1. MISS. RAHIMAH BINTI OTHMAN
ERT 422/4 BIOPROCESS PLANT DESIGN
MISS. RAHIMAH BINTI OTHMAN (

2. COURSE OUTCOMES CO1 CO2 CO3 COs OUTLINES
Ability to CLASSIFY and RECOMMEND safety and risk assessment on the bioprocess plant system.
CO2
Ability to DESIGN the typical control strategies for the safe plant operation and RECOMMEND the waste management for any visual impact from the process effluent to meet the environmental friendliness of the products.
CO3
Ability to APPLY the technique used for estimation of plant economics and COMPARE economic feasibility of the process plant for project evaluation and process optimization.

3. LIST OF CHAPTERS CHAPTER TITLE WEEK 1
INTRODUCTION TO THE BOTTOM LINE PROCEDURES OF GENERALIZED BIOPROCESS VIEW 2
CONTROL SYSTEM INSTRUMENTATION 3
PIPING AND INSTRUMENTATION DIAGRAM (P&ID)
3 - 4

4. LIST OF CHAPTERS CHAPTER TITLE WEEK 4
PLANT SAFETY & LOSS PREVENTION SYSTEM
6 - 7 5
ENVIRONMENTAL ASSESSMENT IN BIOPROCESS PLANT DESIGN 8 6
ECONOMIC ASSESSMENT IN BIOPROCESS PLANT DESIGN
9 - 10 7
PROFITABILITY ANALYSIS AND PROCESS OPTIMIZATION
12 -13

5. TEACHING PLAN No. Week. CONCLUSION
* Note : Please refer to Teaching Plan.
No.
Week.
CONCLUSION 1.
1-13
Lecture class. 2.
3 , 4, 8, 11, 14
PBL/ Design 3.
4 & 9
Midterm Test 1 & 2 4. 8
Submission 1 : “Chapter 6 & 7” 5. 13
Submission 2 : “Chapter 8 & 9” 6. 14
Submission 3 : “All Chapters” 7. 15
Oral Presentation 8. 16
Total Report : Design Project 2

6. Synthesis and Design Process Bioprocess Plant Design
DESIGN PROJECT 2
Courses
Report Submissions
Chapters
ERT 416
Synthesis and Design Process 1
Chapter 1: Literature Review and Process Background.
Chapter 2: Design Simulation and Process Flow Diagram. 2
Chapter 3: Integration of Energy Process.
Chapter 4: Process Design of Equipment.
Chapter 5: Mechanical Design of Equipment. 3
Combination of Chapter 1 to 5 reports.
ERT 422
Bioprocess Plant Design
Chapter 6: Control System and Piping.
Chapter 7: Environmental Analysis.
Chapter 8: Plant Safety Analysis.
Chapter 9: Economical Assessment.
Combination of Chapter 6 to 9 reports.
FINAL REPORT
Combination of all the Chapters (from Chapter 1 to 9)

7. SUBMISSION 1 -cont’ Outlines Chapters 6
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 are;
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 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.

8. SUBMISSION 1 Outlines Chapters7
ENVIRONMENTAL PROTECTION AND ENVIRONMENTAL IMPACT ANALYSIS
Prepare an environmental impact analysis for the proposed bioprocess plant system by including;
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.

9. SUBMISSION 2 Chapters Outlines 8 PLANT SAFETY
List down all the hazards 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.

10. SUBMISSION 2 –cont’ Outlines Chapters 9 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.

11. SUBMISSION 2 – cont’ Outlines Chapters 9 – 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.

12. DESIGN PROJECT GROUPS SUPERVISOR Group GROUP MEMBERS TITLES
Dr. Muhammad Syarhabil A1
ANG ZE SIANG (L)
ABDUL MALEK BIN ABDULLAH
BIDATTUL SYIRAT BT ZAINAL
SUGANTHI A/P SUDARMAN
Plant Design for the Production of Biofertilizer from Agrowaste.
Mr. Zulfakar A2
GOH ZHEN JOON (L)
ADIB ZUBAIDI BIN RASHID
'ADILAH CHE SULAIMAN
NOR HANIM BINTI SHAARI
Plant Design for the Production of High-Fructose Corn Syrup from Corn.
Mr. Akmal Hadi A3
LAI MOON TING (L)
ERNIE FARIDAH BINTI MAT NORDIN
IZZAT BIN SHAHARUDDIN
MUHAMMAD NAJIB BIN ABDUL WAHAB
Plant Design for the Production of Polyhydroxyalkanoate (PHA).
Mrs. Hairul Nazirah A4
NOR HIDAYAH BT BOHARI (L)
HAMILAH BINTI MOHD AB GHANI
RONNY LING LEH LUNG
SITI FAEEZAH BT SHUKRI
Plant Design for the Fractionation of Human Blood Plasma.
Mrs. Hafiza A5
NOR MUNIRAH BINTI CHE OTHMAN (L)
MOHD ROZAIMI BIN RAMLY
SAFWAN BIN SULAIMAN
NADIA BINTI ANWAR
Plant Design for the Production of L-lysine.
Mr. Lee Boon Beng A6
NURUL AFIDAH BINTI UMORUDDIN (L)
RAJA AHMAD IZZAT B RAJA ZAZALI
NG WEN JIA
MOHD REDZUAN BIN SUTIMIN
Plant Design for the Production of Bio Detergents.

13. SUPERVISOR
Group
GROUP MEMBERS
TITLES
Mr. Mohd Sanusi A7
NURUL NADIA MOHAMED SUPIAN (L)
ILYA FATEHAH BINTI AZIZAN NASHRIBY
RANDY BIN RAMLI
NOR SAHEILA BINTI ISHAK
Plant Design for the Production of Biofuel.
Miss. Mismisuraya A8
YAP PHOOI FUNG (L)
SOLIHAH BINTI ABDULLAH
NUR IDRIN BT ROSNI
MUHAMMAD HAZRIQ BIN ARIS
Plant Design for the Production of Citric acid Using Artocarpus Spp. Starch.
Miss. Rahimah A9
MOHD AMIR IDHZUAN BIN JOHARI (L)
KELLY LIEW KAR MEE
NORFADHILA BT ABDULLAH ZAWAWI
ZULFADLI BIN AHMAD
Plant Design for the Production of Pullulanase Enzyme From Klebsiella Pneumonia.
Mr. Zulkarnain
A10
OOI AI CHIAW (L)
SURAYA BINTI MOHD TAJUDDIN
NOR ADILA BT RAMLEE
Plant Design for the Production of Citric acid from empty fruit bunches by Aspergillus niger.
Mr. Fahrurrazi
A11
LOH PEI CHEN (L)
NURFATIMAH BINTI MOHD THANI
MOHAMAD SYAFIQ BIN SA'ODI
RAJA MUHAMMAD FARID RAJA S
Plant Design for the Production of Cellulase from palm oil mill effluent (POME) by Trichoderma reesei.
Mr. Huzairy
A12
THAM CHEE FAI (L)
MOHD ZAKWAN BIN NAWI
SITI NUR AMIRAH BINTI IDRIS
NUR FARIZAH BINTI JABARULLAH
Plant Design of Downstream Processing of Protease Enzyme.
Mrs. Siti Jamilah
A13
NURUL SYUHADA HAJI BAHARUDIN (L)
ZARINA BINTI ZAWAWI
SAROJINI A/P JEYARAMAN
NOR HIDAYAH OTHMAN
Plant Design for the Production of Amylase Enzyme.

14. IMPORTANT DATELINES (DESIGN PROJECT 2)
NO.
SUBMISSIONS
ACTIONS
DATELINES 1.
Submission 1 Report
Students
24 Feb 2011 (THURSDAY) 2.
Submission 2 Report
31 Mac 2011 (THURSDAY) 3.
Submission 3 Report
7 April 2011 (THURSDAY) 4.
ORAL PRESENTATION
ALL supervisors and students
Week 15
(will be planned)

15. Total Design Project Marks
GRADING SCHEME
Total Design Project Marks
Supervisor
(30 %)
Sub 2
(10 %)
Sub 1
(10%)
Final report
Examiner
Mid Term Test
(20 %)
Test 1
Test 2
Oral Presentation
(20%)

16. 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)
Communication skills and creativity (10m) [this part need to be filled by supervisor]
TOTAL ( 60m)
This mark will be encountered in Sub 1 &2.

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

18. REFERENCE BOOKS
Elmar, H., Arno, B. and Charles, C. (2006). Development of Sustainable Bioprocesses Modelling and Assessment. John Wiley& Sons, Inc.
Atkinson,B. and Mavituna, F. (Latest edition). Biochemical Engineering and Biotechnology Handbook. Amerika: The Nature Press.
Peters, M.S. and Timmerhaus, K.D. (2002). Plant Design and Economics for Chemical Engineers. 5th Edition, New York, McGraw-Hill.
D.Barnes, P. J. Bliss, B.W. Gould & H.R. Vallentine. (1989). Water and Wastewater Engineering Systems. A Pitman International Text.

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