Workshop on Teaching Aspects of Process Integration

Dominic C. Y. Foo University of Nottingham

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Modules with PI elements (UoN) Taught modules: H82PLD – Plant Design (year 2) H84PSD – Process Synthesis & Design (MEng Y4/MSc) H84PDO – Process Design & Optimisation (MEng Y4

optional, MSc) Student projects: H83DPX – Design Project H84MEP – MEng Project

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The “Onion diagram”

Reactor

Separation & recycle

Heat exchange network

Utilities (Linnhoff et al., 1982; Smith 1995, 2005)

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H82PLD – Plant Design (Y2) Week Content

1 Introduction 2 Phase separation, gas/liquid separator design 3 Pump design

5 – 6 Heat exchanger design 6 – 10 Heat exchanger network (HEN) synthesis

•CC & PTA for utility targeting •GCC for utility selection •PDM for HEN synthesis

11 – 12 Process economic evaluation

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Recommended texts

Smith, R. (2005). Chemical Process Design and Integration. New York: John Wiley & Sons (heat exchanger design, heat exchanger network synthesis, economic analysis).

Smith, R. (1995). Chemical Process Design. McGraw Hill (heat exchanger network synthesis).

H84PSD – Process Synthesis & Design (Y4; Malaysia campus)

Workshop on PI Teaching 6 Copyright@Dominic Foo

Week No Lecture Topic 1 Introduction to process synthesis; heuristics for process synthesis 2 Synthesis of separation trains – column sequencing 3 Synthesis of separation trains – residual curve maps for azeotropic

mixture 4 Off for Coursework 1 5 Presentation for Coursework 1 (23/10) 6 Synthesis of resource conservation network (RCN) – targeting

techniques 7 Synthesis of RCN – network design & evolution techniques 8 Off for Coursework 2 9 Synthesis of RCN – source interception/regeneration 10 Synthesis of RCN – waste treatment and total RCN 11 Off for Coursework 2 12 Presentation for Coursework 2 (18/12)

H84PSD – Process Synthesis & Design (Y4; UK campus)

Week No Lecture Topic 1 - 2 Nil

3 Introduction; heuristics for process synthesis (10 Oct, Wed, 9 am) Synthesis of separation trains – column sequencing (12 Oct, Fri, 2 pm)

4 Synthesis of separation trains – residual curve maps for azeotropic mixture (15 Oct, Mon, 9 am)

5 - 6 Off for Coursework 1 7 Presentation of Coursework 1 (7 Nov, Wed, 9 am)

Synthesis of resource conservation network (RCN) – Data Extraction and Graphical Targeting (9 Nov, Fri, 2 pm)

8 Synthesis of RCN – Algebraic Targeting (12 Nov, Mon, 9 am) Synthesis of RCN – Network Design & Regeneration (13 Nov, Tue, 2 pm) Presentation of Coursework 2 (14 Nov, Wed, 9 am)

9 Off for Coursework 2 10 - 12 Nil

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3/27/2013 Workshop on PI Teaching 8 Copyright@Dominic Foo H84PSD - Process Synthesis & Design Lecture 1 - 8

Recommended texts

Part 1: Seader, W. D. Seider, J. D. & Lewin, D. R. (2003). Product & Process Design

Principles, New York: John Wiley & Sons. Biegler, L.T., Grossman, E. I. and Westerberg, A. W. (1997). Systematic

Methods of Chemical Engineering and Process Design, Prentice Hall, New Jersey (distillation trains & azeotropic distillation).

Part 2: Foo, D. C. Y. (2012). Process Integration for Resource Conservation, CRC

Press, Boca Raton, Florida, US. El-Halwagi, M. M. (2006). Process Integration, Elsevier, Amsterdam

(alternative: El-Halwagi, M. M. (1997).

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H84PDO – Process Design & Optimisation (Y4)

Week Content 1 Introduction to process optimisation

2 Optimisation technique 1 – Automated targeting model (ATM) for resource conservation networks (RCNs)

3 Optimisation technique 2 – Superstructural model for RCNs 4 Optimisation technique 2 – ATM for biorefinery 5 Optimisation technique 2 – Superstructural model for biorefinery 6 Presentation for Coursework 1

7 Optimisation technique 3 – Superstructural model for energy supply chain

8 Optimisation technique 3 – Biomass supply chain synthesis 9 Introduction to molecular design techniques

10 Optimisation technique 4 – Superstructural model for molecular design

11 Off for Coursework 2 12 Presentation for Coursework 2

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Recommended texts

El-Halwagi, M. M. (2006). Process Integration, Elsevier, Amsterdam.

Foo, D. C. Y. (2012). Process Integration for Resource Conservation, CRC Press.

Assessment schemes Plant Design Process Synthesis

& Design Process Design &

Optimisation

Exam Marks: 55% Format: 3 questions in 2 hrs

NIL NIL

Courseworks Marks: 45% Format: CW1 – 15% CW2 – 30%

Marks: 100% Format: CW1 – 50% CW2 – 50%

Marks: 100% Format: CW1 – 50% CW2 – 50%

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Student projects H83DPX – Design Project (year 3; 30 credits) Section VI - Heat recovery & utility balances

H84MEP – MEng Project (year 4; 20 credits) Advanced heat integration Material recovery Column sequencing

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Two-days workshop on water integration (Day 1) Introduction to resource conservation network

(RCN) Session 1 – Data extraction principles Session 2 – Graphical targeting for direct

reuse/recycle Lunch

Session 3 – Algebraic targeting Session 4 – RCN design & evolution

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Two-days workshop on water integration (Day 2) Session 5 – Process changes Session 6 – Synthesis of material regeneration

network Lunch

Session 7 – Synthesis of RCN with mathematical optimisation techniques

Overview of other advances

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Photos (UoN M’sia campus)

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Photos (UoN UK campus)

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Photos (professional training)

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Example worksheets

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Source Fi (kg/s) Ci (ppm) mi (mg/s) SR1 0.8 0 0 SR2 5.0 14 70.0 SR3 5.9 25 147.5 SR4 1.4 34 47.6 Σi 13.1 265.1

Lim

iting

mas

s lo

ad (m

g/s)

Flowrate (kg/s) 5 10 15

50

100

150

200

250

300

SR1

SR2

SR3

SR4

FFW = 2.1 FWW = 8.2

Example worksheets

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Example worksheets

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SK1 F = 50 t/h

C = 20 ppm m = 1000

SK2 F = 100 t/h C = 50 ppm m = 5000

SK3 F = 80 t/h

C = 100 ppm m = 8000

SR1

SR2

SR3

SR4

20 t/h 65 t/h 35 t/h

25 t/h

30 t/h 35 t/h

SK4 F = 70 t/h

C = 200 ppm m = 14000

35 t/h F = 50 t/h C = 50 ppm

F = 100 t/h C = 100 ppm

F = 70 t/h C = 150 ppm

F = 60 t/h C = 250 ppm

10 t/h

5 t/h

FW

25 t/h

35 t/h 30 t/h

F = 70 t/h C = 0 ppm

Example worksheets

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Textbook on resource conservation

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Supplementary material

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Software tool (FOC!)

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Questions?