Introduction to Process Design Don Robinson September 2003

History of a Typical Plant Design Project And How the Course Relates to This

Introduction to Process Design CourseDon Robinson Steps (Don Robinson, Dave Mody, not covered) Need Identification Data Gathering Conceptual Design Prelim Equip Design & Cost Estimate Profitability Analysis Approval of Development Funds Detailed Equipment Design Accurate Cost Estimate Approval of Construction Funds Construction Startup Post Mortem

Introduction to Process Design CourseDon Robinson Identification of a Need Sales increasing New process technology New product Environmental regulations Costs not competitive Product Deficiencies Obsolete equipment Opportunity Problem

Introduction to Process Design CourseDon Robinson Data Gathering Info from existing process Literature data Data from simulation program Plant tests Lab experiments

Introduction to Process Design CourseDon Robinson Conceptual Design Map out structure of process Heat and mass balances Evaluate alternatives Primary tool is process simulation program

Introduction to Process Design CourseDon Robinson Preliminary Cost estimate Not all that accurate (20-30%) Based on shortcut methods Some additional design work needed Required for the “do we proceed” decision

Introduction to Process Design CourseDon Robinson Profitability Analysis Will the expected return justify the expenditure? A process to direct resources to what is valued most by society

Introduction to Process Design CourseDon Robinson Approval of Development Funds Get sufficient $ to do a proper design Perhaps order long delivery time equipment

Introduction to Process Design CourseDon Robinson Detailed Equipment Design Sufficient detail to pin down costs Much of the work done by suppliers

Introduction to Process Design CourseDon Robinson Accurate Cost Estimate Improved accuracy Required for control of construction

Introduction to Process Design CourseDon Robinson Approval of Construction Funds Confirm that the profitability picture is still good A chance to bail out if conditions have changed

Introduction to Process Design CourseDon Robinson Implementation Construction Startup Postmortem (learnings for future projects)

Introduction to Process Design CourseDon Robinson Sections of the Course Concepts & tools – Barrie Jackson & Geoff Whitfield Process analysis & modeling – Don Robinson Equipment design and costing – Dave Mody

Introduction to Process Design CourseDon Robinson Concepts and Tools Project management Capital cost estimation Engineering economics Profitability analysis Health & safety issues Thermodynamics Distillation

Introduction to Process Design CourseDon Robinson Process Analysis & Modeling HYSYS® tutorial and practice session Process Analysis Digest the information Partial mass balance Catalyst research

Introduction to Process Design CourseDon Robinson Process Analysis (cont.) Initial HYSYS model Refined Model Optimized distillation column Detailed design of heat exchanger Energy minimization Profitability analysis

Introduction to Process Design CourseDon Robinson Equipment Design & Costing P&ID’s Sizing & costing of specific equipment Hazard analysis Materials of construction Cost of overall project

Introduction to Process Design CourseDon Robinson Computer Facilities Accounts CD Software Web Site Information on Server

Introduction to Process Design CourseDon Robinson Computer Software HYSYS process simulation to build models CapCost (comes with the text) crude estimates of equipment costs compiling overall capital costs profitability analysis Excel for various calculations Word for writing reports Internet Explorer for viewing material

Introduction to Process Design CourseDon Robinson Computer Accounts Security pass Password CD containing course documentation Cost is $20 See Ann Tobin in room 201 Must be done by Wednesday afternoon

Introduction to Process Design CourseDon Robinson Web Site info.chee.queensu.ca/CHEE470 Course description & schedule Info about staff and facilities Group lists Message log Documents added after start of course

Introduction to Process Design CourseDon Robinson Information on Server home folder (Z:) for your private storage group folder (R:) used by all group members course folder (P:\CHEE470\start.wsf) course material (a copy of the CD) Available in Computer Cluster only

Introduction to Process Design CourseDon Robinson Work Groups Groups of 4 At least two chemical engineers At least one engineering chemist At least one not attending CSChE conf. Designated A1,A2... B1,B2... For some work the class will be split – while the A groups do modeling, the B groups will do workshops