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ERT 416/3 INTRODUCTION TO SYNTHESIS AND PROCESS DESIGN MISS. RAHIMAH BINTI OTHMAN (Email: rahimah@unimap. ERT 416/3 INTRODUCTION TO SYNTHESIS AND PROCESS DESIGN MISS. RAHIMAH BINTI OTHMAN (Email: rahimah@unimap. edu. my)

COURSE OUTCOMES OUTLINES DESCRIBE and DISCUSS the nature and methodology of design process, typical COURSE OUTCOMES OUTLINES DESCRIBE and DISCUSS the nature and methodology of design process, typical design steps for chemical and biochemical process.

OUTLINES q Nature and methodology of design process. q Typical design steps for chemical OUTLINES q Nature and methodology of design process. q Typical design steps for chemical and biochemical process.

CITRIC ACID PRODUCTION CITRIC ACID PRODUCTION

WHAT IS THE NATURE AND METHODOLOGY OF DESIGN PROCESS? ? üWhat is the required WHAT IS THE NATURE AND METHODOLOGY OF DESIGN PROCESS? ? üWhat is the required size of process equipment and supporting utilities? üWhat are the required amounts of raw materials and utilities? üCan the product be produced in an existing facility or a new plant is required? üWhat is the total capital investment? ü What is the manufacturing cost? ü What is the optimum batch size? üHow long does a single batch take? üHow much product can be generated per year? üDuring the course of a batch what is the demand for various resources (e. g. , raw materials, labor, utilities, etc. )? üWhat is the total amount of resources consumed? üWhich process steps or resources constitute bottlenecks? üWhat changes can increase throughput? üWhat is the environmental impact of the process (i. e. , amount and type of waste materials)? ü Which design is the “best” among several plausible alternatives?

GENERALIZED VIEW OF BIOPROCESS RAW MATERIALS UPSTREAM PROCESSES Inoculum Preparation Equipment Sterilization Media Formulation GENERALIZED VIEW OF BIOPROCESS RAW MATERIALS UPSTREAM PROCESSES Inoculum Preparation Equipment Sterilization Media Formulation and Sterilization BIOREACTOR - FERMENTER Reaction Kinetics and Bioactivity Transport Phenomena and Fluid Properties Instrumentation and Control DOWNSTREAM PROCESSES Separation Recovery and Purification Waste Recovery, Reuse and Treatment THE BOTTOM LINE REGULATION ECONOMICS HEALTH AND SAFETY

TYPICAL BIOPROCESS FLOW SHEET TYPICAL BIOPROCESS FLOW SHEET

TYPES OF DESIGN ESTIMATES DURING THE LIFECYCLE OF A PRODUCT TYPES OF DESIGN ESTIMATES DURING THE LIFECYCLE OF A PRODUCT

OUTLINES q Nature and methodology of design process. q Typical design steps for chemical OUTLINES q Nature and methodology of design process. q Typical design steps for chemical and biochemical process.

STEPS IN PROCESS DESIGN AND RETROFIT Assess Primitive Problem Detailed Process Synthesis Algorithmic Methods STEPS IN PROCESS DESIGN AND RETROFIT Assess Primitive Problem Detailed Process Synthesis Algorithmic Methods Development of Base-case Detailed Design, Equipment sizing, Cap. Cost Estimation, Profitability Analysis, Optimization Plant-wide Controllability Assessment

STEPS IN PROCESS DESIGN AND RETROFIT SECTION A Detailed Process Synthesis Algorithmic Methods Development STEPS IN PROCESS DESIGN AND RETROFIT SECTION A Detailed Process Synthesis Algorithmic Methods Development of Base-case Detailed Design, Equipment sizing, Cap. Cost Estimation, Profitability Analysis, Optimization Assess Primitive Problem Plant-wide Controllability Assessment

STEPS IN PROCESS DESIGN AND RETROFIT STEPS IN PROCESS DESIGN AND RETROFIT

WHAT ARE THE PRIMITIVE DESIGN PROBLEMS? ? The design or retrofit of chemical processes WHAT ARE THE PRIMITIVE DESIGN PROBLEMS? ? The design or retrofit of chemical processes begins with the desire to produce profitably chemicals that satisfy societal needs that arise in the broad spectrum of industries that employ chemical engineers: l l l ¢ petrochemicals, petroleum products industrial gases foods pharmaceuticals l l polymers coatings electronic materials bio-chemicals Partly due to the growing awareness of the public, many design projects involve the redesign, or retrofitting, of existing chemical processes to solve environmental problems and to adhere to stricter standards of safety.

ORIGINS OF DESIGN PROBLEMS Often, design problems result from the explorations of chemists, biochemists, ORIGINS OF DESIGN PROBLEMS Often, design problems result from the explorations of chemists, biochemists, and engineers in research labs to satisfy the desires of customers to obtain chemicals with improved properties for many applications Other design problems originate when new markets are discovered, especially in developing countries Yet another source of design projects is the engineer himself, who often has a strong inclination that a new chemical or route to produce an existing chemical can be very profitable.

TYPICAL PRIMITIVE DESIGN PROBLEM Consider, the need to manufacture vinyl chloride (VC), H H TYPICAL PRIMITIVE DESIGN PROBLEM Consider, the need to manufacture vinyl chloride (VC), H H C C Cl H A typical primitive problem statement is as follows: “An opportunity has arisen to satisfy a new demand for VC monomer (VCM), on the order of 800 million pounds per year, in a petrochemical complex on the Gulf Coast, given that an existing plant owned by the company produces one-billion pounds per year of this commodity chemical. Since VCM is an extremely toxic substance, it is recommended that all new facilities be designed carefully to satisfy governmental health and safety regulations. ”

HOW TO ASSESS PRIMITIVE PROBLEM? ? Process design begins with a primitive design problem HOW TO ASSESS PRIMITIVE PROBLEM? ? Process design begins with a primitive design problem that expresses the current situation and provides an opportunity to satisfy a societal need. Normally, the primitive problem is examined by a small design team, to refine the problem statement and generate more specific problems: Raw materials - available in-house, can be purchased or need to be manufactured? Scale of the process (based upon a preliminary assessment of the current production, projected market demand, and current and projected selling prices) Location for the plant Brainstorming to generate alternatives

STEPS IN PROCESS DESIGN AND RETROFIT Assess Primitive Problem Detailed Process Synthesis Algorithmic Methods STEPS IN PROCESS DESIGN AND RETROFIT Assess Primitive Problem Detailed Process Synthesis Algorithmic Methods Development of Base-case Detailed Design, Equipment sizing, Cap. Cost Estimation, Profitability Analysis, Optimization Plant-wide Controllability Assessment

STEPS IN PROCESS DESIGN AND RETROFIT SECTION A Detailed Process Synthesis Algorithmic Methods Development STEPS IN PROCESS DESIGN AND RETROFIT SECTION A Detailed Process Synthesis Algorithmic Methods Development of Base-case Detailed Design, Equipment sizing, Cap. Cost Estimation, Profitability Analysis, Optimization Assess Primitive Problem Plant-wide Controllability Assessment

STEPS IN PROCESS DESIGN AND RETROFIT STEPS IN PROCESS DESIGN AND RETROFIT

SURVEY LITERATURE SOURCES SRI Design Reports Encyclopedias Handbooks and Reference Books Perry’s Chemical Engineers SURVEY LITERATURE SOURCES SRI Design Reports Encyclopedias Handbooks and Reference Books Perry’s Chemical Engineers Handbook (1997) CRC Handbook of Chemistry and Physics Indexes Kirk-Othmer Encyclopedia of Chemical Technology (1991) Ullman’s Encyclopedia of Industrial Chemistry (1988) See Technion Library Patents and internet

EXAMPLE: VC MANUFACTURE To satisfy the need for an additional 800 MMlb/yr of VCM, EXAMPLE: VC MANUFACTURE To satisfy the need for an additional 800 MMlb/yr of VCM, the following plausible alternatives might be generated: Alternative 1. A competitor’s plant, which produces 2 MMM lb/yr of VCM and is located about 100 miles away, might be expanded to produce the required amount, which would be shipped. In this case, the design team projects the purchase price and designs storage facilities. Alternative 2. Purchase and ship, by pipeline from a nearby plant, chlorine from the electrolysis of Na. Cl solution. React the chlorine with ethylene to produce the monomer and HCl as a byproduct. Alternative 3. Since the existing company produces HCl as a byproduct in large quantities are produced, HCl is normally available at low prices. Reactions of HCl with acetylene, or ethylene and oxygen, could produce 1, 2 dichloroethane, an intermediate that can be cracked to produce vinyl chloride. Alternative 3. Design an electrolysis plant. One possibility is to electrolyze the HCl, available from within the petrochemical complex, to obtain H 2 and Cl 2. React chlorine, according to alternative 2. Elsewhere in the petrochemical complex, react hydrogen with nitrogen to form ammonia or with CO to produce methanol

SURVEY LITERATURE SOURCES SRI Design Reports Encyclopedias Handbooks and Reference Books Perry’s Chemical Engineers SURVEY LITERATURE SOURCES SRI Design Reports Encyclopedias Handbooks and Reference Books Perry’s Chemical Engineers Handbook (1997) CRC Handbook of Chemistry and Physics Indexes Kirk-Othmer Encyclopedia of Chemical Technology (1991) Ullman’s Encyclopedia of Industrial Chemistry (1988) See Technion Library Patents and internet

STEPS IN PROCESS DESIGN AND RETROFIT Assess Primitive Problem Detailed Process Synthesis Algorithmic Methods STEPS IN PROCESS DESIGN AND RETROFIT Assess Primitive Problem Detailed Process Synthesis Algorithmic Methods Development of Base-case SECTION B Detailed Design, Equipment sizing, Cap. Cost Estimation, Profitability Analysis, Optimization Plant-wide Controllability Assessment

STEPS IN PROCESS DESIGN AND RETROFIT STEPS IN PROCESS DESIGN AND RETROFIT

STEPS IN PROCESS DESIGN AND RETROFIT Assess Primitive Problem Detailed Process Synthesis Algorithmic Methods STEPS IN PROCESS DESIGN AND RETROFIT Assess Primitive Problem Detailed Process Synthesis Algorithmic Methods Development of Base-case Detailed Design, Equipment sizing, Cap. Cost Estimation, Profitability Analysis, Optimization Plant-wide Controllability Assessment SECTION C

STEPS IN PROCESS DESIGN AND RETROFIT STEPS IN PROCESS DESIGN AND RETROFIT

ENVIRONMENTAL ISSUES IN DESIGN Handling of toxic wastes 97% of hazardous waste generation by ENVIRONMENTAL ISSUES IN DESIGN Handling of toxic wastes 97% of hazardous waste generation by the chemicals and nuclear industry is wastewater (1988 data). In process design, it is essential that facilities be included to remove pollutants from waste-water streams. Reaction pathways to reduce by-product toxicity As the reaction operations are determined, the toxicity of all of the chemicals, especially those recovered as byproducts, needs to be evaluated. Pathways involving large quantities of toxic chemicals should be replaced by alternatives, except under unusual circumstances. Reducing and reusing wastes Environmental concerns place even greater emphasis on recycling, not only for unreacted chemicals, but for product and by-product chemicals, as well. (i. e. , production of segregated wastes - e. g. , production of composite materials and polymers).

ENVIRONMENTAL ISSUES IN DESIGN (CONT’D) Avoiding non-routine events – Reduce the likelihood of accidents ENVIRONMENTAL ISSUES IN DESIGN (CONT’D) Avoiding non-routine events – Reduce the likelihood of accidents and spills through the reduction of transient phenomena, relying on operation at the nominal steady-state, with reliable controllers and fault-detection systems. Design objectives, constraints and optimization – Environmental goals often not well defined because economic objective functions involve profitability measures, whereas the value of reduced pollution is often not easily quntified economically. – Solutions: mixed objective function (“price of reduced pollution”), or express environmental goal as “soft” or “hard” constraints. – Environmental regulations = constraints

SAFETY CONSIDERATIONS Example Disaster 1 – Flixborough: 1 st June 1974 http: //www. hse. SAFETY CONSIDERATIONS Example Disaster 1 – Flixborough: 1 st June 1974 http: //www. hse. gov. uk/hid/land/comah/level 3/5 a 591 f 6. htm l l 50 tons of cyclohexane were released from Nypro’s KA plant (oxidation of cyclohexane) leading to release of vapor cloud and its detonation. Total loss of plant and death of 28 plant personnel. Highly reactive system - conversions low, with large inventory in plant. Process involved six, 20 ton stirred-tank reactors. Discharge caused by failure of temporary pipe installed to replace cracked reactor. The so-called “dog-leg” was not able to contain the operating conditions of the process (10 bar, 150 o. C)

SAFETY CONSIDERATIONS SAFETY CONSIDERATIONS

SAFETY CONSIDERATIONS Flixborough - What can we learn? Develop processes with low inventory, especially SAFETY CONSIDERATIONS Flixborough - What can we learn? Develop processes with low inventory, especially of flashing fluids (“what you don’t have, can’t leak”) Before modifying process, carry out a systematic search for possible cause of problem. Carry out HAZOP analysis Construct modifications to same standard as original plant. Use blast-resistant control rooms and buildings T. Kletz, “Learning from Accidents”, 2 nd Ed. (1994)

SAFETY CONSIDERATIONS (CONT’D) Example Disaster 2 – Bhopal: 3 rd December 1984 http: //www. SAFETY CONSIDERATIONS (CONT’D) Example Disaster 2 – Bhopal: 3 rd December 1984 http: //www. bhopal. com/chrono. htm ¢ Water leakage into MIC (Methyl isocyanate) storage tank leading to boiling and release of 25 tons of toxic MIC vapor, killing more than 3, 800 civilians, and injuring tens of thousands more. MIC vapor released because the refrigeration system intended to cool the storage tank holding 100 tons of MIC had been shut down, the scrubber was not immediately available, and the flare was not in operation. Bhopal - What can we learn? l Avoid use of hazardous materials. Minimize stocks of hazardous materials (“what you don’t have, can’t leak”). l Carry out HAZOP analysis. l Train operators not to ignore unusual readings. l Keep protective equipment in working order. l Control building near major hazards.

SAFETY CONSIDERATIONS (CONT’D) Example Disaster 3 – Challenger: 28 th January 1986 (http: //www. SAFETY CONSIDERATIONS (CONT’D) Example Disaster 3 – Challenger: 28 th January 1986 (http: //www. onlineethics. com/moral/boisjoly/RB-intro. html) ¢ An O-ring seal in one of the solid booster rockets failed. A high-pressure flame plume was deflected onto the external fuel tank, leading to a massive explosion at 73 sec from lift-off, claiming the Challenger with its crew. The O-ring problem was known several months before the disaster, but down-played by management, who over-rode concerns by engineers. Challenger - What can we learn? l Design for safety. l Prevent ‘management’ over-ride of ‘engineering’ safety concerns. l Carry out HAZOP analysis.

THANK YOU Prepared by, MISS RAHIMAH OTHMAN THANK YOU Prepared by, MISS RAHIMAH OTHMAN

PART 1 • The importance of the process or product selected from Malaysia Bioprocess PART 1 • The importance of the process or product selected from Malaysia Bioprocess Industry point of view. • Information of the chosen process with general data on the plant capacity, total cost in RM (latest currency rate conversion if in $USD, etc. ), location of similar type of units and capacity in Malaysia or outside Malaysia. • Write down at least 3 different alternatives of the process scheme for the production of the desired bio-product. • Choice of the best process supported by data, safety and environmental issues and economical indicators, market analysis, flexibility and controllability. • Process chemistry, reactions, kinetics, thermodynamics data and other physical and chemical properties data (MSDS Sheet of all the raw materials, products and by -products in the process). • Choose the capacity of the plant based on the literature background and provide the justification. Give the accurate reference and complete description of the process. References must be quoted in the standard format. • Selection of the plan site location. • Conceptual design process. • Analysis for the most economical load of the plant. • The general profitability analysis of the plant. • Environmental effects and risks of the plant.

What is the importance of the process or product selected from Malaysia Bioprocess Industry What is the importance of the process or product selected from Malaysia Bioprocess Industry point of view? ? It has been estimated that he global renewable chemicals market is estimated to increase from about US$45 billion in 2009 to US$59 billion in 2014. The increasing awareness of consumer for ‘green’ products, along with governmental support for the industry also contributes to the expansion of the industry. However, the main driving force behind the growth of the biochemical industry is the low requirement of capital for both production and also raw materials [6]. Itaconic acid production is currently a fast rising technology. Currently, there are only five countries in the world that produce itaconic acid; Japan, China, United States of America, United Kingdom and France [7]. Industrial biotechnology has contributed to the growth of renewable chemicals market due to the innovations in biocatalysis for manufacturing renewable chemicals. Beside their application in industry, these chemicals are also used in pharmaceutical and consumer products [6].

PART 1 • The importance of the process or product selected from Malaysia Bioprocess PART 1 • The importance of the process or product selected from Malaysia Bioprocess Industry point of view. • Information of the chosen process with general data on the plant capacity, total cost in RM (latest currency rate conversion if in $USD, etc. ), location of similar type of units and capacity in Malaysia or outside Malaysia. • Write down at least 3 different alternatives of the process scheme for the production of the desired bio-product. • Choice of the best process supported by data, safety and environmental issues and economical indicators, market analysis, flexibility and controllability. • Process chemistry, reactions, kinetics, thermodynamics data and other physical and chemical properties data (MSDS Sheet of all the raw materials, products and by -products in the process). • Choose the capacity of the plant based on the literature background and provide the justification. Give the accurate reference and complete description of the process. References must be quoted in the standard format. • Selection of the plan site location. • Conceptual design process. • Analysis for the most economical load of the plant. • The general profitability analysis of the plant. • Environmental effects and risks of the plant.