529-0459-01L  Case Studies in Process Design

SemesterAutumn Semester 2018
LecturersS. Papadokonstantakis
Periodicityyearly recurring course
Language of instructionEnglish


AbstractThe learning objective is to design, simulate and optimise a real (bio-)chemical process from a process systems perspective. Specifically, a commercial process simulation software will be used for the process simulation and optimisation. Students have to integrate knowledge and develop engineering thinking and skills acquired in the other courses of the curriculum.
ObjectiveSimulate and optimise a chemical production process using a commercial process simulation software.
ContentCreate a model describing the production process
- Students will apply a commercial process simulator systematically for process creation and analysis.
- Students will create a simulation flowsheet for steady-state simulation
- Students will evaluate the sequencing in which process units associated with recycle loops are solved to obtain converged material and energy balances.

Evaluate the performance of the production process
- Students will analyse and understand the degrees of freedom in modelling process units and flowsheets.
- Students will understand the role of process simulators in process creation.
- Students will make design specifications and follow the iterations implemented to satisfy them.
- Students will judge the role of process simulators in equipment sizing and costing and profitability analysis.
- Students will assess the economic performance of the process, including investment and operation costs.
- Students will assess the environmental impact of the production process.

Optimise the design and operating conditions of the production process
- Students will solve sensitivity analyses and optimisations are conducted considering technical and economic criteria.
- Students will generate process integration alternatives to improve the initial production process.
- Students will optimise the production process considering economic and environmental criteria.
Prerequisites / NoticeBefore the case study week, students are encouraged to participate in exercises of the course of Process Simulation and Flowsheeting in order to get familiar with Aspen Plus simulation software (highly recommended).
The problem statement and detailed instructions are provided at the beginning of the case study week.

During the case study week:
- Students work in teams of 3-5 people.
- Students have to pose and solve process equipment and system design related problems.
- Students have to coordinate the activities, the preparation of the written report and the oral presentation.
- Students get support from project assistants, the course supervisor, and industrial expertise.

The groups deliver the written report on a predefined date.
The groups are also asked to critically review a report from another group.

The students receive the comments of their reviewing group and the course supervisors on a predefined date.

Finally, the students participate in a vist to the production site of the process they modelled. There, they present their work to the industrial experts, get valuable feedback and a tour in the industrial facilities.