Department of Chemical & Biomolecular Engineering

National University of Singapore

CN4122: Process Synthesis and Simulation

Lecturers: IA Karimi (E5 02-12, 6516-6359, cheiak@nus.edu.sg)

Suraj Vasudevan (E4 06-03, 6516-8003, chesura@nus.edu.sg)

Tutors & Helpers: Srinivas S Venkataraman (e0408691@u.nus.edu, Tutor), Arravind Subramanian

(e0554253@u.nus.edu, Tutor), Qian Jing (e0201963@u.nus.edu, Tutor), Lyu Jingkuan
e0200733@u.nus.edu, Tutor), Mu Chuan (e0554251@u.nus.edu, Helper), Saeed Askari
(e0554257@u.nus.edu, Helper), Hadi Rouhani (e0671457@u.nus.edu, Helper), Vikas Dhamu
(e0674611@u.nus.edu, Helper)

Module Learning Outcomes (MLOs): A key responsibility of chemical engineers is to design,

construct, and operate chemical plants safely, considering the environmental impact. Safe process
design is a complex team task involving several people and several steps from concept to
commissioning. Holistic design experience is an essential part of the chemical engineering training.
Process development and simulation are essential first steps in designing a chemical plant. This
module aims to introduce you to these steps and prepare you for the full-fledged design project next
semester. However, this is not all. The training and skills acquired in this module are essential for
your future as a Chemical Engineer. In this module, you will learn the tasks, methods, and tools
involved in the development, design, and simulation of a chemical plant. Both general and specific
software tools and systematic procedures exist, which aid in doing these more precisely, more
rigorously, and more quickly. On successful completion of this module, you will be able to:

1. Describe the key data, steps, and considerations for process simulation.
2. Define and develop block flow diagrams (BFDs), process flow diagrams (PFDs), and process
flowsheets.
3. Select appropriate equipment for common unit operations and sequence them to develop
feasible PFDs.
4. Simulate steady-state continuous processes using a commercial process simulator.
5. Perform mechanical design of process equipment.
6. Estimate the capital and operating costs, and assess the profitability of chemical processes.
7. Describe the steps and considerations in process design.

Tentative Evaluation: Tutorials (Attendance, participation, completion) 17%

Individual class assignment 18%
Lecture attendance & participation 5%
Mechanical Design & Costing Project (Prof Suraj) 25%
Final Project (Take Home, Open Book, all topics) 35% (28 + 7)
Tutorials begin the week of Sep 7. Please SAVE all your tutorial work for the term-end viva. No
tutorial work is to be submitted. The tutorial marks will be based on your attendance, exercise
completion, term-end viva, independence, work quality, and self-work. The viva will take place during
the last two weeks (Nov 1 & 8). You must attend the viva, no replacement will be given.

Prerequisites:
This module requires skills and learning from several modules such as CN2116 Chemical Kinetics and
Reactor Design, CN2121 Chemical Engineering Thermodynamics, CN3132 Separation Processes, and
CN3124 Fluid-Solid Systems. While a satisfactory completion of these modules is required, knowledge
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from other modules such as CN2122 Fluid Mechanics, CN3421 Process Modeling & Numerical
Computing, and CN3122 Mass Transfer Operations is also essential.

Recommended References:
1. Chemical Engineering Design, by R Sinnott and G Towler, 5th Edition, Oxford, Butterworth-
Heinemann, 2013.
2. Analysis, Synthesis, and Design of Chemical Processes, by R Turton, RC Bailie, WB Whiting, JA
Shaeiwitz, D Bhattacharya, 4th Edition, Prentice Hall, 2012.
3. Product & Process Design Principles: Synthesis, Design, and Evaluation, by WD Seider, JD Seader,
DR Lewin, S Widadgo, 3rd Edition, John Wiley, 2010.
4. Help in Aspen Hysys.

Tentative Schedule
Dates (Venue) Lecturer (Topics)
Aug 10 to Oct 5 (8 Lectures Karimi (Overview, Learning Objectives, Process synthesis &
on Zoom) simulation, Hysys demonstration, Hysys modules, Process design)
Oct 12 to Nov 9 (5 Lectures Suraj (Mechanical design, Cost estimation & economic analysis)
on Zoom)
Weeks of Sep 7 to Nov 8
(9 Hysys tutorial sessions Tutors (Process synthesis & simulation exercises)
on Zoom)
Weeks of Nov 1 and 8 Viva sessions on the tutorial work
No lecture/tutorials during the week of Sep 20.

Remarks
1. Get ready to ask and answer questions during the class. Marks are assigned to class participation.
2. Please check E-mail and LumiNUS regularly. Keep your mailbox functional. Post your
questions/comments/feedback on the discussion forum or via e-mail.
3. Notes are NO substitutes for texts. Please suggest improvements. Please read assigned chapters
and study relevant examples.
4. We have 450 Aspen Hysys licenses total in PC1 (E1-04-09), PC3 (E2 03-06), E5 03-24, and E5 03-37.
Please install Hysys on your laptop ASAP after we ask you. You will do the demonstration exercises
with me during the lectures.

Prerequisites (Please review)

Basic concepts from earlier ChBE modules (especially CN3132) are required for this module. You must
recall, read about, and fully understand the following concepts, terms, or principles RIGHT AWAY.
Phase rule, Gibbs-Duhem Theorem, phase equilibrium, degrees of freedom, boiling point, bubble
point, dew point, saturated liquid, saturated vapor, vapor pressure, flash, equilibrium stage, ideal
solution, ideal gas, equation of state, activity model, polar, non-polar, centrifugal pump, NPSH,
compressor, turbine, power, efficiency, heat exchanger, exchanger duty, shell & tube exchanger,
tube passes, shell passes, pressure drop, temperature approach, temperature cross, log-mean
temperature difference (LMTD), FT correction factor, stoichiometric coefficient, activation energy,
Arrhenius equation, rate of reaction, rate constant, pre-exponential constant, order of reaction,
reaction kinetics, reaction equilibrium, equilibrium-controlled reaction, rate-controlled reaction,
reversible reaction, irreversible reaction, reaction conversion, distillation, absorption, stripping,
reboiler, condenser (partial and total), reflux ratio, effect of pressure and temperature on separation
processes, purity, recovery, isothermal, adiabatic, etc.

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