ChemCAD

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SIMULATION SUITECHEMCAD SOFTWARE

CHEMCAD PROCESS DESIGN

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PROCESS DEVELOPMENT DESIGN SPECIFICATION

©1938 M.C. E......C..... A.. . B.... . H......

HazardsAssess

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PROCESS DEVELOPMENT

Process Chemistry

Thermodynamics Reaction Kinetics

Physical Properties

Optimize Process

Process Concept

Environment& Hazards

ProcessEconomics

Raw Material Assessment

ProcessSimulations

HAZIDMass - Energy

BalancesFlowsheet Developed

Process Flow Diagrams

Scale-up Process Steps Test UnitOps Budget

Concept Design

Process Inst Diagrams HAZOP

Process Flow Updates

Planning &Compliance

Detailed Design

Equipment Specification LOPAPlant & Piping

Layouts

Implement Phase

Project Management

Testing Calibration Start up Troubleshoot

Optimization

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PROCESS CHEMISTRY

Chemical Input

Process Chemical Output

• Chemical processes that originate from a laboratory all have the following features.

• The Input and output issues for scale up are usually dictated by the physical state of the material SOLID, LIQUID or GAS

• The process issues can be many and varied and relate to the demands and constraints surrounding the chemical reaction, purification and subsequent work up.


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CHEMICAL INPUT

Chemical Input

Gas Form Liquid

Form Solid Form

• Each physical state requires consideration against a series of potential issues.

• This in turn will impact on plant, process, engineering and design.

Issue

Physical Form

Quantity

Alternative states

Stability

Toxicity

Flammability

Common Impurities

Corrosive


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CHEMICAL INPUT ISSUES

Issue Considerations Impact

Physical Form Prills, chips, crystals, flakes, turnings, briquettes, polymers,dimers, chain length, bridging, angle of repose, particle size distribution

Material Handling equipmentEquipment selectionMaterials of constructionLifting equipmentMilling, pre breakingEquipment cleaningStatic controlReaction profileReaction stallingReaction initiation/completionCharge order

Issue

Physical Form

Quantity

Alternative states

Stability

Toxicity

Flammability

Common Impurities

Corrosive

Chemical Input SOLID


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PHYSICAL PROPERTY DATA

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PROCESS CHEMISTRY

Process

Prepare

React

Extract

Issue

Mixing

Solvation

Heating/Cooling

pH Adjustment

Reaction

Distillation

Phase separate

Crystallise

Filtration /Slurry/ wash

Dry

The reaction stage typically has a large impact on engineering design. However, other areas, although less challenging, can have a major impact.


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REACTION CONSIDERATION

Issue

Mixing

Solvation

Heating/Cooling

pH Adjustment

Reaction

Distillation

Phase separate

Crystallise

Filtration /Slurry/ wash

Dry


Reaction KineticsReaction stallingReaction run awayExothermEndothermCritical parametersSafe controlSamplingScale up concernsReflux/ evaporationOff gasCatalystsHomogeneityPhase Change

Cooling designHeating system designTemperature control systemInstrumentation & control Addition rate profile Vessel designAgitation and MixingSafety system designEmergency reliefBlowdown designSafe sampling systems Condenser designScrubbing systemsCatalyst handlingCatalyst recoveryCatalyst storage


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REACTOR Rx STABILITYEXCEL : Batch Reactor Exotherm Stability

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REACTION STABILITYJOB : Batch Reactor Exotherm Stability

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CHEMICAL OUTPUT

Chemical Output

Gas Form Liquid

Form Solid Form

Essentially the same as “Chemical Input”, each physical state requires consideration against a series of potential issues.

Issue

Physical Form

Quantity

Alternative states

Stability

Toxicity

Flammability

Common Impurities

Corrosive


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CHEMICAL OUTPUT ISSUES

Issue

Physical Form

Quantity

Alternative states

Stability

Toxicity

Flammability

Common Impurities

Corrosive

Chemical OutputSOLID


Drying See crystal formTemperature issuesVacuum Is drying required?Re use as a slurryRe dissolve in situChoice of wash solventsAttritionBallingMillingPSDIsolation from water based systemOversizeHomogeneity

Temperature control system designSafety backup systemsDryer Design/ selectionHeat transfer system designAgitation/mixingMilling requirementPacking requirementSievingDust categoriesArea Class


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DESIGN SEQUENCE

UserRequirementSpecification

FunctionalSpecification

Process &InstrumentDiagrams

ProcessConcept

PFDHAZID

ProcessDesignHAZOPSimulate

Model UnitOpsVendorSizing

DetailedDesignLayouts

P & ISoftware

VendorFeedback

AssessProcure

EquipmentSizing &

Specification

AuditTrail

DesignChanges

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DESIGN COST DRIVER

PROJECT COST IMPACTS

0

0.2

0.4

0.6

0.8

1

0 0.2 0.4 0.6 0.8 1

PROJECT TIME

COST

IMPA

CT

Problem Discovery Design Decisions

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DOCUMENTATION

SimulationsCalculations Specifications

Sub-Folders:ProcessInstrumentation

DrawingsSub-folders

ProcessInstrumentation

SoftwareTesting

VendorDocumentsCertificates

User RequirementFunctionalProcess EquipmentInstrumentationControl PanelsElectricalMotor Control CentreSoftwareTest Procedures

Process Flow Diag.P&I DiagramUtility Line DiagramPlant GA & LayoutsPiping LayoutPiping IsometricsElectrical ZoningInstrument SystemInstrument LoopInstrument LogicControl Panel LayoutElectrical & Cable

ProcessInstrumentationElectricalFunctional TestLoop Checks

InstallationOperationMaintenanceCommunicationsProgrammingSparesComplianceCalibrationHazardous AreaMaterial TestPressure Test

ProcessHAZIDHAZOPLOPAPlant ModellingInstrumentationElectricalMechanicalLine Surge

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DOCUMENT NUMBERING

REQUIREMENT : UNIQUE DOCUMENT IDENTIFIER

1. DOCUMENT SECTOR e.g. Administration, Projects2. CLIENT IDENTIFICATION3. PROJECT IDENTIFICATION4. DOCUMENT IDENTIFIER5. DOCUMENT TYPE

CLIENT REF. PROJECT NO. DOCUMENT NO. DESCRIPTOR

AA.XXX.XXX.AAA

QUOTATIONS QUOREPORTS RPTCALCULATION CALMINUTES MINMANUALS MAN

ABSOLUTE KEYTO

DOCUMENT CONTROL