Chapter 1a - Introduction to Process and Sustainable Design
-
Upload
helena-francis -
Category
Documents
-
view
220 -
download
0
Transcript of Chapter 1a - Introduction to Process and Sustainable Design
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
1/29
EP426
Chemical Process Design and Optimization
Chapter 1
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
2/29
Student attainment
CLO1: Identify sustainable processes for chemicalproduction.
C4 – Assessing peer feedback and Critical evaluation of literature.
A4 – Case study, PBL, and Case summary.
P1 - Case history exercise and Case presentation.
PLO9 - ENVIRONMENT AND SUSTAINABILITY
Understand the impact of professional engineering solutions in societal andenvironmental contexts and demonstrate knowledge of and need forsustainable development.
Note:
Teaching method - Lecture & Group Project
Assessment - Test, Final Exam and report presentation.
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
3/29
EP426
Chemical Process Design and Optimization
Chapter 1 – Sustainable Process Design
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
4/29
What is Sustainability?
U.S. Environmental Protection Agency proposed thefollowing definition:
“sustainability occurs when we maintain or improve
the material and social conditions for human healthand the environment over time without exceedingthe ecological capabilities that support them”
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
5/29
Growing interest in sustainability
because of:
1. Increasing population, industrialization, andstandards of living.
2. Dwindling natural resources (for example, fossilfuels) and increase in the consumptions of thenon-renewable resources.
3. Global climatic changes.4. Risk to biodiversity and ecosystems.
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
6/29
What is Sustainability?
“triple bottom line: people, planet, and profit” - (Elkington, 1994).
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
7/29
Sustainable design
Sustainable design of industrial processes may bedefined as:
“the design activities that lead to economic growth,
environmental protection, and social progress for thecurrent generation without compromising the potential of future generations to have an ecosystem
that meets their needs.” - El-Halwagi, 2012
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
8/29
Principal objectives of a sustainable
design:
1. Resource (mass and energy) conservation
2. Recycle/reuse
3. Pollution prevention
4. Profitability enhancement
5. Yield improvement
6. Capital –productivity increase and
debottlenecking7. Quality control, assurance, and enhancement
8. Process safety
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
9/29
Process
Synthesis
Process
Analysis
Structure & Parameters
(unknown)
Process Output
(unknown)
Pillars of sustainable process design
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
10/29
Process Synthesis
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
11/29
Process Analysis
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
12/29
THE DESIGN PROCESS
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
13/29
Schedule The Design Process
• Primitive Design Problems
• Example
• Steps in Designing and Retrofitting Chemical Processes
• Assess Primitive Problem
• Process Creation
• Development of Base Case• Detailed Process Synthesis - Algorithmic Methods
• Process Controllability Assessment
• Detailed Design, Sizing, Cost Estimation, Optimization
• Construction, Start-up and Operation
• Environmental Protection
• Safety Considerations
Ref: Seider, Seader and Lewin (1999), Chapter 1
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
14/29
Primitive Design Problems
The design or retrofit of chemical processes begins with thedesire to produce profitably chemicals that satisfy societalneeds that arise in the broad spectrum of industries thatemploy chemical engineers:
– petrochemicals,
– petroleum products
– industrial gases
– foods
–pharmaceuticals
– polymers
– coatings
– electronic materials
– bio-chemicals
Note: Many design projects involve the redesign, or retrofitting , ofexisting chemical processes to solve environmental problems and to adhereto stricter standards of safety.
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
15/29
Steps in Process Design and Retrofit
Section A
• Assess Primitive Problem
• Development of Base-case
Section B
• Detailed Process Synthesis -AlgorithmicMethods
Section C• Plant-wide Controllability Assessment
• Detailed Design, Equipment sizing, Cap. CostEstimation, Profitability Analysis, Optimization
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
16/29
Steps in Process Design and Retrofit
Assess PrimitiveProblem
Detailed Process
Synthesis -Algorithmic
Methods
Development ofBase-case
Plant-wide
ControllabilityAssessment
Detailed Design,Equipment sizing, Cap.
Cost Estimation,
Profitability Analysis,
Optimization
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
17/29
Steps in Process Design and Retrofit
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
18/29
Steps in Process Design and Retrofit
Assess PrimitiveProblem
Development ofBase-case
Detailed Process
Synthesis -Algorithmic
Methods
Plant-wide
ControllabilityAssessment
Detailed Design,
Equipment sizing, Cap.
Cost Estimation,
Profitability Analysis,
Optimization
SECTION A
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
19/29
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
20/29
Steps in Process Design and Retrofit
Assess PrimitiveProblem
Development of
Base-case
Plant-wide
ControllabilityAssessment
Detailed Design,
Equipment sizing, Cap.
Cost Estimation,
Profitability Analysis,
Optimization
Detailed Process
Synthesis -Algorithmic
Methods
SECTION B
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
21/29
Steps in Process Design and Retrofit
Section B
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
22/29
Assess PrimitiveProblem
Development of
Base-case
Detailed Process
Synthesis -Algorithmic
Methods
Detailed Design,
Equipment sizing, Cap.Cost Estimation,
Profitability Analysis,
Optimization
SECTION C
Plant-wide
ControllabilityAssessment
Steps in Process Design and Retrofit
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
23/29
Steps in Process Design and Retrofit
Section C
From : Dev. of
base-case
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
24/29
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
25/29
Schedule The Design Process
• Primitive Design Problems
• Example
• Steps in Designing and Retrofitting Chemical Processes
• Assess Primitive Problem
• Process Creation
• Development of Base Case• Detailed Process Synthesis - Algorithmic Methods
• Process Controllability Assessment
• Detailed Design, Sizing, Cost Estimation, Optimization
• Construction, Start-up and Operation
• Environmental Protection
• Safety Considerations
Ref: Seider, Seader and Lewin (1999), Chapter 1
Section A
Section B
Section C
Initial
Final Design
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
26/29
5 Environmental Issues in Design
1. Handling of toxic wastesIt is essential that facilities be included to removepollutants from waste-water streams.
2. Reaction pathways to reduce by-product toxicity• Especially those recovered as byproducts, needs to be
evaluated.
• Pathways in large quantities of toxic should bereplaced by alternatives, except under unusualcircumstances.
3. Reducing and reusing wastes• Environmental concerns place even greater emphasis
on recycling for unreacted, product and by-productchemicals
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
27/29
Environmental Issues in Design ( ont’d)
4. Avoiding non-routine events
• Reduce the likelihood of accidents and spills through thereduction of transient phenomena, relying on operation at thenominal steady-state, with reliable controllers and fault-detectionsystems.
5. Design objectives, constraints and optimization
• Environmental goals often not well defined because economicobjective functions involve profitability measures, whereas thevalue of reduced pollution is often not easily quantifiedeconomically.
• Solutions: mixed objective function (“price of reduced pollution”),
or express environmental goal as “soft” or “hard” constraints.
• Environmental regulations = constraints
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
28/29
Design Approaches for Safety
1. Techniques to Prevent Fires and Explosions• Inerting - addition of inert dilutant to reduce the fuel
concentration below the LFL• Installation of grounding devices and anti-static devices to avoid
the buildup of static electricity• Use of explosion proof equipment•
Ensure ventilation - install sprinkler systems2. Relief Devices3. Hazard Identification and Risk Assessment
• the plant is carefully scrutinized to identify all sources of accidentsor hazards.
• Hazard and Operability (HAZOP) study is carried out, in which all
of the possible paths to an accident are identified.• when sufficient probability data are available, a fault tree is
created and the probability of the occurrence for each potentialaccident computed.
-
8/18/2019 Chapter 1a - Introduction to Process and Sustainable Design
29/29
To be continued…
Chapter 1 - Hierarchical approach to process design