OVERVIEW

Process systems engineering deals with the design, operation, optimization and control of all kinds of chemical, physical, and biological processes through the use of systematic computer-aided approaches. Its major challenges are the development of concepts, methodologies and models for the prediction of performance and for decision-making for an engineered system.

AIMS AND CONTENT

LEARNING OUTCOMES

To introduce modern techniques and computed aided tools for the design, simulation and optimization of process systems including sustainability.

AIMS AND LEARNING OUTCOMES

On successful completion of this study, through lessons attendance and training activities such as oral lessons and exercises, the student should be able to:

• Demonstrate an understanding of the key steps in carrying out a process design
• Apply competently the basic principles of process optimization
• Design and assess the performance and the sustainability of a process plant using simulation or optimization tools
• Work effectively as a member of a process design team developing making judgements, learning and communication skills illustrating an industrial case study

PREREQUISITES

The course has no specific prerequisites. However, for a successful learning, basic knowledge on mathematics, chemical and physics are required.

TEACHING METHODS

The course foreseen oral lessons, exercises, educational field trips, use of simulation software

SYLLABUS/CONTENT

• Process Design: Conceptual process design. Process flowsheeting. Sustainability in chemical and process engineering design, incorporating economic analysis and human dimensions
• Process modelling and simulation: Concepts of process modelling and simulation. Principles of measurement systems and process measurement
• Process optimization: Basic principles of optimization. Presentation of a number of industrial case studies
• Case Studies: A number of process simulation and optimization case studies will be carried out using commercial software packages
• Group Project: Teams of students will carry out an industrial process design case study. Each team is expected to present findings and conclusions at various stages and submit a final report for assessment demonstrating making judgements and communication skills

RECOMMENDED READING/BIBLIOGRAPHY

Teaching material and exercises will be available on Aulaweb platform.

The following book and standards could be useful a follow-up.

1. James M. Douglas. Conceptual Design of Chemical Processes. McGraw-Hill Book Company
2. Gerardo Ruiz Mercado, Heriberto Cabezas. Sustainability in the Design, Synthesis and Analysis of Chemical Engineering Processes. Butterworth-Heinemann, 2016
3. MEASURING MATERIAL FLOWS AND RESOURCE PRODUCTIVITY Volume I. The OECD Guide
4. ISO Standards 14040-14044 (2006)

TEACHERS AND EXAM BOARD

Exam Board

ADRIANA DEL BORGHI (President)

PAOLA COSTAMAGNA

MICHELA GALLO

LESSONS

EXAMS

EXAM DESCRIPTION

The exam consists of a project design presentation and of an oral examination. In particular, the project design consists of the realization and the presentation of a report on the analysis and the optimization of an industrial process chosen by the student based on the teacher suggestions. To reach the oral stage, the students must pass the written test with a minimum grade of 18/30. The achieved course grade will be the average between the written and the oral examinations.

Three exam sessions will be foreseen during the winter session (January, February and during the Easter didactic stop of the Polytechnic School) and four exam sessions will be foreseen during the summer session (June, July, September and during the fall stop of the Polytechnic School). No extraordinary further exam sessions will be issued outside the regular Polytechnic School periods, with the exceptions of students without didactic activities in their current academic year curriculum.

ASSESSMENT METHODS

The learning outcomes are assessed through the presentation of a project design and an oral exam.

The project design consists of the following steps:

1. Choose a process/plant/supply chain within the following: traditional processes (steel mills, refineries, glass and cements production plants, waste treatment), “innovative” processes (photovoltaic, fuel cell, bioplastic, biofuels, circular economy)
2. Analyze the process using all the studied tools (MFA, LCA, ETS, CE, process design), retrieving data by scientific literature, publications, public reports using spreadsheets and modeling software.
3. Identify, through the tools listed at point 2., one or more aspects (substances, materials, emissions, waste) significant from an environmental, safety and costs point of view from a process plant, supply chain stock, global level
4. Propose one of more plant/process/supply chain alternatives and study the obtained improvements using the known tools
5. Draw up a report showing: case study, methodology and results
6. Prepare a presentation
7. Have a public discussion

Criteria and scores for the project evaluation are the following:

1. Rigorous technical and scientific basis of the project: 20/30
2. Innovation and topicality of the issue: 3/30
3. Understanding and personal input to the issue: 5/30
4. Quality of the report: 2/30

For a maximum of 30/30.

During the oral examination, there will be questions on process development and modeling. The exam aims to evaluate skills to apply the learning to specific case studies and to critically analyze processes from a comprehensive and holistic point of view. Quality of the presentation, correct terminology, and critical thinking skills will also be evaluated.

Exam schedule