155:427 Chemical & Biochemical Eng. Design & Economics I Fall 2011

Transcription

1 155:427 Chemical & Biochemical Eng. Design & Economics I Fall 2011 Lectures: Mon, Wed 1:40 3:00 pm, SEC 207 Instructor: Dr. A. Constantinides (Dr. C) Engineering C-203A Tel: (732) , acconsta@rci.rutgers.edu Teaching Assistant: John Mattick Biomedical Engineering 019 Tel: (240) , jeanmattique@gmail.com Course Description: In this course, product and process design and economics are covered. Specifically, starting from identifications of marketable products, we proceed to develop ideas of making the products, select workable methods and then design the best and most economical processes for both upstream and down stream processing to produce the final products. Chemical engineering fundamentals are integrated in the design and operations of chemical and biochemical plants. In this course, we give a thorough analysis of the steps involved in the design and economic evaluation of chemical and biochemical processes. We elaborate on the economic considerations involved in the design, construction, and operation of chemical plants, such as investment costs, production costs, depreciation, and profitability analysis. The class is divided into design teams of 3-4 students each, and are assigned a major design project. They first conduct a literature survey related to their project and are required to make a Powerpoint presentation of their findings. The detailed design and economic evaluation of their project forms their major task during the Spring semester design course (155:428 Chemical & Biochemical Engineering Design & Economics II). We conclude the course with a discussion of safety considerations involved in the design of chemical and biochemical processes. We present several cases of chemical plant accidents from the extensive collection published by the US Chemical Safety Board (CSB) and the AIChE Safety and Chemical Engineering Education (SACHE). Course Objectives: This is the capstone course, which utilizes the fundamentals of chemical engineering (material balances, energy balances, transport phenomena, thermodynamics, kinetics, separations, unit operations, control, and safety) in the design and operation of chemical plants. Introduces the concepts and methods of plant design and economic evaluation: planning, cost estimation, fixed capital investments, working capital, production costs, depreciation, rate of return, profitability analysis, discounted cash flow analysis. Raises awareness of the students to the concepts of supply and demand of raw materials, commodity, and specialty chemicals. Introduces the students to the available computational tools for process flow design and economic evaluation. Stresses the importance of professional ethics, honesty, and integrity.

2 Textbooks (required): P. C. Wankat, Separation Process Engineering: Second Edition, Prentice Hall, New York, NY (2007). (Most students should already have this textbook from 155:324 Design of Separation Processes). [Referenced in the Course Outline as Wankat] M. S. Peters, K. D. Timmerhaus, and R. N. West, Plant Design and Economics for Chemical Engineers, 5th Edition, McGraw-Hill Book Company, New York (2003). [Referenced in the Course Outline as P,T,&W]. Textbooks (recommended): J. Wei, Product Engineering: Molecular Structure and Properties, Oxford University Press, Oxford, [Referenced in the Course Outline as Wei] J. D. Seader and E. J. Henley, Separation Process Principles, 2 nd ed., John Wiley & Sons, Inc., (2006). R. G. Harrison, P. Todd, S. R. Rudge, and D. P. Petrides, Bioseparations Science and Engineering, Oxford University Press, Oxford, Prerequisites: 155:303 Transport Phenomena I 155:304 Transport Phenomena II 155:324 Design of Separation Processes Assessment: Homework: 25%, Midterm: 25%, Final exam or design report: 45%, Attendance: 5% Homeworks will be collected on due dates and will be graded. Late homeworks will be penalized for lateness. Any homeworks that are not submitted will receive the grade of zero. Class participation and attendance are important. The professor will circulate the class roster to observe student attendance. It is the responsibility of the student to sign the roster. Students with more than 2 absences per semester will lose up to 5% points. Course Content: Week Subject Reading Assignment 1, 2 Introduction to plant design and economic evaluation Ch. 1 (P, T & W) General design considerations Ch. 2 (P, T & W) Engineering ethics Handout Handout Process design development Ch. 3 (P, T & W) 3,4 Essential flowsheet diagrams Ch. 4 (P, T, & W) Block flow diagrams (BFD) Handouts Handouts Process flow diagrams (PFD) Piping and instrumentation diagrams (P & ID) Equipment descriptions and standard notation Computer-aided design Ch. 5 (P, T, & W)

3 5, 6 Analysis of cost estimation Ch. 6 (P, T & W) Cash flow Capital investments Fixed capital and working capital Types of capital cost estimates Direct and indirect costs Cost indices; Cost scaling factors Ratio factors 7 Production Costs Ch. 6 (P, T & W) Raw materials; Utilities; Operation costs Overhead expenses; Fixed charges Administrative and marketing expenses 8 Interest and Investment Costs Ch. 7 (P,T & W) Simple, compound, continuous interest Present worth, future worth Taxes and Insurance Ch. 7 (P,T & W) Depreciation Methods Ch. 7 (P, T & W) Straight-line method, declining-balance method, Mod ified Accelerated Cost Recovery System (MACRS) 9 Profitability Analysis Ch. 8 (P, T & W) Rate of return on investment Discounted cash flow rate of return Net present worth Payout period 10 Midterm examination 11 Product design Chs 1 &2 (Wei) Product exploration & discovery Product development Guest lecturer: Prof. J. Wei, Princeton University 11 Assignment of design projects Assignment of literature surveys 12 Safety in Design Ch. 2 (P, T & W) Principles of chemical systems safety and health Handouts engineering management US Chemical Safety Board (CSB) Safety Videos AIChE Safety and Chemical Engineering Education (SACHE) Student presentations of design projects

4 ABET Outcomes and Assessment: Program outcomes achieved in this course (a) an ability to apply knowledge of mathematics, science and engineering (c) an ability to design a system, component, or process to meet desired needs (d) an ability to function in multi-disciplinary/multi-functional teams (this can be defined as a mix of biochemical and chemical engineers, or as a group of students working on a different roles of a project) (e) an ability to identify, formulate, and solve engineering problems (f) an understanding of professional and ethical responsibility (g) an ability to communicate effectively (h) the broad education necessary to understand the impact of engineering solutions in a global and societal context (i) a recognition of the need for, and an ability to engage in life-long learning (j) a knowledge of contemporary issues (k) an ability to use the techniques, skills, and modern engineering tools necessary for engineering practice The achievement of outcomes (a), (c), (d), (e), (f), (g),(h), (i), (j) and (k) will be assessed in this course as follows: Outcome (a): an ability to apply knowledge of mathematics, science and engineering Exam and homework problems are mathematical and analytical geared toward problem solving. Outcome (c): an ability to design a system, component, or process to meet desired needs Product and process design are both practiced in final written and oral reports. Outcome (d): an ability to function in multi-disciplinary teams Both chemical and biochemical options students are working together in product design projects. Outcome (e): an ability to identify, formulate, and solve engineering problems The principles of product design through identification of needs, generations of ideas and development of processes to make the products are assessed in the final report. Outcome (f): an understanding of professional and ethical responsibility Discussion on environmental impact and safety issues are also assessed in the final reports. Outcome (g): an ability to communicate effectively Clarity and simplicity of written and oral communication skills are evaluated. Outcome (h): the broad education necessary to understand the impact of engineering solutions in a global and societal context The discussion on globalization-effect on the product designed in the spirit of the world is flat (Thomas Freeman, 2004) in the reports are assessed.

5 Outcome (i): a recognition of the need for, and an ability to engage in life-long learning a knowledge of contemporary issues The ability to engage in life-long learning is very difficult to assess. Students are requested to write a paragraph on how would they be remembered after they are retired, of if they do not object to it, write their own obituary. Students are in the classes to learn how to learn on their own. Open ended questions are used along with group projects. Outcome (j): a knowledge of contemporary issues Contemporary issues such as solar energy, biotechnology, nanotechnology, fuel cells, bio-diesel, ethanol are suggested as final report topics. Reports are assessed on their knowledge on the issue. Outcome (k): an ability to use the techniques, skills and modern engineering tools necessary for engineering practice. Homework problems are used to assess students ability to use modern engineering tools, such as Matlab, Superpro computer software for design of batch processes for the production of specialty chemicals and biochemicals. Continuous process design is covered in the 428 course, the second cap-stone design course. TA uses recitation sessions to teach students these skills.