Cped 02

Chemical Plant Equipment Design
Lecture – 3
18-10-2021
Prof. K.V. Ramesh
Department of Chemical Engineering
Andhra University
In the last class, we came to know that
• Process design is the choice and sequencing of
units for desired physical and/or chemical
transformation of materials.
• Developing steps – design activity

• Executing steps – engineering activity
Chemical Engineering design
It involves
• Process design – rating
• Mechanical design – sizing
• Economic design - costing
Objective of chemical engineering
design
• Design of new chemical plants
• Expansion of existing plants
• Renovation of existing plants
Development of a new plant or a
process is a complex problem
Stages through which a plant design
project moves
Skills required for a chemical engineer
to work on plant-design project
The chemical engineer plays central creative role or
acts as a key advisor. The following are the skills
that are needed:
• Research
• Market analysis
• Design of individual pieces of equipment
• Cost estimation
• Computer programming
• Plant location surveys
Some terms used in this subject
• Plant design
• Design engineer
• Cost engineer
• Process engineering
• Process design
Plant design
• Plant design includes all engineering aspects
involved in the development of either a new,
modified, or expanded industrial plant.
Design engineer
• The design engineer is the chemical engineer
who makes economic evaluations of new
processes, designs individual pieces of
equipment for the proposed new venture, or
develops plant layout for coordination of
overall operation.
Cost engineer
• Cost engineer is the chemical engineer who is
specialized in the economic aspects of design
Process engineering
• Economic evaluation and general economic
analyses of industrial processes is called as
process engineering.
Process design
• Process design means actual design of the
equipment and facilities necessary for carrying
out the process
project moves
1st stage – Inception of the basic idea
• The idea may originate in the sales department
– as a result of customer request (or)
– to meet a competing product
• The idea
– may occur spontaneously to someone who is acquainted with the aims and needs of a
particular company (or)
– may be the result of an orderly research program
– (or) an offshoot of such a program
• The operating division of the company may develop a new or modified chemical,
generally as an intermediate in the final product.
• The engineering department of the company may originate a new process or
modify an existing process to create new products
If the initial analysis indicates that the idea may have possibilities of developing into a
worthwhile project, then preliminary research or investigation program is initiated.
Here a general survey of the possibilities for a successful process is made
considering the physical and chemical operations involved as well as the economic
aspects. Next the project moves to 2nd stage.
project moves
2nd stage – Preliminary evaluation of
economics and market
This is also called as process research phase. It
includes
• Preliminary market surveys
• Laboratory scale experiments
• Production of research samples of final
product
If the potentialities of the process are fairly well
established, the project is ready for
development phase (3rd and 4th stages)
project moves
3rd stage – Development of data
necessary for final design
At this point, a pilot plant or a commercial development plant
may be constructed. Design data and other process
information are obtained during this stage. This
information is used as the basis for carrying out the
additional phases of the design project.
• A pilot plant is a small scale replica of the full-scale final
plant.
• A commercial development plant is usually made from odd
pieces of equipment which are already available and is not
meant to duplicate the exact setup to be used in the full-
scale final plant.
Then the project moves to 4th stage.

project moves
4th stage – Final economic evaluation
At this point, a complete market analysis is made, and
samples of the final product are sent to prospective
customers to determine if the product is satisfactory and if
there is a reasonable sales potential.
• Capital-cost estimates for the proposed plant are made
• Probable returns on the required investment are
determined
• A complete cost-and-profit analysis of the process is
developed
Before going to the next phase, the company management
normally becomes involved to decide if significant capital
funds will be committed to the project.
4th stage – Final economic evaluation
Before going to the next phase, the company management
normally becomes involved to decide if significant capital
funds will be committed to the project.
• At this point, the engineer presents
– Preliminary design work
– Oral reports
– Written reports
• The engineer’s reports act as primary basis on which the
management will decide if further funds should be
provided to the project.
• If the economic picture is satisfactory, the final process
design phase(5th stage) begins.
project moves
5th stage – Detailed engineering design
At this point all design details are worked out including
• Controls
• Services
• Piping layouts
• Firm price quotations
• Specifications
• Designs for individual pieces of equipment
• Other design information necessary for construction of final plant.
A complete construction design is made with
• Elevated drawings
• Plant-layout arrangements
• Other information required for the actual construction of plant.
Then the process moves to the final phase (stages 6 to 9)
project moves
6th to 9th stages – Final phase
The final phase consists of
6th stage
• Procurement of the equipment
7th stage
• Construction of the plant
8th stage
• Start up of the plant
• Overall improvements in the operation
• Development of standard operating procedures to give the
best possible results
9th stage
• Production
Process design development
(stages vs. phases)
Stage Description Phase Description
No. No.
1 Inception 1 Inception
2 Preliminary evaluation of 2 Process research phase
economics and market
3 Development of data 3 Development phase
necessary for final design
4 Final economic evaluation
5 Detailed engineering design 4 Final process design phase
6 Procurement
7 Erection
5 Final phase
8 Startup and trial runs
9 Production
Money spent
• Expensed engineering – the money spent upto
development phase (i.e. upto 4th stage)
• Capitalized engineering – the money spent for
the remaining phases or stages
This distinction is used for tax purposes.

General overall design considerations
• Health and safety hazards
• Loss prevention
• Environmental protection
• Plant location
• Plant layout
• Plant operation and control
• Utilities
• Structural design
• Storage
• Materials handling
• Patent considerations
Thank you

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Chemical Plant Equipment Design

• Developing steps – design activity

Then the project moves to 4th stage.

This distinction is used for tax purposes.

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