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Module Title
Process Integration and Unit Operations
School
Chemical Engineering
Department
Chemical Engineering
Module Code
04 17126
Module Lead
Dr Fotis Spyropoulos
Level
Intermediate Level
Credits
20
Semester
Semester 2
Pre-requisites
Co-requisites
Restrictions
None
Contact Hours
Lecture-40 hours
Tutorial-26 hours
Supervised time in studio/workshop-8 hours
Guided independent study-126 hours Total: 200 hours
Exclusions
Description
This second semester module introduces the methodologies for the synthesis of a new process and discusses the factors governing process selection. The module first introduces problem-solving approaches reflecting current trends in process integration (efficient material and energy usage and emissions reduction). Pinch technology is introduced and used to develop heat exchanger networks, with a number of tutorials designed for students to practice the application of the taught approach. Subsequently, the module proceeds to consider equilibrium stage-wise process design, and starting with the unit operations of absorption, distillation and liquid-liquid extraction, students will be introduced to the concepts of stage to stage calculations and diagrammatic problem solving techniques. They are also introduced to novel processing routes, including a case study on supercritical fluids. The module then progresses to introduce a core set of unit operations (including drying, crystallization, and membrane separations) with particular emphasis on the selection of the appropriate methods to meet process requirements. Elements of process design for each of these unit operations are also discussed. More specifically, mass and energy balances are used together with simplified models of each operation, in order to calculate specific processing parameters (e.g. flow rates) and/or unit-specific characteristics (e.g. unit volume).
Learning Outcomes
By the end of the module the student should be able to:
Apply problem table and energy cascade to determine the minimum hot and cold energy requirements and the pinch point of a heat exchange system;
Design a heat exchanger network for maximum energy recovery or minimum number of exchangers; comment upon the appropriate use of process integration in designing new chemical and process plant and revamping existing plant;
Demonstrate and apply the fundamentals of the major unit operations in Chemical Engineering namely distillation, extraction and crystallization; in terms of the essential requirements for the unit design, detailed calculations to find the number of stages and/or the size of unit needed to perform a certain function;
Explain the principles of supercritical fluid technology, in terms of the supercritical fluids, properties, and the main processes that are based on these properties;
Describe and review the principles and applications of membrane treatment systems and size membranes for single or feed and bleed stage systems;
Appropriately select a unit operation for a particular process need.
