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CDB4022 Plant Design II

Jan 2018
Dr. Oh Pei Ching
Room: 04-03-12
Ext: 7568
Program Outcomes (PO)
1. Engineering Knowledge - Apply knowledge of mathematics, science, engineering
fundamentals and an engineering specialisation to the solution of complex
engineering problems;
2. Problem Analysis - Identify, formulate, research literature and analyse complex
engineering problems reaching substantiated conclusions using first principles of
mathematics, natural sciences and engineering sciences;
3. Design/Development of Solutions - Design solutions for complex engineering
problems and design systems, components or processes that meet specified needs
with appropriate consideration for public health and safety, cultural, societal, and
environmental considerations;
4. Investigation - Conduct investigation into complex problems using research-based
knowledge and research methods including design of experiments, analysis and
interpretation of data, and synthesis of information to provide valid conclusions;
5. Modern Tool Usage - Create, select and apply appropriate techniques, resources,
and modern engineering and IT tools, including prediction and modelling, to
complex engineering activities, with an understanding of the limitations;
6. The Engineer and Society - Apply reasoning informed by contextual knowledge to
assess societal, health, safety, legal and cultural issues and the consequent
responsibilities relevant to professional engineering practice;

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Program Outcomes (PO)
7. Environment and Sustainability - Understand the impact of professional
engineering solutions in societal and environmental contexts and demonstrate
knowledge of and need for sustainable development;
8. Ethics - Apply ethical principles and commit to professional ethics and
responsibilities and norms of engineering practice;
9. Communication - Communicate effectively on complex engineering activities with
the engineering community and with society at large, such as being able to
comprehend and write effective reports and design documentation, make effective
presentations, and give and receive clear instructions;
10. Individual and Team Work - Demonstrate knowledge and understanding of
engineering and management principles and apply these to one’s own work, as a
member and leader in a team, to manage projects and in multidisciplinary
11. Life-long Learning - Recognize the need for, and have the preparation and ability to
engage in independent and life-long learning in the broadest context of technological
12. Project Management and Finance - Demonstrate knowledge and understanding of
engineering and management principles, business acumen and entrepreneurship in
multidisciplinary environments.

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Course Learning Outcomes (CLO)

 By the end of this course, students should be able to:

1. Generate detailed equipment design using acceptable

design code
2. Design eco-friendly and efficient waste treatment
3. Perform detailed cost estimation and economic
4. Employ effective interpersonal, communication and
teamwork skills

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PO-CLO Mapping
No. PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12
CLO1 √ √ √
CLO2 √ √
CLO3 √
CLO4 √ √

CLO 1: Generate detailed equipment design using acceptable design code

CLO 2: Design eco-friendly and efficient waste treatment system
CLO 3: Perform detailed cost estimation and economic evaluation
CLO 4: Employ effective interpersonal, communication and teamwork skills

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Course Summary
2 Credit Values, 100% Project
Process study
Heat Control
PDP I Material integration
(4 Cr) Flow &
Sheeting Energy
Technology Balance

PDP II Economic
(2 Cr) Environmental
PDP I Review

• Application of all undergraduate knowledge and skills to solve design related

• To develop the skills of working in a team, leadership qualities, written and
oral communication, decision making etc.

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Problem Statement
“Design of Methanol Production Plant from Petcoke”
Petroleum coke (Petcoke) is a carbon-rich solid residue from oil refining process.
Petcoke can be used as feed stock to produce methanol.
Your team’s responsibility is to conduct a feasibility study and develop a conceptual
process design for a potential chemical plant, which utilizes Petcoke as raw material
to produce methanol. Your team must design the most cost-effective process plant
while considering the following relevant issues:
 Select the most economical path that utilizes Petcoke as the main feedstock and
produces methanol.
 Suggest the best site location and determine an appropriate plant capacity based
on economics and product demand.
 Design a plant by giving top priority to environmental concerns.
 Recovery and recycling of the reactants and intermediates should be maximized.
 Minimize energy consumption to the extent economically justified.
 Design a plant that is simple and safe to operate, which follows the HSE

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Process Design Tasks

IV. Economic

I. Review of
design performed
in PDP I

II. Detailed Design:

Major and Minor Equipment

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 Utilising a blend of:

• hand calculations,
• spreadsheets,
• mathematical computer packages,
• process simulator to design a process

 Make necessary decisions, judgements and

assumptions in design problems
 Adhere to standard format for Group and
Individual reports

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Final Oral Presentation
 Contents: PDPI + PDPII
 Submit a softcopy of group report one week
before the presentation date
 Evaluators: Internal Experts + Group Supervisor
 40 mins presentation, 20 mins Q&A
 2 types of assessment:
• Group assessment
• Individual assessment

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Final Group Report
 Contents: PDPI + PDPII
 Length: Between 100 to 150 pages
 Each group is required to submit the report in
hard copy (ABBA Earth Binder, Glued, Non PVC,
2D 50 mm capacity) and soft copy (CD)
 Segregate each chapter with a divider
 Use punch hole protection
(reinforcing ring)

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Final Group Report
 (ABBA Earth Binder, Glued, Non PVC, 2D 50 mm capacity)
Must be white color and the correct size

 Chapter Divider  Punch Hole Protection

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Individual Report

 Report on detailed design of 1 major

equipment + 2 minor equipment
 Length: ≤ 60 pages
 Compile all the final individual design report
in 1 hardcopy file
 Segregate with a divider
 Use punch hole protection (reinforcing ring)

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Types of Equipment (Example)

Major equipment: Minor equipment:

Reactor Extraction columns
Distillation column Evaporator
Absorption column Membrane Units
Furnace Cyclone
Cooling tower
Sedimentation tanks

Only one student is allowed to undertake detailed

design of each equipment.

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Paper Size for Drawings
No. Drawings Paper Size
1. Process Flow Diagram (PFD) A1
2. Process and Instrumentation Diagram (P&ID) A1
3. Individual Equipment A3
4. Plant Layout A3

A1 and A3 drawings should be

folded and inserted in
A4 sized plastic wallets

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Assessment of Reports

 Selected expert panels will evaluate the

Group and Individual Reports.
• Example: P&ID and control strategy
section will be evaluated by Process
Control expert panels
• Example: Reactor design will be evaluated
by Reactor expert panels

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Individual Progress Performance
(Official Group Meetings)
 Must be conducted once in every two weeks
 At least 7 official meetings per group
 Minutes of meeting (MOM) must be submitted to the
main supervisor within one (1) week after the
 Supervisor will evaluate the individual progress
 Individual progress performance will contribute 10%
of the overall individual marks
 Students and supervisor may conduct additional
meetings as frequent as required

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Assessment Scheme
Examined by and % Contribution
Assessment Stage Expert Internal Group Individual
Panel Examiner Contribution Contribution
Final Report
10 10 20
Final Report
20 20 40
Final Presentation
10 10
Final Presentation 10
10 20
10 10
C-Factor 0 – 1.0 x
Total 50 30 20 30% 70%

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Summary of Assessment Scheme

 Distribution by contribution
• Group 30%
• Individual 70%

 Distribution by evaluator
• Internal examiner 20%
• Expert panels 30%
• Supervisor 50%

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Individual Progress & C-Factor

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Milestone and Important Dates
WEEK 1 2 3 4 5 6 7 8 9 10 11 12 13 14
January Semester 2018
ACTIVITY Date 15-Jan 22-Jan 29-Jan 05-Feb 12-Feb 19-Feb 26-Feb 05-Mac 12-Mac 19-Mac 26-Mac 02-Apr 09-Apr 16-Apr
Review design performance on PDP I

Softcopy Report

Final Report

Detailed Equipment Design (Individual)

Final Oral

Waste Treatment
Economics Evaluation: Cost Accounting and Estimation
Annual Costs, Earnings, and Profitability Analysis
Finalised Presentation and Reports

Important Dates:
Deadline for Softcopy Report Submission: 28 March (Week 11)
Tentative Date for Final Oral Presentation: 4 April (Week 12)
Deadline of Final Report Submission: 13 April (Week 13)

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Common forms of plagiarism:
 Submitting other people’s work as your own.
 Slightly modifying other people’s work and submitting as your
 Relying heavily on other people’s work and lacking in originality.
 Copying from internet articles/books without accurate citations.
 Using quotations without citing the source.
 Copying text/drawing/graph/table/chart/picture/photos without
acknowledging its source.
 Paraphrasing the work of others without full acknowledgement.
Changing a few words of the original text and/or altering their
order does NOT make your work a legitimate paraphrase.
 Using materials prepared by professional agencies, individual or

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Similarity by:
• Internet sources
• Publications
• Student Report

How can you avoid plagiarism?

 Apply the principles of good academic practices. When in doubt of
the nature/forms of plagiarism, discuss the matter with your
supervisor or coordinator.

What happens if caught to have plagiarized?

 The university considers plagiarism as a serious offense. If a
student is caught committing plagiarism, stern action will be
taken. Penalties may range from marks deduction to a grade of F.

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Final Oral Presentation
 Some comments:
• iCON/HYSYS flowsheet should not be used as PFD
• Clarity and importance of design basis, basis in HAZOP study
• Lack of team work and coordination during presentation
• Lack in design principle and application of fundamental theory:
design margin, McCabe Thiele, static head, phase diagram,
latent heat, etc.
• Control strategy not adequate, wrong philosophy
• Discrepancy in economic analysis: low CAPEX, high OPEX, high

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Group and Individual Reports

 Some comments:
• Did not incorporate the comments given during presentation
• Missing data sheets/spec sheets/equipment drawing
• Executive summary does not address critical issue
• Economic analysis not consolidated
• Not a scaled plant layout, fire station should be outside the
battery limit/process area, parking lot/assembly point close to
control building
• Too much on theory rather than application of the theory
specific to the project
• Report did not follow standard format, improper or inadequate
quoting of reference, report shown minimal creativity, critical
and analytical thinking not evident etc.

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 Available in ULearn (23 ‒ 31 Jan 2018)

[Open from 23 – 31 Jan 2018]

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Industrial Waste Treatment &



TIME : 11.00 AM – 1.00 PM

Ir Mohd Aref Azaddin Boimin
Senior Executive – Health, Safety & Security
Malakoff Power Berhad


All the Best!