## Topic outline

- General
### General

Lecturer:

**Muhammad Abbas bin Ahmad Zaini, Dr.**Semester:

Semester 2 2010/11

**Synopsis:**This course highlights the principles and methodology of product and process design. It emphasizes the key elements of design, i.e., process creation and synthesis, analysis, evaluation and optimization, to generate a inherently safe, economic and environmentally friendly process. The course also features the use of simulation tool for designing a process.

**Course Outcomes:**Students should be able to:

- Describe and apply the 5M approach in process creation and relate it to the detailed systematic steps for product and process design
- Synthesis a process using the 5 keys synthesis steps from Rudd, Powers & Sirrola (1973)
- Apply simulation tools to solve simple process design
- Evaluate process and separation system selection decision using heuristics approach by taking into account the aspects of safety, economy and environment
- Target and design maximum heat recovery network using pinch analysis method
- Generate preliminary equipment sizing and costing using equipment cost correlations and indices
- Define and formulate optimization problem and solve it using graphical method and Excel solver

This work, SKF4153 PLANT DESIGN by **Muhammad Abbas Ahmad Zaini**is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License.

- Topic 1
### Topic 1

**5Ms CONCEPT**

Students should be able to:

- Describe the overall elements of process creation based on the 5Ms concept.
- Relate chemical engineering knowledge with daily activities.
- Critically analyze engineering situations involving ethical problems.

- Topic 2
### Topic 2

**Process Synthesis & Creation**

Students should be able to:- Perform process selection decision using heuristics approach.
- Synthesis a process flow diagram using heuristics approach.
- Simulate a chemical process to generate material and energy balance data using Aspen Plus.

- Topic 3
### Topic 3

**Distillation Sequence**

Students should be able to:- Select and synthesis the best separation alternative using heuristics.
- Calculate and select the best separation alternative using heuristics.

- Topic 4
### Topic 4

**Heat Integration**

Students should be able to:- Apply the 1st and 2nd Law of Thermodynamics in designing heat recovery systems.
- Calculate the maximum energy recovery (MER) targets using graphical (composite curves) and numerical (problem table analysis) approaches.
- Design a network to meet the MER targets using grid diagram.

- Topic 5
### Topic 5

**Process Optimization**Students should be able to:

- Define and formulate linear programming (LP) model to solve optimization problems.
- Solve optimization problems using graphical method and Excel Solver.

- Topic 6
### Topic 6

**Equipment Sizing & Capital Cost Estimation**

Students should be able to:- Select design specification of equipment based on available standard.
- Calculate the equipment bare module cost based on various cost estimation method.