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CHNG9301: Process Plant Design (2020 - Semester 2)

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Unit: CHNG9301: Process Plant Design (6 CP)
Mode: Normal-Day
On Offer: Yes
Level: Postgraduate
Faculty/School: School of Chemical and Biomolecular Engineering
Unit Coordinator/s: Dr Ghadi, Amirali
Session options: Semester 2
Versions for this Unit:
Campus: Camperdown/Darlington
Pre-Requisites: None.
Prohibitions: CHNG5801.
Brief Handbook Description: This unit of study (UoS) will develop technical skills required in chemical engineering design through the synthesis and development of a process flowsheet to meet an identified need within the design constraints. This UoS applies previously acquired knowledge of chemical engineering principles including mass and heat transfer, thermodynamics, fluid mechanics, reaction engineering, design of unit operations, process simulation, and process control to solve real-world chemical engineering problems. Students will develop an understanding of the interaction and integration of the different parts of a process/system. They will gain the technical knowledge required in process/system design through the synthesis of unit operations into a manufacturing process while demonstrating creativity, innovation, and broad range thinking in design a process/system to meet a specification such as effluent handling or waste minimisation. Students will be exposed to a combination of rigorous calculations based on chemical engineering science and experience-based principles (technical heuristics). They will gain confidence in their ability to make design decisions and to justify their choice of the most suitable arrangement of a chemical process when working with incomplete and contradictory information, multiple objectives and constraints.

Students will be exposed to process equipment such as pumps, piping, valves, vessels, etc. by application of equipment selection and sizing practices to address real problems. They will use simulation software such as Aspen HYSYS for the detailed design of major process equipment, such as heat exchangers, tray and packed-bed distillation, absorption, and stripping columns. They will apply pinch analysis and heat integration principles as an example of the systematic approach to process optimisation. Students will demonstrate an appreciation of Safety, Health and Environment (SH&E) requirements when taking into consideration factors such as security, ingress, egress, utilities, natural disasters, and human factors in site selection and plant layout.

This UoS runs concurrently with CHNG3806 (Risk Management for Chemical Engineers) that focuses on the concepts of process safety, risk assessment, economic evaluation, health and environmental issues. Students are expected to gain the experience and working knowledge to carry out the final-year design project in CHNG4802 and CHNG4806 (Chemical Engineering Design A and B).
Assumed Knowledge: CHNG9201 AND CHNG9202 AND CHNG9203 AND CHNG9204 AND CHNG9206.
Lecturer/s: Dr Ghadi, Amirali
Timetable: CHNG9301 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: Lecture: There will a 2-hour lecture each week covering the course contents according to the course schedule. The lectures will consist of short presentations using lecture slides complemented by hands-on, interactive activities for better engagement with the lecture content. Students are encouraged to analyse the given information critically and actively seek meaning and construct their knowledge using their own experience when working on engaging in-class activities.

Tutorials: There will be a 2-hour tutorial each week where students will work on the tutorial/homework questions with the help of the lecturer and the tutors. Students are encouraged to attempt these questions before attending the tutorial session to increase the effectiveness of the tutorial sessions in achieving a deep understanding of the key concepts.

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

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.

(4) Design (Level 2)
1. Proficiency in evaluating the behaviour of heat exchangers, tray and packed-bed distillation and absorption columns using commercial process simulation software
2. Proficiency in selection and sizing of minor process equipment for transport, handling, and storage of fluids, including pumps, compressors, blowers, expanders, storage tanks, pressure vessels, piping, and instrumentation equipment
3. Proficiency in design of heat exchanger networks using heat integration principles and pinch analysis
4. Proficiency in detailed design of tray and packed-bed columns (hydraulic design)
(2) Engineering/ IT Specialisation (Level 3)
5. Proficiency in use of international codes and engineering standards
6. Proficiency in process flowsheet development, evaluation, and selection of the most suitable arrangement of a chemical process on the basis of technical, economic, social and environmental considerations
7. Proficiency in applying sustainable factors in site selection and plant layouts such as process safety, ingress, egress, utilities, natural disasters, human factors, and waste minimisation methods
Assessment Methods:
# Name Group Weight Due Week Outcomes
1 Homework No 40.00 Multiple Weeks 1, 2, 3, 4, 5, 6, 7,
2 Mid-semester Exam* No 30.00 Week 7 2, 4, 5,
3 Final Exam* No 30.00 Week 13 3, 5, 6, 7,
Assessment Description: * indicates an assessment task which must be repeated if a student misses it due to special consideration

Homework: There will be six take-home assignments. Students will work on the homework questions during the tutorial sessions to better understand of the key concepts of the lectures. The lecturer and the tutors will be available to assist students.

Exam: There will be two exams, one mid-semester exam on week 7 and final exam on week 13.
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.
Special Conditions to Pass UoS There may be moderation and/or scaling of the raw marks in each assessment component when combining them to get the final mark in this unit of study.
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.
Recommended Reference/s: Note: References are provided for guidance purposes only. Students are advised to consult these books in the university library. Purchase is not required.

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

Week Description
Week 1 Selection and sizing of minor process equipment-1
Week 2 Selection and sizing of minor process equipment-2
Week 3 Experience-based principles in process design: rules of thumb (technical heuristics) and shortcut method
Week 4 Detailed equipment design (major process equipment)
Week 5 Week in industry
Week 6 Computer-aided equipment design (major process equipment)
Week 7 Process design development and introduction to flowsheet synthesis
Assessment Due: Mid-semester Exam*
Week 8 General steps in flowsheet synthesis and development-1
Week 9 General steps in flowsheet synthesis and development-2
Week 10 Design of heat exchanger network, pinch analysis
Week 11 Instrumentation and process control
Week 12 General site considerations
Week 13 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 (Accelerated) (Chemical & Biomolecular) 2019, 2020
Master of Professional Engineering (Chemical & Biomolecular) 2015, 2016, 2017, 2018, 2019, 2020
Master of Professional Engineering (Sustainability and Environmental Engineering) 2021

Course Goals

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

Attribute Practiced Assessed
(5) Interdisciplinary, Inclusiveness, Influence (Level 2) No 0%
(6) Communication and Inquiry/ Research (Level 2) No 0%
(4) Design (Level 2) No 51%
(3) Problem Solving and Inventiveness (Level 2) No 0%
(2) Engineering/ IT Specialisation (Level 3) No 49%
(1) Maths/ Science Methods and Tools (Level 3) No 0%

These goals are selected from Engineering & IT Graduate Outcomes Table 2018 which defines overall goals for courses where this unit is primarily offered. See Engineering & IT Graduate Outcomes Table 2018 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.