Introduction to Process Design Don Robinson September 2003

Introduction to Process Design

Don RobinsonSeptember 2003

History of a Typical Plant Design Project

And How the Course Relates to This

Introduction to Process Design Course Don Robinson

Steps (Don Robinson, Dave Mody, not covered)

Need Identification Data Gathering Conceptual Design Prelim Equip Design

& Cost Estimate Profitability

Analysis Approval of

Development Funds

Detailed Equipment Design

Accurate Cost Estimate

Approval of Construction Funds

Construction Startup Post Mortem


Identification of a Need

Sales increasing New process

technology New product

Environmental regulations

Costs not competitive

Product Deficiencies Obsolete equipment

Opportunity Problem


Data Gathering Info from existing process Literature data Data from simulation program Plant tests Lab experiments


Conceptual Design Map out structure of process Heat and mass balances Evaluate alternatives Primary tool is process simulation

program


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


Profitability Analysis Will the expected return justify the

expenditure? A process to direct resources to

what is valued most by society


Approval of Development Funds Get sufficient $ to do a proper

design Perhaps order long delivery time

equipment


Detailed Equipment Design Sufficient detail to pin down costs Much of the work done by

suppliers


Accurate Cost Estimate Improved accuracy Required for control of

construction


Approval of Construction Funds Confirm that the profitability

picture is still good A chance to bail out if conditions

have changed


Implementation Construction Startup Postmortem (learnings for future

projects)


Sections of the Course Concepts & tools – Barrie Jackson

& Geoff Whitfield Process analysis & modeling – Don

Robinson Equipment design and costing –

Dave Mody


Concepts and Tools Project management Capital cost estimation Engineering economics Profitability analysis Health & safety issues Thermodynamics Distillation


Process Analysis & Modeling HYSYS® tutorial and practice

session Process Analysis

Digest the information Partial mass balance Catalyst research


Process Analysis (cont.)

Initial HYSYS model Refined Model

Optimized distillation column Detailed design of heat exchanger Energy minimization

Profitability analysis


Equipment Design & Costing P&ID’s Sizing & costing of specific

equipment Hazard analysis Materials of construction Cost of overall project


Computer Facilities Accounts CD Software Web Site Information on Server


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


Computer Accounts Security pass Password CD containing course documentation Cost is $20 See Ann Tobin in room 201 Must be done by Wednesday

afternoon


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


Information on Server

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)

Available in Computer Cluster only


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