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PROSESSISUUNNITTELUN SEMINAARI

PROSESSISUUNNITTELUN SEMINAARI. 1. vaihe. CONTENTS. Info Project definition and knowledge acquirement Process selection Process synthesis Heuristic rules Process flowsheet Process analysis / balances Plant siting and lay-out Cost and profitability estimation

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PROSESSISUUNNITTELUN SEMINAARI

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  1. PROSESSISUUNNITTELUN SEMINAARI 1. vaihe

  2. CONTENTS • Info • Project definition and knowledgeacquirement • Processselection • Processsynthesis • Heuristicrules • Processflowsheet • Processanalysis / balances • Plantsiting and lay-out • Cost and profitabilityestimation • Safety and environmentalaspects

  3. PROSESSISUUNNITTELU • Suunnittelua ei voi viedä loppuun ennen teknisiä valintoja • Teknisten valintojen järkevyydestä ei voi varmistua, ennen kuin • suunnittelu on viety loppuun  iteratiivinen työskentely

  4. PROCESS LIFECYCLE

  5. NATURE OF WORK • ”Openendedtask” • Decisionmaking • Selective • Quantitative • Go/Nogo • Iterative • Analysis of the data, conclusions • Criticalattitude • Ownideas

  6. PROJECT DEFINITION(Chemicalplant design project) PROJECT GOALS • Technical • Schedule • Costs and resources DESIGN BASIS!! • Capacity • Rawmaterials (properties) • Products (properties and requirements) • Utilityspecification • Localconditions

  7. TECHNICAL GOAL • Name of the product(s) • Scope of the project • Grass rootsplantor • ISBL or • Expansion of the plantor • Modification of the plantor • Certainpart of the plant… • Level of detail • Feasibilitystudyor • Basic design • Detailed design • Restrictions • Processdecidedalready • Locationfixed • etc

  8. SCHEDULING • Gantt’sbarchart • Criticalpathmethod(CPM) • Programevaluation and reviewtechnique(PERT) Softwares for projectadministrationavailable CONCURRENT ENGINEERING (Concurrentprocess design engineering impliesthat, in addition to the basis of design, allfactors of possiblerelevance to the process design arebeingconsidered in allstages of a design process /Paulien Herder, Process Design)

  9. SCHEDULE Gantts bar chart

  10. DESIGN COSTS AND RESOURCES • Final design cost RELEVANT FIGURES • Manhours (specially in this case) • Number of documents • Contractors’ fee • Software licences • Etc. The costs of the detailed design aretypically 5-30 % of the totalinvestment, depending on the project. (The costs of conceptual and basic design areless, of course)

  11. DEFINITION OF THE DESIGN BASIS, EXAMPLE • Design capacity 50 000 t/a (feed) minimumfeed 50 % of the design capacity • Feed • Composition • Importantproperties (e.g. grainsize, colour, moisturecontent etc.)

  12. PRODUCT SPECIFICATION, EXAMPLE

  13. EXAMPLE OF UTILITY SPECIFICATION

  14. LOCAL CONDITIONS, EXAMPLE • Windload 85 kg/m2up to 30 m (55+h) kg/m2above 30 m • Earthquakes, notrelevant • Horizontalsnowload 200 kg/m2 • Temperatures: • Outside, max 35 °C • Outside, min -30 °C • Air cooling, design temp. 25 °C

  15. KNOWLEDGE ACQUIREMENT • Properties of subtances • Economicalknowledge • Processknowledge 4. Legal aspects

  16. 1. PROPERTIES OF SUBSTANCES • Rawmaterials • Products • Catalysts • Othermaterialsappearing in the process • Physicalproperties • Dangerousproperties • Environmentalviewpoint

  17. 2. ECONOMICAL KNOWLEDGE Needed for marketsurvey, capacitydecision, roughcostestimation, roughprofitabilityestimation • Production, current and predicted • Use and potential • Demand and supply • Prices, current and predicted • Competing and alternativeproducts • Roughinvestment and productioncosts

  18. SOURCES FOR MARKET RESEARCH • Directcontactswithcompanies, brochures • Congresses, fairs • Professional journals and publications • Specialpublications (ChemicalEconomicsHandbook, SRI) • Internet • Consultants • Industrial federations • Suomen Ulkomaankauppaliitto • Tullihallitus, tilastot • Industrial secretaries (TEKES, UM) • Kauppakamarit Usuallypersonalcontactsare the best

  19. 3. PROCESS KNOWLEDGE How to produce certain chemical. • General chemical engineering knowledge • Internet • Handbooks • Patents • Journals • Fairs, congresses (Achema) • Directcontactswithcompanies, brochures Reliability of the knowledge

  20. PROCESS SELECTION • Licenseorplantpurchase: → processselection • Owndevelopment → processsynthesis

  21. CRITERIA FOR SELECTION • Investmentcosts • Operationcosts • Synergy • Novelty • Technicalrisk • Developmentpotential • Safety • Environmentalaspects • etc

  22. PROSESSIN LAATUKRITEEREITÄ

  23. 1. VAIHE • Projektin määrittely • Tekninen, aikataulullinen (janakaavio), taloudellinen (arvio työtunneista), suunnitteluperusteet • Lähtötietojen hankinta • Lähtöaineet, tuotteet, prosessit; markkinaselvitykset tuotteesta, kysyntä, tarjonta, hinta, käyttökohteet, nyt ja tulevaisuudessa • Prosessivaihtoehtojen lohkokaaviot • Prosessivaihtoehtojen vertailu • Kriteerien perusteella • Suositus prosessiksi ja sen sijainniksi • Suositus kapasiteetiksi

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