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6 Process Design Development PDF

The document discusses the process of process design development. It explains that chemical engineers play a central role in each step of developing a new plant or process. The key stages are inception of the initial idea, preliminary evaluation, development of design data, final economic evaluation, detailed engineering design, procurement, construction, start-up, and production. Successful process design requires skills in research, market analysis, equipment design, cost estimation, computer programming, and plant surveys. The development proceeds logically through increasing levels of time, effort and expenditure, and it is important to carefully analyze the potential at each stage before proceeding further.

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tanveer arshad
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279 views

6 Process Design Development PDF

The document discusses the process of process design development. It explains that chemical engineers play a central role in each step of developing a new plant or process. The key stages are inception of the initial idea, preliminary evaluation, development of design data, final economic evaluation, detailed engineering design, procurement, construction, start-up, and production. Successful process design requires skills in research, market analysis, equipment design, cost estimation, computer programming, and plant surveys. The development proceeds logically through increasing levels of time, effort and expenditure, and it is important to carefully analyze the potential at each stage before proceeding further.

Uploaded by

tanveer arshad
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Process Design

Development
Dr. Muddasar Habib
Deptt. of Chem. Engg.
UET Peshawar, Pakistan.
Introduction to process design
development
• A successful chem. Engr. needs
more than knowledge and
understanding of fundamental
sciences, and related engineering
subjects such as thermodynamics,
reaction engineering, and
computer technology.
Contt…….
• The design of new chem. Plants, and the
expansion or revision of existing ones
requires the use of engineering principles
and theories combined with a practical
realization of the limits imposed by
industrial conditions.
• The development of a new plant or
process from concept evaluation to a
profitable reality is often an enormously
complex problem.
Plant Design Project Stages
• Inception
• Preliminary evaluation of economics and market.
• Development of data necessary for final design.
• Final economic evaluation
• Detailed engineering design
• Procurement
• Erection
• Start-up and trial runs
• Production.
Required Skills
• Research
• Market analysis
• Equipment design
• Cost estimation
• Computer programing
• Plant location survey
• You (chemical engineer) are needed in
each step in a central creative role
and/or as a key advisor.
Chemical Engineering Plant
Design
•PLANT DESIGN: include
all engineering aspects
involved in the
development of either a
new, modified, or
expanded industrial
plants.
Process Design Development
• Inception: the basic idea: This idea may originate
in the sales department, as a result of a customer
request, or to meet a competing product. It may
occur spontaneously to someone who is acquainted
with the aims and needs of a particular company, or
it may be the result of an orderly research program
or an offshoot of such a program. The operating
division of the company may develop a new or
modified chemical, generally as an intermediate in
the final product. The engineering department of the
company may originate a new process or modify an
existing process to create new products.
Contt…..
• if the initial analysis indicates that the idea may have possibilities of
developing into a worthwhile project,
• A preliminary research: or investigation program is
initiated. Here, a general survey of the possibilities for a successful
process is made considering the physical and chemical operations
involved as well as the economic aspects. Next comes the
process-research phase including preliminary
market surveys, laboratory-scale experiments, and production of
research samples of the final product. When the potentialities of
the process are fairly well established, the project is ready for the
development phase. At this point, a pilot plant or a
commercial development plant may be constructed. A pilot plant is
a small-scale replica of the full-scale final plant, while a commercial-
development plant is usually made from odd pieces of equipment
which are already available and is not meant to duplicate the exact
setup to be used in the full-scale plant.
Contt…
• Design data and other process information are
obtained during the development stage. This
information is used as the basis for carrying out the additional
phases of the design project. A complete market analysis is made,
and samples of the final product are sent to prospective
whether
customers
to determine if the product is satisfactory and if there is a
whether

reasonable sales potential. Capital-cost estimates for the proposed


plant are made. Probable returns on the required investment are
determined, and a complete cost-and-profit analysis of the process
is developed. Before the final process design starts, company
management normally becomes involved to decide if significant
capital funds will be committed to the project. It is at this point
that the engineers’ preliminary design work along with the oral
and written reports which are presented become particularly
important because they will provide the primary basis on which
management will decide if further funds should be provided for the
project.
Contt…..
• When management has made a firm decision
to proceed with provision of significant capital
funds for a project, the engineering then
involved in further work on the project is
known as capitalized engineering while that
which has gone on before while the
consideration of the project was in the
development stage is often referred to as
expensed engineering. This distinction is used
for tax purposes to allow capitalized
engineering costs to be amortized over a
period of several years.
Contt…….
• If the economic picture is still satisfactory, the
final process-design phase is ready to begin. All
the design details are worked out in this phase
including controls, services; piping layouts, firm
price quotations, specifications and designs for
individual pieces of equipment, and all the other
design information necessary for the construction
of the final plant. A complete construction design
is then made with elevation drawings, plant-
layout arrangements, and other information
required for the actual construction of the plant.
Contt…..
• The final stage consists of
procurement of the equipment,
construction of the plant, start-up of
the plant, overall improvements in
the operation, and development of
standard operating procedures to
give the best possible results.
In Conclusion
• The development of a design project proceeds
in a logical, organized sequence requiring
more and more time, effort, and expenditure
as one phase leads into the next.
• It is extremely important, therefore, to stop
and analyse the situation carefully before
proceeding with each subsequent phase. Many
projects are discarded as soon as the
preliminary investigation or research on the
original idea is completed.
• The engineer working on the project must maintain
a realistic and practical attitude in advancing
through the various stages of a design project and
not be swayed by personal interests and desires
when deciding if further work on a particular project
is justifiable.
• Remember, if the engineer’s work is continued on
through the various phases of a design project, it will
eventually end up in a proposal that money be
invested in the process. If no tangible return can be
realized from the investment, the proposal will be
turned down.
• Therefore, the engineer should have the ability to
eliminate unprofitable ventures before the design
project approaches a final-proposal stage.
Thank You

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