PROSESSISUUNNITTELUN SEMINAARI

1. vaihe

CONTENTS

• Info• Project definition and knowledge acquirement• Process selection• Process synthesis• Heuristic rules• Process flowsheet• Process analysis / balances• Plant siting and lay-out• Cost and profitability estimation• Safety and environmental aspects

PROSESSISUUNNITTELU

- Suunnittelua ei voi viedä loppuun ennen teknisiä valintoja- Teknisten valintojen järkevyydestä ei voi varmistua, ennen kuin suunnittelu on viety loppuun iteratiivinen työskentely

PROSESSISYNTEESI

PROSESSIANALYYSI

PROSESSIN ARVIOINTI

Prosessin rakenne, yksiköt, laitteet, virrat,

kierrätykset

Valittujen laitteiden toiminnan

analysointi esim. simuloimalla

Taloudellisuus, turvallisuus,

ympäristöystävällisyys, tekniset kriteerit

PROSESSISYNTEESI

PROSESSIANALYYSI

PROSESSIN ARVIOINTI

Prosessin rakenne, yksiköt, laitteet, virrat,

kierrätykset

Valittujen laitteiden toiminnan

analysointi esim. simuloimalla

Taloudellisuus, turvallisuus,

ympäristöystävällisyys, tekniset kriteerit

PROCESS LIFECYCLE

D E M O L IT IO N

F U R T H E R D E V E L O P M E N T

P R O D U C T IO N

S T A R T -U P

IN S T A L L A T IO N A N D C O N S T R U C T IO N

P R O C U R E M E N T

D E T A IL E D D E S IG N

IN V E S T M E N T D E C IS IO N

B A S IC D E S IG N

C O N C E P T U A L D E S IG N

P R O C E S S D E V E LO P M E N T

P R O D U C T D E V E L O P M E N T

ID E A

NATURE OF WORK

• ”Open ended task” • Decision making

– Selective– Quantitative– Go/No go

• Iterative

Analysis of the data, conclusionsCritical attitudeOwn ideas

PROJECT DEFINITION(Chemical plant design project)

PROJECT GOALS1. Technical2. Schedule3. Costs and resources

DESIGN BASIS!!- Capacity- Raw materials (properties)- Products (properties and requirements)- Utility specification- Local conditions

TECHNICAL GOAL• Name of the product(s)• Scope of the project

– Grass roots plant or– ISBL or– Expansion of the plant or– Modification of the plant or– Certain part of the plant…

• Level of detail– Feasibility study or– Basic design– Detailed design

• Restrictions– Process decided already– Location fixed– etc

SCHEDULING

• Gantt’s bar chart• Critical path method (CPM)• Program evaluation and review technique (PERT)

Softwares for project administration available

CONCURRENT ENGINEERING(Concurrent process design engineering implies that, in

addition to the basis of design, all factors of possible relevance to the process design are being considered in all stages of a design process /Paulien Herder, Process Design)

SCHEDULE

Gantts bar chart

DESIGN COSTS AND RESOURCES• Final design cost

RELEVANT FIGURES– Manhours (specially in this case)– Number of documents– Contractors’ fee– Software licences– Etc.

The costs of the detailed design are typically 5-30 % of the total investment, depending on the project. (The costs of conceptual and basic design are less, of course)

DEFINITION OF THE DESIGN BASIS, EXAMPLE

• Design capacity 50 000 t/a (feed)

minimum feed 50 % of the design capacity• Feed

– Composition– Important properties (e.g. grain size, colour, moisture

content etc.)

PRODUCT SPECIFICATION, EXAMPLE

EXAMPLE OF UTILITY SPECIFICATION

LOCAL CONDITIONS, EXAMPLE

• Wind load 85 kg/m2 up to 30 m

(55+h) kg/m2 above 30 m• Earthquakes, not relevant• Horizontal snow load 200 kg/m2

• Temperatures:– Outside, max 35 °C– Outside, min -30 °C– Air cooling, design temp. 25 °C

KNOWLEDGE ACQUIREMENT

1. Properties of subtances

2. Economical knowledge

3. Process knowledge

4. Legal aspects

1. PROPERTIES OF SUBSTANCES

• Raw materials• Products• Catalysts• Other materials appearing in the process

Physical properties Dangerous properties Environmental viewpoint

2. ECONOMICAL KNOWLEDGE

Needed for market survey, capacity decision, rough cost estimation, rough profitability estimation

Production, current and predicted Use and potential Demand and supply Prices, current and predicted Competing and alternative products Rough investment and production costs

SOURCES FOR MARKET RESEARCH• Direct contacts with companies, brochures• Congresses, fairs• Professional journals and publications• Special publications (Chemical Economics Handbook,

SRI)• Internet• Consultants• Industrial federations• Suomen Ulkomaankauppaliitto• Tullihallitus, tilastot• Industrial secretaries (TEKES, UM)• Kauppakamarit

Usually personal contacts are the best

3. PROCESS KNOWLEDGE

• General chemical engineering knowledge• Internet• Handbooks• Patents• Journals• Fairs, congresses (Achema)• Direct contacts with companies, brochures

How to produce certain chemical.

Reliability of the knowledge

PROCESS SELECTION

• License or plant purchase:

→ process selection

• Own development

→ process synthesis

CRITERIA FOR SELECTION

• Investment costs• Operation costs• Synergy• Novelty

– Technical risk – Development potential

• Safety• Environmental aspects• etc

PROSESSIN LAATUKRITEEREITÄ

IN V E S TO IN TIK U S TA N N U K S E T

K Ä Y TTÖ K U S TA N N U K S E T

TA L O U D E L L IS E T

JO U S TA V U U S

S Ä Ä D E TTÄ V Y Y S JAV A L V O TTA V U U S

A J E TTA V U U S

TO IM IN TA V A R M U U S

H U O L L E TTA V U U S

K Ä Y TTÖ V A R M U U S

TE K N O L O G IA N U U TU U S

TE K N IN E N S U O R ITU S K Y K Y

TE K N O L O G IA N TA S O

P Ä Ä S TÖ T

R Ä J Ä H D Y S V A A R A

M Y R K Y TY S V A A R A

H S E

1. VAIHE

• Projektin määrittely– Tekninen, aikataulullinen (janakaavio), taloudellinen (arvio

työtunneista), suunnitteluperusteet

• Lähtötietojen hankinta– Lähtöaineet, tuotteet, prosessit; markkinaselvitykset tuotteesta,

kysyntä, tarjonta, hinta, käyttökohteet, nyt ja tulevaisuudessa

• Prosessivaihtoehtojen lohkokaaviot• Prosessivaihtoehtojen vertailu

– Kriteerien perusteella

• Suositus prosessiksi ja sen sijainniksi• Suositus kapasiteetiksi