CAPE3000 DESIGN PROJECT (2019-20)

PLANT EQUIPMENT DESIGN REPORT

DESIGN OF … NAME OF THE EQUIPMENT …

PROJECT TITLE: …. As in the Part 1 Report (in

upper/lower case)…..

NAME OF STUDENT: ….…. (in upper/lower case)

GROUP NUMBER: ……..

SUPERVISOR: …Name of the supervisor (in upper/lower

case)

SUBMISSION DATE: 19 March 2020

All report writing instructions given in this template must be removed from the
submitted final report.
Style of report writing: For details, see Appendix 1 (page 6/7) of the Briefing Document for
Part-1 Report.
The report should be typed in 12 point for Times New Roman font or 11 point for Arial font
with 1.5 line space, leaving a margin of about 20 mm at each edge and at the top and bottom
of each page.

EXECUTIVE SUMMARY
1
Page limit: 1 page
State clearly/consciously the scope of the equipment design work. You should provide a
concise and design task outcomes-driven summary and a specific statement of your findings.
It should provide the reader with an overview of the content of the entire report together
with a summary of the most important findings.

2
ACKNOWLEDGEMENTS

Acknowledgments should be made to all who have advised you in carrying out the design
work. You should also include a signed statement attesting that, unless explicitly mentioned
in the References section, the report contains your own work.

3
TABLE OF CONTENTS

Provide a table identifying the titles of each chapter and the headings of its
sections/subsections (with numbers) and the page number they begin on.

4
NOMENCLATURE
Symbols should be used consistently throughout the report. They must be defined and units in
the SI system must be provided. A list of symbols with associated units and Dimensionless
Groups is given below (also available in the Learning Resources in the Module Minerva).
Symbols/Dimensionless Groups not used in the report must be deleted.

Quantity Symbol SI Unit

Absorptivity (radiation) α -
Activation energy of a reaction ∆E J kg-1 = m2 s-2
Amount-of-substance N mol
molar flow rate Ṅ mol s-1
molar 'mass' velocity (=Ṅ Ac-1) ṅ mol m-2 s-1
Angle
α, β, γ,
plane θ, φ rad
solid Ω (ω) sr
of contact θ rad
Area
cross-sectional Ac (S) m2
surface A (As) m2
Coefficient of cubic expansion
[ ¿ v−1 ( d v /d T ) p ] β K-1
Compressibility factor (=p v̇/RT) Z -
Concentration
mass (=M/V) c kg m-3
molar (=N/V) c̃ mol m-3
Coordinates
cartesian x, y, z m, m, m
cylindrical r, φ, z m, rad, m
spherical r, φ, θ m, rad, rad
Density
mass (=M V-1) ρ kg m-3
molar (=N V-1) ~ρ mol m-3
relative (usually to water) dr -
Diffusion coefficient D m2 s-1
thermal DT m2 s-1
Diffusivity δ m2 s-1
thermal κ m2 s-1
Dryness fraction (=quality) x -
of flow x* -
Emissivity (radiation) ε -
Energy E J = kg m2 s-2
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 kinetic Ek J = kg m2 s-2
potential Ep J = kg m2 s-2
transfer per unit time (power) Ẇ, Q̇̇ W = kg m2 s-3
Enthalpy (=U+pV) H J = kg m2 s-2
specific, molar h, h̃ J kg-1 , J mol-1
of phase change at constant p
fusion hsl, h̃sl J kg-1 , J mol-1
sublimation hsg, h̃sg J kg-1 , J mol-1
evaporation hlg, h̃lg J kg-1 , J mol-1
of reaction ∆ H⊖ J = kg m2 s-2
Entropy S J K-1 = kg m2 s-2 K-1
specific, molar s, s̃ J kg-1 K-1 , J mol-1 K-1
of phase change at constant p
fusion ssl, s̃sl J kg-1 K-1 , J mol-1 K-1
sublimation ssg, s̃sg J kg-1 K-1 , J mol-1 K-1
evaporation slg, s̃lg J kg-1 K-1 , J mol-1 K-1
Equilibrium (dissociation) constant
a
K -
Force F N = kg m s-2
weight (force of gravity) Mg N = kg m s-2
Fraction
mass, of species i xi, yi -
mole, of species i x̃i, ỹi -
void ε -
of volume flow ε* -
Frequency f Hz = s-1
circular ω rad s-1
Gas constant
J mol-1 K-1 = kg m2 s-2 mol-1
molar (universal) R̃ K-1
specific, of species i Ri J kg-1 K-1
Gibbs function (=H-T S) G J = kg m2 s-2
specific (= h - T s) g J kg-1 = m2 s-2
molar (=h̃ - T s̃) g̃ J mol-1 = kg m2 s-2 mol-1
Gravitational acceleration g m s-2
standard gn m s-2
Heat
quantity of Q J = kg m2 s-2
rate (power) Q̇ W = kg m2 s-3
flux (Q̇A-1) q̇ W m-2 = kg s-3
Heat capacity C J K-1 = kg m2 s-2 K-1

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 specific (constant ν or p) cν, cp J kg-1 K-1 = m2 s-2 K-1
J mol-1 K-1 = kg m2 s-2 mol-1
molar (constant ν or p) c̃ν, c̃p K-1
ratio cp/cν γ -
Heat transfer coefficient α (h) W m-2 K-1 = kg s-3 K-1
overall U W m-2 K-1 = kg s-3 K-1
Helmholtz function (U - T S) F J = kg m2 s-2
specific (= u - T s) f J kg-1 = m2 s-2
~
molar (=~ u−T ~s) f J mol-1 = kg m2 s-2 mol-1
Internal energy U J = kg m2 s-2
specific, molar u, ũ J kg-1, J mol-1
of phase change at constant p
fusion usl, ũsl J kg-1 , J mol-1
sublimation usg, ũsg J kg-1 , J mol-1
evaporation ulg, ũlg J kg-1 , J mol-1
of reaction ∆U⊖ J = kg m2 s-2
Joule-Thompson coefficient
[= (dT/dp)h] μJT m2 K N-1 = m s2 K kg-1
Length ℓ (L) m
diameter d (D) m
radius r (R) m
breadth b (B) m
height z (Z) m
width w (W) m
thickness δ (∆ℓ) m
distance along path s m
liquid film thickness δ m
Loading
mass of species i Xi, Yi -
molar, of species i X̃i, Ỹi -
Mass M kg
flow Ṁ kg s-1
flux (flow per unit area = Ṁ Ac-1) ṁ, ρ u kg m-2 s-1
flux of species i ṁi, ρi ui kg m-2 s-1
Mass transfer coefficient βm (k) m s-1
Molar mass M̃ kg mol-1
Mean free path λ̃ m
Moment of force (vector product) Fxr N m = kg m2 s-2
Pressure p Pa = N m-2 = kg m-1 s-2
drop ∆p Pa = N m-2 = kg m-1 s-2
partial of species i pi Pa = N m-2 = kg m-1 s-2
Reaction
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 rate of species i ri mol m-3 s-1 or mol kg-1 s-1
rate constant of species i k various
extent of reaction of species i ξ i , ξ̇i mol, mol s-1
fraction of conversion of species i γi -
Reflectivity (radiation) ρ -
Relative mass
atomic Ar -
molecular Mr -
Shear stress τ Pa = N m-2 = kg m-1 s-2
Stoichiometric coefficient ν -
Surface tension σ N m-1 = kg s-2
Temperature
absolute T K
Celsius (= T - 273.15 K) TC °C
difference or interval ∆T K
logarithmic mean difference ∆T̅ln K
Thermal conductivity λ (k) W m-1 K-1 = kg m s-3 K-1
Time t s
Torque, moment of couple
(vector product) Fxr N m = kg m2 s-2
Velocity u m s-1
components in Cartesian
coordinates, x, y, z u, v, w m s-1
View factor (geometric or
configuration factor) F 12 sr
Viscosity
dynamic (absolute) η (μ) Pa s = N s m-2 = kg m-1 s-1
kinematic (=η ρ-1) ν m2 s-1
Volume V m3
flow rate V̇ m3 s-1
specific, molar v,~v m3 kg-1, m3 mol-1
Work W J = kg m2 s-2
rate (power) Ẇ W = kg m2 s-3
Wavelength λ m

Dimensionless Groups

Name Notation Formula Interpretation

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 Heat Transfer αL surface conductance  conduction
Bih
Biot number λs of heat
Mass Transfer βm L surface conductance  conduction
Bim
Biot number D AB of mass
2
g ( ρ l− ρ g ) L gravitational forces  surface
Bond number Bo
σ tension forces

Coefficient of τ
Cf dimensionless surface shear stress
friction ρ ~u 2 /2
u2
~ kinetic energy of the flow 
Eckert number Ec enthalpy difference of the
c p ( T w −T b ) boundary layer
λs t Kt rate of conduction of heat  rate
Fourier number Foh 2
=
ρc p L L2 of storage of energy
Mass transfer D AB t rate of species diffusion  rate of
Fom
Fourier number L 2 storage of species
~u
Froude number Fr inertial forces  gravity forces
√ gh
Δp dimensionless pressure drop for
Friction factor f 2
( L/d ) ( ρ ~
u /2 ) internal flow
~
d u ρc p d d heat transfer by convection in the
Graetz number Gz × = RePr entrance regionheat transfer by
L λ L conduction
ρ2 gβΔ TL3
μ2
Grashof number Gr buoyancy force viscous force
gβ ( T s −T ∞ ) L3
¿ 2
υ
Colburn j factor 2 /3 dimensionless heat transfer
jh St h Pr
for heat transfer coefficient
Colburn-Chilton j
dimensionless mass transfer
factor for mass jm St m Sc2/3 coefficient
transfer
c p ( T w −T sat ) sensible heat  latent heat
Jakob number Ja
h fg +
Sc μ λ K diffusion of heatdiffusion of
Lewis number Le = × =
Pr ρ D AB c p μ D AB mass
αL temperature gradient at the wall
Nusselt number NuL
λf overall temperature difference
~
u ρc p L heat transfer by convection heat
Peclet number PeL =RePr
λ transfer by conduction

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 μ cp υ diffusion of momentumdiffusion
Prandtl number Pr =
λ Κ of heat
~u ρL ṁ L
Reynolds number ReL = inertia forces viscous forces
μ μ
μ υ diffusion of momentum 
Schmidt number Sc =
ρD AB D AB diffusion of mass
Sherwood βm L concentration gradient at the wall
ShL
number D AB  overall concentration difference
Heat transfer
Stanton number α α Nu heat transfer at the wallenergy
Sth = =
(Modified uρ c p ṁc p Re ×Pr transport by the stream
Nusselt number)
Mass transfer
Stanton number β m Sh mass transfer at the wall mass
(Modified Stm =
~u Re ×Sc transport by the stream
Sherwood
number)
2
Weber number We
ρ~
u L inertial forces  surface tension
σ forces

Subscripts and superscripts

Quantity Symbol
Bulk b
Free-stream s
Wall w
Fluid (Liquid or gas) f
Solid or saturated solid s
Liquid or saturated liquid l or f
Gas or saturated vapour g
Saturated sat
Change of phase at constant p
Fusion sl or sf
Sublimation sg
Evaporation lg or fg
Critical state c
Inlet in, 1
Outlet out, 2
At constant value of property p, v, T, etc
Mean ❑´
Molar (per unit of amount-of-substance) ~
❑
Stagnation (subscript) 0
At standard state (superscript)
p⊖=1 ×10 5 N m 2=1 ¯¿ ⊖
0
T =298.15 K 0
Radiation between two surfaces 12
Transfer between species AB
10
Heat transfer h
Mass Transfer m

ABBREVIATIONS

Provide a list of abbreviations if used in the report.

11
Chapter 1: INTRODUCTION

This report should be self-contained - provide the project brief and the final PFD (without
stream data tables) used in Part 1 Report. State clearly (highlighting in the PFD) which piece
of equipment and auxiliary units are designed, its function and design basis/requirements. The
final PFD with stream data tables should be provided in the Appendix.
A PFD (using the standard flowsheet symbols) of the equipment and auxiliary units (with
names/codes as in the Part-1 Report PFD) showing all streams entering/leaving the equipment
(stream numbers should be the same as in the Part 1 Report PFD) with flow rates,
compositions, phases, temperatures and pressures must be provided.

Note: This will be assessed under “Presentation of Design Basis” in the Chemical
Engineering Design (see the marking scheme).

Throughout the report, information obtained from literature and from handouts
must be fully acknowledged with proper references (including page/slide numbers).
Proper cross-reference to link information, data, calculations, figures/table etc.
within the report should be used.
Texts from CAPE3000 module/technical briefing documents and handouts must not
be copied directly into the report without proper paraphrasing and referencing.
The University’s published rules on plagiarism and academic malpractice must be
read, understood and followed (see for details, Dr Cochrane’s lecture slides) in order
to avoid high Turnitin similarity scores which will trigger plagiarism investigation.

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Chapter 2: CHEMICAL ENGINEERING DESIGN
Chapter weighting: 50%

2.1 Selection of Main Plant Equipment

The reasons for the choice of a particular type of equipment (including internal components)
where more than one option exists must be given.

2.2 Design of Main Plant Equipment

2.2.1 Design calculations
The detailed calculations using appropriate methodologies for sizing the main equipment must
be presented clearly. All major components of the equipment must be covered in the
calculation. All calculations must be carried out using SI system of units. Data obtained from
literature in different units must be converted to SI units. The symbols provided in the
Nomenclature must be used. All assumptions must be stated clearly and justified. Reliable
physical/thermochemical data and correlations must be used and referenced adequately.

2.2.2 Pressure drop

Present calculation of pressure drop through the equipment.

2.2.3 Insulation thickness

If required, present calculation of insulation thickness.

2.2.4 Performance prediction of clean heat exchanger

When a heat exchanger is designed as the main equipment, its performance prediction for
clean operating conditions must be carried out.

2.3 Overall Sizing of Auxiliary Items

A short-cut design (overall sizing) of auxiliary items, which are integral parts of the main
equipment, should be included here. For details, see page 4 of the briefing document.

2.4 Equipment Specifications

Provide a specification sheet of the main equipment containing calculated design data.

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Chapter 3: PIPELINE SYSTEM DESIGN
Chapter weighting: 15%

3.1 Optimum Pipe Diameters

Calculate optimum/economic diameters of the pipelines connecting the main equipment with
upstream and downstream plant items.

3.2 Materials of Construction of Pipes

Specify with justifications materials of construction of pipes.

3.3 Standard Pipe Sizes

Specify standard pipe sizes, including inner/outer diameters & wall thickness and Schedule
number, based on the optimum diameter calculated in Section 3.1.

3.4 Isometric Drawing of Pipelines

Present an isometric drawing of the pipelines containing appropriate valves and pipe fittings.
Specify lengths of different sections of the pipelines.

3.5 Pressure Drop

Calculate pressure drop through the pipelines.

3.6 Fluid Motive Devices

If needed, specify the types of fluid motive devices (i.e., pump, fan, blower or compressor) and
calculate power requirements.

14
Chapter 4: MECHANICAL ENGINEERING DESIGN OF
MAIN EQUIPMENT

Chapter weighting: 10%

4.1 Materials of Construction

Specification of materials of construction of the main equipment with justifications.

4.2 Vessel Details

Calculate wall thickness of the main vessel (i.e., equipment). Specify the types of vessel heads
(i.e., top and bottom or both ends) with justifications.

4.3 Openings and Connecting Pipes/Nozzles

Calculate sizes of the openings and connecting pipes/nozzles. Specify types of joints.

15
Chapter 5: ENGINEERING DRAWING OF MAIN
EQUIPMENT

Chapter weighting: 5%

Provide a good quality, scaled drawing of the main equipment (not a block or line diagram)
and show all dimensions.

Show all branches & nozzles in their exact positions and the details of the internals, e.g.,
baffles, linings, support grids, agitators, plates, etc. For details, see page 4 of the Module
Briefing Document, S2.

16
Chapter 6: CONTROL OF MAIN EQUIPMENT

Chapter weighting: 10%

6.1 Objective of Control

Describe the principal objective of controlling the main equipment. Identify the controlled and
manipulated variables.

6.2 Control Scheme

Select an appropriate control scheme (e.g., feedback, feedforward, or cascade control) with
justifications and describe with a schematic block diagram.

6.3 Instrumentation
Identify the key process parameters need to be measured, monitored and integrated with
the control loop. Specify the types of instruments for the measurement of process variables.

6.4 P&I Diagram

Provide a P&ID to show the control scheme.

17
Chapter 7: COST ESTIMATION
Chapter weighting: 5%

7.1 Main Equipment

Estimate the cost of the main equipment and describe the basis/method used. Specify the
accuracy. Provide the source of data.

7.2 Auxiliary Items

Estimate the costs of the auxiliary items (such as pump, valves, etc.). The above points should
be taken into account.

18
Chapter 8: CONCLUSIONS

The conclusions should summarise your report and pull together the information in the
individual chapters: it should not contain any additional discussion.

Check the final document for English and editorial errors (e.g., typos, grammar, spelling,
etc.)

The page limit for the main body of the report is 45 pages. The page count starts
from the Introduction and finishes at the end of Conclusion (here).
Penalties will be applied for exceeding the page limit at a rate of 1 point per page.

19
REFERENCES

You must provide a list of references detailing the literature you have used as sources of
information for your project here.

Provide a list of references detailing the literature you used as sources of information for your
project.
Use a consistent method of referencing and abbreviating titles of journals and if possible quote
the ISBN for a book. If a particular piece of information has been taken from a source then
that source should be properly referenced, down to the page number(s).
Specific advice/suggestion given by your consultant/supervisor which you have used in the
work must be cited in text only as Personal Communications. In-text examples: …….. (A. B.
Jones, personal communication, month date, year) ......... or A. B. Jones (personal
communication, month date, year)……..

Two hard copies of the report should be suitably bound using a spiral or a coil binding with
card front/back covers and a clear plastic sheet at the front. Reports submitted in a lever arch
file or ring binder will not be accepted.

For details on the submission procedure see Appendix 1 of the Module Briefing Document
for S1.

20
APPENDIX A: TIMESHEET OF MEETINGS WITH
CONSULTANTS

Include the signed timesheet of weekly meetings with consultants.

APPENDIX B: MINUTES OF MEETINGS WITH SUPERVISOR

Include minutes of all weekly group meetings with your supervisor.

APPENDIX C: ……Title ………





APPENDIX ?: ……Title ………

Examples of other materials which could be included in the above appendices:

 Final PFD with stream data tables (from Part-1 Report),
 Derivations of equations,
 Graphs/charts from literature,
 Thermophysical property tables from literature,
 Large drawings,
 Auxiliary calculations/tables (not for assessment, only for information).

Important calculations must not be presented in an appendix.

All instructions given in this document must be removed from the final
submitted report.

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