CHEN90012, Design and Construction of Equipment, Major Assignment 2024
S2.
Note the assignments of this year is substantially different from past. Comprehend the
description of the question with caution as follows:
Overview
1. This assignment makes up 60% of the total marks for PED. You must achieve 50% or more on
this assignment to pass the subject.
2. This assignment is due in three parts
Part 1 is due on 21 Aug at 5 PM. (20 marks)
Part 2 is due on 18 Sep at 5 PM. (25 marks)
Part 3 is due on 16 Oct at 5 PM. (15 marks)
If the assignment is late the following penalties will apply
Turned in on the following morning before 10AM: -5% of total marks for that part of
assignment.
Turned in on the following day before 5PM: -10% of total marks for that part of
assignment.
Turned in five days late: -50% of total marks for that part of assignment.
3. Each individual must make their own submission by the deadline.
(a) Submit your overall report including text, calculations or drawing together via Turnitin.
Make sure all your drawings are following the guidelines for “mechanical drawing” as
provided in the additional resources in LMS.
Generate your 2D drawing using an appropriate software (e.g. MS Visio or AutoCAD)
rather than do it in manual, and generate 3D drawing using AutoCAD 3D, SketchUp or
similar for 3D objects required in the assignment.
Original files of the 3D drawing must be uploaded in a separate file.
(b) Submit your calculation toll in a single sheet Excel spreadsheet in the format of Excel
Worksheet .xlsx or .xls to a secondary Turnitin portal and name your Excel spread sheet
in your own name and student number, e.g.
John Smith_123456_Assignment 1
For Excel sheet, you can refer to the guidelines given in the lecture note on “Calculation
Tools” but DO NOT COPY the note.
The Excel sheet must be clear, logical, and working!
4. Bonus marks
Bonus marks of 1.5 are applicable to each assignment.
Submissions that demonstrate original critical thinking and exceptional quality of design
will be considered for bonus marks.
You are allowed to discuss your design with your fellow students but:
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You cannot use the same spread sheet as another student.
You cannot submit the same text, calculations or drawing as another student.
You must submit only your own work.
5. Plagiarism and other matters
The definitions of Plagiarism and Collusion and their consequences are outlined in the
coversheet that you must sign. Keep a copy of your assignment; you will need it to start
parts 2 and 3 even before the previous part is returned to you.
The whole report should be written by Calibri style with font 12 for the whole text and 14
bold for headings, equipment labels of 10 bold, and 1.5 line space.
6. This is an individual assignment
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The Design Problem
Aggressive measures need to be taken to address the greenhouse gas emissions in hard-to-
abate industries, such as marine shipping and aviation. Air-to-fuel has been identified as a potential
pathway to produce carbon-neutral or carbon-negative chemical fuels from air components and
renewable energy.
Here, you are leading the design of an air-to-fuel plant with a daily production rate of 200
ton methanol (based on pure MeOH). A direct air capture (DAC) unit (denoted as D1 for flowsheet)
based on amine scrubbing has been selected to produce high purity CO from air. Assuming 50%
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capture efficiency, and 500 ppm CO in the atmosphere, the gases CO produced by the stripper is
2 2
pressurized by a compressor (C1) to 3 MPa and stored in buffer tanks (T1) at ambient temperature
for the next step process.
A water splitting unit operating at ambient pressure has been selected to produce high purity
hydrogen gas. The Faradaic efficiency towards H and current efficiency of the electrolyser (E1) is
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100%, and 65% (i.e. 35% energy loss by joule heat), respectively. The electrolyser temperature
must be kept in the working range of 80 – 95 °C which is achieved by removing around 85% of the
joule heat by active cooling. Hot electrolyte (30% KOH aqueous solution) at 95 °C bleeds from one
end of the electrolyser and feeds to a heat exchanger (HE1); after cooling to 80 °C by ambient
running water, the electrolyte is mixed with 80 °C makeup water re-enters the electrolyser from the
other end. The product H is pressurized by a compressor (C2) to 3 MPa and stored in tanks (T2)
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temporarily for subsequent processes.
The aforementioned H and CO gas at 3MPa are mixed at 3:1 ratio (v/v) and stored in tanks
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(T3). The mixed gas is then directed to a multi-cycle catalyser operating at 250 °C at 30 MPa to
produce methanol, via the following reaction:
3H + CO == CH OH + H O (1)
2 2 3 2
For practical purpose, 100% conversion of the raw gas and 100% MeOH selectivity are
assumed. The products are fully condensed by a heat exchanger (HE2) to produce liquid MeOH and
H O. A distillation unit (D1) is employed to enrich the MeOH to 99% in the distillate while the
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residue should contain no more than 1% MeOH.
The final product MeOH is stored in ambient tanks (T4) and shipped by trucks for sale.
The DAC and the catalyser are running continuously 24/7. Due to the intermittent nature of
solar energy, the water electrolyser is powered by compatible solar power facility during the
daytime and there is no power supply to the electrolyser during the nighttime.
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Provide design specifications and equipment drawings for the following pieces of
equipment:
(1) tank T2
(2) heat exchanger HE1, and
(3) distillation tower D1
The design specifications must follow the step-by-step calculations as shown during the
examples done in class following the outline in the lecture notes. For each piece of equipment you
must include:
1) a maximum one page executive summary
2) an equipment specification sheet
3) the detailed design calculations and discussion stating assumptions used in the
calculations. (Follow the Calculation Tools to make clear and legible calculations, or see
specific requirements of the individual assignments)
4) an engineering drawing of the equipment.
5) a 3D drawing of the equipment. (or see specific requirements of the individual
assignments)
5) description of the managerial, operational procedures and safety considerations for each
piece of equipment. Explain how all rules and regulations of the statutory authorities are
met.
6) references used for the design (must use Harvard style).
Marks will be deducted if the submission is not clear and legible or if the information is not
presented in an organised and logical manner. Demonstration of original thinking will be required
in order to gain full marks or even bonus. Some template of equipment specification sheet on
Canvas may not represent perfect example, and exact copying of that template will compromise
your marks.
Propose a reasonable equipment layout. The storage tanks should be located at least 100m
from other units of operation. The flash drum and heat exchanger can be placed between 40 to 50m
from the distillation tower. A process flow sheet and equipment layout (plan view) drawings of the
entire plant are also required.
Design data such as physical properties of the liquids and gasses can be found using Hysys,
Aspen, or in Perry’s Chemical Engineers Handbook and C&R Vol. 6 for example. The benzene-1-
pentanol VLE data are attached at the end of this assignment sheet. Steam at a maximum pressure
of 6 atm and utility water (returned from an evaporative cooling tower) at 15°C are available.
Marking rubric available on LMS.
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CHEN90012, Major Assignment 2024 S2.
Part 1
This part of the assignment makes up 20% of the total marks for PED.
Part 1 is due on 21 Aug at 5 PM. (20 marks)
Maximum 40 pages for text, calculations or drawing.
Provide design specifications and equipment drawings for the storage tanks (T2). Include details
about inlet and outlet nozzles etc. also a sketch of the tank farm layout.
The submission should include the following sections:
1). Report for overall design
a. Executive Summary 4% of total marks
b. Equipment Specification Sheet 15% of total marks
c. Process Flow Sheet and mass balance for the entire plant. 10% of total marks
c. Equipment Drawings 2D 20% of total marks
d. Detailed Calculations and Discussion 30% of total marks
e. Managerial Aspects (safety, operation, compliance, etc.) 5% of total marks
f. References (List & Appendices) 1% of total marks
2. Calculation Tool (Excel sheet) 15% of total marks
The Calculations and Discussion must be clearly legible. The Discussion should include
assumptions, justifications, procedures and conclusions from Calc. Tool design. The Managerial
Aspects should include any safety issues, operational and managerial issues, compliance with
regulations etc.
3). 3D drawing - optional - up to 5% bonus
Up to 10% of the marks will be based on evaluation of the writing (structure, readability, grammar
and Figures) and originality of the submission.
Submissions that demonstrate original critical thinking and exceptional quality of design will be
considered for bonus marks.
Remember to keep a copy of your submission so that you can work on the following part even
before this part is returned back marked.
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CHEN90012, Major Assignment 2024 S2.
Part 2
This part of the assignment makes up 25% of the total marks for PED.
Part 2 is due on 18 Sep at 5 PM.
Maximum 40 pages.
(25 marks)
Provide design specifications and equipment drawings for a shell-and-tube heat exchanger (HE1).
Note the cooling utility water should not exit the heat exchanger at more than 50oC. You must show
the step by step design, as in the example, but may use output from Hysys to validate your
calculations. (20 marks).
The submission should include the following sections:
1. Report for overall design
a. Executive Summary 4% of total marks
b. Equipment Specification Sheet 15% of total marks
c. Equipment Drawings 20% of total marks
d. Detailed Calculations and Discussion 30% of total marks
e. Managerial Aspects (safety, operation, compliance, etc.) 5% of total marks
f. References (List & Appendices) 1% of total marks
2. Calculation Tool (Excel sheet) 15% of total marks
The Calculations and Discussion must be clearly legible. The Discussion should include
assumptions, justifications, procedures and conclusions from Calc. Tool design. The Managerial
Aspects should include any safety issues, operational and managerial issues, compliance with
regulations etc.
3. Original file of 3D equipment drawings. 10% of total marks
Level of details: apart from the external shell, you must show the 3D of the tube bundle (with tube
sheet on). You can choose to present the tube bundle as an internal part of the HEX. Or, you can
present the tube bundle separately side by side of the shell.
Up to 10% of the marks will be based on evaluation of the writing (structure, readability, grammar
and Figures) and originality of the submission.
Submissions that demonstrate original critical thinking and exceptional quality of design will be
considered for bonus marks.
Remember to keep a copy of your submission so that you can work on the following part even
before this part is returned back marked.
Hint: Use an Excel spreadsheet to do the calculations so that you can easily change parameters and
recalculate the flow rates, pressure drops, overall heat transfer coefficients etc more easily. Once
you have made a final selection of configuration, tube diameter, length, number etc. etc, then you
should write out the step by step calculations for that final design.
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Comparing and contrasting the advantages and disadvantages of more than one design will be
considered favourably.
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CHEN90012, Major Assignment 2024 S2.
Part 3
This part of the assignment makes up 15% of the total marks for PED.
Part 3 is due on 16 Oct 5PM.
Maximum 50 pages.
(15 marks)
Provide design specifications and equipment drawings for the plate distillation tower (D1). You
must show the step by step design, as in the example, but may use output from Hysys or Distil to
validate your calculations. (15 marks).
The submission should include the following sections:
1. Report for overall design
a. Executive Summary 5% of total marks
b. Equipment Specification Sheet 10% of total marks
c. Equipment Drawings (2D) 20% of total marks
d. Plant Layout 5% of total marks
e. Detailed Calculations and Discussion 40% of total marks
f. Managerial Aspects (safety, operation, compliance, etc.) 5% of total marks
g. References (List & Appendices) 1% of total marks
h. Appendix: Provide a drawing of the plant layout (plan view) for the entire processing
facility.
14% of total marks
2. Original file of 3D equipment drawings. up to 5% bonus marks
The Calculations and Discussion must be clearly legible. The Discussion should include
assumptions, justifications, procedures and conclusions from Calc. Tool design. The Managerial
Aspects should include any safety issues, operational and managerial issues, compliance with
regulations etc.
Up to 10% of the marks will be based on evaluation of the writing (structure, readability, grammar
and Figures) and originality of the submission.
Submissions that demonstrate original critical thinking and exceptional quality of design will be
considered for bonus marks.
Remember to keep a copy of your submission so that you can work on the following part even
before this part is returned back marked.
Hint: Use an Excel spreadsheet to do the calculations so that you can easily change parameters and
recalculate the flow rates, pressure drops, back up heights, residence times, flooding, entrainment
etc. etc more easily. Once you have made a final selection of configuration, tray spacing and
layout, number and size of holes, column diameter etc. etc, then you should write out the step by
step calculations for that final design.
Comparing and contrasting the advantages and disadvantages of more than one design will be
considered favourably.
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VLE data of MeOH-H2O can be found in literature.
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