MISS. RAHIMAH BINTI OTHMAN ERT 422/4 BIOPROCESS PLANT DESIGN MISS. RAHIMAH BINTI OTHMAN (Email: rahimah@unimap.edu.my)

IMPORTANT DATELINES DATELINES ACTION SUBMISSION 1 19 April 2012 (TODAY) STUDENTS SUBMISSION 2 24 May 2012 (THURSDAY) SUBMISSION 3 28 May 2012 (MONDAY) 31 MAY 2012 (THURSDAY) VIVA 4 – 6 June 2012 (MONDAY – WEDNESDAY) & SUPERVISORS

PEER EVALUATION Assessment Name of Team Members A B C D E Average role in group activities/displayed initiative (10m) Information gathering skills (10m) Enthusiasm towards the project, energy exhibited (10m) Reliability, dependability to perform assigned tasks (10m) Quality and accuracy of work, attendance, punctuality (10m) TOTAL (50 M) This mark will be encountered in Sub 1, 2 & 3.

SUBMISSION 1 -cont’ Outlines Part 5 I. PIPING & INSTRUMENTATION DIAGRAM (P&ID) P&ID should include all details of equipment, piping details of size, length and type (together with calculation in the Appendix) of valves and fittings. Shows all the piping arrangements with valves, fittings and equipments. II. IDENTIFICATION & DRAWING OF CONTROL LOOPS Identify and draw control loops required on each piece of equipment needed for steady state operation. These loops may contain; a. Level Control b. Flow Control c. Pressure Control d. Temperature Control Identify the key process variables that must be controlled to achieve the specified product quality. Identify and include any additional control loops that is necessary for safe operations mode. Discuss process control strategy for the overall process and the instrumentation system. III. COMPLETE PROCESS & INSTRUMENTATION DIAGRAM (P&ID) Prepare a complete P&ID for the plant using standard notations and symbols.

Synthesis and Design Process Bioprocess Plant Design DESIGN PROJECT 2 Courses Report Submissions Parts ERT 416 Synthesis and Design Process 1 Part 1: Literature Review and Process Background. Part 2: Design Simulation and Process Flow Diagram. 2 Part 3: Process Design of Equipment. Part 4: Mechanical Design of Equipment. 3 Combination of Part 1 to 4 reports. ERT 422 Bioprocess Plant Design Part 5: Control System and Piping. Part 6: Pollution Control Analysis. Part 7: Plant Safety Analysis. Part 8: Profitability Analysis. Combination of Part 5 to 8 reports. Final Report (ERT 416 & ERT 422) Combination of all the Part (from Part 1 to 9) Part 9: Conclusions and Recommendations

SUBMISSION 1 Outlines Part 6 ENVIRONMENTAL PROTECTION AND ENVIRONMENTAL IMPACT ANALYSIS Prepare an environmental impact analysis for the proposed bioprocess plant system with considering to; Estimation of effluent (waste) produced such as solid, liquid, gaseous and aqueous discharge from the plant. Propose the methods for the safe disposal of the wastes. List down planned, fugitive and emergency emissions in the plant. Treatment of unwanted chemicals (by-product) and the concentrations of liquid discharges during normal operation. The handling of major chemical accident, any subsequent reaction products and clean up. Scheme for waste management and treatment plant. The scheme can include physical treatments, chemical treatments and biological treatments for wastes. Show how the environment and surroundings will be affected after building and operation of the plant.

SUBMISSION 2 Part Outlines 7 PLANT SAFETY List down all the hazard procedures to overcome associated equipment design and operation. Suggest any procedures on how to overcome these hazards from safety point of views. Describe HAZOP study of the two most critical equipment of your plant. Plant start-up safety review: This review should cover the safety aspect of the process during the start up before any processing occurs on the site. List down the safety aspects of the plant shut down procedures. It should be given as Gantt Chart (time schedule) with each step of standard procedure of shut down of the plant.

SUBMISSION 2 –cont’ Outlines Part 8 ECONOMICAL ASSESSMENT Capital Cost Estimation List down all the equipment, capacity/size, materials of construction and operating conditions. Estimate bare module cost of each equipment using correlations, equations/graph and CAPCOST.xls Software. Compare your values for the both processes. Shows the summary of any essential utilities required for all the requisite equipment that have been identified in your PFD and obtained total yearly utility costs for the process in a Tubular form using EXCELL. Use any suitable method to obtain a total capital cost estimation of the plant (study estimate). Compare total capital cost evaluation using different methods such as the Ratio method, Factorial (Lang factor) method and Method of Guthrie. Calculate the cost of manufacture (COM) for the produced chemical using any selected process. Include the cost of operating labour, utilities, waste treatment and raw materials. Represent different components of COM by Pie Chart with the total investment. Calculate the total production costs.

SUBMISSION 2 – cont’ Outlines Part 8 – cont’ II. PROFITABILITY ANALYSIS The costs of project plant should consist of; a. Land cost b. Fixed Capital Investment c. Working Capital d. Plant lifetime e. Start-up time f. Revenues from sale g. Design capacity and operating capacity h. COM (with and without depreciation) i. Tax rate j. Depreciation Method k. Internal Rate of Return l. Plant Operation Describe a cumulative (non-discounted and discounted) after tax cash flow diagram. Calculate; a. Cumulative cash position (CCP) and Cumulative cash ratio (CCR) b. Payback period c. Rate of return on Investment d. Venture Profit e. Net Present Value and NPV ratio f. Discounted payback period g. Discounted cash flow rate of return (DCFROR) Make a conclusion of your designed plant via profitability analysis of view. Explain any unusual results that you have find and give your recommendations. The report must include Investment Summary.

Total Design Project Marks GRADING SCHEME Total Design Project Marks Supervisor (40 %) Sub 2 (15 %) Final report (10 %) Sub 1 (15%) Examiner (20 %) Mid Term Test Test 1 Test 2 Oral Presentation (20%)

SUMMMARY OF GRADING SCHEME Evaluation by Supervisor/ Examiner (60%) Presentation / Examination (40%) Final Grade 100% Continuous evaluation (30%) Final Project Report (30%) Total Marks 60% Oral presentation Midterm Test 1 & 2 Total Marks 40% Sub 1 Sub 2 From Supervisor External Examiner 15% 10% 20% 20 %

ACTIONS SHOULD BE TAKEN AFTER VIVA DO THE CORRECTIONS. COMPILE THE WHOLE THESIS. LIST OF COMMENTS. SHOW TO YOUR SUPERVISOR & COORDINATOR FIRST BEFORE PRINT & BIND INTO HARD COVER (THERE IS A FORM TO BE FILLED) SEND TO THE COORDINATOR ONE COPY OF HARD COPY THESIS + FORM + CD SOFTCOPY

Prepared by, MISS RAHIMAH OTHMAN Thank you Prepared by, MISS RAHIMAH OTHMAN