RUTGERS UNIVERSITY Department of Chemical and Biochemical Engineering

155:428 CHEMICAL & BIOCHEMICAL ENGINEERING DESIGN AND ECONOMICS II

SPRING 2012 (4 credits) Professor: Dr. A. Constantinides SOE, room C-203A (732) 445-3678 e-mail: acconsta@rci.rutgers.edu Teaching Assistant: None Class time: MW 1:40-3:00 p.m. Location: SEC 209 W 12:15-1:10 p.m. Location: SEC 210 or SOE C233 Course description Design and economics of large chemical/biochemical plants. The design details and economic considerations involved in the design, construction, and operation of chemical/biochemical plants using basic principles and modern computer software. Engineering ethics, plant safety practices, and OSHA concerns. Course objectives This is the capstone course, which utilizes the fundamentals of chemical/biochemical engineering

(material balances, energy balances, transport phenomena, thermodynamics, kinetics, separations, unit operations, control, and safety) in the design and operation of chemical/biochemical plants.

Introduces the concepts and methods of plant design and economic evaluation: planning, cost estimation, fixed capital investments, working capital, production costs, depreciation, rate of return, profitability analysis, discounted cash flow analysis.

Raises awareness of the students to the concepts of supply and demand of raw materials, commodity, and specialty chemicals.

Introduces the students to the available computational tools for process flow design and economic evaluation.

Stresses the importance of professional ethics, honesty, and integrity. ABET outcomes applicable to this course (a) an ability to apply knowledge of mathematics, science and engineering (c) an ability to design a system, component, or process to meet desired needs (d) an ability to function in multi-disciplinary/multi-functional teams (this can be defined as a mix of biochemical and chemical engineers, or as a group of students working on a different roles of a project) (e) an ability to identify, formulate, and solve engineering problems (f) an understanding of professional and ethical responsibility (g) an ability to communicate effectively (h) the broad education necessary to understand the impact of engineering solutions in a global and societal context (i) a recognition of the need for, and an ability to engage in life-long learning (j) a knowledge of contemporary issues (k) an ability to use the techniques, skills, and modern engineering tools necessary for engineering practice

2

Textbooks (required) M. S. Peters, K. D. Timmerhaus, and R. N. West, Plant Design and Economics for Chemical Engineers, 5th Edition, McGraw-Hill Book Company, New York (2003). [Referenced below as P,T,&W]. ASME Steam Tables - Compact Edition, ASME 2006, ISBN: 079180254X Textbook (recommended) D. A. Crowl and J. F. Louvar, Chemical Process Safety: Fundamentals with Applications, Prentice-Hall, 3rd Edition, 2011. [Referenced below as C&L] Prerequisites 155:324 Design of Separation Processes 155:415 Process Engineering I 155:427 Chemical and Biochemical Engineering Design and Economics I Homework and grading policy Assignments 45% Quizzes 5% Final design report 45% Attendance 5% 100% Class participation and attendance are important. The professor will circulate the class roster to observe student attendance. Students with more than 2 absences per semester will lose points (One % point for each absence, maximum 5% points). Design Project The major requirement of the course is the design, cost estimation, and profitability analysis of a complete chemical/biochemical process plant to be described later. For this project, students will be placed in groups of two, three, or four to work jointly, including the final design report. Your choice of partners may remain the same as in 155:427. The following are critical to your success in this course: 1. Begin early: The case study is very time-consuming with no room for procrastination. 2. Attend all lectures: Assignments will be handed out at lectures with full discussion of the

current problem at that time. If you miss the discussion, you may have difficulty with the assignment.

3. Cooperate with partners: Share the load, but understand that all partners need to know all the

design material. If you find inter-personal problems hindering the teamwork, bring them to the attention of the professor immediately. Do not wait until the end of the semester.

4. Use every resource: Utilize the textbook, the handouts, the library, the computer, the assistant,

and the professor as sources of information for this project.

3

5. Complete assignments thoroughly and timely: Several assignments will be completed during the design project. These assignments will be collected and graded. They will count for 45% of the course grade. The final design report, which is due at the end of the semester, will count for 45% of the grade.

6. Exams: There will be 1-3 quizzes to be scheduled during the semester. These will test the

student's knowledge of the material being covered in class and in the reading assignments. References R. Turton, R. C. Bailie, W. B. Whiting, and J. A. Shaeiwitz, Analysis, Synthesis and Design of Chemical Processes, 2nd edition, Prentice Hall, Upper Saddle River, New Jersey (2003). W. D. Seider, J. D. Seader, S. R. Lewin, and S. Widagdo, Product & Process Design Principles, 3rd edition, J. Wiley & Sons, Inc., New York (2009). H. F. Rase, Chemical Reactor Design for Process Plants, Volumes I & II, J. Wiley & Sons, Inc., New York (1977). W. D. Baasel, Preliminary Chemical Engineering Plant Design, 2nd Edition, Van Nostrand Reinhold, New York (1990). Perry's Chemical Engineer's Handbook, 8th Edition, McGraw-Hill Book Company, New York (2007). L. Kniel, 0. Winter and K. Stork, Ethylene: Keystone to the Petrochemical Industry, Marcel Dekker, Inc., New York (1979). P. C. Wankat, Separation Process Engineering: Second Edition, Prentice Hall, New York, NY (2007). (Used in 155:324 Design of Separation Processes course, Spring , 2011).

4

Course Outline Week Subject Reading Assignment 1 Brief review of what we did in Design I Engineering Code of Ethics

Plant design project(s) Possible flow sheets Handouts and References Establishment of design basis Physical properties needed 2-3 Reactor design Handouts and References Cracking ethane to produce ethylene Derivation of reactor model Discussion of reactor conditions Discussion of reactor limitations

Simulation of reactor model 2 Introduction to SuperPro Designer (for Biochemical Engineers) 4 Design and Cost Estimating Handouts Materials handling equipment (pumps, compressors) Ch. 12 (P,T & W) 5 Heat transfer equipment (heat exchangers) Ch. 14 (P, T & W) Liquid-vapor separators (flash drums) Wankat(2nd ed.), pp 45-49 6 Design and Cost Estimating Refrigeration systems Thermodynamics book and references 7 Mass transfer and reactor equipment Ch. 16 (P, T & W) Handouts 8-9 Design project details and implementation 10-11 Safety in Design Handouts and (C&L)

Principles of chemical systems safety and health engineering management US Chemical Safety Board Safety Videos

Process plant layout of ethylene plant with safety considerations 12-13 Design project details and implementation 14 The Design Report Ch. 11 (P, T & W) Contents; flow diagrams; equipment lists Fixed capital investment; Production costs Profitability analysis Design projects are due on May 7, 2012.