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Load:
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1. komponenta
| Lecture type | Total |
| Lectures |
30 |
| Laboratory exercises |
30 |
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Description:
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COURSE OBJECTIVES:
To provide students with a sound understanding of the fundamentals of chemical engineering design, from the initial design brief through conceptual design to the preparation of a basic engineering design. The course also aims to develop the ability to integrate and apply knowledge acquired during undergraduate studies.
COURSE CONTENT AND SCHEDULE:
Week 1
Introduction to chemical engineering design: the main objectives and the role of the chemical engineer in process design. The role of chemical engineering design within overall project documentation and the structure of a design project. Project documentation and project contents. Types of chemical industry products and their impact on process design.
Week 2
Principles of process simulation and the role of process simulators in engineering design. Standards, regulations and recommended practices. Organisation of a chemical engineering design project, required level of accuracy and design safety factors. Structure and contents of the design brief.
Week 3
Main steps in chemical engineering design: process flowsheets (block flow diagram, PFD + HMB, P&ID) and supporting process information. Standards and conventions for process diagrams, including equipment tagging, stream numbering and utility identification. Standard forms used in project documentation. Process operating instructions.
Week 4
Hierarchical approach to process synthesis. Selection between batch and continuous operation. Input/output structure of a process. Main sections of a process plant. Recycle structure. Case study: toluene hydrodealkylation process.
Week 5
Synthesis of separation systems. Selection of separation methods. Batch and continuous distillation. Shortcut and rigorous distillation calculations. Synthesis of distillation sequences. Process intensification in separation processes.
Week 6
Synthesis of separation systems ? continued. Intensified separation processes. Thermally integrated distillation sequences. Dividing-wall columns.
Week 7
Knowledge assessment covering material from previous lectures.
Assessment of knowledge acquired through practical exercises.
Week 8
Separation of azeotropic mixtures. Residue curves and singular points. Feasibility analysis using residue curve maps. Separation of azeotropic mixtures by pressure-swing distillation.
Week 9
Separation of azeotropic mixtures ? continued. Homogeneous azeotropic distillation. Heterogeneous azeotropic distillation. Extractive distillation.
Week 10
Equipment sizing: standard and custom-designed equipment. Piping and pumps. Rules of thumb and standards for pipe sizing, including pipe Schedule (Sch). Pump selection and operating ranges. Pump sizing and power calculation. Compressor operating ranges.
Week 11
Sizing of distillation columns, absorbers and strippers. Tray columns. Column hydraulic operating limits and stability. Packed columns. Column internals.
Week 12
Heat exchangers: basic classification and the TEMA standard, including shell types and front- and rear-end head configurations. Criteria for heat exchanger selection. Heat exchanger sizing and design guidelines.
Week 13
Separators and vessels. Sizing of vertical and horizontal separators and vessels. Residence time. Design criteria and sizing guidelines.
Week 14
Plant layout. Process safety and environmental considerations. Process hazards including toxicity, fire, explosion, ionising radiation and uncontrolled pressure rise. Hazard assessment: Dow and Mond-Dow indices, Fire and Explosion Index (FEI) and risk analysis. HAZOP study. Safety review checklists. Safe plant preparation, commissioning and start-up.
Week 15
Knowledge assessment covering material from previous lectures.
Assessment of knowledge acquired through practical exercises.
PRACTICAL EXERCISES:
Practical exercises are carried out independently in a computer laboratory. Through a series of progressively more complex assignments, students become familiar with process simulators used for different engineering applications.
The exercises are performed using CHEMCAD for steady-state process simulation and Aspen HYSYS for dynamic process simulation. Learning outcomes are assessed during the semester through two practical tests.
Exercise 1: Use of process simulators for the estimation of physical properties
Exercise 2: Thermodynamic models and prediction of phase equilibria
Exercise 3: Modelling of distillation processes
Exercise 4: Development of a process model for natural gas condensate stabilisation
Exercise 5: Development of a process model for dimethyl ether production by methanol dehydration
Exercise 6: Design and sizing of unit operations introduced in previous exercises
Exercise 7: Development of a pressure-driven process model as a basis for dynamic simulation
Exercise 8: Development of a dynamic model of a simple process including the process control system
The expected outputs include completed process models in CHEMCAD and Aspen HYSYS, together with completed worksheets.
STUDENT REQUIREMENTS:
A minimum attendance of 75% at lectures and practical exercises. Successful completion of partial assessments in theory and practical exercises.
TEACHING METHODS:
Lectures, practical exercises and independent assignments.
ASSESSMENT AND EXAMINATION:
Two (2) partial theory assessments, worth a total of 20 points.
Two practical exercise tests, worth a total of 30 points.
Only one failed or missed test may be retaken.
Students who achieve at least 60% of the available points in each of the four assessments are exempt from the written examination.
Attendance contributes a maximum of 6 points: three points for attendance at practical exercises and three points for attendance at lectures.
The final grade is determined on the basis of the total number of points achieved, according to the following scale:
Sufficient (2) 60% of the total available points
Good (3) 70% of the total available points
Very good (4) 80% of the total available points
Excellent (5) 90% of the total available points
Students who are not satisfied with the grade obtained on the basis of continuous assessment may take the written and oral examination. The same grading scale applies.
QUALITY ASSURANCE:
Student course evaluation survey
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Learning outcomes:
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- Evaluate the role of a chemical engineer in process design.
- Integrate the acquired knowledge and apply it to process synthesis, addressing a design task in a sustainable and economically optimal way.
- Recommend an approach to process design for various chemical product types.
- Select appropriate separation methods and their sequences.
- Analyise a process using process simulation (CHEMCAD).
- Evaluate the impact of mass and energy balances to equipment sizing, as well as capital and operating expenses.
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Literature:
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Nastavni tekstovi na mrežnim stranicama FKIT-a, I. Dejanović, G. Lukač,
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Product and Process Design Principles: Synthesis, Analysis and Evaluation, 3rd Editon, W.D. Seider at al., Wiley, 2010.
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Chemical Process Design and Integration, R. Smith, Wiley, 2005.
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Projektiranje procesnih postrojenja, F. Šef, Ž. Olujić, HDKI, 1988.
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Analysis, Synthesis, and Design of Chemical Processes, R. Turton, R. C. Bailie, W. B. Whiting, J. A. Shaeiwitz, Prentice Hall, 2003.
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Priručnik za dimenzioniranje uređaja kemijske industrije, E. Beer, HDKI, 1994.
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Chemical Engineers Handbook, Perry and Chilton, McGraw Hill,
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