Video summary
This course serves as a critical culmination for both third and fourth-year students, designed to bridge theoretical curriculum knowledge with the practical application of building a complete chemical plant. The department considers this subject highly important, ensuring its continuity even as other courses evolve, with the ultimate goal of fostering future entrepreneurs in the core chemical sector. Students are organized into groups that will work on specific chemicals, potentially replicating successful alumni projects to launch their own ventures. The course structure involves a tight weekly schedule where classes are split into two divisions: one group performs the practical work while the other presents findings, with roles rotating to ensure comprehensive learning and engagement for all participants.
The technical workflow of the course progresses from initial literature reviews and background research to detailed flow sheet development and mass balance calculations based on patent data or journal articles. Students will utilize steady-state simulation tools like DWSIM, with special workshops provided for third-year students who have not previously encountered such software. A key component of the coursework involves comparing results obtained from linear mass balances against rigorous simulator outputs, requiring students to justify any discrepancies. Furthermore, the curriculum includes parametric studies where students analyze the sensitivity of operating parameters such as residence time and reboiler duty, with specific guidance to avoid economically nonsensical optimizations like excessively high reflux ratios that would lead to prohibitive energy costs.
Academic integrity and report presentation standards are strictly enforced throughout the project lifecycle. Students must submit reports in stages via Google Docs or LaTeX, adhering to a plagiarism index limit of 20% to avoid severe penalties, while also ensuring that figures are redrawn rather than copied to prevent clutter and maintain originality. The Process Flow Diagrams (PFDs) are central to the assessment, requiring a minimum font size of 10 points and logical segmentation into reaction and separation sections for readability. Stream data must be presented in mass units like tons per hour with temperatures in Celsius, allowing for quick visual verification of mass balances. Additionally, students are expected to validate their plant costs against similar existing facilities using scaling factors and to clearly describe non-obvious design choices in their reports.
The course concludes with a final evaluation that includes an industry assessment where top-performing groups may be selected for review by external experts, mirroring real-world industrial scrutiny. Throughout the semester, faculty members from various departments, including simulation experts and alumni entrepreneurs, will provide support and motivation to help students overcome technical challenges like unavailable kinetics or thermodynamic data. The instructors emphasize that while the course is rigorous and demanding, akin to a complex role-playing game, it offers immense opportunities for growth and may even change students' perspectives on chemical engineering. Ultimately, the department stands ready to support any student aspiring to enter the core sector, providing necessary resources and guidance to turn their projects into viable industrial realities.
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okay uh really delighted to meet you
all um and happy New Year hope uh this
will turn out to be a wonderful year for
all of
you so this is a course to be taken by
both third year students and fourth year
students
right um can all the third year students
raise your
hands okay
Okay I uh my eyesight is not very good
so I'm going to ask the fourth Years
also fourth
years yeah
thanks thank
you so this course is uh considered very
important by the department that is why
it said that it will continue as it is
for the third years even though many
courses got changed merged and so
on this course will remain more or less
the same uh except for for one small
change which I will point out as we go
along it is also the culmination course
that means you learn a lot of things in
the in the
curriculum and then the proof of the
pudding is in building a plant which is
what you're going to do in this
course right as a matter of fact we
asked uh all of you whether you you
would like to work on any specific
chemical in the fourth year batch uh
there were four groups that said that
they wanted to work on a chemical of
their
choice okay we
assigned the reason being that
um uh we had um our Alum prep
jaura I think he graduated in 73 if I'm
not mistaken 72 or
73 he wanted to work on a particular
chemical in a similar
course and uh he took the head's
permission he worked on it afterwards he
went on to establish the same plant and
he is a successful
entrepreneur as a matter of fact he has
set up an award for this course for the
project that does well so we will I
assume that we will do that one for uh
fourth years and one for third
years and uh I strongly believe in fact
many of my colleagues share this that it
is
possible uh to uh have some
entrepreneurs out of you who will go
into the core sector I'm sure that there
will be some of you who will have some
it internet and you know so on and and
so forth but it is the core sector in
which you know you'll be the you know
most competent person compared to
possibly anybody else okay and uh we
believe that um such a thing will happen
and this course uh could be the first
step in that direction and in case any
of you would want to do that the
department will be more than happy to uh
support all of you
uh so the way we are going to do that is
uh this lecture is um uh I'm going to
give a overview of how this course will
be
run then we have Prof Sanjay mahajani he
will give a um short
presentation and uh we have Professor
Rahul naar you all know him he teaches
the Fine Chemicals course how many of
you have registered for that course
okay okay it's better to ask how many of
you have not registered almost everybody
seems to have raised your hand okay so
he's our uh star batsman he's going to
do it afterwards and then Professor yra
shastri will come and talk um he will
talk about um um you know uh
sustainability and carbon footprint and
you know some of these things okay
so these are some of the references that
will be
used okay and here is um a Texas andm
University uh they have given a link so
we thought that many of the references
in that will be useful so I given the
link for that
also I want to show you the weekly
schedule it's a very very tight course
it is not possible to uh postpone any
lecture it is not possible to cancel any
lecture because we cannot make up for
that
okay so there is a weekly schedule which
I will uh
show uh we will put the weekly schedule
also on the
model so we have shown uh CL 331 and cl
452 separately in case uh there are
going to be any differences because of
your uh you know previous courses and
you know things like that but let me
open this CL 452 weekly U
schedule so we have um uh the first week
on the date is given 14th January 17th
January so we will have this class on
Tuesdays and Fridays Tuesday afternoon
and Friday
afternoon and
uh in every um class so whatever I'm
saying is going to be applicable to the
third years as well as the fourth years
the class will be divided into two
halves one half will do the work and the
other half will make the presentation so
in other words um so you will have uh PR
water this called a b uh you will have
two divisions A and B in each class so
division a will make presentation and
division B will do the work for their
presentation on the next class right
that division B who does the word they
are not presenting they will be here so
in this class this is the classroom for
both third years and the fourth years
who are doing the actual work okay who
are not presenting they'll come here and
we'll have two Tas
here and those who are presenting will
be divided into three panels there are
going to be two faculty members in
charge of each of the
panels and uh so we have some of the
faculty members here and as you can see
the department has uh assigned 12
faculty members to teach this
course um six for 331 and six for U 452
each will have three panels okay so it's
an important course that's why the
department said that they will assign
six uh 12 faculty members to teach this
course now uh so we'll have um so this
written as division a and division B
division a will start presenting 14th
January and then 17th January division B
will make presentation and what they are
supposed to do is given here explained
as the task literature review and
background
work then detailed uh flow sheet
development here uh I call it as mass
balance mass balance means
uh you will have to say something like I
have this
column I expect this kind of split or I
have the reactor I expect this amount of
conver
conversion so you will put that put
those numbers and based on that you'll
be able to do the mass balance it is not
based on detailed calculation rather it
is not based on a simulator work
simulator is going to come later right
you will have to say that this is what I
want from this or this is what I see in
the patent in the patent they say that I
will get a 9010 split so you put that so
you'll be able to do a mass balance
using that information right similarly
for reactor separator so on and so forth
mixer whatever you have right so you
have to do that kind of mass balance
here after that comes steady state St uh
flow sheet
simulation uh the fourth year students
have already been exposed to DW Sim so
you may find it convenient to use DW Sim
if some of you want to use some other
Simulator for whatever reason it's okay
for example you might say thermodynamics
is better or that property is present in
uh Aspen plus but not in DW Sim I'm
going to use some other simulator that
is okay
or some of you might say that I have a
difficulty in convergence maybe Asen
plus has better model people have
reported that there is a problem of
course it is possible that if you don't
try hard enough it may not converge in
which case it it will be a waste of time
to shift to a new simulator you would
rather make sure you put in the effort
in the old simulator and make it work
right the third year students have not
had a course in DW
Sim and um the department said that let
them learn dwsim as a part of this
course all right otherwise you won't
have fourth year free to do whatever you
want right that's what you wanted right
we wanted to release the free time for
you so what we are going to do is by the
way dwsim learning is extremely simple
and you can learn without any problem
and for you for the CL 331 students
stents on Friday in this very classroom
PRI and his team will conduct a workshop
on DW
Sim okay so all of you come over and
those of you even four five2 students in
case anybody wants to be here you're
welcome um dwc will be covered and we
have learning material through what is
known as spoken tutorial which is
created for self- Learning and uh so you
can figure it out yourself right it's
not a it's uh it's very easy I know that
you can figure out all new things and DW
Sim is no exception
right so in this um one of the things
that you would also do in this week in
week
four yeah week
four week four of course the dates are
given here one of the things that you
have to do is you have to compare
compare the results obtained from mass
balance and simulation and justify the
difference remember you did a linear we
called it linear mass balance here right
perform linear mass balance so you got
some values you said I want this split I
want this conversion I want this Purity
accordingly you came up with a mass
balance okay how to arrive at that how
did you get that you got it from a
reference uh literature uh
uh Journal article patent or whatever it
is so you put those numbers right so
without asking without doing a detailed
study of how you are going to get it
okay so you have the mass balance energy
balance you don't do only mass balance
okay but when you go to the steady state
flow flow sheet simulation using
whatever simulator you are going to use
you will do the simulation and then you
will compare the results obtained from
mass balance and simulation and you have
to justify the
difference okay so in other words the
the steady state simulation the flow
sheet based simulation is done to arrive
at the splits convergence conversion so
on and so forth right that's what this
is
for then after that you will do
parametric study of operating parameters
so in this um can you suggest some
parameters that you want you would want
to uh you want to study can you think of
any parameters whose sensitivity you
would want to
find name some parameters anyone a
reactor for example
okay so you can think of it as a
residence time for example right you can
think of it as a Rea temperature feed
temperature right you can think of as
um um maybe whether it is arotic or
operating temperature one is of course
Fe temperature the operating temperature
so on and so forth you may want to
perturb some of these things so that it
will tell you for
some in some range there is no change at
all then it allows you to choose a
particular value that is that makes
economical sense or sense makes sense
from safety point of view and so on
right what about a distillation column
what do you
think reboiler Duty okay so reboiler
duty means you will you may say I want
to change the purity
right in some cases it may be possible
some cases if it allows you if it if you
can operate in a band then it is okay
you can do that okay anything
else ah this is what I wanted to hear so
reflex ratio is supposing supposing you
say that I'm going to do 10 times the
minimum reflex
ratio will the Purity get better
it might right so is there a
consequence if you use a very large
reflex ratio what will
happen let's have the product reboiler
Duty what did that person
say what will happen to reboiler
duty reboiler duty will also increase
because you have to reflex you're
sending lot of things
below and then you have to heat
it right so you may say I'm going to get
.1% Improvement but your energy cost is
going to shoot
up so please do not so which means you
actually don't have any freedom in
working with reflex ratio most of the
time the simulator will give you
simulator will say I can do a
sensitivity study of the distillation
column using reflex ratio
but please don't do that because if you
do that it will say put very large
reflex ratio because you will get better
Purity but you will go
bankrupt right you'll go bankrupt
because truly
speaking if you want to see the effect
you should include the energy cost
also but then you may not have done the
costing by that time so it's not
possible to do that so it is better to
stay away from the reflex ratio please
all of you remember if anybody perts The
Reflex
ratio I'm going to flunk
you okay anybody comes up with reflex
ratio and say I'm going to use 10 times
The Reflex ratio and do such uh uh you
know meaningless simulation
studies you will get at least one grade
less if not getting flued is that okay
is that clear
why you should not use reflex ratio as a
sensitiv as a parameter of parameter for
sensitivity
studies okay
so here you
see uh look at line number 10 it says
evaluation stage one here you will
submit a
report you have to submit a report until
this time so this says on 28th January
on 31st January on that day you will
submit a report and there will also be a
presentation
okay and then you have U steady state
flow sheet
simulation parametric study of operating
parameters and then in the in
this um
week stage two report will be
submitted and uh there is nothing
additional here but you will complete
the specific tasks given by The Faculty
panel faculty panel will say do this do
that or some of the things you may not
have done this week is given to catch up
right and after 21st February you're
going to come back only on 7th of
March why is
that mid semester exam and uh uh in fact
the mid semester exam will start
immediately right in fact all of the
next
week we could have started on the next
Monday itself but then the students will
come and say I didn't have time to
prepare right so we are we are giving
the Monday off so that you have time to
prepare so the next presentation will be
on 7th March Friday is that
clear then it shift then division B
comes first and division a comes next
okay why is that
because in the past division B students
have
complained uh sorry division a students
have
complained I have an advantage
disadvantage because I'm presenting
first so we are going to make them
present second after mid semester is
that okay so equipment sizing of all
equipment economics uh profor Sanjay
maaj has has quite a few things to talk
about about
economics uh detailed design of one
equipment that you have to do and then
the date is given evaluation stage three
then we have environmental uh impact
assessment report submission and final
presentation and then we have final
valuation uh so your classes will uh end
on 11th
April what we might do we did this last
year we might do it this year also we
might select one or two um groups maybe
two groups from each
panel and uh we will forward them to the
industry industry assessment and select
the top two last year we actually had
the industry people coming and looking
at all six remember we are going to
select best two from each of the three
panels
and they will go through it and select
the top
two last year we had a presentation by
these six groups to the industry uh
experts I'm not sure whether we are
going to do it this this time or not
because we have to do it for two years
and I I don't know whether we have slots
okay but we will play it by the year we
might still do that but assessment by
the industry that we will try to
do and that is where
the any question on
this whatever we discussed just
now
okay so that was weekly
schedule grading pattern okay let me
show
that so
here are the breakup of marks weekly
tasks
30% okay weekly task means whatever you
are going to
present and then evaluation so this
means this is only for presentation
right PR weekly
tasks evaluation stage one 10% this is
for the
report report and vaa okay so evaluation
stage one 2 three and four four we call
it final evaluation those marks are
separate both presentation and vaa both
presentation and the report okay by the
way presentation means it is vaa also
because we will ask you questions and um
uh you know we can have discussion on
how the presentation will be made and
how we will assess you and so on we can
uh talk about it later
but the weeks in which you are going to
submit the reports will be referred to
as evaluation stage 1 2 3 and final
evaluation stage okay those together
will carry 70% marks all other weeks
presentations will carry
30% is that okay and the evaluation
stage breakup vaa will carry 60% and
report will carry
40% the report will have common Mark for
everybody but vaa will have different
marks depending on how you present have
you whether you have uh done the work
not not done the work okay whether you
are able to answer the questions and so
on and so forth based on that we will
give 60% of this which means evaluation
stage one six marks will be for vaa four
marks will be for the
report is it okay 60% of this
10% uh report will be 40% of this 10%
stage two and three it will be 60% of
15% and so
on uh by the way all the files
everything that I'm showing will be
uploaded on mood so in case you missed
out something don't worry it'll be
there um so during the weekly tasks a
soft copy of the presentation should be
uploaded onto Moodle by 11:00 a.m. on
the day of the presentation okay all the
presentation should be uploaded onto
Moodle by 11:00 a.m. onto the Moodle and
that's what will be used and if there is
any um late this thing there will be a
penalty and uh and it will be that
presentation which you will use for
presenting you cannot say I made a
mistake I have a corrected one will not
permit you you better put it by 11:00
a.m. and use that so in other words you
do everything ahead of time we don't
have time to do all these things it it
has to it has to this course has to go
as a Clockwork
okay we will do a plagiarism check on
every report and institute's Norms will
be followed in case of any plagiarism
extremely important extremely important
okay heads of many important people have
rolled because they plagiarized or there
was a
suggestion so we are no exception right
so we will use the plagiarism check
software that IIT has
enabled the plagiarism index has to be
less than
20% if it exceeds 20% by x% there will
be a penalty
of 5x % up to 40%
similarity okay so in other words if
there is an index of 25% that extra 5%
Time 5 so 25% penalty will be
applied okay Beyond 40% similarity the
report will not even be accepted it will
be rejected okay please take the
plagiarism extremely
seriously next one one of the things
people have the habit of copying all
kinds of
figures unnecessary things you do a
literature search some figure came
beautiful looking fig figure copy paste
it so up to 45 figures can be copied
from other sources provided that the
source is acknowledged for any figure
Beyond this there will be a penalty of
5% for each figure we don't want you to
do that you redraw
it okay don't put unnecessary figures
don't clutter the thing don't make it
look jassy with lots of beautiful
looking color pictures we are going to
penalize if you do it if you w do
it we have Tas every panel will have one
ta there are six panels for two courses
and there will be two Tas here okay
they'll also be available for any um
Makeup Session and so
on as I already told you there will be a
dwc workshop for cl 331 on Friday 10th
January 2025 in this Hall
okay uh report writing Professor sandip
R suggested that can we use Google doc
so we are we said that it'll be okay um
we will use Google do Google doc create
a folder for every group and um separate
PDF for each stage so that we know what
you submitted we know what we looked at
in the previous one and of course um you
have to submit two physical copies of
the
report uh by the way this report
submission comes four times okay and
there is only one copy U you don't have
to have there might be six uh people in
a group you don't have to submit six
copies uh only one copy actually two
copies are required one for each
examiner there are two examiners in each
panel so you have to
submit but the Google Doc person say
will be only one you it will evolve okay
so that will allow that the same Google
doc same report is you can look at it at
various stages
okay is that okay are you comfortable
using Google
doc for writing the
report okay in case somebody doesn't
want to do it you would rather use
lattic you're welcome okay
okay this is an important thing a few
years ago I think it was
2020 uh there was a group that
found that their
chemical was studied in reasonable
detail and that a report was already
available some European
University what the group did was they
took
it and submitted in stages
okay but uh you know some of us have
also
undergone education like you in
institutions like
yours
right so it was a serious problem we C
and they got
F
okay it was a fourth year batch so it
was a problem for
them so
if such a thing happens what we want you
to do is please report
it please report it so that you don't
get into difficulty it also makes our
work totally
unpleasant do you think we like enjoy we
enjoy giving
F we have sleepless nights if you have
to give F
right it may be possible that we might
might allow you to use that we might say
okay that chemical is okay good that
somebody has done let's add to that it
may be possible that's what I meant by
reported add to it for
example you might say that okay they
have done it in this through this route
I'm going to take some other roote I'll
produce the same chemical it's
fine and compare
contrast maybe from let's say carbon
footprint point of view it may be a lot
better
the new one that you propose for example
right you may want to do p and I diagram
for
example you may want to do a detailed
design of more units because we have in
one week you are supposed to do a
detailed design of one of the units here
you might say do do a detailed design of
the whole
thing
right or you might say that let me do a
dynamic simulation of a critical unit
there are any possibilities I'm not I'm
just giving an
example or you might say that I don't
want to do this chemical it has already
been done Please assign some other
chemical that's also
fine okay but please don't do that
plagiarism you'll get into big trouble
Big Time trouble don't want to do that
is that
okay another thing you'll find kinetics
may not be
available so Prof Sanjay vajani will
help come up with similar chemicals that
have the required Property
Data
okay what if thermodynamics are not
available group contribution method
Professor sandip Ray will help or other
thermodynamics faculty members here will
help simulation report simulation
support we have
professor professor Malik one of the I
would say outstanding experts on this
topic in the country
he'll be here he retired but I have
requested him to be with us on Tuesdays
on Fridays by the way that's one reason
why we kept them together the third year
and fourth year together I cannot expect
Professor Malik to come from here T four
times a week so now he has to come only
twice a week he'll be here all your
simulation doubts and so on he'll be
here to help
we will have some uh meetings by
industry experts to be organized by I
mean our own uh people Professor Rahul
nabar may give some talks Sanjay mahini
may give some talks
um they may also bring in some experts
Professor guru's classmates some of them
are entrepreneurs he may bring some of
them some of the alumni are um extremely
passionate about this in fact last year
we had one I think
1972 Alum he came and gave a talk and um
and you you should listen to them
talk and uh you know you feel as if
you'll feel that you
know this is what made their life I mean
designing the plant I mean it's
incredible the kind of um enthusiasm
they can uh they can transfer to you
possibly we should have one some of
those courses right in the beginning so
that will probably motivate our students
so 4:30 p.m. uh Wednesday we will have
that so all your questions please ask it
will be an optional um uh meeting and
um uh the venue has to be identified so
we'll have to find a classroom where we
can do
this so we have some guidelines
uh on how the report should be created
and so
on and the
presentation so this is one guideline
that uh um we implemented and uh it's
very good whenever you make a
presentation from the second
presentation
onwards please find out this point out
the suggestions made in the previous
presentation you
presented the examiners told you do this
do this do this make make a note of it
and the when next time when you come you
say these are the suggestions made and
then explain how you attended to
them do this as I mentioned earlier at
the beginning of every presentation and
then go on to the new work that you
did okay so that will make it very clear
so there is a continuity of what we
suggested and what you
did next we take up capacity of the
plant
so I have suggested choose the capacity
of your plant as large as the largest
plant anywhere in the world when you do
a literac search you will find that
except when you have strong arguments
against it it may be carbon footprint it
may be the chemical nobody makes nobody
uses whatever it is if you have a strong
argument come up with a new set of
capacity that is okay but from economics
point of view uh you should use the
largest plant
um so and then of course plants Roots
Etc locate the available capacity for
your chemical all over the world
identify the year of okay here you are
going to tabulate you're going to do a
literature survey say this chemical uh
this is the capacity year of
commissioning of each plant what
technology is used tabulate all of these
okay this is especially use useful for
your first week report
process flow diagram is extremely
important um so I'm going to spend some
time explaining what is expected of
you this is the most important part of
the report every group has to
submit uh that has all the information
about your project okay creating good
PFD is extremely
important this presentation gives a set
of rules in the creation of PFD and
writing the
report okay
uh use a minimum of 10 point font size
so that it is readable when you give the
report some of you you know the P PFD
will go on becoming bigger and bigger so
how do you accommodate you put small
font font 9 font 8 font six can't
read okay so then how do we accommodate
a large PFD that I will tell
you split the PFD into Parts okay with
10 point minimum font size constraint
the PFD stream data may become
large if large split the PFD into more
than one page so as to include all
streams if possible split the PFD into
logical sections reaction section
separation section Etc I'm going to give
an
example so here is
um a sample report a submit subed by uh
one of your seniors in the year 2020 21
this report by the way will be uploaded
as a sample report on
mle and
um they got the best project uh award in
that
year so for example
so this is PFD 2 part
two so this this is the this is a
diagram PFD this is the stream
data similarly you have PFD part
four that's what I mean don't make the
font size small by trying to put the
whole thing split it right
split into if possible split the PFD
into logical sections reaction section
separation section and so on if that
becomes big split that
also and do not split the pfds
unnecessarily okay just because somebody
else has five pfds doesn't mean that
there are some people who have done that
in two pfds okay without creating too
many
problems try to use the space
efficiently don't leave a lot of white
space okay try to put them uh compact
them drawing mode use the portrait or
landscape mode as
appropriate you might use a combination
of these what is important is
readability of the stream information
and listing of all important
streams
okay provid space for stream
information okay for example you might
say that this is the space available for
drawing PFD this is the space you saw in
De Smith's
report what they have
done
okay providing stream
information variables on rows streams on
columns okay please follow
this these are variable uh stream uh
numbers 17 18 19 20 because those are
the numbers given here 17 18 and so
on and then you have the variables face
pressure temperature composition of flow
rate of each of them these are all flow
rates by the way and look at the units
look at the units you have to give tons
per hour don't give kg per
second okay tons unless you have a
specialty chemical small
number give it in tons so that you have
reasonable numbers here and then you
should also
give total mass flow
rate total mass flow rate so that I can
do mass balance by just by
observation just by observation I can do
a mass balance total flow
rate and this should be in mass units
not in molar units don't do this in
molar units do it in mass units you
might use molar thing for uh
stochiometry and things like that but
that's okay but here it should be on
mass balance Mass rates mass units so
that just by observation I'll be able to
do the mass balance
I should be able to say this stream is
coming in this stream is going these
streams are going out take a calculator
just quickly add these and check what
you are
doing okay in fact you may want to do
that by yourself somebody is doing the
mass balance one of you have six uh
people in the team somebody can quickly
do the mass
balance okay you can do the overall mass
balance you can also do the component
mass balance where there is only
separation you can quickly do that okay
so please you will come up with various
things please don't do that this is
something that we have found to be very
useful just follow
this so this is what I have I've given
an example but then I Illustrated with
de smi's
report um stream units mention the units
of all applicable uh variables units
tons per
hour uh degre Celsius okay give the
temperature in degrees celsius don't
give it in Fahrenheit don't give it in
ranking don't give it in
kelvin okay give it in engine give it in
degrees celsius
okay okay this is something I have
already
mentioned give the time units as hours
not minutes not
seconds uh giving the time units as
hours will help you calculate the
capacity of the
plant for a year that is capacity of the
plant right how do you do that how many
working hours in a year
roughly anybody told you
this yeah somebody said
that so you can take 3:30 working
days about 24
hours so if you multiply that it comes
to about
8,000 right so 8,000 hours so one can
quickly if you give it in hours one can
find the capacity of the plant just by
multiplying by 8,000 so give it in hours
not minutes not
seconds okay temperature should be in
degrees celsius not kin not degree F not
ranking and so
on what streams to include
critical streams that help understand
the operating conditions of a plant for
example Outlet stream of a distillation
column immediately as they leave so that
I can understand what is a pressure what
is a temperature and so on please put
that it is possible that at the time of
um when you get get it from the patent
some information may not be there you
might leave it out but you must figure
that out and make it available at least
subsequently because I need to know we
need to know at what temperature this
stream is coming
out
right Outlet streams of reactors outward
streams of special
units and then streams that help do a
quick mass balance of every unit by
observation if there are many streams
obvious ones or that can be explained in
the report can be left out for example
supposing the only the pressure changes
so you can leave it out okay the
pressure increases
or temperature only increases it's only
a heater nothing else changes so some of
these can be left out why you want to do
that you may want to do that otherwise
there might be too many streams you may
want to leave out some of them but don't
leave out the important ones that's a
message
okay in general all streams that
matter give numbers to pfds as pfd1 PFD
2
Etc give stream give stream numbers such
that we can find out which PFD they
belong to
I'll show you that here for
example look at
this DM says from PFD 1 number
17 right this is PFD part two if you go
to PFD
one look at the 17 here
look at the 17 here and it goes to PFD
2 so you say where this is
going and where it is coming from okay
here it says from PFD to stream 26 if
you do that
right if you do
that without this information PFD stand
isolated not get connected they will be
hanging loose you to tie them okay and
then of course you can give some naming
convention you can pfd1 can be numbered
as hundreds 100 110 101 whatever uh 200
210 whatever you can do it like this uh
it is okay whatever convention you use
but please use a consistent notation for
the equipment for the streams and so on
and so
forth
okay description of the pfds in the
report describe the flow with a special
emphasis on the unobvious parts of the
pfds for example reasons for a
particular choice of equipment or
operating conditions for example you
might say I use Le chart as principle or
series of compressors required to
achieve high compression rate ratio I
cannot achieve that ratio in one
compressor so I'm putting two of them
three of them whatever
right I'm using low temperature because
I want to prevent decompos so that
cannot be included in the PFD per se but
in the accompanying report you can
actually write about that that is how
your report should be your report should
explain the obvious I mean unobvious not
the one that you can easily see in the
PFD and leave out the important ones
don't do
that and then low concentration required
to prevent the poisoning of the Catalyst
Etc is applicable okay if you do that
then your description will be very good
and then it'll be very easy for us to
read the report and understand what
you're
doing I would want you to maintain two
sets of
pfds the approximate PFD with linear
mass balance that you had presented that
that is there of course we can always go
back and check what you have done you
would have submitted that report that is
there the other PFD is a so you may just
want to add a new PFD and this is a new
PFD you can take it modify it but keep a
copy of it this is what I proposed
previously that's linear mass balance
and then these are the this is the new
one that is evolving one right the
second
one okay pfds with stream data with
values this is the linear mass balance
and this is with the
simulator okay this is something I have
already mentioned compare the results of
the above two Mass balances and enter
all results in a
table if the difference is more than 1
person for any unit explain the reason
okay the second set of PFD with stream
data from converged
simulation has to be used in the rest of
the course okay because the first PFD is
approximate gut feeling based on linear
mass balance and so on that's fine later
on you arrived at more concrete more
rigorous please use the subsequent one
for all future uh uh work
so whenever the mass balance can be
checked by the observation in the PFD no
need to report repeat in the report it's
already there I can easily check that
right some people have the habit of copy
pasting the PFD and putting it here that
part of the PFD putting it please don't
do all that not
required okay I mean it's fine it makes
your report maybe look colorful and
maybe increases the number of pages but
not required
right do mass balance only when not
obvious from PFD for example calculate
and verify reaction stomry if any this
is something you must do because in your
uh in your table you're giving it in
mass flow mass units so here if you want
to validate something you might have you
might have to you will have to show it
in reaction reactors for
example and there are many input and
output streams you may want to show that
do carry out energy balances in the
report this may be done after the
simulation after the simulation please
do energy balance
also uh this is what I have said do not
copy paste we can read from the PFD
itself that's why I keep saying PFD is
extremely important try to produce a
good PFD and we can go look at it put
all your effort to come up with a nice
one all the information should be there
right
yeah it's important to create a good set
of pfds and refer to them
repeatedly so simulating the flow sheet
you might want to say what simulator you
used whether it is partially converged
fully converged extent of convergence
any comment regarding how the flow sheet
was converged
um for some of you this may not make
sense but uh you know do keep this it'll
be useful to say what is it you have
done
details of reactors if possible what are
the different reactors what reactor did
he use did you use a conversion reactor
did use rigorous kinetics so on and so
forth equilibrium reactor there are
different kinds of reactors you might
use distillation shortcut column
rigorous column KF column there are
different columns that are there in
whether it is dwc or S Plus you may just
want to mention these are the units uh
the equipment number and this is the
model and then absorption extractive
column and so
on so you might say uh equipment list
provide summary information of the
equipment in a table like this how many
pumps heat exchanger compressor whatever
you don't have to give the cost uh
details here in fact
um um one of our previous examiners will
say you know don't give the cost here
information on
pumps uh Delta P head type what fluid do
not provide cost information in the
above it does not make sense to know
about the cost of pumps in a plant for
example what is the total cost of all
the pumps in a plant she says it didn't
make sense it makes more sense to know
about the total cost of all the
equipment in the section of the plant
say the reaction section
information on heat
exchangers process
fluid the fluid that is getting um heat
exchanger fluid whether it is water in
out what Duty what material and so
on column
information please mention whether the
numbering is from the top or from the
bottom okay numbered from Top numbered
from bottom right then it becomes very
easy for the reader to understand what
you're doing okay where is the feed
stage okay and where you might have
multiple feeds so it'll be better to say
that
okay validation of the plant cost one of
the important things is you will come to
the you will calculate the cost of the
plant there will be an there is an
indirect way there is a second way to
validate
it with the cost of a similar plant
somebody else might have uh come up with
a plant and in fact we found
interestingly for many of the plants
this exercise could be
done okay
somebody come up somebody inaugurated a
new plant started it went into
production okay by so and so capacity
this so much cost I mean these are all
rough
numbers published in papers so take the
information apply the scaling factor in
estimating the cost if it is established
at some other year apply the time factor
in estimating the cost if it is in some
other country apply the country
conversion factor so it should be
possible to do that and say this is what
is the cost and I have arrived at this
cost right by doing detailed calculation
saying that my I'm using this
distillation column you know I'm using
this reactor I'm using this pump the
cost is this detailing the cost of each
unit totaling it this is the cost right
and of course there are other rules um
as you would see in the in the
references that I pointed out operating
cost and you know various other cost so
on I think this is the we are very close
to the end do not increase the pages do
not increase the number of pages
unnecessarily long report does not mean
higher
marks okay okay a sample report I
already showed uh this is the d smi's
report uh if you click this uh it'll
take you if you are already logged into
Moodle it'll be posted
there um is a link to a report that
follows these rules whatever I mentioned
right so that is the last slide that I
have so I try to
summarize uh you know the conduct of the
course there will be many other things
as we go along it's very difficult to uh
you know put all of those in the form of
rules and
regulations
um although I said that
finally your panel
examiners uh decision is final okay
because they might say I want to want
you to do it in this particular way so
that that's perfectly fine okay
supposing I had said that use landscape
mode for PFD and your panel says no
portrait absolutely fine please do
portrait so I'm going to go by whatever
uh your panel uh your examiners tell
you and um
um it I I believe that it's a very very
exciting course okay very exciting
course but uh you know it it might even
be um like Dungeons and Dragons right
very I don't know how many of you have
played Dungeons and Dragons anybody
played okay not so bad you don't get
killed here right Dungeons and Dragons I
used to get killed so many times right
but uh and by the way I wanton it once
right only once in of course I don't
play now I'm too old to play but I used
to play when I was young and
um lot of uh exciting things lot of
opportunities right I think you will
like the
course if you like chemical engineering
you like the course it is possible in
fact I would believe that some of you
would start liking the liking chemical
engineering after doing this course okay
it is possible that some of you didn't
like chemical engineering so much but
after this course it's a very really
really exciting course okay so I'm going
to stop here
thank you