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PROSESSISUUNNITTELUN SEMINAARI 1. vaihe. CONTENTS Info Project definition and knowledge acquirement Process selection Process synthesis Heuristic rules.

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Presentation on theme: "PROSESSISUUNNITTELUN SEMINAARI 1. vaihe. CONTENTS Info Project definition and knowledge acquirement Process selection Process synthesis Heuristic rules."— Presentation transcript:

1 PROSESSISUUNNITTELUN SEMINAARI 1. vaihe

2 CONTENTS Info Project definition and knowledge acquirement Process selection Process synthesis Heuristic rules Process flowsheet Process analysis / balances Plant siting and lay-out Cost and profitability estimation Safety and environmental aspects

3 PROSESSISUUNNITTELU - Suunnittelua ei voi viedä loppuun ennen teknisiä valintoja - Teknisten valintojen järkevyydestä ei voi varmistua, ennen kuin suunnittelu on viety loppuun  iteratiivinen työskentely

4 PROCESS LIFECYCLE

5 NATURE OF WORK ”Open ended task” Decision making –Selective –Quantitative –Go/No go Iterative Analysis of the data, conclusions Critical attitude Own ideas

6 PROJECT DEFINITION (Chemical plant design project) PROJECT GOALS 1.Technical 2.Schedule 3.Costs and resources DESIGN BASIS!! -Capacity -Raw materials (properties) -Products (properties and requirements) -Utility specification -Local conditions

7 TECHNICAL GOAL Name of the product(s) Scope of the project –Grass roots plant or –ISBL or –Expansion of the plant or –Modification of the plant or –Certain part of the plant… Level of detail –Feasibility study or –Basic design –Detailed design Restrictions –Process decided already –Location fixed –etc

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9 SCHEDULING Gantt’s bar chart Critical path method (CPM) Program evaluation and review technique (PERT) Softwares for project administration available CONCURRENT ENGINEERING (Concurrent process design engineering implies that, in addition to the basis of design, all factors of possible relevance to the process design are being considered in all stages of a design process /Paulien Herder, Process Design)

10 SCHEDULE Gantts bar chart

11 DESIGN COSTS AND RESOURCES Final design cost RELEVANT FIGURES –Manhours (specially in this case) –Number of documents –Contractors’ fee –Software licences –Etc. The costs of the detailed design are typically 5-30 % of the total investment, depending on the project. (The costs of conceptual and basic design are less, of course)

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14 DEFINITION OF THE DESIGN BASIS, EXAMPLE Design capacity t/a (feed) minimum feed 50 % of the design capacity Feed –Composition –Important properties (e.g. grain size, colour, moisture content etc.)

15 PRODUCT SPECIFICATION, EXAMPLE

16 EXAMPLE OF UTILITY SPECIFICATION

17 LOCAL CONDITIONS, EXAMPLE Wind load 85 kg/m 2 up to 30 m (55+h) kg/m 2 above 30 m Earthquakes, not relevant Horizontal snow load 200 kg/m 2 Temperatures: –Outside, max 35 °C –Outside, min-30 °C –Air cooling, design temp. 25 °C

18 KNOWLEDGE ACQUIREMENT 1.Properties of subtances 2.Economical knowledge 3.Process knowledge 4. Legal aspects

19 1. PROPERTIES OF SUBSTANCES Raw materials Products Catalysts Other materials appearing in the process  Physical properties  Dangerous properties  Environmental viewpoint

20 2. ECONOMICAL KNOWLEDGE Needed for market survey, capacity decision, rough cost estimation, rough profitability estimation  Production, current and predicted  Use and potential  Demand and supply  Prices, current and predicted  Competing and alternative products  Rough investment and production costs

21 SOURCES FOR MARKET RESEARCH Direct contacts with companies, brochures Congresses, fairs Professional journals and publications Special publications (Chemical Economics Handbook, SRI) Internet Consultants Industrial federations Suomen Ulkomaankauppaliitto Tullihallitus, tilastot Industrial secretaries (TEKES, UM) Kauppakamarit Usually personal contacts are the best

22 3. PROCESS KNOWLEDGE General chemical engineering knowledge Internet Handbooks Patents Journals Fairs, congresses (Achema) Direct contacts with companies, brochures How to produce certain chemical. Reliability of the knowledge

23 PROCESS SELECTION License or plant purchase: → process selection Own development → process synthesis

24 CRITERIA FOR SELECTION Investment costs Operation costs Synergy Novelty –Technical risk –Development potential Safety Environmental aspects etc

25 PROSESSIN LAATUKRITEEREITÄ

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28 1. VAIHE Projektin määrittely –Tekninen, aikataulullinen (janakaavio), taloudellinen (arvio työtunneista), suunnitteluperusteet Lähtötietojen hankinta –Lähtöaineet, tuotteet, prosessit; markkinaselvitykset tuotteesta, kysyntä, tarjonta, hinta, käyttökohteet, nyt ja tulevaisuudessa Prosessivaihtoehtojen lohkokaaviot Prosessivaihtoehtojen vertailu –Kriteerien perusteella Suositus prosessiksi ja sen sijainniksi Suositus kapasiteetiksi


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