2.

Process Design Development

Ousman R.
Concept development process
Three components:
 clarifying requirements,
 concept generation and
 concept selection.
Product design process

Product
quality

Product cost

Idea development
Selection affected by:

Customer
satisfaction

Overall
manufacturability
Figure 1 - The design process with the three detailed stages of concept development
 ………cont
 The role of a chemical engineer is:
 Design

 Construction and

 operation of chemical plants.

 The engineer must continuously search for

additional information to assist in these
functions.
Types of Design–Project
 The methods for carrying out a design project:
divided into the following classifications,
depending on the accuracy and details required:

1. Preliminary or quick-estimate designs

2. Detailed-estimate designs

3. Firm process designs or detailed designs

Cont’d
1. Preliminary design
 Approximate process methods, and rough cost
estimates are prepared.

 Few details are included, and the time spent on

calculations is kept at a minimum.

 Basis for determining whether further work should

be done on the proposed process.

 It serves eliminating an undesirable project before
large amounts of money and time are expended.
Cont’d
2. Detailed-estimate designs
• It will be developed, if the results of the preliminary
design show that further work is justified

• The cost & profit potential of an established process

is determined by detailed analyses and calculations.
• However, exact specifications are not given for the
equipment
Cont’d
3. Firm process designs or detailed designs
• When the detailed-estimate design indicates that the proposed project
should be a commercial success, the final step before developing
construction plans for the plant is the preparation of a firm process
design.
• Complete specifications are presented for all components of the plant,
• Accurate costs based on quoted prices are obtained.
• Includes:
• complete plant layout
• piping diagram,
• blueprints and
• sufficient information to permit immediate development of the final plans for
constructing the plant.
Feasibility Survey

 Before any detailed work is done on the design,

the technical and economic factors of the
proposed process should be examined.

 A preliminary survey gives an indication of the

probable success of' the project and what
additional information is necessary to make a
complete evaluation.
Factors considered in feasibility survey
 Raw materials (availability, quantity, quality, cost)

 Thermodynamics and kinetics of chemical reactions

involved(equilibrium, yields, rates & optimum conditions)

 Facilities and equipment available at present

 Facilities and equipment which must be purchased

 Estimation of production costs and total investment

Cont’d
 Markets (present and future supply and demand, price
range for products, number of possible customers)
 Profits (Per birr of product and per year, return on
investment, payback period)
 Competition (overall production statistics, comparison of
various manufacturing processes, product specifications of
competitors)
 Sales and sales service (method of selling and distributing)

 Plant location
 Process Development
 Process development on a pilot-plant is usually
desirable in order to -obtain accurate design data
 In developing the process the following information
are required
 Grades of raw materials and products
 Process conditions (Temperature, pressure)

 Yield

 Operating conditions (batch, continuous)

 Comparison of Different
Processes (Routes)
 In a course of a design project it is necessary to determine
the most suitable process for obtaining a desired product.

 Several manufacturing methods may be available for

making the same material, and various processes must be
compared in order to select the one best method.

 The comparison can be accomplished through the

development of complete designs.
Cont’d
 However, in many cases all but one or two of
the possible processes can be eliminated by a
weighted comparison of the essential variable
items without conducting detailed design
calculations.

 The following items should be considered in a

comparison of this type:
Cont’d

1. Technical factors
2. Raw materials
a. Process flexibility
a. Present and future
b. Continuous operation
availability
d. Commercial yields
b. Processing required
e. Technical difficulties involved
f. Energy requirements c. Storage requirements

g. Possibility of future d. Materials handling

developments problems
h. Health and safety hazards
involved
Cont’d
3. Waste products & by- 4. Equipment
products
a. Amount produced a. Availability

b. Value b. Materials of construction

c. Potential markets c. Initial costs

and uses d. Maintenance and
d. Manner of discard installation costs
e. Environmental e. Replacement requirements
aspects
Cont’d
5. Plant location
6. Costs
a. Amount of land required
a. Raw materials
b. Transportation facilities
b. Energy
c. Proximity to markets and
c. Depreciation
raw-material sources
d. Other fixed charges
d. Availability of service and
e. Processing and
power facilities
overhead
e. Availability of labor

f. Climate
Design-Project Steps
The design-Project is achieve by the following stages

1. Establish the bases for design.

 Specification for the product (Product quality)

 Production capacity

2. Preparing a simplified Flow diagram

 Decide upon the unit operations which will be required.

 Flow rates and stream conditions can evaluated by complete

material balances, energy balances and

a knowledge of raw-material and product specifications

Cont’d
Cont’d
 The chemical engineer uses flow diagrams to show
the sequence of equipment and unit operations in
the overall process
 These diagrams may be divided into three general
types:
 Qualitative
 Quantitative
 combined-detail.
Cont’d
 A qualitative flow diagram indicates the flow
of materials, unit operations involved and
equipment necessary

 A quantitative flow diagram shows the

quantities of materials required for the
process operation.
Example:
Qualitative flow diagram (Detergent production)
Example:
Quantitative flow diagram (50,000 Ib/year Detergent production)
3. Design of equipment
 Equipment specifications are generally
summarized and included with the final design
report.
For example: Distillation column
 Number of plate
Column diameter
Material of construction
Operating conditions
Cont’d
4. Economic analysis (evaluation)
 The utilities and labor requirements can be
determined

 Estimates of the capital investment

 Fixed capital investment

 Working capital

 The total product cost

Cont’d

 Economic evaluation plays an important part in any

process design.
 Not only in the selection for a specific process,
choice of raw materials used, operating
conditions chosen, but also in the specification
of equipment.
 No detail design of a piece of equipment or a
process is complete without an economical
evaluation.
Cont’d
5. Optimization

Why optimize? •Cost minimization

 Improved yields, reduced pollutants •Profit maximization

 Reduced energy consumption

 Higher processing rates

 Reduced maintenance, fewer shutdowns

Cont’d

6. Reporting
• The final step, and an important one in

preparing a typical process design, involves

writing the report which will present the
results of the design work.
Thanks!

30
 Sequence of plant design project steps
Time sequence

Process identification
Laboratory scale process research
Bench scale investigations
Preliminary economic evaluation
Process development
Mass and energy balance
Detailed process design

Project Steps Site selection

Refined economic evaluation
Design Fixed
Detailed economic evaluation
Engineering flow scheme
Basic design
Detailed construction plan
Detail design
Procurement
Construction
Startup
Supplementary Material
 The initial concept development process is important be
cause
 A better design process leads to a better design outcome.
 Decisions made during the early stages of design tightly
constrain future options.
 It is estimated that 70% cost of a product is determined in
the first 30% of the design cycle.
Ways to innovate
There are three main sources of innovation:
 technology,
 market and
 users.

Though in reality, all products are a combination of more tha

n one source.
 Technology
 Innovation can be achieved through a new form of technology, eit
her by
 creating or
 utilizing it.
Inventing a new technology can be slow due to the nature of res
earch and development and is often a risky process financi
ally.
The better option is to think “we have a new technology, what is
it good for?”
Example ,phone App Inventor is our new technology and it is
good for creating Android apps, thus narrowing down the type of p
roduct we will create.
 Market
 Market innovations come from changes in the market T
hese changes can be changes
 in demographic trends, such as aging baby boomers, or
changes in competitors. The Galaxy
 E.g,Tablet was invented when Samsung’s competitor, A
pple, came out with the iPad. Market innovations.
 Market inspired product designs are often based on exi
sting product concepts.
 Users
Product needs can be found by observing an individual.
 It does not necessarily assume a pre-existing concept.
 While observation process can require only a few participa
nts, the result may not be representative.
 Concept generation
 Concept generation is the process of generating new ideas.

 It is supposed to be synthetic rather than analytical.

 The purpose is not to judge the feasibility of solutions but
instead to keep coming up with ideas regardless of pract
icality.
 there is no right answer in brainstorming and they are
to not think critically about their solutions.
There are four steps in the creative process.
1.Preparation

collecting information about a problem

2. Incubation -
unconscious recombination of ideas (requires conscious thinking about the problem)

3. Illumination

moment of inspiration

4.Verification-

implementation/testing of the idea

 2. Process Design Development
2.2 The Design Process
The design process is achieve by following 10 stages.
 1-Identify the problem/product innovation
 2-Define the working criteria/goals
 3-Research and gather data
 4-Brainstorm / generate creative ideas
 5-Analyze potential solutions
 6-Develop and test models
 7-Make the decision
 8-Communication and specify
 9-Implement and commercialize
 10-Perform post-implementation review and
assessment
Stage -1: Identifying the problem/product
innovation

• Engineers are problem solvers: and the problems they

solve are often identified as the specific needs and
problems of customers
• Example:
 increased gas mileage
 Safety devices for kid, monitors, etc..
Stage 2: Define the working criteria and goals

 How much will it cost?

 Will it be difficult to produce?
 What will be the size, weight, strength?
 What will it look like?
 Will it be easy to use?
 Are there legal concerns?
 Will it be reliable?
 Will it meet the EPA standard?
 Is this what the customer truly wanted?
 Will our customers want to purchase it?
 version instead of a competitor’s product?
 Is it feasible for our customers to buy it?
Stage 3: Research and gather data

What information has been published about the problem?

 Is there a solution to the problem that already may be
available?
 If the answer to the above is yes, who is producing it?
 What are the advantages of their solution?
 What are the disadvantages to their solution?
 What is the cost? , Is the cost significant issue?
 What is the ratio of time compared to overall cost?
 Are there legal issues to consider?
 Are there environmental concerns which must be
considered?
Information
Libraries
can be obtained
 Professional Society
 Journal, publications and newsletter
 Newspapers and magazines
 Market assessment surveys
 Government publications
 Patent searches and listings
 Technical salespersons and their references catalogs
 Professional experts including researchers, professors
and other scientists
 The competition’s product (how they designed it?
Disassemble their product and study it.
 Stage 4: Brainstorm
(Generate creative ideas

 Creative problem solving is a major method of generating

multiple ideas to a problem by a technique called
brainstorming
 No preliminary judgments are made about any
member’s idea, and no negative comments are allowed
 The goal here is to list as many ideas as possible
Stage 5: Analyze potential solutions

 Computer analysis technique

 Analysis of compatibility
 Consistency of testing
 Estimation
 Economic analysis
 Common sense
 Analysis using basic engineering principles and laws
 Stage 6: Develop and test models

 Mathematical models
 Computer models
 Scale model
 Diagrams or graphs
 Durability
 Ease assembly
 Reliability
 Strength
 Environmental
 Quality consistency
 Safety
 Stage 7: Make the decision

 Cost Point Available #1 #2

 Production Difficulty 20 17 15
 Size, weight, strength 15 8 12
 Appearance 10 7 8
 Convenient to use 5 3 3
 Safety 10 7 8
 Legal issues 5 4 3
 Reliability/Durability 15 9 11
 Recyclability 5 4 2
 Customer Appeal 10 8 9
Stage 8:Communication and specify

Communicate data and design for each specific

solution and get input

Stage 9:Implement and commercialize

 Implement the best solution
 Apply methods of business for profit
tage 10:Perform post-
mplementation review and assessment

•Check if the final product is giving you what you

actually wanted from feasibility and if the consumer
like it, etc.
Onion model of a design process
 Sequence of plant design project steps
Time sequence

Process identification
Laboratory scale process research
Bench scale investigations
Preliminary economic evaluation
Process development
Mass and energy balance
Detailed process design

Project Steps Site selection

Refined economic evaluation
Design Fixed
Detailed economic evaluation
Engineering flow scheme
Basic design
Detailed construction plan
Detail design
Procurement
Construction
Startup
A sample model for Plant Design

Step 1. Recognizing the need.

Step 2. Defining the problem.
Step 3. Planning the project.
Step 4. Gathering information.
Step 5. Conceptualizing alternative approaches.
Step 6. Evaluating the alternatives.
Step 7. Selecting the best alternative.
Step 8. Communicating the design.
Step 9. Implementing the preferred design.

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57
 1.Raw material storage:
 Raw materials have to be stored for days or weeks
and even for months to avoid production
interruptions so that the plant operates sustainably.
Even when the materials come from an adjacent
plant, some provision is usually made to store raw
materials for few days’ or even weeks’ that enable
the plant to continuously operate for 24 hours.

58
 Cont…

The storage requirement depends on the nature of the

raw materials, the method of delivery, and what
assurance can be placed on the continuity of supply.
If materials are purchased from foreign sources and
delivered by ship several weeks’ stocks may be necessary,
whereas if they are coming from domestic sources less
storage will be needed.
In the operation of a process plant adequate storage
facilities for raw materials, intermediate products, final
products, recycle materials, off-grade materials, fuels,
cleaning agents, packaging materials and other items.

Storage of raw materials permits operation of the process

plant regardless of temporary supply of delivery
difficulties. 59
 Cont…

 Storage of intermediate products may be necessary during plant

shutdown for emergency repairs. this is not practical for food
systems since they are sensitive to contamination)

 Storage of products makes it possible to supply the customer even

during a plant difficulty or unforeseen shutdown.

 An additional need for adequate storage is encountered when it is

necessary to meet seasonal fluctuations.

 Depending on the physical and chemical properties of the

materials storage conditions should be determined.

60
 Bulk storage of liquids is generally handled by closed
spherical or cylindrical tanks to prevent escape of volatiles
and minimize contamination.

 High-pressure gas is stored in spherical or horizontal

cylindrical pressure vessels.

 Solid products and raw materials are either stored in air-

tight tanks with sloping floors or in outdoor bins or
mounds. Solid products are mostly packed directly on
retail packages.
61
 2.Raw material preparation:

 Raw materials preparation and purification is necessary to

make the feed sufficiently pure and are in the right form to be
fed to the Physical & Chemical Material Transformation unit
operations.

 Feed contaminants that can poison process catalysts, enzymes,

or micro-organisms must be removed. Solid materials may
need crushing, grinding, and screening while Liquid feeds need
to be vaporized before being fed to gas-phase reactors
62
 3.Material Transformation unit operation:

 The Material Transformation stage is the heart of a chemical

manufacturing process. The raw materials are brought together
under conditions that promote the production of the desired
product both at the physical transformation unit or the reactor.

 Byproducts will also be formed during the Physical and

chemical process by side reactions or from reactions of
impurities present in the feed.

63
 4.Product separation:

 The products and byproducts are separated from any un

reacted inputs and undesirable side products after the
Material Transformation units.

 In certain processes repetitive or multiple steps could be

required, each followed by one or more separation steps. If
the un reacted inputs are in sufficient quantity, it will be
recycled back to Material Transformation units or to the raw
material purification and preparation stage. The byproducts
should be also separated from the products at this stage
64
 5.Product Purification:

 The main product will often need purification before sale

to meet product specifications. If produced in economic
quantities, byproducts may also be purified before sale.

6.Product storage:

 Finished product must be held to match production with

sales or to store unsold products. Products must be packed
and stored depending on the nature of the product.

65
 7. By product storage:

 By products require storage.

8. Waste treatment plant :
 Wastes generated particularly from raw material preparation,
Product separation and Product Purification units must be
treated before it is discharged into the environment
9. Materials Handling

 Materials handling equipment used for transportation of solids,

liquids and gases are divided into two main groups as
continuous or batch.

66
 Cont…

 Liquids and gases are handled by means of pumps and blowers

in pipes and ducts and in containers such as drums or
cylinders. (hydraulic conveying)

 Solids may be handled by conveyors, elevators, lift trucks and

pneumatic systems.
 Gravity or manually powered conveyors

 Powered conveyors as; roller conveyors, belt conveyor, slat

conveyors, chain conveyors, vibratory conveyors, magnetic
conveyors, screw conveyors and flight conveyors.
67
Cont…

 Package elevators and bulk elevators

 Trucks with low and high vertical lifts

 Pneumatic equipment where air is used to reduce solid-

solid friction, either ‘air-cushion’ principle or solid
fluidization or solid suspension.

 The selection of materials handling equipment depends upon

the cost and the work to be done.

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Thank you for your attention!!!

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