• Blended Learning & Flipped Classroom

The goal of the first part of the course is to make students understand flow diagrams commonly employed in the process industry (P&Is, PFD, …), use a simulation software (ASPEN HYSYS^®) to solve flowsheets, analyze the general “modus operandi” of engineering companies (typical project iter for an engineering contractor), etc. Attention is also paid to issues relevant to new or existing process plants, mainly plant evaluation (cost functions, capital cost estimating classifications, scaling factors, module costing technique), feasibility studies (economic vs. energy/exergy profitability indexes, discounted cash flow), efficient use of energy, managing of consumption peaks, etc. In case commercial software tools can be used. The second part of the course deals with an in-depth analysis of common systems in chemical processes and their typical process flow diagrams and P&Is. Seminars by experts from the industrial world are scheduled.

The course is taught in innovative teaching mode with approach blended learning / flipped classroom for 3 CFU. According to this approach, when dealing with some topics, students are introduced to the learning material before the lesson, and the classroom time is used to deepen the understanding through discussion with peers and problem-solving activities in small groups supported by the teacher. After the lesson, students think about the feedback they have received and use this to further improve their learning.

The course will allow students to:

• know how to draw the common diagrams daily used by the process engineer, which are the main issues in a process plant, how to manage a plant and how to perform an economic analysis, which are the service facilities and the systems out of battery limits of a process plant (conoscenza e comprensione – knowledge and understanding);
• be able to apply the acquired knowledge to specify all the main units needed in a process plant, including those of service facilities fundamental for the operation of the production units and to evaluate the optimal layout of a plant considering safety, energy and economic issues (capacità di applicare conoscenza e comprensione – applying knowledge and understanding);
• know how to use the simulation software ASPEN HYSYS^® to solve and optimize flowsheets (conoscenza e comprensione – knowledge and understanding);
• be able to autonomously learn new topics and apply theoretical ideas to find solutions to problems referring to fields different from the one presented during the course (capacità di apprendimento legata alla modalità di didattica innovativa – learning skills related to innovative teaching approach);
• be able to clearly explain the strategy used for solving problems, to impressively communicate the obtained results and to write a technical report (capacità di applicare conoscenza e comprensione legata alla modalità di didattica innovativa – applying knowledge and understanding related to innovative teaching approach).

The course is based on lectures and exercises, with part of the course (focusing on diagrams and on the main issues in process plants) taught in innovative teaching mode with a blended learning / flipped classroom.

The following topics will be covered:

• Diagrams: process scheme, BFD, PFD, P&Is, utility diagram. Use of process simulator (ASPEN HYSYS^®) to solve flowsheets;
• Main issues in process plants: economic evaluation, energy saving (hints on pinch technology), degrees of freedom and factors affecting productions, plant flexibility in response of variations of production demand;
• Common systems in chemical plants: pipelines, pipeline network; safety system, safety and risk, venting from pressure vessels, systems for conveying discharge, flares; service facilities; steam generation and condensate recovery (balances on steam and on condensate; diagrams; high-P, medium-P and low-P steam; description of the plant; boilers); fuel supply, fuel oil and fuel gas plants; water treatment; cooling water (open loop, closed loop, cooling towers); water treatment for boilers; instrument air system; systems out of battery limits; storage (atmospheric storage, pressure storage, refrigerated storage, heated storage; criteria for use and design); waste disposal system (hints); wastewater treatment (hints); loading systems for road and trail transport;
• Plant management: production target, test run, start-up, plant commissioning, shut-down and safety shut-down, emergency procedures (hints).

Seminars by experts from the industrial world are scheduled.

The exercises will focus on the application of the theory to case studies, with the use of the software ASPEN HYSYS^® to simulate the process and of Excel to analyze the results.

The students will also have the possibility of better understanding the development of separation processes starting from the analysis of phase equilibria by demonstration with experimental unit.

Students are required to know how to solve material and energy balances, phase equilibria and the basic principles of unit operations (columns, heat exchangers, …).

The final evaluation of learning will be obtained through an oral test, with questions about all the topics covered during the course. Each student must prepare a short technical report on all the exercises and problems considered during the course, which will be presented and discussed during the oral exam.

After having passed the examination, the student must be able to talk about and critically discuss all the topics presented during the course, showing the capabilities described in “Risultati di apprendimento attesi”.