Chemical Engineering Design 2

The design of chemical process plants represents the capstone experience of chemical engineering education, requiring the integration of core knowledge from thermodynamics, transport phenomena, reaction engineering, separation processes, and process economics. This course addresses the critical need for students to synthesize their cumulative learning into a realistic and rigorous design experience that mirrors professional engineering practice. Focused on bridging the gap between academia and industry, the course prepares students to tackle complex, open-ended problems that demand not only technical proficiency, but also creativity, collaboration, and sound engineering judgment. Students apply engineering principles, design methodologies, process simulation tools, and sustainability metrics in the conceptualization, design, and evaluation of full-scale chemical plants. Working in teams, students undertake a comprehensive design project encompassing process synthesis, flow sheeting, equipment sizing, energy and material integration, economic evaluation, safety and risk assessment, environmental impact analysis, and ethical decision-making. Emphasis is placed on the practical use of modern process simulation software and on developing professional skills in technical communication, teamwork, and project management. Key topics include process modeling and simulation, plant layout and operability, economic feasibility analysis, hazard identification and mitigation strategies, and sustainability in chemical process design. By the end of the course, students will be capable of delivering a complete, professional-quality process design that is technically sound, economically viable, environmentally sustainable, and ethically responsible. They will also demonstrate competence in multidisciplinary integration, collaborative design practice, and informed decision-making, preparing them to contribute effectively to engineering teams in industry or pursue advanced design-focused studies.

• Apply multidisciplinary engineering knowledge, including thermodynamics, transport phenomena, reaction engineering, separation processes, and process economics, to conceptualize and evaluate full-scale chemical process plants that address complex, real-world challenges.

• Develop innovative and feasible chemical process plant designs by applying systematic design methodologies, process synthesis strategies, and techno-economic analysis, while considering safety, operability, scalability, and compliance with regulatory standards.

• Utilize advanced process simulation tools and engineering software to model, analyze, and optimize integrated chemical processes, including energy and material integration, equipment sizing, control strategy formulation, and plant-wide performance evaluation.

• Conduct comprehensive project evaluations that include economic feasibility, environmental sustainability assessment, safety and risk assessment (e.g., HAZOP, HIRAC, FMEA), to support responsible and data-informed design decisions.

• Communicate technical content effectively through the preparation and delivery of professional-quality reports, engineering documentation, and oral presentations tailored to various audiences, including technical experts, management, and non-specialist stakeholders.

• Demonstrate ethical, professional, and sustainable design practices by evaluating the societal, environmental, health, and economic impacts of engineering decisions and consistently upholding principles of integrity, equity, and global responsibility in design work.

• Collaborate effectively within multidisciplinary teams by contributing to design planning, task execution, problem-solving, and project management, while demonstrating leadership, adaptability, accountability, and constructive team dynamics.

• Adapt to evolving industry practices by independently utilizing digital platforms, engineering databases, and modern process design software to support continuous learning, innovation, and the integration of emerging technologies into plant design solutions.

1. Lecture 1a:  Introduction to the Design Process - The Design Basis

2. Lecture 1b: The Market Study

3. Lecture 2: The Process Flow Diagram

4. Lecture 3: Heuristics for Process Synthesis - Part 1

5. Lecture 4: Heuristics for Process Synthesis - Part 2

6. Lecture 5: Heuristics for Process Synthesis - Part 3

7. Lecture 6: Heuristics for Process Synthesis - Part 4

8. Lecture 7: Engineering Economics - Part 1

9. Lecture 8: Engineering Economics - Part 2

10. Lecture 9: Estimation of Capital and Operating Costs - Part 1

11. Lecture 10: Estimation of Capital and Operating Costs - Part 2

12. Lecture 11: Heat Exchanger Network

13. Lecture 12: Plantwide Process Control

14. Lecture 13: Investment Analysis Modeling

15. Lecture 14: Profitability Analysis

• Grading System

• Guidelines for the Capstone Project

• Rubrics for Written Manuscript and Oral Presentation

Please visit this link for the updated class schedule.

Please visit this submission bin for class submissions.

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. Plant Design & Economics PDE By Shailendra Kumar

3. Process Design and Economics

4. Chemical Engineering Process Simulations using Aspen Plus by The Process Engineer

5. Chemical Engineering Economics by Professor Yanir Maidenberg

6. Process Equipment Design by IIT Roorkee

7. Equipment Design: Mechanical Aspects by IIT Roorkee

8. Process Design Engineering by Payos Academy

9. Process Equipment Design by Chemical Engineering Department LJIET