Review for Design I Exam

CHEN 4253

Terry A. Ring

Materials CoveredWeek 1-22 AugustChapt 1 (p.1 -25), Chapt 2, Chapt 3 Product Design-

Introduction to course – Product and Process DesignProduct Design-1 OverviewProduct Design-2 Property Estimation

Week 2-29 August Chapters 16 and 17

Product Design-3 Innovation MapsProduct Design-4 Six Sigma in Product DesignProduct Design-5 Engineering Ethics

Week 3–5 September (Holiday Monday)Chapt 1 (p25-31) Chapter 4 Process Creation-

Ethics in Chemical EngineeringProcess Safety

Process Design OverviewProcess Creation

Materials Covered-con’t

Week 4–12 September (Celanese in Class Monday)Chapt 4&5&6 Aspen for Process Creation–

Use of Aspen for Process Creation-1Use of Aspen for Process Creation-2Heuristics for Process Simulation

Week 5 – 19 September Chapt 4&5 Aspen Tutorials and Problems Solved in Class (Reserve the ICC) -Week 6 - 26 September (Away Wednesday and Friday)Chapt 5&6 ProMax Tutorials and Problems Solved in Class (Reserve the ICC) - Week 7–3 OctoberChapter 22-22 (p543-558) &23 Profitability Analyses -

Annual CostsEarningsProfitability Analysis

Week 8- 11 October FALL BREAK

What have we really covered?

• Product Design (Ethics) Chapt. 1,2&3

• Process Creation Chapt 4– Heuristics for Process Synthesis Chapt 6

• Process Simulators Chapt 5– Aspen– Promax

• Capital Cost Estimates Chapt 22

• Profitability Analyses Chapt 23

Chapters 1, 2,3 & 4• Chpt. 1 - The Design Process

– Ethics in Chemical Engineering– Product design

• Chpt. 2 – Product Development• Chpt. 3 - Molecular Structure Design

– Property estimation• Chpt. 4 – Process Creation

– Gross Profitability Analysis– Process Synthesis

• Start with the reactor (differences in molecular type)• Separation (differences in composition)• Heat transfer, pumping, compression, flash tanks

(differences in temperature, pressure, and phase)• Integraton

Chemical Product Design

Pyramid

Figure of Merit

Physical Property Estimation

• Hansen Solubility Parameters• Group Contribution Methods

– Polymer properties– Surface tension– HLB– Heat of Mixing

• Drago E and C

– Work of Adhesion• Wetting

• Bio-concentration factor• Oil-water distribution Coefficient• Lethal Dose

• Flash Point Temp.

Chapters 5 and 6

• Chapter 5 – Simulation to Assist in Process Creation– Steady-state flow sheet simulation

• Table 5.1 – Unit Subroutines• Recycle (tear streams)

– Recycle convergence

• Chapter 6 – Heuristics for Process Synthesis– Summary on page 174, Table 6.2– Using these as a start in design/simulation

Process Creation

• Process Economics – Gross Profitability Analysis

• Focus on Reactor– Equilibrium– Kinetics or Conversion

• Focus on Separation System

• Heuristics in Process Design

Chapter 22 - Costing

• Accounting – Debits/credits; annual report; balance sheet

• Cost Indexes• Capital investment costs (Table 22.9,pg. 547)

– Bare model costs– Total depreciable capital– Total permanent investment– Total capital investment

• Estimation of Total Capital Investment– Order-of-magnitude– Study estimate– Preliminary estimate– Definitive estimate

Investment Chapter 23 - Costing

• Estimation of total capital– Order-of-magnitude (method of Hill)

• See page 498• +/- 50%

– Study estimate (Method of Lang)• See page 500• +/- 35%

– Preliminary estimate (method of Guthrie)• See page 503• +/- 20%• Most likely used• Need fob equipment purchase cost

– More definitive• Aspen Icarus (but we do not have this license)

Process Economics

• Capital Cost Estimation– Cost Indexes– Three types

• Scaleup of Capital Investments - 6/10th rule• Order of Magnitude Estimate (±50%) - Hill• Study Estimate (±35%) - Lang

• Profitability Analysis– ROI, PBP, IRR, VP, Cash Flow Calcs.

• Accounting

Format for Exam

• Exam in 2 parts– Wednesday, 20 October 2009

• In class written exam• Open book, open notes• Last Year’s Exam

– Friday, 22 October 2009• In class, open book, open notes

– 1- Aspen Problem– 1- ProMax Problem

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