1. Review for Design I Exam
CHEN 4253
Terry A. Ring

2. 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

3. 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 September (Away Wednesday and Friday)
Chapt 5&6 ProMax Tutorials and Problems Solved in Class (Reserve the ICC) -
Week 7–3 October
Chapter (p ) &23 Profitability Analyses -
Annual Costs
Earnings
Profitability Analysis
Week October FALL BREAK

4. 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

5. 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

6. Chemical Product Design Pyramid
Figure of Merit

7. 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.

8. 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

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

10. 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

11. 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)

12. 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

13. 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