PROCESS PLANT DESIGN PROJECT 2020/2021 Rev : 2

PROGRAM KEJURUTERAAN KIMIA

FAKULTI KEJURUTERAAN & ALAM BINA

UNIVERSITI KEBANGSAAN MALAYSIA

PROCESS PLANT DESIGN PROJECT

SEM 1 (KKKR4774) & SEM 2 (KKKR4852)

2020/2021

PRODUCTION OF RAW MATERIAL FROM

RENEWABLE RESOURCES FOR
NON-ALCOHOL-BASED HAND SANITIZER

PROGRAM KEJURUTERAAN KIMIA Page 1

FAKULTI KEJURUTERAAN & ALAM BINA
UNIVERSITI KEBANGSAAN MALAYSIA
PROCESS PLANT DESIGN PROJECT 2020/2021 Rev : 2

1.0 OVERVIEW

This project serves as a tool to assess the ability of the students to solve an assigned practical
chemical engineering design problem by working in a team. The exercise simulates an actual scenario
of a team of chemical engineers who are required to come up with a design of a process plant of
production of a desired product, and present their proposal or recommendation to the relevant
stakeholders such as the company’s top management or potential investors. This project will
challenge the students to not only apply fundamental chemical/ biochemical engineering principles
in performing their tasks, but also their research and analytical skills in searching for supporting data
readily available from secondary sources. All information obtained must be attributed to their original
sources.

The students are required to write their report in English (UK). All terms and symbols must follow
the standard Scientific and Engineering terminology. The citation format for in-text referencing must
be in the form of name and date, while the listing of references in the reference section must follow
the UKM’s thesis writing style. The report should not contain more than 20,000 words in total and
must be printed in A4 size. All engineering drawings must follow BS or ANSI standard. All
mechanical unit drawings should follow ASME VIII.

All values must be reported in SI units. Students are expected to use computer-aided design software
programs such as iCON, HYSYS, SUPERPRO, VISIO and AutoCAD® as the tools to complete their
design task. They are expected to meet their respective supervisors on a regular basis or at least once
a week to consult on technical guidance as well as to report their work progress. Plagiarism is
strictly prohibited. Should any students be found to have plagiarised the work of others and
reproduced the plagiarised materials in their design reports, their marks will be penalised
accordingly.

The design project is divided into two semesters. In the first semester, students will conduct
preliminary feasibility study and detailed design work, and in the second, they will look into
improving the work performed in the first semester. The feasibility study and detailed design work
will be evaluated in a series of presentation, discussion, and feedback sessions. (Please refer to Table
1 for the tentative time (week) for these sessions). The actual date may change and will be
communicated accordingly. Students are expected to submit a progress report for each session/
section. In addition, students are required to give a presentation of their progress work in front of a
panel of judges among the academics of the department. Students will then be required to make all
the corrections and address all the comments/feedback received during their presentation/ discussion
sessions (four sessions in total) before the submission of their final design report. The submission of

PROGRAM KEJURUTERAAN KIMIA Page 2

FAKULTI KEJURUTERAAN & ALAM BINA
UNIVERSITI KEBANGSAAN MALAYSIA
PROCESS PLANT DESIGN PROJECT 2020/2021 Rev : 2

the final detailed design report and the final presentation are scheduled to take place in the 13 and
14th week of the first semester, respectively. Students will present their final report in front of
experienced lecturers and industrial experts, which will be followed by a comment and feedback
session.

Based on the comments/feedback received during the final presentation and evaluation in the first
semester, students are required to use the outcome of this discussion to improve their design in the
second semester. A group presentation on the improved design, alongside a constructed replica of the
designed chemical plant is scheduled to take place in the 7th week. In addition, each student will be
required to design one selected process unit. In this individual process unit design, a complete
mechanical drawing must be provided for this process unit in accordance with ASME VIII standard.
Finally, the very final version of the report must be submitted to the main office in the 13th week.
(Please refer to the Table 2).

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FAKULTI KEJURUTERAAN & ALAM BINA
UNIVERSITI KEBANGSAAN MALAYSIA
PROCESS PLANT DESIGN PROJECT 2020/2021 Rev : 2

The dates of evaluation and activities related to the final design work will be communicated in due
time. The following table shows the tentative week for presentation session and submission of
reports.

Table 1 Tentative week for presentation sessions and submission of reports in semester 1

Week No. (Semester 1) Task

1 Design project briefing

3 Presentation/ discussion on feasibility study and overall

material balance

5 Presentation/ discussion on conceptual design, preliminary

PFD, material and energy balances

7 Presentation/ discussion on PFD, conceptual design

9 Presentation/ discussion on PID, design of unit operation,

safety

11 Presentation/ discussion on process economic and waste

management

13 Submission of detailed design report

14 Presentation on detailed design

14 Comment/ feedback session

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FAKULTI KEJURUTERAAN & ALAM BINA
UNIVERSITI KEBANGSAAN MALAYSIA
PROCESS PLANT DESIGN PROJECT 2020/2021 Rev : 2

Table 2 Tentative week for presentation sessions and submission of reports in semester 2

Week No. (Semester 2) Task

3 Presentation/ discussion on HAZOP/PID after HAZOP/

safety
5
Presentation/ discussion on detailed process
design/mechanical drawing

7 Presentation on the Improved Detailed design, mechanical

drawing and Chemical Plant Replica

7 Comment/ feedback session

13 Submission of Final Report

Students are grouped into a team of five or six members with the group name labelled as 1 through
15. For the 2020/2021 academic year, students are required to design and propose an economically
and commercially viable production plant of raw material for non-alcohol hand sanitizer production.
The feedstock must be from renewable resources such as plants. Students are allowed freedom in
making reasonable assumption when setting the production rate, but the decision made must be
supported based on appropriate consideration of various factors such as market demand, feedstock
availability, safety and health, etc. Students are also expected to relate to and highlight the
sustainability aspects of the process to demonstrate efforts towards supporting the sustainable
development initiative by our government. This project requires an excellent teamwork, whereby
each group is required to search for and gather all the necessary information pertaining to the
production processes, which include as well good manufacturing practice (GMP). Students can gather
the information such as process description, reaction equations, kinetic and thermodynamics data,
feed material, product output purity and others by various means and from various sources such as
the library, journals, news clips, annual reports, the internet, etc. Each group will be supervised by
several lecturers, and it is mandatory for the students to meet them every week and record the
meeting properly in a logbook.

PROGRAM KEJURUTERAAN KIMIA Page 5

FAKULTI KEJURUTERAAN & ALAM BINA
UNIVERSITI KEBANGSAAN MALAYSIA
PROCESS PLANT DESIGN PROJECT 2020/2021 Rev : 2

1.1 Project titles

Production of Raw Material from Renewable Resources for Non-Alcohol-Based Hand Sanitizer.

1.2 Feasibility study

The terms of reference for the feasibility studies are;

1) Usage of the specified product
2) Demand, output/supply and present and future market potential.
3) Most economical feed.
4) Suitable location.
5) Hazards case studies
6) Design concept for the production of the product.
7) Mass and heat balance by manual calculation and iCON/HYSIS/SUPERPRO.

1.3 Detailed design

1) Prepare detail discounted cash flow analysis to account for the payback period, rate of return,
net Present Value (NPV) and internal rate of return in order to determine the profitability of
the plant operation.
2) Prepare process flow chart using standard engineering drawings from heat and mass balance,
indicating the mass flow rate of all components, total mass flow rate, temperature, pressure,
enthalpy and phases of component streams and utility services required. Application of
engineering design programs such as iCON, HYSIS, SUPERPRO and
PROCEDE/AUTOCAD is compulsory. All calculations must be shown.
3) Perform heat integration exercise on the design plant and then modify the process flow
diagram.
4) Design the plant control system. Prepare piping & instrumentation diagram (P&ID) for the
plant to indicate all the important devices, instruments, piping and the relevant required
services. All decisions and calculation must be shown.
5) Prepare detail process and mechanical design for all major processing units such as reactors,
membrane system, distillation columns, phase separator units, heat exchangers and others.
6) Every student is required to design one process unit. Chemical process and mechanical
design must be reported in separate chapters. Complete mechanical drawing must be
provided for each process unit and it must be in accordance with ASME VIII standard.

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FAKULTI KEJURUTERAAN & ALAM BINA
UNIVERSITI KEBANGSAAN MALAYSIA
PROCESS PLANT DESIGN PROJECT 2020/2021 Rev : 2

7) Students are also expected to design the utility systems required for the plant operation (e.g.
steam system, cooling water system or refrigeration system).
8) Prepare the plant site drawing by taking into consideration the safety factors on the actual
site. Students are also required to fabricate a model/ replica of their designed plant.
9) Design a waste treatment system based on the requirements set by Akta Alam Sekitar
Malaysia (AASM) 1974 and WHO for the level of air and water discharged from the plant.
Determine the size of every unit involved in the treatment system and prepare the process
flow diagram accordingly. Include the principles of waste minimisation in the wastewater
treatment plant design.
10) Prepare risk assessment by conducting HAZOP analysis on the P&ID produced and list
suggestions and advices to improve and reduce the risk. Attach the MSDS for every
chemicals involved.

2.0 REFERENCES

Students are expected to find all relevant references and information on their own. The references
from which the information used in the design are obtained must be listed in the final report.

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FAKULTI KEJURUTERAAN & ALAM BINA
UNIVERSITI KEBANGSAAN MALAYSIA
PROCESS PLANT DESIGN PROJECT 2019/2020 Rev : 2

3.0 GROUP MEMBERS

NO. MATRIK STUDENT GROUP SUPERVISORS (SVs)

A164216 HO DANY PROF. DATO’ IR. DR. WAN RAMLI WAN DAUD
A163419 MASHITAH BINTI MOHD HISBAN K1 DR. ANG WEI LUN
A164021 HAZWANI KHALIESAH BINTI MAT NAZRI HAH CHIEW KHEN (HENYUANG REFINING)
A163472 ARINA ATIQAH BINTI AZHAR MUHD HELMI ASHAR (ALLNEX)
A163509 MUHAMMAD HAMIZAN BIN AZMAN

A162891 TEO TZYY LING PROF. MADYA NOORHISHAM TAN KOFLI

A163977 NURUL SAFIKAH SHAHIRAH BINTI SHARANI K2 PROF. MADYA DR. LUQMANUHAKIM BAHARUDIN
A163551 MUHAMMAD RIDZWAN LUBIS BIN FAHRUDIN LUBIS FIRDAUS HASSAN (ENQUEST)
A163605 SITI NUR DIANA BINTI MOHD SAHARUDDIN IR. ANWAR AHMAD (AFNAN ENGINEERING)

A163352 JAGA SAHSINY A/P JAGANATHAN PROF. IR. DR. SITI KARTOM KAMARUDIN
A163853 ANAS SYAFIK BIN MAT SAAD K3 DR. PEER MOHAMED
A164093 NURFATIN NABILA BINTI ZAINI MOHD FIRDAUS ABD RAHIM (EXXONMOBIL)
A164208 NOR SABRINA ALLIAH BINTI SUFFIAN TAN CHUNG CHUAN (EXXONMOBIL)
A163427 MUHAMMAD IDHAM BIN AMLA

A163705 SU YIEN YIEN PROF. MADYA DR. NURINA ANUAR

A163894 FATIN NOR AIN BINTI MASRON K4 DR. FERIAL GHAEMI
A163801 GAGENTHIRAN A/L GANESAN ADLY ISMAIL (PETROFAC)
A163766 EISYAH NAILI BINTI MOHD MARIZAN NOR AIN MOHD HANAFI (PETRON REFINING)
GUNARAJ RAMAN (MCKINSEY)

A163988 SITI NUR UMIRAH BINTI ZULKIFLI PROF. MADYA DR. NORLIZA ABD. RAHMAN
A163664 SYARIFAH NORNABILAH BINTI SYED MUAZ K5 DR. NURTANTIYANI ALI OTHMAN
A164032 SHAKIR AHMAD BIN MOHAMED SULTAN JUNAIDIY MAT JANI (PETRONAS RESEARCH)
A163578 YOGADEVAN A/L VIJAYAN FAZRINA AYU AZLAN (ADVISIAN)
A163589 NADIA ISMAHANI BINTI ISMAIL

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FAKULTI KEJURUTERAAN & ALAM BINA
UNIVERSITI KEBANGSAAN MALAYSIA
PROCESS PLANT DESIGN PROJECT 2019/2020 Rev : 2

NO. MATRIK STUDENT GROUP SUPERVISORS (SVs)

A164131 NUR KHAIRUNNISA BINTI ABDULLAH PROF. MADYA IR. DR. HASSIMI ABU HASSAN
A163940 NURAISHA BINTI HUSSAIN K6 DR. EBRAHIM MAHMOUDI
A164038 POONGKULALI A/P Y NADARAJAN NOR FAHEJAH RENTE (BASF ASIA PACIFIC)
A164275 MOHD DANNIL BIN FAHRUDDIN UNGKU HEZLEN UNGKU ABD KADIR (CARIGALI HESS)
A163471 AMIRUL SYAHMI BIN ANUAR NAWAREE SUVANMANI (PETRONAS CHEMICALS GROUP)

A164257 NOR IZZATI BINTI MOHAMAD KAMAL IR. DR. NOR YULIANA YUHANA
A163686 SHARMILA A/P PRAGASH SUNDARAM K7 DR. JARINAH MOHD ALI
A163737 NUR ASYIQIN BINTI AZAHAR MIRA EZORA ZAINAL ABIDIN (PETRONAS GTS)
A163139 AHMAD FAIZZUDIN BIN MOHD JAAFAR FARAHZILA M SAHAT (PETRONAS GTS)
A164350 NUR AIDA BINTI MOHD NOOR

A163777 PUTRI NATASHA BINTI MEGAT JOHAR PROF. MADYA DR. MASLI IRWAN ROSLI
A164337 SWATIGA PANICKAR A/P GOPINATH PANICKAR K8 DR. NOORASHIKIN MD SALEH
A164298 KHAIRUNNISA BINTI SHAMSULAZMIL FADHLI OMAR (MTC FLOATING SOLUTIONS)
A163859 KAMAL AIKAL BIN DAHLAN HEMAVATHI SILVAMANY (SIME DARBY)
A164175 AHMAD NASRUL MUIZZ BIN AHMAD NAZRI YEOW EU LUN (FAETH ASIA PACIFIC)

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FAKULTI KEJURUTERAAN & ALAM BINA
UNIVERSITI KEBANGSAAN MALAYSIA
PROCESS PLANT DESIGN PROJECT 2019/2020 Rev : 2

NO. MATRIK STUDENT GROUP SUPERVISORS (SVs)

A164628 LOSHINNI A/P S MATHURAY VEERAN PROF. IR. DR. SITI ROZAIMAH SHEIKH ABDULLAH
A165003 WAHIDA AMALIN BINTI KALET K9 PROF. MADYA TS. DR. WAN NOR ROSLAM WAN ISAHAK
A165299 MUHAMMAD HAIKAL BIN MOHD HANAFIAH IR. ANDRINY RUSMAN (PETRONAS GTS)
A164979 NURHARIZAH BINTI ABDUL RAHMAN MARINA MOSIR (PETRONAS GTS)
A159743 MUHAMMAD NABIL BIN LOKMAN

A165501 OOI YIK PENG PROF. DATO’ IR. DR. ABDUL WAHAB MOHAMMAD
A166401 AHMAD AFNAN BIN FAHIMI K10 DR. DARMAN NORDIN
A164383 NUR ARMIDHA NADIHAH BINTI AMIR SABRI ABDUL RAHIM NORMAN, CENG (PETRONAS GTS)
A164710 RAMPRASAD RAO A/L SUBBARAO IR. FADZRUL IZWAN M ALI (PETRONAS GTS)

A166633 MUHAMMAD RIDHWAN HIDAYAT BIN MUHAMAD PROF. MADYA IR. DR. MASTURAH MARKOM
A164712 NURUL NAJWA BINTI MOHAMAD SHAHABUDIN K11 DR. ABDULLAH AMRU INDERA LUTHFI
A165492 NUR HAFLIA SAFIKA BINTI SAHARI ZALINA HARUN (PETRONAS GTS)
A165198 KOTANDA RAM REDDY A/L RAJA RAM REDDY FARAH SYAMIM ANWAR (PETRONAS GTS)
A165023 MARISSA WIDYA BINTI BABA HAIZAL

A165024 YEO LIP QIN PROF. IR. DR. MOHD. SOBRI TAKRIFF
A164550 ANIS SYUHADA BINTI NORLIZAM K12 IR. DR. TEOW YEIT HAAN
A164830 NOR HAJARTUL AKMAL BINTI MOHAMED HELIFAH RIDHUAN AFFANDI ABU BAKAR (BUREAU VARITAS)
A165107 MUHAMMAD FIRDAUS BIN ISMAIL MOHD FITRI MOHD LIAS (REPSOL OIL & GAS)

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FAKULTI KEJURUTERAAN & ALAM BINA
UNIVERSITI KEBANGSAAN MALAYSIA
PROCESS PLANT DESIGN PROJECT 2019/2020 Rev : 2

NO. MATRIK STUDENT GROUP SUPERVISORS (SVs)

A166757 LOW FU HAO PROF. DR. JAMALIAH MD JAHIM

A165059 NUR AIN NADHIRAH BINTI MOHAMAD RAZALI K13 TS. DR. MOHD SHAIFUL SAJAB
A165597 SUHAINA BINTI SUHAIMI IR. AMIZA SURMI (PETRONAS RESEARCH)
A164654 NAZIFA BINTI MOHD ZANURI MOHD KHAIDIR ABDUL HAMID (PETRONAS RESEARCH)
A165084 MAHAKIM BIN MARZUKI

A164889 CHONG SHUN FATT PROF. MADYA TS. DR. ROSIAH ROHANI
A164481 NUR SABRINA BINTI NORDIN K14 DR. MANAL ISMAIL
A165074 ARNIE NAZIRA BINTI TAHIR TAN JUN XIAN (EAST ONE-ZERO-ONE)
A165189 NAJAH HAFIZAH BINTI MUSA LIM ZHI HENG (DESMET BALLESTRA)
A164534 FATHI `AFIFI BIN ISMAIL

A165187 HALIMUNNISHA BINTI SAHUL HAMEED PROF. MADYA DR. MOHD SHAHBUDIN MASTAR@MASDAR
A164913 CHIA HAN XIAN K15 DR. AHMAD RAZI OTHMAN
A164908 FATIN NAZIRAH BINTI MUHAMAD HARIZAL MOHAMAD HAZIMIN GHAZALI (MALAYSIAN REFINING)
A164826 MAISARAH HAZIQAH BINTI HAMZAH HASROHA ARIFIN (PETRONAS UPSTREAM)
A164636 MANJA AZFAR BIN HASSAN

GA04276 THUUSHREN A/L RAGUNATHAN PROF. IR. DR. ZAHIRA YAAKOB

A164892 NOR AFIDA BINTI ABU SAMAH K16 IR. DR. SHUHAIDA HARUN
A164488 MOHAMAD HANIF BIN ZAKARIA NOORHIDAYAH HUSSEIN (PETRONAS GTS)
A165361 AZIZI BIN SALIM DANG SRI ANNIM ABDUL HALIM (PETRONAS GTS)
A165303 NUR FAIQAH BINTI SHAMSUL AMRAN

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FAKULTI KEJURUTERAAN & ALAM BINA
UNIVERSITI KEBANGSAAN MALAYSIA
PROCESS PLANT DESIGN PROJECT 2019/2020 Rev : 2

4.0 TENTATIVE SCHEDULE

MINGGU/TARIKH 1 2 3 4 5 6 7 CPS 8 9 10 11 12 13 14 15 16 17 18
12/ 19/1 26/ 2/ 9/ 16/ 23/ 30/1 7/ 14/ 21/ 28/ 4/ 1 11/ 18/1 25/ 1/2/2021-
AKTIVITI 10 0 10 11 11 11 11 1 12 12 12 12 1 1 19/2/2021
(exam)
PROJEK REKA BENTUK - KKKR4774
Taklimat projek (pembahagian kumpulan Isnin, 12/10/2020
dan tajuk) @DK1/DK2
Seminar 1 TBD
Perjumpaan pelajar-pensyarah (buku log) 19/10/2020-22/1/2021
Pembentangan/Perbincangan I Jumaat, 30/10/2020
(Ketersauran dan Imbangan Jisim (SH, SKK)
Keseluruhan)
Pembentangan/ Perbincangan II Jumaat, 13/11/2020
(Prelim PFD, Material and Energy (SH, SKK)
Balances –up to level 3)
Pembentangan/ Perbincangan III Jumaat, 27/11/2020
(PFD, Conceptual Design Process –up to (SH, SKK)
level 5)
Pembentangan/ perbincangan IV Khamis 18/12/2020
(PID, Detailed design of unit operation, (NAR, MIR, PM, JMA)
process control & safety)
Pembentangan/ perbincangan V Khamis, 31/12/2020
(Waste management, Economic process) (SRSA, DN, RR, HAH)
Penghantaran laporan akhir oleh pelajar Isnin, 18/1/2021 (hard
copy)
Bengkel Penilaian Bersepadu Selasa, 19/1/2021
Pembentangan lisan bersama industri Rabu 20/1/2021@F2F
Sesi Ulasan Khamis, 21/1/2021

*CPS – Cuti Pertengahan Semester

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FAKULTI KEJURUTERAAN & ALAM BINA
UNIVERSITI KEBANGSAAN MALAYSIA