1. Final Exam Review This Powerpoint is a list of what we covered in Design I. Anything from this coverage may be on your final exam. (Obviously, I will emphasize the material after the mid-term exam in the final exam.)

2. Exam Format Open Book Open Notes –Example of previous Final Exam in HW section of course website No solution is given Reminder of Course Grading and Final Schedule Weekly Homework: 20% Minor Design Reports 30% Mid-Term Exam 20% Final Exam 30% –( Monday, December 12, 2011 8:00 – 10:00 am, in classroom)

3. Chapters 1, 2, and 3 Chpt. 1&2 - The Design Process –Ethics in Chemical Engineering –Product design 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

4. Chapters 4 and 5 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

5. Chapter 7 – Reactor Design Reactor models –PFR, CSTR, Equilibrium, Stoichiometric –Custom made models CSTR & PFR –Kinetics used to size the reactors –Catalytic reactors Equilibrium reactors –Temperature effects Heat effects Reactor Design for selective product distribution

6. Chapter 8 - Separation Common separation methods –Table 8.1 – p. 211 Criteria for selection of a separation method – Separation Factor (SF) –Energy separation agent (ESA) Distillation –Types: Tray vs. Packed towers –Reflux ratio –Equil. Trays –Column design –Design issues –Heuristics – page 161 –Separation train synthesis - p. 219 –Mass separation agent (MSA) Needs a recycle loop

7. Chapter 18 – Heat Exchangers Heat duty Temperature driving force Type of equipment –Shell and Tube Temperature driving force –Correction factors (Figs. 18.14-16) Heat transfer coefficients and pressure drop –Table 18.5 – Typical overall heat transfer coeff. –Boiling HT ΔT = 45F for Nucleate Boiling, Fig 18.5 Tube sheet layouts – Table 18.6, Figure 18.9

8. Chapter 19 – Separation Tower Design Distillation –FUG method –Plate efficiency –Tower Diameter –Pressure drop Absorption/Stripping –Kremser method –HETP values –Tower Diameter –Pressure drop

9. Chapter 20 – Pumps, Compressors, & Expanders Pumps –Various Types Compressors and Expanders –Various Types

10. Chapter 22 - Costing Accounting –Debits/credits; annual report; balance sheet Cost Indexes Capital investment costs (Table 22.32,pg. 591) –Bare model costs, Table 22.11 –Total depreciable capital –Total permanent investment –Total capital investment Estimation of Total Capital Investment –Order-of-magnitude –Study estimate –Preliminary estimate –Definitive estimate

11. Chapter 22 - Costing Estimation of total capital –Order-of-magnitude (method of Hill) See page 553, six tenths rule +/- 50% –Study estimate (Method of Lang) See page 555 +/- 35% –Preliminary estimate (method of Guthrie) See page 557 +/- 20% Most likely used for decisions Need fob equipment purchase cost

12. Chapter 22 - Costing Purchase cost –Pumps and Motors – Figs. 22.3-6 –Fans, Blowers, Compressors – Figs. 22.7-9 –Heat exchangers, Fired Heaters – Figs. 22.10-12 –Pressure vessels and Towers – Fig. 22.13 and equations for trays, etc. –Other equipment See equations and Table 22.32, pg. 591-5

13. Chapter 23 – Profitability Analysis Total Production Cost – Table 23.1, p. 604 –C = COM + general expenses –COM is sum of direct manufacturing costs plus operating overhead plus fixed costs –General expenses are selling, research, admin cost, incentive pay Profit (gross earnings) or pre- tax earnings = S – C where S is annual sales revenue Profit (gross earnings) or pre-tax earnings = S – C where S is annual sales revenue Net earnings or profit = (1-t) gross earnings where t = ~37%

14. Chapter 23 – Profitability Analysis Profitability Measures –Return on Investment (ROI) Definition, pg. 602 Eq. 23.1 & pg. 616 Eq. 23.7 ROI should be greater than commercial interest rate, I Moderate risk: ROI = 25% –Payback Period (PBP) Time required for the annual earning to equal the original investment, pg. 616 Eq. 23.8 Low risk should be less than 2 yr. Simple replacement should be less than one year –Venture Profit (VP) Annual earnings in excess of minimum acceptable return on investment, pg. 617 Eq. 23.9 –Annualized Cost Sum of production cost and a reasonable return on the capital investment, pg. 617 Eq. 23.10

15. Chapter 17 – Profitability Analysis Time value of money –Table 23.6 – Single Payments –Table 23.8 – Annuity Factors – Uniform Series Payments –Equal payments p times per year, interest compounded m times per year, Eq. 23.29 p.623 –Equal payments p times per year, continuous compounding interest, Eq. 23.31 p. 623

16. Chapter 23 – Profitability Analysis Time value of money –Comparing equipment purchases Present worth, p 620 Capitalized costs and perpetuities, p. 626-627 Depreciation –Straight line –ACRS and MACRS

17. Chapter 23 - Profitability Rigorous methods –Net Present Value (NPV) Cash flows are computed for each year of projected life of the plant –Investor’s rate of return (IRR) Interest rate where NPV is zero

18. The last 2 weeks Trouble Shooting –Several Articles

19. Typical Economics Problem Problem 1 You have determined that you will retired at 60 (assume you are now 25!) and you want $90,000 a year until you are 80. How much money must you invest with an effective interest rate of 8% per year? (HINT: First calculate the present worth of the money needed and then calculate the annuity amount). Solution Funds needed from 60-80 years of age with annuity (A) of $90K/yr (20 years). Use Eq. 17.32 with I = 0.08, n=20: P = A*{(1.08)^20 – 1}/(0.08*(1.08)^20) = $883,633 You pay for 35 years; use Eq. 17.28: A = 883,633 * 0.08/{0.08*(1.08^35)} = $5130 per year

20. The End Have a Great Semester Break! Design II –The challenges of putting a whole chemical plant together and making it operated efficiently.