Review for Design I Exam CHEN 4253 Terry A. Ring

Materials Covered Week 1-22 August Chapt 1 (p.1 -25), Chapt 2, Chapt 3 Product Design- Introduction to course – Product and Process Design Product Design-1 Overview Product Design-2 Property Estimation Week 2-29 August Chapters 16 and 17 Product Design-3 Innovation Maps Product Design-4 Six Sigma in Product Design Product Design-5 Engineering Ethics Week 3–5 September (Holiday Monday) Chapt 1 (p25-31) Chapter 4 Process Creation- Ethics in Chemical Engineering Process Safety Process Design Overview Process Creation

Materials Covered-con’t Week 4–12 September (Celanese in Class Monday) Chapt 4&5&6 Aspen for Process Creation– Use of Aspen for Process Creation-1 Use of Aspen for Process Creation-2 Heuristics for Process Simulation Week 5 – 19 September Chapt 4&5 Aspen Tutorials and Problems Solved in Class (Reserve the ICC) - Week 6 - 26 September (Away Wednesday and Friday) Chapt 5&6 ProMax Tutorials and Problems Solved in Class (Reserve the ICC) - Week 7–3 October Chapter 22-22 (p543-558) &23 Profitability Analyses - Annual Costs Earnings Profitability Analysis Week 8- 11 October FALL BREAK

What have we really covered? Product Design (Ethics) Chapt. 1,2&3 Process Creation Chapt 4 Heuristics for Process Synthesis Chapt 6 Process Simulators Chapt 5 Aspen Promax Capital Cost Estimates Chapt 22 Profitability Analyses Chapt 23

Chapters 1, 2,3 & 4 Chpt. 1 - The Design Process Ethics in Chemical Engineering Product design Chpt. 2 – Product Development Chpt. 3 - Molecular Structure Design Property estimation Chpt. 4 – Process Creation Gross Profitability Analysis Process Synthesis Start with the reactor (differences in molecular type) Separation (differences in composition) Heat transfer, pumping, compression, flash tanks (differences in temperature, pressure, and phase) Integraton

Chemical Product Design Pyramid Figure of Merit

Physical Property Estimation Hansen Solubility Parameters Group Contribution Methods Polymer properties Surface tension HLB Heat of Mixing Drago E and C Work of Adhesion Wetting Bio-concentration factor Oil-water distribution Coefficient Lethal Dose Flash Point Temp.

Chapters 5 and 6 Chapter 5 – Simulation to Assist in Process Creation Steady-state flow sheet simulation Table 5.1 – Unit Subroutines Recycle (tear streams) Recycle convergence Chapter 6 – Heuristics for Process Synthesis Summary on page 174, Table 6.2 Using these as a start in design/simulation

Process Creation Process Economics – Gross Profitability Analysis Focus on Reactor Equilibrium Kinetics or Conversion Focus on Separation System Heuristics in Process Design

Chapter 22 - Costing Accounting Cost Indexes Debits/credits; annual report; balance sheet Cost Indexes Capital investment costs (Table 22.9,pg. 547) Bare model costs Total depreciable capital Total permanent investment Total capital investment Estimation of Total Capital Investment Order-of-magnitude Study estimate Preliminary estimate Definitive estimate

Investment Chapter 23 - Costing Estimation of total capital Order-of-magnitude (method of Hill) See page 498 +/- 50% Study estimate (Method of Lang) See page 500 +/- 35% Preliminary estimate (method of Guthrie) See page 503 +/- 20% Most likely used Need fob equipment purchase cost More definitive Aspen Icarus (but we do not have this license)

Process Economics Capital Cost Estimation Profitability Analysis Cost Indexes Three types Scaleup of Capital Investments - 6/10th rule Order of Magnitude Estimate (±50%) - Hill Study Estimate (±35%) - Lang Profitability Analysis ROI, PBP, IRR, VP, Cash Flow Calcs. Accounting

Format for Exam Exam in 2 parts Wednesday, 20 October 2009 In class written exam Open book, open notes Last Year’s Exam Friday, 22 October 2009 In class, open book, open notes 1- Aspen Problem 1- ProMax Problem Competency Test