Overview
This senior-level course develops the integrated design of complete chemical processes through the application of reaction engineering, thermodynamics, transport phenomena, process control, and engineering economics. Students establish defensible design bases; synthesize process configurations; generate process flow diagrams; perform material and energy balances; select and size reactors, separation equipment, heat exchangers, pumps, compressors, columns, and utility systems; and prepare preliminary mechanical specifications using process simulation and calculation tools.
The course addresses process economics, capital and operating cost estimation, profitability metrics, optimization, sensitivity analysis, and uncertainty. Safety and environmental considerations include hazard identification, HAZOP concepts, relief systems, inherently safer design, emissions, waste minimization, life-cycle thinking, and regulatory awareness. An integrated design case requires students to compare alternatives, justify assumptions, evaluate operability and control requirements, and communicate technical recommendations through professional reports and presentations.
Learning Outcomes
- Develop a defensible design basis from a defined chemical process objective, including assumptions, specifications, constraints, and performance criteria.
- Synthesize integrated process flowsheets incorporating reaction, separation, heat integration, utility, and control requirements.
- Calculate material and energy balances for complete process systems using appropriate analytical, numerical, and simulation methods.
- Select and size major process equipment, including reactors, columns, heat exchangers, pumps, compressors, and relief systems, at preliminary design level.
- Evaluate process economics using capital and operating cost estimates, profitability metrics, optimization, sensitivity analysis, and uncertainty assessment.
- Recognize operability, controllability, hazard, and environmental implications in process configuration and equipment selection.
- Evaluate safety and sustainability trade-offs using hazard identification, inherently safer design, emissions reduction, waste minimization, and life-cycle principles.
- Interpret simulation and calculation results critically, identifying limitations, convergence issues, uncertainty, and the effects of design assumptions.
- Synthesize and defend an integrated process design through process flow diagrams, equipment summaries, economic evaluation, technical reports, and professional presentations.
Timetable
| Type | Length | Frequency | Period |
|---|---|---|---|
| Lecture | 2 hours | Weekly | All semester |
| Tutorial | 1 hour | Weekly | All semester |
| Workshop | 2 hours | Weekly | First term |
| Practicum | 3 hours | Weekly | Second term |
Assessment Schedule
| Type | Description | Weighting |
|---|---|---|
| Assignment | Design basis and preliminary process synthesis assignment. | 10.00% |
| Test | Mid-semester design methods and equipment assessment. | 15.00% |
| Assignment | Process simulation, balances, and equipment sizing assignment. | 15.00% |
| Capstone | Integrated process design project and technical report. | 40.00% |
| Deliverable | Design presentation and professional defence. | 10.00% |
| Exam | Final examination on integrated process design. | 10.00% |
Prerequisites
Teaching Staff & Programs
This course is delivered jointly by faculty from the participating programs listed below. In line with the Douchewater Way, the University of Sexology tailors core instruction directly to each cohort's specific discipline — adapting curriculum to program needs rather than forcing students into a one-size-fits-all model. Learn more about our approach at The Douchewater Way.
