CMET401 Plant Design & Economics

The Design Process II

Dr. Abdel-Karim Mahgoub

04/02/2021 CMET401 The Design Process II 1

 Introduction To Design II
Key Learning Objectives:

1. Outline The Structure of a Chemical Engineering Project

2. Sketch the Anatomy of a typical Chemical Manufacturin

g Process

3. Why engineers in industry use codes & standards in

design

4. Why it is necessary to build margins into a design

04/02/2021 CMET401 The Design Process II 2

The Organization Of A Chemical Engi
neering Project

CMET401 The Design Process II

04/02/2021 3
 The Organization Of A Chemical
Engineering
The Organization Project
Of A Chemical engineering Project

The structure of a chemical

engineering project
CMET401 The Design Process II
04/02/2021 4
 The Organization of A Chemical
Engineering
The Organization Project
Of A Chemical engineering Project
Project organization.

04/02/2021 CMET401 The Design Process II 5

Anatomy of a Chemical Manufacturing Pr
ocess

CMET401 The Design Process II

04/02/2021 6
Anatomy of a Chemical Manufacturing Process
Continuous & Batch Processes

04/02/2021 CMET401 The Design Process II 7

Anatomy of a Chemical Manufacturing Process
Batch Processes

 are economical for small volumes;

 are flexible in accommodating changes in product formulation;
 are flexible in changing production rate by changing the number of batches made in
any period of time;
 allow the use of standardized multipurpose equipment for the production of a variety of
products from the same plant;
 are best if equipment needs regular cleaning because of
fouling or needs regular sterilization;
 are amenable to direct scale-up from the laboratory and
 allow product identification. Each batch of product can be clearly identified in terms of
when it was manufactured, the feeds involved and conditions of processing
(pharmaceuticals and foodstuffs).
04/02/2021 CMET401 The Design Process II 8
 Project Documentation

04/02/2021 CMET401 The Design Process II 9

 Codes and Standards
Modern engineering standards cover:

Standards
BSI: British Standard Institution ISO: International Organization for
Standardization IEC: International Electrotechnical Commission
NIST: National Institute of Standards & Tecchnology
ANSI: American National Standards Institute API: American Petroleum
Institute ASTM: American Society for Testing & Materials
NFPA: National Fire Protection Association TEMA: Tubular Exchanger
Manufacturer Association ISA: Instrumentation, Systems and Association
Society ASME: American Society of Mechanical Engineers.

04/02/2021 CMET401 The Design Process II 10

 Codes and Standards
 The terms standard and code are used interchangeably, tho
ugh code should really be reserved for a code of practice cov
ering, say, a recommended design or operating procedure; a
nd standard for preferred sizes, compositions, etc.

 Equipment manufacturers also work to standards to produ

ce standardized designs and size ranges for commonly used
items, such as electric motors, pumps, heat exchangers, pip
es, and pipe fittings.

04/02/2021 CMET401 The Design Process II 11

 Codes and Standards
 For the designer, the use of a standardized component size
allows for the easy integration of a piece of equipment into
the rest of the plant.

 For an operating company, the standardization of equipme

nt designs and sizes increases interchangeability and reduc
es the stock of spares that must be held in maintenance sto
res.

 Disadvantages (constraint). The nearest standard size will

not necessarily be the optimum size; though as the standar
d size will be cheaper than a special size, it will usually be t
he best choice from the point of view of initial capital cost.

04/02/2021 CMET401 The Design Process II 12

 Design Factors (Design Margins)
 To ensure that the design that is built meets product specific
ations and operates safely, experienced engineer include a de
gree of overdesign: design factor, design margin, safety fact
or. This is because of uncertainties in available design data.

 In mechanical and structural design, the design factors that

are used to allow for uncertainties in material properties, des
ign methods, fabrication, and operating loads are well establ
ished (e.g. pressure vessel design).

 Design factors are also applied in process design to give som

e tolerance in the design. For example, the process stream av
erage flows calculated from material balances are usually inc
reased by a factor, typically 10%, to give some flexibility in pr
ocess operation. This factor will set the maximum flows for e
quipment, instrumentation, and piping design.
CMET401 The Design Process II
04/02/2021 13
 System Of Units

CMET401 The Design Process II

04/02/2021 14
 System Of Units
 The unit t denotes a metric ton of 1000 kg.
 Ton is generally used to describe a short ton or US ton of 20
00 lb (907 kg). a long ton or UK ton of 2240 lb (1016 kg).
 In US, the prefixes M and MM are often used to denote thou
sand and million, In SI the use of M as an abbreviation for m
ega (×106).

CMET401 The Design Process II

04/02/2021 15