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CHEP8029 - Chemical Eng Design: Group

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Title:Chemical Eng Design: Group
Long Title:Chemical Eng Design: Group
Module Code:CHEP8029
 
Duration:1 Semester
Credits: 5
NFQ Level:Advanced
Field of Study: Chemical & Process Eng
Valid From: Semester 1 - 2016/17 ( September 2016 )
Module Delivered in 1 programme(s)
Module Coordinator: NIALL MORRIS
Module Author: AISLING O GORMAN
Module Description: The final year design project is undertaken by all students, and is a “capstone” project for the course. The project scope includes process selection together with safety, environmental and economic assessments of the type of project that the students would expect to meet in a work situation. Activities include process selection, development of mass and energy balances and the application of chemical engineering methods and the systems approach to safety, health, environmental impact and other elements of a complex process as well as considering ethics and commercial and economic viability.
Learning Outcomes
On successful completion of this module the learner will be able to:
LO1 Apply chemical engineering methods to the integrated design of the complex systems that are required to manufacture chemical and biopharmaceutical products
LO2 Address social, environmental and economic issues pertaining to the project
LO3 Operate in areas of technical uncertainty where decisions are based on real analysis and evaluation of alternatives through the use of the technical and patent literature
LO4 Critically assess the outcomes of the project
LO5 Drive the project forward with effective application of software tools, problem solving techniques, team working skills, project planning and communication skills
LO6 Integrate the principles of risk and safety management, and apply techniques for the assessment and abatement of process and product hazards
Pre-requisite learning
Module Recommendations
This is prior learning (or a practical skill) that is strongly recommended before enrolment in this module. You may enrol in this module if you have not acquired the recommended learning but you will have considerable difficulty in passing (i.e. achieving the learning outcomes of) the module. While the prior learning is expressed as named CIT module(s) it also allows for learning (in another module or modules) which is equivalent to the learning specified in the named module(s).
Incompatible Modules
These are modules which have learning outcomes that are too similar to the learning outcomes of this module. You may not earn additional credit for the same learning and therefore you may not enrol in this module if you have successfully completed any modules in the incompatible list.
No incompatible modules listed
Co-requisite Modules
10365 CHEP8030 Chemical Eng Detailed Design
14534 CHEP8030 Chemical Eng Detailed Design
Requirements

This is prior learning (or a practical skill) that is mandatory before enrolment in this module is allowed. You may not enrol on this module if you have not acquired the learning specified in this section.

No requirements listed
 

Module Content & Assessment

Indicative Content
Project Charter & Innovation Map
Project Charter: specific goals, project scope, and the deliverables and time line followed. Innovation Map (Technology Readiness Assessment): An innovation map should be presented showing the new technologies (materials, process manufacturing, and product technologies) upon which the process/product is based.
Market Analysis
Describe the market for the product and identify the principal competitors. Provide production levels and annual sales where available. Include sales projections for the new product.
Process Synthesis: Consideration of Alternatives
Alternative process flow sheets should be presented with a discussion of the most promising flow sheets. Use of heuristics. Appropriate software tools may be used to evaluate the most promising flow sheets. Methods used to minimise the use of solvents and other mass separating agents as well as to minimise energy usage and waste should be described. Appropriate criteria to be selected to assess most promising flow sheets. Assembly of Database: The principal thermophysical and transport property data should be presented, together with chemical kinetics data and toxicity data with prices for the principal chemicals.
Preliminary EHS and economic evaluation
Preliminary identification of safety and environmental risks. Inherent safety considerations; resource consumption, waste and emissions production. Approximate Costing Methods: This section should provide estimates of the cost sheet of annual costs, the working capital and how it was estimated and the total capital investment required. Approximate profitability measures such as ROI or venture profit (VP) should be used.
PFD, Mass and Energy Balances
Mass balance: The flows or quantities of all materials should be accounted. The design basis, in particular any assumptions or simplifications should be identified, justified and assessed for impact. Energy Balance and Utility Requirements: In describing most chemical processes, it is desirable to have a section that discusses the energy requirements of the process and the measures adopted to improve the plant economics and resource efficiency by energy and mass conservation. In this section all of the heating, cooling, power and other utility demands should be identified (with numerical values provided), and the methods of satisfying these demands shown. A pinch analysis may be applied to optimise the heat flows. The outcomes should be communicated graphically by a PFD, textually by a process description and numerically by mass and energy balance tables
Batch Processes
Design calculations for batch processes, Gantt charts and scheduling, cycle times, time limiting equipment, regulatory environment, multivariate control
Sustainability, Safety, Health and Environmental Assessment
An opportunity for the design team to draw attention to the importance of sustainability, safety, health, environmental and ethical approaches in developing the process/product design. Application of relevant Best Available Techniques under the IPPC/industrial Emissions Directives for design, resource and energy use, reduction, treatment and abatement of emissions to air, water and land. Safety and health concerns. Application of HAZAN, HAZOP, LOPA. lLfe cycle assessment and sustainability metrics, pinch analysis. Techniques for analysing, throughout the lifecycle, the interaction of process, product and plant with the environment. Implications of site layout on economic, safety and environmental impacts.
Detailed Economic Evaluation and Profitability Analysis
Equipment Cost Summary, Fixed Capital Investment Summary: methods for estimating the fixed capital investment, beginning with the purchase costs. Business Case: rigorous measure of profitability (time value of money), cost of manufacture and economic analysis, cost sheets, cost of utilities. Working capital. Total capital investment. net present value and investor’s return on investment (discounted cash flow rate of return), depreciation schedule, annual cash flows, sensitivity analyses and optimisation.
Assessment Breakdown%
Course Work100.00%
Course Work
Assessment Type Assessment Description Outcome addressed % of total Assessment Date
Project Process Synthesis and Evaluation, PFD and Mass and Energy Balances 1,2,3,4,5,6 60.0 Sem End
Project EHS Assessment 1,2,3,4,5,6 20.0 Sem End
Project Detailed economic evaluation and profitability analysis 1,2,3,4,5 20.0 Sem End
No End of Module Formal Examination
Reassessment Requirement
Repeat the module
The assessment of this module is inextricably linked to the delivery. The student must reattend the module in its entirety in order to be reassessed.

The institute reserves the right to alter the nature and timings of assessment

 

Module Workload

Workload: Full Time
Workload Type Workload Description Hours Frequency Average Weekly Learner Workload
Lecturer-Supervised Learning (Contact) Weekly Meeting with Supervisor 0.5 Every Week 0.50
Independent & Directed Learning (Non-contact) Project Activity 6.5 Every Week 6.50
Total Hours 7.00
Total Weekly Learner Workload 7.00
Total Weekly Contact Hours 0.50
Workload: Part Time
Workload Type Workload Description Hours Frequency Average Weekly Learner Workload
Lecturer-Supervised Learning (Contact) Weekly meeting with Supervisor 0.5 Every Week 0.50
Independent & Directed Learning (Non-contact) Project activity 6.5 Every Week 6.50
Total Hours 7.00
Total Weekly Learner Workload 7.00
Total Weekly Contact Hours 0.50
 

Module Resources

Recommended Book Resources
  • Warren D. Seider, J.D. Seader, Daniel R. Lewin, Soemantri Widagdo, 2010, Product and Process Design Principles: Synthesis, Analysis and Design, 3rd Edition, 3rd Edn. Ed., Wiley [ISBN: 9780470414415]
  • Turton, R., Bailie, R.C., Whiting, W.B., Shaeiwitz, J.A. and Bhattacharyya, D. 2013, Analysis, synthesis, and design of chemical processes, Fourth Edition Ed., Pearson [ISBN: 0132940299]
  • Gavin Towler, & Sinnott, R.K. 2012, Chemical Engineering Design, Second Edition, Butterworth Heinemann [ISBN: 978-0080966595]
  • Peters, M.S., Timmerhaus, K.D., & West. R.E 2003, Plant design and economics for chemical engineers, 5 Ed., McGraw Hill [ISBN: 0071198725]
This module does not have any article/paper resources
Other Resources
  • Software: AspenTechAspen Engineering Suite
 

Module Delivered in

Programme Code Programme Semester Delivery
CR_ECPEN_8 Bachelor of Engineering (Honours) in Chemical and Biopharmaceutical Engineering 8 Mandatory

Cork Institute of Technology
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Email: help@cit.edu.ie