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Review for Design I Exam. CHEN 4253 Terry A. Ring. 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

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review for design i exam

Review for Design I Exam

CHEN 4253

Terry A. Ring

materials covered
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 3–5 September (Holiday Monday)

Chapt 1 (p25-31) Chapter 4 Process Creation-

Ethics in Chemical Engineering

Process Safety

Process Design Overview

Process Creation

materials covered con t
Materials Covered-con’t

Week 4–12 September (Celanese in Class Monday)

Chapt 4&5&6 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 4&5 Aspen Tutorials and Problems Solved in Class (Reserve the ICC) -

Week 6 - 26 September (Away Wednesday and Friday)

Chapt 5&6 ProMax Tutorials and Problems Solved in Class (Reserve the ICC) -

Week 7–3 October

Chapter 22-22 (p543-558) &23 Profitability Analyses -

Annual Costs

Earnings

Profitability Analysis

Week 8- 11 October FALL BREAK

what have we really covered
What have we really covered?
  • Product Design (Ethics) Chapt. 1,2&3
  • 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
chapters 1 2 3 4
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
physical property estimation
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.
chapters 5 and 6
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
process creation
Process Creation
  • Process Economics – Gross Profitability Analysis
  • Focus on Reactor
    • Equilibrium
    • Kinetics or Conversion
  • Focus on Separation System
  • Heuristics in Process Design
chapter 22 costing
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
investment chapter 23 costing
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)
process economics
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
format for exam
Format for Exam
  • Exam in 2 parts
    • Wednesday, 20 October 2009
      • In class written exam
      • Open book, open notes
      • Last Year’s Exam
    • Friday, 22 October 2009
      • In class, open book, open notes
        • 1- Aspen Problem
        • 1- ProMax Problem
          • Competency Test