Plant Design and Economics

Saeed Eini
Department of Chemical and Petroleum Engineering
Sharif University of Technology

1401 ‫پاییز‬
http://che.sharif.edu/~ProSET
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology

Introduction
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Your Background
• Basic principles and calculations

• Thermodynamics

• Fluid mechanics

• Heat transfer

• Mass transfer

• Unit operations

• Reaction engineering
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Gap
• Develop a process flowsheet?

• The main aspects during process/plant design?

• Which type of separation? Separation sequences?

• Heat integration?

• Cost of a heat exchanger?

• Does it worth to construct a plant? Or invest on another option?!

• Product/feed price?

• Does it worth to revamp a process?

• Calculate the repayments of a loan?

• Get a loan?

• Solve an optimization design problem?

Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
What is a process?

• A process is a sequence of steps done one after another

• In (bio)chemical processes it consists of equipment, (pipe)lines, instrumentation and

control systems, …
• Process design is probably one of the most creative activities enjoyed by chemical
engineers.
• Process design is concerned with the selection of processing units and their interaction
and the setting of conditions in processing systems.
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
What is a process?

Process design is intended to include the following tasks:

• Process material and heat balances;
• Process cycle development, correlation of pilot or research data, and correlation of
physical property data;
• Auxiliary services material and heat balances;
• Flowsheet development and detailed completion;
• Chemical engineering performance design for specific items of equipment required for a
flowsheet, and mechanical interpretation of this to a practical and reasonable
specification.
• Instrumentation as related to process performance, presentation, and interpretation of
requirements to instrument specialists;
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
What is a process?
• Process design tasks:
o Synthesis: The flowsheet structure is chosen
from the synthesis where the particular
equipment is being used and its
interconnections are selected. The synthesis
step allows one to set initial values for the
variables.
o Analysis: it is broken into three parts: solving
the heat and material balances, sizing and
costing the equipment, and economic
evaluation.
o Optimization: The parametric and structural
variables are determined.
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
What is a process?
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
What is a plant?

• A plant is a complex of process/non-process units that manufactures chemicals

Process unit 1 Process unit 2 Process unit 3

Distribution Env./safety
Utility System
System related Systems

• Plant Design: development of either a new, modified, or expanded industrial plant;

related directly to the complete plant, such as plant layout, general service facilities,
and plant location
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Design vs Simulation
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Multi scale nature of process design
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Oil and Gas industry - overview
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Gas processing plant - overview
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Gas processing plant - overview
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Gas processing plant - overview
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Gas processing plant - overview
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Why engineering economics?

• The purpose of chemical processes is to make money.

• Process economics has three basic roles in process design:
o Evaluation of design options: Costs are required to evaluate process design options;
for example, should a membrane or an adsorption process be used for purification?
o Process optimization: The settings of some process variables can have a major
influence on the decision-making in developing the flowsheet and on the overall
profitability of the process. Optimization of such variables is usually required.
o Overall project profitability: The economics of the overall project should be
evaluated at different stages during the design to assess whether the project is
economically viable.
‫‪Saeed Eini‬‬
‫‪Dep. of Chem. and Petrol. Eng.‬‬
‫‪Sharif Uni. of Technology‬‬
‫‪Chemical engineering program‬‬

‫‪Prerequisites‬‬
‫‪• Unit Operations‬‬
‫‪• Reaction Engineering‬‬

‫بررسی مقدماتی طرح‬

‫مهندسی واکنشهاي‬ ‫اصول محاسبات‬

‫ترمودینامیک‬ ‫عملیات واحدها‬
‫شیمیایی‬ ‫مهندسی شیمی‬

‫کارگاه نرم افزار مهندسی‬ ‫کارگاه نقشه کشی و نقشه‬

‫انتقال حرارت‬ ‫مکانیک سیاالت‬
‫شیمی‬ ‫خوانی مهندسی‬
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Course outlines

• Process design procedure and considerations

• Heuristics for Process Synthesis
• Flowsheet Synthesis and Development
• Computer-aided process design
Process
• Process equipment design and cost
Design
estimation
• Heat Integration
• Basics of process optimization
• An introduction to supply chain design
Engineering
Economics
• Cost estimation (CapEx and OpEx)
• Time value of money
• Profitability
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Learning objectives
You will learn how to:
Hard skills:
• Apply the process design procedure
• Develop a process flowsheet
• Use computer-aided methods to simulate a process/equipment
• Size process equipment
• Estimate the cost of process equipment
• Evaluate the profitability of a project
• Learn to formulize and solve simple optimization problem
Soft skills:
• Multiscale attitude
• Problem solving in large scale projects
• Reporting
• Team work
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Course outlines

• Workshops
o Process simulation Package (Aspen Hysys)
o Optimization Package (MATLAB and GAMS)
o Process documents
o Reporting
o Business Plan Preparation

• Speakers from industry

• Visiting industries
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Evaluation

Evaluation Structure:

• Homework assignments: 40 %

• Final Project: 40 %

• Final Exam: 20 %
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Should and shouldn’t

Class lectures:
• Active participation

Workshops and invited lectures

• Active participation

Homework and project:

• Rules by TAs
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Textbooks

Plant Design and Economics for Chemical Process: Design and Product and Process Design Principles, Systematic Methods of Chemical
Chemical Engineers, 5th edition, Integration, 2nd edition, Smith, Analysis, Synthesis and Evaluation, Process Design, Biegler, Grossmann,
Peters, Timmerhaus, West, 2005. 2016. Fourth edition, Seider et al., 2017. Westerberg, 1997
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
The structure of process design textbooks

(1) General process design considerations, approaches, and techniques

(2) Computer-aided tools (software/packages)

(3) Equipment sizing and cost estimation

(4) Process integration

(5) Optimization

(6) Engineering economics

 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Plant Design and Economics for
Chemical Engineers, 5th edition,
Peters, Timmerhaus, West, 2005.
Textbooks
Chapter 1 Introduction
Chapter 2 General Design Considerations
Chapter 3 Process Design Development
Chapter 4 Flowsheet Synthesis and Development
Chapter 5 Software Use in Process Design
Chapter 6 Analysis of Cost Estimation
Chapter 7 Interest, Time Value of Money, Taxes, and Fixed Charges
Chapter 8 Profitability, Alternative Investments, and Replacements
Chapter 9 Optimum Design and Design Strategy
Chapter 10 Materials and Fabrication Selection
Chapter 11 Written and Oral Design Reports
Chapter 12 Materials-Handling Equipment— Design and Costs
Chapter 13 Reactor Equipment—Design and Costs
Chapter 14 Heat-Transfer Equipment— Design and Costs
Chapter 15 Separation Equipment—Design and Costs
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Chemical Process: Design and
Integration, 2nd edition, Smith,
2016.
Textbooks
Chapter 1: The Nature of Chemical Process Design and Integration
Chapter 2: Process Economics
Chapter 3: Optimization
Chapters 4,5,6: Chemical Reactors
Chapters 7,8,9,10,11: Separation
Chapter 12: Heat Exchange
Chapter 13: Pumping and Compression
Chapter 14: Continuous Process Recycle Structure
Chapter 15: Continuous Process Simulation and Optimization
Chapter 16: Batch Processes
Chapters 17,18,19: Heat Exchanger Networks
Chapters 20,21,22: Heat Integration
Chapter 23: Steam Systems and Cogeneration
Chapter 24: Cooling and Refrigeration Systems
Chapter 25: Environmental Design for Atmospheric Emissions
Chapter 26: Water System Design
Chapter 27: Environmental Sustainability in Chemical Production
Chapter 28: Process Safety
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Product and Process Design Principles, Chapter 16 Cost Accounting and Capital Cost Estimation
Analysis, Synthesis and Evaluation,
Fourth edition, Seider et al., 2016.
Textbooks
Chapter 1 Introduction to Chemical Product Design
Chapter 2 Introduction to Process Design
Chapter 3 Design Literature, Stimulating Innovation, Energy, Environment, Sustainability, Safety, Engineering Ethics
Chapter 4 Molecular and Mixture Design
Chapter 5 Design of Chemical Devices, Functional Products, and Formulated Products
Chapter 6 Heuristics for Process Synthesis
Chapter 7 Simulation to Assist in Process Creation
Chapter 8 Synthesis of Networks Containing Reactors
Chapter 9 Synthesis of Separation Trains
Chapter 10 Second-Law Analysis
Chapter 11 Heat and Power Integration
Chapter 12 Heat Exchanger Design
Chapter 13 Separation Tower Design
Chapter 14 Pumps, Compressors, and Expanders
Chapter 15 Chemical Reactor Design
Chapter 17 Annual Costs, Earnings, and Profitability Analysis
Chapter 18 Six-Sigma Design Strategies
Chapter 19 Business Decision Making in Product Development
Chapter 20 Plantwide Controllability Assessment
Chapter 21 Design Optimization 597Chapter 22 Optimal Design and Scheduling of Batch Processes
Chapter 23 Written Reports and Oral Presentations
Chapter 24 Case Study 1—Home Hemodialysis Devices
Chapter 25 Case Study 2—High Throughput Screening Devices for Kinase Inhibitors
Chapter 26 Case Study 3—Die Attach Adhesive: A Case Study of Product Development
Chapter 27 Case Study 4—Ammonia Process
 Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Systematic Methods of Chemical
Process Design, Biegler, Grossmann,
Westerberg, 1997
Textbooks
Chapter 1. Introduction to Process Design.
Chapter 2. Overview of Flowsheet Synthesis.
Chapter 3. Mass and Energy Balances.
Chapter 4. Equipment Sizing and Costing.
Chapter 5. Economic Evaluation.
Chapter 6. Design and Scheduling of Batch Processes.
Chapter 7. Unit Equation Models.
Chapter 8. General Concepts of Simulation for Process Design.
Chapter 9. Process Flowsheet Optimization.
Chapter 10. Heat and Power Integration.
Chapter 11. Ideal Distillation Systems.
Chapter 12. Heat Integrated Distillation Processes.
Chapter 13. Geometric Techniques for the Synthesis of Reactor Networks.
Chapter 14. Separating Azeotropic Mixtures.
Chapter 15. Basic Concepts for Algorithmic Methods.
Chapter 16. Synthesis of Heat Exchanger Networks.
Chapter 17. Synthesis of Distillation Sequences.
Chapter 18. Simultaneous Optimization and Heat Integration.
Chapter 19. Optimization Techniques for Reactor Network Synthesis.
Chapter 20. Structural Optimization of Process Flowsheets.
Chapter 21. Process Flexibility.
Chapter 22. Optimal Design and Scheduling for Multiproduct Batch Plants.
Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
References
Other references:

• Conceptual Design of Chemical Processes, Douglas, 1988

• Applied process design for chemical and petrochemical plants, Ludwig, 2001

• Analysis, Synthesis and Design of Chemical Processes, Turton et al., 2012

• Kirk-Othmer Encyclopedia of Chemical Technology (Vol 1-27), 2001

• Ullmann s Chemical engineering and plant Design (Vol 1,2), Ullman , 2005

• Chemical Engineering Design: Principles, Practice and Economics of Plant and Process Design, Towler and

Sinnott, 2013

• Chemical Process and Design Handbook, Speight, 2002

• Optimization of chemical processes, Edgar, Himmelblau, Lasdon, 2001

• Rules of Thumb for Chemical Engineers, Hall, 2018

• The properties of gases and liquids, Poling, Prausnitz, O'Connell, 2000

Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
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Saeed Eini
Dep. of Chem. and Petrol. Eng.
Sharif Uni. of Technology
Contact info

Teacher Assistant:
• Mr Mohammad Mahdi Heydari

Direct contact:
• Email address: saeed.eini@sharif.edu