Department of Chemical Engineering
Process Design IV (PQD470S) – Project and Process Simulation
Service Learning Project
The Service Learning Project is a form of experiential learning activity in which students participate
by applying knowledge from their field in a project that yields practical benefits. At the same time,
the project must fulfil the rigour and scope of a chemical engineering design project at Advanced
Diploma level.
Introduction
There is scope for the Department of Chemical Engineering to extend the existing pilot plant facilities
and equipment, some of which have lain dormant for over a decade, to perform pilot plant or semi-
industrial scale processes, or to use in community based projects, involving small batch distillation of
fermented products. Examples of such projects include the production of fruit spirits, and the
recovery of ethanol from fermentation of biomass. The availability of such a facility would make it
possible to investigate the preceding fermentation stages at pilot plant scale for research and
process design purposes.
The existing equipment comprises a distillation unit, with a steam generation unit and a cooling
tower. It has not been used in more than a decade, and thus its processing capacity is currently
unknown. Nevertheless, it should be possible to, based upon the ratings of each individual unit,
develop a process model and use it to investigate the feasibility of performing small batch processes.
The cost of such a process can be estimated, and thus providing a basis for the determination of the
technical and commercial feasibility of a proposed process.
Problem Statement
Suggest a small batch distillation process that can be carried out using the semi-industrial scale
equipment located in the Chemical Engineering Pilot Plant Laboratory in the Old Building. Using the
known characteristics of each equipment, develop a process model for your suggested process and
determine the commercial feasibility of your process.
Perform a practical inspection of the distillation unit, steam generation plant and cooling tower Pay
particular attention to the ratings details on the name-plates, and the dimensions of each unit.
Request for operational manuals if available, or look up the equipment on the internet if needs be.
Use the information to develop a process model using a computer package (spreadsheet or process
simulator).
Execution
The project will be performed in groups of four. Equal participation and contribution is expected
from each group member.
Report
Present your process development in the form of a report that includes the following sections:
Process Concept, Material balance, Unit Sizing, Process Model Development, Environmental and
economic Impact.
Evaluation
The evaluation rubric is attached.
Alignment with Graduate Attributes
SECTION Responding to which GA
1. Process concept 2.1: Problem solving: Learning outcome: Apply
Generate a process concept, and synthesise a production engineering principles to diagnose and solve broadly-
process that utilises the three units described, plus any defined engineering problems systematically. (See
other process units of your choice. document E-02-PT for Level Descriptor for broadly-
defined engineering problem).
2. Material Balance 2.2: Application of scientific and engineering
Perform a material balance for a given production knowledge: Learning outcome: Apply knowledge of
capacity and estimate all major material streams. mathematics, natural science and engineering
sciences to define and applied engineering
procedures, processes, systems and methodologies
in order to solve broadly-defined engineering
problems. (See document E-02-PT for Level
Descriptor and Range Statement)
3. Unit sizing 2.3: Engineering design: Learning outcome: Perform
Perform a detailed sizing calculation for one process unit procedural and non-procedural design of broadly
(distillation column, steam generator or cooling tower) defined components, systems, works, products and
and determine the utility requirements for your chosen processes within applicable standards, codes of
process. practice and legislation to meet desired needs. (See
document E-02-PT for Range Statement for GA
4. Process model development 2.5: Engineering methods, skills and tools, including
Develop a steady state or batch process model using a information technology: Learning outcome: Use
process simulator, and use your process model to appropriate techniques, resources and modern
simulate your process at the envisaged production engineering tools, including information technology,
capacity. prediction and modelling for the solution of broadly-
defined engineering problems, with an
Determine the sensitivity of the product quality to mild understanding of the limitations, restrictions and
disturbances (+-10%) changes in the performances of premises. (See document E-02-PT for Range
one of the process units or utility supplies. Statement for GA 5)
5. Environmental and economic impact 2.7: Sustainability and impact of engineering
Perform a preliminary environmental impact assessment, activity: Learning outcome: Demonstrate knowledge
a gross profit analysis, and point and indicate the zones and understanding of the impact of engineering
requiring safety instrumented systems. activity on the society, economy and industrial and
physical environment and address issues through
What role does your type of process pay in the economy analysis and evaluation. (See document E-02-PT for
in general? Range Statement for GA.
