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by Debangsu Bhattacharyya, Joseph A. Shaeiwitz, Wallace B. Whiting, Richard C. Bail
Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition
Title Page
Copyright Page
Contents
Material on the CD-ROM
Preface
About the Authors
List of Nomenclature
Section I. Conceptualization and Analysis of Chemical Processes
Chapter 1. Diagrams for Understanding Chemical Processes
1.1. Block Flow Diagram (BFD)
1.2. Process Flow Diagram (PFD)
1.3. Piping and Instrumentation Diagram (P&ID)
1.4. Additional Diagrams
1.5. Three-Dimensional Representation of a Process
1.6. The 3-D Plant Model
1.7. Operator and 3-D Immersive Training Simulators
1.8. Summary
References
Short Answer Questions
Problems
Chapter 2. The Structure and Synthesis of Process Flow Diagrams
2.1. Hierarchy of Process Design
2.2. Step 1—Batch Versus Continuous Process
2.3. Step 2—The Input/Output Structure of the Process
2.4. Step 3—The Recycle Structure of the Process
2.5. Step 4—General Structure of the Separation System
2.6. Step 5—Heat-Exchanger Network or Process Energy Recovery System
2.7. Information Required and Sources
2.8. Summary
References
Short Answer Questions
Problems
Chapter 3. Batch Processing
3.1. Design Calculations for Batch Processes
3.2. Gantt Charts and Scheduling
3.3. Nonoverlapping Operations, Overlapping Operations, and Cycle Times
3.4. Flowshop and Jobshop Plants
3.5. Product and Intermediate Storage and Parallel Process Units
3.6. Design of Equipment for Multiproduct Batch Processes
3.7. Summary
References
Short Answer Questions
Problems
Chapter 4. Chemical Product Design
4.1. Strategies for Chemical Product Design
4.2. Needs
4.3. Ideas
4.4. Selection
4.5. Manufacture
4.6. Batch Processing
4.7. Economic Considerations
4.8. Summary
References
Chapter 5. Tracing Chemicals through the Process Flow Diagram
5.1. Guidelines and Tactics for Tracing Chemicals
5.2. Tracing Primary Paths Taken by Chemicals in a Chemical Process
5.3. Recycle and Bypass Streams
5.4. Tracing Nonreacting Chemicals
5.5. Limitations
5.6. Written Process Description
5.7. Summary
Problems
Chapter 6. Understanding Process Conditions
6.1. Conditions of Special Concern for the Operation of Separation and Reactor Systems
6.2. Reasons for Operating at Conditions of Special Concern
6.3. Conditions of Special Concern for the Operation of Other Equipment
6.4. Analysis of Important Process Conditions
6.5. Summary
References
Short Answer Questions
Problems
Section II. Engineering Economic Analysis of Chemical Processes
Chapter 7. Estimation of Capital Costs
7.1. Classifications of Capital Cost Estimates
7.2. Estimation of Purchased Equipment Costs
7.3. Estimating the Total Capital Cost of a Plant
7.4. Summary
References
Short Answer Questions
Problems
Chapter 8. Estimation of Manufacturing Costs
8.1. Factors Affecting the Cost of Manufacturing a Chemical Product
8.2. Cost of Operating Labor
8.3. Utility Costs
8.4. Raw Material Costs
8.5. Yearly Costs and Stream Factors
8.6. Estimating Utility Costs from the PFD
8.7. Cost of Treating Liquid and Solid Waste Streams
8.8. Evaluation of Cost of Manufacture for the Production of Benzene Via the Hydrodealkylation of Toluene
8.9. Summary
References
Short Answer Questions
Problems
Chapter 9. Engineering Economic Analysis
9.1. Investments and the Time Value of Money
9.2. Different Types of Interest
9.3. Time Basis for Compound Interest Calculations
9.4. Cash Flow Diagrams
9.5. Calculations from Cash Flow Diagrams
9.6. Inflation
9.7. Depreciation of Capital Investment
9.8. Taxation, Cash Flow, and Profit
9.9. Summary
References
Short Answer Questions
Problems
Chapter 10. Profitability Analysis
10.1. A Typical Cash Flow Diagram for a New Project
10.2. Profitability Criteria for Project Evaluation
10.3. Comparing Several Large Projects: Incremental Economic Analysis
10.4. Establishing Acceptable Returns from Investments: The Concept of Risk
10.5. Evaluation of Equipment Alternatives
10.6. Incremental Analysis for Retrofitting Facilities
10.7. Evaluation of Risk in Evaluating Profitability
10.8. Profit Margin Analysis
10.9. Summary
References
Short Answer Questions
Problems
Section III. Synthesis and Optimization of Chemical Processes
Chapter 11. Utilizing Experience-Based Principles to Confirm the Suitability of a Process Design
11.1. The Role of Experience in the Design Process
11.2. Presentation of Tables of Technical Heuristics and Guidelines
11.3. Summary
References
Problems
Chapter 12. Synthesis of the PFD from the Generic BFD
12.1. Information Needs and Sources
12.2. Reactor Section
12.3. Separator Section
12.4. Reactor Feed Preparation and Separator Feed Preparation Sections
12.5. Recycle Section
12.6. Environmental Control Section
12.7. Major Process Control Loops
12.8. Flow Summary Table
12.9. Major Equipment Summary Table
12.10. Summary
References
General Reference
Problems
Chapter 13. Synthesis of a Process Using a Simulator and Simulator Troubleshooting
13.1. The Structure of a Process Simulator
13.2. Information Required to Complete a Process Simulation: Input Data
13.3. Handling Recycle Streams
13.4. Choosing Thermodynamic Models
13.5. Case Study: Toluene Hydrodealkylation Process
13.6. Electrolyte Systems Modeling
13.7. Solids Modeling
Appendix 13.1. Calculation of Excess Gibbs Energy for Electrolyte Systems
Appendix 13.2. Steps to Build a Model of a Distillation Column for an Electrolyte System Using a Rate-Based Simulation with a Film Model for Mass Transfer, the Parameters Required at Each Stage, and P
13.8. Summary
References
Short Answer Questions
Problems
Chapter 14. Process Optimization
14.1. Background Information on Optimization
14.2. Strategies
14.3. Topological Optimization
14.4. Parametric Optimization
14.5. Lattice Search Techniques versus Response Surface Techniques
14.6. Process Flexibility and the Sensitivity of the Optimum
14.7. Optimization in Batch Systems
14.8. Summary
References
Short Answer Questions
Problems
Chapter 15. Pinch Technology
15.1. Introduction
15.2. Heat Integration and Network Design
15.3. Composite Temperature-Enthalpy Diagram
15.4. Composite Enthalpy Curves for Systems without a Pinch
15.5. Using the Composite Enthalpy Curve to Estimate Heat-Exchanger Surface Area
15.6. Effectiveness Factor (F) and the Number of Shells
15.7. Combining Costs to Give the Eaoc for the Network
15.8. Other Considerations
15.9. Heat-Exchanger Network Synthesis Analysis and Design (HENSAD) Program
15.10. Mass-Exchange Networks
15.11. Summary
References
Short Answer Questions
Problems
Chapter 16. Advanced Topics Using Steady-State Simulators
16.1. Why the Need for Advanced Topics in Steady-State Simulation?
16.2. User-Added Models
16.3. Solution Strategy for Steady-State Simulations
16.4. Studies with the Steady-State Simulation
16.5. Estimation of Physical Property Parameters
16.6. Summary
References
Short Answer Questions
Problems
Chapter 17. Using Dynamic Simulators in Process Design
17.1. Why is there a Need for Dynamic Simulation?
17.2. Setting Up a Dynamic Simulation
17.3. Dynamic Simulation Solution Methods
17.4. Process Control
17.5. Summary
References
Short Answer Questions
Problems
Chapter 18. Regulation and Control of Chemical Processes with Applications Using Commercial Software
18.1. A Simple Regulation Problem
18.2. The Characteristics of Regulating Valves
18.3. Regulating Flowrates and Pressures
18.4. The Measurement of Process Variables
18.5. Common Control Strategies Used in Chemical Processes
18.6. Exchanging Heat and Work Between Process and Utility Streams
18.7. Logic Control
18.8. Advanced Process Control
18.9. Case Studies
18.10. Putting it all Together: The Operator Training Simulator (OTS)
18.11. Summary
References
Problems
Section IV. Analysis of Process Performance
Chapter 19. Process Input/Output Models
19.1. Representation of Process Inputs and Outputs
19.2. Analysis of the Effect of Process Inputs on Process Outputs
19.3. A Process Example
19.4. Summary
Problems
Chapter 20. Tools for Evaluating Process Performance
20.1. Key Relationships
20.2. Thinking with Equations
20.3. Base-Case Ratios
20.4. Analysis of Systems Using Controlling Resistances
20.5. Graphical Representations
20.6. Summary
Reference
Problems
Chapter 21. Performance Curves for Individual Unit Operations
21.1. Application to Heat Transfer
21.2. Application to Fluid Flow
21.3. Application to Separation Problems
21.4. Summary
Reference
Short Answer Questions
Problems
Chapter 22. Performance of Multiple Unit Operations
22.1. Analysis of a Reactor with Heat Transfer
22.2. Performance of a Distillation Column
22.3. Performance of a Heating Loop
22.4. Performance of the Feed Section to a Process
22.5. Summary
References
Short Answer Questions
Problems
Chapter 23. Reactor Performance
23.1. Production of Desired Product
23.2. Reaction Kinetics and Thermodynamics
23.3. The Chemical Reactor
23.4. Heat Transfer in the Chemical Reactor
23.5. Reactor System Case Studies
23.6. Summary
References
Short Answer Questions
Problems
Chapter 24. Process Troubleshooting and Debottlenecking
24.1. Recommended Methodology
24.2. Troubleshooting Individual Units
24.3. Troubleshooting Multiple Units
24.4. A Process Troubleshooting Problem
24.5. Debottlenecking Problems
24.6. Summary
References
Problems
Section V. The Impact of Chemical Engineering Design on Society
Chapter 25. Ethics and Professionalism
25.1. Ethics
25.2. Professional Registration
25.3. Legal Liability [13]
25.4. Business Codes of Conduct [14, 15]
25.5. Summary
References
Problems
Chapter 26. Health, Safety, and the Environment
26.1. Risk Assessment
26.2. Regulations and Agencies
26.3. Fires and Explosions
26.4. Process Hazard Analysis
26.5. Chemical Safety and Hazard Investigation Board
26.6. Inherently Safe Design
26.7. Summary
26.8. Glossary
References
Problems
Chapter 27. Green Engineering
27.1. Environmental Regulations
27.2. Environmental Fate of Chemicals
27.3. Green Chemistry
27.4. Pollution Prevention During Process Design
27.5. Analysis of a PFD for Pollution Performance and Environmental Performance
27.6. An Example of the Economics of Pollution Prevention
27.7. Life Cycle Analysis
27.8. Summary
References
Problems
Section VI. Interpersonal and Communication Skills
Chapter 28. Teamwork
28.1. Groups
28.2. Group Evolution
28.3. Teams and Teamwork
28.4. Misconceptions
28.5. Learning in Teams
28.6. Other Reading
28.7. Summary
References
Problems
Appendix A. Cost Equations and Curves for the CAPCOST Program
A.1. Purchased Equipment Costs
A.2. Pressure Factors
A.3. Material Factors And Bare Module Factors
References
Index
Chapter 0. Outcomes Assessment
0.1. Student Self-Assessment
0.2. Assessment by Faculty
0.3. Summary
References
Other References
Chapter 29. Written and Oral Communication
29.1. Audience Analysis
29.2. Written Communication
29.3. Oral Communication
29.4. Software and Author Responsibility
29.5. Summary
References
Problems
Chapter 30. A Report-Writing Case Study
30.1. The Assignment Memorandum
30.2. Response Memorandum
30.3. Visual Aids
30.4. Example Reports
30.5. Checklist of Common Mistakes and Errors
Appendix B. Information for the Preliminary Design of Fifteen Chemical Processes
B.1. Dimethyl Ether (DME) Production, Unit 200
B.2. Ethylbenzene Production, Unit 300
B.3. Styrene Production, Unit 400
B.4. Drying Oil Production, Unit 500
B.5. Production Of Maleic Anhydride From Benzene, Unit 600
B.6. Ethylene Oxide Production, Unit 700
B.7. Formalin Production, Unit 800
B.8. Batch Production Of L-Phenylalanine And L-Aspartic Acid, Unit 900
B.9. Acrylic Acid Production Via The Catalytic Partial Oxidation Of Propylene [1, 2, 3, 4, 5], Unit 1000
B.10. Production Of Acetone Via The Dehydrogenation Of Isopropyl Alcohol (IPA) [1, 2, 3, 4], Unit 1100
B.11. Production Of Heptenes From Propylene And Butenes [1], Unit 1200
B.12. Design of a Shift Reactor Unit to Convert Co To Co2, Unit 1300
B.13. Design of a Dual-Stage Selexol Unit to Remove CO2 And H2S From Coal-Derived Synthesis Gas, Unit 1400
B.14. Design of a Claus Unit For the Conversion of H2s to Elemental Sulfur, Unit 1500
B.15. Modeling a Downward-Flow, Oxygen-Blown, Entrained-Flow Gasifier, Unit 1600
Appendix C. Design Projects
Project 1. Increasing the Production of 3-Chloro-1-Propene (Allyl Chloride) in Unit 600
PROJECT 2. Design and Optimization of a New 20,000-Metric-Tons-per-Year Facility to Produce Allyl Chloride at La Nueva Cantina, Mexico
PROJECT 3. Scale-Down of Phthalic Anhydride Production at TBWS Unit 700
PROJECT 4. The Design of a New 100,000-Metric-Tons-per-Year Phthalic Anhydride Production Facility
PROJECT 5. Problems at the Cumene Production Facility, Unit 800
PROJECT 6. Design of a New, 100,000-Metric-Tons-per-Year Cumene Production Facility
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