| chapter-2 Process Design Development UIntraduction_ eee . ss Aprinciple esponsibility of chemical. engineer is thedesignncee ___and aperation of chemical plant ‘The enginess-must continuously. ____Ladditvonal_infarmation to assist Var ious functions chemical -engit often members consultants oF advisors-of ‘even the basic bes¢ which 1s, developing anew process-ol-tmpkaving-and 1 ewising es: — __pesign=praqact procedute oS _—___—_ 4) Types of-desiqns —————— a cid preliminary designs /quick estimate design — ae iD pe this. determines whether furthuruiotk should. bedone.on-nrapased. aie pracess methods. and taug! |__ process . The design is.based.on- capproxinn ____.cost estimates ar e.prepared _and time spend_on_cal culations 's minions — | _—__ tit) Detnited ~ estimate desi |__mthis the castand profit potential of establi’ hed process isdetermi- [ned by detatled analyses-and.caleulatfons.ere-evack specifications ake. Eire process designs ————-———~ — _ __, Here proper teamwork )Co-okdination and communication. should_be ____ there complete Specifications aye presented forall components.of. plant _ land accurate cost-is obtained ————— —— ——4)-Feas ibility Survey — a |-Following_is lisk of items that should be considered. in. making. feasibility TT fetesegs _ —_ ____—¢ Raw materials —— |lah) Available Cquipments and facilitres . tiv Requived equipments.and facilities (w Estimation of production costs and total investment icv) Profits. Reaction kinetics and Thermodynamics (oun) Material of construction = + = I) Safety consiclerations 7 ee x) Markets. eee 3) Competition - 2. et “cn Properties. of products. _ - SS - yy, Sales and Sales Service = — — ——lex Process develapment - a = |cxiv) Shippthg eee eereewree Hox) Plant location. a 3) Process.s development. oe 2 = - - | Process development an pilot-plant or Semiwork.scal eis usually destra- |i) Frest step tn preliminary destgnts to assume ‘suitable basis’ for designing. e - ‘\ple tin order to abtain.ciccurate design data: Valuatle infotmation.on Matertal ¢_£nergy balance. is obtained & process canditions canbe exa- mined. to supply dato on temperature,.pressurcy -yrelds .rates grades of. taw materials % praducts..Moc, operating Conditions 4 design variables | ' - ii) Preparing « Simple flaw.diagram showing Various. reocesses_and | ‘paring i gt ee Pp unit operations required ©... pe ii) Preliminary. materfal_and + energy balance — ee ivy Equipment specification included with final designs aa = +¥ i ee = 3,5). Constructian. Gul opent extion ___ 4. When construction of plantismade theres. es dena Juick_plont startup Therefore timing is very important fact ot in tructron- Long delay.may-be encountered in falrication_o4 mojor + :€quipmentend deliveries often lag ja behind dake of ordering . | These-factor roust:be consider while-developing_plant.and. me’ | prj ect _evaluotion § review techniqt ue (PERT) oF critical path:c The chemical engineet Should alwys work closely with consti fi | duning.: final stages of construction and_purchase design. —— HH 1 A Literature sutvey 1540 obtain arecent | et dealing tul-nthe Design infatmation fram Literatuke under investi gation __ Ke abstract = eS = __Thi's_published semimonthly by-th. American chemica), saciety! con ated fax compueh ensive literature Survey.an chemical. came Soper [i i The gotlawing periodicals ave suggested_as val uable. eae spinfovinabie for_chernical €ngineer-— : Americaninstitute of ape Engineers. + journals .chemtea.. engineering Progress. chemical and engineering news, chemical week.chernical nginet _sring Science 1Industeal_and engineering chemistry fundamentals Industé and_engg- chemistry, Process design 4 4 development. Journal of American chemical! a a processing..€ngineering news. record Flaw diagrams. — _-The_chemical_engineers uses flow diagrams to show sequenc. re of equip= |-ment& Unit operations in overall_ptocess..These diagrams divided intothree eneral types‘Agu fintivefiow diagram indreates the flow of materials Unit oper Lions involved 1 equiprnent necessary, pressure, temperature “A quantitative flow diagram shows the quaantities. of materials re= B quired for the process operation. a A Typical combined ~ detail’ flow diagram shows location of eceepentnt ‘and pressure Fegulators ¢ indicators as well.as.crétical. contro! Valves and._ |Special tnstruments I a |Pretimainary.design |) Problem statement iyiliterature Survey —_ |g) Materfaland energy balance. A} Equipment Destqn_and Selection | It Involves. evaluation of site of equipment , Volume flow tate and Surface cdrea. \ |5).Econamics rs || From the purchase cost of process equipment we can found production leost syate of return and payback time - i" 1. + _..Equipment design and specifications A) Safety factor /over designed actor This Fepresents the amount of overdesign that would be used be acc. ount for changes In the operating performance withtime Design factor | Should be lo-15) {Examples of-over designed factor ‘Packed column .- 151 | Reboiler nist Spray Column. - 201+ =, Heat exchanger = 151 .compressor_____= 40+} a48) Seale up indesign : Dusting Sate up Some regulaitons.drethere It bequires“wuher dataate not available inthe literature of when past experience, give any design basis. is having. some litnitations ancl chernica’ __.Should know how to Select the essential design variables a i ___|Factors sin equiprnent Seale-up 4 design — —{ man -h scale up babfo _ Compressor | Spray column —_—__— __| Heat exchanger————— condense — ____.ay Specifications = ___— ____ Specifurcatron.for_equipm __ ) Identification — SS ci) _Eunctian— ent Should Show-the followling ~~ ; div) Material handled ——— lev Basicdesign-data —_——-— ___-ew)_Essential controls ————-— _evil) Insulation kequirements tui TolRrances—— ___tyx)_Spectal_information.C Moc. gasket support. installation_etc) inal_specifications canbe prepared by engineer ond_engineer should allow the potential manufocturers.olfabricators-to make suggestion befats design-can.tnclud€ Smatl. +-Making— detailed speci fications..In-this way, Final. changes.to reduce cost ti ith.no.decrease ine srectiveness of the equipmentopt atin sheft tor peat Heat Exchanger a { Tener rcatfon_- Heat exchang? 5 { [eae ae ee TONES |) Function: {FE = _. + { Type: Horizontal Duty : +At tonne Flow rate s pressure: temperature | Passes, BwWo.Tube Material i a —— _ Shell side. - | shell: Flow rake -temperature pressure Passes, Baffles Tube steer. _ — —-—|Tubes: L : | Utilities cooling water — - | | | Conttol., Insulation, Tolerances —— Ee - = | | ' | fa) material of constructron (moc) 1 In chemical. inclustry res Corraston + ersosion eff ects are Important » i vo chemical resistance and physical properties of Construction mate- tals are important-along with adequate structural strength sresistance | Veo physical_ot thermal sheck / ease of fabrication, maintenances and ‘ qenetal type of Seruice required for Inclucling operating temperature 4 Irie ttre ia choice af construct fon material \ ™ a let