chapter 2: part i process, product design, process ......learning outcomes after studying this...
TRANSCRIPT
Intro to PD - 1
CHAPTER 2: Part I Process, Product Design,
Process Creation & Sustainability (Intro.)
Learning Outcomes After studying this topic, participants should: • Recognise the significance of design project for chemical/process engineers.
• Be able to describe the life cycle of a chemical process and identify the
activities associated with it.
• Have an appreciation of the key steps in carrying out a product/process design.
• Be knowledgeable about the kinds of design decisions that challenge product and process design teams.
• Be familiar with the key roles of a chemical/process engineer.
• Be aware of the various techniques and steps involve during process creation.
Introduction & definition of concepts
• Product centric process design • Chemical product design
• Sustainable process design
Chemical process design
Process Flowsheet?
Raw material Products
Operating condition?
Equipment parameters?
Chemical process design involves the determination of the process flowsheet and the corresponding condition of
operation and equipment design that converts the selected raw materials to the desired products
Are our products & processes sustainable?
Only 25 wt. % of what goes into the pipe comes out as goods and services – scope for significant improvements (Adapted from Driolli, 2005)
Natural Resources
Goods and Services
Pollution, Waste and Environmental Disturbances
Need for significant improvement
Note: Without signficant improvements, our products-processes are not sustainable
Sustainable chemical process design
6
As a new definition of process design
Chemical Product Chemical Process ?? Raw Material
Chemical process design is about finding a sustainable process that can convert the raw materials to the desired
chemical products
Sustainable in terms of economic, low environmental impact, low waste, efficient operation, correct raw material, …..
Raw material, solvents, water, power, steam, …
Products, solvents, water, power, steam, unconverted materials, …
Chemical Process
time
D
eman
d
R
eser
ve
Sustainability of total system and sub-systems
Sustainability limit
Concept of sustainability 1 (Prolong the life of the process)
• Boundary: process and its connections
• Compared to a base-case design and generate alternatives that improve the following
• Operability, energy consumption, waste reduction, environmental impact, safety, cost, ….
• Sustainability metrics (as defined by IChemE): 49 Environmental (resource usage; emissions, effluents, waste), economic (profit, value, tax; investments), societal (workplace, society)
Raw material, solvents, water, power, steam, …
Products, solvents, water, power, steam, unconverted materials, …
Chemical Process
Concept of Sustainability 2 (Measure of sustainability)
• Improve the following:
• Operability, energy consumption, waste reduction, environmental impact, safety, cost, ….
• Sustainability metrics (as defined by IChemE)
Raw material, solvents, water, power, steam, …
Products, solvents, water, power, steam, unconverted materials, …
Chemical Process
Apply a systematic analysis of the mass and energy paths within the process to determine a set of mass and energy indicators that will help to define attainable targets for improvement;
generate alternatives that meet these targets through a “reverse” approach
(How to achieve sustainability?)
Concept of Sustainability 3
“The sustainability of an industrial process can be evaluated using a set of three-dimensional (3D) indicators that represent all three dimensions of sustainability: economic, environmental, and societal”
Sustainability Metrics defines by IChemE
• Process Design – whose job?
• Design project in the context of a chemical process engineer’s role
• Process Design Definition
• Process Design Procedure
• Process Design Activities
• Process Life Cycle
• Levels of Design Accuracy
Introduction to Process Design Job
One day in a job interview…...
What is your field of study? Chemical-polymer
Engineering!
Then, our chemistry lab might be the best place for you ? Oh no!
Not again...
The manager
The fresh grad
Chemical/Process Engineering
..is the field of study that involves the process of converting resources into value-added (VA) products
What a Chemical Process Engineer* Does for a Living
1. Process Development
2. Process Design
3. Construction
4. Manufacturing
5. Technical Sales
6. Research
*A person whose job is related to the process of transforming materials into value-added products
1. Process Development
• Design • Construction • Operation - testing - reaction & catalyst - process conditions - process control scheme - materials of construction
Pilot Plant (10 kg/hr) Chemical
Lab (10g)
Commercial Scale
(100 tonne/hr)
2. Process Design
Process Parameters: • production rate • process conditions (T, P) • type of vessels • control systems • safety & pollution control system
Chemical Engineers Jobs’:
INPUT Process Flowsheet: • equipment & streams P & I Diagram Equipment Specifications • size • dimension • materials of construction • min/max capacity
OUTPUT
3. Construction - “Moment of Truth”
Chemical Engineers Jobs’:
• Ascertain that equipment operates correctly?
• Are involved in plant commissioning (start up)
• Identify any problems with process and equipment
• Specify redesign requirements (as required)
4. Commercial Production
Chemical Engineer
Troubleshooting Supervision Quality Control Debottlenecking
Energy Conservation Raw material conservation Pollution control Process control
Routine Operation
Process Improvement
5. Technical Sales (or Sales Engineer)
Chemical Engineer Jobs’:
• Provide process and product recommendations
• Provide advice on development of new process & products
• “Networking” with experts from other fields in solving
process/equipment problems to meet customer needs
6. Research
Chemical engineers Jobs’:
• Cooperate with chemist, scientists and
engineers from other fields to produce
new products.
• Develop new processing techniques.
• Improve & optimise process
operations.
• Design new equipment or improve the
existing ones.
What a Chemical Process Engineer* Does for a Living
1. Process Development
2. Process Design: to be discussed?
3. Construction
4. Manufacturing
5. Technical Sales
6. Research
*A person whose job is related to the process of transforming materials into value-added products
Discussion Sessions: Process Design Issues
Discuss among your group members:
• What is a good definition for Process Design? • What are the basic prerequisites? • What do you think are the key steps involved in Process Design? • What initial key information do you think would be needed?
A design project
• Survey/feasibility studies
• Project team
• Project structure/planning (milestone)
• Process and Product Design
Desired Products
PROCESS ?
Raw materials?
Process Structure
Class of Chemical Products
• Thousands of chemical products are manufactured.
• 3M company (formerly known Minnesota Mining & Manufacturing Company) – developed over 60 000 chemical products since 1904.
• Thus, chemical products roughly classified as; Basic chemical products, Industrial products and Consumer products.
• Basic chemical products:
- manufactured from natural resources such as commodity chemicals (ethylene, acetone, vinyl chloride) , specialty chemicals (difluoroethylene, ethylene glycol monomethyl, diethyl ketone), biomaterials (pharmaceuticals, tissue implants), polymeric materials (ethylene copolymer, polyvinyl chloride (PVC), polystyrene).
- Categories as well-defined molecules/mixture of molecules.
- Not sold directly to the consumer.
Class of Chemical Products
• Industrial products:
- Begins with basic chemical products.
- Such as: films, fibers (woven, nonwoven), paper, creams, pastes (cements, glues, adhesives)
• Consumer products:
- Manufactured from basic chemicals and industrial chemical products.
- Such as: dialysis devices, hand warmers, ink-jet cartriges, transparencies for
overhead projector, drug delivery patches, fuel cells, cosmetics, detergents.
- Sold directly to customer.
Manufacture of Chemical Products
Natural
Resources
Basic
Chemical
Products
Industrial
Products
Manufacturing
Process
Manufacturing
Process
Manufacturing
Process
Basic Chemical
Products
(Commodity and
Specialty Chemicals,
Biomaterials,
Polymeric Material)
Industrial Products
( Films, Fibers, Paper,..)
Customer Products
(Paper bag, Dialysis
Devices, Post-it Notes,
Transparencies, Drug
delivery Patches,
Cosmetics,..)
Manufacturing
Process
Manufacturing
Process
Manufacturing
Process
Manufacturing
Process
Manufacturing
Process
Manufacturing
Process
Methane
Ammonia
Methanol
Ethylene
Oxide
Chloralkali
Plant
Ethane
Propane
Ammonia
MTBE
Urea
Formadehyde
Ammonia Urea
Ammonium Nitrate
Ammonium
Phosphate Polyvinyl Chloride
Titanium Dioxide
Silicones
Polyethylene LDPE
Glycol
Surfactant
Polypropylene
Acrylics
Acrylonitrile
Caprolactam Terephthalic
Acid Polystyrene
ABS, SAN
MTBE
Unsaturated Esters
Butane
Benzene
Type of Process: Fractionated of Raw Natural Gas
Middle Distillates
Basic Chemical Products
What is a Process/ Product Design?
A project/endeavor/task to determine the structure of a process to produce a product in the way that is economical, safe, and environmentally friendly.
Among other things, a project would involve management, planning, assessment and evaluation
Process Design in Top Management Level
Board of Director (BOD)1
(ideas, project scope)
What Product? Project “Green Light” Budgetary Requirements New Routes/Off-the Shelf Problems?
Executive Committee2
(feedback, feasibility studies, market survey)
Discussions/interviews with • Authority • Plant managers • Management team • Community
Decisions/Activities
Planning/Organisational Design
• Project Structure/Team • Project Milestone/Planning • Process/Product Design
1Client (Prospective owner), Project Manager, Investor 2Project Manager, CMT, Contractor, Authority
(Seider et al., 2004)
Figure: Process Life Cycle– A Bird’s Eye View
Steps in Development of Process/Product Design
Process Design – Basic Components at Project Team Level
• Steps in the design of a chemical process: 1. Project Conception
2. Process Synthesis/Creation
3. Equipment Design
4. Economic Analysis
5. Optimisation
(Ulrich, 1984)
Process Design – Process Synthesis/Creation
Process Simulation
parameter
optimisation
Optimised Design
Material and Energy Balances
(manual & simulation)
Process Synthesis/
Flowsheeting
Process
Modelling/Analysis
(Manan, 2001)
structural optimisation
Process Creation (details)
• Product design team identifies needs and generate ideas for new product that meets customer requirement.
• Brainstorming sessions for alternatives
• Select promising alternatives for further research and development
• Base on the principles of thermodynamics, chemical kinetics, heat & mass transfer etc
Create & Access Primitive Problem
From lab or established database e.g. Knovel website, NIST (National Institute of Standard & Technology) chemical webpage, patents, research journals & etc.
Process Creation and Detailed Design
Final Design & Operation
Construction and Operation
Layout and
3-D Modelling
Construction
Startup and
Commissioning
Plant Operation
Debottlenecking
Decommisioning
Some common terminology
• Process flow diagram (PFD) / process flowsheet – “interconnections of the individual process operations (e.g. drying, mixing, etc.) together with the quantitative variables (e.g. P, T, flowrates and composition)”
THANK YOU