BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, Pilani Pilani Campus AUGS/ AGSR ion FIRST SEMESTER 2020-21 COURSE HANDOUT Date: 18.08.2020 In addition to Part I (General Handout for all courses appended to the Time Table), this portion gives further specific details regarding the course. Course No. : CHE F314 Course Title : Process Design Principles I Instructor-in-Charge SURESH GUPTA Instructor (Tutorials) + HK Mohanta, Smita Raghuvanshi, Anil Kumar K Course Description Process invention using heuristics and analysis (The Design process, Process creation and heuristics for process synthesis, Role of process simulators like Aspen Plus in process creation), Strategic designs in process synthesis and analysis, Detailed process synthesis using algorithmic methods with emphasis on reactor networks, separation trains, batch processes, heat and mass integration, energy integration analysis; pinch technology. Scope & Objective This course introduces the student to the strategy of process engineering and provides an insight into various aspects of process design. This course mainly deals with the process synthesis part of process design. It covers in detail the preliminary process synthesis, developing base case design and use of heuristics for choosing the best from various process alternatives. ‘Text Books Tl Warren D. Seider, J. D. Seader, and Daniel R. Lewin, “Product & Process Design Principles: Synthesis, Analysis, and Evaluation”, Wiley-India Edition, India, 2° Edition (2004), 12 JamesM_ Douglas, “Conceptual Design of Chemical Processes” MeGrawHill, New York, International Edition (1988), Reference Books: RI Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph A. Shaeiwitz, and Debangsu Bhattacharyya, “Analysis, Synthesis, and Design of Chemical Processes", Intemational Edition, Pearson Education International, New Jersey (2012). R2 Robin Smith, “Chemical Process Design”, Intemational Editions, McGraw Hill, Singapore (2000) R3___ Dale F. Rudd, and Charles C. Watson, “Strategy of Process Engineering”, John Wiley & Sons, New York (1968).BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, Pilani Pilani Campus AUGS/ AGSR ion Course Plan Module | Lecture session/Tutorial | References Learning outcomes session Introduction | LT. Introduction to Process | Ch. 1 of TI Apply the creative aspects and generate to process | Design Principles: Process | and T2 ideas for producing new materials & synthesis | Synthesis and Analysis. upgrading the existing materials and analysis [2. Creative aspects, Ch. 3 0f TI Develop hierarchical approach to conceptual Hierarchical approach to | and Ch. 1 of design and demonstrate using a case study conceptual design, HDA | T2 Generate all the five levels of hierarchy of Process. process flow sheets from the detailed flow 3. Preliminary Process sheet Synthesis with examples. TI. Practice problem on Hierarchical approach to conceptual design Economic | L4. Engineering Ch. 20FT2 Collect the cost information required and to Decision | Economics for Conceptual calculate capital and operating costs using Making | Design, important cost different methods as well as using simplified terms cost models depending upon the data 15-9. Design of asolvent | Ch. 3 of T2 availability recovery system, Problem List and compare the possible alternatives definition, Design of a gas for a given case study with the help of absorber, Flow sheet, important aspects associated with the material and energy economic decision making balances, and stream costs, Apply the design aspects associated with Equipment design various unit operations and to discuss the considerations, Rules of effect of various design variables on thumb. equipment design considerations Carryout the sensitivity analysis with respect to design variables & and process parameters and to cite the limitations of rules of thumb (heuristics) for various possible cases Process | LI0-IT. Concepts of Ch. 4 of TT Initial concept of process simulator in Simulation | process simulation, Steady | and Class obtaining data and carrying out material and and unsteady state notes energy balance simulation, Introduction to Development of process flow sheet in Aspen Plus. ASPEN HYSIS software. Input [C1214 Input information, [ Ch. 4 of T2 List the required input information for a Information | Level-I decision (Batch vs. given problem and to demonstrate the and Batch | continuous), Systematic importance of input information at the start vs, procedure for the design of of conceptual design Continuous | batch processes. Economic To apply the heuristics and to propose the Potential (EP-1). guidelines for selection of batch processes Ys, continuous processes Tnput- | L15-18. Level-2 Decisions | Ch. 5 of T2 Apply the decisions required to be made for Output | (input-output structure), different aspects at level-2 (Input-Output Structure of | Design variables, structure of the flow sheet) of economic the Flow | Selectivity and reaction decision making sheet__| stoichiometry, OverallBIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, Pilani Pilani Campus AUGS/ AGSR ion material balances, Stream ‘Identify the possible design variables and to costs, Process alternatives, list the information required to develop the Economic potential (EP-2). material balances at level-2 (input-output structure) Estimate the economic potential at level-2 (EP2) and to find alternatives at this level by relaxing some of the assumption made Recycle _ | L19-23. Level-3 Decisions | Ch. Gof TI | * Estimate the number of reactor systems and Structure of | (Recycle structure), and Ch. 6 of the number of recycle streams required for a the Flow | Recycle material balances, | T2 given process at level-3 (recycle structure) sheet Reactor heat effects, ‘© Develop the recycle material balances and Equilibrium limitations, to compute the various flows associated Compressor design and with a recycle structure of process flow costs, Reactor design, sheet Economic potential (EP-3). © Estimate the economic potential at level-3 (EP3) and to show the effect of design variables on EP3 Separation | 124-26, General structure, [ Ch. 7oFTI | Generate the possible alternatives for the System | Vapor recovery system, | and Ch. 7 of ‘general structure of flow sheet and to Liquid separation system, | T2 examine the phases of the reactor effluent Azeotropic systems, stream Rigorous material ‘Discuss the decisions associated with vapor balances, Economic recovery systems and to find the sequence potential (EP-4), of separation systems © Develop rigorous material balances (linear material balancing) and to estimate the economic potential at level-4 (EP4) for the general structure of a flow sheet Energy | L27-37. Heat-Exchanger | Ch. 10 of TT_[ + Estimate the net heat available in the given Integration | Network Synthesis and Ch. 8 of process plant using I & II law of Analysis | (HENS), First law analysis, | 72 thermodynamics Cascade diagrams, ‘© Identify the appropriate pinch and hot & ‘Temperature-Enthalpy cold utililty requirements from the cascade Diagrams, Grand diagram composite curve, Multiple ‘Draw the temperature-Enthalpy diagram utilities, Area estimates, and estimate the total area requirement, « Design of MER Networks, priori, network proposal Loops and paths, Final © Generate design alternatives in terms of design, Stream splitting, feasible matches in the network and Complete design propose the MER (maximum energy algorithm, Heat and power recovery or minimum energy requirement) integration. network ‘Propose the final Heat Exchanger Network after breaking all the loops and restore ATnin as and when there is a violation Mass | 138-40. Introduction, Ch. TT of TT_| Able to compute the minimum usage of external Integration | Minimum mass separation mass-separating agent (MSA) agent, Mass exchanger Able to design mass exchanger network (MEN) networks. which meets minimum operating cost targetBIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, Pilani Pilani Campus AUGS/ AGSR ion Evaluation Scheme EC m component | Duration | Weightage Date and time Nature of No. (Minutes) | (100) component 1 30 5 Closed Book 2 30 15 Closed Book 3 30 15 Closed Book 2_[ Quizes/Assignment = 20 = ‘Open 4 | Comprehensive 120 35 ‘Open Book Examination “Total three surprise tests will be conducted. Out of these, the performance in best two surprise tests will be considered for final evaluation “Conceptual design oriented problems/case studies will be given as Assignment, Chamber Consultation Hour: To be announced in the class. Make-up policy: Make-up will be granted only for genuine reason(s) (medical ground only) for not appearing in the regular test. Proper proofs (medical certificate, prescription etc. from Medical Center) must be submitted along with Make-up application, Prior permission of IC is compulsory Notices: All notices concerning this course will be displayed on the Notice Board of Chemical Engineering Department and will also be available online on Google Classroom Portal. Instructor-in-charge CHE F314