Faculty of Engineering

Department of Chemical Engineering

Bellville Campus

Learner Subject Guide
2014
Subject name: Chemical Process Design IV
Subject Code: PQD400S
Lecturer: Dr. Isa Y.M.
NQF level: 7


Credits

480 Credits
(120 are gained through experiential learning)


Revision No Approved Date






Purpose Statement for Qualification
This qualification is intended for process or chemical engineering technicians working in the process
related industries. Learners achieving this qualification have the competence to apply existing
process technologies to chemical engineering problems in chemical processes and plant operations.

Template: National Diploma
TABLE OF CONTENTS


1. WELCOME ................................................................................................................................... 3
2. GENERAL INFORMATION ........................................................................................................... 3
2.1 Lecturer information ............................................................................................................... 3
2.2 Other information ................................................................................................................... 3
2.3 Purpose of the Subject ........................................................................................................... 3
2.4 Subject offering ...................................................................................................................... 4
3. RULES AND RESPONSIBILITY ................................................................................................... 4
3.1 Subject Termination ............................................................................................................... 4
3.2 Class attendance, participation and punctuality ..................................................................... 4
3.3 Code of Conduct .................................................................................................................... 5
3.4 Plagarism and intellectual property rights ............................................................................... 5
4. SUBJ ECT TEACHING METHODOLOGY AND ASSESSMENTS ................................................. 5
4.1. Structure of the subject .......................................................................................................... 5
4.2 Formative and Summative assessments ................................................................................ 6
4.5 Assignments/Projects ............................................................................................................ 7
4.6 Submission and late submission policy for all tutorials/assignments/projects/practicals ......... 8
4.7 Assessments, dates and weights ........................................................................................... 9
4.8. Prescribed books, recommended books and/or notes ............................................................ 9
5. COURSE OUTLINE .................................................................................................................... 10
5.1 Critical Cross field outcomes ................................................................................................ 10
5.2 Exit level outcomes .............................................................................................................. 10
5.3 Syllabus ............................................................................................................................... 11
5.3 Articulation with other subjects in this programme ............................................................... 11
5.5 Work scheme and learning outcomes .................................................................................. 11



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1. WELCOME

As we work towards ensuring that you get the necessary Chemical Engineering knowledge and skills
that will see you through the beginning of your careers in the near future, be rest assured that the
experience to be gained from this course will give you an insight into design from engineering,
economic and environmental views. It is our hope and plans to make your study a very pleasant one.
This guide is to remind the students of their general responsibilities while studying, it particularly
emphasises the expectations from them while doing Chemical Process Design IV. The general
assessment format has also been mentioned.

2. GENERAL INFORMATION

2.1 Lecturer information

Name of Lecturer: Isa Yusuf
Position : Senior Lecturer
Room : O1
Tel number: 021 959 6050
Fax number: 021 959 6323
Fax2Email:
Email: isay@cput.ac.za


2.2 Other information

Name Building Room Tel no email
Lab assistant
Tutor assistant To be
appointed

Teaching assistant


2.3 Purpose of the Subject

Chemical Process Design IV (PQD400S) is a platform for learners to apply the knowledge of Basic Sciences,
Chemical Engineering and Economics in designing and analyzing Chemical Processes. A design project will be
used to assess the ability of students to design single units and integrate them into a plant while applying
Engineering good practice. The B Tech plant design project is conceptually similar to a feasibility study.
However, in some respects the level of detail may be greater than usual and this will be reflected in a
B Tech design project report.


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2.4 Subject offering


Day
Time Venue
Lectures Monday 13:45-16:00
L17, Business
Building
Lectures Wednesday 10:45-13:00
L17,Business
Building
Practical s
Tutorials
Subject Consultation
Friday
As the course progresses, part of Wednesday Lessons will be
for consultation
09:00-10:00
L19 A,
Business
Building
Duration of course Total = 23 weeks




3. RULES AND RESPONSIBILITY

3.1 Subject Termination

To cancel this subject, please fill in a cancellation form at the Faculty office. Registered students that
discontinue the subject without cancelling it at the faculty office will have this subject as failed on their academic
records.


3.2 Class attendance, partici pation and punctuality

Attendance, absence and class participation:

Students are expected to attend all classes. Class attendance and participation is an important part of the class
sessions. Absence for a class or submission of reports, assignments or projects if due to illness, require a
medical certificate and if due to death, a death certificate for immediate relatives only.

It is the students responsibility to bring the matter to the lecturers attention within 3 days. Certificates will
not be asked for and must be submitted on the first day of return. Any work given in class during normal
scheduled sessions may be used for assessment. Missed classes will require students to find out what material
was covered from one of his/her peers and not the lecturer. Absence does not excuse a student from doing
work which may have been handed out and which might have been missed.

Religious holidays should be discussed with lecturers in advance.

NB: The design project requires an intensive effort. Lecturers will give guidance, but a great deal of
emphasis i s placed on self-learning. Students will have to manage their own time, but in general should
expect to work over weekends during this period.

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Penalti es for late hand-in of sections will be strictly enforced.

The penalty for late submission of reports is a deduction of 10% of the mark obtained per day late. No
submissions will be entertained after three days from the stated date of submission.


Punctuality

Punctuality for classes is important in order to ensure that you do not miss any content and more importantly to
ensure that you do no disrupt and disturb a class that has already started. Should you have a valid and
acceptable reason for being late then you will be excused, but persistent late coming will not be tolerated. Out of
respect for your fellow peers and the lecturer, should you arrive late and you have a valid excuse, then wait
until a break in the class and ask the lecturer if you can then join.


3.3 Code of Conduct

Copying from previous years or from peers and any irregular behaviour are dishonest. Students who make
themselves guilty of either copying or allowing someone to copy or any irregular and dishonest behaviour will
both receive a zero mark and further disciplinary action will be taken.


3.4 Plagarism and intell ectual property rights

Any information used that is cited in any work that has been taken from any secondary source should be
acknowledged in the text where it is used (in text referencing) and at the end of the report under a complete list
of references. Students who do not acknowledge their sources and that hand in reports that do not contain in
text references, make themselves guilty of plagiarism, and those reports will be given a " zero mark. All
referencing should be done according to the Harvard Method.




4. SUBJECT TEACHING METHODOLOGY AND ASSESSMENTS


4.1. Structure of the subject

Some formal lectures will be presented during the initial contact periods, but the contact periods will mainly be
for information sharing, guidance and problem solving. Students will have 24-hour access to the design resource
room and computer facilities.

The designs are done in groups of 3 students, with each group having a different design with respect to feed
flow rate and/or feed or product specifications. Students are prepared for the benefits and potential problems
associated with working in groups through a series of discussions. Some sections of the design project will be
assessed individually while others will be group assessed.
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The problem of ensuring that individuals contribute equitably to group sections is addressed by discussing the
potential problems prior to the start of the course, emphasising that any student can lodge a complaint if s/he
feels that a fellow student in a group does not contribute equitably, insisting that each student signs an
appropriate declaration as part of a group hand-in, and by asking each student at the oral examination if s/he
contributed equitably to the final product. Problems that arise during the course are addressed by counselling. In
extreme cases, if problems cannot be resolved, a group may be split and/or individual marks adjusted in
accordance with the difference in individual contributions.

Students are encouraged to consult various information sources such as books, journal articles and the Internet,
and may discuss problems with their fellow students and lecturers. However, all work submitted for
evaluation must be the students own work. Any assistance must be full y referenced and acknowledged.



4.2 Formative and Summative assessments

Lectures will run over a period of 14 weeks. Class lectures that are manly a revision of modules covered in
previous courses will run concurrently with Computer Aided Design. While lectures will be held over a period of
fourteen weeks, learners should note that the plant design project is a design and will be assessed based on
how it is presented; learners are therefore advised to ensure that they meet all submission dates of their projects
notwithstanding the pace at which the revision classes go. The final project report submission and oral defence
dates will be announced later, however it will be held at the end of the third term. All designs and reports
involving calculations should be submitted with their accompanying excel spreadsheets. In the course of study,
a number of class tests, one project, oral presentations and quizzes will be conducted. During the course of
study, Students who miss any assessment must comply with section 3.2 and will be re-evaluated; no class
averages will be used.

A student has to prove competency for a specified Exit Level Outcome. In this subject, the following
competencies are evaluated:

ELO 1:Apply engineering principles to systematically diagnose and solve well-defined engineering
problems.
ELO 2: Apply knowledge of mathematics, natural science and engineering sciences to applied
engineering procedures, processes, systems and methodologies to solve well-defined engineering
problems.
ELO 3 Perform procedural design of well-defined components, systems, works, products or processes to
meet desired needs normally within applicable standards, codes of practice and legislation.
ELO 4: Conduct investigations of well-defined problems through locating and searching relevant codes
and catalogues, conducting standard tests, experiments and measurements.
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ELO 5: Use appropriate techniques, resources and modern engineering tools including information
technology for the solution of well-defined engineering problems, with an awareness of the limitations,
restrictions, premises, assumptions and constraints.
ELO 7: Demonstrate knowledge and understanding of the impact of engineering activity on the society,
economy, industrial and physical environment, and address issues by defined procedures.
ELO 10: Understand and commit to professional ethics, responsibilities and norms of engineering
technical practice.
-
In order to prove competency the following is expected to:
Formulate, identify, assess and solve process related technical and operational problems creatively and
innovatively.
Solve problems theoretically applying the knowledge of basic sciences.
Design process equipment or modify existing sections of the plant.
Use data bases in different forms including tables and charts for extraction of relevant design information
Express ideas effectively orally, writing as well as schematically
Plan and implement the production of required chemical products.
Have knowledge of the Safety, Health and Environmental (SHE) impacts of chemical processing
activities in order to identify the impacts and measures used to control these impacts.
Use I.T in the application of engineering methods, skills and tools.


Should a student fail to prove competency:
The student will have to repeat the course in another offering .






4.5 Assignments/Projects

Assignments/ projects are given during the semester since report writing and self-study are an integral of the
learning process. Assignment topics and due dates will be made known in class, however any late submission
attracts a penalty of 10%/day.




Directives for Assignments
All assignments / projects must be computer generated according to the directives below. Students not in
possession of a computer can use one of the computer rooms provided on campus. Assignment length will be
handled in class. Each assignment/project/report should contain a literature consulted section that should be
in accordance to The Student Guide to Helpful Hints with Bibliographical References available on the
University website.

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All assignments/projects must be generated according to the directives bel ow:

A4 paper
1.5 spacing
Font: Arial
Headings: Size: 12 and bold
Sub-headings: Size 12 and bold
Text: Size 11 and justified



The front page should contain the following information:

Institution Name and Campus
Course
Subject
Student Name and Number
Groups Members: Names and Student Numbers (Where applicable)
Lecturer
Due date

Assessment criteria
Evaluation Criterion: Assignment/Proj ect






4.6 Submission and late submission poli cy for all tutorials/assignments/projects/practical s
Each assignment/project is to be handed in by the student involved on the due date and time as communicated
in class or on the notice boards. No late submission of any tutorial/assignments/project/practical will be accepted
unless the student complies with section 3.2.

For late submissions a penalty of 10% of the maximum mark will be deducted per day for the first 3 days. After 3
days no submission will be accepted and a zero mark will be allocated.

% Mark
Synopsis / Executive summary 10
Introduction 15
Technical Contents 45
Conclusions 5
Literature consulted 15
General Impression 10
TOTAL: 100
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4.7 Assessments, dates and weights

With the exception of the Design Project, all other forms of assessment will be based on the Departmental
assessment time table. Leaners are advised to confirm with the department concerning the assessment dates

A final mark of at least 50% is required to successfully complete this subject. Students who do not obtain a final
mark of 50% will have to repeat the subject the next time it is offered again. A subminimum of 50% is placed on
all reports and presentations. Should a student obtain less than 50% in the design project, the student will fail
the course and the entire course will need to be repeated.
The Design Project will have a final weighting of 75% while other class assessments will make up the remaining
25%.



4.8. Prescribed books, recommended books and/or notes
1. Kirk-Othmer Encyclopedia of Chemical Technology (5
th
ed.). Hoboken, NJ : Wiley-Interscience. ISBN 0-471-
48810-0. (appropriate sections).
2. Sinnot, R. and Towler, G. (2009) Chemical Engineering Design 5
th
ed. Butterworth-Heinemann Limited.
ISBN 978-0-7506-8551-1
3. Peters, M. S., and Timmerhaus K. D. (1991). Plant Design and Economics for Chemical Engineers (4
th
ed.).
McGraw Hill. ISBN 0-07-100871-3.
4. Robin Smith (2005) Chemical Process Design and Integration, 2
nd
ed. Wiley. ISBN 0 471 48680 9
5. Chemical Process Simulators: ASPEN Plus Users Guide.
6. J . M. Smith, H. C. Van Ness and M. M. Abott (2001). Introduction to Chemical Engineering Thermodynamics
(6
th
ed.). McGraw Hill. ISBN 0-07-240296-2.
7. Mccabe, W. L., J . Smith and P. Harriott (2005) Unit Operations of Chemical Engineering, 7
th
ed. McGraw-Hill
Education. ISBN 0-07-284823-5.
8. Ernest J .H., Seader, J . D. and Roper, K.D. (2011). Separation Process Principles. 3
rd
ed. New York: Wiley.
ISBN 0-471-58626-9.
9. Himmelbau, David M. (1996). Basic Principles and Calculations in Chemical Engineering (6
th
ed.). Prentice-
Hall. ISBN 0133057984.
10. Perry, Robert H. and Green, Don W. (1984). Perry's Chemical Engineers' Handbook (8
th
ed.). McGraw-Hill.
ISBN 0-07-049479-7.





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5. COURSE OUTLINE



5.1 Critical Cross field outcomes

At the end of this course, learners should be able to:

Identify and solve problems that involve critical and creative thinking.
Tackle problems in a team.
Organise and manage time and actions responsibly and effectively.
Collect, analyse, organise and critically evaluate information.
Communicate effectively using visual, oral and written presentations.
Apply science and technology effectively and critically, showing responsibility towards the environment and
health of others.
Demonstrate an understanding of the world as a set of inter related systems by recognising that problem-
solving contexts do not exist in isolation.
Be culturally and aesthetically sensitive across a range of social context.
Develop entrepreneurial opportunities.




5.2 Exit l evel outcomes
On meeting the requirements, the learner should be able to:
Identify, evaluate, formulate and solve process related technical and operational
problems.
ELO 1
Design process equipment in order to modify existing sections of a plant or for new
additions.
ELO 2
Plan and implement the production of required products. ELO 3
Have knowledge of the Safety, Health and Environmental (SHE) impacts of chemical
processing activities in order to identify the impacts and measures used to control
these impacts.
ELO 6
Use I.T in the application of engineering methods, skills and tools ELO 7











Page 10 of 12

5.3 Syll abus
Overview of Chemical Process Design Principles
Computer Aided Design- Aspen Plus ,MS Visio, MS word, spreadsheet
Process Creation
Process Synthesis- Route selection and Heuristics
Plant Safety and Loss Prevention
Mass and Energy Balances
Energy Integration-Pinch Technology
Plant Costing and Process Economics
Plant Location and Environment
Computer aided Design
Process and Instrumentation Diagram



5.3 Articulation with other subjects in this programme
CET 400S, CET401S and CET402S are co-requistes



5.5 Work scheme and learning outcomes

Week Date(s) Topic(s) Specifi ed learning
outcome(s)
Assessment type
Week 1 3 Feb Overview of Chemical Process Design
Principles
ELO3, ELO4, ELO7 Test
Week 2 10 Feb Computer Aided Design- Aspen Plus ,MS
Visio, MS word, spreadsheet
ELO1, ELO2, ELO3,
ELO7
Test
Week 3 17 Feb Process Creation ELO1, ELO3, ELO7 Report
Week 4-5 24 Feb Process Synthesis- Route selection and
Heuristics
ELO3,ELO4,ELO7 Report
Week 6-7 10 Mar Plant Safety and Loss Prevention ELO6 Report
Week 8 24 Mar Mass and Energy Balances ELO1, ELO3, ELO7 Report/ Tutorials
Week 9 7 Apr Energy Integration-Pinch Technology ELO1, ELO2, ELO3,
ELO4,ELO7
Test
Week 10 14 Apr Plant Costing and Process Economics ELO1, ELO3, ELO7 Report/Tutorial
Week 11 21 Apr Plan Location and Environment ELO6 Report
Week 12 28 Apr ASPEN WORKSHOP ELO5 project
Week 14-
Week15
12 May Process and Instrumentation diagram ELO1, ELO2, ELO3,
ELO4,ELO7
Report
END OF SEMESTER 1

The second semester will focus majorly on the completion of the design project. Group/Individual consultations
and revision of general design principles will be considered




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The final design project will require the design of a full scale plant and will involve the following sections

Report Content Submission Weight
(%)
1 Process synthesis, description and flowsheet
Material and Energy Balance
Reactor System design
Group 25
2 Equipment Sizing including separation systems and
pressure manipulating equipment
Individual 30
3 Process Instrumentation and Safety studies Group 10
2 Process Simulation and optimisation Individual 15
3 Economic Analysis and Environmental Consideration of
Process
Group 15
4 Executive Summary Individual 5

While the submissions will include individual and group reports, a final group report will be written that
will contain the different reports presented in Chapters as described in the design project statement.
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