Design

1. Conceptual design: develop a preliminary flowsheet using approximate methods. 2. Preliminary design: use rigorous simulators to evaluate steady-state and dynamic performance of proposed flowsheet. 3. Detailed design: specify type of trays, no. of sieve tray holes, piping, pumps etc.

1.1 Creative Aspects of Process Design

The propose of engineering is to create new material wealth. Process and plant design is the creative activity whereby generate idea and then translate them into equipment and processes for producing new materials or for significantly upgrading the value of existing materials.

In any particular company, we might try to generate new idea: To produce a purchased raw material To convert a waste by-product to a valuable product To create a completely new material (synthetic fibers, food, bioprocessing) To find a new way of producing an existing product (a new catalyst, a bioprocessing alternative) To exploit a new technology (genetic engineering, expert systems)

Level of Engineering Designs

TABLE 1.1-1 Types of design estimates
1. 2. 3.

4.

5.

Order of-magnitude (ratio estimate) base on similar previous cost data; probable accuracy exceed +40% Study estimate (factored estimate) base on knowledge of major item of equipment; probable accuracy up to +25 Preliminary estimate (budget aut!ori"ation estimate; scope estimate)based on sufficient data to permit t!e estimate to be budgeted; probable accuracy wit!in +#2 Definition estimate (project control estimate) based on almost complete data$ but before completion of drawing and specifications; probable accuracy wit! +% Detail estimate (contractor&s estimate) based on complete engineering drawings$ specifications$ site surveys; probable accuracy wit! +'
Frome A. Pikulik and H.E. ia!" #$ost Estimating %a&or Process Equipment"' $hem. Eng." ()*+,-. ,/0*,122-

TABLE 1.1-2 Engineering Costs to Prepare estimates 1!""#

3ess than 4 , million 7ype of estimate 8tudy *4 thousandsPreliminary*4 thousandsPlant 65,6 ,6596

4,546 million Plant ,+59/ 9/50/

46546/ million Plant +/5)/ 6/51/

efinitive *4 thousands-

+650/

0/5,+/ ,//5+9/

Frome A. Pikulik and H.E. ia!" #$ost Estimating %a&or Process Equipment"' $hem. Eng." ()*+,-. ,/0*,122-

,.+ A Hierarchical approach to $onceptual esign

E$ample %ydrodeal&ylation of Tol'ene

$H9 7 o lu en e H+ : en ! en e $H)

+ : en ! en e ip h en y l

H+

%DA Process
.oluene + * 2 ,en"ene +-* / 2 ,en"ene +ip!enyl + * 2 H = 2#5') Btu ( mol

Basic information: 1. Reactions take place between 11501300 F. 2. Pressure is about 500 psi. 3. E cess !"#ro$en %5&1 ratio' pre(ents cokin$. ). Effluent $as must be *uenc!e# to 1150 F in or#er to pre(ent cokin$.
1

HDA Process

,/

HDA Process

,,

HAD Process

,+

As a vapor re overy system !e ould use one of t"ese

$ondensation*high P or low 7" or bothAbsorption Adsorption A membrane process

Simplified #lo!s"eet for t"e Separation Systems

,)

$e y le Stru ture of t"e #lo!s"eet

,6

%nput-Output Stru ture of t"e #lo!s"eet

,0

Possi&le 'imitation
Hierarchy of decisions______________ 1. Batch versus continuous 2. Input-output structure of the flowsheet . !ecycle structure of the flowsheet ". #eneral structure of the separation system a. vapor recovery system $. li%uid recovery system &. 'eat-exchanger networ(______________
The goal (f concept'al design is to find the ,2

S"ort ut Solutions De omposition Pro edures for ()isting Pro esses ,. ;emove all the heat exchangers" drums" and storage vessels. +. <roup all the distillation columns *liquid separation system block9. 8implify the general structure of the separation system *similar to fig. ,.+56). 3ump *group all units in single box- the complete separation system *similar to fig. ,.+50,(

%PA Plant

,1

(t"y&en*ene Pro ess

+/