Product and Process Design II

Modeling and Simulation in Chemical Engineering

Dynamics and Control Processes
Health, safety and enviroment

CAPSTONE PROJECT
MIDDLE TERM WORKSHOP
Competences:
- An ability to apply engineering design to produce solutions that meet specified needs with
consideration of public health, safety, and welfare, as well as global, cultural, social,
environmental, and economic factors
- An ability to identify, formulate, and solve complex engineering problems by applying
principles of engineering, science, and mathematics
- An ability to include planning concepts in the project management
- An ability to communicate effectively with a range of audiences
RPA:
- To design a process and a production plant, providing the process diagrams, the equipment
specifications and the plant layout
- To optimize the operational conditions setting the equipment and plant design parameters
- To project the activities and the resources to develop the process and plant design
- To evaluate between several options the process specifications, and to choose the most
appropriate chemical process condition to reach the restrictions.
- To argue coherently and referenced each decision making during the project in oral and
writing presentations

Instructions:
Congratulations!!! Your design has been approved by the Senior Committee, but they need more
information about rigorous reactions and rigorous separations. Now, each working group must
present the proposed corrections to your design (using the feedback received in the first term) and
you must refine your proposal. This middle term workshop will be focused on:

• Reactor Design
• Separation design
• Additional equipment
• Process scheduling
• Dynamic process design.
This assignment will be a continuation of your Design Engineering Proposal, which must include as
minimum:
Description Dynamic Modeling
Process
process and
Deliverable Item Design
and Simulation
II
control in Che Eng
Requirements and You must list all X
Process Design –
restrictions identification requirements/restrictions
Reaction path
the reaction unit must
(Max 15 pages)
satisfy

Forecasting of the best
thermodynamic conditions
to carry out the reactions
Define your reaction
system
Use the Mathematical
Modeling of the attainable
region and its
implementation on a
softwareto compare
alternative of the reactor
systems. (If applies)
Running Simulations for
comparing three
alternatives of the reactors
system (If applies)
Use the batch scheduling
tool to compare alternatives
of the reactors system (if
applies)
Technical selection tool
Mathematical modeling of
the chosen reactors
(Chemical
reactors/bioreactors) and its
implementation on a
numerical software
Running Simulations for
the calculation of reactors
Product and Process Design II
Modeling and Simulation in Chemical Engineering
Dynamics and Control Processes
Health, safety and enviroment
By using Gibbs reactors, X X
you can support the best
thermodynamic
conditions for a given
reaction. Please support
the best conditions by
means of sensitivity
analysis.
Deliverable: Sensitivity
analysis to support the
best conditions
Present three different X
alternatives (reactor
network) by using the
appropriate technical tool
between The attainable
region analysis, the use
of modelling and
simulation, or the batch
scheduling.
Implement the analysis X
of the attainable region
for your reaction system
if it applies. Remember:
when modeling you must
state your suppositions
and restrictions.
You may implement a X
simulation of three
alternatives of the reactor
system to select the best
option. You are free to
choose the modeling
tool.
You may implement the X
batch scheduling of the
process to compare
alternatives of the
reactors system.
Resume the use of the X
technical tool to choose
the best alternative for
your reaction system.
Options: attainable
region, simulation, batch
scheduling.
You must select a X
reactors and model it
rigorously. Remember:
when modeling you
must state your
suppositions and
restrictions
Deliverable: Selected
equations to model your
system
You must implement in a X
numerical analysis tool

Reactor technical datasheet
including operational
conditions
Requirements and
restrictions identification
Using the thermodynamic
analysis made in the first
term workshop to evaluate
three different separation
alternatives using shortcut
calculation in a commercial
simulator
Separation train
Using information from
shortcut calculations,
implement the rigorous
separations using
commercial simulators
Process Design – Hint: You can use
Separation path rectification towers or
(Max 15 pages) azeotropic/extractive
distillation. It all depends
on the thermodynamic
analysis
Hint2: If the proposed
operation unit is not
supported by commercial
simulators, it must be
implemented on a
numerical software
Hint3. In this rigorous
design you must make
technical decisions about
the purity of your product.
They must be specified in
the simulator
Separation technical
datasheet including
operational conditions
Product and Process Design II
Modeling and Simulation in Chemical Engineering
Dynamics and Control Processes
Health, safety and enviroment
the mathematical model
for the reactors. You are
free to choose the
modeling tool.
Deliverable the
mathematical model on a
numerical analysis tool
and the conclusions
For each reactor system X
present the
thermodynamic analysis
and design specifications
of each reactor
You must list all X
requirements/restrictions
the separation train must
satisfy
Evaluate three different X
separation alternatives
implementing shortcut
units.
Deliverable: A running
flowsheet (in a
commercial simulator)
using shortcut
distillations
Present and argue the X
separation train selected
Deliverable: A complete X X
flowsheet using rigorous
distillation or rigorous
units.
For each separation X
equipment present
thermodynamic analysis
(if applied) and design
specifications

Process Design – Mathematical model of
Additional additional units (You are
equipment path free to choose whatever
(Max 15 pages) you want: Mills, filters,
dryers, etc)
Running simulations for
the calculation of the
additional equipment.
Table of equipment
Supporting equipment
datasheet including
operational conditions
Process Design – Present and argue a Gantt
Booking path diagram of the scheduling
(Max 5 pages) of your chemical plant
Definition of measured
variables and the
mechanism used to achieve
that (for example,
analytical sensors based on
conductivity, relative
humidity, etc)
Dynamic mathematical
modeling of three
operations and their
simulation
Complete transfer function
Chapter 6 -: of those equipment.
Dynamic Process
Design – Stability
analysis (Max 15 Stability analysis using the
pages) transfer functions
Stability analysis using
State-space matrix
Simulation of the transfer
functions using Simulink
and provide three different
perturbations for some
variables and analyze the
response.
Based on the preliminary
PDF (or BFD defined in
Supporting
the first-term workshop)
Material
and the results obtained in
the previous item, you must
Product and Process Design II
Modeling and Simulation in Chemical Engineering
Dynamics and Control Processes
Health, safety and enviroment
Deliverable: The selected X
equations to model a
single unit.
Deliverable: The X
implementation of the
mathematical model on a
numerical analysis tool
and the conclusions
Deliver a summary table X
with all the equipment of
the process, capacity,
dimensions, and
requirements
Deliverable: For each X
supporting equipment
present thermodynamic
analysis (if applied) and
design specification
X
X
Deliverable: The X
mathematical model used
to obtain the transfer
functions
Deliverable: Block X
diagram that shows the
transfer functions from 3
control loops
Deliverable: Stability X
analysis using transfer
functions for 3 control
loops
Deliverable: Stability X
analysis using State
Space Matrix for 3
control loops
Deliverable: Simulation X
using SImulink of your
blok diagram
A refined PFD which X
shows:
• Definitive
reactive system
 Product and Process Design II
Modeling and Simulation in Chemical Engineering
Dynamics and Control Processes
Health, safety and enviroment

update your diagram • Definitive

process.
A complete simulated PFD
which shows:
• Definitive
reactive system
• Definitive
separation train
Requirement Traceability
matrix, WBS, Minutes of
meetings
Refined P&ID based on the
previous PFD.
Hint: Please take into
account that your
manipulated variable must
be the one with the highest
gain.
Stability analysis
separation train
The PFD includes
• Equipment
diagram
• A table
summarizing
the streams
information
A table summarizing the
equipment specification
Based on the preliminary X
PDF (or BFD defined in
the first-term workshop)
and the results obtained
in the previous item, you
must update your
diagram process. That
means, you must define
the unit operation to use
in order to make the
separation, as well as
define the stream
conditions and the
separation objective for
each involved stream
Deliverable: The FINAL
SIMULATED PFD
running on a commercial
simulator.
Include all the elements X
for the project
management, the
traceability matrix, WBS
and minutes of meeting
updated.
Deliverable: A P&ID for X
the whole plant using
ISA norms to describe it
X

A single document will be delivered with the information showed in the previous table. This
document should be attached with the files that support the design process (Excel, simulations,
Matlab) and sent to your respective dynamics, design and simulation teachers. The final PFD and
P&ID must be printed in A2 format and delivered according to NTC 1687.
All decisions taken should be supported by logical engineering arguments and the equipment
selection, sizing, optimization and economic estimation must be detailed in the proposal, showing in
 Product and Process Design II
Modeling and Simulation in Chemical Engineering
Dynamics and Control Processes
Health, safety and enviroment

this way the analysis worked in class. We remind you that the process simulations are supporting
material for the calculations presented in your designs.
RULES
• The design is leveraged by your previously knowledge for modeling unit operations and it is
not solely based on the use of a simulator. In that sense, the work must not be restricted to the
members who take the three courses simultaneously. You are a team and you must divide your
work wisely. For that reason, the amount of work is divided in the number of team member taking
the respective course.
• If an advisor (professor) requires a technical defense (or a feedback), it will be on charge of
a single student (RANDOMLY CHOSEN BY THE RESPECTIVE ADVISOR). This member
must be familiarized with the work made by the whole team.
• All decisions taken should be supported by logical engineering arguments and the equipment
selection, sizing, optimization and economic estimation must be detailed in the proposal,
showing in this way the analysis worked in class. We remind you that the process simulations
are supporting material for the calculations presented in your designs.
• The proposal must be clear, concise and presented in pdf format. The delivery deadline
is presented in the virtual sabana link. Late proposals will not be received under no circumstances
and the final assigned grade will be 0.0 (zero dot zero).
• The final grade is on the FILES you have delivered. Missing or incomplete files WILL NOT
BE GRADED (even when the students show them in their computers). Additional spreadsheets
or material will no be reviewed
• All chapters exceeding the maximum length will not be reviewed. The grade for exceeding
chapters will be 0.0 (zero dot zero)
• You are free to choose the language for writing the document.