Higher Institute of Engineering and Technology, Menoufia

Chemical Engineering Department

Chemical Plant Design & Management (CHE452)
Lecture (2)

Lecture (2) Process design development

Process design development definition :

Process design development refers to:

➢ the structured approach to creating, planning, and optimizing processes within an

organization or system.
➢ This involves defining steps and operations necessary to convert raw materials into final
products or services, ensuring efficiency, quality, and cost-effectiveness.

In essence, process design development helps in:

➢ Structuring operations in a logical sequence.

➢ Ensuring that resources (materials, labor, and energy) are utilized effectively.
➢ Reducing costs while maintaining product quality and meeting production targets.
➢ Achieving a reliable and sustainable process suitable for long-term operations.

The process typically follows several phases:

1. Conceptual Design:

Conceptual design is the initial phase of process design development where the basic framework
of a process or system is defined. It involves outlining the main goals, requirements, and feasibility
of the project. steps include:

1. Problem Identification:

Understanding the core issue or need that the process aims to address.

2. Feasibility Study:

Assessing whether the process is technically, economically, and operationally viable.

3. Preliminary Process Flow:

Creating a basic process flow diagram (PFD) that shows the sequence of operations, inputs, and
outputs.

4. Initial Cost Estimation:

1
Higher Institute of Engineering and Technology, Menoufia
Chemical Engineering Department
Chemical Plant Design & Management (CHE452)
Lecture (2)

Providing rough cost estimates for materials, equipment, and operations.

The goal of conceptual design is to establish a clear vision and foundation before moving to
more detailed stages of development.

2. Preliminary Design:

Preliminary design is the stage where the basic concept is further developed into a more detailed
and actionable plan. It involves refining the process to ensure it will function as intended. activities
include:

1. Material and Energy Balances:

Quantifying the inputs (e.g., raw materials, energy) and outputs (e.g., products, waste).

2. Process Simulation:

Using software to model the process and predict its performance under different conditions.

3. Equipment Selection:

Identifying the machinery, reactors, or systems required for the process based on design
specifications.

4. Cost Estimation:

Developing a more detailed cost analysis for the equipment, materials, and operations.

The goal is to ensure the process is feasible, efficient, and ready for detailed design, where
technical specifications will be finalized.

3. Detailed Design:

Detailed design is the phase where the process plan is fully developed into technical specifications
that guide the construction and implementation. It focuses on creating detailed documentation and
refining all aspects of the process. steps include:

1. Piping and Instrumentation Diagrams (P&IDs):

Creating detailed diagrams that map out piping, equipment, control systems, and instrumentation
for the process.

2. Equipment Specifications:
2
Higher Institute of Engineering and Technology, Menoufia
Chemical Engineering Department
Chemical Plant Design & Management (CHE452)
Lecture (2)

Defining the exact technical requirements for all equipment and materials, such as sizes, materials,
and operating parameters.

3. Optimization:

Fine-tuning the process for efficiency, safety, and cost-effectiveness, considering aspects like
energy usage and environmental impact.

4. Safety and Compliance:

Ensuring the process meets all safety, regulatory, and environmental standards.

This phase provides the complete blueprint for constructing and operating the process, enabling a
smooth transition to procurement and implementation.

Important factors to be considered before entering in Detailed estimate design:

Before entering the detailed estimate design phase, it is crucial to consider several key factors to
ensure that the project is well-planned and that the detailed design can be executed smoothly.
These factors include:

1. Project Scope and Objectives:

➢ Clear Definition: Ensure the project’s goals, deliverables, and boundaries are well-defined
to avoid scope creep during the detailed design.
➢ Alignment with Stakeholders: Confirm that all stakeholders (clients, engineers,
contractors) agree on the scope, objectives, and expectations.

2. Preliminary Design Validation:

➢ Feasibility Confirmation: Review the preliminary design and simulations to confirm that
the process is technically viable and optimized for performance.
➢ Cost Estimates: Ensure that preliminary cost estimates are within acceptable limits and do
not exceed budget constraints.

3. Budget and Funding:

➢ Detailed Cost Analysis: Have a clear understanding of the expected costs for equipment,
labor, materials, and other resources.
➢ Contingency Planning: Allocate contingency funds for unexpected issues during the
detailed design and implementation phases.

4. Material and Equipment Selection:

3
Higher Institute of Engineering and Technology, Menoufia
Chemical Engineering Department
Chemical Plant Design & Management (CHE452)
Lecture (2)

➢ Availability: Confirm that the necessary materials and equipment are readily available or
have known lead times.
➢ Quality and Standards: Ensure materials and equipment meet required standards (e.g.,
ASME, ASTM) and will deliver reliable performance.

5. Site Conditions:

➢ Environmental Considerations: Assess the environmental impact, site access, terrain,

and climate factors that may affect design choices.
➢ Infrastructure Readiness: Ensure that utilities like power, water, and transportation
infrastructure are available and suitable for the project.

6. Safety and Regulatory Compliance:

➢ Legal Requirements: Understand and integrate all relevant regulations, industry

standards, and safety codes.
➢ Risk Assessment: Perform a hazard and operability study (HAZOP) or other safety
evaluations to identify potential risks in the process.

7. Technology and Innovation:

➢ Process Optimization: Evaluate whether incorporating newer technologies or more

efficient methods is feasible and beneficial.
➢ Automation and Controls: Ensure that automation, control systems, and instrumentation
are adequately considered.

8. Project Schedule:

➢ Time Constraints: Establish a realistic timeline for detailed design, including

procurement, construction, and testing phases.
➢ Milestones: Define key milestones and deadlines to ensure project tracking and timely
completion.

9. Interdisciplinary Coordination:

➢ Team Involvement: Coordinate with mechanical, electrical, civil, and process engineers
to ensure all disciplines are aligned.
➢ Documentation: Ensure proper communication and documentation are in place for
seamless integration between different teams.

By addressing these factors, we can mitigate risks, ensure the detailed design is feasible, and set
the project up for successful execution.

4
Higher Institute of Engineering and Technology, Menoufia
Chemical Engineering Department
Chemical Plant Design & Management (CHE452)
Lecture (2)

Important factors to be considered before entering in Detailed estimate design for chemical
processes :

1. Manufacturing process
2. Material and energy balances
3. Temperature and pressure ranges
4. Raw material and product specification
5. Yield, reaction rate and time cycle
6. Material of construction
7. Utilities(Steam ,water and fuel)
8. Plant site(Plant location)

4. Implementation:

1. Procurement:

This step involves purchasing materials, equipment, and services needed to build the process.
Vendors are selected based on specifications, quality, cost, and delivery timelines. Efficient
procurement ensures that everything required for construction and assembly is available on time
to avoid delays.

2. Construction and Assembly:

During this phase, the process components, such as equipment, piping, and control systems, are
built and assembled according to the detailed design specifications. This includes setting up the
infrastructure, installing equipment, and ensuring that the plant or system is physically ready for
operation.

3. Testing and Commissioning:

After construction, the process is tested to check if it functions as intended. This involves running
the system under operational conditions, calibrating equipment, and optimizing settings for
production. Any issues are identified and corrected to ensure that the process is fully ready for
production and meets performance standards.

5
Higher Institute of Engineering and Technology, Menoufia
Chemical Engineering Department
Chemical Plant Design & Management (CHE452)
Lecture (2)

5. Operation and Maintenance:

1. Process Monitoring:

➢ Continuous Monitoring:

In the operation phase of plant design, continuous monitoring involves using various sensors and
control systems to track key process parameters (such as temperature, pressure, flow rates, and
chemical concentrations) in real-time. This helps ensure that the plant operates within desired
specifications and performance targets.

➢ Data Collection and Analysis:

Data from monitoring systems is collected and analyzed to identify trends, detect anomalies, and
assess overall system performance. This information can help operators make informed decisions
about adjustments needed to maintain optimal conditions.

➢ Alerts and Alarms:

Monitoring systems are equipped with alert mechanisms to notify operators of any deviations from
set parameters, enabling prompt corrective actions to prevent potential equipment failures or
product quality issues.

➢ Optimization:

Continuous monitoring allows for the fine-tuning of processes to improve efficiency, reduce
energy consumption, and enhance product quality.

2. Maintenance Plans:

➢ Scheduled Maintenance:

A well-defined maintenance plan outlines schedules for routine inspections, servicing, and
preventive maintenance activities aimed at minimizing equipment downtime and extending its
operational lifespan. This includes checks for wear and tear, lubrication, and replacement of parts
as necessary.

➢ Protocols and Procedures:

The maintenance plan includes detailed protocols for each type of maintenance activity, ensuring
that maintenance personnel know the steps to follow, tools required, and safety precautions to take.

➢ Predictive Maintenance:

6
Higher Institute of Engineering and Technology, Menoufia
Chemical Engineering Department
Chemical Plant Design & Management (CHE452)
Lecture (2)

In addition to scheduled maintenance, predictive maintenance techniques may be employed, using

data from monitoring systems to anticipate equipment failures before they occur. This approach
helps in planning maintenance activities during non-productive hours to minimize disruptions.

➢ Documentation:

Keeping accurate records of all maintenance activities, including dates, findings, and actions taken,
allows for better tracking of equipment health and aids in making future maintenance decisions.

➢ Training:

Regular training for maintenance personnel ensures they are up to date with the latest techniques
and safety practices, improving the effectiveness of the maintenance plan.

effective process monitoring and maintenance plans are crucial components of the operation and
maintenance phase in plant design. They ensure that the plant operates efficiently and safely while
minimizing downtime and maintaining product quality. By implementing robust monitoring and
maintenance strategies, facilities can enhance performance and extend the lifespan of their
equipment.

feasibility survey:
➢ A feasibility survey in process design development is a critical step that assesses the
viability of a proposed project or process before significant resources are committed.
➢ This survey evaluates various aspects of the project to determine whether it is technically,
economically, and operationally feasible.
There are the components and steps involved in conducting a feasibility survey:

➢ Objective and Scope Definition:

✓ Define project objectives and outline the scope of the feasibility study.

Types of feasibility:

➢ Technical Feasibility

✓ Assess the viability of the proposed process with existing technology and
resources.
✓ Review equipment requirements and analyze process flow.

➢ Economic Feasibility

✓ Evaluate financial viability, including capital and operational costs.

7
Higher Institute of Engineering and Technology, Menoufia
Chemical Engineering Department
Chemical Plant Design & Management (CHE452)
Lecture (2)

✓ Perform cost-benefit analysis and financial modeling for ROI estimation.

➢ Market Feasibility

✓ Analyze market conditions and demand for the product.

✓ Conduct market research to identify target markets and competitors.

➢ Regulatory and Environmental Feasibility

✓ Assess compliance with laws and regulations.

✓ Evaluate environmental impacts and the need for permits.

➢ Operational Feasibility

✓ Evaluate the organization’s ability to implement and support the process.

✓ Assess workforce requirements and training needs.

➢ Risk Assessment

✓ Identify potential risks and uncertainties associated with the project.

✓ Develop mitigation strategies for identified risks.

➢ Report and Recommendations

✓ Compile findings into a comprehensive report.

✓ Provide recommendations on whether to proceed, adjust, or abandon the project.
✓ Include an action plan for next steps if the project is deemed feasible.

Example of steps of feasibility Survey steps for chemical process :

Following is a list of items that should be considered in making a feasibility survey

1. Raw materials ( quantity, quality, cost)
2. Thermodynamics and kinetics of chemical reactions involved ( yields, rates, optimum
conditions)
3. Facilities and equipment available at present
4. Facilities and equipment which must be purchased
5. Estimation of production costs and total investment
6. Profits (probable and optimum, per pound of product and per year, return on investment)
7. Materials of construction
8. Safety considerations

8
Higher Institute of Engineering and Technology, Menoufia
Chemical Engineering Department
Chemical Plant Design & Management (CHE452)
Lecture (2)

9. Markets (present and future supply and demand, present uses, new uses, present buying
habits, price range for products and by products, character, location, and number of
possible customers).
10. Competition (overall production statistics, comparison of various manufacturing processes,
product specifications of competitors)
11. Properties of products (chemical and physical properties, specifications, impurities, effects
of storage)
12. Sales and sales service (method of selling and distributing, advertising required, technical
services required)
13. Shipping restrictions and containers
14. Plant location
15. Patent situation and legal restrictions
Flow diagrams:
➢ Flow diagrams are essential tools in process design that visually represent the sequence of
operations, interactions, and data flow within a system.
➢ Flow diagrams help in understanding complex processes, identifying inefficiencies, and
communicating ideas clearly among stakeholders.
The importance of Flow diagrams:
➢ Shows the arrangement of the equipment selected to carry out the process
➢ Shows the streams concentrations, flow rates compositions
➢ Shows the operating conditions
➢ During plant start up and subsequent operation, the flow sheet from a basis for comparison
of operating performance with design It's also used by operating personnel for the
preparation of operating manual and operator training
These diagrams may be divided into three general types:
1. A qualitative flow diagram indicates the flow of materials, unit operations involved,
equipment necessary, and special information on operating temperatures and pressures.

9
Higher Institute of Engineering and Technology, Menoufia
Chemical Engineering Department
Chemical Plant Design & Management (CHE452)
Lecture (2)

Figure : Qualitative process flow diagram for the manufacture of nitric acid by the
ammonia-oxidation process.
2. A quantitative flow diagram shows the quantities of materials required for the process
operation.

10
Higher Institute of Engineering and Technology, Menoufia
Chemical Engineering Department
Chemical Plant Design & Management (CHE452)
Lecture (2)

Figure: Quantitative process flow diagram for the manufacture of nitric acid by the
ammonia-oxidation process.

3. combined detail flow sheet diagram is a combination of the two types of quantitative and
qualitative

11
Higher Institute of Engineering and Technology, Menoufia
Chemical Engineering Department
Chemical Plant Design & Management (CHE452)
Lecture (2)

Figure : Combined process flow diagram for the manufacture of nitric acid by the
ammonia-oxidation process.
the main types of flow diagrams used in process design:

1. Process Flow Diagram (PFD):

✓ High-level overview of the process.

✓ Shows major equipment and flow paths.

2. Piping and Instrumentation Diagram (P&ID):

✓ Detailed view of piping, instruments, and control systems.

✓ Essential for construction and maintenance.

3. Block Flow Diagram (BFD):

✓ Simplified representation of major process blocks and interactions.

12
Higher Institute of Engineering and Technology, Menoufia
Chemical Engineering Department
Chemical Plant Design & Management (CHE452)
Lecture (2)

✓ Useful for initial design discussions.

4. Data Flow Diagram (DFD):

✓ Illustrates how data flows within a system.

✓ Shows processes, data sources, and storage.

5. Workflow Diagram:

✓ Maps the sequence of tasks and decisions required to complete a process.

✓ Helps identify bottlenecks and redundant tasks.

6. State Diagram:

✓ Represents states of a system and transitions based on events.

✓ Useful in control systems where state management is critical.

7. Utility Flowsheet (Process Engineering Utility Flow Diagram ):

✓ Used to summarize and detail the interrelationship of utilities such as
air and water.
✓ It is a document containing information on The main distribution or
arrangement of each individual utility system.
8. Process Safeguarding Flow Diagram (PSFD):
✓ Used for Types and levels of protection offered by the devices installed and
their interrelation to demonstrate the plant’s safety

Benefits of Flow diagrams:

➢ Visual Representation: Offers a clear view of processes.

➢ Communication Tool: Facilitates discussion among engineers, management, and operators.
➢ Identification of Improvements: Helps in spotting inefficiencies and areas for optimization.
➢ Documentation: Serves as a reference for training, maintenance, and operations.

Flow diagrams are essential in process design for understanding operations, enhancing
communication, and optimizing performance.

13
Higher Institute of Engineering and Technology, Menoufia
Chemical Engineering Department
Chemical Plant Design & Management (CHE452)
Lecture (2)

Questions on lecture (2)

Answer the following questions:
1. Defined the following:

A. Process design development

B. Conceptual design

2. Write short notes about the following :

the main Types of feasibility survey.
the benefits of Flow diagrams.
3. Write briefly on Operation and Maintenance activities
4. What are the Important factors to be considered before entering in Detailed estimate design?

Best wishes
Asso.Prof :Wafaa Ahmed

14