RUTGERS UNIVERSITY

Department of Chemical and Biochemical Engineering

155:428 CHEMICAL & BIOCHEMICAL ENGINEERING DESIGN AND ECONOMICS II
SPRING 2012 (4 credits)
Professor: Dr. A. Constantinides
Teaching Assistant: None
Class time: MW 1:40-3:00 p.m.
W 12:15-1:10 p.m.

SOE, room C-203A

(732) 445-3678
e-mail: acconsta@rci.rutgers.edu
Location: SEC 209
Location: SEC 210 or SOE C233

Course description
Design and economics of large chemical/biochemical plants. The design details and economic
considerations involved in the design, construction, and operation of chemical/biochemical plants
using basic principles and modern computer software. Engineering ethics, plant safety practices, and
OSHA concerns.
Course objectives

This is the capstone course, which utilizes the fundamentals of chemical/biochemical engineering
(material balances, energy balances, transport phenomena, thermodynamics, kinetics, separations,
unit operations, control, and safety) in the design and operation of chemical/biochemical 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.

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 below as
P,T,&W].
ASME Steam Tables - Compact Edition, ASME 2006, ISBN: 079180254X
Textbook (recommended)
D. A. Crowl and J. F. Louvar, Chemical Process Safety: Fundamentals with Applications, PrenticeHall, 3rd Edition, 2011. [Referenced below as C&L]
Prerequisites
155:324 Design of Separation Processes
155:415 Process Engineering I
155:427 Chemical and Biochemical Engineering Design and Economics I
Homework and grading policy
Assignments
Quizzes
Final design report
Attendance

45%
5%
45%
5%
100%

Class participation and attendance are important. The professor will circulate the class roster to
observe student attendance. Students with more than 2 absences per semester will lose points (One %
point for each absence, maximum 5% points).
Design Project
The major requirement of the course is the design, cost estimation, and profitability analysis of a
complete chemical/biochemical process plant to be described later. For this project, students will be
placed in groups of two, three, or four to work jointly, including the final design report. Your choice
of partners may remain the same as in 155:427. The following are critical to your success in this
course:
1.

Begin early: The case study is very time-consuming with no room for procrastination.

2.

Attend all lectures: Assignments will be handed out at lectures with full discussion of the
current problem at that time. If you miss the discussion, you may have difficulty with the
assignment.

3.

Cooperate with partners: Share the load, but understand that all partners need to know all the
design material. If you find inter-personal problems hindering the teamwork, bring them to the
attention of the professor immediately. Do not wait until the end of the semester.

4.

Use every resource: Utilize the textbook, the handouts, the library, the computer, the assistant,
and the professor as sources of information for this project.

5.

Complete assignments thoroughly and timely: Several assignments will be completed during
the design project. These assignments will be collected and graded. They will count for 45% of
the course grade. The final design report, which is due at the end of the semester, will count for
45% of the grade.

6.

Exams: There will be 1-3 quizzes to be scheduled during the semester. These will test the
student's knowledge of the material being covered in class and in the reading assignments.

References
R. Turton, R. C. Bailie, W. B. Whiting, and J. A. Shaeiwitz, Analysis, Synthesis and Design of
Chemical Processes, 2nd edition, Prentice Hall, Upper Saddle River, New Jersey (2003).
W. D. Seider, J. D. Seader, S. R. Lewin, and S. Widagdo, Product & Process Design Principles, 3rd
edition, J. Wiley & Sons, Inc., New York (2009).
H. F. Rase, Chemical Reactor Design for Process Plants, Volumes I & II, J. Wiley & Sons, Inc.,
New York (1977).
W. D. Baasel, Preliminary Chemical Engineering Plant Design, 2nd Edition, Van Nostrand Reinhold,
New York (1990).
Perry's Chemical Engineer's Handbook, 8th Edition, McGraw-Hill Book Company, New York
(2007).
L. Kniel, 0. Winter and K. Stork, Ethylene: Keystone to the Petrochemical Industry, Marcel Dekker,
Inc., New York (1979).
P. C. Wankat, Separation Process Engineering: Second Edition, Prentice Hall, New York, NY (2007).
(Used in 155:324 Design of Separation Processes course, Spring , 2011).

Course Outline
Week Subject
Assignment
1

2-3

2
4
5
6

7
8-9

Reading

Brief review of what we did in Design I

Engineering Code of Ethics
Plant design project(s)
Possible flow sheets
Establishment of design basis
Physical properties needed

Handouts and References

Reactor design
Cracking ethane to produce ethylene
Derivation of reactor model
Discussion of reactor conditions
Discussion of reactor limitations
Simulation of reactor model
Introduction to SuperPro Designer (for Biochemical Engineers)

Handouts and References

Design and Cost Estimating

Materials handling equipment (pumps, compressors)

Handouts
Ch. 12 (P,T & W)

Heat transfer equipment (heat exchangers)

Liquid-vapor separators (flash drums)
Design and Cost Estimating
Refrigeration systems

Ch. 14 (P, T & W)

Wankat(2nd ed.), pp 45-49
Thermodynamics book
and references

Mass transfer and reactor equipment

Ch. 16 (P, T & W)

Handouts

Design project details and implementation

10-11 Safety in Design

Handouts and (C&L)
Principles of chemical systems safety and health engineering management
US Chemical Safety Board Safety Videos
Process plant layout of ethylene plant with safety considerations
12-13 Design project details and implementation
14

The Design Report

Contents; flow diagrams; equipment lists
Fixed capital investment; Production costs
Profitability analysis
Design projects are due on May 7, 2012.

Ch. 11 (P, T & W)