ChE 405: Process Design – I

Course outline

Dr. Syeda Sultana Razia

Professor
Department of Chemical Engineering, BUET

Chemical Engineering Design

 Let’s Start with the basics…
• What is Chemical Engineering?
• Starting from a vaguely defined problem statement
such as a customer need or a set of experimental
results, chemical engineers can develop an
understanding of the important underlying physical
science relevant to the problem and use this
understanding to create a plan of action and set of
detailed specifications which, if implemented, will lead
to a predicted financial outcome.

• What are the differences between Chemistry and

Chemical Engineering? Mechanical Engineering
and Chemical Engineering? 2

Chemical Engineering Design

 Chemical Engineering Project

• Phase 1 :Process Design

• Covers steps from initial selection of the process to be
used through to the issuing of process flowsheets and
includes selection, specification and chemical
engineering design equipment

• Phase 2:Plant Design

• Includes detailed mechanical design to equipment, the
structural, civil, and electrical design and specifications
and design of ancillary services

Chemical Engineering Design

 Process Design vs Plant Design
• Process engineering is used in connection with economic
evaluation and general economic analyses of industrial
processes, while process design refers to the actual design
of the equipment and facilities necessary for carrying out
the process
• The general term plant design includes all engineering
aspects involved in the development of either a new,
modified, or expanded industrial plant. plant design is
directly to the complete plant, such as plant layout, general
service facilities, and plant location.
• Role of a chemical engineer as a design engineer:
– making economic evaluations of new processes, designing
individual pieces of equipment for the proposed new venture, or
developing a plant layout for coordination of the overall operation.
Chemical Engineering Design
 AIChE Code of Professional Ethics:
Fundamental Principles
• Engineers shall uphold and advance the integrity, honor,
and dignity of the engineering profession by
– Using their knowledge and skill for the enhancement
of human welfare
– Being honest and impartial and serving with fidelity
the public, their employers and clients
– Striving to increase the competence and prestige of
the engineering profession

Chemical Engineering Design

 AIChE Code of Professional Ethics:
Fundamental Canons
• Engineers shall hold paramount the safety, health and
welfare of the public in the performance of their
professional duties
• Engineers shall perform services only in areas of their
competence
• Engineers shall issue public statements only in an
objective and truthful manner
• Engineers shall continue their professional development
throughout their careers and shall provide opportunities
for the professional development of those engineers
under their supervision

Chemical Engineering Design

 Where is Design used in
Industry?
• New Process design: less than 5% design
activity of industry
• Plant design of established processes : 45% of
industrial design activity
• Plant Improvement/modifications :
– Debottlenecking Plant
– Increase Plant Capacity
– Increase Plant Efficiency
– Decrease Costs
– Pollution Minimization
50% of industrial design activity
Chemical Engineering Design
Importance of Process Design

Chemical Engineering Design

 Importance of Process Design

• In Preliminary Process Design

– 98% Operating Costs Committed
– 80% Capital Costs Committed

• Less than 10% $ Spent

Design is Very Important

Chemical Engineering Design

Typical Design Steps for Chemical
and Biochemical Processes

Chemical Engineering Design

Chemical Engineering Design
 How is Design Practiced
• Process Conception •Detailed Design
• Preliminary Design •Mechanical Engineering
– Process Concepts •Equipment +
– Process Economics Supports
• Management decision to go •Where are all the
forward nuts and bolts
• Intermediate Design •Piping elevation
– P&ID’s •Electrical/Power
– Ask vendors for prices Engineering
major pieces of equipment •Utilities
• Reactor, Separators, •Process Economics
HX, Utilities, tank farms •Management decision to go
– Process Economics forward
• Management decision to go
forward

Chemical Engineering Design

 Process Design Related Courses in
ChE,, BUET
ChE
• ChE 405: Process Design I ( 3 credit)
– Objective: Design consideration, Equipment design,
Economic analysis and profitability

• ChE 407: Process Design II (2 credit)

– Objective: Project engineering: steps required to
complete a chemical plant project

• ChE 408: Plant Design sessional (4.5 credit)

– Objective: Conceptual Design, Process diagrams,
Layouts, Calculations and Documentations

Chemical Engineering Design

 Course Information
• Course No. ChE 405 (3 credit hours)
• Name of the course: Process Design-I
• Hours per week: 3 (Saturday, Monday and Wednesday)
• Room no. OAB 254
• Instructors: Dr. Syeda Sultana Razia and Dr. Ruhul
Amin
• Text Book:
– Max S Peters, Klaus D Timmerhaus, Ronald E. West; Plant
Design and Economics for Chemical Engineers (5th Edition)
McGraw Hill, 2003
– Gavin P. Towler, R. K. Sinnott; Chemical Engineering Design:
Principles, Practice, and Economics of Plant and Process Design
(2nd Edition) Elsevier, 2013
– Daniel A Crowl, Joseph F. Louvar; Chemical Process Safety:
Fundamentals with Applications (3rd edition) Prentice Hall, 2011

Chemical Engineering Design

 Course Outline
• Introduction to Chemical Engineering Design
• General Design Considerations
• Process Design Development
• Analysis of Cost Estimation
• Optimum Design and Design strategy
• Materials and Fabrication Selection
• Design and Costs of
– Materials Handling equipment
– Vessels
– Reactors
– Separation equipment
– Heat transfer equipment
Chemical Engineering Design