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Review for Design I Exam

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

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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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