Course detail

Systems Engineering III

FSI-KS3Acad. year: 2011/2012

The course title "Systems Engineering (III)-integration and optimization" covers the number of activities focused on best solution of process plant, its subsystems and individual equipment by systematic way, for both cases - new design solution and retrofit solution for new purposes. Course, besides necessary theoretical background, introduce students through the illustrative practical industrial examples to the following process systems activities:
- initial evaluation of production and product cost based on results of process heat and material balance;
- selection of type of production plant (batch vs. continuous) and its apparatus compound (topology, flowsheeting);
- optimization of operating conditions of key process equipment and its performance (one vs. multistage solution) for selected apparatus composition of process;
- balance of suitable interconnection of process and surrounding plants (total site analysis);
- conceptual optimization of choice process topology with optimum operating conditions - i.e. process integration and integration (synthesis) of process subsystems (HEN subsystem, subsystems of hot and cold utilities);
- integration, optimization and detail design of important individual process equipment;
- application of optimization in common engineering practice (optimization of pipelines and insulations, algorithms for selection of suitable types of process equipment, etc.).

Language of instruction

Czech

Number of ECTS credits

6

Mode of study

Not applicable.

Guarantor

doc. Ing. Zdeněk Jegla, Ph.D.

Department

Institute of Process Engineering (ÚPI)

Learning outcomes of the course unit

Students will be able to apply the knowledge of thermodynamic, physical and chemical regularities to the solution of process plant and its sybsystems and make a qualified decision if more solutions appear. They will dispose of orientation in complexity of technical-economic requirements of production and environment protection. They will improve their working skills with the professional design softwares and implementations (ChemCAD, Maple, VBA, etc.).

Prerequisites

Basic knowledge of process engineering problematics, especially knowledge of heat and mass transfer and fluid flow together with knowledge of basic problematic of energy and emmisions, process design and control and designing of process and energy systems.

Co-requisites

Not applicable.

Planned learning activities and teaching methods

Teaching methods depend on the type of course unit as specified in the article 7 of BUT Rules for Studies and Examinations.

Assesment methods and criteria linked to learning outcomes

Course-unit credit requirements: active participation in seminars and elaboration of individual work.
Form of exam: Written test (practical calculation example) followed by oral examination.

Course curriculum

Not applicable.

Work placements

Not applicable.

Aims

The course objectives are:
- to make students familiar with the methods for sytems solution and optimization of process
plants, their subsystems and individual equipment;
- to develop of student ability to apply previous obtained knowledge of thermodynamic, physics
and chemical patterns to given process concept and its equipment and to decide in case
varian solutions;
- to provide basic orientation in complexity of technical-economic requirements of production
and environment protection;
- to enable improvement of working skills connected with professional softwares (Maple,
ChemCAD, VBA, etc.).

Specification of controlled education, way of implementation and compensation for absences

Lessons are held in the computer laboratory. Attendance is checked.

Recommended optional programme components

Not applicable.

Prerequisites and corequisites

Basic literature

Seider W.D., Seader J.D., Lewin D.R.: Products & Process Design Principles. Synthesis, Analysis and Evaluation. Fourth edition, John Wiley and Sons, USA (2017). (EN)
Biegler, L.T, Grossmann, I.E. and Westerberg, A.W.: Systematic Methods of Chemical Process Design, Prentice-Hall, Upper Saddle River, New Jersey (1997). (EN)

Recommended reading

Stehlík, P.: Integrace procesů a její význam pro redukci spotřeby energie a škodlivých emisí -základní principy, Nakladatelství “Procesní inženýrství“, edice MAPRINT, Praha (1995). (CS)

Classification of course in study plans

  • Programme M2I-P Master's

    branch M-PRI , 2. year of study, summer semester, compulsory

Type of course unit

 

Lecture

26 hours, optionally

Teacher / Lecturer

doc. Ing. Zdeněk Jegla, Ph.D.

Syllabus

1. Introduction to optimizationb and integration in process systems engineering –
clarification of terms and concrete activities during solution of process plant. Overview
of computational methods and techniques, aspects of mathematical models creation and
objective functions. Importance of different approaches for process balance. Examples
of different forms of optimisation and evaluation duting initial design phase of process
plant.
2. Mathematical methods for optimization, i.e. search for extremum of function of one or more
variables. The most often incident types of problems and used methods solution (LP, NLP).
Accesible optimization softwares.
3. Optimization of operating condition of "key" process equipment – reactors and separators.
Thermophysical properties of process fluids in optimization problems.
4. Synthesis of multi-stage systems of "key" process equipment - multistage reactor and
separator systems.
5. Overview of methods for integration of processes and plants (total site analysis).
Classification and properties of methods for synthesis or integration of heat exchanger
networks (HEN).
6. The mostly used methods for synthesis or integration of heat exchanger networks in case of
grassroot design.
7. The mostly used methods for synthesis or integration of heat exchanger networks in case of
retrofit design.
8. Integration of hot and cold utilities. Methods and techniques for integration the most
expensive „hot utilities“.
9. Optimization of hot and cold utilities. Methods for optimisation of „hot utilities“ for
grassroot and retrofit design.
10. Application of optimization during detail design of equipment I. - equipment with chemical
reaction (reactors, reacting furnaces).
11. Application of optimization during detail design of equipment I. - complex heat transfer
equipment.
12. Selected methods for synthesis, integration and optimisation of batch processes.
Algorithms for optimum design of pipelines and pipeline insulations.
13. Utilizing of optimization principles in common engineering practice (selecting algorithms,
databases, simulating softwares).

Exercise

26 hours, compulsory

Teacher / Lecturer

doc. Ing. Zdeněk Jegla, Ph.D.

Syllabus

1. Material balance of complex process plant with recycle and chemical reaction - comparison
sequential and global calculation method.
2. Optimization of "key" equipment for mass transfer (absorber) – complexity of
technical/economic/environment solution.
3. Optimization of "key" equipment for heat transfer (multistage evaporating system) –
optimization of system arrangement, size of stages and their operating conditions.
4. Application of LP methods – optimization of production capacity of complex process plants,
minimisation cost of production, production variability.
5. Comparison of „transportation model LP- HEN“ vs. results „Pinch analysis“.
Aspects of practical solution of obtained results „HEN/utility systems“ in consideration
of plant control and technical-economic solution of hot and cold utilities.
6. Application of modern mathematical methods: LP (transportation/transhipment model),
MILP and NLP in case of grassroot design of HEN.
7. Application of multistage method for HEN retrofit:
- diagnosis LP model for "network pinch";
- optimization NLP model pro retrofit HEN.
8. Integration of process tubular furnaces as the most energy expensive hot utility.
Aspects of integration in case of grassroot design and retrofit.
9. Optimization procedures for process tiubular furnaces in case of v případě grassroot design
and retrofit.
10. Technical-economic optimization of reacting furnace tube coil system.
11. Computational applications of different optimisation strategies for individual
plate and shell-and-tube heat exchangers.
12. Optimization of pipelines and pipeline network. Optimization of insulation layer thickness
for pipelines and equipment of process plants for given conditions.
13. Examples of databases for optimum selection of equipment type and their algorithms.