CCB4023 Plant Design II

Briefing
January 2015
Dr. Muhammad Moniruzzaman
Room: 04-03-10
Ext: 7572
E-mail: m.moniruzzaman@petronas.com.my
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Program Outcomes
1. Engineering Knowledge - Apply knowledge of mathematics, science, engineering
fundamentals and an engineering specialisation to the solution of complex
engineering problems;
2. Problem Analysis - Identify, formulate, research literature and analyse complex
engineering problems reaching substantiated conclusions using first principles of
mathematics, natural sciences and engineering sciences;
3. Design/Development of Solutions - Design solutions for complex engineering
problems and design systems, components or processes that meet specified needs
with appropriate consideration for public health and safety, cultural, societal, and
environmental considerations;
4. Investigation - Conduct investigation into complex problems using research-based
knowledge and research methods including design of experiments, analysis and
interpretation 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, to
complex 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;

CCB4023 Plant Design II Briefing

Program Outcomes
7. Environment and Sustainability - Understand the impact of professional
engineering solutions in societal and environmental contexts and demonstrate
knowledge of and need for sustainable development;
8. Ethics - Apply ethical principles and commit to professional ethics and
responsibilities and norms of engineering practice;
9. Communication - Communicate effectively on complex engineering activities with
the engineering community and with society at large, such as being able to
comprehend and write effective reports and design documentation, make effective
presentations, and give and receive clear instructions;
10. Individual and Team Work - Demonstrate knowledge and understanding of
engineering and management principles and apply these to ones own work, as a
member and leader in a team, to manage projects and in multidisciplinary
environments;
11. Life-long Learning - Recognize the need for, and have the preparation and ability to
engage in independent and life-long learning in the broadest context of technological
change;
12. Project Management and Finance - Demonstrate knowledge and understanding of
engineering and management principles, business acumen and entrepreneurship in
multidisciplinary environments.

CCB4023 Plant Design II Briefing

Learning Outcomes
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

CCB4023 Plant Design II Briefing

PO-CLO Mapping
No.
CO1

PO1

PO2

PO3

PO4

PO5

CO4

PO7

PO8

PO9

PO10 PO11 PO12

CO2
CO3

PO6

CO5

CO6

CCB4023 Plant Design II Briefing

Course Summary
3 Credit Values, 100% Coursework

Application of all undergraduate knowledge and skills to solve design

related problems.
To develop the skills of working in a team, leadership qualities,
written and oral communication, decision making etc.
CCB4023 Plant Design II Briefing

Problem Statement
Design of Formalin Production Plant
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, trimethylol-propane, neopentyl glycol, pentaerythritol and
hexamethylenetetramine.
The
most widely
produced grade is formalin which is 37 wt. %
formaldehyde solution in water.

CCB4023 Plant Design II Briefing

Process Design Tasks

IV. Waste Treatment
Strategy
V. Economic
Evaluation

III. Safety
Analysis HAZOP

I. P& ID and
Control
Strategy

II. Detailed Design:

Major and Minor
Equipment

CCB4023 Plant Design II Briefing

Expectation
Utilising a blend of:

hand calculations,
spreadsheets,
mathematical computer packages,
process simulator to design a process

Make necessary decisions, judgements and

assumptions in design problems
Adhere to standard format for Group and
Individual reports
CCB4023 Plant Design II Briefing

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

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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

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Individual Report
Report on detailed design of 1 major
equipment + 2 minor equipment
Length: 40 pages

Compile all the final individual design report

in 1 hardcopy file
Segregate with a divider
Use punch hole protection (reinforcing ring)

CCB4023 Plant Design II Briefing

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Types of Equipment (Example)

Major equipment:
Reactor
Distillation column
Absorption column
Furnace

Minor equipment:
Extraction columns
Evaporator
Membrane Units
Cyclone
Filter
Cooling tower
Sedimentation tanks

Only one student is allowed to undertake detailed

design of each equipment.
CCB4023 Plant Design II Briefing

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Paper Size for Drawings

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

A1 and A3 drawings should be

folded and inserted in
A4 sized plastic wallets

CCB4023 Plant Design II Briefing

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Assessment of Reports
Selected expert panels will evaluate the
Group and Individual Reports.
Example: P&ID and control strategy
section will be evaluated by Process
Control expert panels
Example: Reactor design will be evaluated
by Reactor expert panels

CCB4023 Plant Design II Briefing

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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 the
main supervisor within one (1) week after the
meeting
Supervisor will evaluate the individual progress
Individual progress performance will contribute 10%
of the overall individual marks
Students and supervisor may conduct additional
meetings as frequent as required

CCB4023 Plant Design II Briefing

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Assessment Scheme
Examined by and % Contribution
Assessment Stage
Final Report
(Group)
Final Report
(Individual)
Final Presentation
(Group)
Final Presentation
(Individual)
Individual
Progress
C-Factor
Total

Supervisor

Expert
Panel

10

20

10

10

10

External
Group
Individual
Examiner Contribution Contribution

30
20
20

30

10

10

10

10

0 1.0
50

30

20

CCB4023 Plant Design II Briefing

x
60%

40%
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Summary of Assessment Scheme

Distribution by contribution
Group
60%
Individual 40%
Distribution by evaluator
External examiner 20%
Expert panels
30%
Supervisor
50%

CCB4023 Plant Design II Briefing

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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, high
ROR

CCB4023 Plant Design II Briefing

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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 the
battery limit/process area, parking lot/assembly point close to
control building
Too much on theory rather than application of the theory
specific to the project
Report did not follow standard format, improper or inadequate
quoting of reference, report shown minimal creativity, critical
and analytical thinking not evident etc.

CCB4023 Plant Design II Briefing

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Milestone and Important Dates

Final Oral
Presentation:
April 08, 2015
(Tentative)

Submission of
Report (softcopy):
March 26 , 2015

Wk 1

Wk 2

Wk 3

Wk 4

Wk 5

Wk 6

Group:
P&ID and Control Strategy
Safety & Loss Prevention
Waste Treatment Strategy
Scaled Plant Layout
Economic Evaluation

Wk 7

Wk 8

Wk 9

Submission of Final
Report:
April 18, 2015

Wk 10

Individual:
Detailed
design Major
and Minor
Equipment

CCB4023 Plant Design II Briefing

Wk 11

Wk 12

Wk 13

Wk 14

Reports
Preparation

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All the Best!