Plant Design and Economics Course

Lesson 1 • Process Flow and Block Diagrams

Introduces process flow diagrams and block diagrams as primary communication tools. Students translate verbal process descriptions into structured visual representations.

Lesson 2 • Introduction to Industrial Plant Design

Defines plant design scope, objectives, and stakeholder roles. Connects design decisions to operational performance and economic outcomes.

Lesson 3 • Design Basis and Project Scope

Covers how to define a design basis document and establish project scope boundaries. Provides the foundation for all subsequent engineering decisions.

Lesson 4 • Regulatory and Safety Frameworks

Surveys regulatory compliance requirements and safety standards governing plant design. Students map applicable standards to design deliverables.

Lesson 1 • Process Simulation Software Basics

Introduces steady-state process simulation tools for automating mass and energy balances. Students build and validate simple simulation models.

Lesson 2 • Recycle, Purge, and Bypass Streams

Analyses recycle loops, purge streams, and bypass configurations in process flowsheets. Students solve iterative balance problems involving recycle convergence.

Lesson 3 • Principles of Mass Balance

Establishes conservation of mass as the analytical foundation for process design. Students apply steady-state and dynamic balance equations to simple systems.

Lesson 4 • Sensitivity Analysis and Design Cases

Uses parametric studies to evaluate how input variations affect process performance. Students generate design cases that inform equipment sizing decisions.

Lesson 1 • Heat Exchanger Design and Sizing

Covers shell-and-tube and plate heat exchanger sizing using LMTD and effectiveness-NTU methods. Students calculate required heat transfer area for given duties.

Lesson 2 • Equipment Datasheet Preparation

Translates sizing results into standardised equipment datasheets for procurement. Students practise completing datasheets that meet vendor inquiry requirements.

Lesson 3 • Pump, Compressor, and Driver Sizing

Sizes rotating equipment using hydraulic and thermodynamic calculations. Students develop pump curves and compressor performance maps for design conditions.

Lesson 4 • Equipment Classification and Selection Criteria

Categorises process equipment by function and establishes selection criteria based on process conditions. Students match equipment types to process requirements.

Lesson 5 • Separation Equipment Fundamentals

Introduces distillation columns, absorbers, and flash drums as core separation units. Students apply shortcut methods to determine stage counts and column dimensions.

Lesson 1 • Control Philosophy and Loop Design

Introduces process control objectives and the design of basic control loops on P&IDs. Students specify controllers for flow, pressure, level, and temperature.

Lesson 2 • Plant Layout Principles

Establishes spacing, access, and safety separation requirements for plant layout. Students evaluate layout alternatives against operability and maintenance criteria.

Lesson 3 • Piping and Instrumentation Diagram Standards

Covers standard symbols, line designations, and annotation conventions for P&IDs. Students read and mark up P&IDs to identify design gaps.

Lesson 4 • Hazard and Operability Studies

Introduces HAZOP methodology as a structured technique for identifying process hazards. Students conduct a guided HAZOP on a sample P&ID.

Lesson 1 • Cost Estimation Classification

Defines AACE estimate classes by accuracy, effort, and project maturity. Students select the appropriate estimate class for a given project phase.

Lesson 2 • Factored and Lang Factor Methods

Applies equipment-based factoring methods to generate order-of-magnitude capital estimates. Students calculate total installed cost using Lang and Hand factors.

Lesson 3 • Contingency and Escalation

Quantifies contingency allowances and applies escalation factors to future-year costs. Students justify contingency levels using risk-based reasoning.

Lesson 4 • Estimate Documentation and Basis

Structures estimate basis documents that communicate assumptions, exclusions, and accuracy. Students produce a complete estimate package for peer review.

Lesson 5 • Equipment Cost Correlations

Uses published cost correlations and cost indices to estimate purchased equipment cost. Students adjust historical costs to current values using index ratios.

Lesson 1 • Production Cost Summary

Consolidates all cost elements into a unit production cost and total annual cost. Students identify cost reduction opportunities through sensitivity analysis.

Lesson 2 • Raw Material and Utility Costs

Calculates raw material consumption from mass balances and prices utility streams. Students build a utility summary table linked to equipment energy demands.

Lesson 3 • Labour and Maintenance Costs

Estimates operating labour headcount and maintenance cost as a fraction of capital. Students apply staffing models and maintenance factor methods.

Lesson 4 • Operating Cost Structure

Distinguishes fixed from variable operating costs and maps each to design parameters. Students classify cost items and identify the primary cost drivers.

Lesson 1 • Sensitivity and Scenario Analysis

Identifies key economic drivers through tornado diagrams and scenario comparisons. Students quantify how price, cost, and yield uncertainties affect project NPV.

Lesson 2 • Cash Flow Modeling

Constructs project cash flow models spanning capital expenditure, ramp-up, and steady-state operation. Students build annual cash flow tables from cost and revenue inputs.

Lesson 3 • Profitability Metrics

Calculates NPV, IRR, payback period, and return on investment from project cash flows. Students interpret metric results in the context of investment decision criteria.

Lesson 4 • Risk-Adjusted Economic Analysis

Incorporates probability distributions into economic models using Monte Carlo simulation. Students interpret probability distributions of NPV and IRR for decision support.

Lesson 5 • Time Value of Money Principles

Establishes present value, future value, and annuity concepts as the basis for economic analysis. Students solve discounting problems relevant to capital project evaluation.

Lesson 1 • Feasibility Study Presentation

Delivers the completed feasibility study as a written report and oral presentation. Students respond to technical and economic questions from a review panel.

Lesson 2 • Project Definition and Scope Development

Establishes the design basis, project scope, and deliverable list for the capstone project. Students align on objectives and divide work across disciplines.

Lesson 3 • Process Design and Simulation

Develops the process flowsheet, mass and energy balances, and simulation model for the selected case. Students validate simulation outputs against design targets.

Lesson 4 • Capital and Operating Cost Estimation

Produces a capital cost estimate and operating cost model for the project case. Students document all assumptions and assign accuracy ranges.

Lesson 5 • Economic Evaluation and Recommendation

Completes the full economic evaluation including sensitivity and risk analysis. Students formulate a go/no-go investment recommendation supported by quantitative evidence.