542-0521/02 – Design of process lines (ppl)

The objective of this course is to familiarize students with modern approaches and methodologies for the design of production lines, with a focus on productivity and production quality. Emphasis will be placed on expanding and deepening students’ knowledge in the field of design. The course aims to prepare students to solve complex tasks related to the design and planning of production lines, with an emphasis on their technical functionality, operational reliability, safety, productivity, and production quality.

The course focuses on the design of process plants and technological production lines used primarily in mineral processing, recycling, waste treatment, and other industrial sectors that involve the handling and processing of particulate materials. Students gain an understanding of the individual stages of industrial plant development, from conceptual design and preparation of project documentation to permitting procedures and commissioning of technological systems. Emphasis is placed on the integration of technological requirements, civil engineering solutions, legislative regulations, occupational safety, and economic efficiency. The course introduces students to the legal framework governing industrial project development, including construction legislation, related technical regulations, and administrative procedures associated with permitting and approval processes. Particular attention is paid to the design of facilities in undermined areas, integration with technical infrastructure networks, and coordination between technological and civil engineering disciplines. A significant part of the course is dedicated to the design of technological units within process plants, especially systems for storage, handling, and transportation of bulk solids, as well as crushing, screening, storage, discharge, and belt conveying technologies. The course also covers process control systems, material flow logistics, product dispatch, and quality assurance through sampling and monitoring procedures. Furthermore, students become familiar with occupational health requirements, workplace ergonomics, noise and dust control measures, fire protection systems, and principles of occupational safety. Professional Knowledge Students explain the fundamental principles and methodologies used in the design of process plants and technological production lines. They describe the stages of project preparation and implementation and understand the legal and technical requirements associated with industrial project development, including construction legislation, technical standards, permitting procedures, and project approval processes. Students characterize the principles of industrial plant design, including projects located in undermined or geotechnically challenging areas and facilities requiring connection to technical infrastructure networks. They explain the interactions between technological, structural, transportation, and utility systems and their impact on the functionality of the overall process plant. Students describe the design principles of storage, handling, and transportation systems for bulk solids and explain the functions of individual technological units within process lines. They characterize the operational principles, design features, and applications of crushing, vibrating, storage, discharge, and conveying equipment and explain their role in ensuring production continuity and efficiency. Students explain the principles of process control, material flow management, product dispatch, and quality control systems. They describe the requirements related to occupational safety, workplace hygiene, noise and dust mitigation, and fire protection in industrial facilities. Professional Skills Students analyse technological requirements and develop basic process plant concepts with consideration for production capacity, product quality, operational reliability, and economic performance. They evaluate process relationships between individual operations and propose appropriate layouts of technological units. Students are able to interpret technical and project documentation, apply relevant legislation and technical standards, and use them in solving practical design tasks. They assess regulatory requirements and prepare documentation necessary for industrial project approval procedures. Students design basic solutions for the storage, handling, and transportation of bulk materials, including storage bins, transport routes, and associated technological equipment. They evaluate alternative design solutions with respect to material properties, plant capacity, spatial constraints, and technological requirements. Students identify potential risks related to plant operation, occupational safety, fire protection, and workplace hygiene, and propose suitable technical and organizational measures. They assess material flow logistics and design efficient systems for product dispatch and quality control. Generic Competencies Students independently solve complex engineering problems related to the design of process plants and production lines while integrating technological, structural, economic, safety, and legislative considerations. They critically evaluate technical data, design alternatives, and their implications for plant functionality, productivity, and operating costs. Students communicate effectively with engineers, technology specialists, investors, contractors, and public authorities and collaborate efficiently within multidisciplinary project teams. They clearly present and justify proposed solutions, supporting their decisions with technical and economic arguments. Students continuously develop their professional knowledge in the field of process plant design, monitor developments in engineering standards, legislation, digital design tools, and modern industrial technologies, and apply new knowledge to the design and modernization of industrial facilities. They perform their professional activities in accordance with the principles of occupational safety, fire protection, environmental responsibility, and sustainable industrial development.

CROWL D. A., LOUVAR J. F. Chemical Process Safety: Fundamentals with Applications. 5th Edition. Boston: Pearson, 2024, ISBN 978-0137879366. BAUSBACHER E., HUNT R. Process Plant Layout and Piping Design. Updated Edition. Houston: Gulf Professional Publishing, 2021, ISBN 978-0128239964. RAO D. V. Engineering Design of Material Handling Systems. Cham: Springer, 2022, ISBN 978-3030893217. INTERNATIONAL SOCIETY OF AUTOMATION. Automation, Control and Monitoring for Process Industries. Research Triangle Park: ISA, 2021. KUZNETSOV Y. (ed.) Advances in Bulk Material Handling and Conveying Systems. Cham: Springer, 2022.

A credit project with their successful exam in the group. Examination with written and oral parts.