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 Design is creative activity.

 The design or retrofit (redesign) of chemical
process begins with the desire to produce
profitably chemicals that satisfy the societal
needs.
 Besides, the process designs are also directed to
meet environmental and safety regulation.

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2.0 DESIGN PROCESS
 Determination of design objective either
1. Producton of new product based on
specified quality and capacity
2. Introduction of new process to produce
existing product at specified capacity and
quality.
3. Prodcution of raw material for other
process based on specified quality and
capacity
4. Establihment of new technology for the
cuurent production plant
5. Improving the existing processes
(retrofit)
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When considering possible ways of design,
the designer will be constraint by many
factors like:
Economic consideration are obviously a
major constraint of any engineering design:
plants must make profit.
Time- The time available for completion of a
design will usually limit the number of
alternative design that can be considered.

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Type of constraints
External constraints: the constraints
that are outside the designer’s
influence: economic, etc…
Internal constraints: controlled by
the designer such as choice of
process, process conditions,
materials, equipment

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 Resources

Process
condition

Plausible
designs

Time

Goverment Controls
Figure 1 : Type of constraints 6
1. Define the design objectives
(the needs)
2. Data Collection
3. Generation of possible design
solutions
4. Selection

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A. THE DESIGN OBJECTIVES (THE NEEDS)
 Chaddock (1975) defined design as the
conversion of an ill-defined requirement into
a satisfied customer
 Design of chemical/biochemical process
need to fulfill:
(a) public needs for the product
(b) Commercial opportunity
 Identify:
(a) sub-objectives;
(b) the needs and wants of the design
(c) The project /equipment specifications
(d) internal and external constraints

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B. DATA COLLECTION
 Assemble all the relevant facts and data required.
Include information as following:
(a) on possible processes
(b) equipment performance/parameters
(c) physical property data
(d) material of construction
(e) costs
 Type of Data source:
(a) Data manual
(b) National Standard
(c) International Critical tables
(d) Handbooks like Perry Handbook
(e) Encyclopedia Of Chemical Technology, etc..

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C. GENERATION OF POSSIBLE DESIGN
SOLUTIONS
 Creative part of design process is generation of
possible solutions to the problem for analysis,
evaluation and selection
 Chemical engineering projects can be divided into
three type:
(a) Modifications and additions to existing plant:
usually carried out by the plant design group.
(b) New production capacity to meet growing
sales demand- repetition of existing designs with
only minor design changes.
(c) New process, developed for lab, through pilot
plant to a commercial process. Most of the equipment
of the unit operations and process equipment will use
established designs.

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STEP IN DEVISING NEW PROCESS DESIGN:
(a) sketch out a rough block diagram showing the
main stages in the process
(b) to list the primary function (objective) and the
major constraints for each stage
(c) discuss some methodology of the design
(d) review some of the special techniques
(e) Possible solution to a design problem

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D. SELECTION
 Start with a set of possible solution bounded by
external constraints
 By a progressive and selection, narrow down the
range of candidates to find the best design
 The selection process can be considered to go
through the following steps:
(a) Possible design (credible) – within the
external constraints.
(b) Plausible designs (feasible) – within the
internal constraints
(c) Probable designs – likely candidates
(d) Best design (optimum) – judged the best
solution to the problem
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 Figure 2 summarized the design process

Objective
Data
Collection

Generation of
Possible designs

Selection & evaluation Final

(optimization) design

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 Figure 3 show the basic components of a typical
chemical/bio chemical process.

Recycle of un-reacted material By-products

Waste

Raw Product Product

Feed
Material Reaction Separation purification
storage preparation
Stage 4 Stage 5
Stage 1 Stage 2 Stage 3

Product
Sales storage

Stage 6
Figure 3: General Anatomy Of Chemical Process
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 Each block represents a stage in the overall process
for producing a product from the raw materials.
 Not all the stages will be needed for any particular
process and the complexity of each stages will
depend on the nature of the process
 Stage 1. Raw material storage
- also called as essential materials/feed stocks
-The storage required will depend on the nature of
the raw materials, the method of delivery, and what
assurance can be placed on the continuity of supply. If
the material delivered by ship, several weeks stocks
may be necessary; where as if by road/rail, in smaller
lots, less storage will be needed.

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 Stage 2: Feed preparation
-Some purification and preparation of the
raw materials will usually be necessary
before there are sufficiently pure or in the
right form.
 Stage 3: Reactor
-The reaction stage is the heart of a
chemical manufacturing process.
-In the reactor, the raw materials are
brought together under condition that
promote the production of the desired
product; invariably, by-product and
unwanted compound (impurities) will also
be formed
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 Stage 4: Product separation
-In the first stage after the reactor the
products and by-products are separated
from any un-reacted material.
-If in sufficient quantity, the un-reacted
material will be recycled to the reactor.
-they may be returned directly to the
reactor or to the feed purification and
preparation stage.
- the by-products may also be separated
from the products at this stage.
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 Stage 5 –Purification
-Before sale, the main product will usually need
purification to meet the product specification.
- If produced in economic quantities, the by-
products may also be purified for sale
 Stage 6-Product Storage
- Some inventory of finished product must be held
to match production with sales
-Provision for product packaging and transport
will also be needed, depending on the nature of
the product.
- Liquid will normally be dispatched in drums and
in bulk tankers (road, rail and sea), solids in
sacks, cartons or bales
-The stock held will depend on the nature of the
product and the market
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 Ancillary processes
-in addition to the main process staged shown in
Figure 3, provision will have to be made for the
supply of the services (utilities) needed; such as
process water, cooling water, compressed air,
steam.
-Facilities will also be needed for maintenance,
fire fighting, offices and other accommodation,
and laboratories

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The design work required in the engineering
manufacturing process can be divided into two
broad phases:

Phase 1: Process design which covers the steps

from the initial selection of the process to be
used, through to the issuing of the flow-sheets,
includes the selection, specification, chemical
engineering design of equipment and
preparation of the piping and instrumentation
diagrams.
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Phase 2:
 The detailed mechanical design of
equipment's: The structural, civil and
electrical design; and the specification
and design of the ancillary services.
 Cost estimation and the purchase and
procurement of equipment and materials
 The sequence of steps in the design,
construction and start-up of a typical
chemical process plant

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 Effective co-operation depends on effective
communication and all design organization
have formal procedures for handling projects
information and documentation.
 The documentation will include:
1. General correspondence within the design
group and with:
(a) government departments
(b) equipment vendors
(c) site personnel
(d) the client
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2. Calculation sheets:
(a) design calculations
(b) costing
(c) computer print-out
(d) flow-sheet
3. Drawings:
(a) piping and instrumentation diagrams
(b) layout diagrams
(c) plot/site plans
(d) equipment details
(e) piping diagrams
(f) architectural drawings
(g) design sketches
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 The need for standardization arose early in the
evolution of the modern engineering industry: by
Whitworth introduced the first standard screw
thread to give a measure of interchangeability
between different manufacturer
 Modern engineering cover wider function like:
1. Materials, properties and compositions
2. Testing procedures for performance,
compositions and quality
3. Preferred sizes: for example tubes, plates,
sections
4. Design methods, inspection, fabrication
5. Codes of practice for plant operation and safety
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 The terms STANDARD and CODE are used
interchangeably.
 CODE – reserved for a code of practise
covering say a recommeded design or
operating prosedure
 STANDARD – for preferred sizes,
compositions, etc
 In UK, the preparation and promulgation of
national standards are the responsibility of
the British Standard Institute (BSI)

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 In US, the National Bureau Of Standards
responsible for coordinating information on
standard.
 For Chemical Engineers, issued by the
American National Standard Institute (ANSI),
The petroleum Institute (API), The American
Society for testing Material (ASTM), The
American Society of Mechanical Engineers
(ASME)
 The International Organization For
Standardization (ISO) coordinates the
publication of international standards
 Equipment manufacturer also works to standard
to produce standardized designs and size
ranges for commonly used item; such as
electric motors, pumps, pipes and pipe fitting

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Design is an inexact art, errors and
uncertainties will arise from the
uncertainties in the design data
available and in the approximation
necessary in the design calculation.
To ensure that the specification is met,
factors are included to give a margin of
safety in the design, named as Design
factor

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In mechanical and structural design, the
magnitude of the design factors used to
allow for uncertainties and material
properties, design methods, fabrication and
operating loads are well established.
Design factors are also applied in process
design to give some tolerance in the design.
When selecting the design factor to use a
balance has to be made between the desire
to make sure the design is adequate and the
need to design to tight margins to remain
competitive.
The greater the uncertainty in the design
methods and data, the bigger the design
factor that must be used.
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 In mechanical and structural design, the
magnitude of the design factors used to
allow for uncertainties in material
properties, design methods, fabrication and
operating load.
 A factor of around 4 on the tensile strength.
 About 2.5 on the 0.1 per cent proof stress is
normally used in general structural design.
 The process stream average flow increased
by 10 per cent to give flexibility in process
operation.

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 Flow-sheet is the key document in process design &
diagrammatic model of the process
 It shows the arrangement of the equipment selected
to carry-out the process, Exp: stream connections;
stream flow-rates and compositions; and the
operating conditions.
 Flow-sheet will be used as the basis for design &
drawn up from material balances and energy
balance
 It include piping, instrumentation, equipment
design and plant layout.
 It will also be used by the operating personnel for
the preparation of operating manuals and operating
training.
 During start-up plant and subsequent operation, the
flow-sheet forms a basis for comparison of
operating performance with design. 30
1. Block diagrams
- the simplest form of presentation
-Each block represent a single piece of
equipment
- representing a process in a simplified
form in reports and text books
-The stream flow-rates and composition
can be shown on the diagram near to
the stream line
- The block can be any shape

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 Expander
Pump

Reactor

Valve

Heater Distillation
column

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2. Pictorial representation
-the equipment drawn is a stylized
pictorial form.
- use The symbols given in British
Standard, BS 1553; Graphical Symbols
For General Engineering; Piping
System and Plant; The American
National Standard Institute, ANSI;
German Standard DIN 28004.

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FIGURE 2: PICTORIAL PRESENTATION
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3. Presentation Of Stream Flow-rates
-The data on flow-rate of each
individual components, on the total
stream flow-rate, and the percentage
composition can be shown on the flow-
sheet in various ways.
- The simplest is to tabulate the data in
blocks alongside the process stream
lines (figure 3). Limited of amount of
information can be shown in this way
and its is difficult to make neat
alteration or add additional data

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FiGURE 3: SIMPLEST PRESENTATION OF STREAM FLOW RATES
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 A better method for the presentation
of data on flow-sheets is shown in
figure 4 and 4a. In this method, each
stream line is numbered and data
tabulated at the bottom of the sheet.
Alteration and additions can be easily
made.
 Typical commercial Piping and
Instrument Flow Diagram (PI&D) flow-
sheet is shown in figure 5.

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FIGURE 4a: DETAIL PRESENTATION OF STREAM FLOW RATES
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FIGURE 4b: DETAIL PRESENTATION OF STREAM FLOW RATES
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FIGURE 5: TYPICAL PRESENTATION PI&D
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 Design synthesis
approach proposed by
Douglas 1988
 Integrated design
synthesis at preliminary
design stage
 Different from the
traditional design
synthesis where the
optimum design is
achieved at detail
design level

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 Information on design and process selection before starting
the process synthesis.
 Common problem: gathering new information for new
product/process/technology.

Plant Process Design

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  Analyzing the current market scenario is important task to determine
the economic viability
 Basis for the plant capacity/scale
 Provide economic data which will determine which process
alternatives to choose from as well as equipment capacities
 Expandable plant - should be design for the largest production
capacity
 Ref: Peters & Timmerhaus 2003; Seider et al. 2004)

• Option of raw material

• Present & future availability
• Local & global source

• Present & future

• Locally & globally
• Current producers/competitors 43
• Current production scale
 Understand what product to be produced
 Existing or new product
 Potential reaction paths
 Reactor/fermenter – core unit/component in the process
 Reaction information - obtain from literature such as text
book/database, journal, patent, hand books, experiments or
estimation etc.

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45
Physical/Chemical/Biochemical Properties
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• Constraints that can be controlled
• How can you control?

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• Should be established prior to detail design and influences the design
success
• Location should result in minimum cost & distribution
• Among factors to be considered:

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Selection Techniques

A. Subjective
Techniques
1. Industry Precedence • Basic assumption => if a location was best for similar plant in the past, it must be the
best for the new one now.
• No need for conducting a detailed location study.
• Location decision is thus subject to the principle of precedence - good or bad.
2. Preferential Factor • Dictated by a personal factor
• Depends on the individual preferences e.g. if one belongs to a particular state, he
/ she may like to locate his / her unit only in that state.
• Such factors may override factors of cost or profit in taking a final decision.
• This could hardly be called a professional approach though such methods are
probably more common in practice than generally recognized.

3. Dominant Factor • Some cases of plant location are influenced by the dominant factors
• Mining or petroleum drilling operations must be located where the mineral
resource is available.
B. Qualitative Factor • Identify the important location factors.
Rating • Rate each factor according to its relative importance, i.e., higher the ratings is
indicative of prominent factor (1 = Poor, 10 = Excellent).
• Assign each location according to the merits of the location for each factor.
• Calculate the rating for each location by multiplying factor assigned to each
location with basic factors considered.
• Find the sum of product calculated for each factor and select best location having
highest total score.
C. Quantitative Factors • Factors are assigned weights based on relative importance and weightage score
Weight - Rating for each site using a preference matrix is calculated.
• The site with the highest weighted score is selected as the best choice. 50
Example 1: Qualitative Factor Rating
Merit Rating
Factor Factor Rating
s (1 = Poor, 10 = Excellent) Location 1 Location 2 Location 3
Rating Total Rating Total Rating Total
Factor 8 3 24 5 40 4 32
A
Factor 5 4 20 3 15 5 25
B
Factor 6 4 24 5 30 5 30
C
Factor 3 1 3 2 6 3 9
D
Factor 5 5 25 3 15 3 15
E

Total - - 96 - 106 - 111

Location 3 – Best location

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Example 2: Quantitative Factor Weight - Rating
Merit Rating (Out of 5)
Factor Factor Weight Rating
s ( Weight %) Location 1 Location 2 Location 3
Rating Total Rating Total Rating Total
Factor 0.30 3 0.9 5 1.5 4 1.2
A
Factor 0.18 4 0.72 3 0.54 5 0.9
B
Factor 0.21 4 0.84 5 1.05 5 1.05
C
Factor 0.11 1 0.11 2 0.22 3 0.33
D
Factor 0.20 5 1 3 0.6 3 0.6
E

Total - - 3.57 - 3.91 - 4.08

Location 3 – Best location

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 Process Mode

Production
Capacity

Market Demand & Steady market demand & Inconsistent market

Life Time of longer life time demand & short life time

Product
Economic for slow
Fast rate of processing processing rate and
Rate of Processing without frequent
maintenance
product with high
fouling like slurry type of
product

Reactor Single application

Multiple application
(heating, reaction,
Application separation)
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1.10 SYNTHESIS AND ANALYSIS - DESIGN

Determination of the necessity and objective of design

from the problem occurs

Conceptual design from the a few alternative design

Design variables from heuristic /experience

/mathematical model

Part and component design based on heuristic

/experience /mathematical model

Analysis by computer tools : ICON/HYSYS/SUPER PRO,

etc

Final design analysis based on performance

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