Process Design & Economics
Front-end design and the investment decision for a bio-based ethyl acetate line at a corn ethanol plant in Cedar Rapids, Iowa: project stages and estimate classes, flowsheet synthesis, recycle balances, pinch analysis, sizing of columns, exchangers, pumps, reactors and storage, factored capital estimates, cost of production, discounted cash flow with tax depreciation, sensitivity and Monte Carlo analysis, life-cycle carbon footprint, inherently safer design and permitting, ending with a design report and investment recommendation.
CHE-446 Year 4 3 credits 12 lessons · 4 h 15 min ▶ Video lessons coming soon
Offered by HSM University · Chemical Engineering
This is the American version of this course. See the Canadian version.
What you'll learn
- Explain the stages of front-end loading, the AACE estimate classes and the contents of a design basis for a new process line.
- Synthesize and screen flowsheet alternatives using the onion model, atom economy and economic potential.
- Solve recycle material and energy balances for a flowsheet and build a stream table.
- Apply pinch analysis to set minimum utility targets and recognize when process changes beat heat exchange.
- Size vessels, columns and heat exchangers with shortcut methods and choose materials of construction.
- Size pumps, compressors, reactors and storage tanks and assemble a complete equipment list.
- Prepare a factored capital estimate using cost indices, capacity scaling, installation factors and contingency.
- Build a cost of production with variable and fixed costs, opportunity-cost pricing and reduced-rate effects.
- Evaluate profitability with discounted cash flow, NPV, IRR, payback, tax depreciation rules, sensitivity and Monte Carlo analysis.
- Estimate a cradle-to-gate carbon footprint and green chemistry metrics and identify the largest contributors.
- Apply inherently safer design, early hazard review, environmental design and permitting schedules to a process design.
- Compare design and commercial options on value and risk and write a design report that supports an investment decision.
Course content
12 lessons · 4 h 15 min total · final exam
- 1 The design process and project stages 24 min · quiz
- 2 Flowsheet synthesis 22 min · quiz
- 3 Material and energy balances for the flowsheet 21 min · quiz
- 4 Heat integration and pinch analysis 21 min · quiz
- 5 Sizing vessels, columns and heat exchangers 21 min · quiz
- 6 Pumps, compressors, reactors and storage 21 min · quiz
- 7 Capital cost estimation 21 min · quiz
- 8 Operating costs and raw materials 19 min · quiz
- 9 Profitability analysis 22 min · quiz
- 10 Sustainability and life-cycle assessment 21 min · quiz
- 11 Safety, environment and permitting in design 21 min · quiz
- 12 Capstone: design report and investment decision 21 min · quiz
- E Final exam 20 questions
Requirements
Recommended background. You can start any course at any time.
Description
Front-end design and the investment decision for a bio-based ethyl acetate line at a corn ethanol plant in Cedar Rapids, Iowa: project stages and estimate classes, flowsheet synthesis, recycle balances, pinch analysis, sizing of columns, exchangers, pumps, reactors and storage, factored capital estimates, cost of production, discounted cash flow with tax depreciation, sensitivity and Monte Carlo analysis, life-cycle carbon footprint, inherently safer design and permitting, ending with a design report and investment recommendation.
Part of the Engineering stream, typically taken in year 4.