PLANT DESIGN AND ECONOMICS

FOR CHEMICAL ENGINEERS

Submitted To:
Fahad Ali Rabbani
Submitted By:
Muhammad Hassan Bashir
2020-CH-243
 Chapter 1. Introduction to Chemical Engineering Plant Design
• A successful chemical engineer needs a knowledge and full understanding of the fundamental science and
the related engineering concepts of material and energy balances, thermodynamics, reaction kinetics, heat
transfer, mass transfer, and computer technology.
• Chemical engineering design of new chemical or biochemical processes and the expansion or revision of
existing processes require the use of engineering principles and theories combined with a practical
realization of the limits imposed by environmental, safety, and health concerns.

Chemical Engineering Plant Design

• Plant design includes all engineering aspects involved in the development of a new, modified, or expanded
commercial process in a chemical or biochemical plant.
• The chemical engineer will be making economic evaluations of new processes, designing individual pieces
of equipment for the proposed new venture, or developing a plant layout for coordination of the overall
operation.
• Process engineering is used in connection with economic evaluation and general economic analyses of
commercial processes, while Process Design refers to the actual design of the equipment and facilities
necessary for providing the desired products and services.
 General Overall Design Considerations
The development of a complete plant design requires consideration of many different factors such as:

• Plant location • Storage

• Site and plant layout • Waste disposal
• Plant operation and control • Health and safety
• Utilities • Materials handling

Process Design Development

• Process design development refers to the systematic approach of creating and refining
processes within an organization to improve efficiency, productivity, and quality. It involves
analyzing existing processes, identifying areas for improvement, designing new processes, and
implementing them in a structured manner.
 Table 1-1) Typical design steps for chemical and biochemical processes

1. Recognize a societal or engineering need.

a. Make a market analysis if a new product will result.
2. Create one or more potential solutions to meet this need.
a. Make a literature survey and patent search.
b. Identify the preliminary data required.
3. Undertake preliminary process synthesis of these solutions.
a. Determine reactions, separations, and possible operating conditions.
b. Recognize environmental, safety, and health concerns.
4. Assess profitability of preliminary process or processes (if negative, reject process and create new
alternatives).
5. Refine required design data.
a. Establish property data with appropriate software.
b. Verify experimentally, if necessary, key unknowns in the process
6. Prepare detailed engineering design.
a. Develop base case (if economic comparison is required).
b. Prepare process flowsheet.
c. Integrate and optimize process.
d. Check process controllability.
e. Size equipment.
f. Estimate capital cost.
7. Reassess the economic viability of process (if negative, either modify process or investigate other
process alternatives).
8. Review the process again for environmental, safety, and health effects.
9. Provide a written process design report.
10. Complete the final engineering design.
a. Determine equipment layout and specifications.
b. Develop piping and instrumentation diagrams.
c. Prepare bids for the equipment or the process plant.
11. Procure equipment (if work is done in-house).
12. Provide assistance (if requested) in the construction phase.
13. Assist with start-up and shakedown runs.
14. Initiate production.
 Flowsheet Development
• Flowsheet development is a critical process in various industries, including chemical engineering,
process engineering, and manufacturing. It involves the creation of a schematic representation or
diagram that illustrates the sequence of steps involved in a process, the equipment used, and the flow
of materials or fluids.
• The chemical engineer must establish separate flowsheets or road maps for each solution. Preliminary
process synthesis for each solution begins with the designer creating flowsheets involving just the
reaction, separation, temperature change and pressure change operations.
• Here are the key steps typically involved in flowsheet development:
1) Process Understanding 5) Equipment Selection and Sizing
2) Block Flow Diagram (BFD) 6) Piping and Instrumentation Diagram (P&ID)
3) Process Flow Diagram (PFD) 7) Safety and Environmental Considerations
4) Material and Energy Balances 8) Documentation and Communication
Overall, flowsheet development is a crucial step in process design and optimization. It allows engineers
to visualize, analyze, and communicate the process effectively, leading to efficient and safe operation of
industrial system
 Computer-Aided Design

• Computing hardware and software have become indispensable tools in process and plant
design. The capabilities provided by computers for rapid calculations, large storage, and
logical decisions plus the available technical and mathematical software permit design
engineers to examine the effect that various design.
• Process simulators are often useful in generating databases because of their extensive data
banks of pure-component properties and physical property correlations for ideal and nonideal
mixtures.
• Spreadsheet software is another tool used by all chemical engineers because of the ease of
use, This software is especially useful for mass and energy balances, approximate sizing of
equipment, cost estimating, and economic analysis steps of process design.
 Cost Estimation

• As the final process design stage is completed, it becomes possible to make accurate cost
estimations because detailed equipment specifications and definite plant facility information
are available.
• No design project should proceed to the final stages before costs are considered.
• Evaluation of costs in the preliminary design phases is referred to as predesign cost estimation.
Such estimates should be capable of providing a basis for company management to decide
whether further capital should be invested in the project.
• The chemical engineer (or cost engineer) must be consider all possible factors when making a
cost analysis. Fixed costs, direct production costs for raw materials, labor, maintenance,
power, and utilities must all be included along with costs for plant and administrative
overhead, distribution of the final products, and other miscellaneous items.
 Profitability Analysis of Investments

• Money, or any other type of capital, has a time value. When a manufacturing enterprise invests
money, it expects to receive a return during the time the money is being used.
• As time passes, money can be invested to increase at the interest rate. If money is needed for
investment in the future, the present value of that investment can be calculated by discounting
from the time of investment back to the present at the assumed interest rate.
• Expenses for various types of taxes and insurance can materially affect the economic situation
for any industrial process. Because various taxes can account for a major portion of a
company's net earnings, it is essential that the chemical engineer be conversant with the
fundamentals of taxation. For example, income taxes apply differently to projects with
different proportions of fixed and working capital. Profitability, therefore, should be based on
income after taxes.
 Optimum Design

• Optimum design, also known as optimization design, is a process of finding the best possible
solution to a design problem or decision-making challenge.
• The goal of optimum design is to maximize performance, minimize costs, or achieve a balance
between various competing factors.
• In almost every case encountered by a chemical engineer, several alternative methods can be
used for any given process or operation. For example, formaldehyde can be produced by
catalytic dehydrogenation of methanol, by controlled oxidation of natural gas, or by direct
reaction between CO and H2 under special conditions of catalyst, temperature, and pressure.
• Each of these processes contains many possible alternatives involving variables such as the
gas-mixture composition, temperature, pressure, and choice of catalyst. It is the responsibility
of the chemical engineer, in this case, to choose the best process.
• Strategies that can be used to establish the desired results in the most efficient manner.
1) Optimum Economic Design: If there are two or more methods for obtaining exactly
equivalent final results, the preferred method is the one involving the least total cost. This is the
basis of an optimum economic design.
• A graphical representation showing the meaning of an optimum economic pipe diameter is
presented. The pumping cost increases with decreased size of pipe diameter because of
frictional effects, while the fixed charges for the pipeline become lower when smaller pipe
diameters are used because of the reduced capital investment. The optimum economic
diameter is located where the sum of the pumping costs and fixed costs for the pipeline
becomes a minimum, since this represents the point of least total cost. This point is
represented by E.
 Optimum Operation Design

• Optimum operation design, also known as operational optimization or process

optimization, focuses on finding the best operating conditions or strategies for a given system
or process. It aims to maximize efficiency, productivity, and performance while minimizing
costs, energy consumption, and waste.
• Optimum operation design involves analyzing and improving the operational parameters,
controls, and strategies to achieve optimal results.`
• Many processes require specific conditions of temperature, pressure, contact time, or other
variables if the best results are to be obtained.
 Example
• Determination of operating conditions for the catalytic
oxidation of sulfur dioxide to sulfur trioxide.
• Suppose that all the variables, such as converter size, gas
rate, catalyst activity, and entering-gas concentration, are
fixed, and the only possible variable is the temperature at
which the oxidation occurs.
• If the temperature is too high, the yield of SO3 will be low
because the equilibrium between SO3, SCT, and O2 is
shifted in the direction of SO2 and O2.
• On the other hand, if the temperature is too low, the yield
will be poor because the reaction rate between SO2 and O2
will be low.
• Thus, there must be one temperature at which the amount of
sulfur trioxide formed will be a maximum. This particular
temperature would give the optimum operation design.
 The Design Approach
• The design approach refers to the methodology or process used to develop and create new
products, systems, or solutions. It encompasses the systematic and creative problem-solving
methods employed by designers to address user needs, technical requirements, and aesthetic
considerations.
• In original design work, the engineer must deal with many different types of experimental and
empirical data. The engineer may be able to obtain accurate values of heat capacity, density,
vapor liquid equilibrium data, or other information on physical properties from the literature.
• In the engineer's approach to any design problem, it is necessary to be prepared to make many
assumptions. Sometimes these assumptions are made because no absolutely accurate values or
methods of calculation are available. At other times, methods involving close approximations
are used because exact treatment would require long and laborious calculations giving little
gain in accuracy.
 ENGINEERING ETHICS IN DESIGN
1) Hold paramount the safety, health, and welfare of the public in performance of their professional duties.
2) Formally advise their employers or clients (and consider further disclosure, if warranted) if they
perceive that a consequence of their duties will adversely affect the present or future health or safety of
their colleagues or the public.
3) Accept responsibility for their actions and recognize the contributions of others; seek critical review of
their work and offer objective criticism of the work of others.
4) Issue statements or present information only in an objective and truthful manner.
5) Act in professional matters for each employer or client as faithful agents or trustees, and avoid conflicts
of interest.
6) Treat fairly all colleagues and co-workers, recognizing their unique contributions and capabilities.
7) Perform professional services only in areas of their competence.
8) Build their professional reputations on the merits of their services.
9) Continue their professional development throughout their careers, and provide opportunities for the
professional development of those under their supervision.
 CHAPTER 2. General Design Considerations

The development of a complete plant design requires consideration of many different factors such
as:

 Site Selection  Storage

 Site and plant layout  Waste disposal
 Utilities  Structural Design
 Operation and control  Health and safety
 HEALTH AND SAFETY HAZARDS

 The potential health hazard to an individual by a material used in any chemical process is a
function of the inherent toxicity of the material and the frequency and duration of exposure.
 It is common practice to distinguish between the short-term and long-term effects of a
material.
 Acute (short-term) effects show up immediately or soon after exposure to the chemical. They
may be minor, like nose or throat irritation, or they could be serious, like eye damage or
passing out from chemical vapors.
 The inherent toxicity of a material is measured by tests on animals. Dermatitis is a general
term that describes a common skin irritation. It has many causes and forms and usually
involves itchy, dry skin or a rash. Or it might cause the skin to blister, ooze, crust or flake off.
 The short-term effect is expressed as LD50—the lethal dose at which 50 percent of the test
animals do not survive.
 Long-Term Exposure is continuous or repeated contact with a toxic substance over a long period of
time. If a chemical is used every day on the job, the exposure would be chronic. Over time, some
chemicals, such as lead

Depending on the chemical, longer-term health effects might include:

•cancer.
•organ damage.
•weakening of the immune system.
•development of allergies or asthma.
•reproductive problems and birth defects.
 Sources of Exposure
• The main objective of health-hazard control is to limit the chemical dosage of a chemical by
minimizing or preventing exposure.
• It is not practical to measure or control the chemical dosage directly; rather, exposure is
measured and limits are set for the control of such exposure.
• Main sources of exposure are Inhalation, ingestion, skin contact or absorption.
• The most common and most significant source of workplace exposure to chemicals and also
the most difficult to control is inhalation.
• Workers become exposed when the contaminant is picked up by the air they breathe.
• For example, mechanical abrasions of solid materials by cutting, grinding, or drilling can
produce small particles that can form an airborne dust cloud or solid aerosol.
• Contaminant vapors are normally formed by allowing the liquid to evaporate into the air.
• Pumps and valves are probably the major source.
• Contamination of air with such gas occurs from leaks or from venting. Essentially all closed systems
leak to some degree.
• Flammable materials likewise are carefully controlled because a leak may lead to a fire and a possible
major loss in life and facility
• In typical well-maintained plants, pumps and valves are probably the major source of fugitive
emissions.
• Maintenance of any closed system can pose a hazardous exposure problem.
 Exposure Evaluation

• If health hazards are to be controlled, they must be recognized and evaluated.

• A logical place to initiate the process of health hazard recognition is with a total inventory of
all materials present in the various stages of the process.
• An estimate of the toxicity or intrinsic hazard is required by the OSHA Hazard
Communication Standard in the form of a Material Safety Data Sheet (MSDS).
 Summary of a material safety data sheet

1. Product identification
a. Precautionary labeling
b. Precautionary label statements
c. Laboratory protective equipment required
2. Hazardous components
3. Physical data
4. Fire and explosion hazard data
a . Fire extinguishing media
b. Special fire-fighting procedures
c. Unusual fire and explosion hazards
d. Toxic gases produced
5. Health and hazard data
a. Effects of overexposure
b. Target organs
c. Medical conditions generally aggravated by exposure
d. Emergency and first aid procedures
6. Reactivity data
7. Spill and disposal procedures
a. Steps to be followed in the event of a spill or discharge
b. Disposal procedure
8. Protective equipment
9. Storage and handling precautions
a. Special precautions
10. Transportation data and other information
a. Domestic
b. International
 Control of Exposure Hazards

• There are three general control principles utilized in reducing the exposure of workers to
occupational health hazards. These involve source controls, transmission barriers and
personal protection.
• Personal protection against exposure by inhalation can be accomplished by respirators.
• Dilution ventilation, on the other hand, adds a dilutant to a contaminant-filled space. The
objective of dilution ventilation is not to prevent any exposure, but to keep the exposure to
acceptable levels by dilution. This strategy should only be used in low release-rate, low-
toxicity (low-hazard) situations.
• Personal protection against exposure by inhalation can be accomplished by respirators. Such
devices are capable of providing considerable protection when selected and used properly.
 Personnel Safety
• Every attempt should be made to incorporate facilities for health and safety protection of plant
personnel in the original design.
• This includes, but is not limited to, protected walkways, platforms, stairs, and work areas.
• Physical hazards, if unavoidable, must be clearly defined.
• In such areas, means for egress must be unmistakable.
• All machinery must be guarded with protective devices.
• In all cases, medical services and first aid must be readily available for all workers.
 Loss Prevention

• The phrase loss prevention in the chemical industry is an insurance term where the loss
represents the financial loss associated with an accident.
• Summarized under the following broad headings;
1.Identification and assessment of the major hazards.
2.Control of the hazards by the most appropriate means, for example, containment,
substitution, improved maintenance, etc.
3.Control of the process, i.e., prevention of hazardous conditions in process operating
variables by utilizing automatic control and relief systems, interlocks, alarms, etc.
4.Limitation of the loss when an incident occurs.
Thank You