Objective: The purpose of the Design Projects is to provide you with an opportunity to place your course work knowledge into a process context.

Scope: The emphasis in design is on the upstream section of a process involving: 1.) bioreactor design with a careful analysis of the growth kinetics, mass and heat transfer requirements, 2.) air sterilization, 3.) media sterilization, 4.) utilities and raw materials requirements. A downstream process flow diagram should be synthesized based on ideas from the literature or good engineering judgement. The sizing and costing of this section of the plant can be done with BioProDesigner or any other process simulator.

Process Economics: An economic analysis should be done to assess the operating and fixed costs for the process. A sensitivity analysis is required to determine the effect of primary operating parameters on economic return and to suggest a program for R&D for process improvement.

Report Format: Each team should prepare a single report documenting the design and presenting the results. A typical organization includes:

Introduction - describe the process, product and market, competitive processes and products. Pertinent literature or patent references should be included.

Design Rationale - This should describe in detail the basis for selecting the process configuration and size of the plant

Process Description - A process flow diagram (PFD) should be presented showing all major pieces of equipment. The text should describe the flow of materials and any significant steps.

Process Design - This section should take one through each major unit operation, provide the information on which the unit was designed and sized. Important calculations can be included here or placed in an appendix. A stream report and equipment list should be provided. All assumptions should be noted and documented where appropriate.

Economic analysis - A base case economic analysis should be presented along with a discussion of major costs. A set of sensitivity analysis should be done to test the design for its weak points and to provide the basis for R&D recommendations.

Conclusion and Recommendations - Should you commit the capital to build and operate the process as you designed it. What changes would or could be made to improve the process relative to your base case?

Presentations: At the end of the term, each team wll make a presentation of their design.