CE 1701/Course Handout/OM & SM/Summer Term 2018

MANIPAL UNIVERSITY – JAIPUR

Department of Chemical Engineering

CE 1701 PROCESS PLANT DESIGN

Course Coordinator: Dr. Subhajit Majumder Session: 2018/Summer Term

Instructors: Dr. Oayes Midda and Dr. Subhajit Majumder
Lectures & Tutorials: M-W-F, 11-12 Noon; 3-4 PM

Course Description
Process invention using heuristics and analysis (The Design process, Process creation and heuristics
for process synthesis, Role of process simulators like Aspen Plus in process creation), Strategic
designs in process synthesis and analysis, Detailed process synthesis using algorithmic methods with
emphasis on reactor networks, separation trains, batch processes, heat and mass integration, energy
integration analysis; pinch technology.

Scope & Objective

This course introduces the student to the strategy of process engineering and provides an insight into
various aspects of process design. This course mainly deals with the process synthesis part of process
design. It covers in detail the preliminary process synthesis, developing base case design and use of
heuristics for choosing the best from various process alternatives.

Grading
The following shall be the grading scheme for this course:

Un-announced Short-quizzes 10%

2 Mid – Semester Exams 40%
1 End – Semester Exam 30%
Home Assignments & Project 20%
------------
Total 100%

Examination
Mid-Sem I: Closed Book
Mid-Sem II: Open Book
End-Sem: Closed Book + Open Book

Absence from Class

It is strongly recommended that you do not miss any of my classes – if you miss one of my classes,
it will become difficult for you to catch up with me. PLEASE ATTEND ALL CLASSES.
I emphasize punctuality also – if I can be on time, so can you! Also, it is unfair to your fellow students
who are on time and disrupts the class causing distractions and disturbing the train of thought.
PLEASE BE ON TIME.

No make-up for missed short quizzes or exams will be allowed except in extenuating
circumstances, with prior permission of the instructor(s), and the decision of the instructor(s) in this
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regard shall be final.

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Tutorials
Total 8 short quizzes will be conducted during lecture hour. No late-comers will be allowed to take
the quiz, MAKE SURE YOU ARE ON TIME! No make-up for missed short quizzes will be allowed.
Problem discussion and solution shall also be a part of the tutorials.

Home Assignments & Project

Home assignment is an integral part of this course. Mainly design oriented problems will be assigned
along with the due date for handing it over. No late assignments/projects handed after the due
date shall be accepted under any circumstance. It is expected that the students shall work on the
assignments independently and not ‘copy’ the solutions from each other. Students are encouraged to
discuss problems with their instructor during chamber consultation hour. Students are advised to meet
the instructor in case of any difficulty related to assignments and course related matters. Total four
assignments will be given as a part of home assignments. One design oriented project will be
given to each student. Conceptual design oriented problem/case study will be given as
assignments and project. Students need to make use of Aspen Plus/ HYSYS.

All assignments are to be done in pen, only and are to be handed in on A4 size white paper in the
following format:

Notices
All notices concerning this course will be displayed on the Notice Board of Chemical Engineering
Department and will be mailed to students. Students are responsible for regularly checking their group
email ID.

Chamber Consultation Hour: Saturday, 11-11.30 AM.

Text Books
T1 James M. Douglas, “Conceptual Design of Chemical Processes”, McGraw Hill, New York,
International Edition (1988).
T2 Warren D. Seider, J. D. Seader, and Daniel R. Lewin, “Product & Process Design Principles:
Synthesis, Analysis, and Evaluation”, Wiley-India Edition, India, 2nd Edition (2004).

Reference Books:

R1 Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph A. Shaeiwitz, and Debangsu
Bhattacharyya, “Analysis, Synthesis, and Design of Chemical Processes”, International
Edition, Pearson Education International, New Jersey (2012).
R2 Robin Smith, “Chemical Process Design”, International Editions, McGraw Hill, Singapore
(2000).
R3 Dale F. Rudd, and Charles C. Watson, “Strategy of Process Engineering”, John Wiley & Sons,
New York (1968).
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CE 1701/Course Handout/OM & SM/Summer Term 2018

Course Plan
CE 1701: Process Plant Design [L-T-P-C] [3-1-0-4]
Lecture Learning Objectives Topics to be covered Reference Mode of
No. Chapter Delivery
(Book)
1 Introduction Introduction to Process Design Decisions: Ch. 1 of Lecture
Process Synthesis and Analysis. T1 and T2
2-4 Nature of Process Creative aspects, Hierarchical approach to Ch. 3 of Lecture
Synthesis and conceptual design, HDA Process. T2 and
Analysis Preliminary Process Synthesis with Ch. 1 of
examples. T1
5-7 Engineering Important cost terms, Cost information, Ch. 2 of Flipped
Economics for Capital and operating cost estimation, Total T1 Class
Conceptual Design capital investment for process.
8-13 Economic Decision Design of a solvent recovery system, Ch. 3 of Lecture
Making Problem definition, Design of a gas T1
absorber, Flow sheet, material and energy
balances, and stream costs, Equipment
design considerations, Rules of thumb.
14-15 Simulation to assist Concepts of process simulation, Steady and Ch. 4 of Flipped
in Process Simulation unsteady state simulation. Introduction to T2 and Class
Aspen Plus. Class
notes
16-17 Input Information Input information, Level-1 decision (Batch Ch. 4 of Lecture
and Batch vs. vs. continuous), Systematic procedure for T1
Continuous the design of batch processes. Economic
Potential (EP-1).
Mid- Semester I Examination (May 31, 2018)
18-22 Input-Output Level-2 Decisions (Input-output structure), Ch. 5 of Lecture
Structure of the Flow Design variables, Selectivity and reaction T1
sheet stoichiometry, Overall material balances,
Stream costs, Process alternatives,
Economic potential (EP-2).
23-28 Recycle Structure of Level-3 Decisions (Recycle structure), Ch. 6 of Lecture
the Flow sheet. Recycle material balances, Reactor heat T2 and
Reactor Design and effects, Equilibrium limitations, Ch. 6 of
Reactor Network Compressor design and costs, Reactor T1
Synthesis design, Economic potential (EP-3).
29-34 Separation System General structure, Vapor recovery system, Ch. 7 of Flipped
Liquid separation system, Azeotropic T2 and Class
systems, Rigorous material balances, Ch. 7 of
Economic potential (EP-4). T1
Mid- Semester II Examination (June 20, 2018)
35-42 Energy Integration Heat-Exchanger Network Synthesis Ch. 10 of Lecture/
Analysis (HENS), First law analysis, Cascade T2 and Flipped
diagrams, Temperature-Enthalpy Diagrams, Ch. 8 of Class
Grand composite curve, Multiple utilities, T1
Area estimates, Design of MER Networks,
Loops and paths, Final design, Stream
splitting, Complete design algorithm, Heat
and power integration.
43-48 Mass Integration Introduction, Minimum mass separation Ch. 11 of Lecture
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agent, Mass exchanger networks. T2

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CE 1701/Course Handout/OM & SM/Summer Term 2018

Attendance Policy

It is strongly recommended that you do not miss any of my classes. ATTEND ALL CLASSES.
University rules of 75% attendance will be strictly followed and no relaxations will be allowed
– please do not make any excuses and apply for relaxation towards the end of the semester for
whatever reasons! Nobody will be allowed to enter the class five minutes past the scheduled time
of class. All festivals (sports/cultural/technical/annual etc.), conferences, sick are included in the 25%
relaxation.
PARTICIPATION CERTIFICATES IN THE EVENTS WILL NOT BE ACCEPTED.
No make-up for missed quizzes/assignments/projects or examination will be allowed except in
extenuating circumstances, with prior permission of the instructor, and the decision of the instructor
in this regard shall be final.

Sickness and other problems

Students should immediately consult with the instructor if they have any problems that could affect
their performance in the course. Where appropriate, the problems should be documented. The student
should seek advice from the Instructor regarding how best to deal with the problem. Failure to notify
the Instructor immediately (or as soon as possible thereafter) will have a negative effect on any appeal.

Undertaking

I, hereby, inform that I have gone through the details mentioned above regarding attendance policy
for CE 1701 (Process Plant Design). I will maintain minimum 75% attendance in this course.

Name of the Student Signature of the Student

Reg. No.

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