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  • Chemical Process Design / Procesos Químicos de Fabricación (2011)

    procesos quimicos.jpg                  

    Chemical Process Design / Procesos Químicos de Fabricación (2011)

         

    Teaching Faculty

    Javier R. Viguri Fuente

    Department of Chemical Engineering and Inorganic Chemistry

     

     

     

     

     

     

     

    The course Chemical Process Design introduces the student to the methods and training required for the conceptual design of processes based on chemical, physical and/or biological transformations of raw materials in products.

    Particular attention is paid to the use of modern approaches, employed in industry, addressing problems of current interest. Each group of students is assigned the synthesis, design and evaluation of an industrial project, preparing three consecutive design reports and an oral presentation.

    El curso de "Diseño de Procesos Químicos de Fabricación" introduce al estudiante en los métodos y formación necesarios para el diseño conceptual de procesos basados en transformaciones químicas, físicas y/o biológicas de materias primas en productos.

    Se presta especial atención en el uso de enfoques modernos, utilizados en la industria abordando problemas de interés actual. A cada grupo de estudiantes se le asigna la síntesis, diseño y evaluación de un proyecto industrial, preparando tres informes consecutivos de diseño y una presentación oral.

     

    Keywords

    Diseño de Producto, Process Synthesis, Balances de Materia y Energía, Diseño Sostenible, Design and Scheduling of Batch Process, Diseño de Procesos, Sustainable Design, Process Design, Diseño y Planificación de Procesos Discontinuos, Material and Heat Balance, Product Design, Sintesis de Procesos, Dimensionado, Costes y Evaluación Económica, Sizing, Costing and Economic Evaluation.

    • Syllabus

      programa

       

       

      Course Description

      • Course: Procesos Químicos de Fabricación

      • Code: 2191

      • Department: Department of Chemical Engineering and Inorganic Chemistry

      • Degree: Grado en Ingeniería Química

      • Faculty: Escuela Técnica Superior de Ingenieros Industriales y de Telecomunicación

      • Credits ECTS: 7,5

      • Language: English

      • Professor: Javier R. Viguri Fuente

       

       

      • PDF-icon  Here you can download the Syllabus in PDF format.

         

         

         

          Syllabus    

         

      • Abilities, course-specific objectives and mechanisms in the learning outcome context of the Chemical Process Design course.

         

      Chemical engineering

      degree abilities

      Course-specific

      objectives

      Mechanism

      Industrial chemistry specific abilities (CTQ)

      Competencias específicas de la química industrial (CTQ)

      • CTQ-2. Ability to analysis, design, simulation and optimization of process and products.

      Conceptual design of process flowsheet in group project – open ended project for industrial process; synthesis of distillation sequences and heat exchanger networks.

      Lecture; homework and project memos.

      • Ability to identify, formulate and solve engineering problems.

      Formulate and solve mass & energy balance and design equations for process flowsheets; formulate equations for process and economic evaluation.

      Lecture; homework.

      • Ability to design experiments/interpret data.

      Empirical shortcut equations for evaluation and sizing; graphical representation of data: compression and refrigeration.

      Homework and project memos.

      General abilities (CG)

      Competencias generales (CG)

      • CG-2. Knowledge on basic and technological subjects, to learn new methods and theories, and to gain versatility to adapt new and changing situations.

      Mass balances, shortcut design calculations; thermodynamic property relations, interest calculations.

      Lecture; homework.

      Transversal abilities (CT) & complementary (CC)

      Competencias trasversales (CT) y complementarias (CC)

      • CT-3. Ability to communicate effectively.

      Three engineering reports required for design project; oral presentation of project.

      Memos; oral presentation.

      • CT-5. Ability to use modern engineering tools.

      Excel; AspenPlus, web site.

      Use in lecture and homeworks; communications.

      • CT-9. Ability to function on multidisciplinary teams.

      Design groups for project; informal collaboration on homework.

      Homework and memos.

      • CT-16. Understanding of ethics.

      Design project; discussion on safety and environmental issues.

      Homework and memos.

      • CT-17. Appreciation and capability for lifelong learning.

      Understand importance of decision-making with limited information; CRC Handbook, Perry’s Handbook, extensive literature in process technology, web-resources; industrial speakers.

      Places to find process information and properties; talks by industrial visitors.

      • CT-17. Knowledge of contemporary issues.

      CO2 management; excerpts from chemical engineering magazines on processing technology and economic market; industrial speakers.

      Discussions in lecture.

      • CT-26. Ability to understand impact of engineering in a global/societal context.

      Design project related to energy issue: economic and environmental impact.

      Homework and memos.

      • CC-1. Develop intuition.

      Question orders of magnitude, signs, trends, cause-effect relationships.

      Lecture and homework.

         

         

         

          Lectures    

        

      Module I. Introduction

      • Lecture 1. Introduction to the Chemical Process Design course.

      • Lecture 2. Introduction to process design.

         

      Module II. Generation, analysis and evaluation of preliminary designs

      • Lecture 3. Overview of processes synthesis.

      • Lecture 4. Chemical product design.

      • Lecture 5. Introduction to sustainable design.

      • Lecture 6. Analysis by mass and energy linear balances.

      • Lecture 7. Equipment sizing and costing.

      • Lecture 8. Economic evaluation.

         

      Module III. Basic concepts in process synthesis

      • Lecture 9. Process synthesis: distillation sequences.

      • Lecture 10. Process synthesis: Heat Exchangers Network Synthesis (HENS).

         

      Module IV. Batch processes

      • Lecture 11. Design and scheduling of batch processes.

         

         

         

          Practical work    

        

      • 7 homework. Individual work.

      • 3 project memos and oral presentation. Group work.

      • 2 seminars of professional from industry.

    • Bibliography

      bibliografia

        

       

      • PDF-icon  Here you can download the Bibliography in PDF format.

       

       

       

          Textbooks particularly recomended    

       

      • Biegler, L.; Grossmann, I. & Westerberg, A. (1997): «Systematic methods of chemical process design». Prentice Hall.

      • Douglas, J. (1988): «Conceptual design of chemical processes». McGraw-Hill.

      • Seider, W.; Seader, J.; Lewin, D. & Widadgo, S. (2010): «Product & process design principles». 3rd Ed. John Wiley & Sons.

      • Cussler, E. & Moggridge, G. (2001): «Chemical product design». Cambridge. University Press.

       

       

       

          Other textooks with modern approaches to process design    

       

      • Sinnot, R. & Towler, G. (2009): «Chemical engineering design». 5th Ed. Coulson & Richardson´s Chemical Engineering Series. Elsevier.

      • Erwin, D. (2002): «Industrial chemical process design». McGraw-Hill.

      • Turton, R.; Bailie, R.; Whiting, W. & Shaeiwitz, J. (2003): «Analysis, synthesis and design of chemical processes». Prentice Hall PTR.

       

       

       

          Economic aspects    

       

      • Peter, M.; Timmerhaus, K. & West, R. (2005): «Plant design and economics for chemical engineers». 5th Ed. McGraw-Hill.

      • Valle-Riestra, J. (1983): «Project evaluation in the chemical process industries». McGraw-Hill.

       

       

       

          Rules of thumbs    

       

      • Branan, C. (Ed.) (2005): «Rules of thumbs for chemical engineers». 4th Ed. Elsevier.

      • Jones, D. (1997): «Elements of chemical process engineering». John Wiley & Sons.

      • Ulrich, G. & Vasudevan, P. (2004): «A guide to chemical engineering process design and economics». 2nd Ed. John Wiley & Sons.

       

       

       

          Product design    

       

      • Wei, J. (2007): «Product engineering - Molecular structure and property». Oxford University Press.

       

       

       

          CACHE process design case study series    

       

      • Vol 1. Separation system for recovery of ethylene and light products from a Naptha pyrolysis gas steam.

      • Vol 2. Design of an ammonia synthesis plant.

      • Vol 3. Design of an ethanol dehydrogenation plant.

      • Vol 4. Alternative fermentation processes for ethanol production and economic analysis.

      • Vol 5. Retrofit of a heat exchanger network and design of a multiproduct batch plant.

      • Vol 6. Chemical engineering optimization models with GAMS.

      • Vol 7. Design of an ethylbenzene production plant.

      • Vol 8. Nitrogen from air. (Versión on-line).

      • Vol 9. Conceptual Design of Second Generation Bioethanol Production via Gasification of Lignocellulosic Biomass.

       

       

       

          Textbooks in Spanish language    

       

      • Branan, C. (Ed.) (2000): «Soluciones prácticas para el ingeniero químico». 2ª Ed. McGraw-Hill.

      • Happel, J. & Jordan, D. (1981): «Economía de los procesos químicos». 2ª Ed. Reverté.

      • Jimenez-Gutierrez, A. (2003): «Diseño de procesos en ingeniería química». Editorial Reverté, S.A.

      • Puigjaner, L.; Ollero, P.; De Prada, C. & Jimenez, L. (2006): «Estrategias de modelado, simulación y optimización de procesos químicos». Editorial Síntesis.

      • Roberts, R. (2010): «Serendipia: descubrimientos accidentales en la ciencia». Alianza Ed.

       

       

       

          Encyclopedias and handbooks on chemical engineering    

       

      • Kirk, R.E. & Othmer, D.F. (1961): «Enciclopedia de tecnología química». México. Unión Tipográfica Ed. Hispano-Americana.

      • Mcketta, J.J. (1976-2002): «Encyclopedia of chemical processing and design». New York. Basel Marcel Dekker, cop.

      • Ullmann, F. (1999): «Ullmann's encyclopedia of industrial chemistry». 6th Ed. Electronic release. Weinheim. Wiley-Vch.

       

       

       

          Chemical engineering design project. Case study approach    

       

      • Ray M. & Sneesby M. (1998): «Production of phtalic anhydride». 2nd Ed. Gordon Breach Science Publishers.

      • Ray M. & Johnston D. (1989): «The manufacture of nitric acid». Gordon Breach Science Publishers.

      • CACHE. Process Design case study series.

         

         

         

          Further reading and references    

       

      • Carrillo-Hermosilla, J.; Del Río González, P. & Könnölä, T. (2009): «Eco-innovation: when sustainability and competitiveness shake hands». Palgrave Macmillan.

      • Doherty, M. & Malone, M. (2003): «Conceptual design of distillation systems». 1st Ed. Tata McGraw Hill Education.

      • Dupont, R.; Theodore, L. & Ganesan, K. (2000): «Pollution prevention». CRC Press LLC.

      • El-Halwagi, M.M. (1997): «Pollution prevention through process integration». Academic Press.

      • Floudas, C.A.; Ciric, A.R. & Grossmann, I.E. (1986): «Automatic synthesis of optimum heat exchanger network configurations». AIChE Journal, 32 (2). Pp. 276-290.

      • Galán, B. & Grossmann, I.E. (1998): «Optimal design of distributed wastewaters treatment networks». Industrial and Engineering Chemistry Research, 37 (10). Pp. 4036-4048.

      • Galán, B. & Grossmann, I.E. (2011): «Optimal design of real world industrial wastewater treatment networks». European Symposium on Computer-Aided Process Engineering ESCAPE-21. E.N. Pistikopoulos, M.C. Georgiadis & A.C. Kokossis (Editors).

      • Graedel, T. & Howard-Grenville, J.A. (2005): «Greening the industrial facility». Springer.

      • Grossmann, I.E. & Guillén-Gosálbez, G. (2010): «Scope for the application of mathematical programming techniques in the synthesis and planning of sustainable processes». Computers and Chemical Engineering, 34. Pp. 365-1376.

      • Hendrickson, C.; Lave, L. & Matthews, S. (2006): «Environmental life cycle assessment of goods and services». RFF.

      • Joback, K.G. & Reid, R.C. (1987): «Estimation of pure-component properties from group contributions». Chemical Engineering Communications, 57. Pp. 233-243.

      • Kemp, I. (2007): «Pinch analysis and process integration». 2nd Ed. Elsevier.

      • Korevaar, G.; Harmsen, G. & Lemkowitz, S. (2005): «Sustainable technology». TUDelft.

      • Majozi, T. (2010): «Batch chemical process integration. Analysis, synthesis and optimization». Springer.

      • Nakamura, S. & Kondo, Y. (2009): «Waste input-output analysis. Concepts and Application to Industrial ecology». Springer.

      • Ng, K.; Gani, R. & Dam-Johansen, K. (Eds.) (2007): «Chemical product design: toward a perspective through case studies». Elsevier.

      • Nhakore, S.B. & Bhatt, B.I. (2007): «Introduction to process engineering and design». 1st Ed. Tata McGraw Hill Education.

      • Nimitz, J. & Skaggs, S. (1992): «Estimating tropospheric lifetimes and ozone-depletion potentials of one-and two-carbon hydrofluorocarbons and hydrochlorofluorocarbons». Environmental Science and Technology, 26 (4). Pp. 639-744.

      • OECD (2009): «Eco-innovation in Industry. Enabling green growth».

      • Papoulias, S. & Grossmann, I.E. (1983a): «A structural optimization approach in process synthesis-I: utility systems». Computer and Chemical Engineering, 7. P. 695.

      • Papoulias, S. & Grossmann, I.E. (1983b): «A structural optimization approach in process synthesis-I: heat recovery network». Computer and Chemical Engineering, 7. P. 707.

      • Papoulias, S. & Grossmann, I.E. (1983c): «A structural optimization approach in process synthesis-III: total processing systems». Computer and Chemical Engineering, 7. P. 723.

      • Poling, B.; Prausnitz, J. & Connell, J. (2001): «Properties of gases and liquids». 5th Ed. NY. McGraw-Hill.

      • Seader, J.D. & Westerberg, A.W. (1977): «A combined heuristic and evolutionary strategy for synthesis of simple separation sequences». AIChE Journal, 23. P. 951.

      • Smith, R.M. (2005): «Chemical process: design and integration». John Wiley & Sons.

      • Treybal, R. (1980): «Mass transfer operations». 2nd Ed. McGraw Hill.

      • Tyler Miller, G. (2007): «Living in the environment: principles, connections, and solutions». 15th Ed. Thomson.

      • Van Krevelen, D.W. (1990): «Properties of polymers». Elsevier, Amsterdam.

      • Yee, T. & Grossmann, I. (1990): «Simultaneous optimization models for heat integration-II. Heat exchangers networks synthesis». Computers and Chemical Engineering, 14, 10. Pp. 1165-1184.

    • Course Materials

      materiales

       

       

      Module I. Introduction

      • MC-F-001Lecture 1. Introduction to the Chemical Process Design course.

      • MC-F-002. Lecture 2. Introduction to process design.

         

      Module II. Generation, analysis and evaluation of preliminary designs

      • MC-F-003. Lecture 3. Overview of processes synthesis.

      • MC-F-004. Lecture 4. Chemical product design.

      • MC-F-005. Lecture 5. Introduction to sustainable design.

      • MC-F-006. Lecture 6. Analysis by mass and energy linear balances.

      • MC-F-007. Lecture 7. Equipment sizing and costing.

      • MC-F-008. Lecture 8. Economic evaluation.

         

      Module III. Basic concepts in process synthesis

      • MC-F-009. Lecture 9. Process synthesis: distillation sequences.

      • MC-F-010. Lecture 10. Process synthesis: Heat Exchangers Network Synthesis (HENS).

         

      Module IV. Batch processes

      • MC-F-011. Lecture 11. Design and scheduling of batch processes.

    • Practical Classes

      practicas

        

       

      Homeworks

         

      Projects

    • More Resources

      otros_recursos

       

       

      • OR-F-001. American Institute of Chemical Engineers (AIChE).
      • OR-F-002. Reference documents (BREF). European IPPC Bureau (EIPPCB). European Commission's Joint Research Centre (JRC).
      • OR-F-003. Computer Aids for Chemical Engineering (CACHE).
      • OR-F-004. European Chemical Industry Council (CEFIC).
      • OR-F-005. Engineer Salaries - International Comparison.
      • OR-F-006. European Federation of Chemical Engineering (EFCE).
      • OR-F-007. Federación Española de Ingenieros Químicos (FEIQ).
      • OR-F-008. Federación Empresarial de la Industria Química Española (FEIQUE).
      • OR-F-009. GlobalSpec. Find industrial product suppliers & service providers.
      • OR-F-010. Institution of Chemical Engineers (IChemE). Advancing chemical engineering worldwide.
      • OR-F-011. SusChem 2009. The European Technology Platform for Sustainable Chemistry. IAP Update 2009. Reaction & process design.
      • OR-F-012. The Tubular Exchanger Manufacturers Association, Inc. (TEMA).
      • OR-F-013. World Chemical Engineering Council (WCEC).
    • Evaluation

      evaluacion

        

       

          Exam samples    

       

      • PE-F-001. Examen febrero 2010 (Castellano).
      • PE-F-002. Exam february 2010 (English).
      • PE-F-003. Examen febrero 2011 (Castellano).
      • PE-F-004. Exam february 2011 (English).

        

        

        

          Criteria for evaluation    

       

        

       

      Grading

      %

      • Exam 1: 50 points (to prepare memo 2).

      • Exam 2: 50 points (to prepare memo 3).

       

      • Memo 1: 10 points (Flowsheet).

      • Memo 2: 20 points (Balances).

      • Memo 3: 30 points (Final Report. $).

      • Oral Presentation: 10 points.

       

      • Homework (6): 30 points.

      --------------------------------------------------------------------

      • TOTAL: 200 points

      25

      25

       

      5

      10

      15

      5

       

      15

      -----------

      100

       

       

      • The individual work Homework/Tareas, the Group work Project MEMOS and the Exams would be returned to the students as learning mechanism.

      • The general comments to the Homework and Memos would be available to the students by OCW, Blackboard and by hand.

      • The Project Oral presentation will be assessing by the course responsible in collaboration with a professional from the industry.   

        

        

        

          Grading of memos    

       

      Grading MEMO 1 - 100 points
      • A.25 … Impact - A subjective assessment of how well you wrote the memo. Have you examined alternatives? Is your memo easy to follow, well presented?

      • B.12Quality of your search: Extent - Number and diversity of sources (patents, handbooks, text, encyclopedias, chemical engineering journals (academic, trade), webpages, etc.

      • C.10Spelling, grammar, punctuation.

      • D.04Format - 1 point if you have adhered to the conventions of the AIChE J., else 0.

      • E.04Relevance - Judged from your annotations.

      Flowsheet

      • F.20Reasonable & accurate - Does your flowsheet make physical sense?

      • Some common mistakes:

        • Do heat exchangers resemble mixers?

        • Do you have pumps (instead of compressors on vapour streams?

        • Does the liquid feed to a reboiled stripper enter the bottom of the column?

        • Any missing equipment?
      • G.10Neatly and clearly drawn.

      Equipment lists - Appendix

      • H.05Calculation of gross profit.

      • I.05Organization - Arrange in some coherent fashion e.g.: by section of the process, in order of decreasing importance, by flow of streams; etc. No equipment is missing in the list.

      • J.05Nomenclature - Your naming scheme makes sense, and you are consistent in applying it.

        

       

      Grading MEMO 2 - 100 points
      • A.25Makes sense. No errors in pumps, heat exchangers, columns and compressors. Flowsheet symbols drawn correctly and used consistently. Mass and energy is conserved, etc.

      • B.20Calculations for units and basic calculations.

      • C.15Complete - All requested results are shown: T, P, Component flow, total flow, phase (liquid, vapour, or vapour fraction if two-phase).

      • D.10Cover letter. Major results (overall conversion, energy consumption, etc.).

      • E.10Assumptions, description procedure, data clearly organized.

      • F.10Neat flowsheet, stream table: 6 = legible; 10 = beautiful.

      • G.05Spelling, grammar, punctuation.

      • H.05References - Sources of all physical properties are clearly identified. Follow the conventions of the AIChE J. (Annotations not required).

       

       

      Grading MEMO 3 - 100 points
      • A.20Makes sense. No major errors in flowsheet, equipment sizes, cost and economic evaluation.

      • B.20Quality of discussion.

      • C.20Calculations for units and basic calculations.

      • D.15Complete - All requested results are shown: flowsheet with heat loads, equipment parameters, major items for economic evaluation.

      • E.10Cover letter. Major results (NPV, investment, operating cost, overall conversion, energy consumption, etc.).

      • F.05Spelling, grammar, punctuation.

      • G.05References - Sources of all physical properties are clearly identified. Follow the conventions of the AIChE J. (Annotations not required).

      • H.05Neat presentation.

    • Calendar

      guia

       

       

    • Lecturers

      profesor

       

       

      javier_viguri.jpg

      Javier R. Viguri Fuente

       

      Department of Chemical Engineering and Inorganic Chemistry

      UNIVERSIDAD DE CANTABRIA
       
      More information

       

       

        

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