054402 Design and Analysis II

LECTURE 1: THE DESIGN PROCESS

Daniel R. Lewin
Department of Chemical Engineering
Technion, Haifa, Israel

1 DESIGN AND ANALYSIS II - (c) Daniel R. Lewin The Design Process

 Objectives
On completing this part of the course, you should:
 Be knowledgeable about the kinds of design decisions that
challenge process design teams.
 Have an appreciation of the key steps in carrying out a
process design. This course, as the course text, is
organized to teach how to implement these steps.
 Be aware of the many kinds of environmental issues and
safety considerations that are prevalent in the design of a
new chemical process.
 Understand that chemical engineers use a blend of hand
calculations, spreadsheets, computer packages, and process
simulators to design a process.

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 Schedule - The Design Process
 Primitive Design Problems
– Example
 Steps in Designing and Retrofitting Chemical Processes
– Assess Primitive Problem
– Process Creation
– Development of Base Case
– Detailed Process Synthesis - Algorithmic Methods
– Process Controllability Assessment
– Detailed Design, Sizing, Cost Estimation, Optimization
– Construction, Start-up and Operation
 Environmental Protection
 Safety Considerations
Ref: Seider, Seader and Lewin (1999), Chapter 1

3 DESIGN AND ANALYSIS II - (c) Daniel R. Lewin The Design Process

 Primitive Design Problems

 The design or retrofit of chemical processes begins

with the desire to produce profitably chemicals that
satisfy societal needs that arise in the broad spectrum
of industries that employ chemical engineers:

– petrochemicals, – polymers
– petroleum products – coatings
– industrial gases – electronic materials
– foods – bio-chemicals
– pharmaceuticals

 Partly due to the growing awareness of the public, many

design projects involve the redesign, or retrofitting, of
existing chemical processes to solve environmental
problems and to adhere to stricter standards of safety

4 DESIGN AND ANALYSIS II - (c) Daniel R. Lewin The Design Process

 Origins of Design Problems

 Often, design problems result from the explorations of

chemists, biochemists, and engineers in research labs to
satisfy the desires of customers to obtain chemicals with
improved properties for many applications
 However, several well-known products, like Teflon (poly-
tetrafluoroethylene), were discovered by accident.
 In other cases, an inexpensive source of a raw material(s)
becomes available
 Other design problems originate when new markets are
discovered, especially in developing countries
 Yet another source of design projects is the engineer
himself, who often has a strong inclination that a new
chemical or route to produce an existing chemical can be
very profitable.

5 DESIGN AND ANALYSIS II - (c) Daniel R. Lewin The Design Process

 Typical Primitive Design Problem
Consider, the need to manufacture vinyl chloride (VC),
H Cl
C C
H H

A typical primitive problem statement is as follows:

“An opportunity has arisen to satisfy a new demand for VC

monomer (VCM), on the order of 800 million pounds per
year, in a petrochemical complex on the Gulf Coast, given
that an existing plant owned by the company produces one-
billion pounds per year of this commodity chemical. Since
VCM is an extremely toxic substance, it is recommended
that all new facilities be designed carefully to satisfy
governmental health and safety regulations.”

6 DESIGN AND ANALYSIS II - (c) Daniel R. Lewin The Design Process

 Steps in Process Design and Retrofit

Assess Primitive
Problem

Detailed Process Plant-wide

Synthesis - Development Controllability
Algorithmic of Base-case Assessment
Methods

Detailed Design,
Equipment sizing, Cap.
Cost Estimation,
Profitability Analysis,
Optimization

7 DESIGN AND ANALYSIS II - (c) Daniel R. Lewin The Design Process

 Steps in Process Design and Retrofit
SECTION A
Assess Primitive
Problem

Detailed Process Plant-wide

Synthesis - Development Controllability
Algorithmic of Base-case Assessment
Methods

Detailed Design,
Equipment sizing, Cap.
Cost Estimation,
Profitability Analysis,
Optimization

8 DESIGN AND ANALYSIS II - (c) Daniel R. Lewin The Design Process

 Steps in Process Design and Retrofit

9 DESIGN AND ANALYSIS II - (c) Daniel R. Lewin The Design Process

 Assess Primitive Problem
 Process design begins with a primitive design problem that
expresses the current situation and provides an
opportunity to satisfy a societal need.
 Normally, the primitive problem is examined by a small
design team, who begins to assess its possibilities, to
refine the problem statement, and to generate more
specific problems:
– Raw materials - available in-house, can be purchased or need
to be manufactured?
– Scale of the process (based upon a preliminary assessment of
the current production, projected market demand, and
current and projected selling prices)
– Location for the plant
 Refined through meetings with engineering technical
management, business and marketing.
 Brainstorming to generate alternatives
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 Example: VC Manufacture
 To satisfy the need for an additional 800 MMlb/yr of VCM,
the following plausible alternatives might be generated:
Alternative 1. A competitor‟s plant, which produces 2 MMM
lb/yr of VCM and is located about 100 miles away, might be
expanded to produce the required amount, which would be
shipped. In this case, the design team projects the purchase
price and designs storage facilities.
Alternative 2. Purchase and ship, by pipeline from a nearby
plant, chlorine from the electrolysis of NaCl solution. React
the chlorine with ethylene to produce the monomer and HCl as
a byproduct.
Alternative 3. Since the existing company produces HCl as a
byproduct in large quantities are produced, HCl is normally
available at low prices. Reactions of HCl with acetylene, or
ethylene and oxygen, could produce 1,2-dichloroethane, an
intermediate that can be cracked to produce vinyl chloride.

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 Survey Literature Sources
 SRI Design Reports
 Encyclopedias
– Kirk-Othmer Encyclopedia of Chemical Technology (1991)
– Ullman‟s Encyclopedia of Industrial Chemistry (1988)
– ...
 Handbooks and Reference Books
– Perry‟s Chemical Engineers Handbook (1997)
– CRC Handbook of Chemistry and Physics
– ...
 Indexes
– See Technion Library
 Patents
 Internet

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 Steps in Process Design and Retrofit

Assess Primitive
Problem

Detailed Process Plant-wide

Synthesis - Development Controllability
Algorithmic of Base-case Assessment
Methods

SECTION B
Detailed Design,
Equipment sizing, Cap.
Cost Estimation,
Profitability Analysis,
Optimization

13 DESIGN AND ANALYSIS II - (c) Daniel R. Lewin The Design Process

 Steps in Process Design and Retrofit

14 DESIGN AND ANALYSIS II - (c) Daniel R. Lewin The Design Process

 Steps in Process Design and Retrofit

Assess Primitive
Problem

Detailed Process Plant-wide

Synthesis - Development Controllability
Algorithmic of Base-case Assessment
Methods

Detailed Design,
Equipment sizing, Cap.
Cost Estimation,
SECTION C
Profitability Analysis,
Optimization

15 DESIGN AND ANALYSIS II - (c) Daniel R. Lewin The Design Process

 Steps in Process Design and Retrofit

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 Environmental Issues in Design
 Handling of toxic wastes
– 97% of hazardous waste generation by the chemicals and
nuclear industry is wastewater (1988 data).
– In process design, it is essential that facilities be included to
remove pollutants from waste-water streams.
 Reaction pathways to reduce by-product toxicity
– As the reaction operations are determined, the toxicity of all
of the chemicals, especially those recovered as byproducts,
needs to be evaluated.
– Pathways involving large quantities of toxic chemicals should be
replaced by alternatives, except under unusual circumstances.
 Reducing and reusing wastes
– Environmental concerns place even greater emphasis on
recycling, not only for unreacted chemicals, but for product
and by-product chemicals, as well. (i.e., production of
segregated wastes - e.g., production of composite materials
and polymers).

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 Environmental Issues in Design (Cont’d)
 Avoiding non-routine events
– Reduce the likelihood of accidents and spills through the
reduction of transient phenomena, relying on operation at the
nominal steady-state, with reliable controllers and fault-
detection systems.
 Design objectives, constraints and optimization
– Environmental goals often not well defined because economic
objective functions involve profitability measures, whereas the
value of reduced pollution is often not easily quntified
economically.
– Solutions: mixed objective function (“price of reduced
pollution”), or express environmental goal as “soft” or “hard”
constraints.
– Environmental regulations = constraints

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 Safety Considerations
 Example Disaster 1 – Flixborough: 1st June 1974
http://www.hse.gov.uk/hid/land/comah/level3/5a591f6.htm
– 50 tons of cyclohexane were released from Nypro‟s KA plant
(oxidation of cyclohexane) leading to release of vapor cloud
and its detonation. Total loss of plant and death of 28 plant
personnel.
– Highly reactive system - conversions low, with large inventory
in plant. Process involved six, 20 ton stirred-tank reactors.

– Discharge caused by
failure of temporary pipe
installed to replace
cracked reactor.
– The so-called “dog-leg”
was not able to contain
the operating conditions
of the process (10 bar,
150 oC)
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 Safety Considerations
 Flixborough - What can we learn?
– Develop processes with low inventory, especially of flashing
fluids (“what you don‟t have, can‟t leak”)
– Before modifying process, carry out a systematic search for
possible cause of problem.
– Carry out HAZOP analysis
– Construct modifications to same standard as original plant.
– Use blast-resistant control rooms and buildings

T. Kletz, “Learning from Accidents”, 2nd Ed. (1994)

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 Safety Considerations (Cont’d)
 Example Disaster 2 – Bhopal: 3rd December 1984
http://www.bhopal.com/chrono.htm
– Water leakage into MIC (Methyl isocyanate) storage tank
leading to boiling and release of 25 tons of toxic MIC vapor,
killing more than 3,800 civilians, and injuring tens of
thousands more.
– MIC vapor released because the refrigeration system
intended to cool the storage tank holding 100 tons of MIC
had been shut down, the scrubber was not immediately
available, and the flare was not in operation.
 Bhopal - What can we learn?
– Avoid use of hazardous materials. Minimize stocks of
hazardous materials (“what you don‟t have, can‟t leak”).
– Carry out HAZOP analysis.
– Train operators not to ignore unusual readings.
– Keep protective equipment in working order.
– Control building near major hazards.

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 Safety Considerations (Cont’d)
 Example Disaster 3 – Challenger: 28th January 1986
http://www.onlineethics.com/moral/boisjoly/RB-intro.html
– An O-ring seal in one of the solid booster rockets failed. A
high-pressure flame plume was deflected onto the external
fuel tank, leading to a massive explosion at 73 sec from lift-
off, claiming the Challenger with its crew.
– The O-ring problem was known several months before the
disaster, but down-played by management, who over-rode
concerns by engineers.

 Challenger - What can we

learn?
– Design for safety.
– Prevent „management‟ over-
ride of „engineering‟ safety
concerns.
– Carry out HAZOP analysis.

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 Safety Issues: Fires and Explosions
Flammability Limits of Liquids and Gases
LFL and UFL (vol %) in Air at 25 oC and 1 Atm
Compound LFL (%) UFL (%)
Acetylene 2.5 100
Cyclohexane 1.3 8
Ethylene 2.7 36
Gasoline 1.4 7.6
Hydrogen 4.0 75

These limits can be extended for mixtures, and for elevated

temperatures and pressures (see Seider et al, 2003).
With this kind of information, the process designer makes sure
that flammable mixtures do not exist in the process during
startup, steady-state operation, or shut-down.

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 Design Approaches for Safety
 Techniques to Prevent Fires and Explosions
– Inerting - addition of inert dilutant to reduce the fuel
concentration below the LFL
– Installation of grounding devices and anti-static devices to
avoid the buildup of static electricity
– Use of explosion proof equipment
– Ensure ventilation - install sprinkler systems
 Relief Devices
 Hazard Identification and Risk Assessment
– the plant is carefully scrutinized to identify all sources of
accidents or hazards.
– Hazard and Operability (HAZOP) study is carried out, in which
all of the possible paths to an accident are identified.
– when sufficient probability data are available, a fault tree is
created and the probability of the occurrence for each
potential accident computed.

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 The Design Process - Summary
 Steps in Designing and Retrofitting Chemical Processes
– Assess Primitive
Assess Primitive Problem
Problem - covered today
– Process Creation
Process Creation - next week
– Development of Base Case
– Detailed Process Synthesis - Algorithmic Methods
– Process Controllability Assessment
– Detailed Design, Sizing, Cost Estimation, Optimization
– Construction, Start-up and Operation
 Environmental Protection
– Environmental regulations  design constraints
 Safety Considerations
– Should strive to design for “inherently safe plants”

25 DESIGN AND ANALYSIS II - (c) Daniel R. Lewin The Design Process