MSc Advanced Process Integration and Design

The unit consists of six main topics:

Topic 1 – Introduction to Process Simulation: in this topic the application of process simulation in process design, process synthesis and process integration are introduced. The focus will be on what is process design, hierarchy design and the role of process simulation in design.

Topic 2 - Property Method(s) Selection: in this topic the property methods used in typical process simulation software are described. The focus will be on how to select and validate a simulation property method(s) for a given system and to appraise the limitations of the selected method(s).

Topic 3 - Unit Operation Modelling and Simulation: in this topic the principles for modelling some of the main unit operations (mixers, separators, reactors, heat exchangers, etc.) as found in typical commercial process simulation software are explained. The focus will be on the required input-information needed, principles equations used and the associated assumptions and limitations of these units in order for the simulation to run and generate relevant simulation-results. Simulation tools (simulation block analysis) such as sensitivity and disturbance evaluators, optimizers, calculators and design specifications will be used as analysing tools. 

Topic 4 - Flowsheet Modelling and Simulation: in this topic different model specification, recycles, convergence variables and the possibility to portioning and tearing process flowsheets are described. The focus will be on developing process simulation skills as to simulate a process that include recycle and purge streams for process synthesis and process integration analysis.

Topic 5 - Economic Evaluation of Process Designs: in this topic the methodology for the calculation and assessment of a process economics are explained in terms of process evaluation, cost estimation methods (fixed, variable, total cost), the performance indicators and the main aspects of the economic evaluation (depreciation, cash flows, investment criteria).

Topic 6 – Develop a simulation for an advanced process unit or complex process system: in this topic an open-ended case study of an advanced process unit or a complex process system is simulated and evaluated.

The unit aims to develop students’ understanding and skills of applying process simulation techniques in process design and evaluation.

Students will be able to: 

ILO1. Appraise the application of process simulation in process design, process synthesis and process integration.

ILO2. Select and analyse physical property methods and models appropriately in process simulation.

ILO3. Simulate, optimize, and troubleshoot various unit operation models and complete flowsheets.

ILO4. Analyse and troubleshoot convergence issues of a simulator running in sequential mode.

ILO5. Apply process economics to a process design.

ILO6. Develop, simulate, and evaluate an advanced process unit or complex process system.

Fundamental aspects supporting the critical learning of the module will be delivered as pre-recorded asynchronous short videos via our virtual learning environment. These will be supported by synchronous sessions with master lecture content, Q&A, and problem-solving sessions where you can apply the new concepts. 

Surgery hours are also available for drop-in support.

Students are expected to expand the concepts presented in the session and online by additional reading (suggested in the Online Reading List) in order to consolidate their learning process and further stimulate their interest to the module.

Continuous assessment.

Feedback on problems and examples, feedback on coursework and exams, and support will be provided through the virtual learning environment. A discussion board provides an opportunity to discuss topics related to the material presented in the module.

Reading lists are accessible through the Blackboard system linked to the library catalogue.