Review for Design I Exam

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Review for Design I Exam

• CHEN 4253
• Terry A. Ring

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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 35 September
(Holiday Monday) Chapt 1 (p25-31) Chapter 4
Process Creation- Ethics in Chemical
Engineering Process Safety Process Design
Overview Process Creation
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Materials Covered-cont
Week 412 September (Celanese in Class
Monday) Chapt 456 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 45 Aspen
Tutorials and Problems Solved in Class (Reserve
the ICC) - Week 6 - 26 September (Away Wednesday
and Friday) Chapt 56 ProMax Tutorials and
Problems Solved in Class (Reserve the ICC) -
Week 73 October Chapter 22-22 (p543-558) 23
Profitability Analyses - Annual
Costs Earnings Profitability Analysis Week 8-
11 October FALL BREAK
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What have we really covered?

• Product Design (Ethics) Chapt. 1,23
• 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

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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

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Chemical Product Design Pyramid
Figure of Merit
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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.

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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

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Process Creation

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

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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

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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)

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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

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Format for Exam

• Exam in 2 parts
• Wednesday, 20 October 2009
• In class written exam
• Open book, open notes
• Last Years Exam
• Friday, 22 October 2009
• In class, open book, open notes
• 1- Aspen Problem
• 1- ProMax Problem
• Competency Test