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Process Design Development: Akhilesh Gupta

The document discusses factors to consider when conducting a feasibility survey and comparing different manufacturing processes for a new product. A feasibility survey examines technical, economic, market, and other factors to evaluate a project's probable success. When comparing processes, considerations include raw materials, waste/byproducts, equipment, plant location, costs, time factors, and process-related issues. The goal is to analyze these essential variables to select the best suited process for existing conditions and eliminate less viable options.

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39 views9 pages

Process Design Development: Akhilesh Gupta

The document discusses factors to consider when conducting a feasibility survey and comparing different manufacturing processes for a new product. A feasibility survey examines technical, economic, market, and other factors to evaluate a project's probable success. When comparing processes, considerations include raw materials, waste/byproducts, equipment, plant location, costs, time factors, and process-related issues. The goal is to analyze these essential variables to select the best suited process for existing conditions and eliminate less viable options.

Uploaded by

akhileshguptamnre
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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Process Design

Development

Akhilesh Gupta
Feasibility Survey
Before the detailed work is done on the design, the technical and economic
factors of the proposed process should be examined. The various reactions
and physical processes involved must be considered, along with the existing
and potential market conditions for the particular product. A preliminary
survey of this type gives an indication of the probable success of the project
and also shows what additional information is necessary to make a complete
evaluation. Following is a list of items that should be considered in making a
feasibility survey:
i. Raw materials (availability, quantity, quality, cost)
ii. Thermodynamics and kinetics of chemical reactions involved (Equilibrium,
yields, rates, optimum conditions)
iii. Facilities and equipment available at present
iv. Facilities and equipment which must be purchased
v. Estimation of production costs and total investment
vi. Profits (probable and optimum, per pound of product and per year, return on investment)
vii. Materials of construction
viii. Safety considerations
ix. Markets ( present and future supply and demand, present uses, new uses, present buying habits,
price range for products and by products, character, location, and number of possible customers)
x. Competition (overall production statistics, comparison of various manufacturing processes,
product specifications of competitors
xi. Properties of products (chemical and physical properties, specifications, impurities, effects of
storage)
xii. Sales and sales service (Method of selling and distributing, advertising required, technical
services required)
xiii. Shipping restrictions and containers
xiv. Plant location
xv. Patent situation and legal restrictions
Comparison of different processes
• In a course of a design project it is necessary to determine the most suitable
process for obtaining a desired product. Several different manufacturing
methods may be available for making the same material, and various
processes must be compared in order to select the one best suited to the
existing conditions.
• The comparison can be accomplished through the development of
complete designs. In many cases, however all but one or two of the possible
processes can be eliminated by a weighted comparison of the essential
variable items, and detailed design calculations for each process may not be
required.
• The following items should be considered in a comparison of this type:
• Technical factors
i. Process flexibility
ii. Continuous operation
iii. Special controls involved
iv. Commercial yields
v. Technical difficulties involved
vi. Energy requirements
vii.Special auxiliaries required
viii.Possibility of future developments
ix. Health and safety hazards involved
• Raw materials
i. Present and future availability
ii. Processing required
iii. Storage requirements
iv. Materials handling problems

• Waste products and by-products


i. Amount produced
ii. Value
iii. Potential markets and uses
iv. Manner of discard
v. Environmental aspects
• Equipment
i. Availability
ii. Materials of construction
iii. Initial costs
iv. Maintenance and installation costs
v. Replacement requirements
vi. Special designs
• Plant location
i. Amount of land required
ii. Transportation facilities
iii. Proximity to markets and raw material sources
iv. Availability of service and power facilities
v. Availability of labor
vi. Climate
vii.Legal restrictions and taxes
• Costs
i. Raw materials
ii. Energy
iii. Depreciation
iv. Other fixed charges
v. Processing and overhead
vi. Special labor requirements
vii.Real estate
viii.Patent rights
ix. Environmental controls
• Time factor
i. Project completion deadline
ii. Process development required
iii. Market timeliness
iv. Value of money

• Process considerations
i. Technology availability
ii. Raw materials common with other processes
iii. Consistency of product within company
iv. General company objectives.

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