PROCESS PLANT DESIGN

International Teaching PROCESS PLANT DESIGN

0622200011
DIPARTIMENTO DI INGEGNERIA INDUSTRIALE
EQF7
CHEMICAL ENGINEERING
2021/2022



OBBLIGATORIO
YEAR OF COURSE 2
YEAR OF DIDACTIC SYSTEM 2019
PRIMO SEMESTRE
CFUHOURSACTIVITY
660LESSONS
Objectives
KNOWLEDGE AND UNDERSTANDING:
ELEMENTS OF CONCEPTUAL DESIGN OF A PROCESS PLANT. OPTIMIZATION PRINCIPLES IN SINGLE VARIABLE AND MULTIVARIABLE, CONSTRAINED VARIABLE, LINEAR AND NONLINEAR PROBLEMS. STRUCTURE OF A PROCESS SIMULATION SOFTWARE. USING A PROCESS SIMULATION SOFTWARE FOR ASSISTED DESIGN. OPTIMIZATION OF A TRAIN OF PROCESS UNITS, WITH CORRESPONDING OPERATING CONDITIONS, EVEN WITH THE USE OF A SIMULATOR. USING A PROCESS SIMULATION SOFTWARE FOR THE THERMAL OPTIMIZATION OF A PLANT, FOR THE DEVELOPMENT OF ECONOMIC ANALYSIS AND THE PREPARATION OF THE TECHNICAL DESIGN REPORT.

APPLYING KNOWLEDGE AND UNDERSTANDING – ENGINEERING ANALYSIS
ABILITY TO ANALYZE A COMPLETE PROCESS PLANT AND ASSESS ALTERNATIVE PROCESS FLOW SHEETS. ABILITY TO ANALYZE THE OPERATION CONDITIONS OF THE PROCESS UNITS.

APPLYING KNOWLEDGE AND UNDERSTANDING – ENGINEERING DESIGN
ABILITY TO DESIGN A COMPLETE PROCESS PLANT BY MEANS OF PROCESS SIMULATION SOFTWARE, TO CHOOSE EQUIPMENT SIZE AND OPERATING CONDITIONS, TO PERFORM HEAT INTEGRATION, TO ESTIMATE CAPITAL AND OPERATING COSTS AND PROFITABILITY INDICATORS OF A PLANT.

MAKING JUDGMENTS - ENGINEERING PRACTICE:
ABILITY TO USE A PROCESS SIMULATION SOFTWARE.

TRANSVERSAL SKILLS -COMMUNICATION SKILLS:
ABILITY TO WORK IN A GROUP AND TO WRITE A TECHNICAL REPORT OF A PLANT PROJECT.

LEARNING SKILLS – TRANSVERSAL SKILLS:
ABILITY TO APPLY KNOWLEDGE IN DIFFERENT SITUATIONS THAN THOSE PRESENTED IN THE COURSE AND TO STUDY THE SUBJECT CONTENTS FROM DIFFERENT SOURCES

INVESTIGATION SKILLS – TRANSVERSAL SKILLS:
ABILITY TO OBTAIN INFORMATION USEFUL FOR THE DESIGN OF PROCESS PLANTS FROM PATENTS AND THE TECHNICAL AND SCIENTIFIC LITERATURE ABILITY TO REFINE OWN KNOWLEDGE.
Prerequisites
A DEEP KNOWLEDGE OF NON IDEAL THERMODYNAMICS OF VAPOR-LIQUID EQUILIBRIA, OF UNIT OPERATIONS OF CHEMICAL ENGINEERING, OF CHEMICAL REACTION ENGINEERING AND OF PROCESS DIAGRAMS IS REQUIRED. IT IS HIGHLY RECOMMENDED THE KNOWLEDGE OF CONTENTS ON MULTICOMPONENT DISTILLATION AND ON PROCESS HEAT INTEGRATION GIVEN IN THE COURSE OF ADVANCES IN UNIT OPERATIONS.
Contents
INTRODUCTION TO CONCEPTUAL DESIGN (5H LECTURE): PROJECT ORGANIZATION; CONCEPTUAL DESIGN OF A PROCESS PLANT; HIERARCHICAL STRUCTURE OF THE PROCESS; METHODS OF DESIGN AND INTEGRATION; FORMULATION OF A BASE CASE.

FUNDAMENTALS OF OPTIMIZATION (4H LECTURE, 2H EXERCISE): OBJECTIVE FUNCTIONS; SINGLE VARIABLE AND MULTIVARIABLE OPTIMIZATION; CONSTRAINED OPTIMIZATION; OPTIMIZATION OF LINEAR AND NONLINEAR PROBLEMS.

COMPUTER AIDED PROCESS ENGINEERING (2H LECTURE, 10H LAB): STRUCTURE OF A PROCESS SIMULATOR; SEQUENTIAL-MODULAR AND EQUATION-ORIENTED APPROACH; MASS AND ENERGY BALANCES; EQUIPMENT DESIGN AND RATING; SENSITIVITY ANALYSIS AND OPTIMIZATION METHODS.

INTEGRATED DESIGN (12H LECTURE, 15H LAB): OPTIMIZATION OF REACTOR CONFIGURATION AND CONDITIONS; OPTIMIZATION OF SEQUENCES OF REACTORS; SEPARATION SYSTEM DESIGN; SEPARATION UNITS SEQUENCING; PROCESS RECYCLES.

APPLIED HEAT INTEGRATION (2H LECTURE, 3H LAB): PINCH ANALYSIS RECAP; THERMAL DATA EXTRACTION FROM THE PROCESS FLOWSHEET; SOFTWARE FOR HEAT EXCHANGER NETWORK DESIGN; UTILITY SELECTION; DETAILED DESIGN OF A HEAT EXCHANGER.

ECONOMIC ANALYSIS AND REPORT OF A DESIGN PROJECT (5H LECTURE): SUMMARY OF ELEMENTS OF ECONOMIC ANALYSIS; ASSESSMENT OF CAPITAL AND OPERATING COSTS; PROFITABILITY ANALYSIS INDICATORS; STRUCTURE OF THE TECHNICAL REPORT OF A DESIGN PROJECT.
Teaching Methods
ATTENDANCE AT THE LECTURES IS STRONGLY RECOMMENDED. 
THE LANGUAGE OF INSTRUCTION IS ITALIAN, OR, IN THE PRESENCE OF INTERNATIONAL STUDENTS, ENGLISH. THE COURSE INCLUDES LECTURES (30H), CLASSROOM EXERCISES (2H), AND COMPUTER LABORATORY PRACTICE (28H). A DESIGN PROJECT OF A CHEMICAL PROCESS PLANT IS ASSIGNED TO STUDENTS, DIVIDED INTO WORKING GROUPS OF 4-6 MEMBERS, TO BE DEVELOPED DURING AND AFTER THE COURSE. 
Verification of learning
THE ACHIEVEMENT OF THE OBJECTIVES OF THE COURSE IS CERTIFIED BY PASSING AN EXAM WITH MARKS BETWEEN 18 AND 30. THE EXAM CONSISTS IN A 30-MINUTE ORAL EXAMINATION INCLUDING: A) A DISCUSSION OF A TECHNICAL REPORT OF A CHEMICAL PLANT DESIGN PROJECT PRODUCED BY THE STUDENTS IN WORKGROUPS OF 4-6 COMPONENTS; B) A DISCUSSION OF THE THEORETICAL CONTENTS OF THE COURSE. EVALUATION OF THE ATTAINMENT OF THE EXPECTED OBJECTIVES WILL BE ACHIEVED BY VERIFYING THE CORRECTNESS OF THE DESIGN PRINCIPLES APPLIED IN THE WRITTEN DESIGN REPORT AND BY THE ASSESSMENT OF THE ABILITY TO DEVELOP ALTERNATIVE DESIGN SOLUTIONS IN AUTONOMY DURING THE ORAL INTERVIEW. THE MINIMUM EVALUATION CRITERION IS BASED ON ACHIEVED DESIGN SOLUTIONS BASED ON LITERATURE DATA AND WITH APPROXIMATE SIZING OF PROCESS UNITS. THE EVALUATION OF EXCELLENCE REQUIRES THE ACHIEVEMENT OF ECONOMICALLY OPTIMIZED DESIGN SOLUTIONS AND THE SIZING OF THE UNITS WITH RIGOROUS METHODS.
Texts
MAIN TEXTBOOKS
SMITH, R. CHEMICAL PROCESS: DESIGN AND INTEGRATION, WILEY
AL-MALAH, K.I.M., ASPEN PLUS® CHEMICAL ENGINEERING APPLICATIONS, WILEY
OTHER LEARNING MATERIAL (PRESENTATIONS, CHAPTERS, AND SCIENTIFIC ARTICLES) WILL BE MADE AVAILABLE IN THE SHARED FOLDER OF THE COURSE.

FURTHER READINGS:
SEIDER, W.D., SEADER, J.D., LEWIN, D.R. PRODUCT AND PROCESS DESIGN PRINCIPLES: SYNTHESIS, ANALYSIS AND EVALUATION, WILEY
TURTON, R., BAILIE, R., WHITING, W., SHAEIWITZ, J. ANALYSIS, SYNTHESIS, AND DESIGN OF CHEMICAL PROCESSES, PRENTICE HALL
SINNOTT, R.K., CHEMICAL ENGINEERING DESIGN, ELSEVIER BUTTERWORTH HEINEMANN
SCHEFFLAN, R. TEACH YOURSELF THE BASIC OF ASPEN PLUS, WILEY
More Information
PLACE AND TIME OF DELIVERY
THE COURSE IS DELIVERED AT THE DEPARTMENT OF INDUSTRIAL ENGINEERING. PLEASE LOOK UP INTO THE DEPARTMENT WEBSITE (HTTPS://CORSI.UNISA.IT/INGEGNERIA-CHIMICA/DIDATTICA/CALENDARI) FOR THE INDICATION OF THE TIMETABLE AND OF THE CLASSROOM.
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