PLANT DESIGN PROJECT

(SKKK 4824) BRIEFING 9 FEBRUARY 2020

14 February 2016

Presented by:
Azizul Azri Mustaffa, Ph.D
 LIST OF COORDINATORS
Department of Chemical Engineering (SKKC)
• Coordinator: Ir. Ts. Dr. Zaki Yamani Zakaria (SN 01)
• Co-Coordinator: Dr. Azizul Azri Mustaffa (SN 02)
• Co-Coordinator: Dr. Zarina Ab. Muis (SN 03)

The academic office will distribute you

according to these 3 sections
 PRE-REQUISITES

• Mass Balance (SKKC 1113)

• Energy Balance (SKKC 2133)
• Transport Processes (SKKC 2313)
• Separation Processes (SKKC 3323)
• Plant Design (SKKC 4143)
 OBJECTIVES

• Students will acquire the skills for hands on

application and integration of the principles of
chemical engineering required to design a process
plant.

• This project also is also aimed at equipping the students

with the skills and creativity in designing a process
plant in the absence of complete data.

• Students will learn the technique

of writing a comprehensive technical
plant design report.

4
2 DIFFERENT SCENARIOS
 COURSE OUTCOMES
• CO1 - Formulate desired process design objectives
and requirement including project background,
market survey and site location and as well as
possible constraints for a complex chemical process
design problem.

• CO2 - Evaluate process routes for synthesizing

a preliminary chemical process flowsheet by
employing conventional as well as current
practices of process synthesis and design
strategies.

• CO3 - Seek the engineering and scientific data

required for process design from various related
sources.
 COURSE OUTCOMES (Cont’d)
• CO4 - Conduct mass and energy balance
calculations for constructing process flow
diagram (PFD) by employing chemical
engineering principles.

• CO5 - Simulate a process flowsheet and

optimize process parameters using
commercially available software packages.

• CO6 - Propose energy conservation

measures, waste treatment methods and
pollution control of a process design to
comply with governmental/ environmental
regulations.
 COURSE OUTCOMES (Cont’d)
• CO7 - Produce mechanical design and
equipment sizing based on ASME standard.

• CO8 - Conduct profitability analysis to

achieve desired payback period or return of
investment (ROI).

• CO9 - Perform safety assessment of the

chemical process using HAZOP analysis.

• CO10 - Develop control systems of a process

plant to produce piping and instrumentation
diagrams (P&ID).
 COURSE OUTCOMES (Cont’d)
• CO11 - Work as a team for solving a
complex design project and lead a specific
task.

• CO12 - Produce well written project reports

and deliver an effective oral presentation on
design project with appropriate visual aids.

• CO13 - Adopt academic honesty and

professional integrity.

• CO14 – Manage project effectively

 GENERIC SKILLS ASSESSED

• Communication Skills (CS – PO8)

• Teamworking (TW – PO9)
• Critical Thinking & Problem Solving (CTPS – PO7)
• Ethics & Professionalism (EM – PO5)
• Lifelong Learning (LL – PO11)
• Entrepreneurship Skills (KK – PO12)
• Leadership Skills (LS – PO9)
 TEACHING METHODOLOGY
• Beginning of the semester - project briefing by CO

• Students divided into teams (4). Supervisor/s (SV)

assigned to each team - academic and industrial
SVs

• Project topics – given by coordinators together with

discussion among teams/with supervisors.

• Team performances/progress monitored

continuously by the supervisors - according
to the project schedule.

• Regular meetings with supervisors - interview

of all team members and progress reporting.
 TEACHING METHODOLOGY (Cont’d)
• Week 9 - preparation for interim evaluation - report
& oral presentation

• Interim presentation - panelists evaluating the

progress, provide comments - must improve
accordingly – may include industrial panelists

• After interim evaluation - continue with the remaining

parts of the project.

• Series of seminars - covering topics not extensively

covered in the syllabus - useful for project.
 TEACHING METHODOLOGY (Cont’d)

• Week 17 - final presentation session - focuses on the

improvements made on the parts presented during interim
evaluation and the remaining parts – briefing will be
conducted

• Each design team should maintain a log book - record the

progress of their project, attendance during discussion,
points discussed with the supervisor etc. (PIC: Dr. Zarina).

• Students also need to arrange and conduct industrial visit

to relevant industries (PIC: Dr. Azizul).
 TEACHING METHODOLOGY (Cont’d)

• Generic skills - oral communication skills - assessed by

panelists during the interim and final presentation session

• Teamworking and leadership skills - assessed through

peer rating and observation by SV

• Ethics, entrepreneurship and problem solving skills -

assessed by the SVs through observation during
supervision.
 ASSESSMENT
Evaluation Items Tools Evaluator Task %
Interim Report Written Supervisor G 10
Interim Presentation Oral Panel I 10
Final Presentation Oral Panel I 25
Final Report Written Supervisor G 20
Log Book Log Book Coordinator G 5
Leadership (LS) Peer Rating Teammates I 5
Teamworking (TW) Peer Rating Teammates I 5
Ethics & Professionalism Observation Supervisor I 5
Entreprenuership Observation Supervisor I 5
CTPS Observation Supervisor I 5
Industrial Visit and Report Industrial Visit Report Coordinator G 5
TOTAL 100

Breakdown of Evaluators’ Assessment:

• Coordinator – 10 %
• Teammates – 10 %
• Supervisor – 45 %
• Panels – 35 %
 ASSESSMENT (Cont’d)

• Assessment basis - (i) overall team (G) and (ii) the

individual performance (I)

• No permanent team leader - must be rotated among all

team members according to design tasks - discuss with
SV

• Peer rating - each student will be given a confidential

sheet (online) to allow him/her to evaluate/rate his or her
colleagues’ contribution (TW and LS) - 2 stages, after
interim evaluation, after final presentation.
 ASSESSMENT (Cont’d)
• From peer rating – auto-rating factor (between 0.80 to
1.05) generated for each team member.

• Factor will be multiplied with original group marks

• A member obtained a factor lower than 1.00 – get lower

marks

• Justification – a member who does not contribution well

in a group task will get lower marks than members who
contribute well

• Peer rating 1 – interim report and presentation, Peer

rating 2 – final report and presentation
 ASSESSMENT (Cont’d)

• Example auto-rating calculations

Interim Interim
Factor Report Report
Students Ahmad Chong Arivind Philip IA OA
(IA/OA) Marks Marks After
(Original) Auto-Rating
Ahmad 4 4 4 4 4.00 4.00 1.00 8 8

Chong 4 4 4 4 4.00 4.00 1.00 8 8

Arivind 4 4 4 4 4.00 4.00 1.00 8 8

Philip 4 4 4 4 4.00 4.00 1.00 8 8

IA – Individual average
OA – Overall average
 ASSESSMENT (Cont’d)

• Example auto-rating calculations

Interim Interim
Factor Report Report
Students Ahmad Chong Arivind Philip IA OA
(IA/OA) Marks Marks After
(Original) Auto-Rating
Ahmad 5 5 5 5 4.50 4.44 1.01 8 8.1

Chong 4 5 4 4 4.75 4.44 1.05 8 8.4

Arivind 4 4 4 4 4.50 4.44 1.01 8 8.1

Philip 5 5 5 5 5.00 4.44 1.05 8 8.4

IA – Individual average
OA – Overall average
 ASSESSMENT (Cont’d)

• Example auto-rating calculations

Interim Interim
Factor Report Report
Students Ahmad Chong Arivind Philip IA OA
(IA/OA) Marks Marks After
(Original) Auto-Rating
Ahmad 5 5 5 2 4.50 4.19 1.05 8 8.4

Chong 4 5 4 3 4.75 4.19 1.05 8 8.4

Arivind 4 4 4 2 4.50 4.19 1.05 8 8.4

Philip 5 5 5 5 3.00 4.19 0.80 8 6.4

IA – Individual average
OA – Overall average
 ASSESSMENT (Cont’d)

• Example auto-rating calculations

Final
Final Report
Factor Report
Students Ahmad Chong Arivind Philip IA OA Marks After
(IA/OA) Marks
Auto-Rating
(Original)
Ahmad 5 5 5 2 4.50 4.19 1.05 14 14.7

Chong 4 5 4 3 4.75 4.19 1.05 14 14.7

Arivind 4 4 4 2 4.50 4.19 1.05 14 14.7

Philip 5 5 5 5 3.00 4.19 0.80 14 11.2

IA – Individual average
OA – Overall average
 ASSESSMENT (Cont’d)

• Critical thinking and problem solving (CTPS) [CO4] – manual

mass & energy balance calculations – each member perform MEB in
front of SV.

• Ethics [CO13] – based on SV observation, log book, industrial visit

• Entrepreneurship [CO8] - conduct profitability analysis – each

member to show SV how to calculate desired payback period / ROI.

• Industrial visit & report – evaluation based on report – details

will be uploaded in e-learning
 ASSESSMENT (Cont’d)

• Refer the Overall Rubrics in order to know the detailed

assessment items
 GROUP DISTRIBUTION
• Group distribution is based on:
* Cumulative Point Average (CPA)
* Gender (Male, Female)
* Race/Nationality (Malay, Chinese, Indian & Others)

• The final list of groups (with SV & titles) have been uploaded
in e-learning and WhatsApp group.
 PROJECT TOPICS
• 4/5 teams will work on the same topic
(production of the same chemical) and
capacity but different designs

• To create competitiveness between groups of

the same chemical

• The chemicals involved are commodity

chemicals & continuous process, preferably
involving only liquid and vapors.

• The groups with the same topic will present in

front of the same panels during interim and
final presentation
 PROJECT TOPIC SELECTION

• This year – 23 groups – 5 topics. Team 1-5 (Pool 1), Team

6-10 (Pool 2), Team 11-15 (Pool 3), Team 16-19 (Pool 4),
Team 20-23 (Pool 5)

• Theme and topics – selected by Coordinators (CO).

• Capacity - Teams need to do market survey, discuss

with SV (28/1-10/2), present to CO, discuss final capacity
(10-11/2), submit letter of intent (12/2).
 TOPICS FOR 2019
Theme: Commodity Chemical

Refer to the SV-Student Team List

 EXPERT PANELS
• SVs are not experts in all parts of the project. Design
teams might want to consult Expert Panels

• Coordinators will prepare the list of the experts for each

design teams (later refer e-learning)

• Make an appointment first

before meeting them
PROJECT SCHEDULE
 LOG BOOK
Consist of:
1. Project schedule or planning (e.g.: use Gantt
chart: activities, mile stone and due date)
2. Minutes of meeting (issue/topic, action)
3. Plant visit report (data, photo, application letter,
communication with industry proof such as e-
mail, brochure etc.)

How to write ?
Use your professionalism and creativity
 DESIGN REPORT

• A complete design report consists of several

essentially independent parts, with each
succeeding part giving greater detail on the
design and its development.
 ORGANIZATION OF A DESIGN
REPORT
• Part I. Title page
• Part II. Letter of transmittal
• Part III. Acknowledgement
• Part IV. Executive summary
• Part V. Table of contents + List of appendices
• Part VI. Body of report
• Part VII. Appendix
 PART VI. BODY OF REPORT

1. Introduction
2. Process Synthesis and Flowsheeting
3. Process Integration
4. Equipment Sizing and Detailed Equipment
Design Specifications
5. Process Control, Safety, Waste Prevention
and Treatment
6. Economic Analysis
7. Conclusions and Recommendations
8. References to Literature (bibliography)
 BODY OF REPORT (cont’d)
• These sections include the essential information,
graphs, tables and figures.

• The Appendix, gives detailed information which

permits complete verification of the result shown in the
body.

• Tables of data, sample calculations, and other

supplementary material are included in the Appendix.
 DETAILED FORMAT

• Detailed format of the report (i.e. page,

table and figure numbering, line spacing,
referencing, etc.) should follow UTM
thesis/dissertation format.
 IMPORTANT NOTES

• Each chapter should begin with a

separation tab or marker (with a short,
indicative title) for ease of reference.
• All reports should be submitted in spiral
binding.
• Failing to submit the peer rating forms,
marks from the teamworking & leadership
skill part will be zero
 IMPORTANT NOTES (cont’d)

• Failing to submit the end of course survey,

marks from the ethics and professionalism
part will be zero
• All updates will be posted in e-learning.
Check e-learning every week. We will not
responsible for any information missed.
• Updates involve change of information,
new instructions, seminars, rubrics etc.
 IMPORTANT NOTES (cont’d)

• A CD which include the latest version of

the completed report and the converged
simulation results must be submitted to
the course coordinator.
• Any missing files will result in the
students’ grades being withheld.
• The CD must bear the names of the group
members, supervisor and project topic.
 COMPETITION MODE
• Plant design project – competition mode
• Best teams from each pool – certificates
• Top 3 overall – plaques/trophies/cash prizes and
certificates
• Based only on interim report and interim & final
presentation
COMPETITION MODE
 WHATSAPP GROUP

• For fast coordination

• Containing one representative from each team
• Representatives must be very responsive
• To avoid cross communication – only these
representatives will be communicating with the
coordinators.
EXAMPLE OF PFD AND
REAL CHEMICAL PLANT
INEOS Phenol Chemical Plant, Gladbeck, North Rhine-
Westphalia, Germany
SASOL Chemical Plant, Chemcoast Park, Brunsbüttel,
Schleswig-holstein, Germany
Ethanol Biorefinery
 CHALLENGES

• Time management
• Selection of topics
• Lack of data
• Needed knowledge which are not deeply
covered in syllabus
• Team members and supervisors
• Oral presentations
• New instructions and information
 Example of Comments from Panel
during interim/final presentation:
1. Check significant figures.
2. Why too many compressors?
3. Control strategies - Why there are too many controllers at the equipment?
4. Control strategies - Wrong control loop. Check if it should be connected in
parralel or series.
5.Vessel - How LL and HL is decided?
6. Costing - Some vessels are very expensive!
7. Good presentation. However Ahmad, Chong and Rajan need to improve on
their communication skills. No eye contact and have no confidence to answer
questions.
8. Reactor is RM1 billion??? Very costly!
9. Why optimize using the lowest Refluc Ratio 0.2?
10. The reflux ratio calculated is not correct.
11. Round off the cost ot 1000.
12. Heat exchanger too small.
13. What is the vessel XX residence time?
14. Why you need N2 blanket for the mixer?
15. Please use standardized unit in your equipment sizing (not to mixed up the
SI unit with British unit).
16. Revise equipment sizing.
17. Hazop needs to add mitigation, not only alarm.
18. Storage tank size not logical.
19. Utility capital cost doubtful.
20. Include safety system in HAZOP.
Questions & Answers