Learning outcomes

1. Technical and scientific information search, including the literature in a foreign language (English) for the design of a chemical process to manufacture a chemical product on an industrial scale.

2. Use safety and environmental protection criteria in the design of an industrial chemical process.

3. Draw and interpret different flow diagrams (mainly Block Flow Diagram (BFD) and Process Flow Diagram (PFD)).

4. Design a base-case of a chemical process.

5. Prepare and solve the simulation of the process.

6. Use the most suitable heuristics for each design step.

7. Select the most suitable equipment for each operation unit and calcúlate the most appropriate design parameters.

8. Develop process heat integration using Pinch tecnology and design the heat exchanger network.

9. Estimate capital and manufacturing costs.

10. Perform the process profitability analysis.

11. Present the design results in a technical report.

12. Carry out the process design in a team: Contribute to group with ideas, suggestions and efforts; Participate in-group decision making; Give credit for others to contribution;Healthy communicate, actively listen and respect opinions, customs and individual preferences; Recognize collaborators strengths and weaknesses.

13. Plan activities for the design of a chemical process.

14. Analyse the processes for the production of the major chemical components in the chemicals sector, based on the above-mentioned design and operation strategies.

Students will develop the competences of the Specific Technology module, related to this subject: M03CM01, M03CM02, M03CM05, M03CM06, M03CM10 y M03CM15.

Besides, developing team work activities students will achieve the following competences: M03CM11, M03CM12, M03CM13 y M03CM14.

1.- Process and product design. The nature of design. Steps in product and process design. Environmental protection. Safety considerations.

2.- Process synthesis. Preliminary database creation. Preliminary process synthesis. Development of the base-case design.

3.- Process simulation. Introduction. Principles of process simulators. Solution algorithms. Recycling streams.

4.- Process synthesis heuristics. Raw materials and chemical reactions. Distribution of chemicals. Separations. Heat removal from reactors. Heat exchangers and furnaces. Pressure variation. Solid particle size and separation.

5.- Designo of reactors and reactor networks. Reactor evaluation. Ideal kinetic reaction models. Concentration, temperatura, pressure and phases. Real reactors. Reactor design for complex configurations. Reactor network design using the attainable region.

6.- Separation train synthesis. Overall configuration of separation system. de trenes de separación. Criteria for selection of separation methods. Selection of equipment. Sequencing of ordinary distillation columns. Sequencing for the separation of nonideal fluid mixtures. Separation systems for gas mixtures. Separation sequencing for solid-fluid systems.

7.- Heat integration in process plants. Minimum hot and cold utility requirements. Minimum number of heat exchangers. Heat-integrated distillation trains. Heat engines and heat pumps.

8.- Batch process design. Design of batch process units for non-continuous processes. Design of reactor-separator processes. Design of single-and multiproduct processing sequences.

9.- Estimating of costs. Investment, circulating capital and total capital cost. Types and precision of estimations. Manufacturing costs: raw materials, utilities, waste treatment, operating labor. Depreciation.

10.- Profitability analysis. Profitability criteria. Evaluation of risk. Comparing projects. Evaluation of equipment alternatives. Process modification analysis.

11.- Product design. Innovation maps. Product development process. Concept stage. Feasibility stage. Development stage. Manufacturing stage. Product- Introduction stage.

12.- The chemical industry: characteristics. Historic perspective of Chemical Industry. Evolution and trends.

13.- Energy, raw materials and products. Energy in the chemical industry. Utilities. Energy consumption and energetic efficiency. Raw materials and products. Environmental issues.

14.- Industry gases (oxygen, nitrogen and noble gases). Separation of air gases. Cold production. Distillation. Industrial installation. Noble gas production. Products.

15.- The Solvay process. Chemistry. Jaenecke diagram. Solvay plant. Electrolytic processes for chlorine-soda production. Diaphragm, mercury and membrane-cells. Procuts and applications.

16.- Sulphuric Acid. Raw materials. Production steps: combustion, catalysis and absorption. Products and applications.

17.-Construction materials, metalurgy and fertilizers.

18.- Petroleum refining. Fractionation. Catalytic and non-catalytic conversión processes. FCC. Hydrocracking. Delayed coking. Products and applications.

19.- Petrochemical industry. Raw materials. Basic petrochemical processes. Olefin and syngas production. Aromatics. Polymers.

1. Design of a base-case of an industrial process. Team work.

2. Reading and synthesis of reference textbooks.

3. Questionnaires

4. Case and problema solving (simulation, heat integration, cost estimation, profitability analysis, etc.).

5. Lectures

6. Bibliographic search.

7. Oral and written presentations.

8. Exams.

The evaluation system is continuous. Thus, periodically some assessments are scheduled, which are subjected to evaluation, in order to develop progressively the learning outcomes.

EXAM (40 - 60%). Individually. Two partial exams will be carried out in January and May/June. The first exam is focused on a chemical process design and the second one on manufacturing processes of the main products of the chemical industry. In both exams a minimum score of 5 is required. A second chance is given in the final exam (June) for those students who have not passed the partial exams.



INVIDIVUAL AND TEAM WORK (40-60%)



Withdrawing from the continuous assessment, the final evaluation (100%) will consist on some activities (including exams, individual and group works) that will allow the achievement of both competences and learning outcomes.

If you do not wish to participate in the continuous assessment system, you should present, by hand and in writing, your withdrawal from continuous assessment to the professor responsible for the subject. You will have 18 weeks to do this, starting from the beginning of the academic year, in accordance with the centre’s academic calendar (Article 8.3 of the Rules governing student assessment in official degree courses of the UPV/EHU).

Withdrawing from the call (continuous or overall assessment) will mean you will be graded as ‘not presented’. In the case of continuous assessment, the student may withdraw from the call in the period up to one month before the completion of the classes in the corresponding subject. This withdrawal must be presented, by hand and in writing, your withdrawal from continuous assessment to the professor responsible for the subject. If it is a case of overall (final) assessment, non-presentation at the final exam set in the official calendar (in June) will mean the automatic withdrawal from the corresponding call (Article 12 of the Rules governing student assessment in official degree courses of the UPV/EHU).



“If any students cannot carry out the assessment in the terms described above due to sanitary conditions, they will have to follow the assessment guidelines issued by the Rectorate at the time of sitting the exam”.

Software for Process Simulation PRO/II.
The information and material provided in eGela virtual platform.

Basic bibliography

"Product & Process design principles: Synthesis, analysis and evaluation", 3ª ed.

Seider, W.D., Seader, J.D., Lewin, D.R., Widagdo, S., John Wiley & Sons, N.Y, (2010).

"Analysis, Synthesis, and Design of Chemical Processes", 3ª ed.

Turton, R., Bailie, R.C., Whiting, W.B., Shaeiwitz, J.A., Prentice Hall PTR (2009).

"Product Design and Development", 4ª ed.

Vian, A., "Curso de Introducción a la Química Industrial",.2ª edición. Reverté. Barcelona (1999).

Stocchi, E., "Industrial Chemistry". Volumen 1. Inorgánica. Ellis Horwood, London, (1990).

Ulrich, K.T., Eppinger, S.D., McGraw-Hill International Edition(2008).

"Survey of Industrial Chemistry". 3ª ed.

Chenier P. J., Kluwer Academic. New York (2002).

"An introduction to Industrial Chemistry"

Heaton, C.A.(ed), Blackie Academic & Professional (London) 2º ed. (1991)

"Cryogenic Systems". 2ª Ed.

Barron, R. F., Oxford University Press. New York (1985).

"Sulfuric acid manufacture Analysis Control and Optimation".

Davenport, W.G and King, M.J., Elsewvier. Amsterdam (2006).

In-depth bibliography

"Chemical Product Design".
Cussler, E.L., Moggridge, G.D., Cambridge University Press, (2001).
"Chemical Engineering Design", 5ª ed.
Sinnot, R.K., Towler, G., Butterworth & Heinemann, Burlington, MA (2009).
"Plant Design and Economics for Chemical Engineers"
Peters, M.S., Timmerhaus, K.D., West, R.D., 5ª ed., McGraw-Hill, Nueva York (2002).
"Systematic Methods of Chemical Process Design"
Biegler, L.T., Grossman, I.E., Westerberg, A.W., Prentice Hall, N.J. (1997).
"Encyclopedia of Chemical Processing and Desing",
McKetta, John J. (Ed.)., Marcel Dekker, INC. New York (1977- ).
"Inorganic Chemistry - An Industrial and Environmental Perspective",
Swaddle T.; Elsevier, (1997)
"Industrial Organic Chemistry". 3ª ed.,
Weissermel K. & Arpe J., VCH Publishers, Inc. New York (1997).
"Handbook of Industrial Chemistry",
Farhat A., Bassam M.A. and Speight, J.G.; Chauvel A., Lefebvre G., Editions Technip, Paris (1989)