EPF 4803 PROCESS AND FOOD PLANT DESIGN PROJECT

EPF 4803 PROCESS AND FOOD PLANT DESIGN PROJECT (Credit hour : 0 + 2) Semester 1 2017/2018 COORDINATOR (Food Engineering Group): A. P. IR. DR. SITI MAZLINA MUSTAPA KAMAL Email: smazlina@upm. edu. my Office phone no. : 03 -89466294 COORDINATOR (BIO-MATERIAL GROUP): PN ZANARIAH MOHD DOM Email: nana@upm. edu. my

Time line for EPF 4803 Activities WEEK Briefing of projects by coordinator 1 Report 1 submission 3 Oral presentation # 1 7 First Draft 12 Oral Presentation of detail project # 2 13 -14 Submission of hardbound copies to the General Office 16

COURSE OBJECTIVES To design a process and food plant To apply process engineering knowledge and project management skills into real situations To develop appreciation related to equipment design, plant costing and regulatory issues To encourages professional characteristics and team work activities To produce a comprehensive design report

LEARNING OUTCOMES To evaluate the energy balance and prepare a detailed engineering design with P&ID (PO 3) To prepare plant economic evaluation (PO 13) To display detailed process plant design (PO 10) To manage and carry out process plant design project in group (PO 12) To report HAZOP and safety analysis To report on waste treatment (PO 8)

TEACHING MODE A design coordinator : Prof Madya Ir Dr Siti Mazlina : Pn Zanariah Mohd Dom Food Engineering Group Bio-Material Group o A supervisor A set of experts Refer to a list given during the course of EPF 4802 STUDENTS Refer to group list (Refer to Appendix 1 – General Student Guideline)

CALENDER OF ACTIVITIES Week Date Day Student 1 12 th. Sept. 2017 Tuesday Attend process plant design project briefing 3 29 Sept. 2017 Friday Submit Report 1 6 23 – 27 Oct. 2017 Mon. - Friday 7 30 Oct. – 3 Nov. 2017 8 th. Dec. 2017 Mon. - Friday Schedule oral presentation with main supervisor and cosupervisors Oral presentation #1 12 Friday 1 - 14 - 13 -14 13 – 22 Dec. 2017 Tuesday – Thursday 16 5 th. Jan 2018 Thursday Coordinator/ Supervisor Coordinator Supervisors; evaluate, submit mark and report to coordinator Main supervisor helps to arrange oral presentation #1 Supervisors submit mark to coordinator Submit first draft of Supervisors; plant design project evaluate and comments on first draft report Project Progress Supervisors Meeting with supervisors provide technical (minimum 10 times) advises Oral presentation #2 Coordinator gather marks from examiners Submit final plant Examiners; evaluate design project report to and fill assessment

MINUTES OF MEETING Group meeting : Every week during class time (Tuesday : 12. 00 – 2. 00 pm) Write a minutes of meeting and the contents include: Attendance of the group members Dates, time and venue Group discussions Group decision Get approval/verification/signature from the coordinator after the meeting Compulsory to get the approval/verification/signature If coordinator is not available, can get the signature from supervisor on the same day of meeting Meeting with supervisor Once a week for at least 10 times during the semester Need to get the supervisor approval/signature (Refer Appendix 5 – Meeting Form)

Assessment mechanism

Assessment items Item 1 - Report 1 (15%) (Week 3) It is a team submission. The report should consists: - Process technology selection - Process description - A block diagram indicating the process flow - Mass and energy balance with detail process flow diagram (PFD) and flow summary table.

Assessment items Item 2 – Two presentations (15%). For the first presentation (Week 7): Focus on improved process plant design, which include from mass and energy balances to mechanical design. - Presentation performed in front of supervisors. - Each group together with main supervisor will arrange for this presentation. - It is a group mark (5%) For second presentation (Week 14): Detailed process plant design - Compulsory for each member to perform the presentation - Presentation performed in front of examiners (Lecturer and Personnel from industries)

Assessment items Item 3 – Detailed report (60%) Refer to student guideline. -This report is the complete design with all major process components. -Refer APPENDIX 2 for the documentation. -First draft needs to be submitted in Week 12 to supervisors. -Submission of final detailed report to coordinator in Week 16. -It is a group submission. Item 4 – Project work (10%) This is individual assessment. - To conduct design project work

Detailed Design ( Refer Student Guideline for details information) Executive Summary Briefly explain the overall design project. State brief results and conclusion from the design works. Briefly include the plant profit.

Detailed Design ( Refer Student Guideline for details information) Introduction (~6 pages) Brief discussion regarding the plant design project Project objectives/summary Summary overall process description – Decided based on literature review Scope of design work – TASK FOR EACH MEMBER !

Detailed Design ( Refer Student Guideline for details information) Mass and Energy Balances A revise of Mass Balance – Based on preliminary report. Evaluation of energy balances – Show all calculations/analysis. Perform heat integration Indicate the improvement after heat integration Present the PFD flow summary of revise mass and energy balances Prepare process flow diagram using standard engineering drawings Produce flow summary table Indicate the mass flow rate of all components Total mass flow rate Temperature, pressure, enthalpy and phases of component stream and utilities services

Examples PFD with mass and energy balances

Detailed Design ( Refer Student Guideline for details information) Every student is required to design one process unit. Individual focus: -Process Engineering Design -Mechanical Design, Equipment Costing and Sanitary design -Process Instrumentation and Control (Individual + Group) - Safety consideration – HAZOP study Detailed Process Engineering Design Prepare detail process engineering design and analysis Expected to design any utility systems required (e. g. steam system, cooling water etc) Show all the procedure/calculation/assumptions/analysis. Summary on the process unit design

Detailed Design ( Refer Student Guideline for details information) Mechanical Design, Sanitary Design and Equipment Costing Prepare a complete detail mechanical design Show all the procedure/calculation/assumptions/analysis. Provide a complete mechanical drawing Use CAD/Solid. Works software not Microsoft drawing! It must be accordance with ASME standard. Report on sanitary design Focus on your major equipment/process State all the consideration made. For equipment costing Show the analysis of a major and minor equipment costing

Examples of Mechanical Design (Drawing and specification sheet)

Detailed Design ( Refer Student Guideline for details information) Process Instrumentation and Control Prepare Pipe & Instrumentation diagram (P&ID) for your process unit and indicate all the important devices, piping and requires services. Include a detailed specification of each control loop The above points are focus on individual process unit! Produce overall design of plant control system (Overall P&ID) Show overall control strategy in addition to the individual sections. Evaluate the control loops across all the sections to ensure that they do not conflict. For both individual and overall P&ID, show the locations of pressure control valve, types of valve and destination of

Examples of P&ID (Individual unit and Overall P&ID)

Detailed Design ( Refer Student Guideline for details information) CIP system and Safety Consideration Indicate health and safety issues Report on CIP system for your plant State all the consideration made. Show the risk assessment analysis using HAZOP technique For all major process/unit Associated with chemical/physical/ biological/electrical State/list suggestion and advices to reduce the risk Attach the MSDS for every chemicals involves (if applicable to your process)

Detailed Design ( Refer Student Guideline for details information) Plant location and layout • Suitable location – Preliminary report • Prepare the plant layout. Waste treatment (Focus on the environmental issues) Show the process flow of waste treatment Produce waste treatment plan

Detailed Design ( Refer Student Guideline for details information) Economic Evaluation Summary of all equipment (major and minor) costing Show the economic analysis that include estimated capital and operating costs. Sensitivity analysis Overall plant economic analysis Produce the internal rate of return in order to determine profitability of plant.

References Student are expected to find all relevant references and information themselves. Below are some recommendation resources that can be used: • Perry’s Chemical Engineer’s Handbook • Lopez-Gomez, A. , & Barbosa-Canovas, G. V. (2005). Food Plant Design. CRC Press Berk, Z. (2008). Food Process Engineering and Technology. Burlington: Academic Press. Clark J. P. (2009). Case Studies in Food Engineering. New York: Springer. Peters, S. M. , Timmerhaus, R. D. & West, R. (2003). Plant Design and Economics for Chemical Engineers. New York: Mc. Graw Hill. Sinnot, R. K. (2009): Coulson and Richardson’s Chemical Engineering: Chemical Engineering Design: Volume 6 (4 th Edition). Yarnton: Butterworth-Heinemann Towler, G. & Sinnot, R. (2008): Chemical Engineering Design:

Flow of Final Detailed Report Submission Oral Presentation 2 Corrections Signed your report Submit two hardcopies (group) to coordinator/general office Submit one softcopy (group) to coordinator

GOOD LUCK!