CHEN30200 Chem & Bioprocess Eng Design

Academic Year 2023/2024

This module will introduce students to the basic principles of chemical engineering process design, with specific emphasis on equipment design and specification, in the context of a typical mechanically-focussed design project (done individually). However, moving beyond this essential first step, a group-based and open-ended design project will be adopted, where a process approach is a chosen for a given product specification, a plant-wide PFD is developed with mass and energy balances, together with a complete initial economic evaluation. The utility requirements and plant layout shall be developed, with initial equipment specification sheets detailed.

In tackling both of these projects, topics covered include:

- design methods to ensure the safe operation of equipment,
- selection of materials of construction,
- safety and loss prevention in equipment design
- quality-assurance techniques

with which the integrity of the design process can be guaranteed. Emphasis will be placed towards sustainability and environmental impacts of design projects and their regulatory compliance, and all of these aspects will be embedded in a fundamental way in the course instruction and examples/case studies.

A summary of key concepts is as follows:

Basic principles for pressure-vessel design
Combined-stress analysis
Control of exothermic reactions
Pressure relief
Piping design
Selection of materials of construction
Regulatory aspects for process design and operation
P&IDs, PFDs and plant-layout and utility flowsheets, together with equipment-spec sheets
Control schemes
Safety, environmental and sustainability in process design
Quality assurance
Hazardous materials
Basics of Plant Layout & Economics

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Curricular information is subject to change

Learning Outcomes:

On completion of this module, students should be able to:

1. Estimate the shell thickness for a standard pressure vessel, using relevant design codes.

2. Size a relief valve for a variety of upset scenarios.

3. Select a material of construction for a specific application.

4. Complete a mechanically-focussed design project for an equipment item for a specified unit operation on an individual basis, featuring
- complete detailed chemical-engineering design from scratch, with sophisticated process-modelling software
- complete detailed mechanical design in accord with design codes, with full compensation and combined-stress analysis, including support requirements, for a variety of scenarios
- specify pressure relief system
- develop P&ID
- develop start-up standard operating procedure based on P&ID

5. Demonstrate an understanding of the regulatory framework for equipment design.

6. Show a detailed understanding of safety, loss prevention and design practice in the context of embedded sustainability and ethics.

7. Synthesise a plant-scale process flow sheet and complete associated mass and energy balances.

8. Document the plant-wide design appropriately, using PFDs, P&IDs, mechanical drawings, specification sheets and plant layout drawings.

9. Demonstrate an understanding of safety, environmental and sustainability in process design.

10.Carry out plant-economics exercises.

11. Conduct a HAZOP.

Student Effort Hours: 
Student Effort Type Hours
Autonomous Student Learning








Approaches to Teaching and Learning:
This course outlines fundamental aspects of chemical engineering design of equipment and processing plants through a face to face lecture course, which is assessed via in class tests. The bulk of the assessment and application of this theory and practice is centred on project work which is intended to closely mimic design practices and processes used by engineers working in industry to design individual pieces of process equipment through the mechanical design project and entire processing facilities through the Plant Design Project. 
Requirements, Exclusions and Recommendations

Not applicable to this module.

Module Requisites and Incompatibles
CHEN30150 - Chemical Engineering Design

Assessment Strategy  
Description Timing Open Book Exam Component Scale Must Pass Component % of Final Grade
Group Project: HAZOP Exercise and Report Unspecified n/a Graded No


Project: Plant Design Project Throughout the Trimester n/a Graded No


Class Test: In class MCQ Throughout the Trimester n/a Standard conversion grade scale 40% No


Project: Mechanical Design Project Throughout the Trimester n/a Graded No


Carry forward of passed components
Resit In Terminal Exam
Autumn No
Please see Student Jargon Buster for more information about remediation types and timing. 
Feedback Strategy/Strategies

• Feedback individually to students, on an activity or draft prior to summative assessment
• Feedback individually to students, post-assessment
• Group/class feedback, post-assessment

How will my Feedback be Delivered?

The taught components of the course are assessed through an in class tests where results are provided following assessment. The mechanical design project has initial feedback on the chemical design calculations and TA or Lecturer office hours to address questions relating to the project, throughout its duration with feedback based on a final project grade post assesment. Feedback session on HAZOP in class HAZOP exercise is conducted following submission of HAZOP report and via assignment grade. For the plant design project continuous feedback is given in terms of design consultancy meetings, design studio sessions and intermediate group presentation on the Mass and Energy Balance components of the design project. Feedback and examination on the final report and students individual performance will be via final grade and individual design project interview which will also be graded.

Timetabling information is displayed only for guidance purposes, relates to the current Academic Year only and is subject to change.
Lecture Offering 1 Week(s) - 20, 21, 22, 23, 24, 25, 26, 30, 31, 32, 33 Fri 14:00 - 16:50