CDB 3044

PROCESS PLANT DESIGN

Introduction to Plant Design
Dr. Rajashekhar Pendyala
Chemical Engineering Department
University Teknologi PETRONAS

Dr. Rajashekhar Pendyala

 Introduction to Plant Design

Objectives

1. Explain or describe the activities/steps involved in the

design of a process plant

2. Discuss the aspects that need to be considered in each

of the process design step

Dr. Rajashekhar Pendyala

 Introduction to Plant Design
The purpose of engineering is to create material wealth – Douglas, Conceptual
Design of Chemical Processes 1988.
The goal of the engineer is to design and produce artifacts and systems that are
beneficial to mankind – Biegler, Grossman & Westerberg, Systematic Methods of
Chemical Process Design 1997.
How to do so ?
Energy In

Raw
Materials CHEMICA Products +
+ Other L Wastes
Feeds PROCESS

Energy
Out
ABOUT THE CHEMICAL PROCESS
In a chemical process, the transformation of raw materials into desired products usually cannot
be achieved in a single step. Instead, the overall transformation is broken down into a number of
steps that provide intermediate transformations. (Robin Smith, Chemical Process Design 1995)
Dr. Rajashekhar Pendyala
 Introduction to Plant Design

Raw Materials CHEMICAL Products +

+ Other Feeds PROCESS Wastes

Energy Energy

A NUMBER OF PROCESSING STEPS MADE UP THE CHEMICAL PROCESS

QUESTIONS?

- WHAT SORT OF PROCESSINGS ARE LOCATED IN THE CHEMICAL PROCESS?

- HOW DO WE SEQUENCE THE PROCESSING STEPS?
- TO WHAT EXTEND CAN WE EXPECT EACH OF THE PROCESSING STEP TO
PERFORM AND WHAT FEATURES ARE REQUIRED?
- HOW MUCH ENERGY IS REQUIRED AND HOW MUCH IS PRODUCED?
- HOW MUCH FEEDS DO WE NEED AND HOW MUCH PRODUCTS ARE
PRODUCED?
- HOW MUCH WASTES ARE GENERATED?
- HOW MUCH PROFIT COULD BE DERIVED?
HOW DO WE ADDRESS
THIS?
Concept Design for Chemical Process

Dr. Rajashekhar Pendyala

 Introduction to Plant Design

Raw Materials CHEMICAL Products +

+ Other Feeds PROCESS Wastes

Energy Energy

PROCESS PLANT DESIGN IS THE NAME OF THE GAME HERE !

LITTLE OR LIMITED
BEFORE COMING UP WITH A
INFORMATIONS ARE
COMPLETE PROCESS
AVAILABLE

But so many possibilities

or solutions !

Perhaps, the major features that distinguishes design problems from other types of engineering
problems is that they are under defined; i.e., only a very small fraction of the information needed
to define a design problem is available from the problem statement.
(Douglas, Conceptual Design of Chemical Processes 1988)
Dr. Rajashekhar Pendyala
 Introduction to Plant Design
Once the process concept has been designed, which produces process flow sheet

After that, the equipment design has to be performed..

Distillation

Dr. Rajashekhar Pendyala

 Introduction to Plant Design
The equipment design comprises of

1. Performance/Capacity Rating or Sizing

Equipments’ Dimensions
– diameter & height

No. of stages Heat Transfer

for contact Area Needed

2. Vessel Mechanical Design

Internal Design
Wall thickness

Pipe fittings &

Support Design Reinforcement

Dr. Rajashekhar Pendyala

 Introduction to Plant Design
The process safety and control strategy has to be devised

1. Process Safety
- Hazard and Operability Study (HAZOP)

- Risk Assessment
HAZOP
study

2. Process Control Strategy Risk Assessment

Matrix
- Material Control

- Product Control

Overall Plant and Equipment..

Dr. Rajashekhar Pendyala

 Introduction to Plant Design

Waste Treatment/Minimization also need to be addressed..

1. Waste Treatment (conventional)

- Suitable ‘end of pipe’ treatment on the effluent (gases & liquids)

2. Waste Minimization (sustainability)

- Adjusting processes to minimize the generation of waste

REACTOR

SEPARATION
& RECYCLE
SYSTEM

HEAT EXCHANGER
NETWORK

UTILITIES

Dr. Rajashekhar Pendyala

 Introduction to Plant Design
In finalizing the process and equipment design, several stages of
economic analysis could be conducted..

First step;
EP 1 = Revenue – Cost of Raw Material
Second Step (after mass balance developed)
EP 2 = Revenue – Cost of Raw Material - Utility

Third Step (after equipments designed)

EP 3 = Revenue – Cost of Raw Material – Utility – Annualized Cost of Equipment

The economics analysis continues with other costs (manpower, insurance etc)..

Pay back time,

Return on Investment
Internal Rate of Return

with profitability analysis conducted at the end to assess project viability..

Dr. Rajashekhar Pendyala

 Introduction to Plant Design

Finally..

Dr. Rajashekhar Pendyala

 Introduction to Plant Design
Approaches and Stages of Process Plant Design
In the first stage, conceptual process design has to be conducted.
In general conceptual process design has to address two major activities.

1. ADDRESS THE INDIVIDUAL

PROCESS/TRANSFORMATION STEP

RECYCLE

STEAM

FEED REACTOR

PRODUCT 1
CW

PRODUCT 2

2. ADDRESS THE REQUIRED

INTERCONNECTION BETWEEN THE STEPS

Dr. Rajashekhar Pendyala

 Introduction to Plant Design

..and the target is to create the best feasible flow sheet for the process

DEFINITION OF A FLOWSHEET
FLOWSHEET IS A DIAGRAMMATIC REPRESENTATION OF THE PROCESS
STEPS AND ITS INTERCONNECTIONS

RECYCLE

STEAM

FEED REACTOR

PRODUCT 1
CW

Str1 Str2 Str3 Str4 Str5 Str6 Str7 Str8 Str9

F
T
P
x PRODUCT 2

WHAT OTHER INFORMATIONS SHOULD BE

AVAILABLE IN A FLOWSHEET ?
AND HOW DO YOU GET SUCH INFORMATION ?

Dr. Rajashekhar Pendyala

 Introduction to Plant Design

A SYSTEMATIC APPROACH OR METHOD IS REQUIRED

The approach or method should be able to help in addressing these questions …

Why is the unit operation selected ?

How are the unit operations connected ?

What are the utilities required and approximate amount ?

How will it be supplied to the process unit operations ?

What wastes will be generated?

However, as much as we would like to have a systematic approach or method, we must also
recognised that process design is an art !

If we reflect on the nature of process synthesis and analysis, …. , we recognize that process design
actually is an art, i.e., creative process. (Douglas, Conceptual Design of Chemical Processes 1988)

Dr. Rajashekhar Pendyala

 Introduction to Plant Design

Now, what criteria should be adopted besides economics during the design activities?

1. ADDRESS THE INDIVIDUAL

PROCESS/TRANSFORMATION STEP

RECYCLE

STEAM

FEED REACTOR

CW
PRODUCT 1 FLOWSHEET
PRODUCT 2

2. ADDRESS THE REQUIRED

INTERCONNECTION BETWEEN THE STEPS

QUANTIFIABLE NON - QUANTIFIABLE

VERSUS
FACTOR ! FACTOR !

MINIMISE COST HIGH SAFETY & INTEGRITY

MINIMISE WASTES GENERATION GOOD OPERATIONAL ASPECTS

MINIMISE ENERGY CONSUMPTION

..... BUT HOW TO OPTIMISE ?

Dr. Rajashekhar Pendyala
 Introduction to Plant Design

Consider back the flowsheet !

RECYCLE

STEAM

FEED REACTOR
PRODUCT 1
CW

PRODUCT 2

OPTIMISING A SINGLE UNIT/STEP

IN THE PROCESS OPTIMISING THE INTERCONNECTIONS
BETWEEN THE UNITS/STEPS IN THE PROCESS
EG. DISTILLATION COLUMN
MANY POSSIBLE CONNECTIONS WHICH LEAD
TOTAL RR --> ENERGY TO DIFFERENT STRUCTURES OF FLOWSHEET
COST
THUS DIFFERENT ECONOMIC IMPACT EVEN TO THE
EXTENT OF THE INDIVIDUAL UNIT ITSELF!

CONTINUOUS FUNCTION
RR RR --> CAPITAL ?
DIS-CONTINUOUS FUNCTION

PARAMETER OPTIMISATION STRUCTURAL OPTIMISATION

How do we tackle them ?

Dr. Rajashekhar Pendyala

 Introduction to Plant Design
Consider the approaches/methods which have been introduced to deal with such complex
optimisation ?

HEURISTIC METHOD MATHEMATICAL METHOD

ONION MODEL MIXED INTEGER LINEAR/

NON-LINEAR PROGRAMMING
USE A SEQUENTIAL/HIERARCHICAL METHOD
ACCORDING TO FOLLOWING SEQUENCE ; USE A MATHEMATICAL PROGRAMMING METHOD TO
1. REACTOR SOLVE AND GIVE SOLUTION FOR THE PROCESS.
2. SEPARATION AND RECYCLE SYSTEM SIMULTANEOUS SOLUTION OF ALL THE SYSTEM.
3. HEAT EXCHANGER NETWORK
4. UTILITIES
DECISION ARE BASED ON SOLELY MATHEMATICAL
DECISION ARE BASED ON ENGINEERING GUIDELINES OPTIMISATION CRITERIA
ESTABLISHED AND MATHEMATICAL OPTIMISATION
CONCEPT IS BASED ON
CONCEPT IS BASED ON "CREATING AND OPTIMISING A REDUCIBLE
"BUILDING AN IRREDUCIBLE STRUCTURE" STRUCTURE"

Smith R.,Chemical Process Design 1995 Grossman I. E, Comp. Chem. Eng., 9: 463, 1985
Biegler, Grossman & Westerberg, Systematic
HIERARCHICAL APPROACH Method of Chemical Process Design 1997
USE A SEQUENTIAL/HIERARCHICAL METHOD
ACCORDING TO FOLLOWING SEQUENCE ;
1. BATCH VS CONTINUOUS
2. INPUT-OUTPUT STRUCTURE OF THE FLOWSHEET
3. RECYCLE STRUCTURE OF THE FLOWSHEET
4. GENERAL STRUCTURE OF SEPARATION SYSTEM
5. HEAT EXCHANGER NETWORK Douglas.,Conceptual Design of Chemical Process 1988

Dr. Rajashekhar Pendyala

 Introduction to Plant Design

HEURISTIC METHOD – The Onion Model

• Design starts from the centre ( heart of

process ) which is the reactor.
• At each layer, decision has to be made
to complete the design requirement for
the stage.
• As such, many best local optimal
decisions are made since the whole
picture is incomplete.
• Unit/Equipment is added only if it is
economically justified based on the
current available information.
• This keeps the process (structure)
irreducible and features which are
technically/economically redundant are
not included.

The onion model of process design. A reactor is first

designed before the separation and recycle system can
be designed and so on.
Dr. Rajashekhar Pendyala
 Introduction to Plant Design

HEURISTIC METHOD – The Hierarchical Approach

The conceptual design is performed based on 5 different stages. The approach is somewhat
different by tackling the 5 different level that are classified differently. The 5 levels are ;
Level 1 Decision : Batch vs Continuous
Level 2 Decision : Fixing the Input-Output Structure
Level 3 Decision : Determining the Recycle Structure for the Process
Level 4 Decision : Determining the Separation System
Level 5 Decision : Determining the Heat Exchanger Network

WHAT DO YOU NOTICE ON

THE STATEMENT CONTAIN WITHIN
THE SHADED BOX ? At each level except level 1, alternatives have to
be generated and assessed to see its economic
and operational potential. Some level of process
Compare these statements
design has to be conducted on the units/process
to the onion model !
placed at every stages.

Dr. Rajashekhar Pendyala

 Introduction to Plant Design

MATHEMATICAL METHOD – The Mixed Integer Linear/Nonlinear Programming

- CREATION OF SUPERSTRUCTURE/HYPERSTRUCTURE
A major (super) structure is created which embedded within it all feasible
process (including its operations) and all feasible interconnections that
are candidates for an optimal design. The method is completely automated
and depends only on the computer programming to solve it. The design
problem is formulated into sets of mathematical equations which has to be
solved by the mathematical programming. Started off with many redundant
features, the programming optimize and reduce the process (structure)
to an optimal solution.

other process
alternatives

Dr. Rajashekhar Pendyala

 Introduction to Plant Design

From the conceptual process design, a flowsheet is generated for the process. The next
stage would then be to address the equipment design …

RECYCLE

STEAM

FEED REACTOR
PRODUCT 1
CW

PRODUCT 2

Heat Exchanger
Reactor
Distillation

No of stages
Reflux Ratio
Feed Location
Type of Exchanger (Plate / Shell & Tube)
Vapour/Liquid Loading
Heat Transfer Coefficient
Column Sizing
Heat Transfer Area Type of Reactor Internals
Pressure Drop Reaction Kinetics Column Temperature &
Exchanger Configuration Reaction Selectivity Pressure
Reactor Sizing
Reactor Temperature & Pressure

Dr. Rajashekhar Pendyala

 Introduction to Plant Design

There are established methods for performing the design of these equipments ….

Heat Exchanger Reactor Distillation

Kern’s method Reactor

Rating calculation that will

enable the sizing of the heat From the kinetics obtained from
Fenske, Gilliland & Underwood
exchanger to be done experiment, sizing of reactor No of stages calculation versus reflux ratio
could be done based on could be made and the feed location
residence time. determined.
Results are then simulated in rigorous
simulation model for actual design involving
capacity calculation for internals.

Dr. Rajashekhar Pendyala

 Introduction to Plant Design

Given that each of the equipment will normally involved vessel operated at various pressure
and temperature, the design of the pressure vessel has to be conducted. The design is to be
done according to standards…..

Heat Exchanger

Reactor

Pressure Vessel Dimension

Distillation Shell Thickness
Flanges Connection &
Reinforcement
Support type and Design
Corrosion Allowance
Welding specification

American Society of Mechanical Engineers (ASME)

Boiler and Pressure Vessel Code.
ASME Boiler and Pressure Vessel Code (BPVC) is a standard that provides
rules for the design, fabrication, and inspection of boilers and pressure
vessels. It is reviewed every three years.

Dr. Rajashekhar Pendyala

 Introduction to Plant Design
Health, Safety and Environment aspects are increasingly gaining attention in view of their
importance. Therefore the design of process plant has to take into account of the HSE
particularly the safety and environment aspects where it has to be integrated with the design
activities ….

Inherent Safety
Remove or attenuate conditions that
Hazard Analysis
could lead to the 3 incidents such as
high P and T …..

FIRE EXPLOSION TOXIC RELEASE HAZOP

Auto Ignition temp. Chemical Energy vs Physical Time weighed exposure Hazard and
Flammability Limits Energy Short term Exposure Operability
Flash Points Deflagration vs detonation Ceiling Exposure Study.
Minimum Oxygen concentration Confined vs Unconfined LC50 & LD50
Explosions (VCE) DOW Index
Flammable liquids are more
dangerous than flammable gas

Dr. Rajashekhar Pendyala

 Introduction to Plant Design
Health, Safety and Environment aspects are increasingly gaining attention in view of their
importance. Therefore the design of process plant has to take into account of the HSE
particularly the safety and environment aspects where it has to be integrated with the design
activities ….

Environment
Environment

Waste Minimisation Waste Treatment

(Clean Process Technology)
Reactor Air Effluent
Increase conversion if selectivity is not an issue Particulate, CO2, CO, SOx, Nox
Product removal for reversible reaction favoring product Gravity Settlers, Inertial Collectors, Scribbers, Filters,
Set T & P to improve selectivity Electrostatic precipitators, catalytic reaction etc.

Distillation Water Effluent

Recycling waste stream to suppress by product reaction Membrane, Adsorption, Absorption, thermal oxidation,
Feed purification biological treatment, membrane separation etc.
Eliminate use of extraneous material for separation
(entrainer)

Waste stream recovery

Improve heat recovery
Dr. Rajashekhar Pendyala
 Introduction to Plant Design

Finally..

You will develop the construction details for a process plant..

Dr. Rajashekhar Pendyala

 THANK YOU
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Dr. Rajashekhar Pendyala