ChE 216 Second Semester AY 2011-2012 NAME: Online Assignment No.

1 SEC:

1. Enumerate and briefly discuss the NINE (9) steps in the development of a new chemical
plant. 1.1. Inception the start of it, the brainstorming, doing surveys of what people want and need and this is what you will produce in your chemical plant 1.2. Preliminary evaluation of economics and market asking of questions like, Is it still in the market for the next 20 years or more? Are its raw materials always available? Is the plant location a strategic place? 1.3. Development of data necessary for final design do researches regarding your product, do some experiments from raw materials to packaging 1.4. Final economic evaluation determine whether it will do good to you and your countrymen, is it practical, better than the existing products out in the market 1.5. Detailed engineering design determine optimum temperature, pressure, etc. needed to produce an efficient product 1.6. Procurement - acquisition of goods or services involving purchase planning, determination of standards, value analysis, financing, inventory, etc. 1.7. Erection building or construction of the chemical plant from the design, construction materials to the building itself 1.8. Startup and trial runs some trials and pilot tests are done, if successful, apply to big scale 1.9. Production the start of manufacturing, producing now in a large scale 2. Differentiate between: a. Process Design engineer and a Cost Engineer Process design engineer has a good understanding of unit operations and process control, specializes in developing optimum process design, process computer simulation, equipment design, development of PFD's and P&ID's, and preparation of operating instructions while a cost engineer specializes in the economic aspects of the of what a process design engineer does.

b. Plant Layout and a pilot plant A plant layout refers to the arrangement of physical facilities such as machines, equipment, tools, furniture etc. and is the full-scale final plant itself while a pilot plant is its small-scale replica. c. Process Flow Diagram, Piping and Instrumentation Diagram, Qualitative Flow
Diagram and Quantitative Flow diagram Process flow diagram are accomplished before meticulous piping, structural, and electrical design can begin, the layout of process units in a plant and the equipment within these process units must be designed, while a Piping and Instrumentation Diagram is a schematic illustration of functional relationship of piping, instrumentation and system equipment components. A qualitative flow diagram indicates the flow of supplies, unit operations applied, necessary equipment , and information on operating temperatures and pressures. A quantitative flow diagram shows the quantities of materials required for the operation.

d. Equipment Design Variable and Process Design Variable Equipment design variables are the things to be considered in building or buying an equipment such as diameter and length while a process design variables are the parameters measured during the operation such as temperature and pressure.

2. In your own words, define Optimum Design.

Optimum design is the finest development to be integrated into the design of the equipment and methods which will give desired results in the most efficient manner which can also reduce either production time or production cost.

3. Discuss the importance of Safety Factors in design.

Safety factor is used to give a design margin over the theoretical design capacity to allocate for improbability in the design process. The improbability could be any one of a number of the components of the design process including calculations, material strengths, duty, manufacture quality. Its value is related to the lack of confidence in the design process which can cause damage, or even death if not calculated properly.

4. Give two(2) equipment design variables and two (2) process design variables for each
of the following unit operations: operation Flow of fluids Heat exchanger Evaporation Filtration Gas absorption Distillation equipment design variables length, diameter no. of tube passes, length per pass economy, area area, yield no. of ideal plates, recovery no. of trays, stages process design variables temperature, volumetric rate humidity, mass rate temperature, pressure pressure, viscosity temperature, pressure temperature, pressure

5. Enumerate the: a. health and safety hazard commonly encountered in chemical plants
Chemicals may create one or more of the following hazards: toxic, flammable, explosive, reactive and radioactive. One should look not just at the inherent properties but also the degree of exposure to the users. Reduce hazard potentials by: obtaining information substituting hazardous substances and minimizing stocking and using. Limit the consequences by: considering what accidents are liable to happen making an inventory of all potential hazards and developing a system to immediately contain any spilled hazardous substances Prevent accidents by: clearly labeling hazardous products inspecting equipment on a regular basis

establishing an emergency management team and prepare rescue procedures b. factors considered in picking the plant location. The location of a chemical plant is influenced by many factors which are raw materials availability, availability of labor and utilities, transport, market, power supply, environmental impact and effluent disposal, climate and government aid.

c. common utilities used in the operation of chemical plants. Water, air, insulation, refrigeration, steam and power d.
methods of handling solids, liquids, gases in chemical plants.

In handling solids, take an appropriate container to the reagent shelf where the general supply is kept. Solids are somewhat more difficult to transfer than are liquids, so a wide-mouthed container such as a beaker is preferable. During the transfer, hold the stopper or lay it on the bench without contaminating the stopper. Solid chemicals are most easily poured by tipping the general supply bottle and slowly rotating it back and forth. Mere tipping of the bottle alone often causes large chunks to come out very suddenly which leads to spills. If you use your own spatula, be sure that it is absolutely clean. Return the proper stopper to the general supply bottle; do not interchange stoppers. In handling liquids, take an appropriate container to the reagent shelf. Avoid measuring volumes of strong acids and alkaline solutions with your graduated cylinder held at eye level. Support your graduated cylinder on your bench. Add hazardous liquids a little at a time, inspecting after each addition. The most important requirement for safe handling of compressed gases is the correct identification of the gas content. Stamping, labeling, stenciling and colour marking are the means that are used for this purpose.

HONOR CODE On my honor as a Thomasian student, I hereby certify that I did not resort to any form of cheating or plagiarism in answering this Assignment No.1, nor did I coerce others to do so. I understand that any proven violation of this honor code after due process shall mean my failure in this Ch.E. 216 Course. So help me God.

_______________________ Signature of Student