ISERMANN DEPARTMENT OF CHEMICAL AND

BIOLOGICAL ENGINEERING

MEMORANDUM
Date:
To:
From:
Subject:

26 January 2016
Process Design teams
Prof. N. Baysal, Prof. B.W. Bequette and Dr. G. Dalakos
CHME 4050 Chemical Process Design (syllabus)

Course Description
Chemical Process Design is a 4-credit communications intensive course that builds upon
previous undergraduate coursework and introduces new material in process design, safety and
economics that every professional chemical engineer should know. It is expected that you are
already knowledgeable in mass and energy balances, thermodynamics, reactor design, mass
transport, and unit operations. Little time will be spent on reviewing basic concepts in these
areas, unless applied to the main project as deemed necessary.
As opposed to most of your previous classes, this course stresses a larger systems approach at
how unit operations and processes are put together and interact, as well as understand how a
desired product might be produced out of specified feedstock material. Economic analysis is
important, and includes equipment costing and cash flow analysis. Safety must be a first priority
in any chemical plant, and will also be covered.
Texts and Resources
Recommended text for class
1. Towler, G. and R. Sinnott, Chemical Engineering Design: Principles, Practice and
Economics of Plant and Process Design, Butterworth-Heinemann Publishing, Burlington,
MA (2012, Second Edition).
Helpful resources
1. Ulrich, G.D. and P.T. Vasudevan, Chemical Engineering Process Design and Economics,
2nd Edition, Process Publishing, Durham, NH (2004).
2. Strunk Jr., W. and E.B. White, The Elements of Style, 4th Ed., Allyn and Bacon, Boston
(2000).
3. Seider, W.D. (ed.) Guide to Teaching Design with Internet Links, 2nd ed. CACHE
Learning Resource Center (2012). http://cache.org/site/Guide%20to%20Teaching.pdf
(assessed 25 January 2015).
Online resources (such as Perrys Handbook for Chemical Engineers and the CRC Handbook)
are available through the RPI library.
Rensselaer Polytechnic Institute
110 8th Street | Troy, NY 12180-3590 | 129 Ricketts Building
Phone (518) 276-6376 | Fax (518) 276-4030 | bequette@rpi.edu

Learning Objectives
The following learning objectives are important to this course:
Engineering practicum
Acquiring skills in working with others as a member of a team
Developing skills in expressing oneself orally and in writing
Developing sensitivity to economic, environmental, sustainability, manufacturability,
ethical, health and safety, social, and political considerations in engineering practice
Student Expectations
The main technical deliverable for this course will be a feasibility analysis for a chemical plant1
that you will design, cost out and provide information on how it runs and its layout. The first step
in this endeavor will be to first decide which product(s) you will need to make to address your
chosen markets and applications. Within this context, your product will possess specific
performance aspects and properties that can only be accomplished by proper choice and design
of your process and required feedstock material. Other aspects that need to be considered include
(but are not limited to): safety, equipment type, costing, plant location, socio-economic
considerations, etc.
You will have the semester to accomplish this with your group and with the aid of your advisor
to help you along the way. In addition, timely lecture material and handouts will be given to you
when you need them. To assure group progress, interim memo reports by all students as well as
breakout discussions between your group and your advisor will occur throughout the semester. In
order to assess that each group member is competent in all aspects of the course (i.e., individual
assessment within the team), periodic in-class quizzes will be given and advisor/team
assessments will be made.
Your main deliverable is your final feasibility report, which will be the culmination of work done
in multiple areas including oral report-out presentations each due at a different time during the
semester. These parts, in chronological order are:
1. Technical scoping and assessment report This is an initial assessment of the overall
risks and opportunity for such an endeavor. This report should include, but is not limited
to, requirements of the product and throughput needed. Risks shall include safety issues
as well as technical challenges that might be anticipated. The report must also include: (i)
a clearly defined design problem, (ii) an overall market picture for your product(s), (iii) a
review of current processing technology for your facility, (iv) a selection of the best
process with justification, (v) a qualitative description of the process, and (vi) outlines of
health and safety requirements, the environmental impact, and the legal considerations
for your proposed plant and location. Your design team will need to do a general
literature search, compile a bibliography, and define the design specifications. The report
+ appendices for supplementary information (hardcopy of these documents in mailbox,
and electronic copy as single pdf document for the group by e-mail) must be submitted by
the time specified in Table 1 below.
1

This is a loose term to describe your project. This will vary from year to year. Past years have looked at plants
producing biofuel, biodiesel, ethanol, methanol, electricity (co-gen plant), ammonia, syn gas, and others. .

2. Preliminary design presentation This process requirement presentation should

contain a quantitative process description with overall material and energy balances for
your plant. Using the results from your teams process scoping report, you will need to
generate a material flow diagram (i.e., a flowsheet), list assumptions, include
mathematical models, and solutions using a steady-state process simulator (Aspen Plus or
SuperPro Designer), do consistency checks, verify the design specifications, and prepare
stream and physical-property tables. Consider this as the process design part of the
feasibility report. It consists of the chemical processes and infrastructure required for
realizing the required throughput of product as dictated in the initial scoping report. This
is the how do we get there from the initial to the desired end product requirement(s).
Process Simulation (.bkp file) + Oral presentation + written appendices for
supplementary information must be submitted one day prior to group presentation, in the
manner described under 1.
3. Plant economics presentation This process profitability presentation details a more
refined process design with emphasis on the economic potential for your proposed
design. Using the results from your teams findings on the process requirements, include
size estimates of needed equipment such as extractors, reactors, compressors, heat
exchangers, and separation columns in your presentation. In addition, you need to specify
materials of construction for the equipment and estimate the purchased equipment cost
for each piece. Your other main activity will be to figure out profitability of your plant.
Towards this end, you will build an economic valuation model based on the unique
aspects of your plant. Using these models, you will generate an economic analysis and
assessment of your chemical plant in your presentation. Oral presentation + written
appendices for supplementary information must be submitted one day prior to group
presentation, in the manner described under 1.
4. Final feasibility poster presentation This poster presentation represents your final
recommendation based on your scoping, design and economics work as well as aspects
regarding operability, plant layout, and design specific scenario analysis.
5. Final feasibility report (20 pages max.) The final report of the project will put in
words your final feasibility presentation. Remember, you represent the experts in this
area and are confidently suggesting a certain course of action to management based on
assumed thorough and careful analysis. Much of your efforts during this part will be in
preparing a written report, and presenting a final oral presentation/defense on the course
of action proposed to your consultants. Remember, the process feasibility report presents
your teams conclusions and recommendations on the production process to the
management of the venture. It defines the process scoping and assessment, process
requirements, and process profitability. This capstone report must provide sufficient
information to make a decision about the economic and technical feasibility of your
individual projects. Written report + appendices for supplementary information.
Teams, individual performance and project task leadership - As mentioned above, your main
class deliverable will be an all-encompassing final feasibility report and poster presentation. This
is a huge amount of work and you will have to work well as an efficient team unit while
excelling individually. As a result, we will expect every team member to have a good working

knowledge of every aspect of this final feasibility report. It is important to understand each of
these roles to be successful in your project.
Project Groups: Each of you will work in teams of preferably four, possibly three (if no fourth
member is available). You may form your own groups of four within the first week of class.
After the first week, those students without a project group will be assigned to a group by the
instructors. Single- and two-individual groups are not allowed. Effective communication,
teamwork and project management (i.e., how well the project tasks are going to plan) will be key
to success. During the course of the semester, we will provide you with specific background
information related to your projects and general material on Chemical Process Design
(equipment, economics, safety, ethics, etc.).
Group Members: Each group member should govern him- or herself as a responsible member
of a project team. Examples of individual effort within the group include: a balanced portion of
calculations, process simulations, report writing and editing, presentation development, creative
thinking, and innovative ideas. To ensure that there is a balanced effort on the part of all
individual members of a project group, each group member is required to do the following:
1. Attend all scheduled classes and group meetings (except in the case of family or medical
emergency)
2. Attend breakout sessions with your advisor and other group members
3. Participate in all oral presentations
4. Equal amounts of work within the group
5. Serve the group responsibly
Task Leaders: Each group will select a (rotating) task leader for each individual section of the
overall project (Project Scoping/Assessment, Process Design, Plant Economics, and Feasibility
Study/Presentation). The duties of the task leader include:
1. Scheduling and organizing group meetings
2. Responsibility for submitting (on time), status memo, statement of division of labor,
presentation slides and final feasibility technical report (if applicable) on behalf of the
entire group.
3. Writing the memorandum of the task you are leading2:
a. Interim progress memo for the group short summary assessment of where the
group is now and future plans. This should be short; one to two pages of written
text with supporting data as appendices.
b. Statement of Division of Tasks for the group. This must include for each team
member: sub-task description and percentage of overall group effort. This shall be
emailed to the advisor with the intent that the contents shall be shared between the
task leader and advisor. It will not be shared with other group members.
2

When a memo is due, the task leader will be responsible for submitting the task status memo and the statement of
division of labor on behalf of his/her group. The memo and statement should be sent as two separate documents. The
memo will include 1-2 pages of written text describing the status of the task work, broken down by effort from each
team member, major challenges and future work needed for task completion. Along with the written part, please use
as many appendices as needed for example, reference section, figures, tables, equations, etc. The task leader
should email these two documents before the breakout sessions with their advisor.

4. Serving as a liaison between the group and their advisor during their task.
An additional note on reports and memoranda: Good results communicated poorly are only
marginally better than mediocre results communicated well. An acceptable report is neat, well
organized, and written in clear and correct English prose. Major reports also contain complete
and easy-to-follow technical documentation. Major reports are typewritten. Detailed technical
documentation can be provided in neatly handwritten appendices. Please refer to the memo with
the subject line suggestions on writing technical reports. It should be noted that the technical
content of the memo will also be used to assess the memo grade!
Good writing is an absolute necessity when composing reports. Poor writing reflects poorly on
the team and can make an otherwise sound technical proposal appear questionable in quality.
Spelling mistakes, poor grammar and mechanics, and an apparent lack of editing will not be
overlooked when grading. Using the writing center or having a third party read your report
before submitting it is a very worthwhile investment in time. Our assessment of clarity,
organization, neatness, grammar, and style will account for approximately 25% of the total grade
assigned to a report or memorandum. Deadlines are an important aspect of professional practice.
Writing Assessment of Interim Memoranda and Feasibility Study: In addition to checking
the correctness of calculations and simulation results presented in individual and project leader
interim memoranda, we will also assess the written quality of the submissions. The assessment
criteria are given below for the memos as well as the written quality of the final report
(differences noted).
Technical content (50%):
Application of technical engineering concepts
Quantitative insight. It is always better to include numbers versus vague
comparisons. Stating a 15% conversion increase is better than saying, its a more
efficient reaction. Otherwise, the reader is asking him/herself, How much better
is it? 10% better? 50% better? 100% better?
Correct use of equations and formulas
Accuracy of calculations/estimates; correct order of magnitude. That is, does this
make sense?
Correct use of technical terminology
Quality of appended tables and figures
Other technical information
Structure, clarity (25%):
Is the report easy to read by a professional familiar with basic chemical
engineering, and does it clearly convey the main message(s)?
Is there an abstract, which contains the vision and the main results (feasibility
report only)?
Is the material presented in a clear, concise, structured and professional way,
using sections and subsections, clearly written paragraphs, figures and tables with
captions where appropriate, appendices where appropriate?
Is the principal information provided in the main text, with supplementary
information in appendices?

Does the report contain a section summarizing the conclusions and

recommendations, and a section with references (report only)?
Length: Is the memorandum at most 2written pages long, and the final report at
most 20 pages long, excluding appendices?
Language (25%):
Grammar?
Spelling?
Vocabulary, including professional language?
Style? Are the ideas well expressed in clear English?

Submission Policy: You are ultimately responsible for meeting various deadlines. Extending
deadlines is rare to non-existent in most business agreements. Pretend that you are the FedEx
person and let it be your motto to always deliver. Late turned-in assignments also represent an
unfair edge over your other classmates. Helpful suggestions on contingency plans (i.e., the backup plan or plan B) will be covered in class or by your consultants on a one-on-one basis. It is
understood that this is college, so instead of not accepting late assignments as is customary in the
real world, the policy for the class will be one letter grade per day subtracted beyond the original
due date. To conclude, organizing how you will finish your tasks will be ultimately your
responsibility, however, your consultants are happy to assist if you request it.
To assist smooth progress along the semester (and as reflected in commonly held business
reviews or toll-gates, no/no-go decision points, etc.), your consultants will be holding periodic
interim reports/reviews. We expect a brief summary on where you are, any issues, whether or not
things are on track, and possible plan revisions to get you back on track. Again, how you get
there is ultimately up to you.
"Super-Groups": It goes without saying that dishonesty or suspected cheating will not be
tolerated. A modest amount of inter-group consultation is natural and reasonable. However, each
group is solely responsible for its results and recommendations, and is expected to develop its
own design procedures and simulations (except when provided by the consultants). Where
excessive inter-group cooperation is obvious, the total grade for a report will be divided equally
among collaborating groups. Example: Two collaborating groups produce reports of grade 95
(A): grade per group = 95/2 = 48 (F).
Professionalism: As a professional it is expected that you will attend scheduled classes, oral
reports, and team meetings. If you cannot make a class, email notification is expected at least 24
hours in advance for all non-emergencies. Failure to meet your professional and team
responsibilities will be taken into account in your overall evaluation.
The Coonley Prize: The Lewis S. Coonley Prize is awarded to one or more graduating seniors
in recognition of achievement and excellence in the practice of Chemical Engineering Process
Design. We will select the recipient(s) of this award based on a demonstration of outstanding
proficiency in the course.

Course Schedule and Deliverables

Students will be assigned to a project before the end of the first week of classes at the latest. A
major portion of the scheduled time will be allocated for students to work on team activities
related to their projects. Project mentors will meet with teams during lab time to provide
consultation and to discuss team status. Students should plan for regular weekly lectures and
meeting(s) with their project advisor during the following timeframes:
All sections Tuesday & Friday 10:00 to 11:50 AM
Tables 1 and 2 provide the expected due dates for team and individual deliverables. These due
dates may be negotiated with proper justification and the approval of your project mentor and
evaluator. These activities are provided to help you properly scope the project and pace your
efforts in executing the project so that what is proposed is delivered on time. Since each project
is unique, the order of these activities can change. You should discuss your projects needs with
your project mentor and evaluator.
TABLE 1: MILESTONES AND TEAM DELIVERABLES
Week
1
4
9
13
16
16

Date
1/29
2/19 (5 PM)
3/25
4/22
5/10
5/16

Milestones and Team Deliverables

Design Team Assignments: Name, Mission, Project Leaders
1: Technical Scoping and Assessment Report
2: Preliminary Process Design Presentations
3: Plant Economics Presentations
4: Final Poster Presentations
5: Final Feasibility Study Due

TABLE 2: TASK LEADER, INDIVIDUAL DELIVERABLES AND BREAKOUT

SESSIONS
Week
2
3

Date
2/5 (5PM)
2/9

Individual (Project Leader) Deliverables

1: Project Scope Interim Report Due
Breakout session

6
7

3/4 (5PM)
3/8

2: Preliminary Process Design Interim Report Due

Breakout session

11
12

4/8 (5PM)
4/12

3: Plant Economics Interim Report Due

Breakout session

15
15

5/2 (5PM)
5/3

4: Final Feasibility Interim Report Due

Breakout session

15

5/6

Final Semester Exit Survey and Essay

Project Mentors/Advisors
The course instructors will serve as project advisors for each project team. The primary
responsibility of the project advisor is to provide overall guidance, direction, and support for the
team. As advisors, the course instructors provide overall technical guidance, advise on
professional development opportunities, and help ensuring that the project team has not
overlooked important steps in the design process.
B. Wayne Bequette
Office: RI 129
Phone: 276-6377
Email: bequette@rpi.edu

Nihat Baysal
Office: RI 122
Phone: 276-3327
Email: baysan@rpi.edu

George Dalakos
Mailbox: RI 102
Phone: 387-7494
Email: gdalakos@gmail.com

Project Evaluators
The course instructors will also serve as project evaluators for each project team. As project
evaluators, they will provide assessment feedback to the project team and ultimately assign
grades.
Attendance
Design is not a spectator sport. Active participation is required for a meaningful capstone
experience. You are expected to attend and participate in meetings with your faculty advisor and
project team. You are expected to come prepared for short impromptu presentations of your
work in progress during the semester. The quality of presentations will influence your team and
individual grade for the course. So, it is in everyones interest that all team members are
knowledgeable about the state of their project at any given time. You are also expected to make
relevant contributions outside of regularly scheduled class time. Your active participation and
initiative are critical parts of your individual success and that of your team.
Office Hours
Prof. Baysal: Mondays 9-10am by appointment, Prof. Bequette: Tuesdays 12-1pm by
appointment, Dr. Dalakos: Available after most classes please make an appointment
beforehand by email.
Project Deliverables
In the spirit of making this a realistic experience, student teams are challenged to properly scope
the level of effort and seriously consider the resources and time they have available to
successfully accomplish project objectives. Technical quality and accuracy of project results is
the responsibility of the student team. Faculty and staff will serve as advisors to the projects and
will help direct students on appropriate technical approaches, but the ultimate responsibility for
project deliverables resides with the student team. Team success will be assessed based upon a
teams ability to realistically scope project objectives, make plans to achieve those objectives,
and ultimately deliver on the project plan.
Grading

Grades will be assigned on a numerical scale of zero to 100 with 91-100 being the A range, 8189 being the B range, 71-79 being the C range, 61-69 being the D range, and less than 60 being a
failure. Grades of 90, 80, 70, and 60 are considered on the borderline, and other factors may
weigh more heavily in determining the letter grade. A single low grade will not be dropped or
weighted lower in this course. Students should contact their assigned advisors in writing (email)
regarding any grade appeal within one week of receiving it specifically stating the reasons for the
appeal.
Item
Technical Scoping and Assessment Report
Preliminary Design Presentation
Plant Economics Presentation
Feasibility Study
Final Poster Presentation
Individual Performance (8 pts for task leader memo and 20 pts for Quizzes)
TOTAL

% Points
13
16
13
20
10
28
100

Professional Conduct
The team and individual members of the team are responsible for their professional conduct.
This includes punctuality for in-class and out-of-class meetings, acknowledgement of the work
of others, appropriate referencing of information sources, adherence to the project plan,
justification of scope adjustments, due diligence on project deliverables, accommodating external
supplier delivery times, identifying and tracking critical project elements, application of the
scientific method and engineering problem solving methods, design documentation, addressing
client sponsor needs, and the application of the technical, analytical, and practical design
methods to support project findings and decisions. You are expected to communicate to your
faculty advisor(s) any issue regarding your performance in class ahead of time. This includes
absence from important class meetings, late assignments, inability to perform an assigned task,
problems with your group members, the need for extra time on assignments, milestones, etc. You
should be prepared to provide sufficient proof of any circumstances on which you are making a
special request as outlined in the Rensselaer Handbook of Student Rights and Responsibilities.
Students with disabilities should inform their faculty advisor(s) of their needs at the beginning of
the semester. Students must register as disabled in order to receive proper attention and benefits.
Please contact the Assistant Dean of Students. Students who cannot attend some classes due to
religious observance should inform the instructor at the beginning of the semester. Cheating and
dishonesty will not be tolerated. All your course work should provide an honest effort in solving
the assigned problem by yourself and your teammates. You are encouraged to discuss course
material and problems with other students, but your teams solution must be your own. If you are
inspired by another work, or if you are extending an existing approach, you should explicitly cite
this work. Any student found to have participated in academic dishonesty will receive an F in
the class, and may be subject to further disciplinary action. The University Code of Academic
Integrity prohibits students from committing the following acts of academic dishonesty:
academic fraud, copying or allowing ones work to be copied, fabrication/falsification,
plagiarism,
sabotage
of
others
work,
substitution.
For
details,
see
http://doso.rpi.edu/update.do?artcenterkey=676. Letter grades will not be assigned until the end

of the course, after the final project report has been graded. Any letter grade assignment posted
before the end of the class should be regarded as tentative and subject to change. For grade
appeal procedures and information on all issues outlined above, please reference the RPI Student
Handbook of Rights and Responsibilities
http://www.rpi.edu/dept/doso/resources/judicial/docs/20142016StudentHandbookrevOctober2015.pdf

10