Department Department Department Department Department Department Department

Plant Design Laboratory

Course Notes
Faculty Member(Members):
Ioannis K. Kookos
Dimitris Vayenas
Undergraduate, 8th Semester
Core Courses
Course Number: CHM_1041
Credits: 6
ECTS Credits:10

Learning Outcomes

After completing this course a student should be able to: 

  1. undertake preliminary techno-economic study of process relative to chemical engineering,
  2. undertake preliminary techno-economic study for new processes or products,
  3. completion of technical report.


At the end of the course the student will have further developed the following skills/competences: 

  1. ability to understand the structure and analyze Process Flow Diagrams
  2. ability to use process simulators such as HYSYS, UNISIM and ASPEN PLUS in modeling chemical processes
  3. ability to judge the potential viability of investment plans.


The students should have completed successfully the course Plant Design and Economics.

Course Contents

Synthesis of heat exchanger networks. Pinch point and its importance in synthesizing optimal heat exchanger networks. Minimum number of units and minimum consumption of utilities. Rules for synthesizing heat exchanger networks. Applications. Use of process simulators to extract the data necessary for undertaking a heat exchanger synthesis project. Numerical examples and applications.
Applications of mathematical programming in process synthesis and design. Basic principles and definitions. Basic types of optimization problems and conditions of optimality. Non-linear programming and sequential quadratic programming. Optimization software.  (MATLAB και GAMS). Approximate optimization in commercial simulation software. Response surface methodology: advantages and disadvantages. Sensitivity analysis and its implementation in commercial software such as UNISIM/HYSYS.  
Structure and functionality of commercial software. Recycle streams and their implementation in commercial software (such as UNISIM, HYSYS, ASPEN).
Design project. Technical writing. Executive summary, main body and technical appendix. Recent design projects: DME production, Bio-diesel production, Bio-ethanol production from food industry waste streams. 
Keywords: Heat exchanger network synthesis, Optimization; Commercial simulators; Design project.

Teaching And Learning Methods

Lectures, training in using computer software and supervised completion of a design project and technical writing.

Assessment and Grading Methods

Design project (50% of the final mark). The completion of the project incorporates elements of problem based learning. The supervision/assessment of the groups is achieved through weekly meetings with the teaching staff.
Written examination (50% of the final mark)