Department of Chemical & Biomolecular Engineering

National University of Singapore

CN4122: Process Synthesis and Simulation

Lecturers: IA Karimi (E5 02-12, 6516-6359, cheiak@nus.edu.sg)

GP Rangaiah (E5 02-25, 6516-2187, chegpr@nus.edu.sg)
P Linga (E5 02-23, 66011487, chepl@nus.edu.sg)

Tutors & Helpers: Nishu Goyal (a0075545@nus.edu.sg), Ang Ming Li (a0039362@nus.edu.sg),

Chong Zheng Rong (a0055527@nus.edu.sg), Guo Shanshan (a0055483@nus.edu.sg), Tian Kaiyuan
(a0033289@nus.edu.sg), Yap Swee Kun (a0045234@nus.edu.sg), Niu Wendou
(a0082345@nus.edu.sg), and Sreepathi Bhargava Krishna (a0091335@nus.edu.sg).

Learning Outcomes: A key responsibility of chemical engineers is to design, construct, and

operate chemical plants safely, considering the environmental impact. Safe process design is a
complex team task involving several people and several steps from concept to commissioning.
Holistic design experience is an essential part of the chemical engineering training.
Process development and simulation are essential first steps in designing a chemical plant. This
module aims to introduce you to these steps and prepare you for the full-fledged design project
next semester. However, this is not all. The training and skills acquired in this module are essential
for your future as a Chemical Engineer. In this module, you will learn the tasks, methods, and tools
involved in the development, design, and simulation of a chemical plant. Both general and specific
hardware/software tools and systematic procedures exist, which aid in doing these more
precisely, more rigorously, and more quickly. On successful completion of this module, you will be
able to:
1. Define chemical process simulation and describe its main steps
2. Develop process flow diagrams (PFDs) or flowsheets (Process synthesis)
3. Develop block flow diagrams (BFDs) for simulation
4. Simulate steady-state processes using a commercial process simulator (Aspen HYSYS)
5. Describe the steps and considerations in process design
6. Perform detailed mechanical design of plant units
7. Estimate the capital and operating costs of chemical plants
8. Assess the profitability of a chemical process / project

Tentative Evaluation: Tutorials (Attendance, participation, completion) 25%

Mechanical Design Project (Prof P Linga) 10%
Final Exam (Closed Book) 65%

Pre-/Co- Requisites:
This module requires skills and learning from several modules such as CN2116 Chemical Kinetics
and Reactor Design, CN2121 Chemical Engineering Thermodynamics, CN2122 Fluid Mechanics,
CN3132 Separation Processes, CN3124 Fluid-Solid Systems, CN3421 Process Modeling &
Numerical Computing, CN3122 Mass Transfer Operations. Satisfactory completion of these
modules is essential.

Recommended References:
1. Chemical Engineering Design, by G Towler, R Sinnott, 2nd Edition, Oxford, Butterworth-

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 Heinemann, 2013.
2. Analysis, Synthesis, and Design of Chemical Processes, by R Turton, RC Bailie, WB Whiting, JA
Shaeiwitz, D Bhattacharyya, 4th Edition, Prentice Hall, 2012.
3. Help inside Aspen Hysys.
4. Plant Design and Economics for Chemical Engineers, by MS Peters, KD Timmerhaus, 4th
Edition, McGraw Hill, 2001.
5. Product & Process Design Principles: Synthesis, Design, and Evaluation, by WD Seider, JD
Seader, DR Lewin, S Widadgo, Edition 3, John Wiley, 2010.

Tentative Schedule
Lectures / Tutorials Lecturer (Topics)
Aug 13, 20, 27; Sep 3, 10, Karimi (Overview, Learning Objectives, Process simulation, Hysys
17, Oct 1, 8 demonstration, Hysys modules & demos, Process design & synthesis)
Oct 15, 22, 29 Linga (Mechanical design)
Nov 5, 12 Rangaiah (Cost estimation & profitability)
Weeks of Sep 8, 15, 29,
Tutors (Aspen Hysys Tutorial exercises)
Oct 6, 13, 20, 27, Nov 3, 10

Tutorials
1. E-mail and IVLE will be used routinely for feedback, discussion, notes, announcements, etc.
Keep your mailbox functional, and check regularly. Post your questions/comments/feedback on
the discussion forum or via e-mail.
2. Notes are NO substitutes for texts. I welcome suggestions for improvements. You MUST read
the assigned chapters and study relevant examples.
3. Hysys tutorial marks will be based on your independence, attendance, care, participation, work
quality, and self-completion. It is essential that you do and save all your work during the
tutorials and the results from various exercises.
4. 150 Hysys licenses are accessible from PC1 (E1-04-09), PC2 (E1-04-10), PC3 (E2 03-06), and
ChBE PC cluster (E5 03-24).

Prerequisites (Please review)

Basic concepts from your earlier ChBE modules are required for reading this module. It is
absolutely ESSENTIAL that you recall, read about, and fully understand the following key concepts,
terms, or principles from your earlier modules (especially CN3132) RIGHT AWAY.

Phase rule, Gibbs-Duhem Theorem, phase equilibrium, degrees of freedom, boiling point, bubble
point, dew point, saturated liquid, saturated vapor, vapor pressure, flash, equilibrium stage, ideal
solution, ideal gas, equation of state, activity model, polar, non-polar, centrifugal pump, NPSH,
compressor, turbine, power, efficiency, heat exchanger, exchanger duty, shell & tube exchanger,
tube passes, shell passes, pressure drop, temperature approach, temperature cross, log-mean
temperature difference (LMTD), FT correction factor, stoichiometric coefficient, activation energy,
Arrhenius equation, rate of reaction, rate constant, pre-exponential constant, order of reaction,
reaction kinetics, reaction equilibrium, equilibrium-controlled reaction, rate-controlled reaction,
reversible reaction, irreversible reaction, reaction conversion, distillation, absorption, stripping,
reboiler, condenser (partial and total), reflux ratio, effect of pressure and temperature on
separation processes, purity, recovery, isothermal, adiabatic, etc.

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