guidebook pd 2nd phase

7/21/2019 GuideBook PD 2nd Phase

1/14

GUIDELINES BOOK 1

2015

GUIDEBOOK

P L A N T D E S I G Nnd

2 PHASE COMPETITION

IChEC 2015INDONESIA CHEMICAL ENGINEERING CHALLENGE


2/14

SUBMISSION RULES

1. ONLY teams that have passed the 1st phase abstract selection may continue to the 2nd phase

of Plant Design Competition

2. Participating teams must submit the required 2nd phase documents via e-mail to

14 February 2015. Late

submission up to 12 hours after the time stamp will be accepted but heavy penalties will be

given (5 pts deduction for every hour of lateness). No submission is accepted after that and

will result in immediate disqualification

3. The 2nd phase document consists of:

FINAL REPORT

(Details regarding the content and the format are explained in the next chapter)

4. The document must be compressed into a single file (*.zip or *.rar) with the file name and

subject:

XXXXX is your team number

5. Participating teams will receive an e-mail confirmation within 2 x 24 hours after sending the e-

mail

6. Selection process results of the 2nd phase can be accessed on:

7. Participating teams that have successfully passed the 2nd phase selection process will be

further competing in the Grand Final on 27 March 2015. Further details regarding the Grand

Final will be notified via e-mail.

[email protected]

http://www.ichec-itb.com

before the deadline at 11.59 pm (GMT+7) on

IChEC2015_PD2_XXXXX

INDONESIA CHEMICAL ENGINEERING CHALLENGE 20152
http://www.ichec-itb.com/mailto:[email protected]://www.bkpm.go.id/contents/p16/statistics/17http://www.ichec-itb.com/http://www.bkpm.go.id/contents/p16/statistics/17http://www.bkpm.go.id/contents/p16/statistics/17http://www.bkpm.go.id/contents/p16/statistics/17http://www.ichec-itb.com/http://www.bkpm.go.id/contents/p16/statistics/17mailto:[email protected]


3/14

PLANT DESIGN REPORT CONTENT AND

ASSESSMENT CRITERIA

The final report must contain three following main sections, explained in sub-chapterA, B and C, as well as several supporting documents and references.

Executive summary (2 page maximum) should contain a summary or brief description

of the proposed plant design. The executive summary must also deliver arguments that

explain and answer these questions below in the executive summary:

- Why does the proposed plant deserve to be implemented?

- Is the proposed plant a new design or an improvement of an existing plant?

- Can the new plant design produce more efficiently in terms of energy, chemical

reactions, by-products generation, etc.? Make a comparison with similar existing

plants (if any)

- Is the technology used can be categorized as hybrid or part of the green

(sustainable) technologies development?

- How can you guarantee that the plant is designed safely for both humanity andthe environment?

Arguments should correspond to the proposed plant design and are to be written into

paragraphs form, NOT into bullet points. Those questions above are only cues of the

arguments. Headings, relevant figures, equations and/or any other relevant items in

strengthening the arguments are allowed.

Please display your arguments sharply to show that your plant is better than others.

Clearly explain and specify your arguments to avoid overgeneralizing.

The Plant Performance and Economic Summary Sheet template can be downloaded

on our official website (along with this guidebook). Both sheets must be attached to the

front of the report after executive summary. Note that the provided template only

serves as the general guidance of the sheet; participants are highly encouraged to

customize the sheet to suit their own proposed plant design, as the details are

dependent on each own design.

A. Executive Summary

B. Plant Performance and Economic Summary Sheet

3PLANT DESIGN 2ND PHASE COMPETITION GUIDEBOOK


4/14


C. Plant Design Main Report

This section is the most comprehensive aspect of the final report and should consist of

several chapters. The chapter structure and its corresponding score weight factors are

as follows: (Please note that adherence to chapter structure is mandatory, however participants

may add more sub-chapters, as well as the points included in each of it)

CHAPTER WEIGHT FACTOR

A Chapter I Introduction 10

B Chapter II Plant Design Methodology 12

ASSESSMENTCRITERIA

Sub-chapters:

1.1 Background

- Objectives

- Sharpness in seeing opportunities

- Impact to industrial regional sector

1.2 Raw Materials

- Selection of raw materials, availability, suppliescontinuity, etc.

1.3 Market Analysis

- Market research

- Product competiveness in the market (competitors,commodity complementary and substitute)

- Product off taker: local, regional, or internationalmarket? Other companies or direct off taker?

1.4 Site Selection

- Supply plan and access to raw material and utility

- Product marketing plans

- Supporting facilities (facilities and infrastructures,telecommunications, ports, etc.)

- Other related conditions (geographical, social, political,labor, etc.)

Sub-chapters:

2.1 Theoretical Background

- Detailed description to support process selection basisused in the plant

- The whole description must be taken from reliablereferences or thorough personal analysis

2.2 Methodology

- Step-by-step explanation of plant design

- Approaches and assumptions used in designing the plant


5/14

5

C Chapter III Comprehensive Process Description 23

DChapter IV Process Safety and Environmental

Considerations 12

E Chapter V Equipment Specifications 15

Sub-chapters:

3.1 Plant Design Basis

- Plant Capacity

- Specification of feed and product- Ambient environmental conditions (air temperature,

water, wind speed and direction, etc.)

- Mode of the operation (continuous, batch, semi-batch,or semi-continuous)

3.2 Process Flow Diagram (PFD)

Refer to Turton et al (2009) for standard use in this competition(see the Appendix of this guidebook)

- Operating units and operating conditions of mainequipments and streams

- Detailed sequence of processes of raw materials intoproducts

- Mass and energy balances for every stream process

- Energy consumption and release for every unit operationand total energy consumption per production unit

- Process control instrumentation (emphasis onphilosophy of the control itself; complex and specificcode number is not necessary)

3.3 Utility Flow Diagram

- Utilities involved in the process

- Equipments and streams of utilities

Sub-chapters:

4.1 Process Safety

- Hazards that may arise from the plant operation

- Prevention and mitigation to avoid and/or overcomepotential hazards

- Safety-related equipments for hazardous materialshandling process

- Hazardous materials/chemicals that are used orcontained in PFD (MSDS can be attached if necessary)

4.2 Environmental Impact and Waste Management- Government regulations (local and international) of the

environmental impact of waste generated from processoperations

- Types of waste and pollution generated, including theway to handle them

Sub-chapters:

5.1 Consideration in Equipments Selection

- Personal consideration and explanation of selectiondepending on several factors

5.2 List of Equipments

- Specification of primary equipments, including type,

PLANT DESIGN 2ND PHASE COMPETITION GUIDEBOOK


6/14


F Chapter VI Layout 8

G Chapter VII Economic Investment and Calculations 15

Sub-chapters:

6.1 Plot Plan

Schematic layout of various areas in plant consists of:

- Primary infrastructures in process inside plant

- Utilities- Raw materials and products storage

- Office

- Road plan

- Personal additional objects

6.2 Plant Layout

- Detailed equipment layout in the plant (consider factorsof safety, traffic, accessibility of operation andmaintenance)

6.3 Pipe Rack

- Management and placement of pipes across the plant

Sub-chapters:

7.1 Capital Cost Estimation

Refer to Turton et al (2009) on chapter 7 for standard use inthis competition

- Engineering cost

- Procurement cost

- Construction cost

- Commisioning cost

- Start-up cost- Others

7.2 Manufacturing Cost Estimation

Refer to Turton et al (2009) on chapter 8 for standard use inthis competition

- Variable cost

- Raw materials, utilities, labour, fringe, benefits,maintenance, distribution, packaging, storage, salesexpense, R&D, promotion, etc.

- Fixed cost: depreciation, taxes, insurance, patents,royalties, etc.

7.3 Profitability AnalysisRefer to Turton et al (2009) on chapter 9 and 10 for standard

size, material, number, and others

5.3 List of Piping

- Type of pipe, diameter, and total length of the apropriatediameter

5.4 Material Selection and Specifications for Pipe and

Primary Equipments- Operating conditions (pressure and temperature)

- Durability of the materials compared to physicalproperties of the process fluid

- Analysis of materials selection


7/14

7

H Chapter VIII Final 5

APPENDIX

use in this competition

- Cash flow from designing to finishing

- Detailed cash flow can be inserted in Appendix

- Profitability criteria from discounted method

- NPV, DPBP, ROI, DCFROR (IRR)

- IDC (interest during construction), taxes, O&M cost,amortization, and depreciation (Use straight line methodfor depreciation)

7.4 Sensitivity Analysis

Spider web diagram, impact of changes in product prices,sales volume, raw materials, and investment to the valueof IRR

Conclusion of the plant design proposal

1. Specification Sheet: covering the calculation and majorequipement specifications with clear assumptions andreferences (computer typing or manual writing is allowed)

2. Cash Flow Sheet, Economic Summary Sheet, etc.

3. Bibliography and Other References



8/14


COMPETITION TERMS

A. Plant Design Regulations

Regulations are given with the intention to meet minimum reporting standards,uniformity and to facilitate assessment. The regulations are:

1. The drawing of Process Flow Diagram, Plant Layout, etc., must be equipped with

plant name and its capacity (in tons of products/year). It is recommended that the

drawing is made by using a drawing software (i.e. AutoCAD) on A3 paper size and

follows our stated reference for the standard (Turton et al., 2009)

2. Use metric units for the whole calculation, especially in the summary and the

conclusion. Imperial units are only allowed, as long as it is followed by a

conversion to metric unit

3. Do not use scientific number on the Investment and Economic Calculation (use

1341 instead of 1,34 x 103)

4. Use number rounding up to two decimal points

5. Numbering format must be the following: comma for digit separator (,) and dot for

decimal separator (.) e.g. 34,500.23 or 14,225,821.53

6. The economic estimation, if present, must be calculated based in USD. If currency

exchanges are needed, provide the currency rates and its date along

7. Process Flow Diagram must be drawn on A3 size paper

8. Plot Plan and Plant Layout must be drawn on A4 size paper with appropriate scale

9. Include the estimation of revenue (i.e. USD XX,X00,000,000 per year)

10. Include the percentage of corporate tax that follows the standard set by the

government based on revenue per year

11. Include detailed data of total investment (total equipment cost, manufacturing cost,

etc.)

12. Use assumption of 10-year plant life

13. The construction period is standardized to 2 years

14. The inflation and interest rate value depend on the country where the plant is

located (also attach the basis of assumptions or facts)


9/14

9

15. The value of IDC (Interest During Construction) is approximately 10% per annum

16. All relevant references must be inserted in Appendix section of the report

17. Violation of the provisions above will result in score deduction of the report

B. Report Writing Technical Regulations

The plant design report must be written by using proper UK or US English on A4

size paper with a left and upper margin of 3 cm and 2.5 cm for the lower and right

margins. The report should be written using Times New Roman or Calibri

typeface, 11 pt font size, and a minimum spacing of 1.15. Page numbers are to be

given at the bottom right corner on every pages, including the flow sheet. The

content of the report should be no more than 150 pages (Chapter I until VIII,

excluding appendix, executive summary and table of contents/figures/tables). Foreach excess page, there will be 1 point deduction.

C. Competition Rules

Participants are allowed to design the equipments required in the process or

incorporate either standard or non-standard existing design. Equipment designs

must include the design, working principles, and the calculations used for the

design.

1. Design Report Format and Requirements

a. The plant design included in the competition must be original

b. The design must follow all the requirements stated in this guidebook

2. Assessment

a. Assessment will be carried out by international judges drawn from college

academician, industrial practitioners, and others who are determined by

organizing committee

b. Assessment will be carried out based on the reports submitted by the

participants and the decision of the judges is final and cannot be changed

3. Final Presentation

a. Participating teams that are chosen as grand finalists are the top six teams

with the highest overall score

b. Finalists will be immediately informed by e-mail and phone for furtherparticipation in the Grand Final



10/14


c. Regulations regarding the final presentation will be announced in conjunction

with the announcement of the finalists

4. Miscellaneous

a. All submitted plant design reports will become the property of IChEC 2015

organizing committee

b. Only accommodation and transportation of the finalists during the Grand

Final in Bandung will be provided by the organizing committee. Finalists

should provide tickets to and from Indonesia themselves

c. Further information regarding the Grand Final will be delivered later along

with the finalists announcement.


11/14

PLANT DESIGN 2ND PHASE COMPETITION GUIDEBOOK 11

Main Reference:

Turton, R.; Bailie, R.C.; Whiting, W.B.; Shaewitz, J.A. Analysis, Synthesis, and Design ofChemical Processes 3rd Edition. Boston: Pearson Education, Inc., 2009.

Process flow diagram example of a certain plant section (Turton et al., 2009):

Flow table which shows mass and energy balance from the process flow diagram (Turton et al.,

2009):

APPENDIX


12/14


Preliminary equipment summary table from the process flow diagram (Turton et al., 2009):

Utility flow table from the process flow diagram (Turton et al., 2009):


13/14

GUIDELINES BOOK 13

@IChEC2015

www.ichec-itb.com

ichec.2015@gmailcom

CP: Kevin (+6281299069168)

https://www.facebook.com/IChEC2015


14/14


2015

IChEC 2015INDONESIA CHEMICAL ENGINEERING CHALLENGE 2015

Organized by: Supported by:

guidebook pd 2nd phase

Documents