analysis4.4. Project financingProject financing

LT

LIC

LV

Feed

FT

FIC

FV

SteamTrap

Condensate

Vapor

LT

LIC

LV

Feed

FT

FIC

FV

SteamTrap

Condensate

Vapor

0.00

20.00

40.00

60.00

80.00

100.00

120.00

Jan-1990 Jan-1992 Jan-1994 Jan-1996 Jan-1998 Jan-2000 Jan-2002 Jan-2004 Jan-2006

Time

Pric

e (c

ents

/lb)

PX contract PX spot PET bottle resin contract TPA contract TPA spot

Company Name Project Name Adipic acid from phenolAddress Project Number Sheet 1

REV DATE BY APVD REV DATE BY APVD

ECONOMIC ANALYSIS 1 1.1.07 GPTAdipic Acid from Phenol

Form XXXXX-YY-ZZOwner's NamePlant Location Units MetricCase Description On Stream 8,000 hr/yr 333.33 day/yr

$MM/yr $MM Year % FC % WC % FCOP % VCOPMain product revenue 560.0 ISBL Capital Cost 206.5 1 30% 0% 0% 0%Byproduct revenue 4.4 OSBL Capital Cost 82.6 2 70% 0% 0% 0%Raw materials cost 410.8 Engineering Costs 28.9 3 0% 100% 100% 50%Utilities cost 47.3 Contingency 43.4 4 0% 0% 100% 100%Consumables cost 13.1 Total Fixed Capital Cost 361.3 5 0% 0% 100% 100%VCOP 466.8 6 0% 0% 100% 100%Salary and overheads 16.4 Working Capital 59.5 7+ 0% 0% 100% 100%Maintenance 10.8Interest 3.6Royalties 3.0FCOP 33.8

Cost of equity 25% Debt ratio 0.5 Tax rate 35%Cost of debt 5% Depreciation method Straight-lineCost of capital 15.0% Depreciation period 10 years

All figures in $MM unless indicatedProject year Cap Ex Revenue CCOP Gr. Profit Deprcn Taxbl Inc Tax Paid Cash Flow PV of CF NPV

1 108.4 0.0 0.0 0.0 0.0 0.0 0.0 -108.4 -94.3 -94.32 252.9 0.0 0.0 0.0 0.0 0.0 0.0 -252.9 -191.2 -285.53 59.5 280.0 267.2 12.8 36.1 -23.3 0.0 -46.7 -30.7 -316.24 0.0 560.0 500.6 59.4 36.1 23.3 0.0 59.4 34.0 -282.25 0.0 560.0 500.6 59.4 36.1 23.3 8.1 51.3 25.5 -256.86 0.0 560.0 500.6 59.4 36.1 23.3 8.1 51.3 22.2 -234.67 0.0 560.0 500.6 59.4 36.1 23.3 8.1 51.3 19.3 -215.38 0.0 560.0 500.6 59.4 36.1 23.3 8.1 51.3 16.8 -198.69 0.0 560.0 500.6 59.4 36.1 23.3 8.1 51.3 14.6 -184.010 0.0 560.0 500.6 59.4 36.1 23.3 8.1 51.3 12.7 -171.311 0.0 560.0 500.6 59.4 36.1 23.3 8.1 51.3 11.0 -160.312 0.0 560.0 500.6 59.4 36.1 23.3 8.1 51.3 9.6 -150.713 0.0 560.0 500.6 59.4 0.0 59.4 8.1 51.3 8.3 -142.414 0.0 560.0 500.6 59.4 0.0 59.4 20.8 38.6 5.5 -136.915 0.0 560.0 500.6 59.4 0.0 59.4 20.8 38.6 4.7 -132.216 0.0 560.0 500.6 59.4 0.0 59.4 20.8 38.6 4.1 -128.117 0.0 560.0 500.6 59.4 0.0 59.4 20.8 38.6 3.6 -124.518 0.0 560.0 500.6 59.4 0.0 59.4 20.8 38.6 3.1 -121.419 0.0 560.0 500.6 59.4 0.0 59.4 20.8 38.6 2.7 -118.720 -59.5 560.0 500.6 59.4 0.0 59.4 20.8 98.1 6.0 -112.7

Average cash flow 44.7 $MM/yr NPV 10 years -171.3 $MM IRR 10 years -2.0%Simple pay-back period 9.4 yrs 15 years -132.2 $MM 15 years 5.6%Return on investment (10 yrs) 3.32% 20 years -112.7 $MM 20 years 8.4%Return on investment (15 yrs) 5.77% NPV to yr 19 -118.7 $MM

ECONOMIC ANALYSIS

Capital Cost Basis Year 2006Northeast Asia

REVENUES AND PRODUCTION COSTS CAPITAL COSTS CONSTRUCTION SCHEDULE

CASH FLOW ANALYSIS

ECONOMIC ASSUMPTIONS




9.9. Health, Safety & Environment Health, Safety & Environment (Ch 9, 13, 14)(Ch 9, 13, 14)

1.1. Process safetyProcess safety2.2. Pressure reliefPressure relief3.3. Environmental impactEnvironmental impact

Source: EPA




10.10. Equipment Design (Ch 10, 11, Equipment Design (Ch 10, 11, 13)13)

1.1. Reactor designReactor design2.2. Separation column designSeparation column design3.3. Pressure vessel designPressure vessel design




12.12. Heat transfer equipment (Ch12)Heat transfer equipment (Ch12)1.1. Heat exchangersHeat exchangers2.2. Boiling and condensingBoiling and condensing3.3. Heaters and coolersHeaters and coolers

Source: Riggins Company: www.rigginscompany.com



How to Use the BookHow to Use the BookChemical Engineering DesignChemical Engineering Design

Sinnott & Towler, 2007Sinnott & Towler, 2007

•• Ch 1, 2, 3Ch 1, 2, 3•• Introduction and background materialIntroduction and background material•• Should have been covered in earlier classes Should have been covered in earlier classes –– can skim for revisioncan skim for revision

•• Ch 4, 5, 6, 9, 14Ch 4, 5, 6, 9, 14•• Essentials of process designEssentials of process design•• Recommended reading before lecturesRecommended reading before lectures

•• Ch 7, 8Ch 7, 8•• Reference material useful for projectsReference material useful for projects

•• Ch 10, 11, 12, 13Ch 10, 11, 12, 13•• Essentials of equipment designEssentials of equipment design•• Needed for project workNeeded for project work•• Recommended reading before equipment design lecturesRecommended reading before equipment design lectures


Documents

Chemical Engineering Design walk-through - Elsevier · PDF filechapter • ASME boiler and ... Sinnott & Towler Chemical Engineering Design only. ... Return on investment (10 yrs)