prosessisuunnittelun seminaari 1. vaihe. contents info project definition and knowledge acquirement...
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PROSESSISUUNNITTELUN SEMINAARI
1. vaihe
CONTENTS
• Info• Project definition and knowledge acquirement• Process selection• Process synthesis• Heuristic rules• Process flowsheet• Process analysis / balances• Plant siting and lay-out• Cost and profitability estimation• Safety and environmental aspects
PROSESSISUUNNITTELU
- Suunnittelua ei voi viedä loppuun ennen teknisiä valintoja- Teknisten valintojen järkevyydestä ei voi varmistua, ennen kuin suunnittelu on viety loppuun iteratiivinen työskentely
PROSESSISYNTEESI
PROSESSIANALYYSI
PROSESSIN ARVIOINTI
Prosessin rakenne, yksiköt, laitteet, virrat,
kierrätykset
Valittujen laitteiden toiminnan
analysointi esim. simuloimalla
Taloudellisuus, turvallisuus,
ympäristöystävällisyys, tekniset kriteerit
PROSESSISYNTEESI
PROSESSIANALYYSI
PROSESSIN ARVIOINTI
Prosessin rakenne, yksiköt, laitteet, virrat,
kierrätykset
Valittujen laitteiden toiminnan
analysointi esim. simuloimalla
Taloudellisuus, turvallisuus,
ympäristöystävällisyys, tekniset kriteerit
PROCESS LIFECYCLE
D E M O L IT IO N
F U R T H E R D E V E L O P M E N T
P R O D U C T IO N
S T A R T -U P
IN S T A L L A T IO N A N D C O N S T R U C T IO N
P R O C U R E M E N T
D E T A IL E D D E S IG N
IN V E S T M E N T D E C IS IO N
B A S IC D E S IG N
C O N C E P T U A L D E S IG N
P R O C E S S D E V E LO P M E N T
P R O D U C T D E V E L O P M E N T
ID E A
NATURE OF WORK
• ”Open ended task” • Decision making
– Selective– Quantitative– Go/No go
• Iterative
Analysis of the data, conclusionsCritical attitudeOwn ideas
PROJECT DEFINITION(Chemical plant design project)
PROJECT GOALS1. Technical2. Schedule3. Costs and resources
DESIGN BASIS!!- Capacity- Raw materials (properties)- Products (properties and requirements)- Utility specification- Local conditions
TECHNICAL GOAL• Name of the product(s)• Scope of the project
– Grass roots plant or– ISBL or– Expansion of the plant or– Modification of the plant or– Certain part of the plant…
• Level of detail– Feasibility study or– Basic design– Detailed design
• Restrictions– Process decided already– Location fixed– etc
SCHEDULING
• Gantt’s bar chart• Critical path method (CPM)• Program evaluation and review technique (PERT)
Softwares for project administration available
CONCURRENT ENGINEERING(Concurrent process design engineering implies that, in
addition to the basis of design, all factors of possible relevance to the process design are being considered in all stages of a design process /Paulien Herder, Process Design)
SCHEDULE
Gantts bar chart
DESIGN COSTS AND RESOURCES• Final design cost
RELEVANT FIGURES– Manhours (specially in this case)– Number of documents– Contractors’ fee– Software licences– Etc.
The costs of the detailed design are typically 5-30 % of the total investment, depending on the project. (The costs of conceptual and basic design are less, of course)
DEFINITION OF THE DESIGN BASIS, EXAMPLE
• Design capacity 50 000 t/a (feed)
minimum feed 50 % of the design capacity• Feed
– Composition– Important properties (e.g. grain size, colour, moisture
content etc.)
PRODUCT SPECIFICATION, EXAMPLE
EXAMPLE OF UTILITY SPECIFICATION
LOCAL CONDITIONS, EXAMPLE
• Wind load 85 kg/m2 up to 30 m
(55+h) kg/m2 above 30 m• Earthquakes, not relevant• Horizontal snow load 200 kg/m2
• Temperatures:– Outside, max 35 °C– Outside, min -30 °C– Air cooling, design temp. 25 °C
KNOWLEDGE ACQUIREMENT
1. Properties of subtances
2. Economical knowledge
3. Process knowledge
4. Legal aspects
1. PROPERTIES OF SUBSTANCES
• Raw materials• Products• Catalysts• Other materials appearing in the process
Physical properties Dangerous properties Environmental viewpoint
2. ECONOMICAL KNOWLEDGE
Needed for market survey, capacity decision, rough cost estimation, rough profitability estimation
Production, current and predicted Use and potential Demand and supply Prices, current and predicted Competing and alternative products Rough investment and production costs
SOURCES FOR MARKET RESEARCH• Direct contacts with companies, brochures• Congresses, fairs• Professional journals and publications• Special publications (Chemical Economics Handbook,
SRI)• Internet• Consultants• Industrial federations• Suomen Ulkomaankauppaliitto• Tullihallitus, tilastot• Industrial secretaries (TEKES, UM)• Kauppakamarit
Usually personal contacts are the best
3. PROCESS KNOWLEDGE
• General chemical engineering knowledge• Internet• Handbooks• Patents• Journals• Fairs, congresses (Achema)• Direct contacts with companies, brochures
How to produce certain chemical.
Reliability of the knowledge
PROCESS SELECTION
• License or plant purchase:
→ process selection
• Own development
→ process synthesis
CRITERIA FOR SELECTION
• Investment costs• Operation costs• Synergy• Novelty
– Technical risk – Development potential
• Safety• Environmental aspects• etc
PROSESSIN LAATUKRITEEREITÄ
IN V E S TO IN TIK U S TA N N U K S E T
K Ä Y TTÖ K U S TA N N U K S E T
TA L O U D E L L IS E T
JO U S TA V U U S
S Ä Ä D E TTÄ V Y Y S JAV A L V O TTA V U U S
A J E TTA V U U S
TO IM IN TA V A R M U U S
H U O L L E TTA V U U S
K Ä Y TTÖ V A R M U U S
TE K N O L O G IA N U U TU U S
TE K N IN E N S U O R ITU S K Y K Y
TE K N O L O G IA N TA S O
P Ä Ä S TÖ T
R Ä J Ä H D Y S V A A R A
M Y R K Y TY S V A A R A
H S E
1. VAIHE
• Projektin määrittely– Tekninen, aikataulullinen (janakaavio), taloudellinen (arvio
työtunneista), suunnitteluperusteet
• Lähtötietojen hankinta– Lähtöaineet, tuotteet, prosessit; markkinaselvitykset tuotteesta,
kysyntä, tarjonta, hinta, käyttökohteet, nyt ja tulevaisuudessa
• Prosessivaihtoehtojen lohkokaaviot• Prosessivaihtoehtojen vertailu
– Kriteerien perusteella
• Suositus prosessiksi ja sen sijainniksi• Suositus kapasiteetiksi