CCB4023 PDP II Briefing.pdf

CCB4023 Plant Design II Briefing

January 2015Dr. Muhammad Moniruzzaman Room: 04-03-10Ext: 7572E-mail: [email protected]

1

1. Engineering Knowledge - Apply knowledge of mathematics, science, engineeringfundamentals and an engineering specialisation to the solution of complexengineering problems;

2. Problem Analysis - Identify, formulate, research literature and analyse complexengineering problems reaching substantiated conclusions using first principles ofmathematics, natural sciences and engineering sciences;

3. Design/Development of Solutions - Design solutions for complex engineeringproblems and design systems, components or processes that meet specified needswith appropriate consideration for public health and safety, cultural, societal, andenvironmental considerations;

4. Investigation - Conduct investigation into complex problems using research-basedknowledge and research methods including design of experiments, analysis andinterpretation of data, and synthesis of information to provide valid conclusions;

5. Modern Tool Usage - Create, select and apply appropriate techniques, resources,and modern engineering and IT tools, including prediction and modelling, tocomplex engineering activities, with an understanding of the limitations;

6. The Engineer and Society - Apply reasoning informed by contextual knowledge to assess societal, health, safety, legal and cultural issues and the consequent responsibilities relevant to professional engineering practice;

2

Program Outcomes


7. Environment and Sustainability - Understand the impact of professionalengineering solutions in societal and environmental contexts and demonstrateknowledge of and need for sustainable development;

8. Ethics - Apply ethical principles and commit to professional ethics andresponsibilities and norms of engineering practice;

9. Communication - Communicate effectively on complex engineering activities withthe engineering community and with society at large, such as being able tocomprehend and write effective reports and design documentation, make effectivepresentations, and give and receive clear instructions;

10. Individual and Team Work - Demonstrate knowledge and understanding ofengineering and management principles and apply these to ones own work, as amember and leader in a team, to manage projects and in multidisciplinaryenvironments;

11. Life-long Learning - Recognize the need for, and have the preparation and ability toengage in independent and life-long learning in the broadest context of technologicalchange;

12. Project Management and Finance - Demonstrate knowledge and understanding ofengineering and management principles, business acumen and entrepreneurship inmultidisciplinary environments.

3

Program Outcomes


By the end of this course, students should be able to:

1. Demonstrate their chemical engineering skills and knowledge

in a detailed design of a chemical plant

2. Generate cost effective process options while maintaining

operability, safety and environment friendliness of the design

3. Apply appropriate design codes in a detailed design work

4. Develop a piping and instrumentation diagram (P&ID) and

control strategy package

5. Prepare detailed economic evaluation of the proposed

chemical plant

6. Communicate and organize design group as an effective

team member

4

Learning Outcomes


5PO-CLO Mapping


No. PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12

CO1

CO2

CO3

CO4

CO5

CO6

6Course Summary

Application of all undergraduate knowledge and skills to solve designrelated problems.

To develop the skills of working in a team, leadership qualities,written and oral communication, decision making etc.


3 Credit Values, 100% Coursework

Design of Formalin Production Plant

7

Problem Statement


Formaldehyde is an industrially important

chemical used for manufacturing various types of

resins such as phenol formaldehyde, urea

formaldehyde and melamine resin. It is also used

as an intermediate for synthesizing chemical

intermediates such as 1-4 butanediol, trimethyl-

ol-propane, neopentyl glycol, pentaerythritol and

hexamethylenetetramine. The most widely

produced grade is formalin which is 37 wt. %

formaldehyde solution in water.

Process Design Tasks

III. Safety Analysis -

HAZOP

IV. Waste Treatment Strategy

V. Economic Evaluation

II. Detailed Design: Major and Minor Equipment

I. P& ID and Control Strategy

CCB4023 Plant Design II Briefing 8

Expectation

Utilising a blend of: hand calculations,

spreadsheets,

mathematical computer packages,

process simulator to design a process

Make necessary decisions, judgements andassumptions in design problems

Adhere to standard format for Group andIndividual reports


Final Oral Presentation

Contents: PDPI + PDPII

Submit a softcopy of group report two weeks before the presentation date

Evaluators: External Examiner from Industry + Group Supervisor

30 mins presentation, 30 mins Q&A

2 types of assessment:

Group assessment

Individual assessment


Final Group Report

Contents: PDPI + PDPII

Length: Between 100 to 200 pages

Each group is required to submit the report in hard copy (ABBA Lever Arch Folder, 404 Standard) and soft copy (CD)

Segregate each chapter with a divider

Use punch hole protection (reinforcing ring)


Individual Report

Report on detailed design of 1 majorequipment + 2 minor equipment

Length:40 pages

Compile all the final individual design reportin 1 hardcopy file

Segregate with a divider

Use punch hole protection (reinforcing ring)


Types of Equipment (Example)

Major equipment:ReactorDistillation columnAbsorption columnFurnace

Minor equipment:Extraction columnsEvaporatorMembrane UnitsCycloneFilterCooling towerSedimentation tanks


Only one student is allowed to undertake detailed design of each equipment.

Paper Size for Drawings


A1 and A3 drawings should be folded and inserted in

A4 sized plastic wallets

No. Drawings Paper Size

1. Process Flow Diagram (PFD) A1

2. Process and Instrumentation Diagram (P&ID) A1

3. Individual Equipment A3

4. Plant Layout A3

Assessment of Reports

Selected expert panels will evaluate theGroup and Individual Reports.

Example: P&ID and control strategysection will be evaluated by ProcessControl expert panels

Example: Reactor design will be evaluatedby Reactor expert panels


Individual Progress Performance(Official Group Meetings)

Must be conducted once in every two weeks

At least 7 official meetings per group

Minutes of meeting (MOM) must be submitted to themain supervisor within one (1) week after themeeting

Supervisor will evaluate the individual progress

Individual progress performance will contribute 10%of the overall individual marks

Students and supervisor may conduct additionalmeetings as frequent as required


Assessment Scheme

Assessment Stage

Examined by and % Contribution

SupervisorExpert

Panel

External

Examiner

Group

Contribution

Individual

Contribution

Final Report

(Group)10 20 30

Final Report

(Individual)10 10 20

Final Presentation

(Group)10 20 30

Final Presentation

(Individual)10 10

Individual

Progress10 10

C-Factor 0 1.0 x

Total 50 30 20 60% 40%


Distribution by contribution

Group 60%

Individual 40%

Distribution by evaluator

External examiner 20%

Expert panels 30%

Supervisor 50%

Summary of Assessment Scheme


Final Oral Presentation

Some comments: iCON must be used for simulation (e.g., heat integration, mass

balance)

iCON flowsheet should not be used as PFD

Clarity and importance of design basis, basis in HAZOP study

Lack of team work and coordination during presentation

Lack in design principle and application of fundamental theory:design margin, McCabe Thiele, static head, phase diagram,latent heat, etc.

Control strategy not adequate, wrong philosophy

Discrepancy in economic analysis: low CAPEX, high OPEX, highROR


Group and Individual Reports

Some comments: Did not incorporate the comments given during presentation

Missing data sheets/spec sheets

Executive summary does not address critical issue

Economic analysis not consolidated

Not a scaled plant layout, fire station should be outside thebattery limit/process area, parking lot/assembly point close tocontrol building

Too much on theory rather than application of the theoryspecific to the project

Report did not follow standard format, improper or inadequatequoting of reference, report shown minimal creativity, criticaland analytical thinking not evident etc.


Milestone and Important Dates


Wk 2 Wk 3 Wk 6Wk 5Wk 4 Wk 7 Wk 8 Wk 9 Wk 10 Wk 11 Wk 12 Wk 13 Wk 14

Submission of Report (softcopy): March 26 , 2015

Submission of Final Report:

April 18, 2015

Wk 1

Individual:Detailed

design Major and Minor Equipment

Reports Preparation

Group:P&ID and Control StrategySafety & Loss Prevention

Waste Treatment StrategyScaled Plant Layout

Economic Evaluation

Final Oral Presentation: April 08, 2015

(Tentative)

21

All the Best!

CCB4023 PDP II Briefing.pdf

Documents

Transcript of CCB4023 PDP II Briefing.pdf