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Process Plant Design

This course covers the design of entire process plants, focusing on process flow, equipment selection, and plant layout. Students will learn how to integrate chemical processes into a functioning plant and understand the economic and safety considerations involved. The outcome is the ability to design and optimize a complete chemical manufacturing plant.


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  • Process Operation
  • Synthesis Steps
  • Block Flow Diagrams
  • Process Flow Diagrams
  • Conventions for Utilities and Streams
  • Effect of Operating Pressure to Reactors and Separators
  • Effect of Operating Temperature to Reactors and Separators
  • Nonstoichiometric Reactor Feed Compositions
  • Changes in Stream Conditions when Passing through a Single Equipment
  • Heuristics for Process Synthesis
  • Composite Curves
  • Minimum Utility Target
  • Stream Matching
  • Heat Loops in HEN
  • Typical Sites Utility System
  • Boiler Feedwater Treatment
  • Steam Boiler
  • Cooling Water System
  • Refrigeration Cycle
  • Water Treatment Process
  • Atmospheric Emissions
  • Typical Control Systems
  • Basic Symbols and Instrument Lines
  • Applying Control Systems to The Processes
  • Piping and Instrumentations Diagram
  • Plant Siting and Layout
  • Separation Distances between Equipment

  • Capital Cost Estimation: Guthrie's Method
  • Operating Cost Estimation
  • Time Value of Money
  • Cash Flow and Depreciation
  • Cost Breakdown and Product Pricing
  • Profitabiliy Analysis (ROI, IRR, PP, BEP)
  • Sensitivity Analysis

References:

  1. Sieder, W. D., Seader, J. D., Lewin, R. L., & Widagdo, S. (2009). Product and Process Design Principles: Synthesis, Analysis, and Evaluation (3rd ed.). John Wiley & Sons, Inc.
  2. Smith, R. (2005). Chemical Process Design and Integration. John Wiley & Sons, Ltd.
  3. Turton, R., Shaeiwitz, J. A., Bhattacharyya, D., and Whiting, W. B. (2018). Analysis, Synthesis, and Design of Chemical Processes (5th ed.). Prentice Hall.