Topic outline

  • General


    Muhammad Abbas bin Ahmad Zaini, Dr.
    Semester 2 2010/11


    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
  • Topic 1


    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

    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

    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

    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

    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

    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.