This document provides an overview of chemical engineering plant design. It discusses key aspects of the design process including general considerations, optimization, cost estimation, and factors affecting profitability. The document also outlines the stages of a typical plant design project and describes standards and guidelines for plant layout and piping design provided by organizations like ASME, CCPS, OSHA and NFPA. Skills needed for successful plant design include research, cost analysis, computer programming, and surveying.

1. Chemical Engineering Plant Design
1
Introduction to Design
Engr. Dr. Farhan Javed
Lecturer
Chemical Engineering Department
UET FSD Campus

2. What do you understand about

3. Course Learning Outcomes (CLOs)
• CLOs are the skills learnt by the students at
the end of each course in the program.
• The three (3) learning domains characterize by
Bloom’s Taxonomy and their respective levels
of learning are
1. Cognitive (Knowledge) (6 levels)
2. Psychomotor (Skill) (7 levels)
3. Affective (Attitude) (5 levels)

5. Program learning outcomes (Total=12)
1) Engineering Knowledge
2) Problem Analysis
3) Design/Development of Solutions
4) Investigation
5) Modern Tool Usage
6) The Engineer and Society
7) Environment and Sustainability
8) Ethics
9) Individual and Team Work
10) Communication
11) Project Management
12) Lifelong Learning

6. MEASURABLE STUDENT LEARNING OUTCOMES
CLOs Description PLOs Domain
Domain
Level
CLO-1
Create, design and evaluate alternate processes
and equipment for a chemical process and
assess various societal, environmental, and
safety issues associated with such design
PLO-4 Cognitive 6. Create
CLO-2
Apply knowledge acquired in core Chemical
Engineering courses (e.g., Stoichiometry,
Reaction Engineering, Thermodynamics, and
Unit Operations) for selection and design of
materials handling, heat transfer, and
separation process equipment.
PLO-3 Cognitive 3. Apply
CLO-3
Understand the concept of heat integration for
minimization of overall energy footprint of a
chemical process
PLO-5 Cognitive 3. Apply

7. Course description
(1) Introduction to process design and development
(2) General design considerations
(3) Optimal design
(4) Materials of fabrication and their selection
(5) Material transfer handling and equipment design
(6) Heat transfer equipment design
(7) Mass transfer equipment design
(8) Application of computer aided design software

8. WEEK-WISE LECTURE PLAN
Week Topics CLO’s
Week 1
Introduction: General overall design considerations: Process design and flowsheet development, optimum design; practical
consideration and engineering ethics in design
CLO-1
Week 2
General design considerations: Health and safety hazards, importance and objectives of safety, safety measures in equipment design:
Fire and explosion hazards and prevention, Chemical, toxic, electrical hazards, control, precautions and prevention, personnel safety,
loss prevention and safety audit.
CLO-1
Week 3
Environmental protection and development of pollution control systems. Thermal pollution control, toxicological studies, industrial
hygiene, radiation hazards.
CLO-1
Week 4 Plant site location and layout of chemical plant, piping layout, plant operation and control, plant considerations and exercise problems. CLO-1
Week 5
Process design development: Process selection/creation, synthesis and design: equipment design and specifications. Preliminary process
design: screening of process alternatives; economic decision making.
CLO-1
Week 6
Flow sheet synthesis and development: Process information, input-output structure; function and operation diagrams; analysis and
development of process flow sheet.
CLO-2
Week 7
Optimum design and design strategy: defining the optimum problems, programming optimization problems; optimization solution
methodologies; optimization applications and cost analysis.
CLO-2
Week 8
Pinch technology an overview, key steps of pinch technology: Targeting of heat exchanger network: Designing of HEN: Pinch design
methods, Heuristic rules, stream splitting, design of maximum energy recovery (MER)
CLO-3
MID TERM EXAMINATION
Week 10
Materials selection and fabrication: Corrosion and factors contributing to corrosion; corrosion prevention; material properties;
economics involved in materials selection.
CLO-2
Week 11
Materials handling equipment design and cost: Basic concept of fluid transport, frictional losses, selection of piping material, design of
piping system.
CLO-2
Week 12
Computer aided design, cost estimation and profitability analysis of investments, Transport of fluids: selection, design and cost analysis
for pumping, compression, expansion, agitation and mixing of fluids, flow measurement and storage of fluids.
CLO-4
Week 13 Heat transfer equipment design and cost: Basic theory of heat transfer in exchanger, heat exchanger selection criterion. CLO-2
Week 14 General methods for the design of heat exchangers: Design of key heat exchangers CLO-1
Week 15 Separation equipment design and costs: Introduction, selection, general design and cost of equipment for separation process. CLO-1
Week 16
Design and cost for multi-component distillation: Absorption, adsorption membrane separation. Selection and design of filtration
equipment.
CLO-1
FINAL TERM EXAMINATION

9. 1- “Plant Design and Economics for Chemical Engineers” by M. S. Peters, K. D.
Timmerhaus, and R. E. West
2- Coulson and Richardson’s Chemical Engineering — Volume 6: Chemical
Engineering
Text Books:

10. 1- An Applied Guide to process and Plant Design by Sean Moran
2- Process Equipment and Plant Design by Subhabrata Ray
3- Ullmann’s Chemical Engineering and Plant Design
Reference Books:

11. Reference Books:
1. “Ludwig’s Applied Process Design for Chemical and Petrochemical Plants” by A. K. Coker
2. “Chemical Engineering Desgin-Volume 6” by R. Sinnott & Cavin Towler
3. “Chemical Process Equipment: Selection and Design” by J. R. Couper, W. R. Penney, J. R.
Fair, and S. M. Walas
4. “Equipment Design Handbook: For Refineries and Chemical Engineers” by F. L. Evans
5. “Chemical Process: Design and Integration” by R. Smith
6. “The Art of Chemical Process Design” by G. L. Wells, and L. M. Rose

12. The general term plant design includes all
engineering aspects involved in the
development of either a new, modified, or
expanded industrial plant. In this development,
the chemical engineer will be making economic
evaluations of new processes, designing
individual pieces of equipment, or developing a
plant layout. Because of these many design
duties, the chemical engineer is many times
referred to as a design engineer.
Chemical Engineering Plant Design

13. On the other hand, a chemical engineer
specializing in the economic aspects of the
design is often referred to as a cost engineer.
The term process engineering is used in
connection with economic evaluation and
general economic analyses of industrial
processes, while process design refers to the
actual design of the equipment and facilities
necessary for carrying out the process.
Similarly, the meaning of plant design is limited
by some engineers to items related directly to
the complete plant, such as plant layout,
general service facilities, and plant location.
Chemical Engineering Plant Design Cont’d

14. Design Constraints

15. The Design process:

17. Possible Designs and selection:

19. Continuous vs Batch processes:

21. Batch process:

22. A plant-design project moves to completion through a
series of stages
1. Inception
2. Preliminary evaluation of economics and market
3. Development of data necessary for final design
4. Final economic evaluation
5. Detailed engineering design
6. Procurement
7. Erection
8. Startup and trial runs
9. Production
22

23. The chemical engineer is many times referred to
here as a design engineer.
23

24. PROCESS DESIGN DEVELOPMENT
• Inception of the basic idea.
• Originate new process or
modify an existing process.
• The process-research phase.
• Pilot plant or a commercial
development plant.
• Complete market analysis.
• Complete cost-and-profit
analysis.
24

25. GENERAL OVERALL DESIGN
CONSIDERATIONS
• Plant location
• Plant layout
• Materials of construction
• Structural design
• Utilities
• Buildings
• Storage
25

26. Cont’d
• Materials handling
• Safety
• Waste disposal
• Federal, state, and local laws or codes
26

27. COST ESTIMATION
• Fixed costs
• Raw materials costs
• Labor charges
• Maintenance
• Power
• Utilities
• Costs for plant and administrative overhead
• Distribution of the final products
• Other miscellaneous items
27

28. Special Techniques for Cost
Estimation
1. Order of magnitude estimate:(ratio estimate) accuracy typically
+30%, usually based on the costs of similar processes and requiring no
design information.
2. Preliminary estimates (budget authorization/scope estimate):
accuracy typically +20%, They are based on limited cost data and
design detail.
3. Study estimates (factored estimate): based on knowledge of major
items of equipment, accuracy of estimate upto +30%
4. Detailed estimates (contractor’s estimate): accuracy +5%, Complete
specifications, drawings, and site surveys for the plant construction are
required
5. Definitive estimates (project control estimate): accuracy +10%,
Based on complete data but before completion of drawings &
specifications.
28

29. FACTORS AFFECTING PROFITABILITY
OF INVESTMENTS
• Interest
• Insurance
• Taxes
• Depreciation
• Manufacturing costs
• Time value of money
• Rate of return
29

30. OPTIMUM DESIGN
There are several alternative methods which
can be used for any given process or operation,
optimization is to choose the best process and to
incorporate into designing the equipment and
methods which will give the best results.
If there are two or more methods for obtaining
exactly equivalent final results, the preferred
method would be the one involving the least total
cost.
30

31. 2011-ch-303 31

32. Optimum Operation Design
Many processes require definite conditions
of temperature, pressure, contact time, or other
variables if the best results are to be obtained. It
is often possible to make a partial separation of
these optimum conditions from direct economic
considerations. In cases of this type, the best
design is designated as the optimum operation
design.
32

33. 2011-ch-303 33

34. THE DESIGN APPROACH
• Profitable plant design
• Generally overdesign and safety factors
• Optimization of the design by using high-
speed computers
• Make necessary assumptions
• Economic conditions and limitations
34

35. Project structure and organization:

38. Plant documentation:

40. Codes and Standards:

46. Standards Organizations:
• BSI
• ANSI
• API
• ASTM
• ASME
• NFPA
• TEMA
• ISA
• ISO

48. Skills needed for Plant design project
• Research
• Market analysis
• Design of individual pieces of equipment
• Cost estimation
• Computer programming
• Plant-location surveys

50. Organizations involved in providing standards
and guidelines for plant layout and piping design
• American Society for Mechanical Engineers (ASME): Publishes and updates codes
for piping design. The code relevant to the design of piping systems is ASME B31.3
– 2016 Process Piping. (www.asme.org)
• Center for Chemical Process Safety (CCPS): Publishes documents and guidelines
related to process safety. The focus is on preventing or mitigating catastrophic
releases of chemicals, hydrocarbons, and other hazardous materials. CCPS has
published guidelines for “Facility Siting and Layout”. (www.aiche.org/ccps)
• Construction Industry Institute (CII): Provides guidelines for cost effective and safe
construction methods and has several publications on constructability.
(www.construction-institute.org)
• Society of Piping Engineers and Designers (SPED): Promotes excellence and quality
in the practice of piping engineering and design. SPED emphasizes education and
training and has certification programs for piping designers. (www.spedweb.org)
• Occupational Safety and Health Administration (OSHA): Provides regulations and
safety standards for the operation of process plants. (www.osha.gov)
• National Fire Protection Association (NFPA): Provides fire protection standards for
process plants and for gas storage and handling. (www.nfpa.org)