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CHEMICAL ENGINEERING 3G4 Simulation, Modeling and Problem Solving

Winter, 2008/2009 - McMaster University Hamilton, Ontario, Canada INSTRUCTORS: Dr. A.N. Hrymak , JHE 374, ext. 23136, hrymak@mcmaster.ca TEACHING ASSISTANT: Fadi Rishmawi, rishmaf@mcmaster.ca (Tutorial 1) Kyle Skemer, skemerk@mcmaster.ca (Tutorial 2) MEETING TIMES: T, W, F(L) 9:30 - 10:20 BSB 137 W (T1) 14:30 – 16:20 JHE 233/234 Computer Tutorial R(T2) 8:30 – 10:20 JHE 233/234 Computer Tutorial COURSE WEB SITE: http://www.chemeng.mcmaster.ca/courses/ REQUIRED TEXTS:

1. [W] Woods, D.R., "Problem-based Learning: how to gain the most from PBL", distributed by McMaster University, Hamilton, Ontario (1994).

RECOMMENDED TEXT:

2. [SSL] W.D. Seider, J.D. Seader and D.R. Lewin, “Product & Process Design Principles, 3rd edition, Synthesis, Analysis and Evaluation”, Wiley, (2008).

General Course Objectives 1. To use steady-state process simulation programs to aid analysis of chemical process systems

problems. 2. To gain experience gathering and interpreting real plant data. 3. To develop problem solving skills. Specific Objectives Pertaining to Computer Applications and Simulation 1. To be able to convert a real process flow diagram into a form compatible with a computer program

for chemical process simulation. 2. Given a process to be studied in the course, to be able to explain from fundamentals why the process

works and to visualize this on a process flow diagram. 3. To be able to complete a computer simulation or design study for processes to be studied in the

course. 4. To be able to integrate the fundamentals from mass and energy balances, thermodynamics, fluid

mechanics, heat transfer, mass transfer and reaction kinetics/reactor design into a systems understanding of processes.

5. To summarize in writing and verbally the results of activities in this course. Specific Objectives Pertinent to Problem Solving To develop confidence in their ability to 1. ask questions 2. interact with people and to work effectively in groups,

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3. self evaluate, 4. manage change 5. use small group, self directed problem based learning, 6. use visual thinking in practical terms. EVALUATION: This course is a mix of workshops, group activities, tutorials and lectures. Because much of the learning occurs in group activities and workshops you will get little from this course if you do not attend and participate in the activities. Indeed, if you do not participate, you will undoubtedly be required to repeat the course. Your progress will be monitored and we may write to you in mid-term indicating that because of your lack of participation, you should withdraw from the course at that time. If family emergencies come up, or you are sick and you cannot attend a scheduled activity, then contact Dr. Hrymak at ext. 23136 or send an email to hrymak@mcmaster.ca before the lecture/tutorial so that we can work out other arrangements. Many components contribute to the overall assessment in this course. Although some of the components have small weighting, I am counting on you to do them all. The overall average is determined numerically and then translated into a letter grade. The assessed components are:

Assignments 20% Tutorials 10% ( Note: I anticipate 3-4 individual assignments and 6 graded tutorials – equally weighted within each category) PBL Activities 20% Case Study 20% Written Final Exam 30%

The simulation activities comprise homework assignments, written group report for the case study and individual contributions to the reports. The final percentage grades will be converted to letter grades using the Registrar's recommended procedure. The hands-on training for the use of the simulation package is done through a series of self-directed exercises in the tutorials to guide you through the most important features of the flowsheeting package. The instructor reserves the right to adjust the grade distribution. USE OF CALCULATORS: Students should use the McMaster Standard Calculator during the final examination. SENATE AND THE FACULTY OF ENGINEERING POLICIES

“The Faculty of Engineering is concerned with ensuring an environment that is free of all adverse discrimination. If there is a problem, that cannot be resolved by discussion among the persons concerned, individuals are reminded that they should contact the Department Chair, the Sexual Harassment Officer or the Human Rights Consultant, as soon as possible.”

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“Academic dishonesty consists of misrepresentation by deception or by other fraudulent means and can result in serious consequences, e.g. the grade of zero on an assignment, loss of credit with a notation on the transcript (notation reads: “Grade of F assigned for academic dishonesty”), and/or suspension or expulsion from the university.

It is your responsibility to understand what constitutes academic dishonesty. For information on the various kinds of academic dishonesty please refer to the Academic Integrity Policy, specifically Appendix 3, located at http://www.mcmaster.ca/senate/academic/ac_integrity.htm

The following illustrates only three forms of academic dishonesty: • Plagiarism, e.g. the submission of work that is not one’s own or for which other credit has been

obtained. • Improper collaboration in group work • Copying or using unauthorized aids in tests and examinations.” Recommended References: (bold text books are recommended review material) Biegler, L.T., Grossmann, I.E. and Westerberg, A.W., Systematic Methods of Chemical Process Design, Prentice-Hall, 1997.

• The content of this book overlaps with the recommended textbook Cussler, E.L, and Moggridge, G.D., Chemical Product Design, Cambridge University Press, 2001. Felder, R.M. and Rousseau, R.W., Elementary Principles of Chemical Processes, 3rd Ed., Wiley, 1999. [F&R]

• Review the material from 2D4 and 2F4 in Chapters 1-9 Geankopolis, C.J., Transport Processes and Unit Operations, 4th Edition, Prentice-Hall.

• Review Vapour-Liquid Separation Processes Himmelblau, D.M., Basic Principles and Calculations in Chemical Engineering, 7th Ed., Prentice-Hall, 2004.

• An excellent alternative to F&R Incropera, F.P. and Dewitt, D.P., Fundamentals of Heat and Mass Transfer, Fifth Edition

• Review heat exchanger design Perry, R.H., and Green, D.W., Perry’s Chemical Engineers’ Handbook, 7th Edition, McGraw-Hill, 1997.

• The chemical engineering equivalent to the Bible – everything you wanted to know and then some.

Reid, R.C., Prausnitz, J.M and Poling, B.E., Properties of Gases and Liquids, 4th edition, McGraw-Hill, 1987.

• Excellent reference book on selecting thermodynamic correlations. Sandler, H.J., and Luckiewicz, E.T., Practical Process Engineering: A Working Approach to Plant Design, McGraw-Hill, 1987.

• Good reference for practical engineering information

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Sinnot, R.K., Coulson’s & Richardson’s Chemical Engineering, Revised 2nd Ed., Vol. 6, Chemical Engineering Design, Butterworth Heinemann, 1993. Towler, G. and R. Sinnott, Chemical Engineering Design, Butterworth Heinemann, 2008 – the US version of the earlier British text.

• In particular see process flowsheeting (chapter 4) and unit operations (chapters 10-12) Smith, J.M., Van Ness, H.C., Abbott, H.M., Introduction to Chemical Engineering Thermodynamics, 6th Edition, McGraw-Hill, 2001. [SVNA]

• Review volumetric properties of pure fluids (chapter 3); thermodynamics properties of fluids (chapter 6); vapour-liquid equilibrium (chapters 10, 14)

Smith, R., Chemical Process Design, McGraw-Hill, 1995.

• Excellent reference on process synthesis methods

Smith, R., Chemical Process Design and Integration, Wiley, 2005. • Update and expanded version of the earlier book – highly recommended.

Turton, R., et al., Analysis, Synthesis, and Design of Chemical Processes, 2nd Ed., Prentice-Hall, 2003

• Considerable overlap with the recommended text – good discussion of process flow diagrams (chapters 1-3); interpersonal skills (chapters 25, 26); pinch technology (chapter 13)

Woods, D.R., Process Design and Engineering Practice, and Data for Process Design and Engineering Practice, Prentice-Hall, 1995

• Excellent reference for equipment, especially for visualizing equipment and preliminary design calculations.

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CD-ROM There is an impressive set of tutorials included in the CD-ROM with the recommended textbook. Please use them as self-study aids – some will be taken up in class as well, but they are primarily for your study: (Make sure to select the Hysys simulator – the tutorials are different for AspenPlus!)

• Principles of Process Flowsheet Simulation o Brief introduction o Constructs o Getting Started in HYSYS

• Separations o Overview o Flash o Distillation

• Heat Exchangers o Overview o Theory o Heat Requirement Models o Shell and Tube

• Pumps, Compressors and Expanders o Overview o Pumps o Compressors and Expanders

• Chemical Reactors o Overview o Theory o Reaction Definition o Setting up Reactors

• Physical Property Prediction o Package Selection

• Tutorials o Material and Energy Balancing

Ammonia Separation Ethylchloride

manufacture o Heat Transfer

Toluene Manufacture o Separation Principles

Flash and Distillation Multi-draw distillation

o Reactor Design Principles Reactor modeling Ammonia Convertor

o Process Design HEN Multi-draw Ammonia convertor

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Tentative Course Schedule WEEK OF LECTURE TOPICS READINGS TUTORIAL (JHE 233/234) Jan 5 Process Design & Analysis SSL Ch 1 Jan 12 Creating a process – synthesis SSL Ch 4 Intro to HYSYS – not graded Jan 19 Process Simulation SSL Ch 5

F&R- Ch 10, SVNA – chapters 3, 6, 10, 14 Propane refrigeration

Jan 26 Process synthesis – Heuristics SSL Ch 6 Refrigerated Gas Plant Feb 2 Unit Ops: Heat Exchangers;

Separations; Pumps, Compressors, Expanders; Reactors

SSL Ch 18- 20, 7 Incropera, Geankopolis, Smith and Van Ness, Perry

Recycle Operations

Feb 9 PBL: Managing change; Self Directed Learning

W Ch 1-3

Separation Columns

Feb 15(BREAK) Feb 23 PBL: Group Skills W Ch 4-7 Optimizing the process Mar 2 TBA TBA Group Case Study Mar 9 Case Studies See web site Group Case Study Mar 16 Separation Systems SSL Ch 8 Group Case Study Mar 23 Heat Exchanger Networks SSL Ch 9 Heat exchanger networks – targeting Mar 30 HENs Continued Continued Heat exchanger networks - networks Apr 6 (Classes End Apr 7)

Note: References are to SSL 3rd edition – please look for chapter titles for 2nd edition.