Analysis & Design of Analysis & Design of Common Chemical Common Chemical

Engineering SystemsEngineering Systems

What is Analysis?What is Analysis?

Analysis is the process of identifying a Analysis is the process of identifying a question or issue to be addressed, question or issue to be addressed, modeling the issue, investigating model modeling the issue, investigating model results, interpreting the results, and results, interpreting the results, and possibly making a recommendationpossibly making a recommendation..

Typical analysis for process Typical analysis for process design may include:design may include:

Market and Technical FeasibilityMarket and Technical Feasibility Choice of Technology (Proven, Innovative, Choice of Technology (Proven, Innovative,

path/ rating)path/ rating) Identification Process Equipment in the PlantIdentification Process Equipment in the Plant Choice of Design theme and modeChoice of Design theme and mode Availability of raw materials, utilities, human Availability of raw materials, utilities, human

resource and process constraints resource and process constraints Costs of providing the services, skills, Costs of providing the services, skills,

materials, equipment, taxes and other materials, equipment, taxes and other economic issues.economic issues.

Invention and DesignInvention and Design

INVENTIONINVENTIONAn invention is something produced for the An invention is something produced for the

first time through the use of imagination first time through the use of imagination or ingenious thinking and or ingenious thinking and experimentation.experimentation. A famous quote is: A famous quote is: ""Necessity is the mother of inventionNecessity is the mother of invention

DESIGNDESIGN Engineering Design is like an Engineering Design is like an

invention to suit the unique demand of invention to suit the unique demand of the customer (customized solutions).the customer (customized solutions).

What is Design?What is Design?

Design is the human power to Design is the human power to conceive, plan, and realize products conceive, plan, and realize products that serve human beings in the that serve human beings in the accomplishment of any individual or accomplishment of any individual or collective purpose." collective purpose."

Process Design is the sizing of Process Design is the sizing of equipment and facilities necessary to equipment and facilities necessary to carry out the process.carry out the process.

Engineering Design may requireEngineering Design may require

(A). Design for new process

(B). Process design

(C). Mechanical design

(D). 3D design

(E). Fabrication

(A).(A). Design for New Processes Design for New Processes

– What is the Design Process?What is the Design Process?Typical five steps through which scientific Typical five steps through which scientific principles are applied for the solution of principles are applied for the solution of Engineering problems are:Engineering problems are:

1.1. Define the ProblemDefine the Problem

2.2. Finding solutions and ideasFinding solutions and ideas

3.3. Documentation of ideasDocumentation of ideas

4.4. Testing and RefiningTesting and Refining

5.5. ProductionProduction

Defining the Problem

The design process is undertaken after a The design process is undertaken after a specific problem or need has been identified. specific problem or need has been identified. The identification of the problem occurs in the The identification of the problem occurs in the research and development stage of research and development stage of manufacturing. manufacturing.

Once scientists and engineers working in R&D Once scientists and engineers working in R&D have identified the need for a product or have identified the need for a product or discovered a problem, the design process is discovered a problem, the design process is used to make the new product or solve the used to make the new product or solve the problem problem

Either fix the wheel Or add tires so it doesn't brake again

The wagon...

...broke

The design processThe design process

Finding solutions and Finding solutions and IdeasIdeas

In this phase, ideas In this phase, ideas are examined and a are examined and a concept of the overall concept of the overall design is developed. design is developed.

Preliminary sketches Preliminary sketches are used to document are used to document the design and/ or the design and/ or computer software computer software used for it. used for it.

One can document by hand or...

... use a CAD system

Documentation of IdeasDocumentation of Ideas

In this phase, all preliminary drawings In this phase, all preliminary drawings

or sketches from the previous phase or sketches from the previous phase are transformed into a finished are transformed into a finished package. package.

Today, this is accomplished using Today, this is accomplished using Computer Aided Drafting and Design Computer Aided Drafting and Design (CADD) systems. (CADD) systems.

To test, a computer simulation can be made ... ... and examined using virtual reality ....

... and a SLA/ CNC machine can be used to make a physical prototype.

Testing and RefiningTesting and Refining

In this phase, the design is tested in more In this phase, the design is tested in more realistic modes. This usually involves pilot realistic modes. This usually involves pilot plants and computer simulations for better plants and computer simulations for better visualization. visualization.

Machining equipment is used to mass produce the final product.

ProductionProduction

In the production phase, the In the production phase, the design is sent off to be design is sent off to be produced. With the use of a produced. With the use of a CADD system, the data from CADD system, the data from the design is translated into a the design is translated into a form that a Computer Aided form that a Computer Aided Manufacturing (CAM) system Manufacturing (CAM) system can understand. can understand.

Typical examples are CNC and Typical examples are CNC and CIM. Some productions CIM. Some productions processes involve Robotics as processes involve Robotics as well. well.

(B).(B). Process Design Process Design

Process design is the design of processes for desired Process design is the design of processes for desired physical and/or chemical transformation of materials.physical and/or chemical transformation of materials.

The deep understanding of physical, chemical, The deep understanding of physical, chemical, thermodynamic properties in relation with working thermodynamic properties in relation with working conditions, separation phenomena, rates of conditions, separation phenomena, rates of reactions, laws of transfer, transformation etc is reactions, laws of transfer, transformation etc is desired.desired.

The availability of technology and kind of machinery The availability of technology and kind of machinery and it’s range of applicability should be well and it’s range of applicability should be well understood.understood.

The overlapping areas of mechanical, electrical, The overlapping areas of mechanical, electrical, chemical, metallurgical and civil engineering need to chemical, metallurgical and civil engineering need to be well understood.be well understood.

(C).(C). Mechanical Design Mechanical Design Using Drawing boards/CADUsing Drawing boards/CAD(Horizontal Cylindrical Tank supported on compression load cell)(Horizontal Cylindrical Tank supported on compression load cell)

Conical Hopper

(D).(D). 3D design 3D design

Drawing and ModelDrawing and Model

(E).(E). Fabrication Fabrication

Fabrication is a specialized job jointly done Fabrication is a specialized job jointly done by the collaboration of Chemical, Mechanical by the collaboration of Chemical, Mechanical and Instrumentation engineers.and Instrumentation engineers.

How to designHow to design

1). MathematicalModel/Equations 2). Software 3). By Analogy

1). Using Mathematical Model/Equations

(Bernoulli equation)(Bernoulli equation)

(Heat conduction(Heat conduction equation)equation)

(The continuity equation)

2).2). Using Software Using SoftwareDesign software can be categorized as :Design software can be categorized as :

1. Design and Draft1. Design and Draft(e.g AutoCAD)(e.g AutoCAD)

2. Modeling and Simulation2. Modeling and Simulation(Solid Edge, Hysys, AspinPlus, AspinDyn,PRO-II, (Solid Edge, Hysys, AspinPlus, AspinDyn,PRO-II, SuperChem)SuperChem)

3. Analysis Software3. Analysis Software(Hysys, Asys, PRO-II)(Hysys, Asys, PRO-II)

Right software for right job !Right software for right job !

Software Tools for Design

HYSISHYSIS

CONSYDCONSYD

TUTSIMTUTSIM

AUTOPLANTAUTOPLANT

MATRIX-XMATRIX-X

MATLABMATLAB

AUTOCADAUTOCAD

SOLID EDGESOLID EDGE

PIPECADPIPECAD

ASPIN PLUSASPIN PLUS

SOFTWARESOFTWARETOOLSTOOLS

Characteristics of Drafting Characteristics of Drafting SoftwaresSoftwares

Main capability is Drafting Main capability is Drafting (Generate Drawings, Fabrication & Assembly Diagrams)(Generate Drawings, Fabrication & Assembly Diagrams)

Low 3-D capabilitiesLow 3-D capabilities Different Environments available in Software Different Environments available in Software

to suit Mechanical, Civil, Architecture etc.to suit Mechanical, Civil, Architecture etc. Fabrication details can be provided such as Fabrication details can be provided such as

( Materials, welding, grinding, Tolerances and Surface Finish ( Materials, welding, grinding, Tolerances and Surface Finish information)information)

Characteristics of Modeling Characteristics of Modeling SoftwareSoftware

Can generate drawingsCan generate drawings Can model a process for better Can model a process for better

visualizationvisualization Models can be used with other Models can be used with other

softwares for further processingsoftwares for further processing Can Generate machine code for Can Generate machine code for

fabricationfabrication

Model VisualizationModel Visualization

GasifierGasifier

Characteristics of Analysis Characteristics of Analysis SoftwaresSoftwares

Requires most input from other software e. g. Requires most input from other software e. g.

Drawing/Model, Material Properties, Boundary Drawing/Model, Material Properties, Boundary Conditions and other Computational constraintsConditions and other Computational constraints

Elementary Analysis e.g. Assembly, Fixing and Elementary Analysis e.g. Assembly, Fixing and Alignment, Collision, ForceAlignment, Collision, Force

Working in layersWorking in layers Integration with other softwareIntegration with other software Standard procedures need to be followed in the Standard procedures need to be followed in the

designdesign

(Hysys, Fluent, Asys, Aspin etc)(Hysys, Fluent, Asys, Aspin etc)

3). By Analogy

Scale up

Common Chemical Engineering Common Chemical Engineering SystemsSystems

AuxiliariesAuxiliariesAncillariesAncillaries

AuxiliariesAuxiliariesAncillariesAncillaries

CrystallizerCrystallizerCrystallizerCrystallizer

FiltersFiltersFiltersFilters

CentrifugesCentrifugesCentrifugesCentrifuges

ReactorReactorReactorReactor

TanksTanksVesselsVessels

TanksTanksVesselsVessels

BoilerBoilerBoilerBoiler

DistillationDistillation

ColumnColumn

DistillationDistillation

ColumnColumn

Heat Heat ExchangerExchanger

Heat Heat ExchangerExchanger

FurnaceFurnaceFurnaceFurnace

COMMON COMMON ChemicalChemical

Engg.Engg.systemssystems

COMMON COMMON ChemicalChemical

Engg.Engg.systemssystems

Case StudyCase Study

Design & Fabrication of a Design & Fabrication of a Down Draft Gasifier RigDown Draft Gasifier Rig

Facility Developed at Chemical Facility Developed at Chemical Engineering, UETEngineering, UET

Downdraft Gasifier

Wet Scrubbe

r

Blower

Recycle Pump

Water Recirculation

Tank