LESSON PLAN

CHE 604
PLANT DESIGN AND ECONOMICS
COURSE NAME
COURSE CODE
PROGRAM
SEMESTER
CREDIT HOURS
CONTACT HOURS
COURSE STATUS
PRE-REQUISITE

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FACULTY OF
CHEMICAL ENGINEERING
UNIVERSITI TEKNOLOGI MARA

PLANT DESIGN AND ECONOMICS

CHE 604 / CPE604
EH220 / EH241 / EH242
5
4
5
CORE
NIL

1. SYNOPSIS
This course covers the chemical process and plant design through topics relating
to the flow sheeting, product design, heuristics and guidelines in design,
preliminary sizing of equipment, pinch technology, economic evaluations and the
operation of chemical processes.
2. OBJECTIVES
Upon completion of this course, students should be able to:
Decide on conceptual design incorporating utilities and plant layout.
Make selection of suitable and viable process equipments.
Determine process heat integration in the chemical process plant.
Estimate capital and manufacturing costs of chemical process plant.
Estimate depreciation and make profitability analysis.
3. METHODS OF INSTRUCTION
Lectures, tutorials and online blended learning.
4. LESSON PLAN
WK

DURATION

CHAPTER/CONTENT
1. Introduction to Design
1.1. Block Flow Diagrams (BFD)
1.2. Process Flow Diagram (PFD)
1.3. Piping and Instrumentation
Diagram (P&ID)
1.4. Additional diagrams
1.5. 3-D representation of a
process
1.6. The 3-D plant model
2. The Structure and Synthesis of
Process Flow Diagrams
2.1. Hierarchy of process design
2.2. Batch vs. Continuous process

ACTIVITIES

Lectures
Tutorial

Lectures
Tutorial

3.

4.

5.

6.

2.3. The input / output Structure of

the process
2.4. The recycle structure of the
process
2.5. General structure of the
separation system
2.6. Heat-exchanger network or
process energy recovery
system
2.7. Information required and
sources
Chemical Product Design
3.1. Strategies for chemical
product design
3.2. Needs
3.3. Ideas
3.4. Selection
3.5. Manufacture
3.6. Batch processing
3.7. Economic considerations
Tracing Chemicals through the
Process Flow Diagram
4.1. Guidelines and tactics for
tracing chemicals
4.2. Tracing primary paths taken
by chemicals in a chemical
process
4.3. Recycle and bypass streams
4.4. Tracing non-reacting
chemicals
4.5. Limitations
4.6. Written process description
Understanding Process Conditions
5.1. Conditions of special concern
for the operation of separation
and reactor systems
5.2. Reasons for operating at
conditions of special concern
5.3. Conditions of special concern
for the operation of other
equipment
5.4. Analysis of important process
conditions
Suitability of a Process Design
6.1. The role of experience in the
design process

Lectures
Tutorial

Lectures
Tutorial

Lectures
Tutorial

7-8

10

11-12

6.2. Guidelines for equipment

selection
7. Synthesis of the PFD from the
Generic BFD
7.1. Information needs and sources
7.2. Reactor section
7.3. Separator section
7.4. Reactor feed preparation and
separator feed preparation
sections
7.5. Recycle section
7.6. Environmental control section
7.7. Major process control loops
7.8. Flow summary table
7.9. Major equipment summary
table
8. Pinch Technology
8.1. Introduction
8.2. Heat integration and network
design
8.3. Heat-Exchanger Network
Synthesis Analysis and
Design (HENSAD) program
9. Estimation of Capital Costs
9.1. Classifications of capital cost
estimates
9.2. Estimation of purchased
equipment costs
9.3. Estimating the total capital
cost of a plant
10. Estimation of Manufacturing Costs
10.1. Factors affecting the cost of
manufacturing a chemical
product
10.2. Cost of operating labor
10.3. Utility costs
10.4. Raw material costs
10.5. Yearly costs and stream
factors
10.6. Estimating utility costs from
the PFD
10.7. Cost of treating liquid and
solid waste streams
11. Engineering Economic Analysis
11.1. Investments and the time
value of money

Lectures
Tutorial
TEST 1

Lectures
Tutorials

Lectures
Tutorial

Lectures
Tutorial

Lectures
Tutorials

13-14

11.2. Different types of interest

11.3. Time basis for compound
interest calculations
11.4. Cash flow diagrams (CFD)
11.5. Calculations from cash flow
diagrams
11.6. Inflation
11.7. Depreciation of capital
investment
11.8. Taxation, cash flow and
profit
12. Profitability Analysis
12.1. A typical CFD for a new
project
12.2. Profitability criteria for
project evaluation
12.3. Comparing several large
projects: Incremental
economic analysis
12.4. Establishing acceptable
returns from investments:
The concept of risk
12.5. Evaluation of equipment
alternatives
12.6. Incremental analysis for
retrofitting facilities
12.7. Evaluation of risk in
evaluating profitability
12.8. Economic sensitivity
analysis

Lectures
Tutorials
TEST 2

5. ASSESSMENTS

Tests (2)
: 20 %
Mini Design Project (1) : 20 %
Final Examination
: 60 %

6. REFERENCES
Turton, R., Bailie, R.C., Whiting, W. B. and Shaeiwitz, J. A. (2009). Analysis,
Synthesis, Design of Chemical Processes (3rd ed.). New Jersey: Prentice Hall
Coulson J. M., Richardson J. F. and Sinnot R. K. (1998). Chemical
Engineering Vol. 6. London: Pergammon Press
Peters, M. S. and Timmerhaus, K. D. (1992). Plant Design and Economics for
Chemical Engineers. Singapore: McGraw Hill
Vilbrandt, F. C. and Dryden, C. E. (1985). Chemical Engineering Plant
Design. Singapore: McGraw Hill

Blank, L. and Tarquin, A. (2002). Engineering Economy. New York:

McGraw-Hill
Backhurst, J. R. and Harker, J. H. (1983). Process Plant Design. London:
Heinemann
Seider W. D., Seader J. D. and Lewin D. R. (1999). Process Design
Principles. New York: John Wiley and Sons.
Douglas J. M. (1988). Conceptual Design of Chemical Processes. Singapore:
McGraw-Hill.

PREPARED BY:
SIGNATURE:

APPROVED BY:
SIGNATURE:

NAME: Pn.Norin Zamiah Kassim Shaari NAME: Dr. Syed Shatir Asghrar Bin Syed
Dr. Jaganathan Krishnan
Hassan
Prof. Dr. Jailani Salihon
POSITION: Head of Studies Center
POSITION: Lecturer / Senior Lecturer / DATE: 8 September 2014
Professor
DATE: 8 September 2014