Process,

Product Design
& Process Creation &
Sustainability

Presented : Dr. Agus Arsad

Polymer Engineering Department
Faculty of Chemical Engineering
UTM Skudai
 Learning Outcomes
After studying this topic, participants should:

Recognise the significance of design project for chemical/process

engineers

Be able to describe the life cycle of a chemical process and identify

the activities associated with it

Have an appreciation of the key steps in carrying out a product and /

or process design.

Be knowledgeable about the kinds of design decisions that challenge

product and process design teams

Be familiar with the key roles of a chemical/process engineer

Be aware of the various techniques and steps involve during process

creation
 Introduction & definition of concepts

Product centric process design

Chemical product design
Sustainable process design
Product centric chemical process design
Problem Definition
Process Design Product Design

Raw Product Atoms or

Product Product molecules
material Process properties
Flowsheet?
s molecule/
mixture?
Operating Equipment
condition? parameters? Product Molecule or
functions? mixture
Product Application Design synthesis?

Product Performance
Application
process? Integrate Process-Product
Application Equipment & Application
conditions? parameters?
Product centric chemical process design
Examples of Product-Process Integration
Process Design Product Design

Raw Product Atoms or

Products Product molecules
material Process properties
Flowsheet? molecule/
mixture?
Operating Equipment
condition? parameters? Product Molecule or
functions? mixture
synthesis?

Petroleum blends & petroleum products Routinely solved!

Polymers & blends Can be solved!

Process role?
Specialty chemicals (including drugs, .)
Product centric chemical process design
Examples of Product-Process Integration
Product Design
For products such as drugs,
Product Atoms or
pesticides, food, delivery properties
Product molecules
and application is important molecule/
also needs to be validated mixture?
Product Molecule or
functions? mixture
Product Application Design synthesis?

Product Performance
Applicationp
rocess? Production process needs to
Application Equipment be reliable first time right is
conditions? parameters? important
 Chemical Product-Process Connection

Product

development

Product development
In-use properties

and manufacturing
Product function
Process
Physico-chemical properties

Monomer A Process function

Monomer B
Separator
effluent

Solvent (S)

Initiator (I)

Transfer
agent (T)

Process
MIXER
Inhibitor (Z)

REACTOR

SEPARATOR

Copolymer
product
Introduction & definition of concepts

Product centric process design

Chemical product design
Sustainable process design
 Chemical process design
9 Raw
material Process Products

Flowsheet?
Operating Equipment
condition? parameters?

Chemical process design involves the

determination of the process flowsheet and
the corresponding condition of operation and
equipment design that converts the selected
raw materials to the desired products
 Are our products & processes sustainable?
Need for significant improvement
Only 25 wt% of
what goes into Natural Goods and
Services
Pollution, Waste
and Environmental
Resources

the pipe comes Disturbances

out as goods
and services
scope for
significant
improvements
(Adapted from Driolli,
2005)

Without signficant improvements, our products-processes are not sustainable

Introduction & definition of concepts

Product centric process design

Chemical product design
Sustainable process design
 Sustainable chemical process design
12
New definition of process design

Chemical Chemical
Raw Material Process ?? Product

Chemical process design is about finding a sustainable

process that can convert the raw materials to the desired
chemical products

Sustainable: Economic, low environmental impact, low

waste, efficient operation, correct raw material, ..
 Concept of sustainability
Prolong the life of the process
Raw Products,
material, solvents, water,
solvents, Chemical Process power, steam,
water, power, unconverted
steam, materials,
Demand

Reserve
Sustainability limit

time
Sustainability of total system and sub-systems
 Concept of Sustainabilty - II
Measure of sustainability
Raw Products,
material, solvents, water,
solvents, Chemical Process power, steam,
water, power, unconverted
steam, materials,
Boundary: process and its connections
Compared to a base-case design, generate alternatives
that improve the following
Operability, energy consumption, waste reduction,
environmental impact, safety, cost, .
Sustainability metrics (as defined by IChemE): 49 Environmental
(resource usage; emissions, effluents, waste), economic (profit, value, tax;
investments), societal (workplace, society)
 Concept of Sustainabilty - III
How to achieve sustainability?
Raw Products,
material, solvents, water,
solvents, Chemical Process power, steam,
water, power, unconverted
steam, materials,
Improve the following
Operability, energy consumption, waste reduction,
environmental impact, safety, cost, .
Sustainability metrics (as defined by IChemE)

Apply a systematic analysis of the mass and energy paths within

the process to determine a set of mass and energy indicators that
will help to define attainable targets for improvement; generate
alternatives that meet these targets through a reverse
approach
 Intro to Process Design
Introto
PD - 16

Process Design whose job?

Design project in the context of a chemical
process engineers role
Process Design Definition
Process Design Procedure
Process Design Activities
Process Life Cycle
Levels of Design Accuracy
 One day in a job interview...
The
Introto
PD - 17

manager
The What is your
fresh
Chemical-polymer grad field of study?
Engineering!

Then, our
chemistry lab
might be the
Oh no! best place for you ?
Not again...
Introto
PD - 18
Chemical/Process Engineering

..is the field of study that

involves the process of
converting resources into
value-added (VA) products
 What a Chemical Process Engineer*
Introto
Does for a Living
PD - 19

1. Process Development
2. Process Design
3. Construction
4. Manufacturing
5. Technical Sales
6. Research

*A person whose job is related to the process of transforming materials

into value-added products
 1. Process Development
Introto
PD - 20

Pilot Plant
Chemical (10 kg/hr) Commercial
Lab Scale
(10g) Design (100 tonne/hr)
Construction
Operation - testing
- reaction & catalyst
- process conditions
- process control scheme
- materials of construction
 2. Process Design
Introto
PD - 21 OUTPUT
CHEMICAL ENGINEER:
Process Flowsheet
INPUT equipment & streams
P & I Diagram
Process Parameters: Equipment Specifications
production rate size
process conditions (T, P) dimension
type of vessels materials of construction
control systems min/max capacity
safety & pollution
control system
 3. Construction - Moment of Truth
Chemical Engineers:
Introto
PD - 22

Ascertain that equipment operates correctly?

Are involved in plant commissioning, start up
Identify any problems with process and equipment
Specify redesign requirements (as required)
 4. Commercial Production
Introto
PD - 23

Troubleshooting
Routine Supervision
Operation Quality Control
Debottlenecking
Chemical
Engineer
Energy Conservation
Process Raw material conservation
Improvement Pollution control
Process control
 5. Technical Sales
Introto
PD - 24

Chemical Engineer

Provide process and product recommendations

Provide advice on development of new process & products
Networking with experts from other fields in solving
process/equipment problems to meet customer needs
 6. Research
Introto
PD - 25

Chemical engineers:
Cooperate with chemist, scientists and
engineers from other fields to produce
new products

Develop new processing techniques

Improve & optimise process operations

Design new equipment or improve the

existing ones
 What a Chemical Process Engineer*
Introto
Does for a Living
PD - 26

1. Process Development
2. Process Design
3. Construction
4. Manufacturing
5. Technical Sales
6. Research

*A person whose job is related to the process of transforming materials

into value-added products
 Process Design Issues
Introto
PD - 27

Discuss among your group members:

What is a good definition for Process Design?
What are the basic prerequisites?
What do you think are the key steps involved in Process Design
What initial key information do you think would be needed
 A design project
Introto
PD - 28

PROCESS ?
Raw materials?
Process Structure Desired
Products
Survey/feasibility studies
Project team
Project structure/planning (milestone)
Process and Product Design
 Basic Chemical
Manufacturing Products
Natural
Resources Process (Commodity and
Specialty Chemicals,
Biomaterials,
Polymeric Material)

Basic Manufacturing Industrial Products

Chemical Process ( Films, Fibers, Paper,..)
Products

Customer Products
Manufacturing (Paper bag, Dialysis
Industrial
Process Devices, Post-it Notes,
Products Transparencies, Drug
delivery Patches,
Cosmetics,..)
 Middle Distillates
MTBE
Methanol Urea

Methane Formadehyde
Ammonia Urea
Ammonia Ammonium Nitrate
Ammonium Phosphate
Polyvinyl Chloride
Chloralkali Titanium Dioxide

e.g. End Uses of

Plant
Silicones

Fractionated Raw Ethane

Polyethylene LDPE

Natural Gas Ethylene

Glycol

Oxide Surfactant
Polypropylene
Acrylics
Propane
Acrylonitrile
Ammonia
Caprolactam Terephthalic Acid
Polystyrene

Benzene Unsaturated Esters

ABS, SAN
Butane MTBE
 E.g. Naphtha Utilisation For Petrochemicals (1/2)

Cl2
EDC/VCM Polyvinyl Chloride

LDPE Acetic Acid

Vinyl Acetate Polyvinyl Acetate

LLDPE/HDPE

Ethylene O2 H2 PTA Polyester Polyethylene

O
Ethylene Oxide Ethylene Glycol Chips Terephthalate

Benzene (PET)

Ethylbenzene Styrene Polystyrene

Naphtha H2O
O2
Cracker Ethyl Alcohol Ethyl Aldehyde Acetic Acid

Polypropylene

H2O O2 HCN

Propylene Isopropanol Acetone Methyl Methacrylate Polymethylmethacrylate

Benzene Isopropylbenz O2 Cumene Hydroperoxide Cleavage Phenol /

(Cumene) (CHP) Acetone

 E.g. Naphtha Utilisation For Petrochemicals (2/2)
O2
(By Products) n - Butane Acetic Acid
Acrylonitrile
Butene - 1
Mixed C 4
Butadiene Polybutadiene (Synthetic Butadiene Rubber)

H2
HMDA Nylon 6,6
Adiponitrile
Caprolactam
Nylon 6

Butene - 2 Isobutene Polybutene

MTBE (ABS)

Naphtha
Cracker Toluene Toluene Diisocyanate (TDI) Nylon-6

C2
Benzene Ethylbenzene Styrene Polystyrene

Pyrolysis C3 O2
Gasoline Mix-xylene Phenol Cyclohexanone Caprolactam
Acetic Acid EG
Para - xylene Pure Terephthalic Acid (PTA) Polyester Fiber
Fuel Oil

Fuel Gas
 Process/ Product Design
Introto
PD - 33

A project/endeavour/task to determine the

structure of a process to produce a product in
the way that is economical, safe, and
environmentally friendly.

Among other things, a project would involve management, planning,

assessment and evaluation
Process Life Cycle
A Birds Eye View

(Seider et al., 2004)

 Process Design Basic Components
Introto
PD - 36
at Project Team Level
Steps in the design of a chemical process:
1. Project Conception
2. Process Synthesis/Creation
3. Equipment Design
4. Economic Analysis
5. Optimisation

(Ulrich, 1984)
 Process Design Process
Synthesis/Creation
Introto
PD - 37

Process Synthesis/ structural optimisation

Flowsheeting

Material and Energy Balances parameter

(manual & simulation) optimisation

Process
Modelling/Analysis Process Simulation

Optimised Design
(Manan, 2001)
 Process Creation (details)
Introto
PD - 38
 Process Creation and Detailed Design
Introto
PD - 39
Final Design & Operation
Construction and Operation

Layout and
Plant Operation
3-D Modelling

Construction Debottlenecking

Startup and Decommisioning

Commissioning
 Some common terminology
Process flow diagram (PFD) / process flowsheet -
interconnections of the individual process operations
(e.g. drying, mixing, etc.) together with the quantitative
variables (e.g. P, T, flowrates and composition).
Thank You