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Review for Design I Exam

This review covers the materials covered in the Design Exam for CHEN 4253, including chapters on product design, process creation, heuristics for process synthesis, process simulators, capital cost estimates, and profitability analyses.

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Review for Design I Exam

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  1. Review for Design I Exam CHEN 4253 Terry A. Ring

  2. Materials Covered Week 1-22 August Chapt 1 (p.1 -25), Chapt 2, Chapt 3 Product Design- Introduction to course – Product and Process Design Product Design-1 Overview Product Design-2 Property Estimation Week 2-29 August Chapters 16 and 17 Product Design-3 Innovation Maps Product Design-4 Six Sigma in Product Design Product Design-5 Engineering Ethics Week 3–5 September (Holiday Monday) Chapt 1 (p25-31) Chapter 4 Process Creation- Ethics in Chemical Engineering Process Safety Process Design Overview Process Creation

  3. Materials Covered-con’t Week 4–12 September (Celanese in Class Monday) Chapt 4&5&6 Aspen for Process Creation– Use of Aspen for Process Creation-1 Use of Aspen for Process Creation-2 Heuristics for Process Simulation Week 5 – 19 September Chapt 4&5 Aspen Tutorials and Problems Solved in Class (Reserve the ICC) - Week 6 - 26 September (Away Wednesday and Friday) Chapt 5&6 ProMax Tutorials and Problems Solved in Class (Reserve the ICC) - Week 7–3 October Chapter 22-22 (p543-558) &23 Profitability Analyses - Annual Costs Earnings Profitability Analysis Week 8- 11 October FALL BREAK

  4. What have we really covered? • Product Design (Ethics) Chapt. 1,2&3 • Process Creation Chapt 4 • Heuristics for Process Synthesis Chapt 6 • Process Simulators Chapt 5 • Aspen • Promax • Capital Cost Estimates Chapt 22 • Profitability Analyses Chapt 23

  5. Chapters 1, 2,3 & 4 • Chpt. 1 - The Design Process • Ethics in Chemical Engineering • Product design • Chpt. 2 – Product Development • Chpt. 3 - Molecular Structure Design • Property estimation • Chpt. 4 – Process Creation • Gross Profitability Analysis • Process Synthesis • Start with the reactor (differences in molecular type) • Separation (differences in composition) • Heat transfer, pumping, compression, flash tanks (differences in temperature, pressure, and phase) • Integraton

  6. Chemical Product Design Pyramid Figure of Merit

  7. Physical Property Estimation • Hansen Solubility Parameters • Group Contribution Methods • Polymer properties • Surface tension • HLB • Heat of Mixing • Drago E and C • Work of Adhesion • Wetting • Bio-concentration factor • Oil-water distribution Coefficient • Lethal Dose • Flash Point Temp.

  8. Chapters 5 and 6 • Chapter 5 – Simulation to Assist in Process Creation • Steady-state flow sheet simulation • Table 5.1 – Unit Subroutines • Recycle (tear streams) • Recycle convergence • Chapter 6 – Heuristics for Process Synthesis • Summary on page 174, Table 6.2 • Using these as a start in design/simulation

  9. Process Creation • Process Economics – Gross Profitability Analysis • Focus on Reactor • Equilibrium • Kinetics or Conversion • Focus on Separation System • Heuristics in Process Design

  10. Chapter 22 - Costing • Accounting • Debits/credits; annual report; balance sheet • Cost Indexes • Capital investment costs (Table 22.9,pg. 547) • Bare model costs • Total depreciable capital • Total permanent investment • Total capital investment • Estimation of Total Capital Investment • Order-of-magnitude • Study estimate • Preliminary estimate • Definitive estimate

  11. Investment Chapter 23 - Costing • Estimation of total capital • Order-of-magnitude (method of Hill) • See page 498 • +/- 50% • Study estimate (Method of Lang) • See page 500 • +/- 35% • Preliminary estimate (method of Guthrie) • See page 503 • +/- 20% • Most likely used • Need fob equipment purchase cost • More definitive • Aspen Icarus (but we do not have this license)

  12. Process Economics • Capital Cost Estimation • Cost Indexes • Three types • Scaleup of Capital Investments - 6/10th rule • Order of Magnitude Estimate (±50%) - Hill • Study Estimate (±35%) - Lang • Profitability Analysis • ROI, PBP, IRR, VP, Cash Flow Calcs. • Accounting

  13. Format for Exam • Exam in 2 parts • Wednesday, 20 October 2009 • In class written exam • Open book, open notes • Last Year’s Exam • Friday, 22 October 2009 • In class, open book, open notes • 1- Aspen Problem • 1- ProMax Problem • Competency Test

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