NATIONAL UNIVERSITY OF SINGAPORE Department of Chemical & Biomolecular Engineering CN4121 DESIGN PROJECT (AY2011-12)

OBJECTIVES & APPROACH Holistic design experience is an essential part of the chemical engineering curriculum. To impart such an experience is the main goal of this project-based module. The module gives students an opportunity to deal with an open-ended chemical plant design project, the like of which they may face in practice. In this project, the students will carry out the major steps involved in the design and evaluation of a new chemical manufacturing process. The key elements of this design experience are: 1. Working in a team where all members contribute individually as well as collectively with proper communication and coordination; each team member is responsible for the entire project individually and collectively. 2. Applying fundamental chemical engineering principles and data from literature. 3. Making critical design decisions in a safe, creative, practical and cost-effective manner. 4. Reporting work in formal, concise, and easy-to-follow reports.

ORGANIZATION & ASSESSMENT Students form teams of SEVEN (7) members each. The members can be from any tutorial class. Each team must designate a team leader and select a team number. Each student will use his/her unique team number to sign up in IVLE. Each student, including the leader, will opt to do the design of one of the seven sections of the entire process, as described later in the scope (see the last page of this design brief). Each section will be advised by a separate lecturer. In addition, the members of each team are expected to work together on some common parts of the project. It is the collective responsibility of all team members to ensure that they meet and communicate with one another continually throughout the semester to achieve good progress, and consistent and feasible final design. The team leader is responsible for coordinating and facilitating this communication and team work, with inputs and cooperation from all team members. The final grade for CN4121 will have three parts. The marks from CN4121 Part 1 will constitute the first part with a weight of 15%. The individual unit/section design report along with individual oral presentation will be the second part with a weight of 55%. The interim report and the final report on common team tasks will be the third part with a weight of 30%. The actual marks for the last part for a student will depend on the peer evaluation scores that the student receives from his/her team mates. All these components are clearly important, and can affect the final grade significantly. In recognition of additional responsibility, team leader can get up to 3 extra marks, which will be based on peer evaluation by team members and progress of the project as evidenced by the meeting minutes submitted by each team. 1

Each student must sign up for TWO (2) projects in IVLE under his/her own team number. One project is CN4121: Team Members, and the other is CN4121: Section N: xxxx, where N is the section number and xxxx is the name of the Advisor for the unit / section that the student has opted to design. In addition to enrolling in these two projects, each team leader must sign up for one more project (CN4121: Team Leaders) in IVLE. Failure to sign up by the due date or sign up correctly (wrong team, wrong advisor, etc.) will incur penalty on overall marks. Note that this is the only way by which we know team compositions and student responsibilities.

SCHEDULE The PC Clusters [E1-04-09 (PC2), E1-04-10 (PC3), E2 03-06 (PC4), and E5 03-24) are reserved for the project work on Thursdays (0800 - 1800) and Saturdays (0800 2100). Visio software also is available in E5 03-24. All sessions in LT 6 on Thursdays, unless stated otherwise. Date (Week) January 12 (Week 1) Activity Overview of the project (by Prof. Srini) Talk on Team-work Talk on Design & Sustainability in Practice (by Joe Eades) January 26 (Week 3) February 9 (Week 5) February 16 (Week 6) Small Group Meetings (See the footnote for the venues) Small Group Meetings (See the footnote for the venues) Small Group Meetings (See the footnote for the venues) February 18-25 Recess Week March 1 (Week 7) March 8 (Week (8) March 29 (Week 11) Small Group Meetings (See the footnote for the venues) Report Writing Briefing on Cost Estimation & Economic Analysis Briefing on Health, Safety and Environment 14.00 13.00 13.00 14.00 Time 13.00 13.45 14.00 14.00 14.00 14.00

Venues for Small Group Meetings (1) Fired heater (I.A. Karimi): E4 04-03 (2) EB reactor (S. Kawi): E3 06-05 (3) DEB reactor (A. Borgna): E1 06-01 2

(4) (5) (6) (7)

Benzene column (M.P. Srinivasan): E1 06-06 EB purification (M. Bansal): E1 06-07 Heat exchangers & flash (G.P. Rangaiah): E5 02-32 Cooling tower (M.S. Uddin): E3 06-04

Industry Talks: All sessions in LT 6 on Saturdays, unless stated otherwise. Date (Week) 21st Jan (Week 2) 28th Jan (Week 3) 28th Jan (Week 3) 4th Feb (Week 4) 4th Feb (Week 4) 24th Mar (Week 10) Tentative Title Design of Industrial Reactors Design of Furnaces Design of Cooling Towers Design of Separation Columns Design of Heat Exchangers SHE in Practice Time 10.00 9.30 11.00 9.30 11.00 10.00

Weekly meetings with team leaders (or their representatives): Every Thursday, at 3 pm in E5 03-20. Deadlines and Deliverables Date January 19 (Week 2) Deliverables Team Formation: Team number, names of team members and leader; enrol in IVLE for two projects (CN4121: Team Members & CN4121: Team Leaders) Penalty: 1% for failure to enrol or incorrect enrolment Unit Selection: Sign up for IVLE project (CN4121: Section X: xxxx), where X is your section number and xxxx is the name of the advisor for that section. Penalty: 1% for failure to enrol or incorrect enrolment February 16 (Week 6) Interim Report (printed copy): A 2-page interim report (one from each team). Suggested content: Scope, process overview, inputs to and targets for each section, progress in each section, team work plan and milestones, etc. Flowsheet and stream data can be attached as additional pages. 3 During Team Leaders Meeting Submit to IVLE

March 19 (Monday) (Week 10)

Individual Report on Process Development and Design Upload one single (printed and electronic copies) one from each student pdf into your own Page limit per report: 35 pages (including appendices, folder for IVLE project on Section if any) X Penalty: 1% for every 4 pages exceeding the maximum Submit one printed copy for each section separately to the ChBE Department office by 5.30 pm Team Report (electronic copy - one from each team): Executive Summary, SHE + Economics & Profitability, Discussion on New Technology and Sustainability. Page limit for Cost Estimation and Economic Analysis: 20 pages Page limit for SHE: 30 pages Page limit for entire report: 65 pages Penalty: 1% for every 4 pages exceeding the limit. Upload one single pdf into the folder for IVLE project CN4121: Team Leaders

April 9 (Monday) (Week 13)

Week 13

Oral Presentations: On Process Development and design of individual units/sections (No need to cover economic analysis and SHE). Schedule will be announced later. Peer assessment: Each team member will be asked to assess the contribution of other members in his/her team to the common parts. This will be done towards the end of April, and will be taken into account for grading each students performance.

NA

April 30

Online in IVLE

Penalty for late submissions of the above without valid reasons: 2%/day of delay.

REPORT The reports must be written using Times New Roman of size 12 (or equivalent) and 1.5 line spacing on both sides of A4 paper. Graphs and drawings that are submitted with the reports should be of convenient size. References should be given in a consistent format; they should be clearly cited in the appropriate places of the main text where materials from such references are used. All results must be in SI units, and all symbols must be clearly defined. 4

Further details and guidelines for report organization will be discussed in the Report Writing session on 8th March. The reports should be the unaided work of the student or his/her team. Plagiarism in any form whatsoever will not be tolerated and the reports will be checked by software to detect plagiarism. Source codes, algorithms and/or printouts of all computer programs written by the students should be submitted with the report. Students may use legally permitted or published process simulators and computer programs for numerical techniques and graphics. In using application software such as process simulators, students must clearly demonstrate their understanding of the methods and fundamental principles used in these programs, and it should be clearly stated where these are used in the report. For example, it is essential that calculation of or justification for all input specifications to process simulators be clearly shown; a brief description and/or an illustrative sample calculation should be included to demonstrate understanding of the commercial packages.

REFERENCES Recommended Texts 1. Seider, W.D., Seader, J.D., Lewin, D.R., Widagdo, S., Product & Process Design Principles, Wiley, 3rd Edition, 2010 (TP155.7 Sei 2010). 2. Turton R., Bailie R.C., Whiting W.B. and Shaeiwitz J.A., "Analysis, Synthesis, and Design of Chemical Processes", Prentice Hall, 3rd Edition, 2009 (CL RBR TP155.7 Ana 2009). General References 3. Douglas, J.M., Conceptual Design of Chemical Processes, McGraw Hill, 1988 (TP155.7 Dou). 4. Biegler, L.T., Grossmann, I.E., Westerberg, A.W., Systematic Methods of Chemical Process Design, 2nd Edition, Prentice Hall, 1999 (TP155.7 Bie). 5. Silla, H., Chemical Process Engineering Design and Economics, 2003 (TP155 Sil 2003). 6. Green, G.W., Perrys Chemical Engineers Handbook, 8th Edition, McGraw-Hill, 2006 (CL RBR TP151 Per). 7. Couper, J. R., Penny, W. R., Fair, J. R. and Walas, S. M., Chemical Process Equipment: Selection and Design, 2nd edition. Elsevier (CL RBR TP157 Chem 2005). 8. Peters, M.S., Timmerhaus, K.D., West, R.E., "Plant design & Economics for Chemical Engineers", 5th edition, McGraw-Hill, New York, 2003 (CL RBR TP155 Pet 2003). 9. Towler, G., and Sinnott, R., Chemical Engineering Design: Principles, Practice and Economics of Plant and Process Design, Elsevier, Amsterdam, 2008 (TP155 Tow 2008). 10. Sinnot, R., Coulson and & Richardsons Chemical Engineering", Vol. 6, 4th Edition, Oxford, 2005 (TP155 Sin 2005). 11. Wankat, P.C., Separation Process Engineering, 2nd Edition, NJ: Prentice Hall, 2007 (TP156 Sep.Wa 2007).

12. Encyclopedia of Chemical Technology, eds. Mark, H.F. et al. New York: Wiley, c1978c1984. (TP9 Enc). 13. Encyclopedia of Chemical Processing, ed. Lee, S. New York: Taylor & Francis, 2006. (TP9 Ency 2006). 14. Encyclopedia of Chemical Processing and Design, executive editor, McKetta, J.J.. New York : Marcel Dekker, Inc, c1976-<c1999> (TP9 Enc) 15. Kirk-Othmer Encyclopedia of Chemical Technology, executive editor, Kroschwitz, J.I. New York : Wiley, 2004 (TP9 Kir 2004) 16. Ullmann's Encyclopedia of Industrial Chemistry, executive editors, Ullmann F., Gerhartz W., Yamamoto Y.S., Campbell F.T., Pfefferkorn R., et al. Weinheim, Federal Republic of Germany ; Deerfield Beach, FL, USA: VCH, 1985 (TP9 Ull) Specific References 17. Ganji H., Ahari J.S., Farshi A., Kakavand M., Modeling and Simulation of Benzene Alkylation Process Reactors for Production of Ethylbenzene, Petroleum & Coal, 46 (1), 55-63, 2004. 18. Dimian, A.C., and Baldea, C.S., Chemical Process Design: Computer-Aided Case Studies, Wiley-VCH, 2008. Chapter 15. (TP155.7 Dim2008) 19. You, H., Long, W., Pan, Y., The Mechanism and Kinetics for the Alkylation of Benzene with Ethylene, Petroleum Science and Technology, 24, 1079 1088, 2006. 20. http://www.icis.com/V2/Chemicals/9075695/ethylbenzene/process.html (accessed on 6th October 2011). 21. Luyben, W., Design and Control of the Ethyl Benzene Process, AIChE J., March 2011 Vol. 57, No. 3.

DESIGN BRIEF Design a plant to produce ethylbenzene (EB) using vapour phase alkylation of benzene with ethylene. Assume that the plant is to be located in Singapore and the operation time is 8000 h/yr. The plant design specifications for each team are listed below. Design Specifications Plant Capacity (PC) of ethylbenzene (tonne/year): (1) 250,000; (2) 300,000; (3) 350,000; (4) 400,000 Feedstock: Feedstock consists of benzene feed at 298 K, 110 kPa and ethylene feed at 298 K, 2000 kPa. Benzene feed (B) contains either (1) 2 mol% toluene or (2) 3 mol% toluene. Ethylene feed (E) contains either (1) 5 mol% ethane or (2) 7 mol% ethane. Product Specifications (PS): Ethylbenzene should be produced in this purity: (1) 98.5%, (2) 99.0%, or (3) 99.5%. It should be at 313 K and 1 atm.

Team-wise Specifications: Team 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 PC 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 E 1 1 1 1 1 1 2 2 2 2 2 2 1 1 1 1 1 1 2 2 2 2 2 2 B 1 1 1 2 2 2 1 1 1 2 2 2 1 1 1 2 2 2 1 1 1 2 2 2 PS 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 Team 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 PC 3 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 4 4 4 4 E 1 1 1 1 1 1 2 2 2 2 2 2 1 1 1 1 1 1 2 2 2 2 2 2 B 1 1 1 2 2 2 1 1 1 2 2 2 1 1 1 2 2 2 1 1 1 2 2 2 PS 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3

SCOPE OF WORK The report should emphasize the systematic and sound application of chemical engineering principles to the solution of this project. Justification, where required, must be given for the selection of process and raw materials, reaction pathways, equipment types and configuration, heat transfer media, and process conditions. All design equations must be stated and referenced or derived; assumptions should be clearly justified; and any sources of uncertainty should be discussed. Data and results of any computer program used must be clearly presented. 1. Executive summary: Prepare a 750-word summary describing the main features of your proposed design (such as importance of product, process developed, major equipment details, profitability, and safety, environmental & operational issues etc.). Provide values of important operating conditions, sizes, total costs etc. If necessary, refer to the process flow diagram given elsewhere in the report.

2. Process development and design: Identify and explore alternatives for raw materials, reaction pathways, catalysts, separation technologies, process conditions, etc. Identify and explore opportunities for conserving water, fuel, and energy, reducing environmental impact, recycling/reusing/treating materials, etc. Synthesize and evaluate several alternate process configurations based on your above exploration and identify the best process. Use criteria such as feasibility, safety, cost, profitability, controllability and reliability for process evaluation. Develop a complete simulation model, if required, for your proposed process. Select one unit/section from the following for process development and design: (1) Fired heater (Advisor: I.A. Karimi), (2) EB reactor (Advisor: S. Kawi), (3) DEB reactor (Advisor: A. Borgna), (4) Benzene column (Advisor: M.P. Srinivasan), (5) EB purification (Advisor: M. Bansal), (6) Heat exchanger and flash after EB reactor (Advisor: G.P. Rangaiah), (7) Cooling tower (Advisor: M.S. Uddin). Individual report on process development and design must contain a process flow diagram showing principal equipment, along with a table of process stream data. Refer Chapter 3 Chemical Engineering Process Design and Economics (G. D. Ulrich and P.T. Vasudevan, Process Publishing, 2004) for examples on presentation of PFDs. 3. Cost Estimation and Economic Analysis: Prepare an equipment schedule listing all major equipment including tanks and pumps. Perform a complete cost estimation and economic analysis for the whole process. Discuss about the profitability of the proposed plant. Equipment schedule and cost estimation of equipment in a unit/section will be the responsibility of the individual member. So, present these in separate tables for each unit/section. Rest of the cost estimation & economic analysis will be common work. Use utilities and their cost data from Turton et al. (2009). 4. SHE: Prepare an account of safety, health and environmental considerations in the design, including hazard identification and HAZOP studies. Other specific topics such as plant layout, operational safety, treatment and disposal of effluent, product life cycle and personnel protection should also be discussed. 5. New Technology and Sustainability: Review new technologies for ethyl benzene production and discuss their potential as well as the use of renewable energy. Discuss sustainability of the ethyl benzene plant in a location other than Singapore; no cost calculations are required but only qualitative discussion on economic, environmental and societal aspects.