Chemical Engineering Design 1

This course is designed to provide engineering students with a rigorous, application-driven foundation in the design of process equipment and systems, a critical skill set in the chemical and process industries. The rationale for the course lies in the need to translate theoretical knowledge into practical engineering design, addressing real-world challenges in the specification, sizing, and integration of equipment in process plants. The focus begins with establishing a solid design basis and criteria, followed by comprehensive instruction on interpreting and developing process flow diagrams and selecting appropriate materials of construction. Students engage in the detailed design of pipelines, pumps, compressors, and various forms of separators and storage units, learning key principles of sizing and operational functionality. Heat transfer equipment, particularly heat exchangers, are covered extensively from both process and mechanical perspectives, with multi-session design modules emphasizing rigorous analysis. Further topics include the process and mechanical design of mass transfer columns, reactors, evaporators, dryers, and other separation units. The course culminates with multi-part instruction on process simulation, enabling students to integrate and model full-scale systems using software tools. By the end of the course, students will be capable of developing technically sound, economically feasible, and mechanically robust designs of key process equipment. They will also demonstrate proficiency in interpreting engineering drawings, performing sizing calculations, applying relevant design codes, and simulating process systems, skills that are essential for professional practice and further specialization in process engineering and plant design.

• Apply core chemical engineering principles, including material and energy balances, fluid and heat transfer, thermodynamics, and reaction engineering, to design and analyze process equipment and integrated systems that meet industrial specifications and operational requirements.

• Interpret and develop comprehensive engineering documents, such as block flow diagrams (BFDs), process flow diagrams (PFDs), material selection diagrams (MSDs), utiltiy flow diagrams (UFDs), and piping and instrumentation diagrams (P&IDs), to communicate design intent and operational logic effectively.

• Perform detailed equipment sizing and mechanical design for process components such as pipelines, pumps, compressors, heat exchangers, separators, reactors, and mass transfer units, using standard design methodologies and relevant engineering codes.

• Select appropriate materials of construction and evaluate mechanical integrity, corrosion resistance, and operational performance to ensure safe, efficient, and durable process equipment design under varying service conditions.

• Utilize process simulation software and digital tools to model, analyze, and optimize individual equipment and complete process systems, integrating process parameters, control strategies, and system dynamics for full-scale applications.

• Assess and incorporate economic, safety, and environmental considerations into the design process, demonstrating sound engineering judgment and a commitment to sustainability, process safety, and regulatory compliance.

• Communicate design solutions effectively through well-structured technical reports, design packages, and oral presentations, addressing diverse audiences including technical peers, project stakeholders, and regulatory bodies.

• Demonstrate professional and ethical responsibility by engaging in collaborative, multidisciplinary team-based projects, managing design workflows, resolving conflicts, and upholding industry standards and codes of practice.

• Adapt to emerging technologies and contemporary issues in process engineering by integrating advanced design tools, digital platforms, and innovative methodologies to address complex and evolving design challenges.

1. Course Introduction

2. Lecture 1a: Design Basis

3. Lecture 1b: Design Criteria

4. Lecture 2a: Process Flow Diagram Part 1

5. Lecture 2b: Process Flow Diagram Part 2

6. Lecture 2c: Material Selection

7. Lecture 3a: Line Sizing

8. Lecture 3b: Pipe and Tube Sizing

9. Lecture 4a: Pumps and Pump Sizing

10. Lecture 4b: Fans, Blowers, and Compressors

11. Lecture 5a: Storage Tanks

12. Lecture 5b: Two-Phase Vertical Separator

13. Lecture 6a: Two-Phase Horizontal Separator

14. Lecture 6b: Mechanical Design of Vessels

15. Lecture 7a: Heat Exchanger  Process Design

16. Lecture 7b: Heat Exchanger Mechanical Design

17. Lecture 8a: Heat Exchanger Design Part 1

18. Lecture 8b: Heat Exchanger Design Part 2

19. Lecture 8c: Heat Exchanger Design Part 3

20. Lecture 8d: Heat Exchanger Design Part 4

21. Lecture 9a: Process Design of Mass Transfer Column

22. Lecture 9b: Mechanical Design of Mass Transfer Column

23. Lecture 9c: Plate and Packed Column Design

24. Lecture 10: Reactor Design

25. Lecture 11: Design of Evaporators

26. Lecture 12: Design of Dryers

27. Lecture 13: Design of Separation Equipment

28. Lecture 14a: Process Simulation Part 1

29. Lecture 14b: Process Simulation Part 2

30. Lecture 14c: Process Simulation Part 3

31. Lecture 14d: Process Simulation Part 4

1. Design Problem 1: Line Sizing and Hydraulic Calculations

2. Design Problem 2: Vessel Sizing

3. Design Problem 3: Shell and Tube Heat Exchanger (Kern Method)

4. Design Problem 4: Shell and Tube Heat Exchanger (HTRI)

5. Design Problem 5: Bubble Cap Gas Absorber

Please visit this link for the updated class schedule.

1. Rules of Thumb for Chemical Engineers by Branan (3rd Edition)

2. Chemical Process Engineering - Design and Economics by Silla

3. Plant Design & Economics for Chemical Engineers by Timmerhaus (4th Edition)

4. Chemical Engineering Design - Principles, Practice, and Economics of Plant and Process Design

5. ExxonMobil Design Practices

1. Process Design by LearnChemE

2. Process Equipment Design by IIT Roorkee

3. Equipment Design: Mechanical Aspects by IIT Roorkee

4. Process Design Engineering by Payos Academy

5. Process Equipment Design by Chemical Engineering Department_LJIET