Sit down in groups at tables where

you can see a screen.

One A4 handout per person.

1 of each of the 5 A3 sheets per
group (only this amount printed)
CHEE4001
Process Engineering Design Project
Design Study
and
Getting Started
Project and Design Study
You are doing a design study as part of a project. The project
is to make liquid fuels, or their immediate precursors, from
coal in a profitable and sustainable manner.

Your team is part of a consultancy (remember to give it a
name, advisors will ask what it is your first meeting)
commissioned to do a Design Study on a mini-CtL plant for
UQ Energy. Your main contact with UQ Energy is a technical
manager that you meet with once a week. Submissions are to
be addressed to them and they will report to various
stakeholders in UQ Energy.
Project and Design Study
The scope of your work is decided by the Design Brief and the
Design Package instructions. There is some scope for
negotiation on this if something runs into a dead end or an
unexpected problem. Communication is the key!

The deliverables for your project are the Design Packages:

Design Package 1: Conceptual Design and Pre-Feasibility
Design Package 2: Feasibility and Engineering
Design Package 3: Summation and iteration of DP1 and
DP2
Design is what?
What is design?



What is a design specification?



At what level do we make design specifications?
Project and Design Study
Excellence in Design is when:
Deliver Engineer Develop
Overview
Define Input
Client

Feed

Tests

Vendor

Tech.

Environ.
Conceptual

Basis

Description

PFD

M&E
Feasibility

Calculations

Equipment

Materials

Control

Layout
Engineer

Specifications

Data Sheets

P&ID

Hazop

Drawings
Projest

Order

HAZOP

Construct

Manuals

Commission
The Big Picture
Process Designs
Mass and
Energy
Balance
Process
Design
DP2
Control
Safety
Mech.
Design
Quote /
tender
- Not possible
- Cost
- Errors
- Shifted Goal
Posts
- Cannot be built
- Cannot be
transported
- Cost
- Cannot be controlled
- Unsafe
CHEE4001 Limitations
Where we depart from reality by necessity:
Only publicly available information can be used.
The input is arbitrary and does not drive the project.
There is no interaction with other engineers. This is a
major gap compared to a real project. This is both in terms
of some very serious design considerations and the
feedback/re-design loop.
The output is arbitrary and does not drive the project.
BUT
We can still complete a feasible, sustainable (albeit
uneconomical) and safe process designs which is why you
are valuable!
Overview
1.Getting started
2.Narrowing the options
3.Assessing the opportunities
Getting started
Understanding the process
Explore options
Google (of course)
Wikipedia
Kirk-Othmer, McKetta, Ullmanns,
Shreve, The C.P.I.
Monographs
Journals / Trade magazines
Conference Proceedings
Patent literature
Chemical Marketing Reporter (TP1.O4)
Consultants (if you have $s) !
Hints
Be systematic in collecting data
(and write down your method)

Sort and critically analyse as you go and
keep proper reference list (eg use Endnote
or Refworks and include your own notes)
Process orientation
High level assessment
Simple block diagram: process synthesis
High level mass balance
Consider T, P and Phase profile thru process
Develop block diagram: logical choices
! Examine the alternatives formally and as carefully
as you can
! Careful consideration of the extent of integration
Decision Considerations
Potential decision criteria
Hierarchy of Engineering Design Decisions
Excellent: Justified by appropriate engineering calculations
I have modelled the different options realistically from both technical and economic perspectives and the
chosen technology/option/parameter/topology is economically superior and technically achievable [w/ an
economic benefit of X relative to alternatives]
Nearly as good, and much less time consuming uses envelope calculations of the above
Very good: justified by judgement and logic
Only the chosen technology can meet technical requirements and this has been clearly demonstrated
with the following envelope calculations: [!]
Ultimately, this design choice is primarily driven by considerations of factors [A and B] [because !], and
in each of those factors chosen technology Z is superior
Trivial differences separate leading technologies S and T on merit, but alternative technologies Q and R
can be ruled out from particular drawbacks [of ! ]. Technology S was chosen due to trivial advantage of
[!.]
Mediocre: justified by practicality, example, or impression
The chosen option Y was selected as better option Z has less information available.
You could [probably] make use of your 3.5+ years of chemical engineering technical skills and
some assumptions to design a process using option Z.
All the other plants use topology P, so it must be preferable
This may well be the case but you should be able to identify why it is preferred.
After reviewing all the options, chosen parameter was assessed to be the most favourable overall
[perhaps with an associated arbitrary decision matrix]
Note that decision matrices are a useful tool (particularly for obfuscating decision-making
processes!), but in most instances you should be able to tease out more considered reasons for
any particular design choice.
Usefulness of the decision also depends on the quality of judgement/calculation/literature review; e.g.
engineering calculations dont improve a decision if they are clearly wrong.
The Initial Flowsheet
Identify principal processing units
Feed pretreatment, reaction, recovery,
Consider utilities units required
Steam, process water, cooling water, water recovery,
Clearly define battery limits of process for design
Allocate responsibilities to team members
Responsibilities
! Equitable amounts of work across team members
! Overall mass & energy balances for DP1, is a team
responsibility with people accountable within the group for
sections.
! Unit design a largely individual responsibility (DP2)
! Effective team communication and information sharing is
essential for success
CHEE4001
Process Engineering Design Project
Mass and Energy Balances
Previous Experience
CHEE2001: Conservation Principles
CHEE2002: Base Modelling with Aspen
Set Up Flow Sheets
Basic reactors, separation units etc
CHEE3006: Process synthesis (and later control)
These skill sets must now be used in CHEE4001
Mass and Energy Balances
Hand Calculations Excel or similar Aspen or similar
- Useful as a check
- Slow
- Enter equations yourself
- Iterations are fast
- Transferrable
- Built in equations
- Thermo databases
- Fastest Iterations
- High maintenance
Any of these can be used. Use whatever is fit for purpose and
your capability. Aspen can either save or cost a lot of time
depending on your capability. If you are going to use Aspen, start
simple (pseudo-units).
There are lots of ASPEN examples for CtL on the web:
GET THE BASIC BLOCK DIAGRAM RIGHT. DONT
LAUNCH INTO ASPEN OR TRY TO GET TOO FANCY
TOO SOON!
Calculations
Draw (or reference) a flowsheet of what you are
doing calculation on
Identify all streams and units
Write out in full, all assumptions
Identify key process parameters
List and reference sources of data
Set calculations out neatly and clearly
Separate calculations into sections
Take some time to set out correctly, this is useful for
later and makes it easier to find errors.
Calculations
Clearly give units!
Decide on units as a team but stick with SI units.
Design a standard calculation sheet for your team:
Include title block
Date
Who did the calculations
Who checked the calculations (IF checked)
Reference number
You will need a good filing system.
Top 5 M&E mistakes?
Top 5 M&E mistakes?
Examples:Handwritten
Streams
numbered
Standard
Calculation sheet
Examples: Handwritten
Company logo,
client, task
Steps with
intermediate
values and units!
Job page, who,
page number etc
Examples: Spreadsheet
Spreadsheet details
Input Data
Input values
Units column
Examples: Spreadsheet
Stream No.
Equation,
assumptions
Data from input
Results to go into
PFD
Simulators
Same principles but you need to communicate outside
of the simulator:
Simulator flowsheet with labels the same as PFD.
Choices used in the simulation, equation of state,
activity model etc.
Readable summary of each units specifications.
Aspen (/Hysys) Tips
1. Avoid if possible if you have little experience or capability.
2. Choose your thermo carefully (and document).
3. You can go a long way with pseudo units. Be careful of the restrictions that
you place on a system.
4. There are lots of CtL examples available, but be careful of level of
complexity. If you model it, the advisors will expect you to understand it.
5. Critically analyse the results for common sense reality, and try to verify
calculations against a reliable source.
6. You need to get other stuff done: dont spend all your time on this. Abandon
it, if it is causing so much trouble that it is interfering with other work.
7. Use the same units as your flow sheets and across your group (of course).
8. Help files are helpful.
CHEE4001
Process Engineering Design Project
Developing and Drawing
Process Flow Diagrams (PFDs)
Coverage
1.Purpose
2.Types
3.Features
4.Preparation
5.Presentation
Purpose of PFDs
" Communicate the principal operational steps in a process
" Show all major feeds, products, by-products and wastes
" Show all major processing units
" Give basic mass and energy balance details
" Show utility streams and usages
! You need to have various versions at different levels of detail
for discussion in meetings and to support explanations in
your reports.
! Use your BFD/PFD (and later P&ID) for advisor meetings to
catalyze discussion. Take a PDF on a USB to project on the
screen at each meeting.
Types of Process Flow Diagrams
Block PFDs
Uses rectangular blocks to encapsulate key operational
units
Shows key feeds, products, by-products and wastes
Often shows operating conditions
(T, P, F)
Types of Process Flow Diagrams
Engineering PFDs
All previous features
Increased detail necessary
Mass and energy balance table
Uses equipment icons (AS, ANSI, BS, DIN), i.e. standard
ones in VISIO Process Engineering Templates
Equipment coding included
Both block and engineering PFDs are tools for your
development of your process and the largest part of your
communication to people outside your group. Their clarity will
help you in the project and with your marks.
Block PFD
By-product B
Drawn: ITC
Checked: CJS
Value Added Shale Oil Products
Preliminary Block Process Flow Diagram
SIZE FSCM NO DWG NO REV
A4 BPFD-1001 A
SCALE NTS SHEET 1 OF 1
Drawn: ITC
Checked: CJS
CHEE4001 Process Engineering Design
Block Process Flow Diagram - Preliminary
SIZE DATE DWG NO REV
A4 Feb 23, 2000 BPFD-1001 A
SCALE NTS SHEET 1 OF 1
Primary Reaction
Stage
Product
Separation
Secondary
Blending Process
Feed A
Feed B
Primary
product A
1.2 bar, 250C
1.01 bar, 65C
4.5 bar, 130C
Toluene
Feed
Pretreatment
Light ends
Water treatment
Sewer
Solids removal
Product
purification
Secondary
product B
By-product A
Block diagram
By-product B
Drawn: ITC
Checked: CJS
Value Added Shale Oil Products
Process Flow Diagram - Reaction Stage
SIZE DATE DWG NO REV
A4 Feb 23, 2000 PFD-1001 A
SCALE NTS SHEET 1 OF 1
Feed A
Feed B
Toluene
REVISIONS
REV DESCRIPTION DATE APPROVED
S3
S2
S1
S5
S4
S6
S7
S8
S6
Primary product A
R-101
C-101
P-101
P-102
M-101
R-101 P-101 P-102 C-101 M-101
Toluene
feed pump
2500kg/h
Feed B
feed pump
1500kg/h
Packed bed
reactor
3.6 m
3
Product column
1.2m x 7.8m
By-product
mixer
1.5 m
3
S1 S2
Component A
temperature (C)
pressure (kPag)
Component B
Illustration Only: Do not
use as an exact example
Engineering PFD
Engineering PFD
BP virtual refinery has examples of PFDs (and
P&IDs)
Features of PFDs
All equipment has a code
(e.g. TK-101 = tank 101)
Often company standard
Coding letter relates to equipment
Number relates to item in class
First number often plant section
(cf. TK-101, TK-201)
Coding can include:
CP = compressor, MX = mixer, HX = heat exchanger, TK =
Tank etc.

Use specifications I have given to you.
Features of PFDs
Spatial layout important
Flow from left to right (like reading)
Equipment well spaced
Top section for identifiers and description
Bottom section for M&E Table and title block
Or next page
A good PFD can then be easily adapted for P&ID
Equipment to follow vertical orientation as much
as possible (e.g. dont lay towers down)
Features of PFDs
! Border, Title block, Revision notes
! Icons for all equipment. Retain relative size as much as
possible
! Utilities can enter and leave in the middle of the drawing
! Vapour/vents along top of drawing
! Drains along the bottom
! Lines entering a PFD must either be a raw material or have
its source identified.
! Lines leaving a PFD must either be a final product, or have
its destination identified.
Features of PFDs
Identifiers/Description
M & E Table (Flow Summary)
Revisions
Title Block
Flowsheet
Features of PFDs
Also:
cwr = cooling water return
bfw = boiler feed water
bwr = boiler water return
Features of PFDs
None are necessary,
choose only what is
useful to you. e.g.
Enthalpy may be a
good check of EB
and/or may be a pain
to compile.
Features of PFDs
Typical line thicknesses
1.2 mm (thick, 5 in Visio) for main flow streams
1.0 mm (medium, 3 in Visio) for recycle streams
0.5 mm (thin, 1 in Visio) for services

Other Features
Identifier icons for streams on and off a page
Stream numbers for identification
Streams crossing pages to coincide for continuity
Arrow on line when changing direction
Pumps shown
Control loops not shown**
Features of PFDs
Synthesis Gas Feed
CW
CWR
30
3.5
40
3.2
60
3.5
1000
1000
To Drain
50
3.2
E-201
1
43
3.2
980
HX-101
VS-101
HX-101
Feed Cooler
VS-101
Liquid Separator
20
3
43
3.2
2
Features of PFDs
Stream identifier for
flow changes
Preparation of PFDs
1. Do rough sketch first
2. Select appropriate icons for units, number streams
3. Layout to reduce cross-over lines
4. Do draft drawing
5. Get someone else to check and sign off. These are
controlled documents. If you do not check, do not sign.