Unit Name

PROCESS ENGINEERING

Unit Code

MME 505

Unit Duration

12 weeks

Award

Graduate Diploma of Engineering (Mechanical) Duration: 1 year

Master of Engineering (Mechanical) Duration: 2 years

Year Level

One

Unit Creator/Reviewer

Henry Wickham

Core/Elective

Core

Pre/Co-requisites

Nil

Credit Points

3

Grad Dip total course credit points = 24 (3 credits x 8 (units))

Masters total course credit points = 48

(12 credits (Thesis) + 3 credits x 12 (units))

Mode of Delivery

On-Campus or Online

Unit Workload

Total student workload including “contact hours” = 9 hours per week: Lecture - 1 hour

Tutorial Lecture - 1 hour

Practical / Lab - 1 hour (where applicable) Personal Study recommended - 6 hours

Unit Description and General Aims

This core subject provides the students sufficient depth of understanding of processing engineering in the context of industrial automation. The principles of unit operations, unit processes, fluid transport, and control provide the student with an understanding of how to apply these principles to control and instrumentation systems. This unit will therefore be providing the process background to Industrial Instrumentation (ME 504). Students will be able to perform complex process calculations to enable them to apply control principles in later subjects. Cases studies and/or mini projects form an integral part of this subject and provide a practical understanding to the subject matter.

Learning Outcomes

On successful completion of this subject/unit, students are expected to be able to:

  1. Have a deep understanding of unit operations, unit processes and transport principles in the context of industrial automation.

  2. Acquire knowledge and become aware of recent advances in instrumentation, measurement and control underpinning plant operations.

  3. Acquire an awareness of latest engineering materials and technologies to support process operations.

  4. Understand the methodology of heat and mass balances (and utility balances) and be able to apply principles to generate heat and mass balances for process operations

  5. Synthesise and analyse property data, process information and requirements to create complex process flow diagrams, piping and instrumentation diagrams.

  6. Synthesise and analyse property data, process information and requirements to perform complex process calculations

    Professional Development

    Completing this unit may add to students professional development/competencies by:

    1. Fostering the personal and professional skills development of students to:

      1. Be adaptable and capable citizens, who can communicate effectively, critically evaluate data from whatever source, work collaboratively and use innovative methods to solve complex problems.

      2. Equipping them with an increased capacity for lifelong learning and professional development.

      3. Enable them to plan and organise themselves and others in their sphere of work.

      4. To instil leadership qualities as far as possible in individual students.

      5. Making them aware of ethical issues in the commercial world.

    2. Enhance students’ investigatory and research capabilities through:

      1. Solving basic engineering problems

      2. Accessing, evaluating and critically analysing information

      3. Processes and procedures, also cause – effect investigations

    3. Develop the engineering application abilities of students through:

      1. Assignments

      2. Labs / practical / case studies / self-study (where applicable)

Engineers Australia

The Australian Engineering Stage 1 Competency Standards for the Professional Engineer, approved as of 2013. This table is referenced in the mapping of graduate attributes to learning outcomes and via the learning outcomes to student assessment.

Stage 1 Competencies and Elements of Competency

1.

Knowledge and Skill Base

1.1

Comprehensive, theory based understanding of the underpinning natural and physical sciences and the engineering fundamentals applicable to the engineering discipline.

1.2

Conceptual understanding of the mathematics, numerical analysis, statistics, and computer and information sciences which underpin the engineering discipline.

1.3

In-depth understanding of specialist bodies of knowledge within the engineering discipline.

1.4

Discernment of knowledge development and research directions within the engineering discipline.

1.5

Knowledge of engineering design practice and contextual factors impacting the engineering discipline.

1.6

Understanding of the scope, principles, norms, accountabilities and bounds of sustainable engineering practice in the specific discipline.

2.

Engineering Application Ability

2.1

Application of established engineering methods to complex engineering problem solving.

2.2

Fluent application of engineering techniques, tools and resources.

2.3

Application of systematic engineering synthesis and design processes.

2.4

Application of systematic approaches to the conduct and management of engineering projects.

3.

Professional and Personal Attributes

3.1

Ethical conduct and professional accountability.

3.2

Effective oral and written communication in professional and lay domains.

3.3

Creative, innovative and pro-active demeanour.

3.4

Professional use and management of information.

3.5

Orderly management of self, and professional conduct.

3.6

Effective team membership and team leadership.

Graduate Attributes

Successfully completing this Unit will contribute to the recognition of attainment of the following graduate attributes aligned to the AQF Level 9 criteria, Engineers Australia Stage 1 Competency Standards for the Professional Engineer and the Washington Accord:

Graduate Attributes

(Knowledge, Skills, Abilities, Professional and Personal Development)

EA Stage 1 Competencies

Professional Development

Learning Outcomes

A. Effective Communication

A1. Cognitive and technical skills to investigate, analyse and organise information and ideas and to communicate those ideas clearly and fluently, in both written and spoken forms appropriate to the audience.

2.2, 3.2

A,B

1, 2, 3, 4, 5, 6

A2. Ability to professionally manage oneself, teams, information and projects and engage effectively and appropriately across a diverse range of international cultures in leadership, team and individual roles.

2.4, 3.2, 3.4,

3.5, 3.6

A

2, 3

B. Critical Judgement

B1. Ability to critically analyse and evaluate complex information and theoretical concepts.

1.1, 1.2, 1.3,

2.1

B

1, 2, 3, 4

B2. Ability to creatively, proactively and innovatively apply theoretical concepts, knowledge and approaches with a high level of accountability, in an engineering context.

1.5, 2.1, 3.3,

3.4

A, C

4, 5

C. Design and Problem Solving Skills

C1. Cognitive skills to synthesise, evaluate and use information from a broad range of sources to effectively identify, formulate and solve engineering problems.

1.5, 2.1, 2.3

B, C

1, 6

C2. Technical and communication skills to design complex systems and solutions in line with developments in engineering professional practice.

2.2, 2.3

A, B

5, 6

C3. Comprehension of the role of technology in society and identified issues in applying engineering technology ethics and impacts; economic; social; environmental and sustainability.

1.5, 1.6, 3.1

A

2, 3, 4

D. Science and Engineering Fundamentals

D1. Breadth and depth of mathematics, science, computer technology and specialist engineering knowledge and understanding of future developments.

1.1, 1.2, 1.3,

1.4

A

4, 6

D2. Knowledge of ethical standards in relation to professional engineering practice and research.

1.6, 3.1, 3.5

A

2

D3. Knowledge of international perspectives in engineering and ability to apply various national and International Standards.

1.5, 1.6, 2.4,

3.4

A, C

2

E. Information and Research Skills

E1. Application of advanced research and planning skills to engineering projects.

1.4, 2.4, 3.6

B, C

1, 4, 6

E2. Knowledge of research principles and methods in an engineering context.

1.4, 1.6

B

1, 4, 6

Unit Competency and Learning Outcome Map

This table details the mapping of the unit graduate attributes to the unit learning outcomes and the Australian Engineering Stage 1 Competency Standards for the Professional Engineer.

 

Graduate Attributes

A1

A2

B1

B2

C1

C2

C3

D1

D2

D3

E1

E2

Engineers Australia Stage 1 Competencies and Elements of Competency

1.1

   

       

       

1.2

   

       

       

1.3

   

       

       

1.4

             

   

1.5

     

 

   

   

1.6

           

 

 

2.1

   

             

2.2

       

           

2.3

       

           

2.4

 

             

 

3.1

           

 

     

3.2

                   

3.3

     

               

3.4

 

 

         

   

3.5

 

           

     

3.6

 

               

 

Unit Learning Outcomes

LO1

 

 

         

LO2

     

 

   

LO3

     

         

LO4

 

   

   

LO5

   

 

           

LO6

     

 

   

Student assessment

Assessment Type

(e.g. Assignment - 2000 word essay (specify topic) Examination (specify length and format))

When assessed (eg Week 5)

Weighting (% of total unit marks)

Learning Outcomes Assessed

Assessment 1

Type: Multi-choice test / Group work / Short answer questions / Role Play / Self-Assessment / Presentation

Example Topic: Process Integration & Measurement, Chemical engineering Thermodynamics.

Week 6

20%

1, 2, 3

Assessment 2

Type: Report / Research / Paper / Case Study / Site Visit

/ Problem analysis / Project / Professional recommendation

Example: Report (Midterm Project)

[This will include a progress report; literature review, hypothesis, and proposal for workings]

Word length: 1500

Example Topic: Modelling a typical ammonia process

Week 9

20%

1, 2, 3, 4

Assessment 3

Type: Report (Final Project)

[If a continuation of the midterm, this should complete the report by adding sections on: methodology, implementation / evaluation, verification / validation, conclusion / challenges and recommendations / future work. If this is a new report, all headings from the midterm and the final reports must be included.]

Word length: 4000 (excluding makers’ diagrams and layout drawings.)

Process, control and instrumentation design of a waste water treatment plant for 2 million liters/day of coal seam gas waste water using membrane filtration, ion exchange and reverse osmoses technology showing all calculations, pre-treatment and pump systems and pressures, energy recovery, detailed flow and balances and a concept level cost estimate.

Final Week

40%

1,2,3, 4, 5,

6

Practical Participation

Type: May be in the form of quizzes, class tests, practical assessments, remote labs, simulation software or case studies

Example: Analyse the performance of a refrigeration system (COP) based on the refrigeration cycle, measured cooling effect and electrical power input.

Continuous

15%

4, 5

Assessment Type

(e.g. Assignment - 2000 word essay (specify topic) Examination (specify length and format))

When assessed (eg Week 5)

Weighting (% of total unit marks)

Learning Outcomes Assessed

Attendance / Tutorial Participation

Example: Presentation, discussion, group work, exercises, self-assessment/reflection, case study analysis, application.

Continuous

5%

1, 2, 3, 4, 5,

6

Prescribed and recommended readings

Required textbook(s)

  1. C. J. Geankoplis, Transport Processes and Separation Process Principles, 4th edition, Prentice Hall, UK, 2003

    Reference Materials

    Number of peer-reviewed journals and websites (advised during lectures). Some examples are listed below.

    • N. P. Chopey, Handbook of Chemical Engineering Calculations, 3rd edition, McGraw Hill, 2004

    • R. K. Sinott, Coulson and Richardson’s Chemical Engineering volume 6 – Design, Pergamon Press, 1995

    • Perry’s Chemical Engineers Handbook, 8th edition, McGraw Hill

    • Number of peer-reviewed journals and websites (advised during lectures) [some examples below]

  1. Chemical Engineering Journal

  2. Journal of Chemical and Engineering Data

  3. Oil and Gas Journal

  4. Chemical Engineering

  5. EIT notes

Unit Content:

One topic is delivered per contact week, with the exception of part-time 24-week units, where one topic is delivered every two weeks.

Topic 1

Introduction to Process Engineering

  1. Definition of a process, process modelling and design

  2. Process operations commonly encountered

  3. Concept of process integration

  4. Walk-through typical processes

  5. Process measurement and control – instrumentation, measurement, control and material of construction.

Topics 2, 3 and 4

Principles of Chemical Engineering Thermodynamics

  1. The laws of Thermodynamics

  2. Thermodynamics processes

  3. Common cycles (e.g. Rankine, Brayton)

  4. Equations of state – Major, Cubic and Non Cubic

  5. Mathematical Modelling

    Topics 5 and 6

    Flow Phenomena and momentum transfer

    1. Statics and hydraulics

    2. Flow through a pipe

    3. Laminar and turbulent flow. Flow around objects.

    4. Flow through Packed Beds and Fluidized Beds

    5. Particle flow

    6. Multiphase flow

    7. Momentum transfer

    8. Flow equipment and measurement

Topics 7 and 8

Fundamentals of heat transfer

  1. Concepts of heat and mass transfer

  2. Steady state conduction through simple and composite flat walls

  3. Convective heat transfer, finned walls

  4. Stoichiometry and chemical process calculations

  5. Design Concepts

  6. Application to instrumentation and control

Topic 9

Fundamentals of mass transfer

  1. Diffusion

  2. Convective mass transfer

  3. Fick’s law of diffusion through stagnant layers

  4. Two film theory

  5. Mass transfer coefficients

  6. Mathematic modelling of heat and mass transfer

Topics 10 and 11

Chemical kinetics

  1. Introduction to chemical reaction engineering

  2. Rates and kinetics

  3. Catalysis

  4. Fundamentals of reactor design - Batch and continuous processes, Mixed processes, Plug flow, Mean residence time, Residence time distribution.

  5. Typical reaction process (e.g. steam reforming of natural gas)

Topic 12

Plant layout

Overview of plant layout, emphasising the process engineering aspects.

  1. Considerations in laying out a process plant

  2. Preservation of process intent, controllability

  3. Safety