Heuristics for

Process and
Equipment Design
Plant Design Project I KC43104
 Course Outcomes in this lecture
By the end of this lecture you will be able to:
use the heuristics tools as given in the handout with
knowledge of their limitations to select the most
appropriate process and equipment (CO3)
perform on-the-spot analysis on complex chemical
engineering design problems (CO1)
approximate designs of a system, component, or
process to meet complex chemical engineering
needs within realistic constraints such as economic,
environmental, social, political, ethical, health and
safety, manufacturability, and sustainability (CO2)
Rules of Thumb
Flemings Right Hand Rule

http://physics503.one-school.net/2008/06/magnetics-effects-of-
current-carrying.html
Flemings Left Hand Rule or the Motor Rule

http://www.magnet.fsu.edu/education/tutorials/java
/handrules/index.html
 Handout
53 heuristics are given in the handout covering
process synthesis and equipment design.
Guidelines on separation equipment are also given
in a table. Extracted from Peters and Timmerhaus.
Both qualitative and quantitative rules-of-thumb are
given in the handout. In the latter case, the
calculations are approximate, but not rough. One
can never get away from rigorous estimations.
 Application
Generation of alternative process synthesis: requires
little analysis and simple material balances can be
completed without iterations before proceeding to
the next synthesis step.
Heuristic 1: Selection of Raw Materials involving hazardous and toxic

chemicals, e.g. ethlylene oxide, see section 6.2 on using chlorine and

sodium hydroxide instead.

Heuristics 2: Consume valuable species or toxic and

hazardous species
Heuristics 3: Eliminate inert
species D
 Heuristics 3 Contd
Both 1-
butene and
butadiene
have vapour
pressures
significantly
different
from iso-
butene and
MTBE. On
this basis,
can be
separated
before or
after the
reaction
Other considerations will
operation. CH3OH + iso-butene MTBE determine the final choice.
Heuristics 4: Introduce
Purge Streams
Heuristics 5: Do not purge valuable or toxic and

hazardous chemicals
Heuristics 6: Recycle small quantities of Byproducts to

extinction, e.g. production of biophenyl from benzene

during the toluene hydrodealkylation process

2C6 H6 C12 H10 H 2

Heuristics 7: Selectivity in competing reactions by

adjusting process conditions

 Heuristics 8: Separate products to drive Reversible

reactions to the right in Task Integrated Design

Less volatile
introduced at
upper section

More volatile
introduced at
lower section
 Summary of Heuristics for Processing Operations
Separation involving Liquid and Vapour Mixtures
Heuristics 9 11
Separation involving Solid Particles Heuristics 12 -
20
Heat removal from and addition to Reactors
Heuristics 21 24
Heat Exchangers and Furnaces Heuristics 25 33
Pumping, Compression, Pressure Reduction,
Vacuum and Conveying of SolidsHeuristics 34 52
Removal of Particles from Gases and Liquids
Heuristic 53
Heuristics for Process
Equipment
You can refer to
Appendix E, p.966-
973 of Peters,
Timmerhaus and
West, 5th Ed.
Considerations that apply to
the Entire Flowsheet (1)
Suggestions attributed to A. Brostow of Air Products
and Chemicals, Inc. (p. 173 Seider et al, 3rd edition,
2010)
Considerations that apply to
the Entire Flowsheet (2)
To increase second-law efficiency and reduce
energy consumption, avoid, if possible, the mixing of
streams of different temperature, pressure, or
composition.
Considerations that apply to
the Entire Flowsheet (3)
For a new process, determine how it differs from a
similar conventional process and pinpoint the
advantages and disadvantages of the new process,
making changes where disadvantages are
uncovered.
 Considerations that apply to
the Entire Flowsheet (4)
For a new process, determine the maximum
production rate and yield, and look for opportunities
to increase the production rate and yield. Then,
calculate theoretical efficiencies by applying lost-
work analysis (Smith et al 7th ed., Eqns. 5.25 & 5.28, pp.
181-182). Look for ways to increase the efficiency.
Considerations that apply to
the Entire Flowsheet (5)

Carefully examine the process flowsheet, looking for

ways to eliminate equipment by combining,
rearranging, or replacing process steps.
Considerations that apply to
the Entire Flowsheet (6)
Perform preliminary economic evaluations at
different production rates and corresponding plant
sizes using simple scaling methods, noting that what is
not economical at a small size may be economical
at a large size and vice versa.
 Course Outcomes in this lecture
Now at the end of this lecture you have been shown
how to:
use the heuristics tools as given in the handout with
knowledge of their limitations to select the most
appropriate process and equipment (CO3)
perform on-the-spot analysis on complex chemical
engineering design problems (CO1)
approximate designs of a system, component, or
process to meet complex chemical engineering
needs within realistic constraints such as economic,
environmental, social, political, ethical, health and
safety, manufacturability, and sustainability (CO2)
 Tutorial Problem

Problem 6.1, 6.2 and 6.6 of Handout