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Analysis, Synthesis, and Design of Chemical Processes

ISBN: 9780135705650 | 0135705657
Edition: Disk
Format: Hardcover
Publisher: Pearson College Div
Pub. Date: 11/1/1997

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SummaryTable of Contents
For upper-level undergraduate chemical engineering courses in Chemical Engineering Process Design, an A.B.E.T. requirement.Designed to help chemical engineering students make the transition from solving well-posed problems in a specific subject to integrating and applying all the knowledge they have gained to solving open-ended process problems. It is intended to help students hone their design skills through process design, rather than plant design and move them toward becoming practicing engineers. In that way, the book takes a systems- oriented approach, rather than to simply provide a compendium of design information.
Prefacexvii(4)
List of Nomenclaturexxi
SECTION 0 CHEMICAL PROCESS DIAGRAMS1(38)
Chapter 1 Essential Flow Diagrams for Understanding Processes
5... MORE
1.1 Block Flow Diagrams (BFD)
7(2)
1.1.1 Block Flow Process Diagram
7(2)
1.1.2 Block Flow Plant Diagrams
9(1)
1.2 Process Flow Diagrams (PFD)
9(17)
1.2.1 Process Topology
12(5)
1.2.2 Stream Information
17(2)
1.2.3 Equipment Information
19(3)
1.2.4 Combining Topology, Stream Data, and Control Strategy to Give a PFD
22(4)
1.3 Piping and Instrumentation Diagram (P&ID)
26(6)
1.4 Additional Diagrams
32(1)
1.5 Summary
33(1)
References
33(1)
Problems
34(5)
SECTION 1 ENGINEERING ECONOMIC ANALYSIS OF CHEMICAL PROCESSES39(138)
Chapter 2 Estimation of Capital Costs
41(36)
2.1 Classifications of Capital Cost Estimates
41(5)
2.2 Estimating Purchased Equipment Costs
46(6)
2.2.1 Effect of Capacity on Purchased Equipment Cost
46(3)
2.2.2 Effect of Time on Purchased Equipment Cost
49(3)
2.3 Estimating the Total Capital Cost of a Plant
52(20)
2.3.1 Bare Module Cost for Equipment at Base Conditions
57(5)
2.3.2 Bare Module Cost for Non-Base Case Conditions
62(5)
2.3.3 Grass Roots and Total Module Costs
67(3)
2.3.4 A Computer Program [CAPCOSTXXX] for Capital Cost Estimation Using the Equipment Module Approach
70(2)
2.4 Summary
72(1)
References
73(1)
Problems
73(4)
Chapter 3 Estimation of Manufacturing Costs
77(22)
3.1 Factors Affecting the Cost of Manufacturing a Chemical Product
77(5)
3.2 Cost of Operating Labor
82(3)
3.3 Utility Costs
85(6)
3.4 Raw Material Costs
91(1)
3.5 Yearly Costs and Stream Factors
92(1)
3.6 Estimating Utility Costs from the PFD
93(3)
3.7 Cost of Treating Liquid and Solid Waste Streams
96(1)
3.8 Evaluation of Cost of Manufacture for the Production of Benzene via the Hydrodealkylation of Toluene
96(1)
3.9 Summary
97(1)
References
97(1)
Problems
98(1)
Chapter 4 Engineering Economic Analysis
99(37)
4.1 Investments and the Time Value of Money
100(4)
4.2 Different Types of Interest
104(2)
4.2.1 Simple Interest
104(1)
4.2.2 Compound Interest
105(1)
4.2.3 Interest Rates Changing with Time
106(1)
4.3 Time Basis for Compound Interest Calculations
106(2)
4.3.1 Effective Annual Interest Rate
107(1)
4.3.2 Continuously Compounded Interest
107(1)
4.4 Cash Flow Diagrams
108(4)
4.4.1 Discrete Cash Flow Diagram
109(2)
4.4.2 Cumulative Cash Flow Diagram
111(1)
4.5 Calculations from Cash Flow Diagrams
112(6)
4.5.1 Annuities--A Uniform Series of Cash Transactions
114(1)
4.5.2 Discount Factors
114(4)
4.6 Inflation
118(3)
4.7 Depreciation of Capital Investment
121(5)
4.7.1 Fixed Capital, Working Capital, and Land
121(1)
4.7.2 Different Types of Depreciation
122(4)
4.8 Tazation, Cash Flow, and Profit
126(3)
4.9 Summary
129(1)
Problems
129(7)
Chapter 5 Profitability Analysis
136(41)
5.1 A Typical Cash Flow Diagram for a New Project
136(2)
5.2 Profitability Criteria for Project Evaluation
138(9)
5.2.1 Nondiscounted Profitability Criteria
139(2)
5.2.2 Discounted Profitability Criteria
141(6)
5.3 Comparing Several Large Projects--Incremental Economic Analysis
147(3)
5.4 Establishing Acceptable Returns from Investments: The Concept of Risk
150(1)
5.5 Evaluation of Equipment Alternatives
151(8)
5.5.1 Equipment with the Same Expected Operating Lives
152(1)
5.5.2 Equipment with Different Expected Operating Lives
152(7)
5.6 Incremental Analysis for Retrofitting Facilities
159(5)
5.6.1 Nondiscounted Methods for Incremental Analysis
159(3)
5.6.2 Discounted Methods for Incremental Analysis
162(2)
5.7 Profit Margin Analysis
164(1)
5.8 Summary
165(1)
Problems
165(12)
SECTION 2 TECHNICAL ANALYSIS OF A CHEMICAL PROCESS177(82)
Chapter 6 Structure of Chemical Process Flow Diagrams
179(11)
6.1 The Input-Output Structure of a Flow Diagram
179(5)
6.2 The Generic Block Flow Process Diagram
184(2)
6.3 Categorizing Equipment into Generic Function Blocks
186(2)
6.4 Summary
188(1)
Problems
188(2)
Chapter 7 Tracing Chemicals through the Process Flow Diagram
190(17)
7.1 Guidelines and Tactics for Tracing Chemicals
190(1)
7.2 Tracing Primary Paths Taken by Chemicals in a Chemical Process
191(8)
7.3 Recycle and Bypass Streams
199(4)
7.4 Tracing Non-Reacting Chemicals
203(1)
7.5 Limitations
204(1)
7.6 Written Process Description
204(2)
7.7 Summary
206(1)
Problems
206(1)
Chapter 8 Understanding Process Conditions
207(25)
8.1 Conditions of Special Concern for the Operation of Separation and Reactor Systems
208(2)
8.1.1 Pressure
208(1)
8.1.2 Temperature
209(1)
8.2 Reasons for Operating at Conditions of Special Concern
210(5)
8.3 Conditions of Special Concern for the Operation of Other Equipment
215(4)
8.4 Analysis of Important Process Conditions
219(8)
8.4.1 Evaluation of Reactor R-101
219(7)
8.4.2 Evaluation of High-Pressure Phase Separator V-101
226(1)
8.4.3 Evaluation of Large Temperature Driving Force in Exchanger E-101
227(1)
8.4.4 Evaluation of Exchanger E-102
227(1)
8.4.5 Pressure Control Value on Stream 8
227(1)
8.4.6 Pressure Control Value on Stream from V-101 to V-103
227(1)
8.5 Summary
227(1)
References
228(1)
Problems
228(4)
Chapter 9 Utilizing Experience-Based Principles to Confirm the Suitability of a Process Design
232(27)
9.1 The Role of Experience in the Design Process
233(4)
9.1.1 Introduction to Technical Heuristics and Short-Cut Methods
234(1)
9.1.2 Maximizing the Benefits Obtained from Experience
235(2)
9.2 Presentation of Tables of Technical Heuristics and Guidelines
237(21)
9.3 Summary
258(1)
References
258(1)
Problems
258(1)
SECTION 3 ANALYSIS OF SYSTEM PERFORMANCE259(204)
Chapter 10 Process Input/Output Models
263(9)
10.1 Representation of Process Inputs and Outputs
264(3)
10.2 Analysis of the Effect of Process Inputs on Process Outputs
267(2)
10.3 A Process Example
269(2)
10.4 Summary
271(1)
Problems
271(1)
Chapter 11 Tools for Evaluating System Performance
272(16)
11.1 Key Relationships
272(2)
11.2 Thinking with Equations
274(2)
11.2.1 GENI
274(1)
11.2.2 Predicting Trends
274(2)
11.3 Base Case Ratios
276(2)
11.4 Analysis of Systems Using Controlling Resistances
278(2)
11.5 Graphical Representations
280(6)
11.5.1 The Moody Diagram for Friction Factors
281(1)
11.5.2 The System Curve for Frictional Losses
281(2)
11.5.3 The T-Q Diagram for Heat Exchangers
283(3)
11.6 Summary
286(1)
References
286(1)
Problems
286(2)
Chapter 12 Performance Curves for Individual Unit Operations
288(45)
12.1 Applications to Heat Transfer
290(6)
12.2 Applications to Fluid Flow
296(16)
12.2.1 Pump and System Curves
296(7)
12.2.2 Regulating Flowrates
303(2)
12.2.3 Reciprocating or Positive Displacement Pumps
305(1)
12.2.4 Net Positive Suction Head
306(4)
12.2.5 Compressors
310(2)
12.3 Application to Separation Problems
312(14)
12.3.1 Separations with Mass Separating Agents
312(5)
12.3.2 Distillation
317(9)
12.4 Summary
326(1)
References
326(1)
Problems
326(7)
Chapter 13 Performance of Multiple Unit Operations
333(27)
13.1 Analysis of a Reactor with Heat Transfer
333(5)
13.2 Performance of a Distillation Column
338(7)
13.3 Performance of a Heating Loop
345(7)
13.4 Performance of the Feed Section to a Process
352(3)
13.5 Summary
355(1)
References
356(1)
Problems
356(4)
Chapter 14 Reactor Performance
360(36)
14.1 Production of Desired Product
362(2)
14.2 Reaction Kinetics and Thermodynamics
364(3)
14.2.1 Reaction Kinetics
364(2)
14.2.2 Thermodynamic Limitations
366(1)
14.3 The Chemical Reactor
367(5)
14.4 Heat Transfer in the Chemical Reactor
372(4)
14.5 Reactor System Case Studies
376(16)
14.5.1 Replacement of Catalytic Reactor in Benzene Process
377(5)
14.5.2 Replacement of Cumene Catalyst
382(5)
14.5.3 Increasing Acetone Production
387(5)
14.6 Summary
392(1)
References
392(1)
Problems
392(4)
Chapter 15 Regulating Process Conditions
396(36)
15.1 A Simple Regulation Problem
397(2)
15.2 The Characteristics of Regulating Valves
399(2)
15.3 Regulating Flowrates and Pressures
401(3)
15.4 The Measurement of Process Variables
404(1)
15.5 Common Control Strategies Used in Chemical Processes
405(7)
15.5.1 Feedback Control/Regulation
405(1)
15.5.2 Feedforward Control/Regulation
406(4)
15.5.3 Combination Feedback/Feedforward Control
410(1)
15.5.4 Cascade Regulation
411(1)
15.6 Exchanging Heat and Work between Process and Utility Streams
412(8)
15.6.1 Increasing the Pressure of a Process Stream and Regulating Its Flowrate
413(2)
15.6.2 Exchanging Heat between Process Streams and Utilities
415(5)
15.6.3 Exchanging Heat Between Process Streams
420(1)
15.7 Case Studies
420(6)
15.7.1 The Cumene Reactor R-701
420(2)
15.7.2 A Basic Control System for a Binary Distillation Column
422(3)
15.7.3 A More Sophisticated Control System for a Binary Distillation Column
425(1)
15.8 Summary
426(1)
References
427(1)
Problems
427(5)
Chapter 16 Process Troubleshooting and Debottlenecking
432(31)
16.1 Recommended Methodology
434(5)
16.1.1 Elements of Problem-Solving Strategies
434(3)
16.1.2 Application to Troubleshooting Problems
437(2)
16.2 Troubleshooting Individual Units
439(7)
16.2.1 Troubleshooting a Packed Bed Absorber
439(4)
16.2.2 Troubleshooting the Cumene Process Feed Section
443(3)
16.3 Troubleshooting Multiple Units
446(6)
16.3.1 Troubleshooting Off-Specification Acrylic Acid Product
446(2)
16.3.2 Troubleshooting Steam Release in Cumene Reactor
448(4)
16.4 A Process Troubleshooting Problem
452(5)
16.5 Debottlenecking Problems
457(1)
16.6 Summary
458(1)
References
458(1)
Problems
458(5)
SECTION 4 SYNTHESIS AND OPTIMIZATION OF A PROCESS FLOW DIAGRAM463(96)
Chapter 17 Synthesis of the PFD from the Generio BFD
465(13)
17.1 Information Needs and Sources
466(2)
17.1.1 Interactions with Other Engineers and Scientists
466(1)
17.1.2 Reaction Kinetics Data
466(1)
17.1.3 Physical Property Data
467(1)
17.2 Reactor Section
468(2)
17.3 Separator Section
470(3)
17.4 Reactor Feed Preparation and Separator Feed Preparation Sections
473(1)
17.5 Recycle Section
474(1)
17.6 Environmental Control Section
474(1)
17.7 Major Process Control Loops
475(1)
17.8 Flow Summary Table
475(1)
17.9 Major Equipment Summary Table
475(1)
17.10 Summary
476(1)
References
476(1)
Problems
477(1)
Chapter 18 Synthesis of a Process Using a Simulator and Simulator Troubleshooting
478(31)
18.1 The Structure of a Process Simulator
479(4)
18.2 Information Required to Complete a Process Simulation--Input Data
483(12)
18.2.1 Selection of Chemical Components
483(1)
18.2.2 Selection of Thermodynamic Model(s)
483(2)
18.2.3 Input the Topology of the Flowsheet
485(1)
18.2.4 Select Feed Stream Properties
485(1)
18.2.5 Select Equipment Parameters
486(8)
18.2.6 Selection of Output Display Options
494(1)
18.2.7 Selection of Convergence Criteria and Running Simulation
494(1)
18.3 Handling Recycle Streams
495(2)
18.4 Thermodynamic Models
497(6)
18.4.1 Physical Properties
498(1)
18.4.2 Enthalpy
498(1)
18.4.3 Phase Equilibria
499(2)
18.4.4 Using Thermodynamic Models
501(2)
18.5 Case Study--Toluene Hydrodealkylation Process
503(3)
18.6 Summary
506(1)
References
506(1)
Problems
507(2)
Chapter 19 Process Optimization
509(50)
19.1 Background Information on Optimization
509(6)
19.1.1 Common Misconceptions
511(2)
19.1.2 Estimating Problem Difficulty
513(1)
19.1.3 Top-down/Bottom-up Strategies
514(1)
19.1.4 Communication of Optimization Results
515(1)
19.2 Strategies
515(5)
19.2.1 Base Case
515(2)
19.2.2 Objective Functions
517(1)
19.2.3 Analysis of the Base Costs
518(1)
19.2.4 Identifying and Prioritizing Key Decision Variables
519(1)
19.3 Topological Optimization
520(20)
19.3.1 Introduction
520(1)
19.3.2 Elimination of Unwanted Non-Hazardous By-products or Hazardous Waste Streams
521(2)
19.3.3 Elimination and Rearrangement of Equipment
523(3)
19.3.4 Alternative Separation Schemes and Reactor Configurations
526(2)
19.3.5 Improvements in Heat Integration
528(12)
19.4 Parametric Optimization
540(12)
19.4.1 Single Variable Optimization: A Case Study on T-201, the DME Separation Column
541(3)
19.4.2 Two-Variable Optimization: The Effect of Pressure and Reflux Ratio on T-201, the DME Separation Column
544(3)
19.4.3 Flowsheet Optimization Using Key Decision Variables
547(5)
19.5 Lattice Search Techniques vs. Experimental Design
552(1)
19.6 Process Flexibility and the Sensitivity of the Optimum
553(1)
19.7 Summary
554(1)
References
554(1)
Problems
555(4)
SECTION 5 THE PROFESSIONAL ENGINEER, THE ENVIRONMENT, AND COMMUNICATIONS559(120)
Chapter 20 Ethics and Professionalism
561(31)
20.1 Ethics
562(21)
20.1.1 Moral Autonomy
563(1)
20.1.2 Rehearsal
564(1)
20.1.3 Reflection in Action
565(1)
20.1.4 Mobile Truth
566(2)
20.1.5 Nonprofessional Responsibilities
568(1)
20.1.6 Duties and Obligations
569(1)
20.1.7 Codes of Ethics
570(3)
20.1.8 Whistleblowing
573(8)
20.1.9 Ethical Dilemmas
581(1)
20.1.10 Additional Ethics Heuristics
582(1)
20.2 Professional Registration
583(3)
20.2.1 Engineer-in-Training
584(1)
20.2.2 Registered Professional Engineer
585(1)
20.3 Legal Liability
586(1)
20.4 Business Codes of Conduct
587(2)
References
589(1)
Problems
590(2)
Chapter 21 Health, Safety, and the Environment
592(30)
21.1 Risk Assessment
593(3)
21.1.1 Accident Statistics
593(1)
21.1.2 Worst Case Scenarios
594(1)
21.1.3 The Role of the Chemical Engineer
595(1)
21.2 Regulations and Agencies
596(15)
21.2.1 OSHA and NIOSH
596(10)
21.2.2 Environmental Protection Agency (EPA)
606(4)
21.2.3 Nongovernmental Organizations
610(1)
21.3 Fires and Explosions
611(2)
21.3.1 Terminology
611(2)
21.3.2 Pressure Relief Systems
613(1)
21.4 HAZOP
613(2)
21.5 Inherently Safe Design
615(1)
21.6 Pollution Prevention
616(1)
21.7 Life-Cycle Analysis
617(1)
21.8 Summary
618(1)
21.9 Glossary
618(2)
References
620(1)
Problems
621(1)
Chapter 22 Written and Oral Communications
622(28)
22.1 Audience Analysis
623(1)
22.2 Written Communication
624(12)
22.2.1 Design Reports
625(1)
22.2.2 Transmittal Letters or Memos
626(1)
22.2.3 Executive Summaries and Abstracts
626(1)
22.2.4 Other Types of Written Communication
627(1)
22.2.5 Exhibits (Figures and Tables)
628(1)
22.2.6 References
629(1)
22.2.7 Strategies for Writing
629(2)
22.2.8 WVU Guidelines for Written Design Report
631(5)
22.3 Oral Communications
636(7)
22.3.1 Formal Oral Presentations
638(1)
22.3.2 Briefings
638(1)
22.3.3 Visual Aids
639(1)
22.3.4 WVU Oral Presentation Guidelines
640(3)
22.4 Software and Author Responsibility
643(5)
22.4.1 Spell Checkers
644(1)
22.4.2 Thesaurus
644(1)
22.4.3 Grammar Checkers
644(1)
22.4.4 Graphs
645(1)
22.4.5 Tables
646(1)
22.4.6 Colors and Exotic Features
646(1)
22.4.7 Raw Output from Process Simulators
647(1)
22.5 Summary
648(1)
References
648(1)
Problems
648(2)
Chapter 23 A Report Writing Case Study
650(29)
23.1 Assignment Memorandum
650(2)
23.2 Response Memorandum
652(2)
23.3 Visual Aids
654(6)
23.4 Example Reports
660(16)
23.4.1 An Example of a Portion of a Student Report
661(3)
23.4.2 An Example of an Improved Student Written Report
664(12)
23.5 Checklist of Common Mistakes and Errors
676(3)
23.5.1 Common Mistakes for Visual Aids
676(1)
23.5.2 Common Mistakes for Written Text
677(2)
APPENDICES679(130)
Appendix A Cost Equations and Curves for the CAPCOST(XXX) Program
679(29)
A.1 Heat Exchangers
680(2)
A.2 Process Vessels and Internals
682(3)
A.2.1 Horizontal and Vertical Process Vessels
682(2)
A.2.2 Process Vessel Internals
684(1)
A.3 Pumps with Electric Drives
685(1)
A.4 Fans with Electric Drives
686(1)
A.5 Compressors and Blowers without Drives
687(1)
A.6 Drives for Compressors and Blowers
688(1)
A.7 Power Recovery Equipment
688(1)
A.8 Fired Heaters and Furnaces
688(3)
A.9 Vaporizers and Evaporators
691(17)
Appendix B Information for the Preliminary Design of Four Chemical Processes
708(39)
B.1 Production of Dimethyl Ether (DME) via the Dehydration of Methanol
709(7)
B.2 Acrylic Acid Production via the Catalytic Partial Oxidation of Propylene
716(12)
B.3 Production of Acetone via the Dehydrogenation of Isopropyl Alcohol (IPA)
728(8)
B.4 Production of Heptenes from Propylene and Butenes
736(11)
Appendix C Design Projects
747(62)
Project 1: Increasing the Production of 3-Chloro-1-Propene (Allyl Chloride) in Unit 600
749(15)
Project 2: Design and Optimization of a New 20,000 Metric Tons per Year Facility to Produce Allyl Chloride at La Nueva Cantina, Mexico
764(8)
Project 3: Scale-Down of Phthalic Anhydride Production at TBWS Unit 700
772(12)
Project 4: The Design of a New, 100,000 Metric Tons per Year, Phthalic Anhydride Production Facility
784(5)
Project 5: Problems at the Cumene Production Facility, Unit 800
789(15)
Project 6: Design of a New, 100,000 Metric Tons per Year Cumene Production Facility
804(5)
Index809

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