Process and Plant Design

Course Notes
Faculty Member(Members):
Ioannis K. Kookos
Undergraduate, 8th Semester
Course Type: Core Courses
Language of Instruction: Greek
Course Number: 941
Credits: 5
ECTS Credits:9
Learning Outcomes

After completing this course a student should be able to:

1. generate and solve systematically energy and material balances,
2. build Process Flow Diagrams using systematic procedures,
3. complete the preliminary sizing using minimum information,
4. undertake preliminary economic analysis and evaluation
Competences

At the end of the course the student will have further developed the following
skills/competences:
1. ability to understand the structure and analyze Process Flow Diagrams
2. ability to use process simulators such as HYSYS, UNISIM and ASPEN PLUS in
modeling chemical/biochemical processes
3. ability to judge the viability of investment in new products or processes
Prerequisites

There are no prerequisites for this course. However, students should have basic knowledge of
mass and energy balances and unit operations.
Course Contents

Systematic development and solution of energy and material balances. Degree of freedom
analysis and solution of non-linear equations. Recycle streams and implications to the solution of
the material and energy balances for complete plants.
Thermodynamic data and collection of. Thermodynamic models of ideal and non-ideal mixtures.
Estimation of thermo-physical properties using group contribution methods method of Joback

and method of Gani. Thermodynamic model of Raoult, model of activity coefficients and cubic
(and other) equations of state. Implementation of thermodynamic models into computer software
and selection of appropriate thermodynamic model.
Process flow diagrams (PFDs) (PFDs) and Process and instrumentation diagrams (&IDs).
Preliminary design and costing of classical unit operations. Preliminary sizing of distillation
columns, exctraction columns, absorption columns, heat exchangers, pumps and compressors.
Estimation of f.o.b. equipment cost. Estimation of installed equipment cost, cost of direct labor,
cost of utilities. Depreciation and cost of manufacture. Evaluation of investment plans. Indices of
financial performance. Net present value, return of investment and pay-back time.
Application to production units: production of styrene, bio-diesel, bio-ethanol.
eywords: aterial and energy balances; Design data; Process Flow diagrams; Preliminary
design.
Recommended Reading

.. ookos, Introduction to the Analysis of Chemical Processes, Tziola Publishing,

2009. ISBN: 978-960-418-267-1 (In Greek)
.. ookos, Introduction to Plant Design, Tziola Publishing, 2007. ISBN: 978-960-418173-5 (In Greek)
Peters, Timmerhaus & West, Plant Design and Economics, Tziola Publishing, ISBN: 960418-058-4, Translation in Greek

Teaching And Learning Methods

Lectures, training in using computer software and supervised completion of a design project and
technical writing. Problem based learning is introduced to the students.
Assessment and Grading Methods

Personal design project (25% of the final mark) that includes technical writing and oral
examination/presentation.
Written examination (75% of the final mark)

Plant Design Laboratory

Course Notes
Faculty Member(Members):
Ioannis K. Kookos
Undergraduate, 9th Semester
Course Type: Core Courses
Language of Instruction: Greek
Course Number: 1041
Credits: 4
ECTS Credits:6
Learning Outcomes

After completing this course a student should be able to:

1. undertake preliminary techno-economic study of process relative to chemical
engineering,
2. undertake preliminary techno-economic study for new processes or products,
3. completion of technical report.
Competences

At the end of the course the student will have further developed the following
skills/competences:
1. ability to understand the structure and analyze Process Flow Diagrams
2. ability to use process simulators such as HYSYS, UNISIM and ASPEN PLUS in
modeling chemical processes
3. ability to judge the potential viability of investment plans.
Prerequisites

The students should have completed successfully the course Plant Design and Economics.
Course Contents

Synthesis of heat exchanger networks. Pinch point and its importance in synthesizing optimal
heat exchanger networks. Minimum number of units and minimum consumption of utilities.
Rules for synthesizing heat exchanger networks. Applications. Use of process simulators to
extract the data necessary for undertaking a heat exchanger synthesis project. Numerical
examples and applications.
Applications of mathematical programming in process synthesis and design. Basic principles and
definitions. Basic types of optimization problems and conditions of optimality. Non-linear
programming and sequential quadratic programming. Optimization software. (MATLAB
GAMS). Approximate optimization in commercial simulation software. Response surface
methodology: advantages and disadvantages. Sensitivity analysis and its implementation in
commercial software such as UNISIM/HYSYS.
Structure and functionality of commercial software. Recycle streams and their implementation in
commercial software (such as UNISIM, HYSYS, ASPEN).
Design project. Technical writing. Executive summary, main body and technical appendix.
Recent design projects: DME production, Bio-diesel production, Bio-ethanol production from
food industry waste streams.
Keywords: Heat exchanger network synthesis, Optimization; Commercial simulators; Design
project.
Recommended Reading

. ookos, Introduction to the Analysis of Chemical Processes, Tziola Publishing, 2009. ISBN:
978-960-418-267-1 (In Greek)
.. ookos, Introduction to Plant Design, Tziola Publishing, 2007. ISBN: 978-960-418-173-5
(In Greek)
Peters, Timmerhaus & West, Plant Design and Economics, Tziola Publishing, ISBN: 960-418058-4, Translation in Greek

Teaching And Learning Methods

Lectures, training in using computer software and supervised completion of a design project and
technical writing.
Assessment and Grading Methods

Design project (50% of the final mark). The completion of the project incorporates elements of
problem based learning. The supervision/assessment of the groups is achieved through weekly
meetings with the teaching staff.
Written examination (50% of the final mark)