PROCESS OPERATION AND MANAGEMENT - 2017/8

Module code: ENG3190

Module provider

Chemical and Process Engineering

Module Leader

ALPAY E Prof (Chm Proc Eng)

Number of Credits

15

ECT Credits

7.5

Framework

FHEQ Level 6

JACs code

H800

Module cap (Maximum number of students)

N/A

Module Availability

Semester 2

Overall student workload

Independent Study Hours: 71

Lecture Hours: 8

Tutorial Hours: 32

Assessment pattern

Assessment type Unit of assessment Weighting
Coursework INDIVIDUAL COURSEWORK (2 ELEMENTS) 40%
Project (Group/Individual/Dissertation) SMALL GROUP PROJECT REPORT (STUDENTS WORKING IN A GROUP OF 5 OR 6 OVER A FOUR DAY PERIOD) 30%
Project (Group/Individual/Dissertation) PROCESS OPERATION (STUDENTS WORKING IN A GROUP OF UP TO 24 OVER A FOUR DAY PERIOD) 30%

Alternative Assessment

Re-assessment using the same form of assignment for the first two assessments (individual coursework) but because of the group nature of the “small group project” and “process operation”, and the safety implications of students operating the equipment by themselves, no alternative assessment is possible.

Prerequisites / Co-requisites

Completion of the progression requirements to FHEQ Level 6 of degree courses in Chemical Engineering, Chemical and Chemical and Petroleum Engineering or equivalent.

Module overview

The financial and operational management of a chemical process is essential to Chemical Industry; students who have first-hand experienced these activities will become more rounded and employable graduates.  Following a comprehensive grounding in the science of Crystallisation students will complete a number of Case Studies related to the performance and operation of the pilot plant rig processing a crystallising system.  Following comprehensive training in the safe operation of the pilot plant students will then adopt a number of different rolls in the management and operating structure of the unique pilot plant and will manage/operate the unit in semi-batch mode for 4x12hr consecutive days of production.

Module aims

A comprehensive grounding in the science, design, selection and operation of equipment for Crystallisation

A comprehensive understanding of the management and operation of a pilot plant scale production unit and an opportunity to apply this during a 4 day operating period

An opportunity to develop their teamwork, communication, problem solving and other essential transferable skills in technical context in particular in the area of plant operation and management

Learning outcomes

Attributes Developed
Demonstrate an in-depth knowledge of crystal nucleation thermodynamics and growth kinetics and be able to relate these to the performance of crystallisation processes        KC
Formulate soundly based designs for crystallisers understand the relationship between process conditions and crystal product size distribution  KC
Critically analyse the many inter-related issues associated with production management, process operation, health & safety practice and environmental practice related to a production unit   KCPT
Confidently accept and carry out the duties of a number of management and operating team related to process operation      KPT
Propose logical, financially viable and operationally feasible solutions to some of the conflicts between theoretical and practical engineering KCPT

Attributes Developed

C - Cognitive/analytical

K - Subject knowledge

T - Transferable skills

P - Professional/Practical skills

Module content

Indicative content includes:

Crystallisation              Introduction to the crystalline state

                        Solution, solubility and supersaturation

                        Theoretical crystal yield

                        Nucleation classification, homogeneous nucleation theory

                        Crystal growth kinetics

                        MSMPR crystalliser design and operation

                        Batch crystalliser design and operation

 

Team Working              Introduction, concepts, problems

 

HESS Process              Process operations

                        Safety management

                        Process dynamics and planning

 

Case Studies                Health and Safety

                        Process Operation

                        Plant/Process Management

                        Environmental Management

 

Pilot Plant Operation     Introduction

                                      Maintenance

                                      Start-up trial

                                      Production runs

                                      Process Dynamics

 

Note    To ensure that the University properly fulfil the requirements of current safety legislation it is a pre-requisite of taking part in the Pilot Plant Operation section of the module that students have attended and properly participated in both the Health and Safety and Process Operation sections of the Case Studies.

Methods of Teaching / Learning

The learning and teaching strategy is designed to:

Allow students to experience the safe operation, maintenance and management of a pilot plant scale production process from the perspective of a process operator, maintenance technician, member of the management team and research engineer.  This is achieved by a combination of lectures on scientific fundamentals, presentation and exercises on group working, case studies necessary to process operation, safety and management and hands-on pilot plant operation/maintenance/management.  The module is taught semi intensively using whole days with two days in the first week (usually week 4 of the semester), one day each in the second and third week 4 days in the following week.  

The learning and teaching methods include:


Lectures                                 2 hours per week for 5 weeks           
Lectures/Case Studies           7.5 hours per day for 4 days
Simulation week                    12 hours per day for 4 days
Individual learning                   7.75 hours for 8 weeks


 

Assessment Strategy

The assessment strategy is designed to provide students with the opportunity to demonstrate the full range of learning outcomes.

Thus, the summative assessment for this module consists of:


Coursework (individual): Element 1 – 10%, 8 hours (LO1, LO2); Element 2 – 30%, 22 hours (LO2)
Small group project report – 30%, 3000 words (LO3, LO4)
Process operation – 30% (LO3, LO4)


Formative assessment

Computer-based Pilot-Plant health and safety test (requires a pass mark of 70% before process operation can be allowed); multiple attempts possible.

Feedback

Verbal and written feedback on Coursework 1 and 2

Written feedback on the small group project

Daily verbal feedback during the process operation phase of the module

Reading list

Reading list for PROCESS OPERATION AND MANAGEMENT : http://aspire.surrey.ac.uk/modules/eng3190

Please note that the information detailed within this record is accurate at the time of publishing and may be subject to change. This record contains information for the most up to date version of the programme / module for the 2017/8 academic year.