Chemical Engineering Design 1

Course Description

This course bridges the theoretical foundations of chemical engineering with practical applications in equipment design. It equips students with the knowledge and skills needed to design, analyze, and optimize industrial equipment and processes, which are crucial for addressing real-world engineering challenges. he course covers the fundamentals of design criteria, material selection, and process development, including the creation of process flow diagrams (PFDs) and piping and instrumentation diagrams (P&IDs). Topics include line sizing, pump and compressor design, storage tanks, phase separators, reactors, heat exchangers, and distillation columns. Hands-on laboratory sessions reinforce theoretical concepts through process simulations, equipment sizing, and the use of advanced engineering software. The integration of material and energy balances ensures a holistic approach to process design. By the end of the course, students will develop the ability to design and optimize equipment for industrial processes, utilize engineering software for simulations, and effectively communicate their designs through detailed reports and project defenses. This course prepares students for careers in process and equipment design, contributing to the efficiency and sustainability of industrial operations.

Course Intended Learning Outcomes

• Apply fundamental principles of chemical engineering, including material and energy balances, thermodynamics, and transport processes, in designing chemical processes and equipment.

• Use simulation and design software to model and optimize chemical processes and equipment.

• Evaluate process requirements, material properties, and safety considerations to develop effective chemical engineering designs.

• Develop detailed flow diagrams (PFDs, MSDs) and piping and instrumentation diagrams (P&IDs) for chemical processes.

• Communicate chemical engineering design project through written report and oral presentation tailored to diverse audiences, including technical experts, stakeholders, and non-technical individuals.

• Demonstrate a commitment to designing safe, sustainable, and environmentally responsible chemical engineering processes.

• Work collaboratively in multidisciplinary teams to solve design problems, ensuring ethical and professional practices.

• Apply emerging technologies relevant to chemical process and engineering design to address complex design challenges.

Lecture Materials

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

Design Problems

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

References

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

YouTube Videos

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