King Fahd University of Petroleum & Minerals
DEPARTMENT OF CHEMICAL ENGINEERING
CHE 495 Integrated Design Course (1-6-3)
Dr. Reyad A. Shawabkeh
Web Site: http://faculty.kfupm.edu.sa/CHE/rshawabk/
Dr. Javaid Zaidi
Web Site: http://faculty.kfupm.edu.sa/che/zaidismj/
Development of general engineering skills and judgment needed in the solution of open-ended
problems from a technical-economic viewpoint are the major goals of this course. The design of a
project from conception to implementation including preliminary feasibility study, preparation of
process, flow diagram, process design, pre-construction cost estimate, equipment sizing (design),
selection of materials of construction, and analysis of project.
Applications will be in areas such as petroleum, petrochemicals, emerging chemical industries and
water desalination. Design topics will be assigned to teams of students.
Corequisite: CHE 425
Integrate the knowledge acquired in different chemical engineering
1 courses in the design of a chemical plant
2 Conduct preliminary feasibility study of the plant design assigned
3 Function and work with others in teams
4 Communicate effectively in English especially in presentations
5 Apply modern process simulation software (such as HYSYS, ASPEN)
6 Function professionally and behave ethically
7 Apply safety rules in the design of storage units or in the plant in general
Comply with environmental regulations in the design of the plant,
8 especially separation columns
This is a supplement to the Problem guidelines handed out to you at the beginning of the
semester. The details and dates in this hand out override those of the previous one.
Deadlines: Deadlines for progress reports and final presentation are set out in this handout and will be
announced during the first meeting with students. Deadlines must be strictly followed.
Assessment: Student progress is assessed through regular meetings, reports and one oral
presentation. The oral presentation will be attended by all instructors of the course. The final
presentation grade is equally based on the assessment of ALL instructors.
The oral presentation will improve the students’ presentation skills and will allow better assignment
Attendance and activity 10%
Progress reports 45%
Final report 25%
Oral presentation(s) 20%
Award Program: There are two major prizes for the best design projects:
1. The local AIChE section design awards. Three awards (first 1500 SR) second (1000SR) and
third (500 SR). These prizes are exclusively for KFUPM students
2. SABIC design awards: These are for the best design projects Kingdom wide. First prize
20,000 SR, second prize 15,000 SR and third prize 10,000 SR.
These awards should serve as an incentive for students to do their best not only for their financial
values but also for the recognition and prestige associated with them.
Report # Type Subject Due Date
PART I: Progress Reports
First Individual Literature Review October 21, 2008
Second Group Mass & Energy Balances November 18, 2008
Third Group Simulation of the full PFD December 16, 2008
Fourth Individual Equipment Sizing January 13, 2009
PART II: Final Report
Final Group Economics &
comprehensive January 20, 2009
PART III: Oral Presentations
Presentation January 26 and 27, 2009
First report on Literature Review
This should be done individually and handed in by everybody. It should include:
i. A two page summary of the project (to be refined and updated at a later stage). This is
mainly a summary of the problem statement that shows a good understanding of the task
ii. Information about the problem. This can be obtained from some of the handouts,
references mentioned in this hand out as well as the web.
iii. Information about molecular weights and boiling points of all components in the feed and
products. This information can possibly be obtained from the problem statement, Perry,
HYSYS/ASPEN database, using thermodynamic correlations or other reference books.
iv. An initial block diagram.
v. Literature review on the production process
vi. Information on kinetic data of all the reactions that take place in the process.
This progress report should be handed in INDIVIDUALLY, i.e. every student should work
Second Report on Mass and Energy Balances
This should be done as TEAM work and one report should be handed in by each group. The report
should cover overall mass and energy balances (mass flow rates, enthalpies, and temperatures) of all
streams. Hand calculations must be used. HYSYS can be used as a supporting tool at this stage.
STATE CLEARLY ALL ASSUMPTIONS THAT YOU NEED TO MAKE.
Third Report on Process Simulation
This is a GROUP report that includes a full process simulation of your PFD using ASPEN/HYSYS.
The simulation results must be summarized in an easy to read manner. Only selective results are to be
included as one or more appendices. Please remember that design is not only numbers, but more
importantly what the numbers mean and analysis of those numbers.
Fourth Report on Detailed Equipment Design & Sizing
This is an individual report that includes the specific detailed equipment design assigned to each
student. This report should include detailed calculations of the equipment size, design details.
The first member of each team will design the reactor in detail including using the program
POLYMATH from your CHE 402 course, if needed.
The second member will design the distillation column (diameter, number of trays, reflux ratio,
height, checking for weeping, entrainment, and flooding, detailed tray design, ..etc).
The third member will design the heat exchanger and the cooler. If the group is made of four
members then the fourth member should design the absorber.
Final Comprehensive Report
The economics analysis of the project should be done and included in a final and comprehensive
This is a group and comprehensive report of all that has been done in the design project. The report
should include an abstract, introduction, literature review, mass and energy balances, process
simulation, detailed equipment design for the whole plant, an overall economical analysis, a
conclusion and recommendations. The cost analysis should act as a quick guide regarding the
feasibility of this whole project.
Final Oral Presentations
The instructor of each section will assign well defined tasks and topics that each student will be
include in his final presentation. Each student will be given 20 minutes and each group will present its
design independently of the other groups. ALL instructors will attend all the presentations.
FINAL REPORT FORMAT
Note: For consistency, clarity and understandability, all of the report must be done in SI units.
The format of the final report should be as follows:
1. Title Page
2. Table of Contents
3. Executive Summary Two page maximum condensation of the report
5. Literature Review
6. Mass and Energy Balances (rough hand calculations)
7. Process simulation (detailed mass and energy balances and separations)
8. Detailed Equipment and plant sizing and design
9. Economic Design
10. Conclusions and Recommendations