Design Concept and its steps

Module 1

1
 What is the design?
• Design is a creative activity.

• Design is the synthesis, the putting together, of

ideas to achieve a desired purpose.

• Design is the most creative of engineering

activities, with many opportunities to invent
imaginative new products and processes.
2
 The designer starts with
• a specific objective in mind, a need, and by
developing and evaluating possible designs,
arrives at what he considers the best way of
achieving that objective; a new chemical
product or a stage in the design of a production
process.

3
Chemical Engineers engage in product
and process design face different
challenges including:
• Determining the composition of the chemical
mixtures to provide desired properties.
• Creating complex flowsheets and selecting
operating conditions to produce desired
products with a high degree of yield and
selectivity, little recycle, environmentally
sound, and low utility costs.
• Creating configured industrial and consumer
products.
4
 Source:

Seider, W.D.,
et.al., “Process
Design
Principles:
Synthesis,
Analysis, and
Evaluation”, 2nd
ed., John Wiley,
2005.

5
 Potential opportunities
Create and Assess Primitive problem

Is the chemical
structure known?
No

Yes
Find chemicals or chemical
mixtures that have the desired
properties and performance

Is a process required to
Produce the chemicals?

PART 1
Process creation

Is the gross No
B profit favorable? Reject Project
A 6
 Potential opportunities

Create and Assess Primitive problem

• Identify needs
• Survey literature
• Generate ideas
• Marketing and business studies
• Interview customers

7
Find chemicals or chemical mixtures that have the
desired properties and performance
Environmentally friendly thin polymer films,
Refrigerant,
Solvents for cleaning and extraction
Macromolecules for pharmaceuticals
High tensile strength ceramics

8
Find chemicals or No
Mixtures
Is chemical known ??
Yes

No Need a process ??
Yes
Process creation I
No Rejected
OK ??

Development of Detailed Process

Base case I Synthesis II
No
OK ?? Plantwide Controllability
Assessment
Detailed Design, III
Startup Assessment
Equip. sizing, Optimization
Reliability Safety Analysis
No OK ?? 9
Write a report
 PART 1
Process creation

Preliminary Database Creation

Experiments

Preliminary Process Synthesis

Reactions, Separations
T-P Change Operations
Task Integration
Equipment selection
Batch or Continuous

Yes Is the gross NO

profit favorable? Reject Project

10
Find chemicals or No
Mixtures
Is chemical known ??
Yes

No Need a process ??
Yes
Process creation I
No Rejected
OK ??

Development of Detailed Process

Base case I Synthesis II
No
OK ?? Plantwide Controllability
Assessment
Detailed Design, III
Startup Assessment
Equip. sizing, Optimization
Reliability Safety Analysis
No OK ?? 11
Write a report
 PART 1
Development of Base Case

Create a Process Flowsheet

Process Integration

Create Pilot plant testing Prepare a

Detailed Modified flowsheet Simulation
Database model

Yes
NO Is the process
Still promising?
Go to process creation Detailed design
12
Find chemicals or No
Mixtures
Is chemical known ??
Yes

No Need a process ??
Yes
Process creation I
No Rejected
OK ??

Development of Detailed Process

Base case I Synthesis II
No
OK ?? Plantwide Controllability
Assessment
Detailed Design, III
Startup Assessment
Equip. sizing, Optimization
Reliability Safety Analysis
No OK ?? 13
Write a report
 PART II
Detailed Process Synthesis

Batch or continuous ?

Continuous Batch

Synthesis of Reactor Optimal

Networks
Sequencing
Separation Train synthesis
and scheduling
of Processing
steps
Synthesis of
React- Sep- Recycle
Networks

2nd law Analysis

Heat & Mass
Exchanger Networks
14
Find chemicals or No
Mixtures
Is chemical known ??
Yes

No Need a process ??
Yes
Process creation I
No Rejected
OK ??

Development of Detailed Process

Base case I Synthesis II
No
OK ?? Plantwide Controllability
Assessment
Detailed Design, III
Startup Assessment
Equip. sizing, Optimization
Reliability Safety Analysis
No OK ?? 15
Write a report
 PART III
Is the final product a: Detailed Design, Equip.
Sizing, and Optim
• Commodity chemical
• Specialty chemical
• Configured consumer
• or industrial products

Equipment Sizing Product design

•Heat exchanger design
•Column design
•Pump & Compressor design

Capital Cost Estimation IV

Profitability Analysis

Optimization
16
Find chemicals or No
Mixtures
Is chemical known ??
Yes

No Need a process ??
Yes
Process creation I
No Rejected
OK ??

Development of Detailed Process

Base case I Synthesis II
No
OK ?? Plantwide Controllability
Assessment
Detailed Design, III
Startup Assessment
Equip. sizing, Optimization
Reliability Safety Analysis
No OK ?? 17
Write a report
 PART IV
Plantwide Controllability

Plantwide Controllability
Assessment

Qualitative synthesis of
Control structures

Flowsheet Controllability
Analysis

Startup Assessment

Additional Equipment
Dynamic simulation

Reliability Safety Analysis

III
Lab and pilot plant testing
HAZOP Analysis

18
Find chemicals or No
Mixtures
Is chemical known ??
Yes

No Need a process ??
Yes
Process creation I
No Rejected
OK ??

Development of Detailed Process

Base case I Synthesis II
No
OK ?? Plantwide Controllability
Assessment
Detailed Design, III
Startup Assessment
Equip. sizing, Optimization
Reliability Safety Analysis
No OK ?? 19
Write a report
 When considering possible ways of
achieving the objective the designer will be
constrained by many factors.
Physical laws
External Constraints
Standards & codes
Possible Designs Government Control
Economic constraints
Safety regulation
Resources
Plausible designs

Methods
Choice of process
Process Conditions

Region of all designs Materials

Personnel
20
Source: Coulson, 2000 Time
Internal Constraints