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NORTHEASTERN UNIVERSITY

DEPARTMENT OF CHEMICAL ENGINEERING

SPRING 2012

CHEMICAL PROCESS DESIGN CHME 4703

CLASSROOM HOURS

Monday, Wednesday, and Thursday 1:35 to 2:40 PM, 130 Hurtig OFFICE HOURS

TBD

INSTRUCTOR: PROF. SHASHI K. MURTY

smurthy@coe.neu.edu (617) 373-4017

Design Laboratory Phone Number 617-373-8871

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REQUIRED TEXTBOOK

Peters, M. S., Timmerhaus, K. D., and West, R.E. “Plant Design and Economics for Chemical Engineers,” Fifth Edition, McGraw-Hill, New York (2003) (on reserved for the class under Prof. Willey).

REFERENCE BOOKS

Beer, D.; McMurrey, D. A Guide to Writing as an Engineer, 2nd Edition, Wiley, New York, 2005 (on reserve for the class under Prof. Willey T11 .B396 2005) Crowl, D.A.; Louvar, J.F. Chemical Process Safety Fundamentals with Applications, 3rd Ed. (due out January 2011), Prentice Hall PTR, 2011. If there was only one book that should be on your desk at work, this is it. (the second edition is on reserve for the class under Prof. Willey TP155.5 .C76 2002).

Perry, R.H. and D.W. Green (Editors), Chemical Engineer's Handbook, 8th Edition, McGraw-Hill, 2008, ISBN 978-0-07-142294-9 (in the reference section of the library)

Seider, W.D., Seader, J.D., and Lewin, D.R. Product & Process Design Principles, 2nd ed. John Wiley & Sons, 2004. (on reserve for the class under Prof. Willey – use Chapt 22 for guidelines on written reports TP155.7 .S423 2004) Satterfield, C.N., “Heterogeneous Catalysis in Industrial Practice,” 2nd Ed. McGraw-Hill, New York, 1990 (on reserve for the class under Prof. Willey – use for industrial practice in catalytic processes. ) Ulrich, G.D. and Vasudevan, P.T., “Chemical Engineering Process Design and Economics – A Practical Guide,” Process Publishing Durham, NH, 2004 (the first edition is on reserve under Prof. Willey, use for examples of Process Flow Diagrams, TP155.7 .U46 1984). Yaws, C.L. “Chemical Properties Handbook”, McGraw-Hill, New York 1999, (A 2003 version is on reserve under my name in the library, further, several versions of this book is listed as an eBook in our library collection)

COURSE DESCRIPTION

CHME 4703 – Chemical Process Design: Continues CHME 4701. Requires each student to solve a comprehensive chemical process design problem. Topics include heat and power integration in chemical processing, design and scheduling of batch processes, sequencing separation operations, and safety considerations in process design. Prereq. CHME 4701.

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COURSE OBJECTIVES

At the completion of this course each student shall be able to:

In the area of process economics:

1. Explain the concepts of time-value-of-money and compound interest. 2. Make basic economic decisions based on present value. 3. Estimate capital and operating costs for major items of equipment. 4. Conduct project economic evaluations and select alternatives using economic

decision methods. 5. Conduct an assessment of intellectual property issues. Does someone own the

technology they wish to use? Determine if this changes the economics

In the area of process design:

1. Understand roles of process safety, environmental protection, and society in the practice of chemical engineering.

2. Use heuristics and rules-of-thumb in the analysis and interpretation of information.

3. Understand and appreciate essential elements of the design process that facilitate the application of creative abilities.

4. Appreciate the relationships between design intent, equipment specifications, and process conditions.

5. Identify and specify key process conditions. 6. Develop, read, and interpret flowsheets, process flow diagrams (PFDs), and

piping and instrumentation diagrams (P&IDs). 7. Understand the use and limitations of process simulation in the design process. 8. Appreciate the need for over-pressure protection of equipment and understand the

related design practices. 9. Prepare the preliminary process design to meet defined business, throughput,

quality, and safety/environmental specifications. 10. Initiate detailed design of major equipment items associated with fluid flow,

separations, and heat transfer. 11. Reinforce the transition from theory to practice in the context of equipment

selection, sizing, and specification. 12. Introduce accepted practices and ethics in working with vendors of chemical

process equipment.

In the area of personal development:

1. Improve oral and written communication skills for technical, managerial, and public audiences.

2. Improve team and group work skills.

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3. Become confident in acquiring knowledge on topics that the individual may have little or no previous experience or training.

4. Understand time and project management and succeed in bringing a project to a successful conclusion on a timely basis.

In the area of process safety

Note: Proposed changes for the ABET criteria related to the chemical engineering discipline are in the works. These specific guidelines are being proposed. Your understanding of them, and comments towards their effectiveness will be appreciated.

1. The graduate must understand that they hold paramount the safety, health and welfare of fellow employees, the public, and protect the environment in performance of their professional duties.

2. The graduate must understand the impact of chemical plant accidents and the concept of both societal and individual risk.

3. The graduate must be able to characterize the hazards associated with chemicals and other agents used in a chemical plant. This must include toxic, flammable, and reactive hazards.

4. The graduate must understand and be able to apply concepts of inherently safer design.

5. The graduate must understand how to control and mitigate hazards to prevent accidents. This should include plant procedures and designs to prevent accidents.

6. The graduate should be familiar with the major regulations that impact the safety of chemical plants.

7. The graduate should understand the consequences of chemical plant incidents due to acute and chronic chemical releases and exposures.

8. The graduate should be reasonably proficient with at least one hazard identification procedure.

9. The graduate should have an introduction to the risk assessment procedure.

Resource materials to assist in meeting these requirements can be found on the SACHE web site: www.sache.org

REQUIREMENTS AND POLICIES

Each group will complete one comprehensive project. Groups will be composed of three persons or less. There will be oral presentations for each of the following phases:

- Project Proposal/Business Case - Base Case Design - Detailed Design - Final Design

There will be written reports for each of the following phases: - Project Proposal/Business Case

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- Base Case Design - Detailed Design (not required of student groups planning to work the

National Student Design Contest Problem) - Final Design

Students should come to class prepared to discuss their group projects and to provide constructive input to other projects.

Students taking on the AIChE National Student Design Competition (NSDC) must become members of AICHE

Guidelines and Format for Presentations and Reports

I. Presentations : Business casual attire is required for all presentations. a) Proposal/Business Case Presentations: Each presentation will be 5-10 minutes

followed by a 5 minutes Q/A period. b) Preliminary Business Plan with Base Case Presentations: Each presentation will

be 10 minutes followed by a 5 minutes Q/A period. c) Design and Detailed Design Presentations: Each presentation will be 20 minutes

followed by a 5 minutes Q/A period. d) Final Design Presentations: Each presentation will be 30 minutes followed by a

10 minutes Q/A period. II. Reports : a) Design Proposal Reports: A 1-2 pages memorandum style summary discussing

the problem that you are planning to solve, why are you interested in this problem, initial ideas to solve this problem, and the significance of resolving this problem.

b) Preliminary Business Plan with Base Case Design, Detailed Design, and Final

Design Reports: Your report must be formatted on 8.5 by 11 inch pages as specified below, containing each item listed. Each page should be numbered sequentially in an organized fashion consistent with the pagination in a table of contents. A large format PFD diagram may be folded and included with the body of the report. No binder, other than a one inch, three ring binder, should be used to bind the report. It is conventional practice to include a one page Letter of Transmittal forwarding the final report to the person or distribution list for whom it is intended.

Each report is independent and stands on its own. The following outline applies to

the content and form of the Final Design Report, but should be used to the extent necessary and applicable for the other reports, as well.

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Final report guidelines are offered in Seider, Seader, and Lewin 2nd Edition. This

text is on reserve in the Snell Library for reference. Further details on what major headings should be included in the design report can be found in that text. Write the document from the point of view of the organization’s engineer making a report and recommendation to the organization’s management. Another reference, for flow sheet preparation, is Chapter 3 of “Chemical Engineering Process Design and Economics – A Practical Guide,” 2nd Edition, by G.D. Ulrich and P.T. Vasudevan, Process Publishing, Durham, NH.

Check List of Report Sections and Order of Appearance: A. Letter of Transmittal 1. Title Page 2. Table of Contents List of Figures List of Tables 3. Executive Summary (w/ specific reference to design specifications) 4. Introduction 5. Summary 6. Discussion 7. Conclusions 8. Recommendations 9. Project Premises 10. Heat and Material Balances 11. Main Unit Process Flow Diagram 12. Overall Process Flow Diagram with heat integration and stream flows &

compositions between all units in plant 13. Safety, Health, and Environmental Considerations 14. Equipment Information Summary – with enough design information to cost

equipment 15) Unit Control and Instrumentation Description 16) Economics - In addition to DCF (discounted cash flow), include a summary of

operating costs, utility requirements and energy efficiency 17) Engineering Calculations, Computer Simulation Outputs 18) References 19) Acknowledgements

Grading: Tentative weighting: Final Design Presentation 30% Final Design Report 70%

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SPRING 2012 Design Project Ideas

CHME 4703

1) Natural Gas Turboexpansion Plant 2) The Production of Methyl Methacrylate (MMA) from Methacrylic Acid (MA) 3) Enhanced Ethane Recovery Process from Pipeline Natural Gas 4) Adiabatic Cold Tank Separation and Isobaric Demethanization of Natural Gas for

the Recovery of Liquid Petroleum Gases 5) Separation of Natural Gas by Distillation 6) Optimization of a Natural Gas Processing Plant to Produce Methane Gas and

Natural Gas Liquids 7) Integrated Coal Gasification Combined Cycle Power Generation Plant Design 8) Economical Design of a Natural Gas Plant Using a Turboexpansion Process 9) Cryogenic Turbo-Expansion Demethanizing Natural Gas Plants 10) How to Whey in the Profit 11) Design of a Whey Protein Concentrate 12) Create Automatic, Continuously Recording Bioreactor Sensors 13) Nanoparticles as Drug Delivery Vehicles 14) Production of Methane and Hydrogen from Biomass 15) Design a Green Brewery 16) Design a Process for Extracting Krypton and Xenon from Air 17) Retrofit an Existing Refrigerant Process for Producing R134a Refrigerant 18) Design a Process to Produce Human Insulin from Mammalian Cell Cultures 19) Design a Process for Removing Oxides of Nitrogen from Power Plant Exhaust 20) Design a Process for Producing Methylmethacrylate (MMA) from Propene 21) Design a Process for the Production of Methanol by a New Process Utilizing

Methyl Formate as an Intermediate 22) Design a Reactor for a Process to Produce Polyether 23) Design a Process for Producing a Biologically Useful Compound from Plant Cell

Culture 24) Extraction of Resveratrol Muscadine Grapes on an Industrial Scale 25) Extraction of Delta-9-Tetrahydrocannabinol (THC) from Cannabis Sativa Cell

Cultures for use in Pharmaceutical Compounds 26) Gasification of Coal for Use in Generating Clean Electricity 27) Novel Testing Methods for Detecting Bad Wine without Opening the Bottle 28) Hair Growth Stimulation by Insulin-like Growth Factor 1 29) Production of Organic, Gluten-Free Beer through Green Engineering Practices 30) A Novel Approach to Large Scale Production of an HIV Vaccine 31) Reduced-Toxicity CdSe Quantum Dots for Tumor Imaging 32) Recycling of Greenhouse Gases using Microalgae Bioreactors 33) All-Natural Superfruits Skin and Body Care Product Line 34) Extraction of Spider Silk Recombinant Proteins from Mammalian Process Cell

Cultures for Bulletproof Applications 35) A Novel Approach to Cure HIV 36) Optimizing Energy Recovery of Plasma Arc Waste Disposal

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37) Renewable Energy Technology Development & Renewable Energy Systems Implementation by Ki Systems

38) Production of Enzymatically Converted "O" Type Blood 39) The Production of Twisted Nematic Liquid Crystals 40) Design of a Synthetic Pancreas for Insulin Dependent Diabetics 41) Coal to Methanol Process 42) Solving the Boston Metro Area Waste Management Issue 43) Use of Anaerobic Digestion for the Generation of Power in Municipal Wastewater

Treatment 44) Removal of Carbon Dioxide from the Atmosphere 45) BioButanol Fuel Implementation 46) Extraction of Oil from Oil Shale 47) Production of Gasoline from Biomass 48) Mitigating CO2/NOx Emissions Using Algae Bioreactors via Cogeneration 49) Production of Galanthamine by Plant Cell Culture 50) Designing Pilot Plant for Bulk Chemical Vapor Deposition (CVD) 51) Green Brewery 52) Design of a Modular, Solar-Thermal Power Generation System 53) Propose Your Own Project

Previous National Student Design Competition Projects (NOTE NU’s record very impressive!)

2000 AIChE National Student Design Competition: • Proc. Syn. and Des. of the Power Gen. System for Automobiles: A Fuel Cell Approach

2001 AIChE National Student Design Competition: • Economic Recovery of Edible Protein from Cheese Whey by Ultrafiltration

2002 AIChE National Student Design Competition: • Design for Polyether Synthesis

2003 AIChE National Student Design Competition: • Recycling Nitric Acid from a Radioactive Liquid Waste Stream (NU team of Kevin Cash,

Jeffrey Pierce, and Ellen Brennan receive first place and Cash, Pierce and Brennan receive SACHE safety team award; plus Joshua Jondro, Joshua Grilly, & Nicole Winters win a Safety and Health Division award)

2004 AIChE National Student Design Competition: • Disposal of Cavern-Stored Ethylchloroacetate by Reaction with Caustic (NaOH) (NU

team David Burke, Jamie Tribe & Timothy Leong win SACHE safety award and S&H safety award).

2005 AIChE National Student Design Competition: • Extraction of Carbon Dioxide from the Atmosphere

2006 AIChE National Student Design Competition: • Crystallization of Uranyl Nitrate from Dissolved Spent Nuclear Fuel (SNF) (NU team Edward Viveiros, Jonathan G Leong, & ?? receive honorable mention)

2007 AIChE National Student Design Competition: • Economic Recovery of Pyridine (NU team Melissa Semple, Jeiran Jahani, & Brian

MacMahon receive first place in the competition and win Safety and Health Division safety award)

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2008 AIChE National Student Design Competition: • Coal to Methanol

2009 AIChE National Student Design Competition: • ABE Fermentation (NU team Andrew Grant, Joseph Clegg & Kyle Stephens receive a

tie for first place in the competition and NU team Rhiannon Quirk, James Sims, & Elizabeth Wienslaw win SACHE safety team award)

2010 AIChE National Student Design Competition: • Manufacturing Facility for a Biopharmaceutical: Monoclonal Antibody (NU

teams, Jason Crater, Joseph Masucci, & Lindsey Mathews; as well as Jonathan Allen, Jonathan Goldman, Erin Stokes, received “honorable mention” and Crater, Masucci, & Mathews win the SACHE safety award)