This title presents design as a creative process that integrates both the big picture and the small details – and knows which to stress when, and why. Realistic from start to finish, it moves readers beyond classroom exercises into open-ended, real-world process problem solving. Material on the CD-ROM xix Preface xxiii About the Authors xxvii List of Nomenclature xxix SECTION 1: CONCEPTUALIZATION AND ANALYSIS OF CHEMICAL PROCESSES 1 Chapter 1: Diagrams for Understanding Chemical Processes 5 1.1 Block Flow Diagrams (BFDs) 7 1.2 Process Flow Diagram (PFD) 9 1.3 Piping and Instrumentation Diagram (P&ID) 26 1.4 Additional Diagrams 32 1.5 Three-Dimensional Representation of a Process 33 1.6 The 3-D Plant Model 42 1.7 Summary 44 References 45 Short Answer Questions 45 Problems 46 Chapter 2: The Structure and Synthesis of Process Flow Diagrams 51 2.1 Hierarchy of Process Design 51 2.2 Step 1-Batch versus Continuous Process 52 2.3 Step 2-The Input/Output Structure of the Process 57 2.4 Step 3-The Recycle Structure of the Process 68 2.5 Step 4-General Structure of the Separation System 84 2.6 Step 5-Heat-Exchanger Network or Process Energy Recovery System 84 2.7 Information Required and Sources 84 2.8 Summary 84 References 86 Short Answer Questions 88 Problems 88 Chapter 3: Batch Processing 93 3.1 Design Calculations for Batch Processes 93 3.2 Gantt Charts and Scheduling 100 3.3 Nonoverlapping, Overlapping Operations, and Cycle Times 101 3.4 Flowshop and Jobshop Plants 104 3.5 Product and Intermediate Storage and Parallel Process Units 110 3.6 Design of Equipment for Multiproduct Batch Processes 116 3.7 Summary 119 References 119 Short Answer Questions 119 Problems 120 Chapter 4: Chemical Product Design 123 4.1 Strategies for Chemical Product Design 124 4.2 Needs 126 4.3 Ideas 128 4.4 Selection 129 4.5 Manufacture 131 4.6 Batch Processing 132 4.7 Economic Considerations 132 4.8 Summary 133 References 133 Chapter 5: Tracing Chemicals through the Process Flow Diagram 135 5.1 Guidelines and Tactics for Tracing Chemicals 135 5.2 Tracing Primary Paths Taken by Chemicals in a Chemical Process 136 5.3 Recycle and Bypass Streams 142 5.4 Tracing Nonreacting Chemicals 146 5.5 Limitations 147 5.6 Written Process Description 147 5.7 Summary 149 Problems 149 Chapter 6: Understanding Process Conditions 151 6.1 Conditions of Special Concern for the Operation of Separation and Reactor Systems 152 6.2 Reasons for Operating at Conditions of Special Concern 154 6.3 Conditions of Special Concern for the Operation of Other Equipment 159 6.4 Analysis of Important Process Conditions 163 6.5 Summary 171 References 172 Short Answer Questions 172 Problems 172 SECTION 2: ENGINEERING ECONOMIC ANALYSIS OF CHEMICAL PROCESSES 175 Chapter 7: Estimation of Capital Costs 177 7.1 Classifications of Capital Cost Estimates 177 7.2 Estimation of Purchased Equipment Costs 181 7.3 Estimating the Total Capital Cost of a Plant 187 7.4 Summary 215 References 215 Short Answer Questions 216 Problems 216 Chapter 8: Estimation of Manufacturing Costs 221 8.1 Factors Affecting the Cost of Manufacturing a Chemical Product 221 8.2 Cost of Operating Labor 226 8.3 Utility Costs 228 8.4 Raw Material Costs 244 8.5 Yearly Costs and Stream Factors 246 8.6 Estimating Utility Costs from the PFD 247 8.7 Cost of Treating Liquid and Solid Waste Streams 250 8.8 Evaluation of Cost of Manufacture for the Production of Benzene via the Hydrodealkylation of Toluene 250 8.9 Summary 251 References 252 Short Answer Questions 252 Problems 253 Chapter 9: Engineering Economic Analysis 257 9.1 Investments and the Time Value of Money 258 9.2 Different Types of Interest 262 9.3 Time Basis for Compound Interest Calculations 264 9.4 Cash Flow Diagrams 266 9.5 Calculations from Cash Flow Diagrams 270 9.6 Inflation 276 9.7 Depreciation of Capital Investment 279 9.8 Taxation, Cash Flow, and Profit 286 9.9 Summary 288 References 290 Short Answer Questions 290 Problems 291 Chapter 10: Profitability Analysis 297 10.1 A Typical Cash Flow Diagram for a New Project 297 10.2 Profitability Criteria for Project Evaluation 299 10.3 Comparing Several Large Projects: Incremental Economic Analysis 308 10.4 Establishing Acceptable Returns from Investments: The Concept of Risk 311 10.5 Evaluation of Equipment Alternatives 312 10.6 Incremental Analysis for Retrofitting Facilities 319 10.7 Evaluation of Risk in Evaluating Profitability 325 10.8 Profit Margin Analysis 344 10.9 Summary 345 References 346 Short Answer Questions 346 Problems 347 SECTION 3: SYNTHESIS AND OPTIMIZATION OF CHEMICAL PROCESSES 361 Chapter 11: Utilizing Experience-Based Principles to Confirm the Suitability of a Process Design 363 11.1 The Role of Experience in the Design Process 364 11.2 Presentation of Tables of Technical Heuristics and Guidelines 368 11.3 Summary 371 References 389 Problems 389 Chapter 12: Synthesis of the PFD from the Generic BFD 391 12.1 Information Needs and Sources 392 12.2 Reactor Section 394 12.3 Separator Section 396 12.4 Reactor Feed Preparation and Separator Feed Preparation Sections 415 12.5 Recycle Section 416 12.6 Environmental Control Section 416 12.7 Major Process Control Loops 416 12.8 Flow Summary Table 417 12.9 Major Equipment Summary Table 417 12.10 Summary 418 References 418 Problems 419 Chapter 13: Synthesis of a Process Using a Simulator and Simulator Troubleshooting 423 13.1 The Structure of a Process Simulator 424 13.2 Information Required to Complete a Process Simulation: Input Data 428 13.3 Handling Recycle Streams 441 13.4 Choosing Thermodynamic Models 443 13.5 Case Study: Toluene Hydrodealkylation Process 457 13.6 Summary 460 References 460 Problems 461 Chapter 14: Process Optimization 465 14.1 Background Information on Optimization 465 14.2 Strategies 471 14.3 Topological Optimization 476 14.4 Parametric Optimization 484 14.5 Lattice Search Techniques versus Response Surface Techniques 496 14.6 Process Flexibility and the Sensitivity of the Optimum 497 14.7 Optimization in Batch Systems 497 14.8 Summary 506 References 507 Short Answer Questions 507 Problems 507 Chapter 15: Pinch Technology 521 15.1 Introduction 521 15.2 Heat Integration and Network Design 522 15.3 Composite Temperature-Enthalpy Diagram 539 15.4 Composite Enthalpy Curves for Systems without a Pinch 540 15.5 Using the Composite Enthalpy Curve to Estimate Heat-Exchanger Surface Area 541 15.6 Effectiveness Factor (F) and the Number of Shells 545 15.7 Combining Costs to Give the EAOC for the Network 552 15.8 Other Considerations 554 15.9 Heat-Exchanger Network Synthesis Analysis and Design (HENSAD) Program 559 15.10 Mass-Exchange Networks 560 15.11 Summary 570 References 570 Short Answer Questions 571 Problems 572 SECTION 4: ANALYSIS OF PROCESS PERFORMANCE 579 Chapter 16: Process Input/Output Models 583 16.1 Representation of Process Inputs and Outputs 584 16.2 Analysis of the Effect of Process Inputs on Process Outputs 587 16.3 A Process Example 588 16.4 Summary 590 Problems 591 Chapter 17: Tools for Evaluating Process Performance 593 17.1 Key Relationships 593 17.2 Thinking with Equations 595 17.3 Base-Case Ratios 597 17.4 Analysis of Systems Using Controlling Resistances 599 17.5 Graphical Representations 601 17.6 Summary 606 Reference 607 Problems 607 Chapter 18: Performance Curves for Individual Unit Operations 609 18.1 Applications to Heat Transfer 611 18.2 Application to Fluid Flow 617 18.3 Application to Separation Problems 633 18.4 Summary 647 Reference 648 Short Answer Questions 648 Problems 650 Chapter 19: Performance of Multiple Unit Operations 659 19.1 Analysis of a Reactor with Heat Transfer 659 19.2 Performance of a Distillation Column 664 19.3 Performance of a Heating Loop 671 19.4 Performance of the Feed Section to a Process 677 19.5 Summary 681 References 682 Short Answer Questions 682 Problems 682 Chapter 20: Reactor Performance 699 20.1 Production of Desired Product 701 20.2 Reaction Kinetics and Thermodynamics 703 20.3 The Chemical Reactor 706 20.4 Heat Transfer in the Chemical Reactor 712 20.5 Reactor System Case Studies 715 20.6 Summary 730 References 731 Short Answer Questions 731 Problems 732 Chapter 21: Regulating Process Conditions 737 21.1 A Simple Regulation Problem 738 21.2 The Characteristics of Regulating Valves 740 21.3 Regulating Flowrates and Pressures 742 21.4 The Measurement of Process Variables 746 21.5 Common Control Strategies Used in Chemical Processes 746 21.6 Exchanging Heat and Work between Process and Utility Streams 753 21.7 Case Studies 761 21.8 Summary 767 References 768 Problems 768 Chapter 22: Process Troubleshooting and Debottlenecking 773 22.1 Recommended Methodology 775 22.2 Troubleshooting Individual Units 780 22.3 Troubleshooting Multiple Units 787 22.4 A Process Troubleshooting Problem 792 22.5 Debottlenecking Problems 798 22.6 Summary 799 References 799 Problems 799 SECTION 5: THE IMPACT OF CHEMICAL ENGINEERING DESIGN ON SOCIETY 809 Chapter 23: Ethics and Professionalism 811 23.1 Ethics 812 23.2 Professional Registration 833 23.3 Legal Liability 839 23.4 Business Codes of Conduct 841 23.5 Summary 842 References 842 Problems 844 Chapter 24: Health, Safety, and the Environment 847 24.1 Risk Assessment 848 24.2 Regulations and Agencies 851 24.3 Fires and Explosions 863 24.4 Process Hazard Analysis 865 24.5 Chemical Safety and Hazard Investigation Board 875 24.6 Inherently Safe Design 875 24.7 Summary 876 24.8 Glossary 876 References 878 Problems 879 Chapter 25: Green Engineering 881 25.1 Environmental Regulations 881 25.2 Environmental Fate of Chemicals 883 25.3 Green Chemistry 886 25.4 Pollution Prevention during Process Design 887 25.5 Analysis of a PFD for Pollution Performance and Environmental Performance 890 25.6 An Example of the Economics of Pollution Prevention 891 25.7 Life Cycle Analysis 892 25.8 Summary 893 References 894 Problems 895 SECTION 6: INTERPERSONAL AND COMMUNICATION SKILLS 897 Chapter 26: Teamwork 899 26.1 Groups 899 26.2 Group Evolution 910 26.3 Teams and Teamwork 913 26.4 Misconceptions 916 26.5 Learning in Teams 917 26.6 Other Reading 918 26.7 Summary 920 References 920 Problems 921 Appendix A: Cost Equations and Curves for the CAPCOST Program 923 A.1 Purchased Equipment Costs 923 A.2 Pressure Factors 941 A.3 Material Factors and Bare Module Factors 945 References 954 Appendix B: Information for the Preliminary Design of Eleven Chemical Processes 955 B.1 DME Production, Unit 200 956 B.2 Ethyl Benzene Production, Unit 300 962 B.3 Styrene Production, Unit 400 970 B.4 Drying Oil Production, Unit 500 978 B.5 Production of Maleic Anhydride from Benzene, Unit 600 984 B.6 Ethylene Oxide Production, Unit 700 991 B.7 Formalin Production, Unit 800 1000 B.8 Batch Production of L-Phenylalanine and L-Aspartic Acid, Unit 900 1007 B.9 Acrylic Acid Production via the Catalytic Partial Oxidation of Propylene 1015 B.10 Production of Acetone via the Dehydrogenation of Isopropyl Alcohol (IPA), Unit 1100 1026 B.11 Production of Heptenes from Propylene and Butenes, Unit 1200 1035 Index 1045
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