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CHEP8015 - Process Design

Title:Process Design
Long Title:Process Design and assessment
Module Code:CHEP8015
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 Description: This module is concerned with the methodologies to synthesise a safe and effective process design satisfying specific needs, with particular emphasis on sustainability criteria: economic, environmental and social.
Learning Outcomes
On successful completion of this module the learner will be able to:
LO1 Devise a conceptual process flowsheet for a specified objective, e.g. product manufacture;
LO2 Estimate the total capital investment and cost of manufacturing for a process.
LO3 Assess the economic viability of a process plant.
LO4 Assess the environmental impacts of a project, process or product.
LO5 Assess the sustainability of a process.
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
No Co-requisite modules listed

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
Process design strategy
Synthesis of elementary process flowsheets. Use of hierarchical technique (input-output, functions, operations) to generate base case designs and flowsheet alternatives for realistic processes. Adaptation of the hierarchical procedure to address multi-phase, e.g. solids processes, or to address specific concerns, e.g. waste minimisation. Criteria for success: technical, economic, safety, environmental, social. Information flows in process plant projects. Inter-relationships between engineering disciplines. Stages in a design and associated timings and level of detail.
Batch processes
Determination of schedule for an elementary batch process. Calculation of cycle time and makespan. Impact of structural flexibility: parallel units, transfer policies, intermediate storage. Impact of scheduling policies: campaign strategy, duration of production cycles, product sequences. Calculation of batch size, vessel sizes and inventories. Optimum conditions for cyclic operations.
Cost estimation of process plant. Levels of estimate: timing, data requirements, accuracy. Capital cost estimation: power factors, factorial methods, installation costs. Manufacturing cost estimation: raw materials, labour, utilities, overheads, supervision, insurance, etc. Life cycle costing.
Economic assessment
Measures of profitability. Elementary measures: payback period, return on investment. Cumulative cash flow diagrams. Time value of money: present and future worth of single and regular cash flows. Measures considering time-value: net present worth, equivalent annual worth, discounted cash flow rate of return. Application of profitability measures to projects with equal lives, unequal lives, replacement analyses, consideration of salvage value, incremental and mutually exclusive investments. Capital rationing. Sensitivity analysis of profitability measures: single-parameter variation, multi-parameter variation, scenario analysis.
Environmental impact assessment
Objectives and principles of EIA. Methodology of environmental impact assessment of a project: project phases, environmental topics, comparison of existing environment and proposed development, determination of impact significance. Examination of a scoping study. Public communication. Critical evaluation of recently published environmental impact statements.
Product life cycle assessment
Stages in a product life cycle. Methodology of life cycle assessment. Standards. Strengths and weaknesses. Sources of data. Merits of qualitative life cycle assessment. Software to support life cycle assessment. Evaluation of impacts: environmental themes, eco-points. Assessment of different evaluation schemes. Use of life cycle assessment for process selection and process management. Product improvements: introduction to eco-design, environmental product declarations.
Sustainability assessment
Sustainability dimensions: environmental, economic and social. Environmental aspects: resource consumption, cumulative energy demand, wastes and emissions. Greenhouse gases and carbon footprinting. Economic aspects: eco-efficiency, climate change adaptation, reliance on ecosystem services, altered site and process design criteria. Social aspects: water scarcity and footprinting,
Assessment Breakdown%
Course Work40.00%
End of Module Formal Examination60.00%
Course Work
Assessment Type Assessment Description Outcome addressed % of total Assessment Date
Project Development of a process flow diagram, technical description and evaluation of a process. 1,2,3,4,5 40.0 Week 10
End of Module Formal Examination
Assessment Type Assessment Description Outcome addressed % of total Assessment Date
Formal Exam End-of-Semester Final Examination 1,3,4,5 60.0 End-of-Semester
Reassessment Requirement
Repeat examination
Reassessment of this module will consist of a repeat examination. It is possible that there will also be a requirement to be reassessed in a coursework element.

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
Lecture Lecture / tutorial / case study / discussion 4.0 Every Week 4.00
Independent & Directed Learning (Non-contact) No Description 3.0 Every Week 3.00
Total Hours 7.00
Total Weekly Learner Workload 7.00
Total Weekly Contact Hours 4.00
Workload: Part Time
Workload Type Workload Description Hours Frequency Average Weekly Learner Workload
Lecture Lecture / tutorial /case study / discussion 4.0 Every Week 4.00
Independent & Directed Learning (Non-contact) No Description 3.0 Every Week 3.00
Total Hours 7.00
Total Weekly Learner Workload 7.00
Total Weekly Contact Hours 4.00

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 Ed., Wiley [ISBN: 9780470414415]
Supplementary Book Resources
  • Gavin Towler, Sinnott, R.K. 2012, Chemical Engineering Design: Principles, Practice and Economics of Plant and Process Design, 2nd Edn. Ed., Butterworth-Heinemann [ISBN: 9780080966595]
  • Richard Turton ... [et al.] 2012, Analysis, synthesis, and design of chemical processes, 4th Edn. Ed., Pearson [ISBN: 0132940299]
  • Moran, Sean 2015, An Applied Guide to Process and Plant Design, Butterworth-Heinemann [ISBN: 0128002425]
  • Azapagic, A., & Perdan, S., Eds. 2011, Sustainable development in practice: case studies for engineers and scientists, 2nd Edn Ed., Wiley-Blackwell [ISBN: 9780470718728]
  • Environmental Protection Agency 2003, Advice note on current practice (in the preparation of Environmental Impact Statements, Environmental Protection Agency Co. Wexford [ISBN: 1840951176]]
  • Environmental Protection Agenc 2002, Guidelines on the information to be contained in environmental impact statements, Environmental Protection Agenc WExford [ISBN: 1840950854]
  • Dept. of the Environment, Community and Local Government 2013, Guidelines for Planning Authorities and An Bord Plean├íla on carrying out Environmental Impact Assessment, Dept. of the Environment, Community and Local Government Dublin
  • UNEP SETAC Life Cycle Initiative 2008, LIfe Cycle Assessment Training Manual, UNEP SETAC Life Cycle Initiative
Supplementary Article/Paper Resources
  • Liew, W.T., et al 2014, Sustainability trends in the process industries: A text mining-based analysis, Computers in Industry, DOI 10.1016/j.compind.2014.01.004 [ISSN: 0166-3615]
  • Ho, S.V., et al 2010, Environmental considerations in biologics manufacturing, Green Chemistry, 12, 755-766
Other Resources

Module Delivered in

Programme Code Programme Semester Delivery
CR_ECPEN_8 Bachelor of Engineering (Honours) in Chemical and Biopharmaceutical Engineering 6 Mandatory

Cork Institute of Technology
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