Department of Chemical & Biochemical Engineering Rutgers, The State University of New Jersey 98 Brett Road Piscataway, NJ 08854

155:427 CHEMICAL & BIOCHEMICAL ENGINEERING DESIGN AND ECONOMICS I FALL 2011 (3 credits) Professor: Dr. A. Constantinides (Dr. C) SOE, room C-203A e-mail: acconsta@rci.rutgers.edu Teaching Assistant: John Mattick BME, room 019 email: jeanmattique@gmail.com Class time: MW 1:40 3:00 p.m. Location: SEC 210 Course description In this course, product and process design and economics are covered. Specifically, starting from identifications of marketable products, we proceed to develop ideas of making the products, select workable methods and then design the best and most economical processes for both upstream and down stream processing to produce the final products. Chemical engineering fundamentals are integrated in the design and operations of chemical and biochemical plants. In this course, we give a thorough analysis of the steps involved in the design and economic evaluation of chemical and biochemical processes. We elaborate on the economic considerations involved in the design, construction, and operation of chemical plants, such as investment costs, production costs, depreciation, and profitability analysis. The class is divided into design teams of 3-4 students each, and are assigned a major design project. They first conduct a literature survey related to their project and are required to make a Powerpoint presentation of their findings. The detailed design and economic evaluation of their project forms their major task during the Spring semester design course (155:428 Chemical & Biochemical Engineering Design & Economics II). We conclude the course with a discussion of safety considerations involved in the design of chemical and biochemical processes. We present several cases of chemical plant accidents from the extensive collection published by the US Chemical Safety Board (CSB) and the AIChE Safety and Chemical Engineering Education (SACHE). Course objectives This is the capstone course, which utilizes the fundamentals of chemical engineering (material balances, energy balances, transport phenomena, thermodynamics, kinetics, separations, unit operations, control, and safety) in the design and operation of chemical plants. Introduces the concepts and methods of plant design and economic evaluation: planning, cost estimation, fixed capital investments, working capital, production costs, depreciation, rate of return, profitability analysis, discounted cash flow analysis. Raises awareness of the students to the concepts of supply and demand of raw materials, commodity, and specialty chemicals. Introduces the students to the available computational tools for process flow design and economic evaluation. Stresses the importance of professional ethics, honesty, and integrity. Tel: (732) 445-3678

Tel: (240) 676 4978

ABET outcomes applicable to this course (a) an ability to apply knowledge of mathematics, science and engineering (c) an ability to design a system, component, or process to meet desired needs (d) an ability to function in multi-disciplinary/multi-functional teams (this can be defined as a mix of biochemical and chemical engineers, or as a group of students working on a different roles of a project) (e) an ability to identify, formulate, and solve engineering problems (f) an understanding of professional and ethical responsibility (g) an ability to communicate effectively (h) the broad education necessary to understand the impact of engineering solutions in a global and societal context (i) a recognition of the need for, and an ability to engage in life-long learning (j) a knowledge of contemporary issues (k) an ability to use the techniques, skills, and modern engineering tools necessary for engineering practice Textbooks (required) M. S. Peters, K. D. Timmerhaus, and R. N. West, Plant Design and Economics for Chemical Engineers, 5th Edition, McGraw-Hill Book Company, New York (2003). [Referenced in the Course Outline as P,T,&W]. Textbooks (recommended) J. Wei, Product Engineering: Molecular Structure and Properties, Oxford University Press, Oxford, 2007. [Referenced in the Course Outline as Wei] Prerequisites 155:303 Transport Phenomena I 155:304 Transport Phenomena II 155:324 Design of Separation Processes Assessment: Homework and grading policy Homework assignments Midterm Design poject presentation & report Attendance 30% 35% 30% 5% 100%

Homeworks will be collected on due dates and will be graded. Late homeworks will be penalized for lateness. Any homeworks that are not submitted will receive the grade of zero. Class participation and attendance are important. The professor will circulate the class roster to observe student attendance. It is the responsibility of the student to sign the roster. Students with more than 2 absences per semester will lose points (1% point for each absence, maximum 5% points).

Course Outline Week 1, 2 Subject Introduction to plant design and economic evaluation General design considerations Engineering ethics Process design development Essential flowsheet diagrams Block flow diagrams (BFD) Process flow diagrams (PFD) Piping and instrumentation diagrams (P & ID) Equipment descriptions and standard notation Computer-aided design Analysis of cost estimation Cash flow Capital investments Fixed capital and working capital Types of capital cost estimates Direct and indirect costs Cost indices; Cost scaling factors Ratio factors Production Costs Raw materials; Utilities; Operation costs Overhead expenses; Fixed charges Administrative and marketing expenses Interest and Investment Costs Simple, compound, continuous interest Present worth, future worth Taxes and Insurance Depreciation Methods Straight-line method, declining-balance method, Modified Accelerated Cost Recovery System (MACRS) Profitability Analysis Rate of return on investment Discounted cash flow rate of return Net present worth Payout period Midterm examination Product design Product exploration & discovery Product development Guest lecturer: Prof. J. Wei, Princeton University 3 Chs 1 &2 (Wei) Reading Assignment Ch. 1 (P, T & W) Ch. 2 (P, T & W) Handout Ch. 3 (P, T & W) Ch. 4 (P, T, & W) Handouts

3,4

Ch. 5 (P, T, & W) Ch. 6 (P, T & W)

5, 6

Ch. 6 (P, T & W)

Ch. 7 (P,T & W)

Ch. 7 (P,T & W) Ch. 7 (P, T & W)

Ch. 8 (P, T & W)

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Assignment of design projects Assignment of literature surveys Safety in Design Ch. 2 (P, T & W) Principles of chemical systems safety and health Handouts engineering management US Chemical Safety Board (CSB) Safety Videos AIChE Safety and Chemical Engineering Education (SACHE) Student presentations of design projects

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