review for design i exam chen 4253 terry a. ring
TRANSCRIPT
Materials CoveredWeek 1-22 AugustChapt 1 (p.1 -25), Chapt 2, Chapt 3 Product Design-
Introduction to course – Product and Process DesignProduct Design-1 OverviewProduct Design-2 Property Estimation
Week 2-29 August Chapters 16 and 17
Product Design-3 Innovation MapsProduct Design-4 Six Sigma in Product DesignProduct Design-5 Engineering Ethics
Week 3–5 September (Holiday Monday)Chapt 1 (p25-31) Chapter 4 Process Creation-
Ethics in Chemical EngineeringProcess Safety
Process Design OverviewProcess Creation
Materials Covered-con’t
Week 4–12 September (Celanese in Class Monday)Chapt 4&5&6 Aspen for Process Creation–
Use of Aspen for Process Creation-1Use of Aspen for Process Creation-2Heuristics for Process Simulation
Week 5 – 19 September Chapt 4&5 Aspen Tutorials and Problems Solved in Class (Reserve the ICC) -Week 6 - 26 September (Away Wednesday and Friday)Chapt 5&6 ProMax Tutorials and Problems Solved in Class (Reserve the ICC) - Week 7–3 OctoberChapter 22-22 (p543-558) &23 Profitability Analyses -
Annual CostsEarningsProfitability Analysis
Week 8- 11 October FALL BREAK
What have we really covered?
• Product Design (Ethics) Chapt. 1,2&3
• Process Creation Chapt 4– Heuristics for Process Synthesis Chapt 6
• Process Simulators Chapt 5– Aspen– Promax
• Capital Cost Estimates Chapt 22
• Profitability Analyses Chapt 23
Chapters 1, 2,3 & 4• Chpt. 1 - The Design Process
– Ethics in Chemical Engineering– Product design
• Chpt. 2 – Product Development• Chpt. 3 - Molecular Structure Design
– Property estimation• Chpt. 4 – Process Creation
– Gross Profitability Analysis– Process Synthesis
• Start with the reactor (differences in molecular type)• Separation (differences in composition)• Heat transfer, pumping, compression, flash tanks
(differences in temperature, pressure, and phase)• Integraton
Physical Property Estimation
• Hansen Solubility Parameters• Group Contribution Methods
– Polymer properties– Surface tension– HLB– Heat of Mixing
• Drago E and C
– Work of Adhesion• Wetting
• Bio-concentration factor• Oil-water distribution Coefficient• Lethal Dose
• Flash Point Temp.
Chapters 5 and 6
• Chapter 5 – Simulation to Assist in Process Creation– Steady-state flow sheet simulation
• Table 5.1 – Unit Subroutines• Recycle (tear streams)
– Recycle convergence
• Chapter 6 – Heuristics for Process Synthesis– Summary on page 174, Table 6.2– Using these as a start in design/simulation
Process Creation
• Process Economics – Gross Profitability Analysis
• Focus on Reactor– Equilibrium– Kinetics or Conversion
• Focus on Separation System
• Heuristics in Process Design
Chapter 22 - Costing
• Accounting – Debits/credits; annual report; balance sheet
• Cost Indexes• Capital investment costs (Table 22.9,pg. 547)
– Bare model costs– Total depreciable capital– Total permanent investment– Total capital investment
• Estimation of Total Capital Investment– Order-of-magnitude– Study estimate– Preliminary estimate– Definitive estimate
Investment Chapter 23 - Costing
• Estimation of total capital– Order-of-magnitude (method of Hill)
• See page 498• +/- 50%
– Study estimate (Method of Lang)• See page 500• +/- 35%
– Preliminary estimate (method of Guthrie)• See page 503• +/- 20%• Most likely used• Need fob equipment purchase cost
– More definitive• Aspen Icarus (but we do not have this license)
Process Economics
• Capital Cost Estimation– Cost Indexes– Three types
• Scaleup of Capital Investments - 6/10th rule• Order of Magnitude Estimate (±50%) - Hill• Study Estimate (±35%) - Lang
• Profitability Analysis– ROI, PBP, IRR, VP, Cash Flow Calcs.
• Accounting