GUIDELINES

Plant Design Project I (PDP I)

(CBB/CCB 4013)

FOR

SUPERVISORS AND STUDENTS




CHEMICAL ENGINEERING PROGRAMME
UNIVERSITI TEKNOLOGI PETRONAS
Bandar Sri Iskandar, 31750 Tronoh, Perak Darul Ridzuan
Tel: (05) 3687565 Fax: (05) 3656176

Doc. Ref. No. : UTP-ACA-PROG-PDP-1
Issue Version : 2.0
Date : December 2011

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TABLE OF CONTENTS


1.0 INTRODUCTION 1
2.0 OBJECTIVES 1
3.0 OUTCOMES 1
4.0 SCOPES 2
5.0 DURATION 3
6.0 RESPONSIBILITIES 3
6.1 Students 3
6.2 Plant Design Project Coordinator (PDPC) 3
6.3 Committee of Supervisors 4
7.0 PROCESS FLOW OF PDP I 5
8.0 INTERIM REPORT 7
8.1 Format 7
8.2 Contents of Interim Design Report 8
9.0 PRESENTATION 13
9.1 Interim Oral Presentation 13
10.0 RESOURCES AND SERVICE REQUIREMENTS 14
11.0 ASSESSMENT TECHNIQUE 14
12.0 GRADING SCHEME 15
12.1 Interim Oral Presentation 15
12.2 Interim Report 15
12.3 Individual Progress Performance 15
12.4 Peer Review 15
12.5 C-Factor 15
12.6 UTP Grading Scheme 16
13.0 APPENDICES
Appendix I : Suggested Milestone of PDP I 17
Appendix II : Sample title page 18
Appendix III : Sample certification of approval 20



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Appendix IV : Form PDP I-2 Interim Oral Presentation (Group) 21
Form PDP I-3 Interim Oral Presentation (Individual) 22
Form PDP I-4 Interim Report 23
Form PDP I-5 Individual Progress Performance 24
Form PDP I-6 Peer Review 25
Form PDP I-7 C-Factor 26
Appendix V : Description of Assessment Criteria for Interim Oral
Presentation (Group) 27
Description of Assessment Criteria for Interim Oral
Presentation (Individual) 29
Description of Assessment Criteria for Interim Report 30




1
1.0 INTRODUCTION

As part of the requirements for the Chemical Engineering degree course, the
students have to complete 6 credit hours in Plant Design Project (PDP). The
PDP is divided into Plant Design Project I (CAB 4014) and Plant Design
Project II (CAB 4014). The PDP I and PDP II are offered in the 9
th
and 10
th

semesters respectively. Each PDP course carries 3 credit hours. This guideline
specifically addresses the Plant Design Project I (PDP I).

This guideline provides the necessary information for students/supervisors in
carrying out their duties for PDP I in UTP.


2.0 OBJECTIVES


The main objective of PDP 1 is to train/develop students in the application of
all the elements of knowledge and skills that have been accumulated
throughout the undergraduate program for solving design related problems for
typical process industrial plant. The second objective of the course is to
develop the skills of working in a team and to nurture leadership qualities.
Written and oral communication skills as well as the capability in decision
making are also nurtured by the project.


3.0 OUTCOMES

At the end of this course, students should be able to:
Integrate their chemical engineering skills and knowledge in a detailed
design of a chemical plant.
Screen a variety of potential process routes and identify the most cost-
effective route for a chemical plant
Perform manual mass and energy balance calculation for a chemical
plant

2
Optimize the energy usage by conducting appropriate pinch analysis
for a chemical plant
Carry out simulation for a chemical plant using a computer-aided
design/engineering software (e.g. ICON,ICON, PDS, PROCEDE,
MATLAB)


4.0 SCOPES

The scopes of PDP I are as follows:
Conducting literature survey: properties of the products, usage and cost,
alternative process routes for manufacturing the product, chemical and
physical property data for all the raw materials, intermediates and final
products, environmental considerations, safety considerations, etc.
Identifying and selecting the best process route for a particular design
project.
Developing the best possible process flowsheet for the selected chemical
process route.
Developing the complete material and energy balance calculations for the
selected process.
Using related computer-aided design/engineering software (e.g. ICON,
PDS, PROCEDE, MATLAB) as a tool for the design.
Conducting a heat integration study in the final PFD (if applicable)
Making the necessary decisions, judgements and assumptions in design
problems.


5.0 DURATION

PDP 1 carries 3 credit hours and students are expected to accomplish their
project in 14 weeks during the first semester of their final year. A proposed
milestone of PDP I can be found in Appendix I.


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6.0 RESPONSIBILITIES

6.1 Students

Students must make their own initiative and able to work in a team in
bringing the project to completion. Students will also be required to
exercise teamwork spirit and job co-ordination during undertaking the
design project. The students may elect one of their team members as the
group leader. Among the expected responsibilities are as listed below:
Obtaining information and material rightfully and honestly.
Plagiarism will cause serious consequences.
Seeking advice and guidance from supervisors when necessary.
Maintaining good discipline and personal conduct when searching
for relevant information especially when out of campus.
Preparing themselves against any failure such as work lost due to
computer crashes.
Preparing a logbook for each member and maintain a good record of
individual activity and progress.
Undertaking the detailed design of at least one unit operation per
person.
Submitting all reports on time as specified by plant design project
coordinator.
Giving/putting significant individual contribution or effort towards
the completion of the group task.
Failure to take the above responsibility/responsibilities may lead to
failing the course.

6.2 Plant Design Project Coordinator (PDPC)

Head of Department will appoint a Plant Design Coordinator (PDPC)
and his/her assistants to coordinate PDP I. The responsibilities of PDPC
and his/her assistants include:
Identifying and selecting design project title.
Dividing students into respective groups.

4
Assigning students to respective supervisors.
Planning and managing the schedule for PDP I course
implementation.
Providing briefing on PDP I course requirements to lecturers and
students.
Arranging special seminars in selected topics related to the project to
give additional skills to the students to complete the project.
Coordinating students' oral presentation
Arranging external examiners from industry to participate in the
assessment of students' report and oral presentation.
Compiling and finalizing students' final scores for submission to
examination committee.
The assistants of PDPC will assist him/her in all the above activities.


6.3 Committee of Supervisors

The committee consists of a main and with not more than two assistant
supervisors. The responsibilities of the committee can be summarized as
below:
Advising the students on the preparation of their design projects.
Arranging meeting with students periodically. The supervisors are
expected to meet their students once a week.
Monitoring students progress from time to time.
Assisting students in defining the problem involved accordingly.
Assigning the students to undertake individual detailed calculation of
mass and energy balance
Reviewing and assessing the individual student progress.
Assessing reports and commenting on the work.
Delivering seminar lectures on some special topics if requested by
the PDPC


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7.0 PROCESS FLOW OF PDP I

PDPC will assign the general problem for the manufacture of a certain
product. The required capacity for the plant may also be indicated in the
assignment. As the first step the students have to carry out a literature survey
on the given product covering all the aspect of the design problem. By taking
general design considerations into account, students will then have to
synthesize the best process flow sheet. The next step is to calculate the
material and energy balance for the chosen flowsheet. The students must
perform manual calculations of material balances first. Then only the students
can use available software like ICON for this purpose. However, all the inputs
to the software must be tabulated and justified. At this stage, preliminary cost
estimation for the design should be prepared using short cut methods. The
process flow diagram for the project is shown in FIGURE 1.

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1. PROBLEM
ASSIGNED TO
STUDENTS
2. STUDENTS GROUPS
FORMED
3. SUPERVISOR
TEAMS ASSIGNED
TO THE STUDENT
GROUPS
PERFORM LITERATURE REVIEW
1. PROPERTIES, USE AND ECONOMICS OF PRODUCT
2. PHYSICAL AND CHEMICAL PROPERTIES
3. ALTERNATIVE PROCESS ROUTES
4. SAFETY ISSUES
5. ENVIRONMENT ISSUES
6. COST DATA

CHOOSE THE BEST
PROCESS ROUTE
DETAILED MATERIAL AND ENERGY BALANCE
(Incorporation of MEB into ICON Simulation)

CONCEPTUAL DESIGN

PRELIMINARY ECONOMIC EVALUATION

INTERIM ORAL PRESENTATION

HEAT INTEGRATION AND FINALIZING PROCESS FLOW DIGRAM

FIGURE 1: Process flow of PDP I
SUMMISSION OF INTERIM REPORT


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8.0 INTERIM REPORT

Students are expected to submit their interim reports as provided in the Gantt Chart.

8.1 Format

8.1.1 Language
The report must be written in English Language.

8.1.2 Font and spacing
All text should be one and half spacing (Times New Roman regular font style,
size 12) written on a white A4 paper on one side of each sheet. The following
however should be single spaced:
Foot notes
Tables and figures

8.1.3 Length
The length of report should be not less than 50 and not more than 100 pages of
(excluding appendices). Students are encouraged to use brief and
straightforward wording and avoid jargon as much as possible. The number of
pages for the appendices is unlimited.

8.1.4 Numbering
All pages should be numbered in proper sequence from introduction to the end
of the report. Page number must be positioned at the bottom and centered.

8.1.5 Heading and Margin
Major headings, such as INTRODUCTION, should be capitals, bold and font
size 14. Secondary headings such as Example, should be in bold. The top,
bottom, and right margins are 1 inch except for the left margin, which is 1.3
inch.




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8.1.6 Mathematical Text
Mathematical text must be spaced out; superscript and subscript must be
clearly shown. All equations, terms and symbols must be written in italic.

8.1.7 Tables and Figures
Tables and figures less than a page in size should be inserted into the text near
the point of reference. Tables should not be carried over to the next page.
Margin limits are the same as text full-page. All tables and figures should be
numbered and captioned consecutively. Table heading should be positioned at
the top middle of each table. The figure heading should be positioned at the
bottom middle of each figure.

8.1.8 Bindings
The report must be presented in an ABBA Lever Arch Files (404 Standard).


8.2 Contents

8.2.1 Title Page
The title page should be set out in accordance with the attached specimen
sheet in Appendix II. The project title should be clearly and precisely defined
as has been assigned by the PDPC.

8.2.2 Certification
This section should be approved by supervisor after he/she has satisfied with
the correction or amendment done by the student. See Appendix III for
specimen sheet.

8.2.3 Acknowledgements
Most design teams obtain considerable assistance and advice from supervisors,
industrial consultants, librarians, faculty and fellow students. This section
provides an opportunity to acknowledge their contributions with an expression
of appreciation and thanks.

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8.2.4 Table of Contents
All sections in the report should be listed, including the page numbers on
which they begin. Hence, all pages in the report, without exception, must be
numbered. Each main section must begin with a new page.

8.2.5 Executive Summary
The students should highlight all the important features of the report from the
technical reasons for undertaking the study to the conclusion. Remember that
most readers only read the summaries of reports and every word counts. Avoid
padding phrases and phrases that refer to the reports.

8.2.6 Main Body
The main body of the report must be composed of the following chapters:

Chapter 1: Introduction
Background of the design project, problem statement, objectives, scopes of
work.

Chapter 2: Literature Review
Carry out research to uncover the latest information on feed and product
properties, product price, market and possible site locations that may lead to a
more profitable design. Literature resources include encyclopedias,
handbooks, journals, reports, indexes and even World Wide Web (Internet).
Standard method for quoting must be implemented and standardize throughout
the report.

Chapter 3: Preliminary Hazards Analysis
The preliminary hazard analysis should be carried out during feasibility study
to define/determine safety-related aspects that influence the design. The study
should cover the following points:
Summary of previous accidents on similar type of plants.
Identification of material and chemical hazards in the
process such as feed, intermediates, products and by-

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products, flammability data, toxicity data, chemical
interactions etc. Compile all MSDS in the appendix session.
Discussion on the possibility to reduce potential
consequences of an accident by considering inherent safety
aspects such as substitute hazardous chemicals, reduce
inventories, lower pressure and temperatures, safe location,
siting, plant layout and transportation.
Identification of any requirement/compliance by local
safety regulations and design guidelines

Chapter 4: Conceptual Design Analysis
To evaluate few alternative processes and select the best process among them
for the design.
4.1 Preliminary Reactor Optimization
To optimize the reactor conversion, selectivity and yield with
appropriate recycle block by performing economic potential analysis
based on a simple reactor cost model.

4.2 Process Screening
Developed few process alternatives based on the separation train
sequence using heuristic approach or minimum vapor flow approach.
Perform preliminary mass balance, which must be manually done in
spreadsheet (block form). No ICON simulation should be used here.
Evaluate the alternatives and select the best configuration with
appropriate justifications.

4.3 Economics Evaluation
Conduct a profitable analysis by evaluating the economic potential of
the project. Appropriate comparison to initial economic evaluation
must be performed.


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4.4 Process Flowsheeting
Performing the detailed process flowsheet based on the selected
process with their interconnections (involving the reaction, separation,
and temperature and pressure-change operations). A complete Process
Flow Diagram (PFD) must be generated by using ICON. All inputs to
the flowsheeting software must be listed in the report and
explained and justification for the choice values provided. Process
Flow Diagram should be drawn on A1 size paper, then folded and
inserted in A4 sized plastic wallets, along with the report. All streams
are numbered clearly and all the process units are labelled. In addition,
the drawing should contain a material balance block that is a table
showing for each numbered stream:
Total flow rate
Flow rate of each chemical species
Temperature
Pressure
and other important properties e.g. enthalpy, density etc. All units must
be reported in SI.


Chapter 5: Heat Integration
To optimize the energy usage by conducting appropriate pinch analysis. A
heat integration study may be incorporated in the final PFD if applicable for
the particular flow sheet chosen. In addition, care must be taken to ensure
appropriate heating and cooling media are being applied at the most cost
effective way.

Chapter 6: Process Flowsheeting
Produce a full description of the finalized PFD after heat integration.



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8.2.13 Conclusion and Recommendation
This section is important as it reflects the essence of the report. Hence, the
highlights from Introduction and Theory sections should be included.

8.2.14 References
All references should be cited according to Harvard system. References
including sources of physical data should be listed. The following method of
referencing must be followed. In the text refer to the work by the last name of
the author followed by the year in brackets. If there are 2 authors give the last
name of both the authors. If there are more than 2 authors give the last name
of the first author followed by et.al. In the bibliography list all the references
in the alphabetical order of the last name of the first author. All the authors
must be listed as shown in the examples below, followed by year in bracket,
the name of the article or book, Name of the Journal, Volume, No and page
No. In the case of books the name of the book, edition and publisher should
follow the name of the author and year. For example:

Nozhevnikova et. al (1997) has discussed the methanogenesis reactions taking
place in natural environments. Abu-Absi and Actis (1999) give a detailed
description of different reactions taking place in an anaerobic reactor.
Metcalf and Eddy (1991) discussed about the operational aspects of anaerobic
reactions. Otton(1998) has presented results on anaerobic digestion in
fluidised bed reactors. Adam (2000) gives some interesting insights into the
natural anaerobic processes.

Listing of these references is as shown below.

References
1. Abu-Absi, N.R. and L.A. Actis (1999), Encyclopaedia of Bioprocess
Technology: Fermentation, Bio Catalysis and Bio Separation, Vol 1,
John Wiley and Sons, New York.


13
2. Adam, D. (2000), Where there is muck there is gas,
http://WWW.nature.com/nsu_pf/000420-1.html (date last access)

3. Metcalf. C and R. Eddy (1991), Wastewater Engineering: Treatment,
Disposal and Reuse, 3
rd
Ed., Mc-Graw Hill Inc, New York.

4. Nozhevnikova, A.N., C.Hollinger, A.Amman and A. J. B Zehnder
(1997), Methanogenesis in Sediments from Deep lakes at Different
Temperatures (2-70
o
C), Water Science and Technology, Vol 36, No
3, pp 384-396.

5. Otton, V. (1998), Anaerobic Digestion in Fluidised Bed Reactor, MSc
Thesis, Institute National Polytechnik, Grenoble.

8.2.15 Appendices
Lengthy calculations, figures, results from programming, derivation of design
data, etc. should be enclosed in the appendices. Students must provide a clear
explanation and the author name for each calculation. The Process Flow
Diagram (PFD) should be drawn in an A1-size paper. The drawing should
then be folded and inserted in an A4-size plastic pocket as part of the interim
report.


9.0 INTERIM ORAL PRESENTATION

Within the Week 12 to 13, each group will be assessed by the internal
examiners through the interim oral presentation. This presentation consists of
process flow sheets with complete material and energy balance. During the
presentation, students are expected to be able to explain:
Background of the design project, reasons for and range of study as well as
definition of the problem.
The potential hazard associated to the processes.
Process flowsheeting design

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Potential heat integration.
Basic costing.
Selection of equipment.
Future implementation on the design.

10.0 RESOURCES AND SERVICES REQUIREMENTS

Students are allowed to seek information or any sort of material needed for the
project at any institutions or other places. Application letters to Head of
Programme should be written by the students through the main supervisor.
The main supervisor must fill-up Form PDP I-1 (Appendix IV) and submit to
PDPC together with the application letter. All requisitions are subjected to
approval of Head of Programme.

11.0 ASSESSMENT TECHNIQUE
At the end of the semester, all student works will be assessed and final grade
will be given. Table 1 summarizes the overall technique of assessment. The
internal examiners will be selected among the supervisors to assess the interim
oral presentation and report.

Table 1. Assessment Scheme
Assessment Stage Examined by and % marks % Contribution to
Supervisor

Internal
Examiners
Group mark Individual
mark
Interim Oral
Presentation
25 15 10
Individual Progress
Performance
10 10
Interim Report 25 40 65
C-factor
Total 90% 10%

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12.0 GRADING SCHEME

12.1 Interim Oral Presentation
The interim oral presentation contributes 25% of the overall PDP I marks. The
internal examiners are responsible to assess the presentation in the technical
and non-technical aspects. Samples of score sheets can be referred to Form
PDP I-2 and PDP I-3 (Appendix IV)

12.2 Interim Report
Supervisors and internal examiners will judge the final report. The report
accounts for 65% of the overall marks in which 25% comes from the
supervisor and 40% from the internal examiners. See Forms PDP I-4
(Appendix IV).

12.3 Individual Progress Performance
Each group is required to conduct an official meeting once in every two
weeks. The first official meeting must be held in the first lecture week of the
semester. The last official meeting will be held on week 13
th
, which will
constitute a total of seven (7) official meetings. Minutes of meeting (MOM)
must be submitted to the main supervisor within one (1) week after the
meeting. Supervisors have to evaluate the individual progress performance by
filling up the Form PDP I-5 (Appendix IV). Individual progress performance
will contribute 10% of the overall individual marks. Students and supervisor
may conduct additional meetings as frequent as required.

12.4 Peer Review
Students get to evaluate among themselves through the peer review session by
filling up Form PDP I-6 (Appendix IV) and return it to PDPC.

12.5 C-Factor
C-factor is introduced to assess students on their contribution to the group
work by the supervisors. Supervisors can take the results from the peer review
as a reference in assessing the C-factor. The amount of the group mark that

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can be obtained by individual is depending on the C-factor value that he/she
gets. See Form PDP I-7 (Appendix IV)

12.6 UTP Grading Scheme

The overall marks for PDP will be finalized by PDPC after all the forms have
been completed by the examiners. The final grades will be given according to
Table 2 below:

Table 2: UTP Grading Scheme















Score Grade Point
85 100
80 84.9
75 79.9
65 74.9
55 64.9
50 54.9
45 49.9
40 44.9
0 39.9
A
A-
B+
B
C+
C
D+
D
F
4.00
3.75
3.50
3.00
2.50
2.00
1.50
1.00
0