Product and Process Design II

Modeling and Simulation in Chemical Engineering

Dynamics and Control Processes

CAPSTONE PROJECT
FINAL 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 function effectively on a team whose members together provide leadership,
create a collaborative and inclusive environment, establish goals, plan tasks, and meet
objectives
- 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 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
- To manage resources and time coherently to fulfill the project objectives.
- To project the activities and the resources to develop the process and plant design
Instructions:
It’s time to present your final design! Your team has been working hard enough to get some funding
from external entities, and all of you will have to show that your design fits exactly in the market and
that it is worth of receiving some financial aid from investors.
For that reason, your team will have to provide a final design report. In order to do that you will have
to

• Make the suggested corrections to the prior deliverables

• Finishing your design.

Suggested Corrections
All your advisors have mentioned some structural and supporting corrections to be implemented in
your final design. You will have to incorporate those changes. As a reminder, these were the
conforming elements of your initial-term and middle-term workshop.
Modeling Health
Dynamic
and Process safety
process
Deliverable Item Description Simulati Design and
and
on in II enviro
control
Che Eng. ment
 Product and Process Design II
Modeling and Simulation in Chemical Engineering
Dynamics and Control Processes

Owner requirements Product description, main X

Market analysis
MSDS of product (Annexes)
It must be explicit in the
MSDS which properties are
experimental and which ones
are simulated. As support for
the last ones, you must include
annexes that shows the
mathematical model and the
simulations made
MSDS of feedstock (Annexes)
It must be explicit in the
Chapter 1. MSDS which properties are
Feasibility experimental and which ones
analysis are simulated. As support for
(Product and the last ones, you must include
process design annexes that shows the
II) mathematical model and the
--or--- simulations made
Basis of Design Process synthesis (verified and
(Max 15 pages) corrected)
Standards and regulations
Environmental analysis
Constraints
Minutes of the meeting
(signed by members)
(Annexes)
Complete WBS (Scope, Time
and cost) (Annexes)
Requirement Traceability
matrix
component, feedstocks, plant
capacity, operation mode.
Customers, suppliers, X
producers
The MSDS sheet showing X
experimental and simulated
properties
The MSDS sheet showing X
experimental and simulated
properties. (Annexes)
BFD. X
Define all the normative X
framework of products and
feedstock
Identify the environmental X
risk of the process
List all the constraints your X
team have found.
All meeting minutes showing X
how you track your project
A complete and detailed X
WBS
Does the initial requirements, X
restrictions and suppositions
are satisfied with this
flowsheet? Please checklist
the requirements and its
fulfillment in this simulation.

Description Dynamic Modelin

process g and
Process
and Simulati
Deliverable Item Design
control on in
II
Che
Eng.
Chapter 2. Requirements and restrictions You must list all X
Process identification requirements/restrictions the
Design – reaction unit must satisfy
Reaction path Define your reaction systems According to previous X
(Max 15 calculations (made by means
pages) of simulation in the middle

You must support why you have
chosen the reaction system. You
must include as supporting
material the simulations made in
the middle term (Gibbs,
attainable region, rigorous
simulations and analysis, etc.)
Reactor technical datasheet
including operational conditions
You must support this datasheet
with supporting material as the
simulations made in the middle
term (Gibbs, attainable region,
rigorous simulations and
analysis, thermodynamic
analysis, etc.)
Requirements and restrictions
identification
Separation train
Chapter 3.
Process
You must support why you have
Design –
chosen the separation train. You
Separation
must include as supporting
path
material the simulations made in
(Max 4 pages
the middle term (shortcut and
for each
rigorous simulations)
course) (For
Separation technical datasheet
Modeling and
including operational conditions
Simulation
max 7 pages)
You must support this datasheet
with supporting material as the
simulations made in the middle
term.
Chapter 4. Supporting equipment datasheet
Process including operational conditions
Design –
Additional You must support this datasheet
equipment with supporting material such as
path the simulations made in the
(Max 15 middle term.
pages)
Present and argue a Gantt
diagram of the scheduling of
your chemical plant
Control objectives
Chapter 5.
Dynamic
Process Control requirement
identification
Design –
Stability Control restrictions
analysis (Max identification
15 pages) Identification of control
variables
Product and Process Design II
Modeling and Simulation in Chemical Engineering
Dynamics and Control Processes
term), present the final
alternative (reactor network).
Explain the selection.
For the reactor system X
present the calculation of the
reactor or the results of
simulation. Present the
technical data sheet with the
type of reactor, capacity,
dimensions, operational
conditions, duty, conditions
of inlet and outlet streams
You must list all X
requirements/restrictions the
separation train must satisfy
Present and argue the X
separation train selected (a
table)
For each separation X
equipment present the
calculation or simulation and
design specifications.
Present the technical
datasheets
Deliverable: For each X
supporting equipment present
calculations, simulation and
design specifications.
Present the technical data
sheet of all equipment.
Present a resume table of all
equipment
Present the Gantt Diagram X
and: time of the batch and
cycle, No batch/cycle, No
cycle/year, m/batch, m/cycle
State the control objectives X
for the 3 equipment your
team chose.
Control requirement X
identification
Control restrictions X
identification
For each equipment, you X
must identify
input and output
variables

Dynamic mathematical
modeling of three operations
and their simulation
Complete transfer function of
those equipment.
Stability analysis using the
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.
Completing your design
At the same time, you will have to provide additional information of your design, focused on Heat
Exchangers and Control Structures. You must also redefine your financial indicators (CAPEX and
OPEX) including the additional information. The missing chapters to complete your design report are
described below: (NR: Not Required)
Feature Item
Restrictions
identification
Suppositions
identifications
Chapter 6. Simulation of Heat
Heat integration Exchangers
and impulsion Calculation of the
devices first Heat
(Max 15 pages) Exchange Network
(MER)
Simulation of the
Heat Exchanger
Network
Product and Process Design II
Modeling and Simulation in Chemical Engineering
Dynamics and Control Processes
Deliverable: The X
mathematical model used to
obtain the transfer functions
Deliverable: Block diagram X
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 block
diagram
Description Dyn Proc Health,
Cont Mod Sim Proc Dsg safety and
Che Eng. II envirome
nt
Definition of maximum and X
minimum values (T, P, xi, yi,
flows, etc.) for all streams and
equipment, as well as their
steady-state values, and
additional restrictions
Enumerate all suppositions you X
are assuming (For example, The
dependence of Cp with
Temperature)
Incorporation of shortcut X
Simulation of heat exchangers
Identify all cold and hot process X
stream, including source and
target temperatures and
calculating the heat transfer. It is
accomplished using the simulator
or manual calculations (excel)
Based on the MER, you must X
propose a Heat Exchanger
Network using simulation (using
Aspen Energy Analyzer, Aspen
Plus or any simulation tool)
Deliverable: Running HEN
simulation
 Product and Process Design II
Modeling and Simulation in Chemical Engineering
Dynamics and Control Processes

Mathematical Deliverable: Write down the X

modeling of Heat equations involved to calculate a
Exchangers HE
Model Deliverable: Running models X
Implementation (built on Excel or MATLAB) for
the Heat Exchanger.
Simulation of Heat Deliverable: Rigorous simulation X
Exchangers of heat exchangers in a
commercial simulation tool.
Complete Data Present the TEMA for each heat X
sheet of heat exchanger (annexes)
exchangers
Pumps and Table with the specification of X
compressors engineering datasheet for
selection impulsion devices. Data sheets of
the selected pumps.
The resume table of the pumps.
Overall control X
loop
instrumentation
design
Sensor selection Deliverable: For each control X
loop, you must set up a Decision
matrix comparing 3 sensor
alternatives (each student must
create a decision matrix with
his/her own control loop)
Valve Sizing Deliverable: Calculation of the X
required Cv for each control loop.

Deliverable 2: For each control

loop, you must set up a Decision
matrix comparing 3 valves
alternatives (each student must
Chapter 7. create a decision matrix with
Control loops his/her own control loop)
design
Controller Deliverable: For each control X
(Max 7 pages)
selection loop, you must set up a Decision
matrix comparing 3 controllers
alternatives (each student must
create a decision matrix with
his/her own control loop)
Transfer function Deliverable: The transfer function X
of all control of all control loop elements.
elements
Overall simulation Deliverable: Simulation in X
of the control loop Simulink of the control loops,
analyzing its behavior when the
user modifies a disturbance or the
Set Point.
Tuning Selection and justification of the X
controller parameters.
Stability Justification of stability of control X
evaluation loop
Chapter 8. A CAPEX A CAPEX evaluation X X X
Economical evaluation (Summarized by equipment class
evaluation (Summarized by i. e. reactors, heat exchangers,
(Max 4 pages) equipment class i. separators, among others)
 Product and Process Design II
Modeling and Simulation in Chemical Engineering
Dynamics and Control Processes

e. reactors, heat
exchangers,
separators, among
others)
An OPEX An OPEX evaluation X X X
evaluation
A complete Final A complete PFD which shows: X
PFD • Definitive reactive
system
• Definitive separation
train
• Definitive auxiliary
equipment (pumps, heat
exchangers)
The PFD includes
• Equipment diagram
• A table summarizing
the streams information
• A table summarizing
the equipment
specification

A completes X
simulated PFD
Final P&ID based Deliverable: A P&ID for the final X
on the previous equipment using ISA norms to
PFD. describe it
Chapter 9.
Plant design Hint: Please take
into account that
your manipulated
variable must be
the one with the
highest gain.
Plot plant Present the size calculation of X
areas.
Present the functional relationship
analysis
Present the layout with all
required areas in your plant
(service, process, laboratories,
etc.)
Present the services plot
Plant location The definition of plant location X
3D view of plant Present 3D renders based in your X
distribution plot plant
Hazop Hazard and Operability Analysis X
(HAZOP) for the designed plant.
identifying potential hazards and
operability problems.
Resume of the Present an executive summary X
project with information of product
description, main component,
feedstocks, plant capacity,
stakeholders, operation mode,
customers, suppliers, process
Executive designed
Summary (Máx. A summary of the Consolidated financial X
final CAPEX information
 Product and Process Design II
Modeling and Simulation in Chemical Engineering
Dynamics and Control Processes

2 pages plus PFD AND OPEX and

diagram) financial indicators
A complete PFD A refined PFD which shows: X
• Definitive reactive
system
• Definitive separation
train
• Definitive auxiliary
equipment (pumps, heat
exchangers)
The PFD includes
• Equipment diagram
• Streams table
The 3D view of The 3D view of the plant X
the plant

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
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 virtualsabana 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.
 Product and Process Design II
Modeling and Simulation in Chemical Engineering
Dynamics and Control Processes

• FOR PROCESS DYNAMIC AND CONTROL: You are free to choose whether being
evaluated as a group, or individually. (This item applies when the team member as a whole didn´t
fulfill the amount of control loops, but one or two members did their part of the work)