CCB4023 Plant Design II Briefing
January 2015Dr. Muhammad Moniruzzaman Room: 04-03-10Ext: 7572E-mail: [email protected]
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1. Engineering Knowledge - Apply knowledge of mathematics, science, engineeringfundamentals and an engineering specialisation to the solution of complexengineering problems;
2. Problem Analysis - Identify, formulate, research literature and analyse complexengineering problems reaching substantiated conclusions using first principles ofmathematics, natural sciences and engineering sciences;
3. Design/Development of Solutions - Design solutions for complex engineeringproblems and design systems, components or processes that meet specified needswith appropriate consideration for public health and safety, cultural, societal, andenvironmental considerations;
4. Investigation - Conduct investigation into complex problems using research-basedknowledge and research methods including design of experiments, analysis andinterpretation of data, and synthesis of information to provide valid conclusions;
5. Modern Tool Usage - Create, select and apply appropriate techniques, resources,and modern engineering and IT tools, including prediction and modelling, tocomplex engineering activities, with an understanding of the limitations;
6. The Engineer and Society - Apply reasoning informed by contextual knowledge to assess societal, health, safety, legal and cultural issues and the consequent responsibilities relevant to professional engineering practice;
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Program Outcomes
CCB4023 Plant Design II Briefing
7. Environment and Sustainability - Understand the impact of professionalengineering solutions in societal and environmental contexts and demonstrateknowledge of and need for sustainable development;
8. Ethics - Apply ethical principles and commit to professional ethics andresponsibilities and norms of engineering practice;
9. Communication - Communicate effectively on complex engineering activities withthe engineering community and with society at large, such as being able tocomprehend and write effective reports and design documentation, make effectivepresentations, and give and receive clear instructions;
10. Individual and Team Work - Demonstrate knowledge and understanding ofengineering and management principles and apply these to ones own work, as amember and leader in a team, to manage projects and in multidisciplinaryenvironments;
11. Life-long Learning - Recognize the need for, and have the preparation and ability toengage in independent and life-long learning in the broadest context of technologicalchange;
12. Project Management and Finance - Demonstrate knowledge and understanding ofengineering and management principles, business acumen and entrepreneurship inmultidisciplinary environments.
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Program Outcomes
CCB4023 Plant Design II Briefing
By the end of this course, students should be able to:
1. Demonstrate their chemical engineering skills and knowledge
in a detailed design of a chemical plant
2. Generate cost effective process options while maintaining
operability, safety and environment friendliness of the design
3. Apply appropriate design codes in a detailed design work
4. Develop a piping and instrumentation diagram (P&ID) and
control strategy package
5. Prepare detailed economic evaluation of the proposed
chemical plant
6. Communicate and organize design group as an effective
team member
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Learning Outcomes
CCB4023 Plant Design II Briefing
5PO-CLO Mapping
CCB4023 Plant Design II Briefing
No. PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12
CO1
CO2
CO3
CO4
CO5
CO6
6Course Summary
Application of all undergraduate knowledge and skills to solve designrelated problems.
To develop the skills of working in a team, leadership qualities,written and oral communication, decision making etc.
CCB4023 Plant Design II Briefing
3 Credit Values, 100% Coursework
Design of Formalin Production Plant
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Problem Statement
CCB4023 Plant Design II Briefing
Formaldehyde is an industrially important
chemical used for manufacturing various types of
resins such as phenol formaldehyde, urea
formaldehyde and melamine resin. It is also used
as an intermediate for synthesizing chemical
intermediates such as 1-4 butanediol, trimethyl-
ol-propane, neopentyl glycol, pentaerythritol and
hexamethylenetetramine. The most widely
produced grade is formalin which is 37 wt. %
formaldehyde solution in water.
Process Design Tasks
III. Safety Analysis -
HAZOP
IV. Waste Treatment Strategy
V. Economic Evaluation
II. Detailed Design: Major and Minor Equipment
I. P& ID and Control Strategy
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Expectation
Utilising a blend of: hand calculations,
spreadsheets,
mathematical computer packages,
process simulator to design a process
Make necessary decisions, judgements andassumptions in design problems
Adhere to standard format for Group andIndividual reports
CCB4023 Plant Design II Briefing 9
Final Oral Presentation
Contents: PDPI + PDPII
Submit a softcopy of group report two weeks before the presentation date
Evaluators: External Examiner from Industry + Group Supervisor
30 mins presentation, 30 mins Q&A
2 types of assessment:
Group assessment
Individual assessment
CCB4023 Plant Design II Briefing 10
Final Group Report
Contents: PDPI + PDPII
Length: Between 100 to 200 pages
Each group is required to submit the report in hard copy (ABBA Lever Arch Folder, 404 Standard) and soft copy (CD)
Segregate each chapter with a divider
Use punch hole protection (reinforcing ring)
CCB4023 Plant Design II Briefing 11
Individual Report
Report on detailed design of 1 majorequipment + 2 minor equipment
Length:40 pages
Compile all the final individual design reportin 1 hardcopy file
Segregate with a divider
Use punch hole protection (reinforcing ring)
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Types of Equipment (Example)
Major equipment:ReactorDistillation columnAbsorption columnFurnace
Minor equipment:Extraction columnsEvaporatorMembrane UnitsCycloneFilterCooling towerSedimentation tanks
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Only one student is allowed to undertake detailed design of each equipment.
Paper Size for Drawings
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A1 and A3 drawings should be folded and inserted in
A4 sized plastic wallets
No. Drawings Paper Size
1. Process Flow Diagram (PFD) A1
2. Process and Instrumentation Diagram (P&ID) A1
3. Individual Equipment A3
4. Plant Layout A3
Assessment of Reports
Selected expert panels will evaluate theGroup and Individual Reports.
Example: P&ID and control strategysection will be evaluated by ProcessControl expert panels
Example: Reactor design will be evaluatedby Reactor expert panels
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Individual Progress Performance(Official Group Meetings)
Must be conducted once in every two weeks
At least 7 official meetings per group
Minutes of meeting (MOM) must be submitted to themain supervisor within one (1) week after themeeting
Supervisor will evaluate the individual progress
Individual progress performance will contribute 10%of the overall individual marks
Students and supervisor may conduct additionalmeetings as frequent as required
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Assessment Scheme
Assessment Stage
Examined by and % Contribution
SupervisorExpert
Panel
External
Examiner
Group
Contribution
Individual
Contribution
Final Report
(Group)10 20 30
Final Report
(Individual)10 10 20
Final Presentation
(Group)10 20 30
Final Presentation
(Individual)10 10
Individual
Progress10 10
C-Factor 0 1.0 x
Total 50 30 20 60% 40%
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Distribution by contribution
Group 60%
Individual 40%
Distribution by evaluator
External examiner 20%
Expert panels 30%
Supervisor 50%
Summary of Assessment Scheme
CCB4023 Plant Design II Briefing 18
Final Oral Presentation
Some comments: iCON must be used for simulation (e.g., heat integration, mass
balance)
iCON flowsheet should not be used as PFD
Clarity and importance of design basis, basis in HAZOP study
Lack of team work and coordination during presentation
Lack in design principle and application of fundamental theory:design margin, McCabe Thiele, static head, phase diagram,latent heat, etc.
Control strategy not adequate, wrong philosophy
Discrepancy in economic analysis: low CAPEX, high OPEX, highROR
CCB4023 Plant Design II Briefing 19
Group and Individual Reports
Some comments: Did not incorporate the comments given during presentation
Missing data sheets/spec sheets
Executive summary does not address critical issue
Economic analysis not consolidated
Not a scaled plant layout, fire station should be outside thebattery limit/process area, parking lot/assembly point close tocontrol building
Too much on theory rather than application of the theoryspecific to the project
Report did not follow standard format, improper or inadequatequoting of reference, report shown minimal creativity, criticaland analytical thinking not evident etc.
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Milestone and Important Dates
CCB4023 Plant Design II Briefing
Wk 2 Wk 3 Wk 6Wk 5Wk 4 Wk 7 Wk 8 Wk 9 Wk 10 Wk 11 Wk 12 Wk 13 Wk 14
Submission of Report (softcopy): March 26 , 2015
Submission of Final Report:
April 18, 2015
Wk 1
Individual:Detailed
design Major and Minor Equipment
Reports Preparation
Group:P&ID and Control StrategySafety & Loss Prevention
Waste Treatment StrategyScaled Plant Layout
Economic Evaluation
Final Oral Presentation: April 08, 2015
(Tentative)
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All the Best!