Instructions for Final Year Projects:

All students are advised to strictly follow the instructions given below.

1. Each group will be assigned a project title. The group will work on the project title and
search production methods, flow sheet of each method, comparison of processes,
approximate cost estimation of each method, raw materials availability. The group will
select a process based on comparison of processes after discussion with the project
supervisor. The final and detailed flow sheet along with supportive documents will be
submitted to the project coordinator.
2. A progress presentation will be held at the end of each month. Each group must have
minimum of four group meetings with the project supervisor to be eligible for the
presentation.
3. A progress report will be submitted to the project coordinator at the end of each month to
ensure the completion of the assigned task.
4. The progress report must be signed and verified by the project supervisor to ensure
compliance of instructions before submission. The report must be submitted to the project
supervisor three days before submission for evaluation and corrections.
5. A soft copy of the report must also be submitted to project coordinator for plagiarism
check. If plagiarism of the report is above 30 percent, the report will be rejected and will
require revision.
6. Remember to bring technical information and evidence of your work to your meetings
with supervisors (photocopies, printouts, hand calculations etc.) so you can have concrete
discussions and get concrete answers.
7. The project supervisor and the group leader will keep record of all group meetings and
attendance of each student in group discussions and will submit it to the project
coordinator at the end of each month who would then report to the HOD.
8. All members of a design group should ensure their familiarity with the project work as
they shall be evaluated individually both for sessional work (60 % weightage) and viva
voce examination (40 % weightage) instead of a collective evaluation as a group.
9. The distribution of the sessional marks will be as given below. The presentation marks
will be decided by the panel of faculty members who are present during the presentation.
Presentation 10*7= 70
Physical Plant Layout 10
Poster (Pena-flex) Presentation 10
Attendance 15
Report submission to Project Coordinator 15

10. References and bibliography of all the books and literature used must be given at the end
of the report in proper format available in the design books.
11. It is recommended to use Mendely-Desktop or Endnote for citing the references and
managing the bibliography.
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 12. After the completion of process flow diagram (PFD) and the mechanical equipment
design, each group will prepare a physical plant layout of its entire project.
13. Each group, upon successful completion of the project, will give a Poster (Pena-flex)
presentation that will give brief insight of the project right from the introduction until the
cost estimation and HAZOP study.

Presentations and Report Submission Schedule:

Task Report Submission Presentation Dates
Introduction & Manufacturing Processes, 19th October 2018 22nd October 2018
Process flow Diagram ,capacity selection
Material & Energy Balance 16th November 2018 19th,20th November 2018
Equipment Design & Mechanical Design 28th December 2018 1st,2nd,3rd January 2019
Cost Estimation 8th February 2019 11th, 12th February 2019
Pumps & Compressors Calculations 28th February 2019 4th, 5th March 2019
HAZOP Study, Instrumentation & Control 15th March 2019
Environmental Impact Assessment, Plant 22nd March 2019 25th , 26th March 2019
Simulation
Plant layout 5th April 2019
Project Report Submission 12th April 2019 15th , 16th , 17th April 2019
Final Viva 22nd , 23rd April 2019

Contents of the Report:

Chapter 1 Introduction

 Introduction to Product
 Physical Properties & Thermodynamic Data
 Reactions of the Product
 Industrial Applications
 Handling, storage and safety
 Shipping of the product
 Production and consumption data of product in world ( graphs or pie charts)
 Production and consumption data of product in Pakistan ( graphs or pie charts)
 Market Assesment
 Future Trends

Chapter 2 Manufacturing Processes

 Production Methods

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  Detail of each process (i.e. Reactions, Catalyst, conversion, yield, Reaction Conditions,
side reactions, byproducts and their handling, flow sheet of each process)
 Comparative study of production methods and summarize them in tabulated form.
 Process selection
 Process description
 Capacity selection and its justification based on raw material availability and cost,
production and consumption data in world and Pakistan, capacities of plants currently
working in the world.
 Detailed flow sheet of the process (The flow sheet must include all heat exchangers,
pumps, compressors, storage tanks and must be made in MS Visio. The flow sheet
presentation should be using appropriate symbols as given in the in the text books of
Plant Design and Economics for Chemical Engineers and Chemical Engineering volume
06.)

Chapter 3 Material and Energy Balance

(The presentation of material and energy balance should be in proper matrix format, process
stream number on the top row and components or materials in the vertical column. The stream
number should refer to the streams in original flow sheet prepared in your design project.
MS Excel sheet of material and energy balance calculations must be submitted to project
supervisor and project coordinator.
Reference must be provided for each assumption and data used in material and energy balance
calculations. Any graph, table or equation used for physical property estimation must be shown
in chapter with reference. Use of online calculators is not allowed for physical properties
estimation or any other calculations. Equations and tables provided in books for physical
properties must be used.)

Equipment Selection and Design

All design groups must include the design and specification sheets, in proper format, of each
equipment in process flow sheet. The design of equipment should be based on the fundamental
principles of chemical engineering. Dimensions/ units of quantities must be consistent
throughout your project report. Standard Visio flow sheet of each equipment must be included at
the start of chapter showing the inlet, outlet streams, and composition of each stream,
temperature and pressure of each stream, operating temperature and pressure of the equipment.
Standard Specification sheet of the equipment must be shown at the end of the chapter.

Mechanical Design

 Design temperature and Pressure

 Maximum Allowable Stress
 Thickness of shell and heads
 Materials of construction

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  Weight
 Support design
 Engineering drawing of the equipment for which mechanical design has been done.
 Each equipment should be designed for a specific purpose, objective and relative to the
assigned design project.

Pumps & Compressors Calculations

 Type of unit used

 Selection of the unit ( selection must base on characteristic curves of each unit and data
given in design books)
 No of stages, Inter-stage Temperature/pressure, cooling water requirements
 Power calculation
 Characteristic curves of pumps and compressors
 Specification sheet of each unit

Cost Estimation

 Cost estimation methods and Selection of method for cost estimation

 Cost estimation (Capital as well as Production cost *must be calculated and presented in
proper format. The evaluation of investment by any method (e.g. return on investment) is
mandatory. Moreover, the cost estimation (capital and operational) should be based on
the data available in the literature and calculations must be based on design parameters
for which the cost data is available
 Market Survey ( costs of raw material and price of product in market with reference)
 Profit
 Rate of Return
*As listed in Chapter 6 of Plant Design and Economics for Chemical Engineers by Peter
& Timmerhaus

Safety & HAZOP Study

The HAZOP study must comprise a detailed examination of the streams flowing into and out of
each equipment. All significant aspects of deviation for each of streams must be considered
under ‘Key Word’ headings. It should also contain steam circuit for entire plant. It should also
include the material and safety datasheet (MSDS) for raw material, by-product and for the final
product.
Instrumentation and Control of Major Equipments

 Control Objective
 Manipulated Variables
 Control Variables

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  Disturbances
 Instruments used for measurements and selection of Instruments
 Control Scheme (The control loop must be prepared in proper format given in the design
books, using the standard symbols of instruments. It must also include measurement,
indication and control of the process variables).

Environmental Impact Assessment

 The treatment of unwanted chemicals (by-products) and the concentrations of liquid

discharges and gaseous emissions during normal operation; the handling of a major
chemical accident, including all chemicals within the plant and any subsequent reaction
products, and containment and clean up.
 Use National Environmental Quality Standards (NEQS) and WHO guidelines.
 Exposure evaluation and Control
 Care should be taken for handling the utilities (water, steam, air). Use proper standards
and symbols.
 Emission standards ( threshold limit value( TLV-C), permissible exposure limit(PEL),
IDLH value,
 Safety of the workers

Plant Layout of entire plant

A preliminary determination of the plant layout enabling consideration of pipe runs and pressure
drops, access for maintenance and repair and in the event of accidents and spills, and location of
the control room and must ensure economical construction and efficient operation of the plant.
Simulation of Plant

The simulation of the plant will be done in Aspen HYSYS. The report must include the selection
criteria of property package. The purpose of this exercise is to check design done with the
simulated solution/design.

Report Format:

 Each upcoming report will be in the same word document and format as of preceding
report.
 All preliminary reports must be uniform according to the following format.

Font Style: Times New Roman Font Size: 12 Heading Size: 14

Line Spacing: 1.15 Text Alignment: Justified

Table: Title will be at the top of the table with center alignment

Figure: Figure title will be at bottom of the figure with center alignment
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  Generate table of contents automatically.
 The final report must include self-written dedication, acknowledgment, summary and
abstract in comprehensive way.
 Thesis report will be written in given template as approved by the department.

Guidelines for Poster Presentation:

The Poster Presentation will necessarily include the following:

 Title of the project including capacity, starting (raw) material, name of the selected
process and the end product.
 Brief introduction about the need of the product, its uses, consumption and the existing
plants’ production in Pakistan and in rest of the world.
 Selected process and its brief summary along with major chemical reaction(s).
 Complete process flow diagram (PFD) of the process.
 A table mentioning the material and energy balance of the main streams.
 The mechanical design of the equipment highlighting specific features of major
equipments in the form of table as given in the following example;
Installed Product
Equipment Service/Operation Internals
units Specification
5000 kg-
Distillation Sieve Plates
Separation/Rectification 3 mol/hr (99%)
Column :15
benzene

 A table of estimated cost of each unit, payback period and the unit cost of the product.
 Safety and environmental aspects of the raw materials, by products and the final product.
 Applications/Uses.
 References in proper format.
 Embedded logo of the college and the name of the department.

Guidelines for Physical Plant Layout:

 Use small pipes, tubes, wires, bottles, silver paper, wooden board etc.
 Show the process flow diagram with the help of bottles; join them with pipes/tubes using
glue or with any other suitable material.
 Use standard symbols for the process lines, fittings, equipments, machines, vessels etc.
 Use proper standard colors for each stream and for its name as they are used in industry
http://www.engineeringtoolbox.com/piping-equipment-identification-d_1442.html.

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 Recommended Books:

 PLANT DESIGN AND ECONOMICS FOR CHEMICAL ENGINEERS. 4th edition,

Max S. Peters, Klaus Timmerhaus, Boulder. Ronald E. West.
 Hand book of chemical engineering calculation, Nicholas p. choppy, Tyler G. Hicks.
 Process Heat Transfer, D. Q. Kern, 1st edition.
 Rules of Thumb for Chemical Engineers, 5th Edition.
http://www.sciencedirect.com/science/book/9780123877857.
 Rules of Thumb for Mechanical Engineers
http://www.sciencedirect.com/science/book/9780884157908
 Ludwig's Applied Process Design for Chemical and Petrochemical Plants (All volumes).
http://www.sciencedirect.com/science/book/9780750685245
 Separation Process Principles, Seader, Henley, 3rd edition.
 Chemical Engineering design, Coulson and Richardson, volume 6, 4th edition.
 Fluid flow, heat and mass transfer, Chemical Engineering, Coulson and Richardson,
volume 1, 6th edition.
 Transport Process and Unit Operations, Christie J. Geankoplis, 3rd edition.
 Unit Operations of Chemical Engineering, McCabe Smith, 5th/6th edition.
 Chemical Process engineering design and economics, Harry Silla.
 Metering Pumps: Selection and Application, James P. Poynton.
 BASIC Programs for Chemical Engineering Design, James H. Weber
 Compressors and Expanders: Selection and Application for the Process Industry, Heinz
P. Bloch, Joseph A. Cameron, Frank M. Danowski, Jr., Ralph James, Jr., Judson S.
Swearingen, and Marilyn E. Weightman.
 The Desulfurization of Heavy Oils and Residua, James G. Speight.
 Chemical Reaction and Reactor Engineering, edited by J. J. Carberry and A. Varma
 Modem Control Techniques for the Processing Industries, T. H. Tsai, J.W. Lane, and C.
S. Lin.
 Process Modeling and Control in Chemical Industries, edited by Kaddour Najim.
 Process Engineering Economics, James R. Couper.
 Chemical Reactor Design, Peter Harriott.
 Reaction Kinetics and Reactor Design: Second Edition, Revised and Expanded, John B.
Butt.

_______________

FYP Coordinator _______________________

HOD-Chemical Engineering

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