CN4121 AY13-14

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NATIONAL UNIVERSITY OF SINGAPORE Department of Chemical & Biomolecular Engineering

CN4121 DESIGN PROJECT (AY2013-14)

OBJECTIVES & APPROACH Holistic design experience is an essential part of the chemical engineering curriculum. To impart such an experience is the main goal of this project-based module. The module gives students an opportunity to deal with an open-ended chemical plant design project, the like of which they may face in practice. In this project, the students will carry out the major steps involved in the design and evaluation of a new chemical manufacturing process. The key elements of this design experience are: 1. Working in a team where all members contribute individually as well as collectively with

proper communication and coordination; each team member is responsible for the entire project individually and collectively.

2. Applying fundamental chemical engineering principles and data from literature. 3. Making critical design decisions in a safe, creative, practical and cost-effective manner. 4. Reporting work in formal, concise, and easy-to-follow reports. ORGANIZATION & ASSESSMENT The students should form teams of SEVEN (7) members each by themselves. Each team must select a unique team number and a team leader. All members should sign up on IVLE under their respective teams as described later. The team members can be from different tutorial classes. Teams with fewer than seven students are not allowed, unless no student remains without a team. Students looking for a team and vice versa should post their requests in the Discussion Forum of IVLE, or contact a coordinator. Both team and individual contributions are essential for a successful design project. The plant proposed by each team will be divided into seven sections with one academic advisor for each section. The battery limits of these sections will be fixed or agreed across the sections by the advisors, and identical for all teams. Each student, including the team leader, will take the responsibility for one of the seven sections. S/he will configure a process for that section, and design all its major units in varying details as suggested by the academic advisor. This will be the individual contribution of each student. In addition, s/he should contribute to several team tasks of the design project. Good design also requires proper and timely communications and coordination. All team members must communicate with each other continually throughout the semester to achieve good progress, and a consistent and feasible final design. The leader is to coordinate regular team meetings and facilitate effective communication and team work, with inputs and cooperation from all members.

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The final grade for CN4121 will have three parts. The marks from CN4121 Part 1 will constitute the first part with a weight of 15%. An individual written report on section design and a corresponding individual oral presentation will make up the second part with a weight of 55%. One interim and one final report on the common team tasks will be the third part with a weight of 30%., The actual marks may vary among team members even for the team tasks, as they will be affected by the peer evaluation scores that a student receives from his/her team mates. All three components are important, and any of them can affect the final grade significantly. In recognition of additional responsibility, each team leader can get extra marks up to 2% of those assigned for Part 2. These marks will be based on the evaluation of the leader by the respective team members and project progress as evidenced by the meeting minutes submitted by each team. SCHEDULE E5 03-24 is booked for the project work on Thursdays, Fridays, and Saturdays (0800 1800). The PC Clusters [E1-04-09 (PC1), E1-04-10 (PC2), E2 03-06 (PC3)] are also available on Thursdays and Saturdays (0900 1800) except for a few hours on Feb 6, Feb 13, Feb 20, and Mar 6. E1-04-09 (PC1) is also booked on Fridays (0900-1800). Aspen Hysys is accessible from all these clusters, and Visio is available in E5 03-24.

All sessions in LT 6 on Thursdays, unless stated otherwise.

Date (Week) Activity Time

January 16 (Week 1)

Overview of the project (by Prof. Srini)

Talk on Team-work (by Prof. Rangaiah)

Talk on Design & Sustainability in Practice (by Mr. Joseph Eades)

13.00

13.45

14.00

January 23 (Week 2)

Small Group Meetings (See the footnote for the venues) 14.00

February 6 (Week 4)


February 13 (Week 5)


February 20 (Week 6)


Recess Week: February 22 Mar 2

March 6 (Week 7)

Report Writing

Small Group Meetings (See the footnote for the venues)

13.00

14.00

March 13 (Week 8)


March 27 (Week 10)

Briefing on Cost Estimation & Economic Analysis

Briefing on Health, Safety and Environment

13.00

13.45

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Venues for Small Group Meetings (Thursdays from 2 to 3 pm with the exception of Product Purification section, which will be from 4 to 5 pm; see below)

(1) Oxidation reactor (Kawi): E5-02-32 (2) Concentrator (Karimi): E4-04-03 (3) Cleavage Reactor (Borgna): E4-04-05 (4) Off-gas Scrubber (Srinivasan): E5-03-22 (5) Acetone Recovery (Gautam): E5-03-20 (6) Cumene Recovery (Rangaiah): E5-03-21 (7) Product (Acetone/Phenol/AMS) Purification (Long/Rangaiah): E5-03-20 at 4 pm

Industry Talks: Details of each of the industry talks will be conveyed after the confirmation from speakers, about one week in advance. These sessions are likely to be on Saturday mornings. Weekly meetings with team leaders (or their representatives): Every Thursday, at 3 pm in E5 03-20 beginning January 16th. DEADLINES AND DELIVERABLES

Date Deliverables Submit to

January 20

(Weeks 2)

Team Formation: Team number, names of team members and leader

Under his/her own team number, each member enrols in IVLE project: CN4121: Team Members

Under his/her own team number, each leader enrols in IVLE project: CN4121: Team Leaders

Penalty: 1% for failure to enrol or incorrect enrolment

Online in IVLE

January 23

(Week 2)

Section Selection: Section that each member will design.

Under his/her own team number, each member enrols in IVLE project: CN4121: Section X: xxxx, where xxxx is the name of the section advisor.

Penalty: 1% for failure to enrol or incorrect enrolment

Online in IVLE

February 13

(Week 5)

Interim Report (printed copy): A 2-page interim report (one from each team).

Suggested content: Scope, process overview, inputs to

During Team Leaders Meeting

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and targets for each section, progress in each section, team work plan and milestones, etc. Flowsheet and stream data can be attached as additional pages.

March 20 (Thursday) (Week 9) for Oxidation & Cleavage Reactors

March 27 (Thursday) (Week 10) for Other Units

Individual Report on Process Development and Design (printed and electronic copies) one from each student

Page limit per report: 35 pages (including appendices, if any)

Penalty: (a) 1% for every 4 pages exceeding 35 pages, and (b) 2% for not following the format guidelines

* Plagiarism report should be generated using one of the following programs: (a) Viper available at http://gateway.scanmyessay.com/index.php, and (b) Plagiarisma available at http://plagiarisma.net/

Upload one single .pdf file along with its plagiarism report*, into your own folder under IVLE project: Section X: xxxx.

Submit one printed copy (double sided) of the report (without the plagiarism report) for each section separately to the ChBE Department office by 5.30 pm.

April 14 (Monday)

(Week 13)

Team Report (electronic copy - one from each team): Executive Summary, SHE + Economics & Profitability, Discussion on Alternative Technologies and Sustainability.

Maximum Page limits for each section:

Executive summary: 4 pages

Cost estimation and economic analysis: 20 pages

SHE: 30 pages

For entire Team Report: 65 pages (excluding PFD and stream data)

Penalty: 1% for every 4 pages exceeding the limit.

Upload one single .pdf file into the folder for IVLE project: CN4121: Team Leaders

Upload one Hysys file for complete plant simulation into the folder for IVLE project: CN4121: Team Leaders

Week 13 Oral Presentations: On Process Development and design of individual sections (No need to cover economic analysis and SHE). Schedule for the presentations will be announced later.

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April 30 Peer assessment: Each team member will be asked to assess the contribution of other members in his/her team to the team tasks. This will be done towards the end of April, and will be taken into account for grading each students performance.

Online in IVLE

Penalty for late submissions of the above without valid reasons: 2% per day of delay.

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REPORT The reports must be written on 2-sided A4 papers using Times New Roman of size 12 (or equivalent), 1.5 line spacing, and 2.5 cm margins on all sides. Graphs and drawings that are submitted with the reports should be of convenient size. References should be given in a consistent format; they should be clearly cited in the appropriate places of the main text where materials from such references are used. All results must be in SI units, and all symbols must be clearly defined. Further details and guidelines for report organization will be discussed in the Report Writing session. The reports should be the unaided work of the student or his/her team. Plagiarism in any form whatsoever will not be tolerated. Each student is required to carry out a plagiarism check using the provided links and to submit a plagiarism report to accompany the Process Design and Development Report. Source codes, algorithms and/or printouts of all computer programs written by the students should be submitted with the report. Students may use legally permitted or published process simulators and computer programs for numerical techniques and graphics. In using application software such as process simulators, students must clearly demonstrate their understanding of the methods and fundamental principles used in these programs, and it should be clearly stated where these are used in the report. For example, it is essential that calculation of or justification for all input specifications to process simulators be clearly shown; a brief description and/or an illustrative sample calculation should be included to demonstrate understanding of the commercial packages. REFERENCES Recommended Texts 1. Seider, W.D., Seader, J.D., Lewin, D.R., Widagdo, S., Product & Process Design

Principles, Wiley, 3rd Edition, 2010 (TP155.7 Sei 2010).

2. Turton R., Bailie R.C., Whiting W.B., Shaeiwitz J.A., Bhattacharyya D., "Analysis, Synthesis, and Design of Chemical Processes", Prentice Hall, 4th Edition, 2013 (TP155.7).

3. Towler, G., and Sinnott, R., Chemical Engineering Design, Second Edition: Principles, Practice and Economics of Plant and Process Design, Oxford, Butterworth-Heinemann, 2013 (TP155 Tow 2013).

General References

4. Douglas, J.M., Conceptual Design of Chemical Processes, McGraw Hill, 1988 (TP155.7 Dou).

5. Biegler, L.T., Grossmann, I.E., Westerberg, A.W., Systematic Methods of Chemical Process Design, 2nd Edition, Prentice Hall, 1999 (TP155.7 Bie).

6. Silla, H., Chemical Process Engineering Design and Economics, 2003 (TP155 Sil 2003).

7. Green, G.W., and Perry, R., Perrys Chemical Engineers Handbook, 8th Edition, McGraw-Hill, 2008 (TP151 Per).

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8. Couper, J. R., Penny, W. R., Fair, J. R. and Walas, S. M., Chemical Process Equipment: Selection and Design, 3rd edition. Oxford, Butterworth-Heinemann, 2012 (TP157 Chem).

9. Peters, M.S., Timmerhaus, K.D., West, R.E., "Plant design & Economics for Chemical Engineers", 5th edition, McGraw-Hill, New York, 2003 (TP155 Pet 2003).

10. Sinnot, R., Coulson and & Richardsons Chemical Engineering", Vol. 6, 4th Edition, Oxford, 2005 (TP155 Sin 2005).

11. Wankat, P.C., Separation Process Engineering, 3rd Edition, NJ: Prentice Hall, 2012 (TP156 Sep.Wa 2012).

12. Encyclopedia of Chemical Processing, ed. Lee, S. New York: Taylor & Francis, 2006. (TP9 Ency 2006).

Specific References

13. Kirk-Othmer Encyclopedia of Chemical Technology, executive editor, Kroschwitz, J.I. New York : Wiley, 2007 (TP9 Kir)

14. Ullmann's Encyclopedia of Industrial Chemistry, executive editors, Ullmann F., Gerhartz W., Yamamoto Y.S., Campbell F.T., Pfefferkorn R., et al. 7th Edition, Weinheim, Federal Republic of Germany ; Deerfield Beach, FL, USA: VCH, 2012 (TP9 Ull)

15. Dimian, A.C., and Baldea, C.S., Chemical Process Design: Computer-Aided Case Studies, Wiley-VCH, 2008. Chapter 15. (TP155.7 Dim2008)

16. Hattori, K., Tanaka, Y., Suzuki, H., Ikawa, T., and Kuboto, H., Kinetics of Liquid Phase Oxidation of Cumene in Bubble Column, Journal of Chemical Engineering of Japan, 3 (1), 72 78, 1970.

17. Hendry, D.G., Rate Constants for Oxidation of Cumene, Journal of American Chemical Society, 89, 5433 5438, 1967.

18. Andrigo, P., Caimi, A., Cavalieri dOrol, P., Fait, A., Roberti, L., Tampieri, M., and Tartari, V., Phenol-Acetone Process: Cumene Oxidation Kinetics and Industrial Plant Simulation, Chemical Engineering Science, Vol. 47, No 9 11, 2511 2516, 1992.

DESIGN BRIEF Design a plant to produce phenol and acetone from cumene. The process involves the oxidation of cumene to form cumene hydroperoxide, and subsequent cleavage of hydroperoxide to phenol and acetone. Assume that the plant is to be located in Singapore and the operation time is 8000 h/yr. Design Specifications Plant Capacity (PC) of phenol (tonne/year): (1) 250,000; (2) 300,000; (3) 350,000; (4) 400,000; (5) 450,000 Feedstock: Cumene: 100 %, 298 K and 110 kPa

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Phenol Purity: Phenol should be produced in this purity (weight %): (1) 99.2%, (2) 99.4% and (3) 99.6% Acetone Purity: Acetone should be produced in this purity (weight %): (1) 99.3%, (2) 99.5% and (3) 99.7% Team-wise Specifications:

Team PC Phenol Acetone Team PC Phenol Acetone 1 1 1 1 25 3 3 1 2 1 1 2 26 3 3 2 3 1 1 3 27 3 3 3 4 1 2 1 28 4 1 1 5 1 2 2 29 4 1 2 6 1 2 3 30 4 1 3 7 1 3 1 31 4 2 1 8 1 3 2 32 4 2 2 9 1 3 3 33 4 2 3 10 2 1 1 34 4 3 1 11 2 1 2 35 4 3 2 12 2 1 3 36 4 3 3 13 2 2 1 37 5 1 1 14 2 2 2 38 5 1 2 15 2 2 3 39 5 1 3 16 2 3 1 40 5 2 1 17 2 3 2 41 5 2 2 18 2 3 3 42 5 2 3 19 3 1 1 43 5 3 1 20 3 1 2 44 5 3 2 21 3 1 3 45 5 3 3 22 3 2 1 23 3 2 2 24 3 2 3

SCOPE OF WORK The report should emphasize the systematic and sound application of chemical engineering principles to the solution of this project. Justification, where required, must be given for the selection of process and raw materials, reaction pathways, equipment types and configuration, heat transfer media, and process conditions. All design equations must be stated and referenced or derived; assumptions should be clearly justified; and any sources of uncertainty should be discussed. Data and results of any computer program used must be clearly presented. 1. Executive summary: Prepare a summary, not exceeding 4 pages, describing the main

features of your proposed design (such as importance of product, process developed, major equipment details, profitability, and safety, environmental & operational issues). Provide

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values of important operating conditions, sizes, total costs etc. The executive summary must contain a process flow diagram with stream data (not included in the 4-page limit). Refer Chapter 3 Chemical Engineering Process Design and Economics (G. D. Ulrich and P.T. Vasudevan, Process Publishing, 2004) for examples on presentation of PFDs.

2. Process development and design: Identify and explore alternatives for raw materials, reaction pathways, separation technologies, process conditions, etc. Identify and explore opportunities for conserving water, fuel and energy, reducing environmental impact, recycling/reusing/treating materials, etc. Synthesize and evaluate several alternate process configurations based on your above exploration and identify the best process. Use criteria such as feasibility, safety, cost, profitability, controllability and reliability for process evaluation. Develop a complete simulation model, if required, for your proposed process.

Select one unit/section from the following for process development and design: (1) Oxidation reactor (Advisor: S. Kawi), (2) Concentrator (Advisor: I.A. Karimi), (3) Cleavage reactor (Advisor: A. Borgna), (4) Off-gas scrubber (Advisor: M.P. Srinivasan), (5) Acetone recovery (Advisor: S. Gautam), (6) Cumene recovery (Advisor: G.P. Rangaiah), and (7) Product (Acetone/Phenol/AMS) Purification (Advisor: Y. Long/G.P. Rangaiah). Individual report on process development and design must contain a process flow diagram showing principal equipment, along with a table of process stream data. Refer Chapter 3 Chemical Engineering Process Design and Economics (G. D. Ulrich and P.T. Vasudevan, Process Publishing, 2004) for examples on presentation of PFDs.

3. Cost Estimation and Economic Analysis: Prepare an equipment schedule listing all major

equipment including tanks and pumps. Perform a complete cost estimation and economic analysis for the whole process. Discuss the profitability of the proposed plant. Equipment schedule and cost estimation of equipment in a unit/section will be the responsibility of the individual member. So, present these in separate tables for each unit/section. Rest of the cost estimation & economic analysis will be common work. Use utilities and their cost data from Turton et al. (2012) or any other reliable source.

4. SHE: Prepare an account of safety, health and environmental considerations in the design,

including hazard identification and HAZOP studies. Other specific topics such as plant layout, operational safety, treatment and disposal of effluent and personnel protection should also be discussed.

5. Sustainability: Conduct sustainability assessment of phenol production process in a

location (chosen by the team) different from Singapore; no cost calculations are required but only qualitative discussion on economic, environmental and societal aspects of sustainability.

Documents

CN4121 AY13-14