CHEMICAL ENGINEERING DESIGN PROJECT

CHAPTER ONE (Nitric Acid) as case

study (example)

1. Introduction

1.1 Conception and definition

1.2 Properties and Uses

1.3 The Evolution of (Nitric Acid) Production Processes

 CHEMICAL ENGINEERING DESIGN PROJECT

CHAPTER TWO
Feasibility Study and Literature Survey

2.1 Initial Feasibility Study

THE FEASIBILITY study for a chemical process design investigates both the technical and
economic feasibility of the proposed project.
Decide whether the design project should proceed to the next stage. If no, list all the
reasons (in order of priority) and indicate what changes (if any are possible) would
reverse this decision. If yes, list all the assumptions/restrictions upon which this
decision is based (in priority order).
 CHEMICAL ENGINEERING DESIGN PROJECT

CHAPTER TWO
Feasibility Study and Literature Survey

2.2 LITERATURE SURVEY

The large number of references used in this project were divided into subject categories
according to the content of the articles and the type of information provided, this made
evaluation easier. Five major categories were selected. These are listed below:

1. General Information (G)

2. Process Technology (PT) See pp 16-39 (chemical engineering design projects)

3. Cost Estimation (CE)

4. Market Data (MD)
5. Thermodynamic Data (TD)
 CHEMICAL ENGINEERING DESIGN PROJECT
CHAPTER THREE
Process Selection and Description
3.1 Process Selection

3.1.1 Considerations and

3.1.2 Comparison between all the production process,
3.1.3 finally select the best process.
3.1.4 Process Selection Conclusions
Select the ‘best’ process route for production of the chemical, and justify this decision.
Prepare a detailed process flow diagram, and as far as possible a P&ID.
3.2 Process Description and Equipment List

Prepare a complete equipment list for the chosen process route, include references for all
information and data.
 CHEMICAL ENGINEERING DESIGN PROJECT

3.2 Process Description and Equipment List

The equipment list is used in conjunction with the process flow diagram (or P&ID). Each item
of equipment on the flowsheet should be assigned a unique reference number, and that
number is used to cross reference items in the equipment list. Particular letters may be used
to identify similar items of equipment, e.g. reactors as Rxxx, pumps as P- 001, etc.

The equipment list should include all available information that will be useful for the
detailed design of the equipment. This should include the physical size of an item (if
known), operating temperature and pressure, wall thickness, height of packing, etc.
for more information and details See pp 47-60
(chemical engineering design projects)
 CHEMICAL ENGINEERING DESIGN PROJECT
CHAPTER FOUR
Site Considerations and Economic Evaluation

4.1 Site Considerations

4.1.1 Site Selection

Prepare a list of suitable sites for the construction of a chemical plant, arranged in
descending order of preference.
List all the merits and disadvantages of each site, and explain in detail why the first site
is preferred.
State any factors that need to be monitored throughout the project, e.g. government
policy.
 CHEMICAL ENGINEERING DESIGN PROJECT
CHAPTER FOUR
4.1 Site Considerations
4.1.2 Plant Layout

Prepare a preliminary plant layout, explaining the reasons for particular proposals.

Having selected a suitable site for the chemical plant, it is possible and necessary to make a
preliminary decision regarding the layout of the plant equipment. Although the equipment has not been
designed in detail, preliminary estimates of the physical size of each item should be available in the
equipment list (Chapter 4). Any sizing differences between the initial and final estimates should not be
too excessive, and appropriate areas should be allowed around the plant items when determining the
layout.
for more information and details See Chapter 4 and
5 in (chemical engineering design projects)
 CHEMICAL ENGINEERING DESIGN PROJECT
CHAPTER FOUR
4.1 Site Considerations
4.1.3 Environmental Impact Analysis

This topic needs to be considered at an early stage in the design, in relation to the site considerations, and
reassessed during the detailed design stage (Chapter 8). The effect of the operation of the chemical plant upon the
environment and the population must be considered during the feasibility study and during subsequent design
stages. The formal environmental impact analysis (EIA) has two parts, these relate to:

• the treatment of unwanted chemicals (by-products) and the concentrations of liquid discharges and gaseous
emissions during normal operation;

• the handling of a major chemical accident, including all chemicals within the plant and any subsequent
reaction products, and containment and clean up.
 CHEMICAL ENGINEERING DESIGN PROJECT
CHAPTER FOUR
4.1 Site Considerations
4.1.3 Environmental Impact Analysis
The environmental impact analysis is specific to the plant under consideration, the comments/suggestions made
here are of a general nature.
General Considerations
All waste chemicals from the plant must be disposed of in an acceptable manner. Dumping of the waste may not
be allowed or, if it is, it may be prohibitively expensive. Some form of treatment, e.g. dilution, neutralisation,
purification, separation, etc., may be necessary prior to disposal.
EIA Policy and Scope
Environmental Impact Assessment (EIA) has evolved as a comprehensive approach to project evaluation, in which
environmental factors, as well as economic and technical considerations (e.g. Cost Benefit Analysis), are given
appropriate consideration in the decision- making process. The purpose of an EIA study is to determine the
potential environmental, social and health effects of a proposed development.
 CHEMICAL ENGINEERING DESIGN PROJECT
CHAPTER FOUR
4.2 Economic Evaluation
4.2.1 Capital Cost Estimation

During the feasibility stage of a design project, approximate cost estimates ( ± 20-30%) are required - and usually in
the minimum time possible. Cost correlations and factored estimates are usually sufficiently accurate for the initial cost
estimation study, and they significantly reduce the calculation time required for more detailed estimates.

Cost of Equipment (Major Items)

Major items of equipment include reactors, heat exchangers, columns, vessels, etc. Ancillary equipment such
as process piping and insulation can be estimated after the total cost of the major items is known.

I Cost correlations
Cost correlations provide a convenient method of estimating the capital cost of major
items of equipment.
 CHEMICAL ENGINEERING DESIGN PROJECT
CHAPTER FOUR
4.2 Economic Evaluation
4.2.1 Capital Cost Estimation
Cost of Equipment (Major Items)

II Factored estimate method

The complete plant cost can be estimated by extrapolation from the cost of the major items of
equipment. An accuracy of ± 15-25% is possible if appropriate factors are chosen.

Module Costs
An estimate of the plant capital cost can also be obtained by considering the plant as a set of modules. Each module
consists of similar items of equipment, e.g. heat exchangers, steam generators, etc. The standard cost of each
process module is calculated (for a particular year), corrections are applied for the use of materials other than
carbon steel and for high pressures.
 CHEMICAL ENGINEERING DESIGN PROJECT
CHAPTER FOUR
4.2 Economic Evaluation
4.2.1 Capital Cost Estimation

Auxiliary Services

It is necessary to include the full cost of auxiliary services, e.g. steam, water and electricity
supply and distribution, roads, buildings, communications, etc., in the capital cost estimate
for a new plant.
 CHEMICAL ENGINEERING DESIGN PROJECT
CHAPTER FOUR
4.2 Economic Evaluation
4.2.2 Operating Costs
The operating costs should be considered when the alternative process routes are being
evaluated, and they can significantly influence the final choice that is made. Operating costs can
be divided into two groups (although in some cases the division is arbitrary), these are:

(a) Fixed costs such as laboratory costs, operating labour, capital repayment charges, insurance, etc.
These costs do not depend upon the production rate, and they must be paid even if no chemical is
produced.
(b) Variable costs such as raw materials, utilities (services), shipping, etc. These costs are dependent
upon the amount of chemical produced.
 CHEMICAL ENGINEERING DESIGN PROJECT
CHAPTER FOUR
4.2 Economic Evaluation
4.2.3 Profitability Analysis
The first stage in evaluating the profitability of a proposed new product is to compare the total cost of
the product (for example, per tonne produced) with the current market price. It is also necessary to
estimate future demand for the product, and to determine the trend in the selling price over several
previous years. It is also necessary to estimate the number of years that the product can be sold at a
satisfactory profit, this is more useful than estimating the possible operating life of a plant
Action: Perform a detailed economic analysis of the project including: Capital cost estimates
(by different methods)
Operating cost estimates
Profitability analysis
Re-assess the economic feasibility of the project based upon the complete economic analysis.
for more information and details See Chapter 5 and 6 in (chemical engineering design projects)
 CHEMICAL ENGINEERING DESIGN PROJECT
CHAPTER FIVE
Mass and Energy Balances

MASS AND energy balances must be completed for each item of equipment before the detailed design
of these items can begin. A mass balance is performed for each individual unit shown on the process
flowsheet and included in the equipment list (Chapter 4).

Action:
Preparation of individual mass and energy balances for each item of chemical engineering
equipment (or heat balances over several items of equipment).

Transfer of information to the process flowsheet and equipment list.

for more information and details See Chapter 7 in (chemical engineering design projects)
 CHEMICAL ENGINEERING DESIGN PROJECT
CHAPTER SIX
The Detailed Design Stage

6.1 Detailed Equipment Design

Many different process operations are performed in a chemical plant, e.g. distillation, heat transfer, absorption,
etc., and for each of these operations a wide range of equipment has been developed to suit particular applications
and situations. These include different types of heat exchangers, e.g. plate, shell and tube, carbon block, etc.;
packed and plate distillation columns; CSTR or tubular reactors, etc.

for more information and details See Chapter 8-12 in (chemical engineering design projects)
 CHEMICAL ENGINEERING DESIGN PROJECT
CHAPTER SIX
The Detailed Design Stage
6.2 Process Control and Instrumentation
A control strategy hopefully can then be evolved. It is also necessary to determine the ancillary instruments required for process
monitoring, and for plant commissioning and start-up. It is worthwhile at the design stage including connections for instruments
which may be required in the future. The location (local or a distant control room) and types of recorders must be specified, and
the alarms and interlocks that are required. Control does not occur independently in different units, and an overall and integrated
approach to the control of the plant is required.

Action: Prepare detailed designs for the chemical engineering units in the plant. Consider
energy conservation measures and the process control and instrumentation required as the
designs are
performed. Prepare a design specification sheet for each unit. Detail the specific energy
conservation schemes considered and adopted,
Discuss the process control strategy for the overall process and the instrumentation required.
Prepare a completefor
P more
& ID for theand
information process.
details See Chapter 8-12 in (chemical engineering design projects)
 CHEMICAL ENGINEERING DESIGN PROJECT
CHAPTER SIX
The Detailed Design Stage
6.3 Safety, Loss Prevention and (Hazard and Operability ) HAZOP

Action: Prepare a HAZOP study for a particular item (or section) of the chemical plant.
Identlyy major hazards and necessary actions.
Summarise the conclusions in relation to the design of the plant.

for more information and details See Chapter 8-12 in (chemical engineering design projects)
 Reference

CHEMICAL ENGINEERING
DESIGN PROJECT
A Case Study Approach

By Martyn S. Ray
and
David W. Johnston