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CHNG5801: Foundations of Process Design (2014 - Semester 1)

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Unit: CHNG5801: Foundations of Process Design (6 CP)
Mode: Normal-Day
On Offer: Yes
Level: Postgraduate
Faculty/School: School of Chemical and Biomolecular Engineering
Unit Coordinator/s: A/Prof Abbas, Ali
Session options: Semester 1
Versions for this Unit:
Campus: Camperdown/Darlington
Pre-Requisites: CHNG2801 AND CHNG2802 AND CHNG2803 AND CHNG2804 AND CHNG2805 AND CHNG2806.
Co-Requisites: CHNG3802 AND CHNG3803.
Brief Handbook Description: This unit of study consists of two strands: (1) vapour-liquid equilibrium and distillation and (2) heat transfer and heat exchangers. The central aim is to show how these unit operations interact in the design and operation of process equipment. The first strand focuses on the following; numerical methods for predicting vapour-liquid equilibrium; binary and multi-component distillation; deviations from ideal behaviour. The second strand of this unit of study focuses on the understanding of the differences between various conventional heat exchanger types and their strengths and weaknesses. Students will understand and be able to design a range of conventional heat exchangers using a systematic approach, and will focus on design and heat transfer calculations. The two strands make extensive use of computer software: Excel and Matlab for data manipulation and equation solving; commercial flowsheeting software (Hysys) for solving engineering design problems. This unit of study runs concurrently with another enabling technology unit of study CHNG5802. These two units together provide students with the tools and know-how to tackle real-life engineering problems encountered in the concurrent project-based unit of study, CHNG5803. This integrated course structure is designed to help students become familiar with the multi-disciplinary nature of chemical engineering today.
Assumed Knowledge: Enrolment in this unit of study assumes that all (six) core chemical engineering UoS in second year have been successfully completed.
Lecturer/s: Dr. Chae, Soryong
A/Prof Abbas, Ali
Timetable: CHNG5801 Timetable
Time Commitment:
# Activity Name Hours per Week Sessions per Week Weeks per Semester
1 Lecture 2.00 2 13
2 Tutorial 2.00 2 13
3 Independent Study 4.00 4 13
T&L Activities: Tutorial: Tutorials will enable students to tackle the key aspects of the material. Tutorial question sheets will be handed out to class or uploaded on the course website.

Independent Study: Students are expected to spend about 4 hours of ‘self-learning’ outside the specified contact periods.

Attributes listed here represent the key course goals (see Course Map tab) designated for this unit. The list below describes how these attributes are developed through practice in the unit. See Learning Outcomes and Assessment tabs for details of how these attributes are assessed.

Attribute Development Method Attribute Developed
Students explore and test design options using computer based simulation of process operations (Tutorials, assignments). Design (Level 2)
Students are given concepts and methods for solving operational problems in distillation and heat exchange processes, and extensive practice in doing so (Tutorials, assignments, quiz and exam). Engineering/IT Specialisation (Level 3)
Students construct and analyse complex flowsheets that model dynamic process behaviour (Tutorials, assignments, quiz and exam). Maths/Science Methods and Tools (Level 3)
Flowsheet analysis exercises will provide students with practice in sorting and filtering complex data sets, identifying important implications and justifying the conclusions reached (Tutorials, assignments, quiz and exam). Information Seeking (Level 2)

For explanation of attributes and levels see Engineering & IT Graduate Outcomes Table.

Learning outcomes are the key abilities and knowledge that will be assessed in this unit. They are listed according to the course goal supported by each. See Assessment Tab for details how each outcome is assessed.

Design (Level 2)
1. To develop a suitable process flowsheet that integrates unit operations to achieve a given objective.
2. To understand and be able to design distillation units as well as a range of conventional heat exchangers using a systematic approach.
3. To be able to use modern software tools for mass transfer and heat transfer design calculations.
Engineering/IT Specialisation (Level 3)
4. To understand the differences between various conventional heat and mass transfer operations and their strengths and weaknesses.
5. To understand the roles of heat and mass transfer in Process Engineering.
6. To understand the different modes of heat transfer (radiation, convection and conduction) and their significance in a range of problems.
7. To relate to heat and mass transfer concepts and terminology and to understand the roles heat and mass transfer in process systems engineering.
Maths/Science Methods and Tools (Level 3)
8. Analysing model results and appreciating the limits of such modelling.
9. Appreciating the operational trade-offs that exist in complex flowsheets.
10. Solving such process flowsheets using appropriate software, analysing the results, and appreciating the limitations of such calculations.
11. Using thermodynamic criteria to calculate equilibrium conditions in vapour-liquid systems.
12. Solving the resultant steady-state and dynamic models using the appropriate software.
Information Seeking (Level 2)
13. Appreciate that a diversity of rate-driven processes can be analysed and classified in a unified way
Assessment Methods:
# Name Group Weight Due Week Outcomes
1 Competency in simulation No 5.00 Week 6 1, 4, 9, 11, 13,
2 Quiz (mid-Semester) No 15.00 Week 7 1, 2, 4, 9, 11, 13,
3 Tutorials (Module B) No 10.00 Multiple Weeks 1, 2, 3, 4, 5, 6, 7, 8, 10, 13,
4 Assignments (Module B) No 10.00 Week 12 1, 2, 3, 4, 5, 6, 7, 8, 10, 13,
5 Final Exam No 60.00 Exam Period 1, 4, 9, 11, 13,
Assessment Description: Practical Exercise: PC-based exercise for students to demonstrate competency in simulation work

Quiz: Mid-semester quiz on phase and vapour-liquid equilibrium and distillation.

Tutorials: multiple weeks from week 8 onwards covering heat transfer module.

Assignments: 2 assignments on heat transfer module work.

Final Exam: examination
Grade Type Description
Standards Based Assessment Final grades in this unit are awarded at levels of HD for High Distinction, DI (previously D) for Distinction, CR for Credit, PS (previously P) for Pass and FA (previously F) for Fail as defined by University of Sydney Assessment Policy. Details of the Assessment Policy are available on the Policies website at . Standards for grades in individual assessment tasks and the summative method for obtaining a final mark in the unit will be set out in a marking guide supplied by the unit coordinator.
Policies & Procedures: See the policies page of the faculty website at for information regarding university policies and local provisions and procedures within the Faculty of Engineering and Information Technologies.
Prescribed Text/s: Note: Students are expected to have a personal copy of all books listed.

Note that the "Weeks" referred to in this Schedule are those of the official university semester calendar

Week Description
Week 1 Module A - Introduction to Distillation
Week 2 Module A - Phase and VLE
Week 3 Module A - Flash calculations
Week 4 Module A - Tray-by-tray calculations
Week 5 Module A - McCabe-Thiele graphical method
Week 6 Module A - Binary distillation
Assessment Due: Competency in simulation
Week 7 Module A - Multi-component distillation
Assessment Due: Quiz (mid-Semester)
Week 8 Module B - Forced and natural convection
Week 9 Module B - Stirred tanks and selection of HEs
Week 10 Module B - Shell-and-tube HEs
Week 11 Module B - HYSYS applications for S-T HEs
Module B - Pinch analysis
Week 12 Module B - Plate-and-frame HEs
Assessment Due: Assignments (Module B)
Week 13 Module B - Boiling and condensation
Exam Period Assessment Due: Final Exam

Course Relations

The following is a list of courses which have added this Unit to their structure.

Course Year(s) Offered
Master of Professional Engineering (Chemical & Biomolecular) 2010, 2011, 2012, 2013, 2014

Course Goals

This unit contributes to the achievement of the following course goals:

Attribute Practiced Assessed
Design (Level 2) Yes 22%
Engineering/IT Specialisation (Level 3) Yes 21.5%
Maths/Science Methods and Tools (Level 3) Yes 31.01%
Information Seeking (Level 2) Yes 15.5%
Communication (Level 2) No 0%

These goals are selected from Engineering & IT Graduate Outcomes Table which defines overall goals for courses where this unit is primarily offered. See Engineering & IT Graduate Outcomes Table for details of the attributes and levels to be developed in the course as a whole. Percentage figures alongside each course goal provide a rough indication of their relative weighting in assessment for this unit. Note that not all goals are necessarily part of assessment. Some may be more about practice activity. See Learning outcomes for details of what is assessed in relation to each goal and Assessment for details of how the outcome is assessed. See Attributes for details of practice provided for each goal.