Introduction to the Components of a Good Design Project

okay so uh let's uh let's start I think uh so I think those of you you who are falling asleep hopefully we have you back what I try to do is now we have about an hour so we'll cover some of I think uh Professor Kanan mahajani and shastri already covered the basics I'll try to do more of the nuts and Boards details uh also I'll try to cover some of the mistakes um I see often when students contact or uh we thought some of the common instructions that we give we'll try to cover them uh also the second part is like professor mahaj said what comes after the process simulator right so there is there is stuff you know there's the bare minimum requirements but a good project report has a lot of other stuff and what I'll try to do today is at least expose you to what those elements are and then later in the semester if we need to do more you know detailed uh overviews of some of those areas we are happy to do them but at least we want to you know give you a pep talk or motivate you that you know don't stop at a process simulator you could do a much better report H so we'll start there and uh yeah as you can see this is a very important class I don't think you have ever had so many of us professors in the same uh room for a class so especially this year because there's two batches together right so what I'll try to do is not tell you how to do like I'm not going to the design of it mostly uh the fourth year guys have already had a class or you already had Mass transfer heat transfer reaction engineering where you've done most of it what I'm trying to do is do a bit of a refresher and maybe point you to the references right the right sources the right books and some of these books you may have used some of them you may not have and I don't think these are the only ones but at least if you are stuck you should and I'll post these slides so whenever you are stuck you should be able to think where else have I missed should I find should I look in a book for certain aspects in it other than that it's more a tips and tricks of the trade sort of thing like when I want to find out price ing or Market capacity where do I look at right so I'll try to share some of that with you and you know hopefully so that's the structure of the talk so let's start with resources so so my talk will be in the I'm trying to cover actual stuff some of this you might have already seen and some of it you might not have just just settle down a bit right so Perry's handbook an age-old resource uh but even today uh if you are stuck and I see a lot of guys say okay how do I design a crystallizer we have never been T in the class if you have a situation like that the first point to start should usually be Perry's handbook or or one of the other handbooks I'm showing you because this is a distillation of intelligence and um sometimes what I see is people are tempted to look at articles right but there is a place for scientific articles there's a place for textbooks and hand let me explain what that is you want know whether a reaction Works what temperature what yields are you going to get that's the place to look at an article or a patent right that's going to give you that input but if you if you try to look at how do I design a pump or how do I select a centrifugal pump usually you'll be better of looking at a textbook or a handbook because that's not you're not trying to find an Innovative pump right there'll be there'll be articles people try to find different things but whatever is tried tested and condensed makes it to an handbook right so if you want to find out the design methods Etc look at a handbook if you want to know specific kinetics U you know vle data whatever that is usually an article is so so don't make the mistake of not usually what I see is it's very easy to search on scifinder or Google Scholar so when people are stuck and they want to design a crystallizer they look up on sinder and then you get some articles but they may not they may either only cover a part of the topic or it may be an Innovative process or something like that right so Perry's handbook even for a lot of I won't be able to look cover what all is in it but for materials of construction great chapters which tell you what materials you can use uh for just thermodynamic data for design processes for equipment selection right when should I use a centrifugal pump and where do I want to use uh a positive displacement pump right per handbook is a starting point for thermodynamic data I don't know how many of you have used nist luckily when you have DW Sim or Aspen a lot of data is in there but suppose you want something very specific and it's not there uh don't forget to look up the nist hand and it's all online which makes it very easy I'm just showing you typical material selection table just in case you have not seen it in any of the other courses so um if you're trying to select what material of construction to use and you'll have a lot of different reactants storage tanks whatever it is how do you find out look at a handbook and peris is not the only one but a lot of handbooks will have tables like this they'll also have similar ones for piping systems and let me illustrate something right sometimes you have something corrosive so mild steel will not work you go to stainless maybe stainless doesn't work now you come to halloy right your reactor is high temperature you're using hello fine now the difference between a good enough project and a re good project is one guy will use hasteloy for the reactor and all the piping in hasteloy will work but another guy says that okay the hasto for the reactor of course I'm using high temperatures high pressures metal is imperative so I use hasteloy but for some HCL field piping do I really need to use hallo he looks up a piping compatibility and says okay piping is only at low temperatures I'm going to use the polymer right I'm just giving you an example so project is about creativity you don't have to find the one right answer there is infinite ways of design designing the same plant at the same capacity but when you look at it you sort of get an idea how much thought has the group put into it right the easy thing is to you could choose titanium you could choose tantalum lot of super expensive materials at the end of it like professor mahajani says the plant has to make sense so a lot of very expensive materials get used for plants that are producing really cheap products sodium chloride there's a lot of titanium exchanges in there right so at the end the capex has to balance out so that's what I'm telling you that put some thought and creativity is the material you're using it may be compatible but is it the commercially the right material right and so all lot of that data is out there choosing things like vacuum pumps a lot of fine chemical distillations or even in other commodity chemicals you'll see a lot of vacuum vacuum processes and from last year like Canan said we had industrial um we had industry experienced people and typically the critique is of a following nature suppose you need very high you need a 1 mm vacuum and you just use a vacuum pump or you use a single stage ejector it may not be possible to get there now the question is how are you supposed to know as students doing it for the first time so I think the process design course is a great spot to read a lot of material right so look up this is from Perry's handbook there are tables out there there are selection charts out there you just have to look them up right you have to look them up so I'm just exposing you to the sort of stuff which is out there so the table here for example if you choose the vacuum level it'll tell you what the options are what are the feasible options right this is not a mathematical these are more like huris stics thumb rules and a good design project is going to use a lot of them so suppose you have a certain pressure and you say okay I'm using a Ste three stage steam ejector and suppose The Examiner ask you why did you use it and you say okay I looked up now that that demonstrates a certain higher degree of thought than just picking up a single vacuum pump which may not even work for that level of vacuum H next two other handbooks ulans and K cosar I don't know how many of you have used them but a great starting point if you are lucky enough to have your chemical in one of these it'll already give you a lot of references right one thing is to use Google Scholar find whatever is new but the other one is to go to a article if there is an article on acry onit trial and most of the common Commodities have articles here and they'll give you a lot of they won't give you a design but they'll give you a lot of places here's a study on the properties here's a study on toxicity here's the typical way it's done so don't forget these uh handbooks now coming to search tools I hope you've used scifinder if not we I think we have a subscript destion so that's a great way to find kinetics articles whatever data Etc is required but this is mainly going to Target scientific articles so if there was a journal article published you would get it in scifinder of course it also looks at patents and some other sources uh two other tools Google Scholar for papers and Google patents for patents again right and normally I use multiple tools because sometimes for whatever reason one tool will not discover a resource and in your group you have six people so really there's no excuse not to exhaust all these tools right you have six people a whole sem and in spite of that in the references typically I find people miss a reference like if you say okay there is no kinetics on this it's quite rare it just means you have not done a search which is exhaustive enough and give it enough time if you try to do 15 minutes of a search you'll find the same articles you will have to give two three hours sit at it and then you'll start discovering patterns and uh other things that you want to find out reais the chemists typically use this tool a lot chemical Engineers I don't know if you've used it for a course of or something like that lot of great filters we have a subscription I believe at I and so you can do things like find reactions above a certain temperature or where the yields are above something or only find preparations and not you know all kinds of things it's a very powerful tool in order to discover who has done what and you don't always need to find the article sometimes reais will have a summary so that just looking at the summary on reais you'll figure out if you it's worth digging deeper or it's not something which is very interesting right so that's that's reais and um again I I'll share the slides all I'm trying to do is make sure you cover these tools if you are stuck make sure you've seen the tool and that way uh the quality of the data you find will hopefully be better patents a lot of patents are us patents so if you are looking at us patents the US patents website has a great search and whatever and they have a lot of advanced filters right so sometimes if you just look at acry n trial you'll get a lot of guys using acry oit trial but if you use it in the title or you combine it with the right keywords you are probably more likely to find the right patents and remember for this course I don't think we are looking at infringement so patents for you are not a way to know whether you're infringing something they are a way for you to know what's the most important section for you in a patent you think anyone the examples because a lot of the examples section may not you direct kinetics but suppose you are in the fine chemical or speciality chemicals you will have an example where they say okay I mix these things I heated them for 3 hours and now something was formed at 98% healed so that three hours is the crucial parameter so learn to read these patents Focus uh the claims don't matter much for this course because I don't think you're doing an infringement or a freedom to operate study what matters for you is the example section because there'll be a ton of useful data a lot of people say I don't know what byproducts were formed in a patent normally there'll be an example and that example will have a GC or a gcms where there'll be a table which says these were the other things which were formed right because a patent is supposed to disclose all of that similarly if you want European patents the European patents office has an website called espace net all of these are free websites and uh so if you want patent coverage this is another good resource to look at uh to make sure you have not missed something if you have any questions yeah interrupt me or raise your hands right if something is not obvious let me know uh fine mostly I feel that people have just like very rarely do I come with a group where where the questions they ask and if I ask them have you looked at patents well they probably not discovered and that's why I'm giving this talk to make sure that you know before you before you conclude that I'm not finding something go through these resources there's still a chance that you don't have anything but at least you'll say that okay I've looked at all of this and I'm not finding it right give it enough time and um and you'll find something um coming to the report I'm just going back and forth I think personally I think you should focus more or most I mean you always need to prioritize on the flow sheets that the tables and the figures a lot of people when they read at a report these are the first things they're going to do right so suppose I see your PN ID is excellent or your PFD like Professor Kanan said has all the details in it I'm not likely to read a long boring wall of text right I don't most people don't want to double check all your calculations if something doesn't make sense of course I want your calculations to make sure that you're not bluffing or you not made a mistake or something like that but I would say and this is a flaw I find a lot of people because it's easier to type text right suppose I do a design a lot of the design chapter in the past I've seen we'll have a lot of paragraphs and paragraphs even the symbols are not there whereas what you really want to see is the figure if you have one figure one good PN ID you don't really want to read all the text right so if if if you want to prioritize put a lot of attention into every figure in every flow sheet that you have the PFD the PN ID if those are great uh that's that's what uh conveys like even if say as examiners we as professors we are want to look at it every week but suppose at the end of the study you have one guy who has one hour or 20 minutes to quiz you on it which diagram do you think he goes to the flow sheets the flow sheets are the most important part uh what I find is a lot of you are not used to using tools to sketch but you know the tools to type text hence reports become heavy on text but do not use as many figures all the figures I find are copy pasted you go to a patent copy pasting a figure is easy to the extent that a lot of time reaction chemistry people will copy paste from a patent learn chemdraw learn how to do a balanced reaction it takes some time to master these tools I would almost say within the group I'll look at some software tools each one of you should at least Master One tool if you're going to split the work and that's uh you know how how you get a good report so I think Professor mahajani covered this you know start from conceptual design and then we'll look at some of the other things that we are encouraging you to do this here so this is what he mentioned you know what goes after the process simulation so I would strongly encourage if you want to great report you may not do it for all your equipment but at least for some equipment or some lines there's five things so these are not captured by Professor Canan stable so these are sort of optional in that sense but at least for the third year guys we want to push you to do these one is p and ID and we I'll try to show you examples of each one of these so that you sort of know where we are going so in a PFD you will have all streams you will know what the temperatures pressures flow rates are but normally a PFD will not do things like do I need a pump or a compressor uh how do I control this particular temperature do I have a loop that controls temperature based on composition based on level something else H that's not shown on a PFT but that's very essential to having a good process design project so that's the PN ID and uh you've done the PN ID right in some course maybe process control so you've seen P ID hopefully if not lot of great resources that I'm showing you today we'll have details about what a p ID is process safety like sustainability safety is another important aspect we would love to have you do an hazop of at least one one equipment or a few critical lines I'll show you what a hazop is and what's contained in it and then you know I'll point you to resources or later in the semester we could have an lecture that goes into more detail of a haop plant layouts so what's a layout how is the equipment placed right at a glance if I want to see what are the sections in your plant do you have a distillation section a tank farm how many farms how many tanks are in a tank farm in fact this is a very important thing if you really want to be an enterpreneur because you want to know I need one acre 6 Acres 2,000 acres how big of a plant is there and these are things which take a lot of judgment fortunately there are ways to if you read a book or if you read some of the things you'll probably get a hang at it I'm not saying these are easy things but you six guys one semester I think you should push um you know push yourself to do more uh four is mechanical drawing where you're already doing it I think the flaw I see or the Gap I see is you're focusing on just the calculation but I rarely see any equipment drawn right so if you design a distillation column normally the weight engineer stock is you would have a sketch where you show the dimension how many nozzles are there what's the thickness a detail sketch right and uh we we'll show you the tools and this year we're doing something new there and finally equipment data sheets uh we'll talk about what those are right so that's a PN ID this is a PN ID I'll zoom in and uh like Professor Kanan was saying on this you may not be able to see something but on the next one as you zoom in so a lot of engineering drawings are normally print printed on large size of course you may not print it but at least figure out how to work with word or something like that so that you can draw something so that I can zoom in and everything is legible but I can still zoom out so there is an advantage to this right sometimes you want to see everything on one page sometimes you want to zoom in and this is just mastering your tools figuring out how to do it in the right tool but now this is a PN ID of a distillation column and you'll see stuff like level gauges H your pnid may not have all these details but at least think through what are you measuring in a distillation column right so first time I did a pnid when I was a student you are tempted to control everything and then you have a degrees of freedom issue right if you have the level in a column you can't control both the inputs and outputs otherwise the loops are fighting each other but you will never discover this unless you try to make a PN ID right what are the things that you should really control and lot of the concepts from the process control course Cascade control split range control you will find them in action when you start thinking about how do I control the temperature of my reactor should I control the cooling fluid should I change inerts should I change the temperature that the input is coming at lot of parameters are there and that's the exciting part about process design because you don't really have constraints you're debating amongst yourself you're telling the professors how why you did a certain thing and we are trying to gauge whether you have thought uh thought that through right so PN IDs I think we would strongly encourage at least for one equipment you should do a PN ID so that should include your control loops uh what are the gauges are you measuring pressure temperatures is there a pump and there is motives so for for example on this one I show a typical control valve right so a control valve will normally have a bypass and if you have seen a lot of p and IDs the reason for this is what if the controller if the automatic controller fails you don't want to shut down a plant because of that so suppose the valve the valve which says fo suppose that valve close has some Mal function right because it's an automatic valve you would want to have a bypass line that you're controlling manually in order to make it work and then suppose you want to repair the valve you want to shut it right so these are features of operability and a lot of this you will come you'll figure out by looking at PN IDs in handbooks and things like that you know how do you operate a plant I'm not saying you'll Implement all of that in this but think about these things right suppose you want a control valve to be removed unless you had those two vales on each side of it how do you remove a valve from an operational plant right these are continuous plants for some of you that will run for 3 years at a stretch so you definitely don't want to shut down the whole plant just because one bve went bad right and that's captured in a PN ID another motive centrifugal pumps we'll often have a strainer on the input side because if there is rust if there's something you don't want to come that into the pump and damage the impeller so many of the pumps what you see on the and the symbols I'll show you a PDF that you can look at later like Engineers communicate with a common language and for chemical Engineers this is standard symbols that go into a PN ID so you don't need to remember then all but start using standard symbols because if you have something else sells for a pump and this I've seen in a lot of reports you have a distillation column but they say distill and a circle and somebody somebody who sees it will assume it's a pump or something else or a storage fear and then they find out oh that's a pump right so avoid that by sticking to standard symbols that like here the m is a motor right anybody who sees it knows the m is a motor whatever so stick to standard symbols when you're doing these things operability again so drains V when you do a PN ID suppose it's a batch process and you're filling a heat exchanger with water now where's the air going to go so now you need a vent so these are features for operability uh which should be there in a good plan design so we'll skip that uh one point is I don't know if you have seen this book maybe you have used it have you used it conceptual design or yes how many of you have seen this no maybe some of you okay so do a good conceptual Design This is a good reference because if you make a mistake right like if your concept is not sound suppose you should be using distillation but you're using liquid liquid extraction for whatever reason or there is an aot Trope but it's a phas separation would have worked but it's an aot Trope and now you are wasting a lot of time breaking it so if you make a mistake at conceptual design your Aspen or DW Sim is not going to save you so like Professor Canan was saying the very first week should be Excel should be blog diagrams and don't hesitate to make a diagram whether it's on PowerPoint like I've seen a lot of descriptions where people say okay I'll have a stream go into this equipment and come out and then you have to read the description and anyways make a diagram mentally to figure out what's happening and I sense a hesitation because diagram somehow you you know PowerPoint or whatever you've not done the right tools for making diagrams so you want to just type everything out but doesn't work even when you're are comparing various routes it makes sense for you to draw the diagrams that describe the various routes okay um yeah start with an Excel I think a lot of excel features I don't know whether you know not just for linear but you can always have a convergence Loop that auto converges on Excel so Excel has become quite powerful and I would do it multiple ways right so a simulator is much more powerful than Excel but if you're getting grossly different answers uh you at least have a check you have a sanity check you have a back of the envelope check uh that your simulator you know you might have made a mistake somewhere maybe one of your Loops has not converged or whether what you thought was an equilibrium reactor is really something else things happen like that so always do two different ways and one of them can be Excel or even pen and paper and make sure that what your simulator is producing is at least in the right order of magnitude you know gigo the acronym garbage in garbage out and that applies to a simulator you might have an excellent Aspen simulator if you're using the wrong model your answer should be will be off any questions so far I'm going uh fast but you don't really need to pay attention to everything because you're going to have the slides so uh have you seen this book chemical engineering design so this is by cool and maybe a lot of these are really old books uh but I think they're still pretty good for a process design sort of thing so again if you stuck and you think that I don't know the procedure to design a particular equipment it's not been covered in class look at these books and uh they will definitely have any equipment that you're talking about unless it's super exotic will be covered in um all of these books uh for example one area that I've seen a lot of previous reports uh this is from one of the previous reports um I don't see a detailed equipment list and when I see a detailed equipment list if you're saying I've SE reports which say oh we used eight centrifugal pumps that doesn't mean anything you want to have the relevant parameter for an equipment so suppose you have a heat exchanger and you tell me I have a shell and Tube heat exchanger and the volume is 3 m Cub useless right for a shell and Tube heat exchanger what's the parameter you want to know area right the rating parameter so so like that for some like if you have a pump you want to know the pressure ratio discharge pressures flow rates have a good list of every equipment because whoever the examiners who look at it for the price and things like that they're going to look at the major equipment list and many people will develop a feel for what's a really critical suppose you have a compressor with huge flow rate and a Delta you know a pressure ratio of 50 now they're going to worry whether this is possible right so a good equipment list it's a table with parameters so now how is the book I showed you relevant uh it's because if you look at the appendix you'll see things like equipment specification data sheets now you don't need to and if you see this 10 points it sort of covers most of the common equipment you have heat exchangers vessels would be columns distillation columns absorbers uh you have uh you have reactors other things pumps and what the sheet will give you is a lot of the relevant parameters now of course you may not be able to find all of them that's okay but at least look at a sheet so that let you know that if you are going to go to a vendor and say I want to buy a shell and Tube heat exchanger he's going to ask you certain questions and those should be answered by your design project right you don't have to build the whole heat exchanger usually except for one chapter where you're doing a detailed design but what if you are actually building a plant and suppose you have a compressor and you go to a compressor making company they're going to ask you certain questions and those are very well captured say in kson or other handbooks will give you data sheets as well what I want to do is just expose that this is not like you don't have to sleep at night and dream up right you'll ask me how do I know what is required for a particular piece of equipment it's easy it's all there just look at the right places H so this will probably give you a a better design project because you're answering the right questions suppose you have a centrifugal pump you have al already mentioned the efficiencies whatever are the crucial parameters so that then you can go and identify the right pump so these are equipment specification data sheets you may not do it for all small things but at least for the major piece pieces of equipment you should try to address take a reactor one way this works is this is like a checklist that you can take off normally people will just mention reactor stainless steel but any good person who's reviewing will want to know how are you cooling and heating is there a jacket is there a limpet what is the design pressure on the reactor itself what's the design pressure on the jacket what is the material on construction of each one of them and when you look at a sheet you'll also hear read some that makes you wonder know what is this but then you can always look it up and that's how you're going to learn from the design course um yeah this is a snippet and it's actually from one of the top ones but look at his cstr right a circle which is not a non-standard symbol and so what I encourage you to do is even for the PFD or the schematic use the standard symbols so that people at a glance know which is a column now there's a distillation even if you had to do a block diagram of a distillation you would show it as a a tall something which parallels the equipment you don't always have to use the exact symbol but that's what I encourage you to do that makes it easy to understand like if you show distillation column or a reactor using the standard symbols it's going to be much easier for somebody who even sees your comparative flow sheets suppose you have ABC three processes and you're doing a route selection if you use and I know it's more work you'll have to figure out how to use your tools and maybe you can't do it for everything I mean figure out how much time you have but wherever you are going to do this I think your project is going to look better and if you want to know standard symbols there are various ways even kson peries has it but there are uh There Are Places which tell you the standard symbols and many of these will have 20 different types of pumps you don't care at least have pumps and not reactors when you show a pump show it as a pump and not as a reactor that's all I'm asking right becomes easier to communicate as Engineers uh yeah standard symbols for columns Etc so this is I think from kson Richardson they'll all have them so doesn't matter where you look that's not important but don't show it as something very different like don't show a reactor as a circular vessel right that that becomes difficult now I go to normograms this is again from kson Richardson so one thing is figuring out what is the heat transfer coefficient now there are multiple ways what I want to highlight is sometimes there are multiple ways to check things one way is to you know in DW same or Aspen put in a heat exchanger and you will calculate the output streams and you'll C calate what is your heat transfer coefficient but I would always recommend also look up a normogram or a table right and so these are very approximate but for your initial Design This may be faster and second this provides a sanity check on your simulator so suppose you made a mistake in the simulator and you have an exchanger which is water versus water and suddenly you get a u value of 50,000 now you should stop and think you should recheck your calculations because based on standard sources it's supposed to be between 800 and 1500 as you get experience you develop a feel for it but for starters have multiple ways to check don't believe in the simulator blindly because the simulators are good but if your parameters are wrong or if it has not converged you are going to get nonsensical results and that's how you end up with like a distillation column which is 1 kilometer tall or like a heat exchanger where the overall dimensions are in centimeters right for a commodity plant has happened but how do you avoid it by doing multiple levels and so I'm trying to point you that there are ways to do that now pricing any any questions so far I think we went super fast but uh yeah I don't think we have enough time in this course so nothing anyways so we come to pricing uh one common mistake Sigma M all of that will have prices like take acry nitr right what is the price shown here kilo take a guess based on this slide per kilo and this is where you learn the art of like do you see kilo you see a one lit price what's the typical density what do you think is the density of Organics 81 1.2 nothing nothing outside that range so let's assume a liter is a kilo for order of magnitude and that's very important in a design project you have to make approximations you have to learn to deal with fuzzy data so suppose you're doing a project on acry or nit trial and you looked up this data what do you think the price of acon Nal is 8,000 rupees a kilo right what do you think the real commodity suppose Professor Kanan told you design a plant for 1 million tons of like we doing the largest plants in the world right 1 million tons or 500,000 tons what do you think the price is it's around less than $2 H so so at least this tells you the envelope if you are getting it from a laboratory chemical that's probably the most expensive your real stuff has to be way lower now the question is how do you get real prices now there are various ways there are websites now the rules have changed now we no longer disclose as India because there's a competitive disadvantage but till like 2018 is a lot of the export import shipments the pricing used to be disclosed right so there is a site called zaa and so that they have right now they can't disclose a lot but in the historical data you can easily see and look at the quantities so through kandla from Turkey 400 tons huh so acry nit is a commodity product but this gives you several things like this is Market intelligence it also tells you how things are coming in is it coming in glass bottles no so it's coming in really large quantities either a chemical tanker or a container or several containers price per unit $1.37 so maybe you know 120 rupes 130 rupes a kilo definitely not 8,000 rupees H so learn to find the right sources for your raw material not just product pricing even for raw materials I've seen people use the prices from Sigma and then you you have costic soda and the price will be you know 500 rupees a kilo you all your estimates will be off so learn multiple sources and try to figure out what is and typically for the larger quantities the price will be lower so for small quantities price is high for example the second row is only 45 tons price is a little higher how it varies will change but try to look at these sources another source is chemical weekly so there Maxine called chemical weekly it comes every week and at the back of it or every couple of and I think we have a subscription here H so we you have some prices of course these may be somewhere between a sigma but they are closer to the commodity price the commodity price may be a little lower but this these prices are much closer to that so that's another way to check uh the best way for Commodities is to use sites like plats plats is a site that is for commodity Traders so for all the common stuff costic tyene Benzene tolin you will have a daily price from plats unfortunately the databases are uh uh are not open to everyone however you don't have to worry so plats and there is something similar called Isis they keep publishing articles so this is an article from November 4 and of course you're not an energy Trader so you don't need to do it every day but you'll see a lot of Articles where they're talking about if you look at it now the pricee in China is mentioned right so look at these very reliable sources because in order to sell their products they're having articles which come out and of course we'll also try to see if we can get you some subscriptions but you know a lot of these things are expensive but this is another way of getting prizes look at articles look for capacities as well as prices one way is to look at Publications like hydrocarbon processing or chemical and Engineering news because whenever somebody builds a large plant or even chemical weekly any large Plant in India makes it to the chemical Weekly News Feed always so suppose you want to know who's building large plants what capacity plants are there go to some of these magazines search their archives and you'll find uh you know you'll find somebody built a plant of X capacity y capacity or they'll talk about how there is um a a glut in the market and some guys have shut down or how there's a shortage and prices have shut up so articles of this nature are normally free and open because they want people to read them right and if you look at the Articles uh you'll find out uh there's a bunch of market report websites I don't trust any of them most of them don't even have a report right so some people are tempted oh there's a website saying you know pay me something and get a report most of them will produce the report after you pay them right so these are all fraud mostly they all fraud when in doubt you can ask one of your professors but unless it's a reliable large magazine uh and there's no point in those market reports because this is a project so you are supposed to do a report right you are the guy producing it so why pay the site doesn't make sense don't cheat and it's not going to help you um haops so typically the point behind a hazop is you first should have a PN ID ready right so choose an equipment or a couple of critical equipments have the PN IDs ready what is the role behind has up often times plants have blown up or accidents explosions happen because a certain piece of equipment fails so suppose you have a reactor and uh you know yesterday in CL 678 we saw a video where there was some blockage in the cooling line and it was a highly exothermic reaction and the reaction blows up if a hazop had been done right what you would do is in the real industry you would have a smart set of guys you would have a mechanical engineer and operator a couple of chemical engineers and sit together and go line by line so you can't of course we are doing a Sim ulated hazop but it still makes a lot of sense for you to take your crucial equipment say an exothermic reactor and look at every line in your PN ID and six of you sit together and say what happens so suppose it's cooling water if flow increases high flow usually not a problem but if there is no flow or if there is less flow now you could have a problem now the question is whether you would have a runaway reaction this is the discussion you should be having H so that's the point behind haop systematically go through each line and figure out if the pressure increases what happens is it credible right you can't put and now what do you do suppose you have something very critical you might put an interlock so you might say that if the cooling water fails I will have something where my feed is shut off you might put an alarm for critical you don't put it for every line but that's your judgment call is this a critical line where if something fails you're going to have a catastroph in some cases you may just have a standard operating procedure that we say okay it's too expensive to do it but the operator every morning has to go and check whether it's working but unless you document it people are not going to do it and that's the role behind a hazop so make a PN ID and use a hazop there are excellent books about it I'll show you this is an example of a hazop so right so these are the guide words sorry um and at the end of it you'll come up with recommendations certain cases you say no I don't think this is catastrophic or I don't think it's it's very low probability so it's not going to happen then you ignore it but you document it that's the role behind a has of if you want to know more Trevor clet was sort of the big very famous guy in the process safety area and he has a whole book on haop so if you want to at that point where you come there you want to know more about it there's always great resources but if you do a Haz up you're going to go more on the process safety side just like sustainability and I think the people who read your report are going to be impressed that okay you have given it a thought you may not do it for all the lines it's going to take a lot of time but suppose you did it for five lines six lines the critical ones on a piece of equipment uh it's going to have a report of a better quality because just like sustain ability which Professor shastri was talking about uh you would have now covered um safety okay questions should I slow down so now plant layout this is again we haven't done a lot of it in previous projects but we were just discussing amongst ourselves that okay if you want to have a great report if you've gone to Co on wheels or if you've seen any plants right if you've seen accident reports there's always a layout so what does the plant layout look like for example um and and there's a great book again on it a lot of these things you are not on your own and I'm trying to show you the books there are like 200 Page books about how do you do a good plant layout you just have to know what those are this is the layout right and so that again you it needs some drawing but the quality of your look report looks better if you draw it out don't just say that okay I have three heat exchanges in the top left corner uh that's not engineering and this will indirectly allow you to use the tools forget layout if I told you right now draw this huh how many of you had to a to somebody who's competent it should maybe take an hour or two to draw this out suppose I told you just replicate this on a drawing and so that I can remove something are you able to do it if not you have to figure out the right tools and see there's some way of doing it most equipment you're showing the center lines and things like that you're not showing all the details what's the point behind the layout to know how far you should keep things suppose you have a very high temperature reactor do you want a storage tank right next to it no right a high temperature reactor high pressure reactor is likely to have an incident Suppose there is an incident and a small fire if you have a very large 200,000 L storage tank right next to it then even a small incident will become a big one and if you have visited plants you've seen how the Reliance tank farm was far away from right that's why tank Farms are far away so that comes in the part of a layout and of course you are you're doing it for the first time so we don't expect you'll have the perfect layout but at least come up with something so that you'll put some thought where does the fluid have to travel from you know are fluids traveling you also want to minimize the travel of fluid or sometimes all the pumps are in a certain area all heat exchanges might be next to each other you've seen uh in Plants there are normally compressor houses so all the compressors because they are large they create a lot of noise so if you have ever visited a plant you'll see all the compressors KN next to each other of course that's a that's very you know it comes with time when you read so there's a compressor house here to the top right why because you want to keep all the compressors together but at least try to think forget a optimal layout whatever is on your equipment list you do your best and come up with some layout and then we'll guide you you show it to your professors okay this is the layout at least it'll give you some idea how big of a plant do you need and you're not on your own so I'll show you minimum spacing guidelines so this is an extract from the same book it has a lot of different equipment right so reactors distillation these are all heuristics developed over years of experience from people so these are telling you how close can you keep if you see a plant you never see two equipment very close to each other for example if you have a flare it generates a lot of heat and radiation so you will have a long radius you don't keep a flare right next to your tank farm otherwise things will start catching fire so this is what goes into a layout we're not teaching you how to do a good layout but we are at least exposing that if it's a good report if you have to build your own plant B an enterpreneur you'll definitely have a layout you never order equipment and then decide how to keep it uh this will tell you whether you want to have gravity suppose you have three levels now you can consider gravity flow a lot of Fine Chemicals of Pharma plants the tanks will be on the top level and and the reactors will be at the middle level and you will have a filter at the bottom level at least make some layout if you design your tanks at the bottom and filters at the top when you show it to Professor mahajani in the weekly meeting he'll say okay why don't you do it some other way but try to do it so that you'll have more insights about how you're going to build a good plant um so there's also a lot of Maintenance and operability for example I show you a photo what what is this equipment you think heat exchanger and they're pulling out the tube bundle now I'll tell you how it goes on layout so whenever you're doing a heat exchanger on the left you see the area which is the cross that's the tube bundle removal area so if you for example put a distillation column right next to the reboiler you'll have no space left to pull out the bundles this is the thought that goes I'm not saying this is rocket science or this is like very difficult calculations but I'm just telling you outside of the simulator beyond that when you see a good plant which is well laid out now if you forget this there are plants where when you want to pull the bundle you'll have to take a shutdown and move the whole heat exchanger still happens right because people forget a lot of this knowledge so this is the importance of a layout and so you'll have a lot of different ones if you have an overhead heat exchanger or a vertical one you'll still have to think what is the area in which you shouldn't put not just equipment but piping suppose there's a distillation column you can't take piping in that area otherwise it will obstruct how you pull a heat exchanger so I don't know how much of this you'll put in your reports but I'm just trying to convey there a lot of thought which goes behind and if you don't put the thought as an engineer um the mechanic or the fitter is not going to do it he will do it in the easiest possible way and you will have a boss to answer when six months down the line there's a shutdown now people will ask you why didn't you think of this right and how do you think of all this you read right you read and in the handbooks all these things are mentioned so you will have to do a lot of reading in this course H and uh lot of good design is by looking at other things so this is this Texas City accident remember the largest accident which happened at a refinery in Texas in the report you will have a layout right so a lot of this will come when you look at an environmental clearance or other plants if you look at their layouts now you start thinking where do they keep a control room uh you'll discover a pattern all tank Farms are very far away from the distillation columns things like that you will discover when you look at good designs also p and IDs you should read a lot of p and IDs and you will get inspiration for what should be there on your own design uh common mistake um avoid handwritten Pages a lot of this is very basic but I'm not making this up this is there in actual reports which have been uploaded and I've seen in the past avoid it how much time does it take to your six guys so if I see a page like this all this means is you did it on the last night before the final submission right it may happen once or twice in the intermediate reports but all I'm saying is the final one uh these days processing is so easy there's no real excuse for having scanned handwritten Pages um in in the chapter on mechanical design so you do have a chapter and people are doing designs my observation is everybody is trying to put a lot of text you'll have text saying this is my thickness you'll have pages and pages of text who wants to read it what I want to see is do you have at least one drawing which shows the details huh suppose it's a heat exchanger a reactor whatever it is and I think my my judgment is because you're not very comfortable figuring out how to draw things and maybe in real life you'll have a draftsman or somebody else do it for you but I think it's a skill that you should still have because if if you have a great startup you want to convey something or maybe you don't want to convey but if somebody you want to buy some equipment and they see send you a drawing you should be comfortable interpreting the drawing because you're paying a lot of money for it and if it's your plant you're the entrepreneur you have to tell them no I want something made differently and for that you need to be able to say modify drawing or edit drawing so I would recommend that in your mechanical design whatever you design you should figure out how to do a drawing for it and we we'll tell you some tools later heat exchanges right you should the tube sheet how do you lay out a tube sheet otherwise it's not really a mechanical design you don't have to do it for everything but whatever you choose for a detailed design I think you should go into this level of detail right for whatever suppose it's a heat exchanger go into that level of detail uh another mistake so this is from one of the better reports but it says I think the design is great but it says process flow sheet in Aspen plus showing a separation process now compare this to what say Professor Madu shows you in the chemical processes do I know what the feed stock is wt1 absn so this is the output of DW Sim or Aspen but that's not a flow sheet in a flow sheet you should have labels like Professor Kanan was talking about label the key equipment the key streams show equipment with standard symbols not the symbols on the flow sheet you'll often have people ask what is this symbol the triangle and that's just a a join right in a flow sheet if you have two streams you want to combine them you have a mixer or a joint in a real plant there's no equipment if it's two gases or two liquids they're just going to mix or maybe you have a static mixer right so this is a simulator output but this is not the way you see a flow sheet and how is a flow sheet look at kirmer look at any chemical processes look at Professor Madu slides that's a flow sheet right so that's what I want to um want to emphasize so compare this one with um stuff like this right much better now you see what equipment is there so even in a flow sheet where you are try to use equipment to sort of convey the form of the equipment so that a reactor looks like a reactor or a distillation column should look like a distillation column and this is a proper flow sheet so the bottom table will have flow rates uh don't forget to show whether sometimes you have a two-phase stream then you need to show how much of the phase is vapor how much of it is liquid what pressures temperatures what are Trace elements right so that happens in the table on the bottom but see how well laid out it is because you can see the equipment there'll be numbers for the streams and those are in the table so take some effort but that's that's the difference between just a standard project and a good project bibliography right don't just put links out there if it's a patent you want to know US Patent whatever the name of the person at all whatever the patent number you can still link that's okay but it's lazy to just put links in there because people then don't know you know what's in this people don't know right so find out any standard textbook or a journal article and you'll have a normal way of making a bibliography these are all basic things but I'm not making this up these are from real reports that your you know seniors have submitted and you have a whole semester right you have a lot of time to go through this and improve it so unless you do it on the last day now this the figure complete flow sheet for the process just a screenshot from one of the reports right and um yeah I don't know what's S1 you have no idea so don't just repeat the simulator output the simulator is for simulations but when you're conveying what you have produced to other people you will have to use the right symbols and notation and things like that one suggestion is hyperlink internally a lot of people from like many of the good reports already do it so if you are having an introduction I want to just click on six and go to the page because a lot of uh design projects you'll have to do a back and forth and it's not very difficult to do it just figure out how to do it that that tells you whether you're taking that effort or not this is a screenshot from a report now if you see uh the x-axis can you really figure out what I mean what is the unit and could you like have scientific notation tons per year right to give it a thought and this is one of the better reports I'm not disclosing who the guy is but again on the y- axis recovery so what they're doing is this is an absorber as the amount of water increases obviously the recovery increases but think about what somebody would want to know he would want to know the percent recovery right how do you decide now suppose you keep putting more and more water the recovery goes up that's obvious how do you decide in a project where to stop should I use 49,000 or 540,000 which want to use how do you do it it's a economic trade-off right more and more water is going to cost you more circulation cost or water cost you'll have a utility cost on the other hand your recovery of aconit trial suppose you have a 95% recovery 5% is lost right so that is lost profits for you so normally you're going to do a tradeoff and decide based on that how much of recovery do you want so probably you want a percent recovery on the y- axis and I see why people do this because very often they do the easiest thing in the simulator whatever the simulator this is on the sensitivity analysis chapter so figure out what variables are the ones that your reader wants just don't do random variables another one is recovery of acry nitr or acetonitril versus top stage pressure there's no units on the pressure so I presume this is bar but I don't know it could be tens of bars so don't have graphs without acces again I repeat and use significant figures don't give me the pricing of a column to six decimal places very often and looks ugly because Excel produces it but figure out how to set the number of decimals in Excel right nobody's buying a column in pis if you have a 10 lakh column you don't really write 10 lakh 35 P right people will laugh at it so simple stuff but remember it useful software chem draw has a free trial and there are of course Alternatives there are open source alternatives to chemdraw and maybe prum can tell you what they are even in scifinder or reaxis there is a chemical drawing tool you might use that what you should not do is just pick up random snapshots from patents and articles if you are doing acry on ey trial if there are four reactions in it you should type it out because that's the way you balance a reaction sometimes people have unbalanced reactions and the number of reports where the chemistry is never written out is incredible I have a lot of reports I've seen where the chemistry is not really written out they have described it or they have mentioned it in text but you don't have a set of blocks with the chemistry in it if you don't do that your stochiometry is going to be off you'll have a problem with your chemical kinetics everything's going to be a problem H so draw out a reaction and it doesn't look nice to have you know copy pasted things with one font three reactions three more from another paper with a different font you can very easily figure that this was um you know Hasty work you have a whole semester so you have no excuse not doing it uh for making P IDs other kinds of diagrams one option is Vio and again this is a matter of taste people have lot of software will allow you to do that I recommend viio because I think we have a license for the whole thing and maybe the T will hold a session on some of this but if you want to do a good PN ID and what's a good PN ID so line shouldn't intersect right and that's quite difficult to do in things like PowerPoint like if you try to do a complex PN ID in PowerPoint sooner or later your lines intersect a good PN ID lines will always break where they intersect so that you can trace them right and not even the circuit sort you don't do those loops on a PN ID normally you break lines and uh things like viio will do those Auto routing and things like that so make sure you use the tools and it'll help you later if you're doing other projects as well and so now is a good time to learn and I think so Visio is one option learn something else if you want whole point is can you make a PN ID relatively rapidly so that it looks nice figure out whatever tool you're going to use lots of free and open tools we have now when you come to mechanical drawings um there's things like solid Edge there is a lot of other options but I would recommend I mean I'm probably trying to push you but uh trust me I've done this and like so this is not from this is not stuff I have done but I have done models of reactors and once you know a tool like solid Edge it's a matter of hours it's not very difficult to do a model like this but if you put that in your report I think you're going to impress people and so these days it's all 3D model now you may think okay this is mechanical engineering domain but why not chemical Engineers are supposed to know a bit of everything right so I'm not saying do it for all your equipment but at least for your crucial equipment the one you're doing a mechanical design for try to find some program again there are student editions for free available why not master them them and have that equipment suppose it's a distillation column have a drawing of the trays whatever you're designing once you have designed it represent it and I'm not saying do 3D do a 2d drawing 2D drawing is also great if you do a 3D you can automatically ask the software to do a 2d but do a 2d drawing but do a proper mechanical drawing because that's what your fabricator is going to want if you are actually going to build a plant from this um another option Auto Cad the whole Autodesk suit I believe is free for students and so I got that from their website but somebody can check again the two tools from that which are super important is AutoCAD for drafting making things PN IDs uh just like you could do it in VI you could also do it in AutoCAD a lot of those capabilities are there a lot of the templates are there so don't really think you have to draw the heat exchanges from scratch both viio and AutoCAD will have a template Library where most of the heat exchanges symbols Etc are already there right so learn to be smart about how you're going to use these tools the second one is AutoCAD plant 3D so this this is a special software for chemical engineers and it could help you make things like this right again it's it's a learning curve I'm not saying it's easy but I mean you guys are all smart about learning tools there's are ton of tutorials you don't have to do it for your whole plant but if you have one section The crucial section and you do a layout like this I'll be impressed because it's not very difficult to do but then I know you put the effort and then you can actually visualize how your plant is going to look like so I don't say that all the previous batches have done this but we are trying to push you guys a little more hm so this is learn some tools you have six guys if each one of you Masters a tool you can very easily parallelize things right so in the first week nobody's going to ask you to do that but if you learn the software and try to replicate things then by the end of the semester when you're ready to do a design after the mechanical design uh you're ready to use the tool so you have the whole semester really to learn the software right one day a week you're going to be sitting here I think smart people among you within 3 hours you'll sort of Master it and know how to use it now let's come to design so like distillation column I I present some examples you will often have pack columns right structured packings or random packings uh one question people always have is how do I find flood points how do I know what is my HTTP right many of the vendors who produce these packings will have proprietary programs not all of them but we'll figure out we can talk to szer so some of these programs will if you put in these are not design programs so you'll put in the data from a DW Sim or an aspen and what this tool will tell you is if I use a BX packing a Cy packing how many stages can I fit in a meter or if I use various kinds of packings how close am I to the flood point so I've seen in the past last year people ask what percent of flood Point are you and people don't have a good answer and you can't do these packings with generic correlations so one easy thing is use tools like this suol just put in parameters once your other design is done and it tells you how many stages you're going to need another one is from I think kg Tower also if you just put in your details it's free to download and use so these are tools that you would use in order to design say structured packings random packings right not the typical tray columns uh but for things like that but they even have tray design right like what is your V point and things like that you can always double check your manual calculations uh with a tool like this now we come to batch some of you have a batch plant and the question is okay it's not continuous so what are some unique features in a batch plant design so I just show you some one is unsteady state right many of batch plants will be unsteady State the distillation will be a batch distillation and so you have to use different tools and there are a lot of tools available in order to model that sometimes even Aspen Etc may have an unsteady State simulator in it distillations will be batch distillations one concern is equipment utilization so that's what I show on the bottom right see in a batch plant you're going to have say three four different equipment you'll have a reactor the batch may be 24 hours but filtration may be rather fast so filtration may take only 3 hours what your trying to figure out is every so each row is a different equipment here and wherever there's no color this is idle time right the equipment is not doing something so all the same color are the same batch so it starts from v101 then goes to df11 but once that is done df11 is free so one thought like in in batch processes a diagram like this on the y- axis which are the equipments you have and on the xaxis time this is how you so because I've gotten a question what do I do for a batch process do I do a PFD sure you do a PFD p and ID but how do you convey a batch process this is one way to do it equipment on the y- AIS and what are the operations on the x-axis right so this is how you convey how a batch multi-purpose or even a single product batch plant how are you going to use different equipment second plot curves so suppose you have a batch reactor the temperature varies with time initially room temperature you heat it up you hold it at a certain temperature now you cool it down uh as you do it suppose most reactions are semi bat so you'll take one liquid suppose you take 300 L now the reactor is 300 L occupied now you dose the other liquid another 500 L over 3 hours so the total volume in the reactor changes these are things you want to convey for a batch process how is temperature changing with time pressure changing with time total contents of the reactor how are they changing with time if you convey all that so batch process also very rich but very often if you have not seen it before you don't know what to represent on a batch process so maybe this gives you some idea if you're doing a distillation you're to batch distillation you're going to take various Cuts so you want to convey what is the composition of each one of the cuts that you are having in a batch distillation uh some more tips um if you're choosing collector sometimes I get a tray column but the diameter is only 500 mm and then people will ask the examiners oh is a tray column available in such small diameters how do you get better at this use the selection diagram so what I saw on the left side is a selection diagram if you have the vapor velocity and column diameter it'll tell you what are the right kinds of collectors or what is the right type of column whether a v whether a SE tray is available or a valve tray or do you have to switch normally for smallest diameters you'll have to switch to a pack column so use these These are there in a lot of places but use the selection diagrams uh on the right side I have a HP versus flate column traffic similarly you have flood Point diagrams many of these will not be in your regular textbooks because one way to design is you know use a equation but a lot of times if you go to the vendors whoever selling you packing suzer Etc they will have a lot of data sheets what I'm motivating you is switch between equation oriented design and design based on data sheets lot of people love and it's a realistic design if once you have found out the numbers you go to a data sheet put in the right parameters and actually convince yourself that the HP is whatever or the Delta p is whatever you have assumed right so equations are just one way to design often real design will be based on data sheets another one is selection for compressors based on the pressure ratios and the flow rates how do you know whether you want to use an axial compressor or a centrifugal so if you add this level of detail like professor mahajani said this is what comes after a simulator but this is the real design if you have a really small flow rate you can't use an actual compressor you have to use something else right how do you know what to choose there's a lot of diagrams like this trust me in kson or Perry spend the time to look at them and then in your report if you convey or in your presentation that this is why I chose a reciprocating and not an actal then people like it people like that you put a lot more thought to it pumps centrifugal pumps everyone selects them how do you know which pump and what efficiency and things like that so go to a vendor this is ksb a lot of people who sell centrifugal pumps based on the flow rates and the head y- axis is the head x-axis is the flow rate these are the curves for various pumps and this is how you select whether you want pump 32 or pump whatever 200 right because for whatever application you're doing if you have done the sizing correctly you know your flow rates and heads now you select a pump and conversely I show you this is from a report they say Okay taking the mechanical efficiency is 80% right one way is to just assume but a better way is to look up the curve of the pump find your operating point and then you can say whether it's what's the real efficiency right you don't have to do it for every pump all I'm saying is you do it once so that you convey that you know how to do it and you've you know you gotten your hands dirty at it um we'll skip this um have all your data ready that's the have a very I recommend at the very first meeting you should have an Excel already with all the components that you have ever encountered for your project with all their boiling points molecular weights it'll just make your conceptual design much easier because if you to look all of it then it Things become very difficult instead if you have a slide or a sheet where all the parameters are there your vle equations right the N website will have all the antoin coefficients but you'll have to put put it in Excel and plot them so that then your relative volatilities or other things are readily available if you have a liquid liquid system F Perry has a lot of these diagrams if you're lucky you will find it otherwise search and see whether somebody has looked at your system because you need the vle data or the lle data if you're doing a liquid liquid extraction if you have a solute will it precipitate always think in number of phases if you have a reaction is this single phase two phases three phases if you have a hydrogenation you may have two liquid phases hydrogen as a gas and a solid Catalyst right all the design is based on phases so always figure out is something going to precipitate or is it what's the solubility product and again these are things which are you know available somebody's going to do NAC or things like that uh you would have it yeah let's skip this um we already covered that's it okay and we'll share the slides we went rather fast but uh hopefully it helps you so let's see you know lot of it is pretty ambitious we agree but let's see who produces a 3D design we don't know but let's see thank you and uh thank you for patient uh listening really happy and uh that's all we have is there anything to add Guru you have anything to add anybody else joyjit okay then see you all later