Senior process design-a decade of chemical plants

The senior design course in chemical engineering at Widener University covers two semesters. In the first semester, the students work on a common project selected by the professor. In the Fall 2001 semester, the project was the manufacture of ethylene from propane via steam pyrolysis. In previous years, choices were methanol, ammonia, metathesis and the like. The choice of plant is important since the widest range of design experience is most appropriate. During the four months of the fall term, students learn how to develop and critically evaluate a process design using state of the art simulation tools. In the second semester, students randomly pick a technology out of an envelope. The course requirements are for students to provide a process design package, including all technical and economic details for a world scale manufacturing facility, by the end of the semester. Students are also required to present and defend their design. This course structure is now in its tenth year. Feedback from the students has been positive and they exhibit pride and ownership in their work. Examples of successes, pitfalls, and the course assessment process over the past decade are discussed.