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process-design-expert

Expert-level chemical process design covering process flow diagrams, mass and energy balances, equipment sizing, economic evaluation, and sustainable process design.

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Process Design Expert

Before Starting

  1. Greenfield design or retrofit of existing plant?
  2. Which process chemistry?
  3. Preliminary or detailed design stage?

Core Expertise Areas

Process Flow Diagrams

BFD: block flow diagram, overall process blocks and streams. PFD: process flow diagram, major equipment, streams with conditions and flows. P and ID: piping and instrumentation diagram, all equipment, valves, instruments. Stream tables: document temperature, pressure, composition, flow for each stream.

Mass and Energy Balances

Overall balance: total mass in equals total mass out for steady state. Component balance: each species balanced separately. Recycle streams: iterative solution required, tear stream method. Energy balance: enthalpy difference between inlet and outlet streams. Reference state: choose consistent reference for enthalpy calculations.

Equipment Sizing

Heat exchangers: LMTD and U value determine area, tube and shell sizing. Pumps: head and flow from system curve, pump curve intersection. Compressors: isentropic work, polytropic efficiency, staging for high ratios. Vessels: residence time determines volume, L/D ratio for liquid-vapor separation.

Economic Evaluation

Capital cost: purchased equipment cost, installation factor, total fixed capital. Operating cost: raw materials, utilities, labor, maintenance, overhead. NPV: net present value, discounted cash flows over project life. Payback period: time to recover capital investment from operating profit.

Best Practices

  • Converge mass and energy balances before equipment sizing
  • Use simulation software for complex recycle systems
  • Include contingency and accuracy range in all cost estimates
  • Optimize energy use through heat integration from process start

Common Pitfalls

PitfallFix
Wrong basis for calculationsDefine basis clearly, usually per hour or per year
Ignoring recycle convergenceCheck that recycle streams are converged before proceeding
Underestimating installation costsUse appropriate Lang or Hand factor for total capital
Missing utility costsInclude steam, cooling water, electricity in operating cost

Related Skills

  • reaction-engineering-expert
  • separation-processes-expert
  • process-control-expert

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