Index
Numbers
3-D figures, improper use in oral presentations, 1217
3-D representation of process (plant model)
3-D immersive training simulators (ITS), 45
create preliminary plot plan, 34–37
divide PFD into logical subsystems, 34–35
elevation for all major equipment, 39–41
estimate major process pipe sizes, 37–38
overview of, 34
sketch major process and utility piping, 41
A
ABET engineering program accreditation
engineer-in-training (EIT) certification, 1122–1124
outcomes assessment and, 2
in acid-gas removal (AGR) plant, 457
heuristics for packed towers, 364
input for process simulation, 411
recycling inerts and, 76
separation of allyl chloride with HCl, 402–403
stripping columns as reboiled, 378
Absorption approach, to recycling raw materials, 72
executive summaries vs., 1198–1199
written report guidelines, 1203–1204
Accelerated depreciation schemes, 273
Accelerated successive substitution (or relaxation) methods, in steady-state simulation, 578
Accident statistics, in risk assessment, 1132–1133
Accuracy, in capital cost estimates, 172–174
Acetone production from isopropyl alcohol
making it greener, 1171
overview of, 1338
preliminary equipment summary, 1341–1343
process description, 1338–1339
references, 1346
simulation (CHEMCAD) hints, 1344
stream table, 1340
utility summary table, 1343
ACGIH (American Conference of Governmental and Industrial Hygienists), air contaminants standard, 1135
ACGIH (American Conference of Governmental and Industrial Hygienists), air contaminants standards, 1135
directed graph of, 573
equation-oriented approach, 585–586
flowsheet using chilled methanol, 581–582
steady-state simulation examples, 580–585
ACM (Aspen Custom Modeler), user-added models (UAMs), 563
separation example. See Steam ejectors
troubleshooting off-specification product, 1076–1078
Acrylic acid production from propylene
preliminary equipment summary, 1333–1336
process description, 1330–1331
reaction kinetics and reactor configuration, 1331–1333, 1337
references, 1337
simulation (CHEMCAD) hints, 1337
ACS (American Chemical Society), codes of conduct, 1119
Activated sludge, in biological waste treatment, 390
Activation energy, in reaction kinetics, 1300, 1306, 1375
Active pharmaceutical ingredient (API), production of, 92–97
binary interaction parameters (BIPs) and, 417
for electrolyte systems, 429–430
for hybrid systems, 423
for SLE, 441
using thermodynamic models, 424
Actual rate of interest, compound interest calculations, 254
Adams-Bashford method, 636
Adams-Moulton method, 636
Adiabatic flow, friction factors, 719–720
Adiabatic mixer, tracing chemical pathways, 135–136
identifying recycle and bypass streams, 144–145
tracing chemical pathways, 135–136
Advanced process control (APC), 682–683
AES (Aspen Engineering Suite), dynamic simulation, 626, 628, 630, 641–642
Agitated columns, in extraction equipment, 943–944, 946
AGR. See Acid-gas removal (AGR)
leaks into vacuum systems, 1050–1051
removing heat from process stream, 676–678
Clean Air Act (CAA), 1161
Environmental Protection Agency (EPA), 1140–1142
Air-cooled heat exchangers, LMTD correction factor for, 797
Alcohol fuel, coal to, 12
Allyl chloride (3-chloro-1-propene) production, design for increasing
additional background information, 1386–1388
background, 1381
equipment design parameters, 1384
process description of allyl chloride facility, 1382–1385
process design calculations, 1388–1393
process flow diagram, 1382
reference, 1393
utility summary table, 1383
Allyl chloride production, design new 20,000-metric-tons-per-year facility
Allyl chloride reactor, debottlenecking, 1085–1091
material selection for, 194–197
American Chemical Society (ACS), codes of conduct, 1119–1120
American Chemistry Council, Responsible Care program, 1143
American Conference of Governmental and Industrial Hygienists (ACGIH), air contaminants standard, 1135
American Institute of Chemical Engineers (AIChE)
Center for Chemical Process Safety (CCPS), 1143
code of ethics, 1110–1111, 1127
Design Institute for Emergency Relief Systems (DIERS), 1143
Design Institute for Physical Property Research (DIPPR), 402
Dow Fire & Explosion Index, 1150
Loss Control Credit Factors, 1151
rules and regulations, 1134
American Institute of Chemical Engineers (AIChE), Code of Ethics
American National Standards Institute (ANSI), 1143
American Petroleum Institute (API)
definition of storage tanks, 1016
Recommended Practices, 1143
American Society for Testing and Materials (ASTM), 1143
American Society of Mechanical Engineers (ASME)
boiler and pressure vessel code, 1016, 1143
symbols for flowsheets, 16
Amortization method, evaluating profitability of equipment, 302–303
Analysis of means, parametric optimization, 487
calculating with cash flow diagrams, 260–261
calculating with discount factors, 261–265
Annular fins of constant thickness, 833–837
Annular fins of nonuniform thickness, 829–832
ANSI (American National Standards Institute), 1143
Antifouling chemicals, 223
APC (advanced process control), 682–683
API (active pharmaceutical ingredient), production of, 92–97
API (American Petroleum Institute)
definition of storage tanks, 1016
Recommended Practices, 1143
Application level, Bloom’s Taxonomy, 3
Aqueous electrolyte system, building simulator model, 435–440
ASME (American Society of Mechanical Engineers)
boiler and pressure vessel code, 1016, 1143
symbols for flowsheets, 16
Aspartame. See L-phenylalanine and L-aspartic acid, batch production
Aspen Custom Modeler (ACM), user-added models (UAMs), 563
Aspen Engineering Suite (AES), dynamic simulation examples, 626, 628, 630, 641–642
Assessment, of group effectiveness, 1178–1180
Assigned functions, writing reports using, 1202
Assigned sections, writing reports, 1201–1202
Assignment memorandum, writing reports, 1221–1222
ASTM (American Society for Testing and Materials), 1143
Attenuation, inherently safe design, 1153
in oral communication, 1209, 1214
in written communication, 1196
for written design reports, 1208–1209
Authenticate, in PAR process, 349–351
Auto-ignition temperature, defined, 1143–1144
Auxiliary facility costs, 183, 201–203
Axes, labeling graphs for design reports, 1200
Axial compressors, 708
B
Back-of-the-envelope calculations, heuristics, 348
BACT (best available control technology), pollution prevention, 1166
Baffles, S-T heat exchanger design, 784–788, 810
histograms in design reports, 1200
report guidelines, 1206
algorithm for calculating, 200–201
CAPCOST calculations for, 204–206, 1269–1275
estimating materials of construction (MOCs), 194–199
module costing technique, 185
at non-base conditions, 189–194
in PFD synthesis, 372–375, 388–389
in process simulation, 411, 414–415
as starting point for optimization, 469–470
analyzing condenser performance after scale-down, 938–939
performance of feed section, 753–754
performance of fluid flow equipment, 736–739
troubleshooting steam release in cumene reactor, 1080
troubleshooting via debottlenecking, 1089
Base costs, analyzing in optimization, 471
addition of market constraints, 491–492
considering other equipment, 492–495
optimum cycle time and, 495–497
overview of, 490
problem formulation, 491
scheduling equipment and, 490–491
in chemical product design, 131
deciding to use continuous processes vs., 56–60, 79
defined, 56
design calculations for, 91–97
designing distillation columns and, 409
equipment design for multiproduct, 111–113
Gantt charts and scheduling, 97–98
logic control used in, 680–682
nonoverlapping/overlapping operations and cycle times, 98–101
overview of, 91
parallel process units, 110–111
product storage for single-product campaigns, 106–108
Batch sequencing, 91
BCF (bioconcentration factor), estimating fate of chemicals in environment, 1163
for acceptable rate of return on investments, 298–299
in optimization, 470
Benzene. See also Toluene HDA process
block flow process diagram for production of, 11–12
in cumene production. See Cumene production facility problems
determining profit margin with input/output diagram, 68–69
distillation column performance, case study, 934–942
evaluation of high-pressure phase separator, 164
limitations of tracing chemical pathways in PFDs, 145–146
in maleic anhydride production. See Maleic anhydride production from benzene
piping and instrumentation diagram for production of, 27–29
primary chemical pathways, 137–138
producing via hydrodealkylation of toluene, 7
Best available control technology (BACT), pollution prevention, 1166
Best case scenarios, quantifying risk, 314–315
BFDs. See Block flow diagrams (BFDs)
Bfw. See Boiler feed water (bfw) system
Binary azeotropic distillation, 379–382
Binary interaction parameters (BIPs)
back-calculating for VLE data, 1283, 1361
equations of state and, 417–418
estimating thermodynamic model for VLE calculation, 601–604
gathering physical property data for PFD design, 371
Bioconcentration factor (BCF), estimating fate of chemicals in environment, 1163
BIPs. See Binary interaction parameters (BIPs)
Birmingham Wire Gauge (BWG) tubing, 800–801
Blame, friction in groups from, 1181
Blast wave, in explosions, 1144
bare module factors for, 1274
equipment cost data for, 1249
purchase costs for, 1259
BLEVE (boiling-liquid expanding-vapor explosion), 1144
Block-decomposition algorithm, equation-oriented (EO) approach, 585–586
in design reports, 1200
developing new chemical process using, 10
identifying primary chemicals in, 136
overview of, 11
synthesizing PFD from. See Synthesis of PFD, from BFD
in generic block flow process diagram, 63
unsupported in dynamic simulation, 622
Bloom’s Taxonomy of educational objectives, student self-assessment, 3–4
utility costs for cooling water tower, 221, 223–224
utility costs for steam production, 229
heuristics for, 361
increasing pressure of gases, 707
material factors for, 1272
debottlenecking strategies for reboiler, 939
handling reduction in feed, 935
manipulating when high purity is needed, 411
Boiler feed water (bfw) system
exchanging heat between process streams and utilities, 676–678
regulation scheme for Cumene reactor, 684
utility costs for steam production, 229–234
debottlenecking strategies for, 939
distillation columns requiring reboiler, 477
regulating utility streams in chemical plants, 676
thermosiphon reboilers, 40–41, 633, 779
Boiling heat transfer coefficients
determining critical or maximum heat flux in pool boiling, 815–816
effects of forced convection on, 817–822
for nucleate (pool) boiling, 816–817
typical pool boiling curve, 813–815
Boiling-liquid expanding-vapor explosion (BLEVE), 1144
distillation exploiting, 876
estimating fate of chemicals in environment, 1163
Book value, depreciation and, 270
analysis of fluid flow equipment, 736
debottlenecking to eliminate, 939, 1066
troubleshooting via debottlenecking, 1085–1091
Bottom-up approach, in optimization, 468
Boundary, ternary azeotropic distillation, 386–387
Boundary value design method (BVDM), for azeotropic distillation in ternary systems, 382–383
Boundary value design method (BVDM), for azeotropic distillation in ternary systems., 386
ideas in chemical product design, 127–128
as problem-solving strategy, 1067–1068
using in HAZOP method, 1146–1147
Briefings, oral presentation via, 1211
performance for tear stream convergence, 583
for steady-state simulation, 579–585, 587–588
Bubble cap trays, for separation, 913
Bubble phase, bubbling fluidized bed reactors, 999
fluidized bed reactors, 999–1000
two-phase model, 1002
Business codes of conduct, 1126–1127
Butenes. See Heptenes production
BVDM (boundary value design method), for azeotropic distillation in ternary systems, 382–383, 386
BWG (Birmingham Wire Gauge) tubing, 800–801
choosing separation units for PFD synthesis, 376
eliminating unwanted nonhazardous/hazardous, 477–478
reactor design for PFD synthesis, 373
in batch vs. continuous processes, 56
eliminating nonhazardous, 473–475
reactions producing, 978
recycling, 77
reducing in green engineering, 1164
separator designs and, 64
Bypass streams, in chemical processes, 142–145
C
C programming language, user-added models, 563
CAA. See Clean Air Act (CAA)
CAD (Computer aided design) programs, for 3-D representation, 33
Calculator blocks, in process simulation, 572
Calibration, of thermodynamic model, 422–423
Capacity. See also Heat capacity
of common process units, 356
impacting purchased equipment cost, 175–179
bare module and material factors for heat exchangers, process vessels and pumps, 1267–1271
bare module and material factors for remaining equipment, 1271–1275
calculating plant costs, 204–206
cost curves for purchased equipment, 1247–1263
material factors in equipment cost, 1272–1274
Monte-Carlo (M-C) simulation used with, 325
pressure factors in costs, 1264–1266
in single-variable optimization, 480–481
CAPE-OPEN-compliant UAMs, 563
bare module equipment costs at base conditions, 186–189
bare module equipment costs for non-base-case conditions, 189–194
bare module factor and bare module cost, 199–201
base-case analysis using, 469–470
based on capacity information, 175–179, 206–208
classifications of cost estimates, 172–175
defined, 171
equipment installation, 182–183
expressed in dollars, 213
grassroots and total module costs, 201–202
incremental analysis of, 308–309
materials of construction (MOCs), 194–199
module costing technique, 185
retrofitting evaluated with, 305–309
time impacting purchased equipment cost, 179–181
Capital equipment-costing program. See CAPCOST program
Capital investment, and pollution prevention, 1167–1168
Capitalized cost factor, 300–302
Capitalized cost method, 300–302
outcomes assessment by faculty, 4–6
student self-assessment of outcomes, 2–4
removal. See CO2 and H2S removal from coal-derived syngas
Carbon monoxide (CO), converting to CO2, 1352–1356
Carbon steel, selecting materials of construction, 194–197, 356
Carnot efficiency, for mechanical refrigeration systems, 225–226
heat-exchanger network (HEN) design, 523–524
mass-exchange network (MEN) design, 543–544, 546–547
using HENSAD program to design, 540
using MUMNE algorithm for HENs, 514–516
Cascade regulation, 668–669, 684
distillation column performance, 934–942
regulation and control of chemical processes, 683–688
report-writing. See Report-writing case study
troubleshooting multiple units, 1076
Cash criterion, evaluating profitability, 287–288
Cash criterion, profitability and, 291–293
annuity calculation using, 260–261
capital depreciation using, 268–273
commonly used factors in, 262
cumulative. See Cumulative CFD (cash flow diagram)
cumulative cash flow diagram and, 258–259
discrete. See Discrete CFD (cash flow diagram)
in engineering economic analysis, 255–256
profitability analysis of new project, 285–287
adding to feed, 66
feed purity and, 66
filtration in batch processes, 94–96
matching volume with heat transfer in reactors, 997–999
pollution prevention and, 1165
reaction kinetics data for PFD design, 370–371
reactor design and, 372
Catalytic chemical reactions, 154, 962
maleic anhydride production from benzene, 1305–1311
using dynamic simulation, 618–619
Categorizing grid (memory matrix), in outcomes assessment, 4
Cause analysis, in troubleshooting strategy, 1066
CCP (Cumulative cash position), profitability criteria, 287–291
CCPS (Center for Chemical Process Safety), AIChE, 1143
CCR (Cumulative cash ratio), profitability criteria, 287–291
Ceiling concentration, air contaminant limits, 1135
Center for Chemical Process Safety (CCPS), AIChE, 1143
Center for Engineering, Ethics and Society, 1118
overview of, 708
performance curves for, 749–750
positive displacement compressors vs., 709
Centrifugal extractors, 943, 945–946
increasing pressure/regulating flowrate, 674–675
performance analysis of fluid flow in, 745–749
bare module factors for, 1274
equipment cost data for, 1249
purchase costs for, 1259
CEPCI. See Chemical Engineering Plant Cost Index (CEPCI) index
Ceramics, advantages/disadvantages of, 356
CFDs. See Cash flow diagrams (CFDs)
Change, human trait of resistance to, 369
Charter statement, in forming stage, 1184
Check valves, 706
P&IDs in construction phase as, 31
in Process Hazard Analysis, 1146
CHEMCAD process, single-variable optimization, 480
Chemical components, for PFD synthesis, 401
Chemical Engineering Plant Cost Index (CEPCI) index
changes from inflation, 183–184
changing fuel costs from 2001-2016, 220
values from 1996 to 2011, 179–181
Chemical equilibrium, modeling electrolyte systems, 432
Chemical Market Reporter (CMR), raw material costs, 234, 236–237
Chemical process diagrams. See also Graphical representations
3-D representation of a process, 34–41
additional diagram types, 32–33
BFDs. See Block flow diagrams (BFDs)
immersive training simulators (ITS), 45
linking ITS with OTS systems, 46–48
operator training simulators (OTS), 43–45
P&IDs. See Piping and instrumentation diagrams (P&IDs)
process concept diagrams, 60–61
process flow diagrams. See Process flow diagrams (PFDs)
Chemical process industry (CPI), scope and products, 9
Chemical process industry (CPI), scope and products of, 9
batch processing, 131
as future of chemical engineering, 124
generation of ideas for, 127–128
manufacturing process, 130–131
case study of acetone production, 1339–1341
chemicals required but not consumed, 62
CSTRs used for liquid-phase, 980–984
distillation of reaction products in batch processes, 92–94
endothermic. See Endothermic reactions
excess reactants affecting recycle structure, 76
exothermic. See Exothermic reactions
heat integration and. See Heat integration
heat transfer and, 76
inert materials in controlling, 77, 154
ionic reactions, 432, 435–440, 447
pressure impact on, 150
process concept diagram in identifying, 60–61
rate of. See Reaction rates
reaction kinetics. See Reaction kinetics
reasons for operating at conditions of special concern, 152–154
resource materials for, 84
runaway reactions, 1145
temperature impact on, 150–151
Chemical reactors. See Reactors
Chemical Safety and Hazard Investigation Board, 1153
Chemicals, fate of in environment, 1160–1163
Choked flow, friction factors in, 720–722
CIDs (composition interval diagrams), mass-exchange networks (MENs), 541–543, 546
Circular fins of nonuniform thickness, fin efficiency, 830
Circular flags, in P&IDs, 29–30
Circulating fluid-bed reactors, 1001
for equations in reports, 1207–1208
for figures and tables in reports, 1206
in report references, 1200
Classification, of capital cost estimates, 172–175
Claus process, defined, 1363
Claus unit design, converting H2S to elemental sulfur
major equipment summary, 1367–1368
process description, 1363, 1368–1369
process flow diagram, 1364
references, 1370
simulation (Aspen Plus) hints, 1370
utility summary table, 1367
Claus unit design, defined, 1363
on fugitive emissions, 1166
Risk Management Plan of EPA, 1141–1142
summary of, 1161
EPA regulations, 1161
planned emissions, 1140
Closed-cup measurement, flash point of liquid, 1144
CMR (Chemical Market Reporter), raw material costs, 234, 236–237
CO2 and H2S removal from coal-derived syngas
major equipment summary, 1361–1362
overview of, 1356
process description, 1356–1358
process flow diagram, 1359
references, 1362
simulation (Aspen Plus) hints, 1358, 1362
utility summary table, 1360, 1362
CO2 and H2S removal. See CO2 and H2S removal from coal-derived syngas
PFD for coal to alcohol fuel, 12–13
utility costs and, 219
layouts for L-L separators, 1047–1049
Coast Guard, regulating transport of hazardous cargo, 1141
limiting temperature profiles for, 775
LMTD correction factor for, 791, 797
Cocurrent separations, mass separating agents and, 903
Code of Federal Regulations (CFR)
health, safety and environment, 1134
legal liability of chemical engineers, 1126
American Institute of Chemical Engineers (AIChE), 1110–1112, 1119–1120
National Society of Professional Engineers (NSPE), 1113–1114
overview of, 1110
whistle-blowing requirements in, 1115
Cognitive domain, Bloom’s Taxonomy as, 3–4
Cohen-Coon tuning rule, dynamic simulation, 641
Cohen-Coon tuning rules, process control in dynamic simulation, 641–643
Colburn equation, for continuous differential separations, 906–910
Colburn graph, troubleshooting packed-bed absorbers, 1072
Colors, oral presentations using, 1213, 1217
condensers, reboilers and designing, 923–926
flooding and diameter of, 914–920
labeling in tables for design reports, 1200
COM (cost of manufacturing). See Manufacturing cost estimates
Combination feedback/feed-forward system, 667
defined, 1143
fires, explosions and, 1143–1145
reducing in green engineering, 1165
Committee, writing by, 1202
Commodity chemicals, 123
Common Denominator Method, profitability of equipment with different operating lives, 303–304
audience analysis and, 1196
of optimization results, 468
oral. See Oral communication
written. See Written communication
Competency, choosing group members for, 1182
Component database, simulator features, 398
Composite temperature-enthalpy diagrams
designing with HENSAD program, 540
estimating heat-exchanger surface area, 525–529
showing minimum temperature approach, 523–524
for systems without a pinch, 524–525
Composition interval diagrams (CIDs), mass-exchange networks (MENs), 541–543, 546
Composition, measurement of process variables, 662
Compound adjectives, written report guidelines, 1203
continuously compounded, 255
defined, 252
interest rates changing over time and, 253
time basis in calculating, 254–255
Comprehension level, Bloom’s Taxonomy, 3
Comprehensive Environmental Response, Compensation, and Liability Act (CERCLA)
EPA regulations impacting, 1141
retroactive liability in, 1168
summary of environmental laws, 1161
in single-stage steam ejectors, 1052
steam ejector performance and, 1057–1058
utility costs for refrigeration, 225–228
bare module cost for, 1270
bare module factors for, 1271
capacities of process units in common usage, 356
conditions of special concern for, 155–158
equipment cost data for, 1249
feed section performance and, 751–755
as fluid flow equipment, 707–708
fluid flow performance analysis of, 749–752
heuristics for, 361
increasing pressure of gases, 707
increasing pressure/regulating flowrate with, 674–676
input for process simulation, 406
material factors for, 1272
mechanical energy balance in piping systems and, 700–703
physical property data for PFD synthesis, 371
pressure factors for, 1265
purchase costs for, 1252
utility cost estimates for, 238–240
Computational blocks, steady-state simulations, 571–572
Computational cost, sequential modular approach, 574
Computer aided design (CAD) programs, for 3-D representation, 33
Concentration control, with multiple reactors, 76
Concentration profiles, in nonisothermal plug flow reactors, 987–989
Concept scoring, in chemical product design, 129–130
Concept screening, in chemical product design, 129
Condensate-return header pressure, utility costs for steam, 229
drums used in partial, 911–912
TP-xy diagrams showing partial, 883
impact on performance of distillation columns, 934–942
using partial, 896
utility costs for refrigeration, 225–228
Conditions of special concern (separation and reactor systems)
analyzing and justifying in PCM, 158–164
for operation of other equipment, 155–158
reasons for operating at, 152–154
Confined spaces, Process Safety Management for, 1140
Confined spaces, regulation for workers in, 1140
Conflict of interest, business codes of conduct, 1127
Conjunctive adverbs, written report guidelines, 1203
Connectors, pipe, 705
Constant molar (or molal) overflow, in binary distillation, 890, 893
Constant volume (positive displacement) pumps
increasing pressure/regulating flowrate in streams, 674–676
performance analysis of fluid flow in, 745–746
defined, 464
equality vs. inequality, 464
in mechanical design. See Pinch technology
VLE and, 602
Consumer price index, CEPCI index compared with, 183
Containment, process safety and, 994, 1153–1154
Contaminants, gas permeation for removal of dilute, 950
estimating bare module costs, 201
estimating total capital cost of plant, 183
Continuous differential separations
calculating transfer units, 881
Colburn equation for dilution, 908–910
for dilute solutions, 905
operating line/equilibrium curves in, 905
separations in packed columns as, 901
Continuous phase, in L-L separation, 1044–1047
deciding to use batch processes vs., 56–60, 79
defined, 56
logic controllers in, 680
Continuous stirred tank reactors (CSTRs)
dynamic models for, 632
input for process simulation, 408
performance problems, 1003–1006
Contractor’s estimates, 172–174
business codes of conduct and, 1126–1127
legal issues for chemical engineers, 1126
in dynamic simulation, 639–646
oral presentation guidelines, 1214
of process operations. See Control and regulation of chemical processes
Control and regulation of chemical processes
advanced process control (APC), 682–683
cascade control system, 668–669
characteristics of regulating valves, 657–659
combination feedback/feed-forward control strategy, 667–669
exchanging heat/work between process/utility streams, 674–679
feed-forward control and regulation strategy, 665–667
feedback control and regulation strategy, 663–665
measuring process variables, 662–663
operator training simulator (OTS), 683–688
ratio control strategy, 669–671
regulating flowrates and pressures, 660–662
simple regulation problem, 656–657
split-range control strategy, 671–673
in dynamic simulation, 641–643, 652
identifying/describing in PFDs, 14–15
PFD synthesis and, 390
advanced process control (APC), 682–683
cascade control system, 668–669
combination feedback/feed-forward control, 667–669
dynamic simulation in, 619
dynamic simulation in designing, 619, 640–656
for hazardous materials, 1154
split-range control strategy, 671–673
Control volume, in fluid mechanics, 697–698
Controllability, continuous vs. batch processes and, 59
SISO controllers in dynamic simulation, 640
in split-range control, 671–673
Convection, effects on pool boiling of forced, 817–822
Convective film heat transfer. See Film heat transfer coefficients
Convergence criteria, in process simulation, 411–412
Conversion profiles, adiabatic packed bed reactor, 996–997
bare module factors for, 1274
equipment cost data for, 1249
purchase costs for, 1260
in acid-gas removal, 572–573, 587, 593–596
complex reactor performance problems and, 1004–1006
concentration/temperature profiles in reactors and, 987–989
dynamic simulation and, 625–627, 630
heat exchange between process streams and utilities, 676–678
justifying operations outside temperature range for, 151–152
in nonisothermal PFRs, 991
nonisothermal plug flow reactors and, 991
Cooling water tower, estimating utility costs, 221–225
Cooperative or collaborative learning, in teams, 1189
Coordination, of group effort, 1177–1178
Copper and its alloys, selecting materials of construction, 194–197
Copper, thermal conductivity in heat exchangers, 800–801
Correction factors, estimating fate of chemicals in environment, 1160–1161
allowance in pressure vessel design, 1022
resistance in some materials of construction, 1016, 1019–1020
Corrugated plate settlers, L-L separation, 1046–1047
capital. See Capital cost estimation
chemical product design, 130–131
conditions of special concern for reactors/separators, 150–152
heat integration and, 512
manufacturing. See Manufacturing cost estimates
using continuous vs. batch processes, 60
Cost curves, for purchased equipment
for dust collectors, 1249, 1261
for heat exchangers, 1250, 1256
for process vessels, 1251, 1258
for towers, 1251
classifying cost estimates, 173
effect of time on purchased equipment cost, 179–181
variations over 15 years, 177–179
Cost of manufacturing (COM). See Manufacturing cost estimates
continuous differential separation, 878–879
limiting temperature profiles for, 775
LMTD correction factor for, 791, 797
CPI (chemical process industry), scope and products, 9
Creeping flow, around submerged objects, 724–725
Criminal prosecution, of chemical engineers, 1126
Critical path method (CPM), group scheduling and, 1185
Cross-flow exchangers, LMTD correction factor for, 797
Crude oil, cost of, 220, 236–237
Cryogenic conditions, of special concern, 152
guidelines for choosing separation units, 374
heuristics for towers, 363
of product in batch processing, 96–97
solid-liquid equilibrium (SLE) and, 441
bare module factors for, 1274
equipment cost data for, 1249
L-phenylalanine and L-aspartic acid production, 1328–1329
purchase costs for, 1260
CSTRs. See Continuous stirred tank reactors (CSTRs)
CSTRs (Nonisothermal continuous stirred tank reactors)
performance problems, 1004–1006
basic regulation scheme, 683–685
troubleshooting entire process, 1081–1085
troubleshooting feed-section, 1074–1076
troubleshooting steam release, 1078–1081
Cumene production at new 100,000-metric-tons-per-year facility
background, 1430
cost of manufacture, 1432
reaction kinetics, 1431
report format, 1432
simulation (CHEMCAD) hints, 1432
Cumene production facility problems
background, 1417
equipment summary table, 1425–1426
flow summary table, 1421
process calculations, 1425–1429
process description, 1417–1418
process flow diagram, 1418–1419
pump, system, and NPSH curves, 1423–1424
reaction kinetics, 1417
specifications of products and raw materials, 1419–1420
utility summary table, 1422
Cumulative cash position (CCP), profitability criteria, 287–291
Cumulative cash ratio (CCR), profitability criteria, 287–291
Cumulative CFD (cash flow diagram)
defined, 256
discounted profitability cash criteria, 292–293
discounted profitability interest rate criteria, 295
evaluating profitability of new project, 285–287
nondiscounted profitability criteria, 289–290
Cumulative distribution functions
Monte-Carlo analysis for quantifying risk, 321–324
Cumulative Sum (CUSUM) charts, statistical process control, 682
analyzing centrifugal compressor, 749–750
analyzing from feed section to process, 751–755
analyzing pump and system, 743–749
heat transfer coefficients for pool boiling, 813–815
increasing heat of reaction in reactors, 989
pump and compressor, in phthalic anhydride production, 1405
SISO controllers in dynamic simulation, 640
in split-range control, 671–673
EPA regulations, 1161
planned emissions, 1140
in batch operations of optimum, 495–497
pressure vessel design, 1016–1021
sizing pressure vessels, 1023–1024
Cylinders, falling-film condensation on, 825–828
D
DAEs (differential algebraic equations)
as dynamic simulation solution method, 633–635
method of lines generating, 631
Data output generator, simulator features, 399
Databases, in simulation, 562
DCS (Distributed control system) screen, operator training simulator, 689
DDB (double declining balance) depreciation method, 270–273
Debottlenecking. See also Troubleshooting
analysis of fluid flow equipment, 736
applying to problems, 1085–1091
Decide phase, in troubleshooting strategy, 1084
Decide step, process troubleshooting, 1068–1071
friction in groups from lack of concurrence, 1181
mobile truth and ethical, 1183–1184
role of leadership in groups, 1181–1182
communicating results, 468–469
estimating problem difficulty, 467–468
in flowsheet optimization, 484–487
identifying and prioritizing, 471–472
objective function and, 464
overview of, 464
in parametric optimization, 479
sensitivity studies and, 487
Define phase, in troubleshooting strategy, 1081–1083
Define phase, process troubleshooting, 1068–1071
Definitive (project control) estimate, 172–173
Deflagrations, explosions as, 1144
DEM (dominant eigenvalue method), for steady-state simulation, 578–579
deciding on continuous vs. batch processes, 58
flow around submerged objects and, 723
modeling distillation column for electrolyte system, 448
probability density function, 318–321
separating solids of different, 374
solids modeling and, 442
Department of Transportation (DOT)
legal liability of chemical engineers and, 1126
regulations for hazardous cargo, 1141
Depreciation of capital investment
example of calculating, 270–273
fixed capital, working capital, and land, 269
MACRS method of calculating, 273–274
taxation, cash flow and profits in, 275–277
Descriptive executive summaries, 1198–1199
calculations required for batch processes, 91–97
chemical product. See Chemical product design
heat- (mass-) exchanger networks. See Pinch technology
variables. See Decision variables
writing minutes during meetings on, 1199
Design blocks, in process simulation, 572
Design-by-rule philosophy, pressure vessels, 1016
Design Institute for Emergency Relief Systems (DIERS), AIChE, 1143
Design Institute for Physical Property Research (DIPPR), 402
allyl chloride production at new facility. See Allyl chloride production, design new 20,000-metric-tons-per-year facility
cumene production at new facility, 1430–1432
cumene production facility problems. See Cumene production facility problems
increasing allyl chloride production. See Allyl chloride (3-chloro-1-propene) production, design for increasing
phthalic anhydride production at new facility, 1412–1416
phthalic anhydride production scale down. See Phthalic anhydride production, scaling down
references, 1380
figures and tables in, 1200
written communications as, 1197–1198
Desuperheaters, 937
Detailed (firm or contractor’s) estimate, 172–174
Detonation explosions, 1144
Deviations, HAZOP questioning process, 1147
Diagrams, of chemical processes. See Chemical process diagrams
DIERS (Design Institute for Emergency Relief Systems), AIChE, 1143
Differential algebraic equations (DAEs)
as dynamic simulation solution method, 633–635
method of lines generating, 632
Diffusion coefficients, in electrolyte systems modeling, 433–434
Diffusion, solids modeling and, 442
Dimensionality, equality constraints reduce, 464
Dimethyl ether (DME) production
cascade regulation for, 668–669
chemical process for, 1278–1283
making it greener, 1171
material balance control for overhead product, 655–656
DIPPR (Design Institute for Physical Property Research), 402
Direct manufacturing costs, estimating for chemical product, 213–218
accelerated successive substitution (relaxation) vs., 578
performance for tear stream convergence, 583
steady-state simulation, 578
steady-state simulation examples, 580–585
Discharge coefficient, measuring flowrate, 730–735
Discount factors, calculating annuities, 261–265
Discounted cash flow rate of return (DCFROR)
CAPCOST program using, 325
comparing large projects, 295–298
interest rate criterion, 293–295
reliable results of, 327
sensitivity analysis for quantifying risk, 315
Discounted criteria, evaluating profitability, 291–295
Discounted cumulative cash position, 291
Discounted methods, for incremental analysis, 308–309
Discounted payback period (DPBP)
interest rate criterion, 294
Discrete CFD (cash flow diagram)
for capital depreciation, 268
Disengagement, friction in groups from, 1181
Dished (or torispherical) heads, pressure vessels, 1022–1024
Dispersed phase (droplets), in L-L separation, 1044–1047
Disposal, in life cycle analysis, 1169
approach to recycling raw materials, 72
azeotropic, generally, 378–379
azeotropic, in binary systems, 379–382
azeotropic, in ternary systems, 382–388
batch, 409
design calculations for batch processes, 94–95, 97
designing for optimum energy usage, 1165
energy as separating agent in, 876
exploiting boiling points between components, 876
heuristics for towers used in, 363
mass separating agents compared to, 903–904
McCabe-Thiele method for mass separating agents, 903–905
McCabe-Thiele method using packed columns, 901–902
McCabe-Thiele method using tray columns, 888–901
TP-xy diagrams showing, 883–888
Distillation columns. See also Tray towers
basic control system for binary, 685–687
building model of aqueous electrolyte system, 435–440
case study on performance of, 934–942
design cumene production at new 100,000-metric- tons-per-year facility, 1432
dynamic models and control of, 632–633
input for process simulation, 408–409
McCabe-Thiele method using tray columns, 888–901
modeling for electrolyte systems, 447–450
sequencing for simple distillation, 376–379
single-variable optimization of, 480–481
sophisticated control system for binary, 687–688
Distributed control system (DCS) screen, operator training simulator, 689
Distributed-parameter models, for heat exchangers, 625
in dynamic simulation, 619, 626
input variables as, 617
DMC (dynamic matrix control), model-based, 683
DMO solver, in Aspen+, 594
DO (drying oil) production, 1299–1304
Dominant eigenvalue method (DEM), for steady-state simulation, 578–579
DOT (Department of Transportation)
legal liability of chemical engineers and, 1126
regulations for hazardous cargo, 1141
Double declining balance (DDB) depreciation method, 270–273, 274
Dow Fire & Explosion Index, 1147, 1150–1152
DPBP (Discounted payback period)
interest rate criterion, 294
Drag coefficient, flow around submerged objects, 723–725
Drainage and spill control, in Dow Fire & Explosion Index, 1152
Drivers, heuristics for, 358
bare module cost for, 1270
bare module factors for, 1271
capacities of process units, 356
equipment cost data for, 1249
material factors for, 1272
pressure factors for, 1265
purchase costs for, 1252
Dropwise condensation, 824
Drums, heuristics for. See also Vessels, 358
bare module factors for, 1274
equipment cost data for, 1249
purchase costs for, 1261
Drying oil (DO) production, 1299–1304
Dual-stage Selexol unit design. See CO2 and H2S removal from coal-derived syngas
bare module factors for, 1274
equipment cost data for, 1249
purchase costs for, 1261
Duties and obligations, in ethical problem-solving, 1110
in dynamic simulation, 619, 626
input variables as, 617
Dynamic matrix control (DMC), model-based control, 683
Dynamic simulation integrator algorithms, solutions to DAE systems, 635–637
distillation columns setup, 632–633
dynamic specifications in, 624
equipment geometry and size setup, 622–624
flash separators and storage vessels setup, 630–632
heat exchangers setup, 625
method of lines setup, 632
need for dynamic simulation, 618–619
OTS required for executing, 689
process heat exchangers setup, 627–630
reactors setup, 632
series of CSTRs setup, 632
setting up, 619
topological changes from steady-state simulation, 619–622
utility heaters/coolers setup, 625–627
Dynamic specifications, in dynamic simulators, 624
Dysfunctional group behavior, 1183
E
E-mail, rapid written communication via, 1199
EAOC. See Equivalent annual operating cost (EAOC)
EB production. See Ethylbenzene (EB) production
ECC (equivalent capitalized cost), 301
analysis of engineering. See Engineering economic analysis
capital costs and. See Capital cost estimation
of chemical processes, 149
manufacturing costs. See Manufacturing cost estimates
of pollution prevention, 1165, 1167–1168
profitability analysis in. See Profitability analysis
deciding on continuous vs. batch processes, 57
equipment capacities and, 177–179
Effective annual interest rate, 254–255
Effectiveness charts, heat exchangers, 861–864
Effectiveness factor (F), applied to S-T heat exchangers, 529–534
in group synergy, 1176
of mist eliminators in V-L separation, 1040–1044
using continuous vs. batch processes, 58
EIS (Environmental impact statement), 1140
EIT (Engineer-in-Training) certification, 1122–1125
Elbows, changing flow direction with, 705
cost of, 220
cost of manufacturing benzene, 241–242
utility costs for plant with multiple process units, 222
utility costs for steam production, 228–234
utility costs from PFDs, 238–240
building model of aqueous electrolyte, 435–440
calculating excess Gibbs free energy for, 445–447
calculation of Gibbs free energy for, 430
chemical equilibrium in, 432
diffusion coefficient in, 433–434
modeling distillation column for, 447–519
molar volume in, 432
overview of, 428
thermal conductivity in, 433
Elevation, of equipment, 39–41
Elliptical heads, for pressure vessels, 1022–1024
Emergencies, simulation in training for, 48
Emergency Planning and Community Right to Know Act (EPCRA), 1141, 1161
Emergency release of emissions, EPA, 1141
emergency release of, 1141
fugitive, 1166
green engineering for reduction of, 1159
pollution prevention in process design and, 1165–1166
Employee relations, and business codes of conduct, 1127
hierarchy of reactor configurations for, 986
justifying reactors operating at temperature conditions of special concern, 152–153
reactor design and, 373
reactor design for PFD synthesis, 373
reasons for multiple reactors, 76
affecting supply and demand curves, 313
green engineering minimizing use of, 1159
heat integration efficiency and. See Heat integration
loss due to friction in piping systems, 700–703
recovery system, 83
in McCabe-Thiele method for distillation, 890, 892, 899
MERSHQ (material balance, energy balance, rate equations, hydraulic equations, and equilibrium equations) in, 436–440
nonisothermal CSTRs and, 980–984
performance problems for reactors, 1005
reboilers and, 924
relationships in separations, 877
Engineer-in-Training (EIT) certification, 1122–1125
calculations using cash flow diagrams, 259–265
cash flow diagrams in, 255–259
cumulative cash flow diagram, 258–259
depreciation of capital investment, 268–274
discrete cash flow diagram, 256–258
interest rates changing over time, 253
investments, and time value of money, 248–251
simple interest, 252
taxation, cash flow, and profit, 274–277
time basis for compound interest calculations, 254–255
Engineering ethics, 1104, 1118–1121
“Engineers’ Creed,” code of ethics, 1112
Enthalpy. See also Temperature-enthalpy (T-Q) diagrams
composite enthalpy curves for systems without a pinch, 524–525
composite temperature-enthalpy diagram, 523–524
handling streams with phase changes, 539–540
of mechanical energy balance in piping systems, 700–703
MESH (material balance, phase equilibrium, summation equations, and enthalpy balance), 435–440
solids modeling and, 442
thermodynamic model, 416
defined, 914
performance of steam ejectors, 1057–1058
Envelope method, tracing primary chemical pathways, 139–140
Envirofacts System, EPA, 1141
Environment. See also Health, safety, and environment (HSE)
fate of chemicals in, 1160–1163
green engineering for. See Green engineering
life-cycle analysis (LCA) of product consequences in, 1168–1169
PFD synthesis and, 389
work, 1177
Environmental control block, in block flow diagram, 65
Environmental impact statement (EIS), 1140
Environmental Protection Agency (EPA)
definition of “worst-case release,” 1133
emergency release of emissions, 1141
focus of, 1131
fugitive emissions and, 1166
legal liability and, 1126
overview of, 1140
Risk Management Plan (RMP), 1141–1142
green engineering and, 1159–1160
need for steady-state simulation, 562
Pollution Prevention Act of 1990, 1159–1160
summary of laws, 1161
EO. See Equation-oriented (EO) approach
estimation of physical property parameters, 602–604
solids modeling and, 443
EPA. See Environmental Protection Agency (EPA)
EPCRA (Emergency Planning and Community Right to Know Act), 1141, 1161
Equal percentage (or constant) valves, for regulation, 658
Equality constraints, in optimization, 464
Equation-oriented (EO) approach
converging optimization problem using, 592–595
for linear/nonlinear equations in dynamic simulation, 637–638
optimization of flowsheet convergence and, 590–591
SMod as hybrid of SM and, 586–589
in steady-state simulation, 585–586
Equations, in written design reports, 1207–1208
Equations of state, phase equilibrium model, 417–418
inert materials added to feed for controlling reactions, 67–68
justifying conditions of special concern in reactors/separators in PCM, 158–164
justifying reactors/separators operating at temperature conditions of special concern, 152–154
liquid-liquid. See Liquid-liquid equilibrium (LLE)
MERSHQ (material balance, energy balance, rate equations, hydraulic equations, and equilibrium equations) in, 436–440
MESH (material balance, phase equilibrium, summation equations, and enthalpy balance) in, 435–440
modeling electrolyte systems with chemical, 432
reactor design, 372
reactors, 408
reasons for multiple reactors, 76
solid-liquid equilibrium (SLE), 441–443
solid-vapor equilibrium (SVE), 441–442
vapor-liquid. See Vapor-liquid equilibrium (VLE)
3-D representation of. See 3-D representation of process (plant model)
analyzing important process conditions, 158–164
CAPCOST costs for purchased, 1247–1248
capital cost estimates for, 176
conditions of special concern for, 150–152, 155–158
for continuous vs. batch processes, 57
costs of installation, 182–183
data for optimization base case, 469–470
debottlenecking. See Debottlenecking
depreciation of, 269
with different operating lives, 300–305
disposal, 1169
drawings showing location of plant, 32
duplicating for increased production, 110–111
eliminating for optimization, 475
eliminating or replacing, 17–18
fluid mechanics. See Fluid mechanics
fouling. See Fouling
geometry and size for dynamic simulation, 622–624
heat transfer. See Heat transfer
increasing allyl chloride production, 1384
intermediate storage for, 109
in multiproduct batch processes, 111–113
parameter selection for simulation, 405–411
plant cost estimates. See Plant costs
problem-solving, 1068
process design. See Major equipment summary, in product design
reactors. See Reactors
rearranging for optimization, 475–477
retrofitting, 1091
with same operating lives, 299–300
scheduling batch processes, 97–98, 101–106, 490–494
troubleshooting. See Troubleshooting
Equipment, dynamic simulation setup
dynamic data/specification of, 624
flash separators and storage vessels, 630–632
heat exchangers, 625
method of lines, 632
process heat exchangers, 627–630
reactors, 632
series of CSTRs, 632
utility heaters/coolers, 625–627
knockout drums. See Knockout drums (phase separators)
pressure vessels. See Pressure vessels
steam ejectors. See Steam ejectors
cumene production facility problems, 1425–1426
as final element of PFD, 21–22
scale-down of phthalic anhydride production, 1409–1410
Equivalent annual operating cost (EAOC)
for distillation using McCabe-Thiele method, 900–901
for equipment with different operating lives, 302–303
for heat-exchanger networks, 534–536
for incremental analysis, 309
for large processes using HENSAD, 540–541
objective functions in optimization, 470–471
Equivalent capitalized cost (ECC), 301
Equivalent length method, frictional loss, 710
Errors, common simulation, 412–413
Ethanol, purifying with pervaporation, 380–381
affinity to group and mobile truth, 1183–1184
business codes of conduct, 1126–1127
duties and obligations, 1110
engineer-in-training certification, 1122–1124
ethical heuristics, 1118
Fundamentals of Engineering (FE) exam, 1122–1124
moral autonomy, 1105
moral values and, 1104
nonprofessional responsibilities, 1108–1110
Principles and Practice (PE) exam, 1124–1125
professional registration (certification), 1121–1125
reasons for ethical behavior, 1103–1104
reflection in action, 1106–1107
registered professional engineer, 1124–1125
rehearsal of new skills, 1105–1106
resource materials for, 1118–1121
Ethics Resource Guide, NIEE, 1119
“Ethics Test” video, NSPE code of ethics, 1121
major equipment summary, 1289–1291
making it greener, 1171
process description, 1284
process flow diagram, 1286
references, 1291
simulation (CHEMCAD) hints, 1291
utility summary table, 1288
major equipment summary, 1315–1316
making it greener, 1171
overview of, 1311
process description, 1311–1313
process flow diagram, 1312
references, 1317
simulation (CHEMCAD) hints, 1316
split-range pressure control of, 673
stream table, 1314
utility summary table, 1315
Evaluate step, in troubleshooting, 1068–1071
Evaluation level, Bloom’s Taxonomy, 4
bare module cost for, 1270
bare module factors for, 1271
calculating utility costs for refrigeration, 225–228
equipment cost data for, 1249
material factors for, 1272
pressure factors for, 1265
purchase costs for, 1253
separation and, 876
Evolution, group, 1183
Exams, team, 1189
Excel, user-added models, 563
Exchanger networks. See Pinch technology
Exchangers. See Heat exchangers
report abstract vs., 1198–1199
written report guidelines, 1203–1204
Exhibits (figures and tables), written communications as, 1200
fluidized bed reactors for extreme, 985, 986
hierarchy for nonisothermal plug flow reactors, 984–986
loss of coolant accidents (LOCAs) in, 1145
reactor design and, 373
Expanders, input for process simulation, 406
Expansion valve or turbine, utility costs for refrigeration, 225–228
Experience-based principles, in process design
advantages/disadvantages of materials of construction,, 357
heuristics and shortcut methods, 348–349
heuristics for compressors, fans, blowers, and vacuum pumps, 361
heuristics for drivers and power recovery equipment, 358
heuristics for drums (process vessels), 358
heuristics for heat exchangers, 362
heuristics for liquid-liquid extraction, 365
heuristics for packed towers (distillation and gas absorption), 364
heuristics for piping, 360
heuristics for pressure and storage vessels, 366
heuristics for pumps, 360
heuristics for reactors, 366
heuristics for refrigeration and utility specifications, 367
heuristics for thermal insulation, 362
heuristics for towers (distillation and gas absorption),, 363
heuristics for tray towers (distillation and gas absorption), 364
maximizing benefits of experience, 349–351
physical property heuristics, 355
process unit capacities, 356
references, 368
tables of heuristics and guidelines, 351–355
Expert systems, select model for system, 402
Explicit Euler method, dynamic simulation integrator algorithms, 635
Explicit methods, dynamic simulation integrator algorithms, 635
Explosions. See also Fire and explosions, 1144
fin efficiency for other fin geometries, 830–831
heat transfer coefficients for gases and, 828–829
rectangular fin with constant thickness, 829–830
total heat transfer surface effectiveness, 831–837
centrifugal extractors, 943, 945
mixer-settlers, 943
overview of, 942
pulsed columns, 943
static and pulsed columns, 943
static columns, 943
F
Faculty, outcomes assessment by, 4–6
Failure Modes and Effects Analysis (FMEA), in Process Hazard Analysis, 1146
Fanning friction factor, for frictional losses, 709–711
bare module cost for, 1270
bare module factors for, 1271
equipment cost data for, 1249–1250
heuristics for, 361
increasing pressure of gases, 707
material factors for, 1273
pressure factors for, 1265
purchase costs for, 1254
Fatal accident rate (FAR), 1132–1133
Fatality rate, accident statistics, 1132–1133
Fault diagnosis and identification (FDI), dynamic simulation in, 619
Fault-Tree Analysis (FTA), in Process Hazard Analysis, 1146
FBD (Function Block Diagram), logic control, 680
FCC (Fluidized catalytic cracking), solids modeling, 440
FCI. See Fixed capital investment (FCI)
FDI (Fault diagnosis and identification), dynamic simulation in, 619
FE (Fundamentals of Engineering) exam, 1122–1124
Feasible distillation processes, ternary azeotropic distillation, 382, 386–388
Federal government regulations
health, safety and environment, 1134
industry and commerce, 1126
Federal Insecticide, Fungicide, and Rodenticide Act (FIFRA), 1161
Federal Register (FR), 1126, 1134
additions for stabilization or separation, 67
affecting reflux ratio in separation, 897–898
formulating preliminary PFD for, 78–82
in generic block flow process diagram, 63–64
improving environment with green, 1163–1164
inert materials controlling equilibrium reactions, 67–68
input/output process diagrams and, 68–69
McCabe-Thiele method for distillation, 892–894
non-stoichiometric feed compositions of special concern, 154
performance of feed section to process, 751–755
preparing reactor and separator in PFD synthesis, 388–389
in process concept diagram, 60–61
in process flow diagram, 61–63
reactors transforming into products, 137
recycling with or without purge stream, 73–75
selecting feedstream properties for simulation, 404–405
simulation of toluene HDA process, 427–428
using continuous vs. batch processes for, 56–58, 60
calculator blocks in simulation as, 572
combination feedback and, 667
major process control loops and, 390
model of higher education as, 1–2
oral communication as type o, 669
ratio control as type of, 669
weakness of, 1
written communications as, 1209
Feed preheater, utility cost estimate for, 238–240
Feed pumps, cumene production facility and, 1419
advantages/disadvantages of, 663
basis of, 659
flowrate schemes for pumping liquids, 675
loops for binary distillation column, 685
oral presentations provide type of, 1209
outcomes assessment analogous to, 1
in process control, 640
Fees, in estimating bare module costs, 201
Ferrous alloys, selecting materials of construction, 194–197
Fiduciary responsibilities, business codes of conduct, 1127
FIFRA (Federal Insecticide, Fungicide, and Rodenticide Act), 1161
Figures (graphs and pictures), in design reports, 1200, 1206–1207
Film boiling, heat transfer coefficients for, 822–824
Film heat transfer coefficients
boiling heat transfer. See Boiling heat transfer coefficients
condensing heat transfer, 824–828
correlations for, 803
flow outside of tubes (shell-side flow), 808–813
bare module factors for, 1274
cost curves for purchased equipment, 1262
equipment cost data for, 1250
L-phenylalanine and L-aspartic acid production, 1328
for particles in compressors, 708
Finned tubes, air-cooled heat exchangers, 797
effectiveness for rectangular fins, 864–866
efficiency of rectangular fins with constant thickness, 828–829
total heat transfer surface effectiveness and, 831–837
various types of, 829
Dow Fire & Explosion Index, 1150–1152
pressure-relief systems, 1145
Fired heaters. See Furnaces
First person pronouns, avoiding in written design reports, 1202
Fixed capital investment (FCI)
calculating total capital investment, 269
calculating utility costs, 221
cash flow diagram for new project, 286
depreciation of, 269
estimating EAOC for HENs, 534–536
estimating manufacturing costs, 215, 217, 230–231
interest rate nondiscounted profitability criteria and, 287–291
Monte-Carlo analysis for quantifying risk, 321–322
sensitivity analysis for quantifying risk, 316–318
in single-variable optimization, 480
supply and demand curves affecting, 313
in two-variable optimization, 483
Fixed manufacturing costs, 214–218
Fixed-tubesheet design, S-T heat exchangers, 783–784, 788
Fixing problems, in troubleshooting, 1066
connecting pipes with, 705
minimizing pollution from leaking, 1166
Flares, in pressure-relief systems, 1145
Flash point, of liquid, 1144
Flash separators, dynamic simulation and, 630–632
Flash units, equipment parameters in PFD synthesis, 408
optimization related to, 489–490
using continuous vs. batch processes, 57
calculating diameter for packed tower, 930–931
calculating velocities, 915–916
in mist eliminators, 1038–1040
Flow. See also Fluid mechanics
analyzing pump and system curves, 743–749
compressor curves and staging, 749–752
frictional pipe. See Frictional pipe flow
inside tubes, film heat transfer coefficients, 803–808
net positive suction head (NPSH) for pumps, 739–743
over tubes, film heat transfer coefficients, 808–813
past submerged objects, 723–728
patterns on shell-side of S-T heat exchangers, 785–788
performance of fluid flow equipment, 736
through fluidized beds, 728–730, 999–1004
block flow diagrams. See Block flow diagrams (BFDs)
piping and instrumentation diagrams. See Piping and instrumentation diagrams (P&IDs)
process flow diagrams. See Process flow diagrams (PFDs)
value in communicating information, 9
information in PFDs for, 19–20
PFD synthesis and, 390
for binary distillation column, 685–687
changing with valves, 655
complex problems for reactors, 1004–1006
exchanging heat between process streams and utilities, 678
increasing pressure, and regulating, 674–676
performance curves for, 744–746, 748–750
performance of feed section, 752–755
regulating by manipulating, 655–656
regulating pressure and, 660–662
regulating with valves, 705
Flowsheet builder, simulators, 997
Flowsheet solver, simulators, 997
of chilled methanol in acid-gas removal, 572–573
in flow summary table for PFD synthesis, 390
handling recycle streams, 413–415
optimization using decision variables, 484–487
process simulation with topology input for, 404
selecting topology for PFD synthesis, 404
simulation of toluene HDA process, 427
steady-state simulation examples, 580–585
using tear streams in sequential modular approach, 576–578
using tear streams to solve problems with recycles, 400–401
Flowshop plants, batch processes in, 101–103
Fluid flow equipment, performance
feed section to process, 751–755
net positive suction head (NPSH) for pumps, 739–743
overview of, 736
pump and system curves, 743–749
analyzing pump and system curves, 743–749
basic relationships in, 697–703
compressor curves and staging, 749–752
flow past submerged objects, 723–728
fluid flow equipment performance, 736
fluid flow equipment types, 703–708
force balance, 703
frictional pipe flow. See Frictional pipe flow
mechanical energy balance, 700–703
net positive suction head (NPSH) for pumps, 739–743
overview of, 697
performance of feed section to process, 751–755
bubbling fluidized bed, 999–1000
designing new facility for allyl chloride production, 1394
for extreme exothermic reactions, 985
fast fluidization, 1001
increasing allyl chloride production, 1388–1393
overview of, 999
turbulent fluidization, 1000–1001
Fluidized catalytic cracking (FCC), solids modeling, 440
flow of. See Flow
S-T heat exchanger heuristics, 788–789
FMEA (Failure Modes and Effects Analysis), in Process Hazard Analysis, 1146
Fogler and LeBlanc, problem-solving strategy, 1068–1071
Fonts, improper use in oral presentations, 1217
and flow around submerged objects, 723–728
fluid flow in piping systems, 703
Forced convection, effects on pool boiling, 817–822
in chemical processes, 310–311
supply and demand factors, 311–314
Foreign countries, business codes of conduct for, 1127
Formal oral presentations, preparing for, 1210–1211
defined, 1317
major equipment summary, 1321–1323
making it greener, 1171
process description, 1317–1319
process flow diagram, 1318
reaction kinetics, 1319
references, 1319
simulation (CHEMCAD) hints, 1319
stream table, 1320
utility summary table, 1321
Formation stage, in group evolution, 1184
written communication, 1197
written report guidelines, 1203–1206
Forming stage, in group evolution, 1184
FORTRAN programming language, user-added models, 563
antifouling chemicals, 223
bubble caps prone to, 913
and choice of tube-side fluid, 788
condensing heat transfer and, 824
design algorithm for S-T heat exchangers, 839, 841
design away from pinch and, 520–521
equipment, 59
estimating individual heat transfer coefficients and, 803
and heat transfer coefficients, 800–801
optimum cycle time for cleaning heat exchangers prone to, 497
in separation equipment, 938–940
troubleshooting performance, 1070
water contaminants in steam production causing, 229
FR (Federal Register), 1134
Free convection boiling, 813
Friction (interpersonal), sources of group, 1180–1181
Frictional losses, calculating, 709–711
calculating frictional losses, 709–711
Friendship, choosing group members, 1183
FTA (Fault-Tree Analysis), in Process Hazard Analysis, 1146
Fuel costs. See Utility costs
minimizing pollution from, 1166
Fully developed turbulent flow
friction factors in choked flow, 721–723
frictional losses for, 710
Function Block Diagram (FBD), logic control, 680
Fundamentals of Engineering (FE) exam, 1122–1124
bare module cost for, 1270
bare module factors for, 1271
equipment cost data for, 1250
material factors for, 1273
pressure factors for, 1265
purchase costs for, 1255
in economics of pollution prevention, 1168
estimating fate of chemicals in environment, 1163
Future value (F) of investment
calculating annuities, 261–265
overview of, 249
types of interest used when calculating, 251–253
G
group scheduling and, 1185
multiproduct sequence, 103
reference for developing and using, 1191
scheduling batch processes, 103–105
for single-product and multiproduct campaigns, 104–105
absorption, 363
heat transfer coefficients in packed beds, 992–993
law. See Ideal gas law
permeation membrane separations, 947–950
using mass separating agents, 903
estimating concentrations using ideal gas law, 963–964
exothermic vs. endothermic, 373
justifying reactors/separators operating at conditions of special concern, 152–154
operating reactors and separators outside pressure range of special concern, 163
reactor design for PFD synthesis, 373
reactors operating at conditions of special concern, 154
reasons for multiple reactors, 76
Gas-solid reactor configuration, fluidized beds, 999–1004
Gasifiers, modeling downward-flow/oxygen blown/entrained-flow
major equipment summary, 1375
overview of, 1371
process description, 1371–1373
references, 1377
simulation (Aspen Plus) hints, 1375–1377
Gate valves, controlling fluid flow, 705–706
Gauss-Legendre method, as multistep integrator, 636
Gear’s method, as multi-step integrator, 636
General duty clause, OSHA Act, 1126, 1135
General expenses, cost of manufacturing, 214–218
Generate step, process troubleshooting, 1069–1071
Generic block flow diagrams (GBFDs)
as intermediate step between process concept and PFD, 63–65
synthesizing PFD from. See Synthesis of PFD, from BFD
Generic model control, advanced process control, 683
Geometry of equipment, in dynamic simulation, 622–624
calculating for electrolyte systems, 430, 445–447
solids modeling and, 442
“Gilbane Gold” video, ethics, 1118, 1121
Glass, advantages/disadvantages of, 356
defined, 464
finding, 468
steady-state simulation for competitive advantage, 562
Globe valves, for regulation, 658, 705–706
Grade-level, horizontal, in-line arrangement (plant layout), 34, 36
Grade-point average, choosing group members, 1182
Graetz number, heat transfer coefficients for laminar flow, 806–809
Grammar checkers, imperfect for formal written work, 1215–1216
Grammar, written report guidelines, 1202–1203
McCabe-Thiele diagram for distillation, 888–896
packed columns, 902
guidelines for oral presentations, 1211–1212
mixing text visuals with, 1211
using colors and exotic features in, 1217
common mistakes in presentation, 1229
corrected version for presentation, 1230
in design reports, 1200
Grassroots (green field), vs. total module costs, 201–203
Gravity, L-L separation, 1044–1047
economics of pollution prevention, 1167–1168
environmental fate of chemicals, 1160–1163
environmental regulations, 1159–1160
life cycle analysis in, 1168–1169
overview of, 1159
PFD analysis for pollution/environmental performance, 1166–1167
pollution prevention during process design, 1164–1166
Gross profit margin, base costs in optimization, 471
assessing and improving effectiveness of, 1178–1180
coordinated energy of, 1177–1178
editing reports for consistency, 1203
forming stage, 1184
increased efficiency (synergy) of, 1176
organizational behaviors and strategies in, 1180–1184
performing stage, 1186
teams as subsets of, 1175
work environment in effective, 1177
Groupthink, 1184
Guide words, HAZOP, 1147
H
Hazard assessment, in Risk Management Plan, 1142
Hazard Communication Standard (HazCom), 1136–1138
Hazardous air pollutants (HAP), 1141
Hazardous Substances Data Bank (HSDB), 1135
green chemistry minimizes, 1163–1164
Resource Conservation and Recovery Act (RCRA), 1161
source reduction minimizing, 1159–1160
Hazardous Waste and Emergency Operations (HAZWOPER) rule, OSHA, 1142
Hazards and operability study (HAZOP)
identifying potential industry standards, 1133
process hazards analysis technique, 1146–1147
HCl absorber, process simulation, 402–403
Headers, utility streams supplied via, 655
Heads (end sections), pressure vessel design, 1022, 1023–1024
Health, safety, and environment (HSE)
accident statistics, 1132–1133
chemical engineer’s role in, 1134
Chemical Safety and Hazard Investigation Board, 1153
Dow Chemical Hazards index, 1153
Dow Fire & Explosion Index, 1147, 1150–1152
fires and explosions, 1143–1145
fugitive emissions, 1141
glossary of acronyms for, 1154–1156
Hazard and Operability Study (HAZOP), 1146–1149
Hazard Communication Standard (HazCom), 1136–1138
inherently safe design strategy, 1153–1154
overview of, 1131
planned emissions, EPA, 1140–1141
pressure-relief systems, 1145
Process Hazard Analysis (PHA), 1142, 1145–1146
Registration, Evaluation, Authorization and Restriction of Chemicals (REACH), 1137
Risk Management Plan (RMP), 1141–1142
worse-case scenarios, 1133–1134
Health, safety, and environment (HSE), regulations and agencies
Internet addresses for federal agencies, 1134
list of acronyms for, 1154–1156
nongovernmental organizations, 1143–1144
Process Safety Management (PSM), 1138–1140
exchanging between process streams, 679
exchanging heat/work between process streams/utilities, 676–678
justifying operations outside temperature range for, 151–152
building model of distillation column for electrolyte system, 448
gathering physical property data for PFD design, 371
modeling electrolyte systems, 431–432
simulation of, 416
standard-state, 431
calculating for condensers/reboilers, 899, 924–925
calculating using energy balance, 877, 885, 887
Heat-exchanger network synthesis analysis and design (HENSAD) program, 540–541
Heat-exchanger networks (HENs)
composite enthalpy curves for systems without a pinch, 524–525
composite enthalpy curves to estimate heat-exchanger surface area, 525–529
composite temperature-enthalpy diagram for, 523–524
constructing cascade diagram, 514–516
formulating PFD for, 83
mass-exchange networks vs., 541–542
minimum approach temperature for, 513
minimum number of heat exchangers for, 516–517
pinch or pinch point in, 509–510
temperature interval diagram for, 513–514
Heat exchangers. See also Shell-and-tube (S-T) heat exchangers
adjusting overall heat transfer coefficient for, 679
analyzing conditions of special concern for, 164
bare module and material factors for, 1267–1271
capacities of process units in common usage, 356
condensers/reboilers in distillation columns as, 923–924
conditions of special concern for, 155–158
design algorithm examples, 840–846
design cumene production at new facility, 1432
design equation for, 773
design for pressure drop, 837–838
dynamic models for, 625
dynamic simulation of process, 627–630
equipment cost data for, 1250
exchanging heat between process streams and utilities, 676–678
heat transfer coefficients. See Heat transfer coefficients
heuristics for, 362
input for process simulation, 406–407
nonlinear Q vs. T curves in, 776–777
overall heat transfer coefficient varies with, 777–778
performance problems and, 846–850
physical property data for PFD synthesis, 371
pressure factors for, 1265–1266
purchase costs for, 1256
streams with phase changes, 775–776
Heat exchangers, equipment design
fixed tubesheet/floating tubesheets, 783–784
shell and tube partitions, 784
shell-and-tube (S-T) heuristics, 788–789
shell-side flow patterns, 785–788
problems, using worked examples, 850–859
sizes of standard tubes in, 800, 802–803
thermal conductivity and, 800–802
in tray and packed towers, 933–934
using ratios to determine, 847–850
designing heat-exchanger network using, 517–523
minimum approach temperature for, 513
minimum number of heat exchangers for, 516–517
pollution prevention using, 1165
temperature interval diagram for, 513–516
Heat sensitivity, separation units for PFD synthesis, 376
algorithms, and heat exchanger design for, 837–846
in cocurrent heat exchangers, 773–775
coefficients. See Heat transfer coefficients
cost for hot circulating fluids in, 234
in countercurrent heat exchangers, 771–773
CSTR configurations for, 980–984
equipment design. See Heat exchangers, equipment design
extended surfaces for, 828–837
fin effectiveness and, 864–866
fixed tubesheets and floating tubesheets in, 783–784
heat exchanger effectiveness charts and, 861–864
heuristics for shell-and-tube exchanger designs, 788–789
increasing allyl chloride production, 1384–1385
increasing endothermic reactions in reactors, 984–986
LMTD correction factors. See LMTD correction factors
matching volume in S-T reactors and, 997–999
nonlinear Q versus T Curves, 776–777
overall heat transfer coefficients, 777–778, 798–800
overview of, 771
performance problem examples, 850–859
performance problems and, 846–850
role in reactor design, 990–991
in streams with phase changes, 775–776
Heat transfer coefficients. See also Overall heat transfer coefficient (U)
adjusting for heat exchanger, 679
boiling heat transfer for maximum heat flux in pool, 815–816
boiling heat transfer for typical boiling curve, 813–815
boiling heat transfer in film boiling, 822–824
boiling heat transfer in forced convection, 817–822
boiling heat transfer in nucleate (pool) boiling, 816–817
calculating in nonisothermal PFRs, 992–993
condensing heat transfer, 824–828
flow outside of tubes (shell-side flow), 808–813
for gases. See Extended surfaces
performance problems for reactors, 1005
regulation scheme for Cumene reactor, 684–685
resistances due to fouling, 800–801, 803
resistances in series, 798–800
thermal conductivities of metals and tubes and, 800–803
bare module cost for, 1270
bare module factors for, 1271
capacities of process units in, 356
conditions of special concern for, 155–158
equipment cost data for, 1250
estimating utility costs from PFDs, 238–240
material factors for, 1273
pressure factors for, 1266
purchase costs for, 1255
configurations for heat removal from CSTRs, 980–981
incremental analysis of design oversight in, 306–307
in maximum flow rate for Dowtherm A, 1085–1091
Height equivalent to theoretical plate (HETP), calculating height of packed tower, 929–930
“Henry’s Daughters” video, ethics, 1118, 1121
applying to model of distillation column for electrolyte system, 448
calculating tray efficiency, 921–922
estimating fate of chemicals in environment, 1163
hybrid thermodynamic systems and, 423
liquid-liquid separations, 878
modeling aqueous electrolyte system, 437
modeling electrolyte system, 430
HENSAD (Heat-exchanger network synthesis analysis and design) program, 540–541
HENSs. See Heat-exchanger networks (HENs)
preliminary equipment summary, 1347–1350
process description, 1351
references, 1352
simulation (CHEMCAD) hints, 1352
stream table, 1346
utility summary table, 1350
HETP (Height equivalent to theoretical plate), calculating height of packed tower, 929–930
benefits of experience in creating new, 349–351
for compressors, fans, blowers, and vacuum pumps, 361
for drivers and power recovery equipment, 358
ethical. See Heuristics, ethical
four characteristics of, 1103
guidelines for applying, 351–355
for heat exchangers, 362
for liquid-liquid extraction, 365
for packed towers (distillation and gas absorption), 364
physical property-related, 355
for pipe sizes in 3-D plot plan, 37–38
for piping, 360
for pressure and storage vessels, 359
for process vessels (drums), 358
for pumps, 360
for reactors, 366
for refrigeration and utility specifications, 367
for S-T heat exchangers, 788–789
for thermal insulation, 362
for towers (distillation and gas absorption),, 363
for tray towers (distillation and gas absorption), 364
developing new, 1118
duties and obligations, 1110
ethical dilemmas and, 1117–1118
for mobile truth, 1108
moral autonomy of engineers, 1105
reflection in action, 1107
in conceptual process design, 55–56
endothermic reactions in nonisothermal PFRs, 986
exothermic reactions in nonisothermal PFRs, 984–986
in design reports, 1200
Monte-Carlo analysis for quantifying risk, 322
HiTec molten salt, phthalic anhydride production, 1404, 1407, 1414
Holding-in-place method, intermediate storage, 108
Horsepower, determining pump, 701–702, 713–714
Hot circulating heat transfer fluids, utility costs for, 234
Hourly wage, labor cost of manufacturing, 218–219
HSDB (Hazardous Substances Data Bank), 1135
HSE. See Health, safety, and environment (HSE)
Human machine interface (HMI), OTS system, 43–45
Hurdle rates, acceptable returns from investments, 298–299
Hybrid systems, thermodynamic models, 423
Hydraulic equations, MERSHQ for, 436–440
determining profit margin, 68–69
excess reactant in feed, 162–164
tracing primary chemical pathways for, 140–142
conversion to elemental sulfur. See Claus unit design, converting H2S to elemental sulfur
removal from syngas. See CO2 and H2S removal from coal-derived syngas
I
Icons, identifying process equipment in PFDs, 16–17
for applications involving gas permeation, 883
determining vapor density, 917, 931
estimate concentrations in gas-phase reactions, 963–964
learning for process calculation, 1105
Ideas, in chemical product design, 124–125, 127–128
IDLH (Immediately dangerous to life and health), air contaminant exposure, 1136
IGCC (Integrated Gasification Combined Cycle) coal-fed power plant., 44
Ignition energy, 1144
IL (Instruction List), logic control, 680
IMC-based tuning rule, process control, 642–643
Immediately dangerous to life and health (IDLH), air contaminant exposure, 1136
Immersive training simulator (ITS)
linking with OTS systems, 46–48
overview of, 45
Impact analysis, in life cycle analysis, 1168
Impeller, of centrifugal pumps
performance analysis of fluid flow for, 744, 748–749
Implement step, in troubleshooting, 1068–1071
Implicit Euler method, dynamic simulation, 635
Implicit methods, dynamic simulation, 635
Improvement analysis, in life cycle analysis, 1168
Impurities, considering when to purify the feed, 66–67
In-process recycle, Pollution Prevention Act of 1990, 1160
Incidence rate, OSHA accident statistics, 1132–1133
“Incident at Morales” video, ethics, 1118, 1121
in packed beds, 711
in single-pipe systems, 712–719
comparing large projects in, 295–297
discounted methods in, 308–309
nondiscounted methods in, 305–308
objective functions in optimization, 470
retrofitting facilities using, 305–309
Incremental net present value (INPV), in incremental analysis, 308–309
Incremental payback period (IPBP), in incremental analysis, 305–308
Inequality constraints, in optimization, 464
cost estimate classifications for, 172
effect of time on purchased equipment cost, 179–180
estimating plant costs based on capacity, 206–208
using CEPCI to account for changes due to, 183–184
determining from input/output process diagram, 68–69
needed in PFD synthesis, 370–371
adding stream information to PFD with, 21–23
formulating PFD for, 83
Information (input data), for simulators
chemical component selection, 401
convergence criteria selection, 411–412
equipment parameter selection, 405–411
feed stream property selection, 404–405
flowsheet topology selection, 404
physical property model selection, 401–404
Informative executive summaries, 1198–1199
Initialization step, dynamic simulation, 634
Inlet pressure, performance analysis of pumps using NPSH, 741
Input devices, Ladder Diagram (LD), 680–681
feed purity/trace components in, 66–67
feeds to stabilize/separate products, 67
formulating preliminary process flow diagram, 79–80
in generic block flow diagrams, 63–65
inert feeds to control equilibrium reactions, 67–68
inert feeds to control exothermic reactions, 67
information determined by, 68–69
in process concept diagrams, 60–61
in process flow diagrams, 61–63
solving troubleshooting problems, 1069–1071
troubleshooting/debottlenecking, 1066–1067
troubleshooting packed-bed absorber, 1072–1074
in dynamic simulation, 617
in steady-state simulation, 619–622
INPV (Incremental net present value), in incremental analysis, 308–309
Instruction List (IL), logic control, 680
Instruments, constructing P&IDs, 27–30
Integrated Gasification Combined Cycle (IGCC) coal-fed power plant., 44
Integrated Risk Information System (IRIS), for chemical hazards, 1135
Integrator algorithms, dynamic simulation, 635–639
Intensification, of not using hazardous materials, 1153
Intention, HAZOP use of, 1147
Interactions, group friction from uncomfortable, 1181
discounted profitability, 293–295
evaluating profitability, 288
nondiscounted profitability in project evaluation, 288–291
affecting supply and demand curves, 313
calculations from cash flow diagrams, 259–260
changing over time, 253
determining for annuity, 261–265
in discrete cash flow diagram, 256–258
time basis for compound interest calculations, 254–255
Intermediate storage, for batch processes, 108–110
Internal devices, Ladder Diagram (LD), 680–681
Internal model control, 683
International chemical safety card, for hazardous materials, 1136
citing material from, 1200
for federal agencies, 1134–1135
example, 1231
guidelines for, 1204
improving, 1233
changing during single-product campaign run, 107
in life cycle analysis, 1168
cumulative cash flow diagram for, 258–259
defined, 249
depreciation of capital, 268–274
discrete cash flow diagram for, 256–258
and time value of money, 248–251
defined, 249
discrete cash flow diagram for, 256–258
Ionic reactions, in electrolyte systems
chemical equilibrium, 432
modeling aqueous electrolyte system, 435–440
modeling distillation column, 447, 449
IPBP (Incremental payback period), in incremental analysis, 305–308
IRIS (Integrated Risk Information System), for chemical hazards, 1135
Isentropic work in compressors, 750–752
Isopropyl alcohol. See Acetone production from isopropyl alcohol
Isopropyl benzene. See Cumene
Isothermal flow, friction factors, 719–721
Isothermal work, in compressors, 750–752
Iterations, creating multiple report, 1196
ITS (Immersive training simulator)
linking with OTS systems, 46–48
overview of, 45
J
applying to thermodynamic properties, 563
Broyden’s method and, 582
defined, 564
direct substitution and, 578
equation-oriented (EO) approach and, 585
Wegstein’s method and, 579–580
Jobshop plants, batch processing in, 103–106
Just-in-time (JIT) manufacturing, inherently safe design, 1153
K
K-factor. See Phase equilibrium
estimating shell-side heat transfer, 809–811
Kern’s method for shell-side heat transfer, 811–813
CSTR and plug flow reactors as, 408
data in PFD synthesis, 370–371
designing, 372
justifying conditions of special concern in reactors using PFD, 159–162
developing user kinetic models, 568–571
of mechanical energy balance in piping systems, 700–703
reaction kinetics, 159–164, 370–371, 405
resource materials for, 84
Knockout drums (phase separators)
compressors and, 708
conditions of special concern for, 164
mist eliminators and other internals, 1036–1044
as separation equipment, 911
V-L separation design, horizontal, 1032–1035
V-L separation design, vertical, 1029–1032
Knowledge level, Bloom’s Taxonomy, 3
Kremser equation, for dilute solutions, 905–911
L
L-aspartic acid. See L-phenylalanine and L-aspartic acid, batch production
L-H (Langmuir-Hinshelwood) kinetics
simulating reactions with kinetic reactors, 408
L-L. See Liquid-liquid (L-L) separation
L-L-V separators, 1046, 1048–1049
L-phenylalanine and L-aspartic acid, batch production
overview of, 1323
process description, 1323
process flow diagram, 1324
references, 1229
affecting supply and demand curves, 313
in cost of manufacturing, 214–217
in manufacturing cost estimates, 218–219
Labor needs, deciding on continuous vs. batch processes, 58
Ladder Diagrams (LDs), logic control, 680–682
Land, cannot be depreciated, 269
Lang Factor method, estimating plant cost, 184
Langmuir-Hinshelwood (L-H) kinetics
simulating reactions with kinetic reactors, 408
Large projects, incremental economic analysis for, 295–297
Large temperature driving force, in exchanger, 988–989
Lattice search, vs. response surface techniques, 489
legal liability of chemical engineers, 1125–1126
protecting whistle-blowers, 1115
LCA (Life cycle analysis), in green engineering, 1168–1169
LDs (Ladder Diagrams), logic control, 680–682
Le Chatelier’s principle, for equilibrium reaction, 965
Leaching, as solid-liquid separation, 876
Leadership, group, 1181–1182, 1184
Leading Self-Directed Work Teams (Fisher), 1191
makeup water in steam production due to, 228
minimizing pollution from, 1166
Learning, in teams, 1182, 1189–1190
Legal liability, of chemical engineers, 1125–1126
Leidenfrost point, heat transfer for pool boiling curve, 814
LEL (lower explosive limit), 1144
Letter of transmittal, report format, 1203
LFL (lower flammability limit), 1144
Liability, pollution prevention economics and future, 1168
Licensed professional chemical engineer
engineer-in-training (EIT), 1122–1124
Principles and Practice (PE) exam, 1124–1125
professional registration, 1121–1122
Life cycle analysis (LCA), in green engineering, 1168–1169
Life of equipment, depreciation and, 269
Linear equation solvers, 637–639
Linear programming, 464
Linear quadratic control (LQC), 683
Linear valves, in flowrate control, 658
Liquid level, measuring process variables, 662
Liquid-liquid equilibrium (LLE)
building model of distillation column for electrolyte system, 448
hybrid systems and, 423
liquid-state activity-coefficient models, 419–423
thermodynamic model solver, 399
Liquid-liquid (L-L) separation
energy balances, 877
heuristics for liquid-liquid extraction, 365
input for process simulation, 411
with knockout drums, 1044–1048
using mass separating agents, 903
Liquid-liquid-vapor (L-L-V) separators, 1046, 1048–1049
Liquid-phase reactions, CSTRs used for, 980–984
Liquid-solid reactor configurations, fluidized beds, 999–1004
Liquid-state activity-coefficient models
hybrid systems and, 423
phase equilibrium model, 419–422
Liquids, pumps used to transport, 706
LLE. See Liquid-liquid equilibrium (LLE)
for cross-flow exchangers, 797
for flash separators and storage vessels, 630–632
heat-exchanger effectiveness charts, 861–864
for linear/nonlinear equation solvers, 639
for multiple S-T-pass exchangers, 793–797
simulation errors, 413
for single-pass, double-tube pass (1-2) exchanger, 790–793
for utility heaters/coolers, 626–627
LMTD (log-mean temperature difference)
for cocurrent vs. countercurrent flow, 774–775
in countercurrent flow, 773
nonlinear Q vs. T curves and, 776–777
streams with phase changes, 775–776
Loading, as precursor to flooding, 915
Local optimum, defined, 464
Local truncation error (LTE), in dynamic simulation, 636–637
Log-mean temperature correction factor (F)
for design away from pinch, 521
Log-mean temperature difference. See LMTD (log-mean temperature difference)
Logic control, in control system design, 680–682
Logic ladder diagrams, 32
Longitudinal pin fin constant thickness, 829
Loss control credit factors, Dow Fire & Explosion Index, 1151–1152
Low-alloy steels, materials of construction, 194–197
Lower explosive limit (LEL), 1144
Lower flammability limit (LFL), 1144
Lower-level controllers, as SISO controllers, 640
LQC (linear quadratic control), 683
LSSQP approach, to steady-state simulations, 588–589
LTE (local truncation error), in dynamic simulation, 636–637
Lumped-parameter models, 625
M
MAC (model algorithmic control), 683
Mackay Level III model, 1166–1167
MACRS (modified accelerated cost recovery system) depreciation allowances
current federal tax law based on, 273–274
designing new cumene production facility, 1430, 1432
profitability criteria for project evaluation, 289
report-writing case study, 1222
selecting continuous vs. batch processes, 58
training operators/engineers in virtual plants, 48
Major equipment summary, in product design
Claus unit design converting H2S, 1367–1368
CO2 and H2S removal from coal-derived syngas, 1361–1362
dimethyl ether (DME) production, 1281–1282
downward-flow, oxygen blown, entrained-flow gasifiers, 1375
drying oil (DO) production, 1304–1305
ethylbenzene (EB) production, 1289–1291
ethylene oxide production, 1315–1316
formalin production, 1321–1323
heptenes production, 1347–1350
maleic anhydride production from benzene, 1309–1310
water-gas shift reactor design for conversion to CO2, 1355
Maleic anhydride production from benzene
case study. See Report-writing case study
major equipment summary, 1309–1310
making it greener, 1171
process description, 1305–1306
process flow diagram, 1307
reaction kinetics, 1306
simulation (CHEMCAD) hints, 1311
stream table, 1308
utility summary table, 1309
defined, 617
in process control, 640
setting up dynamic simulation, 626
in split-range control system, 671–673
Manometers, measuring flowrate, 731–734
in chemical product design, 124–125, 130–131
statistical process control in, 682
estimating utility costs from PFDs, 238–240
expressed in units of dollars per unit time, 213
factors affecting COM for chemical product, 213–218
operating labor costs, 218–219
overview of, 213
sensitivity analysis for quantifying risk, 316–318
in single-variable optimization, 480
taxation, cash flow, profit and, 275
treating liquid/solid waste streams, 240–241
utility costs for cooling water tower, 221, 223–225
utility costs for off-site plants with multiple units, 222–223
utility costs for refrigeration, 225–228
utility costs for steam production, 228–234
yearly costs and stream factors, 237–238
Margins. See Profit margins
Margules equation, in solids modeling, 441–442
Marketing department, data for PFD synthesis, 370
batch optimization and, 491
supply and demand in chemical, 311–314
Marshall and Swift Equipment Cost Index, inflationary trends, 179–181
fluid flow in piping systems, 698–699
relationships in separations, 876–877
analyzing PFD for pollution/environmental performance, 1166–1167
applying pinch technology to, 541–549
heat-exchanger networks (HENs) vs., 541–542
pinch or pinch point in, 509–510
defined, 876
in mass balances, 877
McCabe-Thiele method for, 903–905
Mass, sizing pressure vessels, 1023–1024
continuous differential model for, 878–879
obtaining height of packed column, 929
Matching volume/heat transfer area
calculating in nonisothermal PFRs, 997–999
in nonisothermal plug flow reactors, 999–1004
McCabe-Thiele method for distillation, 890–892
and two-film model in distillation column, 902
Material balance, energy balance, rate equations, hydraulic equations, and equilibrium (MERSHQ) equations, 436–440
Material balance, phase equilibrium, summation equations, and enthalpy balance (MESH) equations, 435–440
Material balance, phase equilibrium, summation equations, and enthalpy balance (MESH) equations, 435–440
Dow Fire & Explosion Index, 1152
estimating plant cost for MOCs, 197
for heat exchangers, process vessels and pumps, 1267–1271
for other equipment, 1272–1274
Material safety data sheets (MSDS), HazCom, 1136
Materials of construction (MOCs)
advantages/disadvantages of, 357
bare module and material factors for, 1267–1271
bare module equipment costs, 188–192
bare module factor and costs, 199–201
corrosion allowance for pressure vessels, 1022
corrosion characteristics of some, 1019–1020
in estimating capital costs, 194–199
estimating grassroots vs. total module costs, 201–203
estimating heat-exchanger network costs, 536–539
estimating purchased equipment costs, 175
in life cycle analysis, 1168
module costing technique, 185
sizing pressure vessels, 1023–1024
Maximum likelihood criterion, thermodynamic models, 602
MBTI (Myers-Briggs Type Indicator), choosing group members, 1182
for binary azeotropic distillation, 379–381
determining column diameter, 916–920
for mass separating agents, 903–905
overview of, 888
vs. triangular diagrams for ternary azeotropic distillation, 382–383
McMaster five-step strategy, 1106–1107
McMaster Problem Solving (MPS) program, 1191
Measurement, of process variables, 662–663
analyzing base-case ratio of equipment, 738–739
calculating frictional losses, 709–711
fluid flow in piping systems, 700–703
friction factors in compressible flow, 719–720
friction factors in incompressible flow, 712–719
performance analysis of pumps using NPSH, 741–743
Mechanical flow diagram (MFD). See Piping and instrumentation diagrams (P&IDs)
Melting point, impacting environment fate of chemicals, 1163
recycling raw materials, 72
Memory matrix (or categorizing grid), in outcomes assessment, 4
Memos, for written communications, 1198
MENS. See Mass-exchange networks (MENs)
MESH (material balance, phase equilibrium, summation equations, and enthalpy balance) equations, 435–440
in pressure vessel construction, 1016–1018, 1023–1024
thermal conductivities of heat exchanger, 800–801
determining profit margin, 68–69
excess reactant in feed, 162–164
input/output structure of PFD, 61–63
limitations of tracing chemical pathways in PFDs, 145–146
producing with toluene and hydrogen, 11
tracing primary chemical pathways for, 141–142
Method of lines, in dynamic simulation, 632
MFD (mechanical flow diagram). See Piping and instrumentation diagrams (P&IDs)
Microeconomic theory, changes in supply and demand, 311
Mine Safety and Health Administration (MSHA), 1135
Minimum fluidization velocity, in fluidized beds, 728–730
Minimum Gibbs free energy equilibrium reactor, 408
Minimum number of exchangers (MUMNE)
constructing cascade diagram, 514–516
constructing heat-exchanger network (HEN), 517–523
handling streams with phase changes, 539–540
HENSAD program addressing, 540–541
for mass-exchange networks (MENs), 510, 542–544, 548
minimum approach temperature, 513
minimum number of heat exchangers, 516–517
overview of, 512
pollution prevention design and, 1165
temperature interval diagram, 513–514
Minimum temperature approach, using MUMNE for HENs, 513, 524, 527–529, 535–536
MINLP (mixed-integer nonlinear programming), 464
Minutes from design meetings, 1199
Mission, in group formation, 1184
Droplet distribution/separation efficiency from, 1040–1044
Mixed-integer nonlinear programming (MINLP), 464
Mixer-settlers, extraction equipment, 943, 946
bare module factors for, 1274
conditions of special concern for, 155–158
equipment cost data for, 1250–1251
input for process simulation, 407
purchase costs for, 1262
tracing chemical pathways in PFDs, 135–136
Mixing drums, as separation equipment, 912
Mob effect, organizational behavior, 1183–1184
Mobile truth, ethical decision-making and, 1107–1108, 1183–1184
MOCs. See Materials of construction (MOCs)
Model algorithmic control (MAC), 683
Model-based controls, advanced process control, 683
Model Predictive Control (MPC), 683
Modeling techniques, in steady-state simulation, 562
electrolyte systems. See Electrolyte systems modeling
gas permeation membranes, 949–950
Modified accelerated cost recovery system. See MACRS (modified accelerated cost recovery system) depreciation allowances
sequencing batch operations, 60
solution of DAE in dynamic simulation, 634
Modular method, solutions to DAE systems, 634
bare module equipment costs at base conditions, 186–189
bare module equipment costs at nonbase conditions, 189–194
calculating bare module costs, 199–201
grassroots and total module costs, 201–203
materials of construction (MOCs) and, 194–199
overview of, 185
Molal (constant molar) overflow, in binary distillation, 890, 893
Molar volume, modeling electrolyte systems, 432, 448
Money, investments and time value of, 248–251
CAPCOST program applying, 325
evaluating risks of new technology, 324–325
factoring into economic analysis, 1168
Moody diagram, friction factors, 709
Moody plot, defined, 709
developing. See Ethics and professionalism
in making ethical decisions, 1105
whistle-blowers and, 1115
Mother liquor, recycling raw materials in batch processing, 97
Motivation, friction in groups from low, 1180–1181
MPC (Model Predictive Control), 683
MSDS (material safety data sheets), HazCom, 1136
MSHA (Mine Safety and Health Administration), 1135
design of equipment for, 111–112
parallel process units, 110–111
Multistage steam ejectors, 1054–1057
Multistep methods, numerical integrator methods, 636
MUMNE. See Minimum number of exchangers (MUMNE)
Murphree efficiencies, calculating tray efficiency, 920
MVs. See Manipulated variables (MVs)
Myers-Briggs Type Indicator (MBTI), choosing group members, 1182
N
NAAQS (National Ambient Air Quality Standards), 1140
NAFTA (North American Free Trade Agreement) Ethics, 1119
Napthalene, producing phthalic anhydride from, 1402–1404
NASA (National Aeronautics and Space Administration) library website, 1191
National Aeronautics and Space Administration (NASA) library website, 1191
National Ambient Air Quality Standards (NAAQS), 1140
National Council of Examiners for Engineering and Surveying (NCEES), 1122–1124
National Institute for Engineering Ethics (NIEE), 1118–1119
National Institute for Occupational Safety and Health (NIOSH)
air contaminants standard, 1135–1136
health/safety information for employees/employers, 1135
National Response Center, EPA, 1141
National Society of Professional Engineers (NSPE)
Nationally Recognized Testing Laboratory (NRTL)
calculating Gibbs free energy for electrolyte systems, 430
liquid-state activity-coefficient models, 419–422
as fuel of choice for this text, 220–221
utility costs for, 234
Natural resources, green engineering and, 1159
NCEES (National Council of Examiners for Engineering and Surveying), 1122–1124
Needs analysis, in chemical product design, 124–127
Net positive suction head (NPSH)
heuristics for pumps, 360
pump-system curves and, 744
reasons for elevating equipment, 41
safe pump performance and, 739–743
tray spacing, flooding and, 915
troubleshooting cumene process feed section, 1075
troubleshooting cumene production facility, 1423–1424
comparing large projects, 296–298
discounted profitability criteria for, 291–295
modeling objective functions for, 470, 488–489
new facility design for allyl chloride production, 1395
optimizing flowsheet using before-tax, 597–600
in parametric optimization, 480–484, 487
profitability of equipment for, 299–300, 304
Net present worth (NPW), 291–293
New Source Performance Standards (NSPS), 1140
equation-oriented (EO) approach and, 585–586
modeling distillation column for electrolyte system, 450
performance for tear stream convergence, 583
steady-state simulation algorithms, 579–585
NGOs (nongovernmental organizations), 1134
Nickel and its alloys, materials of construction (MOCs), 194–197
NIEE (National Institute for Engineering Ethics), 1118–1119
NIOSH (National Institute for Occupational Safety and Health)
air contaminants standard, 1135–1136
health/safety information for employees/employers, 1135
NIOSH Pocket Guide to Chemical Hazards, 1135
Nitrogen, alternative schemes for compression of, 156
Nominal annual interest rate, 254
Non-stoichiometric feed conditions
justifying conditions of special concern in PCM, 161–163
reasons for operating at conditions of special concern, 154
Nondiscounted methods, incremental analysis, 305–308
Nondiscounted profitability criteria, 287–291
Nonequilibrium-stage modeling, MERSHQ in, 436–440
Nonfeasible distillation processes, ternary azeotropic distillation, 386
Nonferrous alloys, estimating plant cost, 194–197
Nongovernmental organizations (NGOs), 1134
Nonisothermal conditions, equipment design
fluidized bed reactors. See Fluidized bed reactors
Nonisothermal continuous stirred tank reactors (CSTRs)
performance problems, 1004–1006
Nonisothermal plug flow reactors (PFRs)
cooling medium, 991
hierarchies for exothermic/endothermic reactions, 984–986
matching volume and heat transfer area, 997–999
overall heat transfer coefficient, 992–993
performance problems, 1004–1006
pressure of process gas, 992
reactor concentration and temperature profiles, 987–989
role of heat transfer in reactor design, 990–991
Nonlinear equation solvers, in dynamic simulation, 637–639
in optimization, 464
in steady-state simulation, 590
Nonlinear Q versus T Curves, in heat exchanger relationships, 776–777
Nonoverlapping operations, in batch processing, 98–99
Nonprofessional responsibilities, ethical problem-solving, 1108–1110
Nonreacting chemicals, tracing, 145
Norming stage, in group evolution, 1185–1186
North American Free Trade Agreement (NAFTA) Ethics, 1119
S-T heat exchanger, 781
in tables, 1217
Notes, oral presentation guidelines, 1214
calculating discharge velocity, 702–703
measuring flowrate with, 731, 735
for pressure vessel design, 1023
for single-stage steam ejectors, 1051–1052
sizing pressure vessels and, 1023–1024
NPSH. See Net positive suction head (NPSH)
NPV. See Net present value (NPV)
NPW (net present worth), 291–293
calculating Gibbs free energy for electrolyte systems, 430
liquid-state activity-coefficient models, 419–422
NSPE. See National Society of Professional Engineers (NSPE)
NSPS (New Source Performance Standards), EPA, 1140
Nucleate boiling, 813
for figures and tables in reports, 1206
guidelines for equations in reports, 1207–1208
identifying process equipment in PFDs, 16–17
analysis of falling-film condensation, 824–825
falling-film condensation on cylinders, 825–828
heat transfer coefficients for laminar flow in tubes, 807–809
heat transfer coefficients for turbulent flow in tubes, 804–806
O
base cost analysis in optimization, 471
calculating base case using, 469–470
defined, 464
in easy vs. difficult optimization problems, 468
effect of topological change on parametric optimization, 475–476
identifying and prioritizing key decision variables, 471–472
optimizing flowsheet using, 597–600
sensitivity to changes in decision variables, 487–489
in single-variable optimization, 480
OBL (outside battery limits), estimating plant costs, 206–208
Obligations, in ethical problem-solving, 1110
Occupational Safety and Health Administration (OSHA)
air contaminants standard, 1135–1136
health and safety risk assessment, 1135
incidence rate statistics, 1132–1133
legal liability of chemical engineers, 1126
process safety management (PSM), 1138–1140, 1142
Octanol-water partition coefficient, 1162
ODEs (Ordinary differential equations), in dynamic simulation, 632, 634
Off-site recycle, Pollution Prevention Act of 1990, 1160
On-site recycle, Pollution Prevention Act of 1990, 1160
One-shot rising (OSR) internal device, Ladder Diagram (LD), 681
Open-cup method, measuring flash point of liquid, 1144
Open-loop (OL) response, dynamic simulation and, 639–640, 642–643
changes during parametric optimization, 484
decision variables in parametric optimization, 479
data for optimization base case, 470
discounted methods for incremental analysis, 309
evaluating equipment using EAOC method, 302–305
evaluating equipment with different expected operating lives, 300–302
evaluating equipment with same expected operating lives, 299–300
evaluating profitability of new project, 286
in manufacturing cost estimation, 218–219
Operator training simulator (OTS)
linking with ITS systems, 46–48
regulating and controlling chemical processes, 683–688
training control room operators, 688–689
estimating labor cost of manufacturing, 218–219
operator training simulators (OTS), 43–48
P&IDs used for training, 31
Optimal control, in advanced process control, 683
background information on, 463–464
base case approach to, 469–470
base cost analysis, 471
batch systems and optimum cycle time, 495–497
communicating results of, 468–469
early identification of alternatives in, 477–480
equation-oriented (EO) approach using, 586
estimating problem difficulty, 467–468
flexibility and sensitivity of the optimum, 489–490
flowsheet optimization using decision variables, 484–489
identifying and prioritizing decision variables, 471–472
lattice search, response surface, and mathematical optimization techniques, 489
modeling objective function in terms of decision variables, 488–489
objective functions in, 470–471
parametric. See Parametric optimization
problem-solving 20,000-metric-tons-per-year facility for allyl chloride production, 1395
scheduling equipment for batch processes, 490–494
selecting objective function for, 464
sensitivity of objective function to changes in decision variables, 487
single-variable example, 480–481
steady-state simulation and, 589–592
steady-state simulation examples, 593–600
terminology used in, 464
top-down and bottom-up strategies, 468
topological optimization, 473–479
audience analysis and, 1196
briefings, 1211
formal presentations, 1210–1211
software and author responsibility, 1215–1218
WVU and Auburn University guidelines, 1212–1214
Order-of-Magnitude, capital cost estimates, 172–174
Ordinary differential equations (ODEs), in dynamic simulation, 632, 634
Organizational behaviors, in groups, 1176, 1180–1184
Organizational structure, of group, 1182
Orifice, flowrate measurement, 731–735
OSHA. See Occupational Safety and Health Administration (OSHA)
OSR (One-shot rising) internal device, Ladder Diagram (LD), 681
OTS. See Operator training simulator (OTS)
results of, 1
summary, 6
Outline, oral presentation guidelines, 1212
Output devices (or coils), Ladder Diagram (LD), 680
Output display options, selecting for simulation, 411
in dynamic simulation, 617
equipment geometry/size for dynamic simulation, 622–624
Outside battery limits (OBL), estimating plant costs, 206–208
efficiency of use of raw materials, 70–71
of reactant, 965
Overall heat transfer coefficient (U)
equipment parameters in process simulation, 405
exchanging heat between streams and utilities, 678
in feed-forward control example, 667
in fluidized-bed reactor design, 1388
in heat transfer, 679
process control exercise using, 645–646
in reaction kinetics, 1306
reactor performance problems, 1005
using dynamic simulators in design, 638
variance within heat-exchanger, 777–778
Overlapping operations, in batch processing, 100–103
Overreliance on team members, 1189
P
P-only (proportional-only) controllers, dynamic simulation, 640
Packed-bed absorber, troubleshooting, 1071–1074
Packed bed-absorber, troubleshooting case study, 1071–1074
Packed columns, McCabe-Thiele distillation method for, 901–902
choosing tray towers vs., 933
obtaining height and diameter of, 929–931
packing types and shapes, 928
vapor-liquid separation using, 926–927
bare module cost for, 1270
bare module factors for, 1271
equipment cost data for, 1251
material factors for, 1273
pressure factors for, 1266
purchase costs for, 1257
Paper-and-pencil studies, capital cost estimates as, 174
PAR analysis, creating new heuristics, 349–351
Parallel plate settlers, L-L separation, 1046–1047
Parallel process units, increasing production, 110–111
Parallel reactions, reaction kinetics and, 977–980
modeling distillation column for electrolyte system, 447–448
Monte-Carlo analysis for quantifying risk, 321–324
flowsheet optimization using decision variables, 484–487
overview of, 479
single-variable example of, 480–481
two-variable example of, 481–484
Pareto analysis, of base costs in optimization, 471
Partial differential equations (PDEs), 632
adjusting in heat exchanger for each phase, 679
in S-T heat exchangers, 784–785
in sequential modular approach, 572–578
Passive voice, for written design reports, 1202
Pattern search, parametric optimization, 489
Pavlov equation, frictional losses, 710
discounted payback period (DPBP), 291–293
incremental payback period (IPBP), 305–308
time-related criteria in project evaluation, 287–291
PCM (Process conditions matrix), conditions of special concern, 158–164
PDEs (partial differential equations), 632
PDMS software, from CadCentre, 41
PE (Principles and Practice) exam, 1124–1125
PEL (Permissible exposure limits), OSHA air contaminants standard, 1135
Peng-Robinson (PR) fugacity model, 417–418
fluid flow. See Fluid flow equipment, performance
fluid mechanics. See Fluid mechanics
heat exchangers. See Heat exchangers, performance
heat transfer and. See Heat transfer
knockout drums. See Knockout drums (phase separators)
of Model Predictive Control (MPC) applications, 683
packed and tray towers, 933–934
pinch technology and, 510
pressure vessels. See Pressure vessels
process variables regulating, 662–663
steam ejectors. See Steam ejectors
updating PFD to reflect changes in, 26
Permissible exposure limits (PEL), OSHA air contaminants standard, 1135
Personal income, ways to distribute, 248–251
PERT (program evaluation and review technique), group scheduling, 1185
Pervaporation, for purification of ethanol, 380–381
Pesticides, environmental law for, 1161
PHA (Process Hazard Analysis), 1145–1146
heat exchangers with stream, 775–776
binary interaction parameters (BIPs) in, 417–418
dynamic simulation setup, 621
equations of state in, 417–418
flash units and, 408
liquid-state activity-coefficient models and, 419–423
physical property data for PFD design, 371
unit operation calculations, 563
using thermodynamic models, 425
Phase separators. See Knockout drums (phase separators)
Phenol, production of, 1417
Phenomenological reactor models, 1001
Phthalic anhydride production, at new facility, 1412–1416
Phthalic anhydride production, scaling down
assignment, 1411
background, 1401
equipment summary table, 1409–1410
other information, 1403
phthalic anhydride, 1402
process flow diagram, 1402–2003
pump and compressor curves, 1405
pump curves, 1404
report format, 1411
utility summary table for current operation, 1408
base-case ratios applied to, 737
choosing thermodynamic models, 416
data for PFD synthesis, 371
estimating fate of chemicals in environment, 1160–1163
heuristics for, 355
measuring process variables, 662
models for process simulation, 401–404
parameter estimates for thermodynamic models, 601–604
PI (proportional-integral), controllers, dynamic simulation, 640
Pictures, in design reports, 1200, 1206–1207
PID (proportional-integral-derivative), controllers, dynamic simulation, 640–643, 645
common mistakes made in, 1225
corrected version of, 1226
in design reports, 1200
Pilot plants, developing processes in, 60
Pinch, defined, 509
composite enthalpy curves and, 524–529
composite temperature-enthalpy diagram, 523–525
design away from the pinch, 519, 520–523
design below the pinch, 519–520
determining EAOC for network, 534–535
effectiveness factor (F) and number of shells, 529–534
heat-exchanger network synthesis analysis and design (HENSAD), 540–541
heat integration and network design, 510–513
mass-exchange networks, 541–549
materials of construction and operating pressure issues d, 536–539
multiple utilities and, 539
solving MUMNE problem, 512–521
streams with phase changes and, 539–540
Pinch zone (or pinch temperature)
design of heat-exchanger network above, 518
design of heat-exchanger network below, 519
Pipeless batch processes, 60
calculating frictional losses, 709–711
calculating pipe sizes in 3-D plot plan, 37–38
cumene production facility problems, 1427
drawing isometrics for every pipe in plant, 33
as fluid flow equipment, 703–708
friction factors in incompressible flow, 712–719
heuristics for, 360
major process and utility, in 3-D plot plan, 41
sketching in 3-D plot plan, 41
in system design. See Fluid mechanics
Piping and instrumentation diagrams (P&IDs)
acrylic acid separations process, 1050
in case history, 10
data excluded from, 27
in design reports, 1200
plant construction information in, 27
as starting point for OTS system, 44–45
summarizing equipment in, 21–23
Plagiarism, citations of other work vs., 1200
Planar geometry, overall heat transfer coefficient and, 799
Planned emissions, EPA, 1140–1141
bare module equipment costs at base conditions, 186–189
bare module equipment costs at non-base conditions, 189–194
calculating bare module costs, 185
calculating grassroots vs. total module costs, 201–203
CAPCOST for calculating bare module costs, 204–206
CEPCI and Marshall and Swift indices, 179–181
CEPCI applied for inflation, 183–184
estimating based on capacity, 206–208
Lang Factor technique for, 184
materials of construction (MOCs) and, 194–199
module costing technique for, 185
dynamic modeling for start-up/shutdown, 619
Plastics, advantages/disadvantages of, 356
Plate-and-frame heat exchangers, LMTD correction factor, 797
Plate baffles, S-T heat exchanger design, 785–786
PLCs (programmable logic controllers), 680–682
3-D representation of. See 3-D representation of process (plant model)
locating all equipment in plant, 32–33
Plug flow reactors (PFRs). See also Nonisothermal plug flow reactors (PFRs)
dynamic simulation of, 632
input for process simulation, 408
performance problems, 1003–1006
replacing with series of CSTRs, 632
Pneumatic conveying (transport) reactors, 1001
Poisons, when to purify the feed, 66
design processes to minimize. See Green engineering
economics of preventing, 1167–1168
preventing in process design, 1164–1166
Pollution Prevention Act (PPA), 1159–1161
Polyethylene, life cycle analysis of, 1168–1169
estimating plant cost for MOCs, 194
used for smaller pressure vessels, 1016
Polymorphs, solids modeling and, 440–441
determining critical or maximum heat flux in, 815–816
effects of forced convection on, 817–822
heat transfer coefficients, 813–817
Pop valves, in pressure-relief systems, 1145
Portable devices, in chemical product design, 127, 128
Positive displacement compressors, 709, 750
increasing pressure/regulating flowrate in streams, 674–676
overview of, 706
performance analysis of fluid flow in, 745–746
Postmortem analysis, oral presentation guidelines, 1214
Postrationalization, in justification behavior, 1108
Potential energy, in piping systems, 700–703
bare module cost for, 1270
bare module factors for, 1271
heuristics for, 358
input for turbines in process simulation, 406
purchased costs for, 1273
PPA (Pollution Prevention Act), 1159–1161
PR (Peng-Robinson) fugacity model, 417–418
Practicing, oral communications, 1209
Precedence ordering, in sequential modular approach, 572–574, 577
Precipitators, in batch optimization, 490–494
Predict, PAR analysis for new heuristics, 349–351
Predictive problems, performance, 696
Predictor-Corrector methods, numerical integrator methods, 636–637
Preliminary design of chemical processes
acetone. See Acetone production from isopropyl alcohol
acrylic acid. See Acrylic acid production from propylene
CO2 and H2S removal. See CO2 and H2S removal from coal-derived syngas
converting H2S. See Claus unit design, converting H2S to elemental sulfur
dimethyl ether (DME), 1278–1283
downward-flow, oxygen blown, entrained-flow gasifiers, 1371–1377
drying oil. See Drying oil (DO) production
ethylbenzene. See Ethylbenzene (EB) production
ethylene oxide. See Ethylene oxide production
formalin. See Formalin production
heptenes. See Heptenes production
L-phenylalanine and L-aspartic acid. See L-phenylalanine and L-aspartic acid, batch production
maleic anhydride. See Maleic anhydride production from benzene
material factors in equipment cost, 1272–1274
styrene. See Styrene production
WGS reactor converting CO to CO2, 1352–1356
Preliminary Design (Scope), in cost estimate, 172
Present value ratio (PVR), in project evaluation, 291–293
Presentation mechanics, guidelines for oral, 1213–1214
bare module costs at non-base conditions, 189–194
bare module factor and costs, 199
condenser and reboiler affecting, 925
control system for binary distillation column, 685–687
devices increasing gas, 707
estimating plant cost for MOCs, 197–199
estimating utility costs for cooling water tower, 224
evaluating reactor process conditions, 158–164
fluidized beds and, 728
friction factors in incompressible flow, 713–714
heat exchange between streams and utilities, 676–678
heat transfer coefficients for pool boiling curve, 813–815
increasing and regulating, 674–676
measuring process variables, 662
operating conditions of special concern for reactors/separators, 150–152, 154
physical property variations and, 355
reactor design for PFD synthesis and, 372
reducing with valves, 705
regulating flowrates and, 660–662
in two-variable optimization, 481–484
utility costs for refrigeration and, 227–228
utility costs for steam production and, 228–234
calculating for packed tower, 931–933
calculating in nonisothermal PFRs, 992
for condensers and reboilers, 924–925
debottlenecking allyl chloride reactor, 1087–1088
heat exchanger design considerations, 837–841
increasing allyl chloride production, 1386
matching volume with heat transfer in S-T reactors, 997–999
measuring flowrate by creating, 730–735
S-T heat exchanger design, 844–846
troubleshooting acrylic acid product, 1076–1078
troubleshooting steam release in, 1080–1081
Pressure-flow networks, 619–622
Pressure-relief systems, 1145
Pressure-relief valves, 1095–1096, 1145
guidelines for choosing separation units, 374
recycling raw materials, 72, 77
when applicable, 382
corrosion allowance, 1022
cyclindrical shells, 1016–1021
designing, 1016
heads, 1022
heuristics for, 359
mass of vessels and heads, 1023–1024
material properties, 1016
nozzles, 1023
purpose of, 1015
Pressure wave, in explosions, 1144
Price, supply/demand affecting market, 311–314
justifying conditions of special concern for, 136
for toluene hydrodealkylation process, 137–140
Principal, or present value, of investment, 249
Principles and Practice (PE) exam, 1124–1125
Probabilistic approach to quantifying risk
Monte-Carlo method, 318, 321–324
Monte-Carlo analysis for quantifying risk, 321–324
Problem-Based Learning (Woods), 1190–1191
debottlenecking. See Debottlenecking
estimating problem difficulty, 467–468
in troubleshooting. See Troubleshooting
Process concept diagrams, 60–61
evaluation of exchangers, 164
evaluation of reactors, 159–164
for operating at conditions of special concern, 150–154
of special concern for operation for other equipment, 155–158
of special concern for separation/reactor systems, 150–152
Process conditions matrix (PCM), conditions of special concern in, 158–164
Process design. See Experience-based principles, in process design
Process flow diagrams (PFDs). See also Synthesis of PFD, from BFD
for 3-D representation of process, 34–35
batch processes vs. continuous process, 56–60
in case histories, 10
combining topology, stream data, and control strategy, 21–26
conditions of special concern and. See Process conditions
in design reports, 1200
equipment information in, 21
estimating utility costs from, 238–240
formulating preliminary, 78–83
heat-exchanger network/process energy recovery, 83
hierarchy of process design, 55–56
input/output structure for, 61–63
pollution/environmental performance, 1166–1167
process simulation flowsheets vs., 1217–1218
recycle structure. See Recycle structure
regulation problem using, 655
separation sequence structure in, 83
tracing chemicals. See Tracing chemical pathways, in PFDs
understanding, as central goal of this book, 11
updating changes on, 26
Process fluid mechanics. See Fluid mechanics
Process Hazard Analysis (PHA), 1145–1146, 1149
Process heat exchangers, dynamic models for, 627–630
Process optimization. See Optimization
Process Safety Management (PSM) of Highly Hazardous Chemicals, OSHA
Risk Management Plan (RMP), EPA, 1142
Process streams. See Streams
categorizing information in PFDs, 14–18
changes from steady-state simulation, 619–622
input flowsheet data for process simulation, 404
reaction kinetics data for PFD, 370–371
remaining fixed in parametric optimization, 483
Process vessels. See Vessels
Producer, investment, 249
tracing primary chemicals, 136
troubleshooting off-specification product, 1076–1078
unwanted products impacting equilibrium or reactor operation, 77
Product design. See Chemical product design
Product manufacture, in life cycle analysis, 1169
Product quality, continuous vs. batch processes and, 57
Product specification, choosing separation units for PFD synthesis, 375
for single-product campaigns, 106–108
Product use and reuse, in life cycle analysis, 1169
Professional development hours (PDHs), renewing PE license, 1125
Professional life, whistle-blowing consequences, 1115
Professional registration (certification)
engineer-in-training certification, 1122–1124
Principles and Practice (PE) exam, 1124–1125
Professionalism. See Ethics and professionalism
Profit, impact of tax rate on, 274–277
base costs in optimization, 471
economics of chemical product design, 130–131
information from input/output diagrams, 68–69
recycling raw materials and, 97
cash flow diagram for new project, 285–287
discounted criteria and, 291–295
equipment with different expected operating lives in, 300–305
equipment with same expected operating lives in, 299–300
evaluating risks of new technology, 309–310
forecasting uncertainty in chemical processes, 310–314
incremental analysis comparing large projects, 295–297
incremental analysis for retrofitting facilities, 305–309
Monte-Carlo analysis for quantifying risk, 321–324
nondiscounted criteria, 287–291
probabilistic approach to quantifying risk, 318–321
rate of return on investments, 298–299
risk when using new technology, 324–325
scenario analysis for quantifying risk, 314–315
sensitivity analysis for quantifying risk, 315–318
Programmable logic controllers (PLCs), 680–682
Progress reports, written communications as, 1199
Propellers, vs impellers of centrifugal pumps, 706–707
Proportional-integral-derivative (PID), controllers, dynamic simulation, 640–643, 645
Proportional-integral (PI), controllers, dynamic simulation, 640
Proportional-only (P-only) controllers, dynamic simulation, 640
Proprietary knowledge, business codes of conduct, 1127
Propylene. See also Heptenes production
design new facility for allyl chloride production, 1394–1396
producing acrylic acid from. See Acrylic acid production from propylene
producing allyl chloride from, 1383–1386
producing cumene from. See Cumene production facility problems
producing heptenes from. See Heptenes production
PSM (Process Safety Management) of Highly Hazardous Chemicals, OSHA
Risk Management Plan (RMP), EPA, 1142
Public speaking. See Oral communication
Pulsed columns, extraction equipment, 943
bare module and material factors for, 1267–1271
calculating horsepower requirements, 713–715
capacities of process units in common usage, 356
equipment cost data for, 1251
estimating utility costs from PFDs, 238–240
as fluid flow equipment, 706–707
friction factors in incompressible flow, 712–719
increasing pressure/regulating flowrate in process streams, 674–676
input for process simulation, 406
mechanical energy balance in piping systems, 700–703
performance analysis of pump curves, 743–749
performance analysis using NPSH, 739–743
performance of feed section to process, 751–755
pressure factors, 1266
purchase costs, 1254
Punctuation, in written design reports, 1202–1203
Purge stream, recycling feed and product, 73–75
decision variables in parametric optimization, 479
of raw material streams prior to recycling, 76
recycling raw materials, 71
PVR (present value ratio), in project evaluation, 291–293
Q
defined, 464
flowsheet optimization using Successive QP (SCP), 590–591
solving linear MPC problems, 683
Quantitative assessment, in chemical product design, 129
applying to thermodynamic properties, 563–564
equation-oriented (EO) approach and, 585–586
Question-and-answer period, oral communications, 1210, 1214
R
Radial geometry, overall heat transfer coefficient, 799
Raffinate, defined, 910
Random numbers, M-C analysis for quantifying risk, 321–322
Random packings, packed towers, 928, 930
for flowrate of stream, 660
for fluid flow, heat transfer, mass transfer and chemical reactors, 436–440
kinetic reactors and, 408
in nonequilibrium-stage modeling problem, 436
required in EPA hazard assessment, 1142
Rate expressions, relationships in separations, 882–883
Rate of return on investment (ROROI)
establishing acceptable, 298–299
nondiscounted methods for incremental analysis, 305–308
nondiscounted profitability criteria and, 289–291
objective functions in optimization, 470
applied to water-gas shift (WGS) reactor, 669–671
overview of, 669
affecting supply and demand curves, 313
calculating yearly cost of, 237–238
designing pollution prevention, 1165
determining profit margin, 68–69
efficiency of use, 70–71, 541–549
estimating manufacturing costs, 234–237
green chemistry and, 1163–1164
in life cycle analysis, 1168
profit margin analysis using cost of, 326
purifying prior to recycling, 76
recycle section of PFD synthesis and, 389
recycling to ensure maximum profit, 97
RCRA (Resource Conservation and Recovery Act), 1141, 1161
REACH (Registration, Evaluation, Authorization and Restriction of Chemicals), 1137
evaluating excess in feed, 154
excess affecting recycle structure, 76
justifying conditions of special concern for reactors, 162–163
potential number of recycle streams and, 75–76
in process concept diagrams, 60–61
tracing, 136
choosing thermodynamic models, 415
justifying conditions of special concern in reactors using PCM, 159–160
resources on, 84
role in correct design for chemical reactors, 966–968
in synthesis of PFD from BFD, 370–371
impact of pressure on, 163
impact of temperature on, 162–163, 980
justifying reactors operating at temperature conditions of special concern, 152–153
in reactor and separator feed preparation, 388–389
synthesis of PFD from generic BFD, 371
using continuous vs. batch processes, 59
Reaction vessels. See also Vessels
batch processing equipment design, 111
runaway reactions and catastrophic failure of, 1145
Reactions. See Chemical reactions
Reactor block, in BFDs, 64
Reactor feed preparation block, in BFDs, 63–64
additional mass transfer effects, 965–969
bare module factors for, 1274–1275
batch optimization scheduling issues, 490–494
control system for water-gas shift (WGS) reactor, 669–671
cumene reactor case study, 683–685
dynamic models for, 632
equipment cost data for, 1251
heuristics for, 366
input for process simulation, 407
justifying conditions of special concern for, 150–154
performance problems, 1003–1006
purchase costs for, 1251, 1263
reasons for multiple, 76
recycling unwanted products from, 77
selecting equipment parameters in PFD synthesis, 407
synthesizing PFD from BFD, 372–373
transforming feed chemicals into product chemicals, 137
transport (pneumatic conveying) reactors, 1001
Readability indices, word-processing software, 1216
Reboilers. See also Boilers
debottlenecking strategies for, 939
impact on performance of distillation columns, 934–942
oral presentation guidelines, 1213
written report guidelines, 1205
written report improvements, 1243–1244
Recommended exposure limits (REL), NIOSH air contaminants, 1135
derivation of fin effectiveness for, 864–866
fin efficiency for constant thickness, 829–831
heat transfer surface examples, 833–837
total heat transfer surface effectiveness, 831–832
Recycle block, in BFDs, 65
Recycle loops, defined, 142
in parametric optimization, 479
in PFD synthesis, 389
in process simulation, 413–415
recognizing in chemical processes, 142–145
in sequential modular approach, 576–577
using tear streams to solve problems with, 400–401
effect of excess reactants on, 76
in batch processing, 97
efficiency of raw material usage, 70–71
formulating preliminary process flow diagram, 78–83
identification and definition of, 71–75
methods for unreacted raw materials, 76–77
number of reactors required, 76
overview of, 70
Pollution Prevention Act of 1990, 1160
purifying raw materials prior to recycling, 76
recycling unwanted product/inert, 76–77
Reevaluate, PAR analysis for new heuristics, 349–351
reasons for designing high, 899–900
in single-variable optimization, 480–481
in two-variable optimization, 481–484
Refractory-lined pipes, for high-temperature service, 703
estimating utility costs, 222, 225–228
heuristics for, 367
new chemical products needed for, 125, 127
ranges of cooling, 78
Registered professional engineer, 1124–1125
Registration, Evaluation, Authorization and Restriction of Chemicals (REACH), 1137
of chemical processes. See Control and regulation of chemical processes
health, safety and environment, 1134
legal liability of chemical engineers, 1125–1126
Pollution Prevention Act of 1990, 1159–1160
protection for whistle-blowers, 1115
Internet addresses for federal agencies, 1134
list of acronyms for, 1154–1156
nongovernmental organizations, 1143–1144
Process Safety Management (PSM), 1138–1140
Regulatory control design, dynamic simulation in, 619
in ethical decision-making, 1105–1106
nonprofessional responsibilities and, 1109–1110
and reflection in action, 1106–1107
REL (Recommended exposure limits), NIOSH air contaminants, 1135
energy balances, 877
equilibrium relationships, 877–878
mass transfer relationships, 878–881
overview of, 876
Release of waste, generated in processes, 1160
Relief (or safety) valves, in pressure-relief systems, 1145, 1166
assignment memorandum, 1221–1222
checklist of common mistakes for visual aids, 1244–1245
checklist of common mistakes for written text, 1245–1246
example of improved report, 1233–1244
example with suggestions for improvement, 1231–1233
overview of, 1221
response memorandum, 1222–1224
Residual cost, evaluating profitability of equipment, 300–301
Residue curves, ternary azeotropic distillation, 382–388
Resistances, in heat transfer coefficients, 798–800
Resource Conservation and Recovery Act (RCRA), 1141, 1161
for engineering ethics, 1118–1121
Response memorandum, report-writing case study, 1222–1224
Response surface techniques, parametric optimization, 487, 489
Responsibilities, group member, 1183
Responsible Care program, chemical industries, 1143
Retentate, gas permeation for purifying, 950
Retroactive liability, 1163, 1168
cash flows/profits in terms of, 275
profit margin analysis and, 325–326
sensitivity analysis for quantifying risk, 316–318
Rigorous hydrodynamic models, 1001
Rigorous module, distillation column design, 409–411
assessment, in health and safety, 1131–1134
evaluating profitability, 309–310
forecasting uncertainty, 310–314
Monte-Carlo analysis for quantifying, 321–324
probabilistic approach to quantifying, 318–321
relationship to rate of return, 298–299
scenario analysis for quantifying, 314–315
sensitivity analysis for quantifying, 315–318
Risk Management Plan (RMP), EPA, 1141–1142
Rod baffles, S-T heat exchanger design, 785, 787
Roles, group member, 1183
Rotameters, measuring flowrate, 731
Runaway reactions, 1145
Runge-Kutta family methods, 636
Rupture disks, in pressure relief systems, 1145
S
S (Salvage value), nondiscounted profitability criteria, 288–291
Safety. See also Health, safety, and environment (HSE)
considerations on when to purify the feed, 66–67
decision to use continuous vs. batch processes, 59
simulation in training for, 48
of work environment, 1131–1134
Safety data sheets (SDS), HazCom, 1136–1138
Safety (or relief) valves, in pressure-relief systems, 1145, 1166
Sales volume, in profitability analysis, 310
Salvage value (S), depreciation and, 288–289
SARA (Superfund Amendments and Reauthorization Act)
CERCLA amended by, 1161
overview of, 1141
in condensing heat transfer, 824
heat transfer coefficients for pool boiling curve, 813–815
Scale models, 3-D plant models, 33
as graphs in design reports, 1200
guidelines for reports, 1206–1207
Scenario analysis, for quantifying risk, 314–315
batch processes, 97–98, 490–494
Scheduling charts, design reports, 1200
Scientists, interactions among, 370
Scope (Preliminary Design), in cost estimate, 172
bare module factors for, 1275
equipment cost data for, 1251
purchase costs for, 1263
Screw threads, pipe connections, 705
Scrubbers, in pressure-relief systems, 1145
SDS (safety data sheets), HazCom, 1136–1138
Seals, on compressors, 708
Secure disposal, Pollution Prevention Act of 1990, 1160
in chemical product design, 124–125, 128–130
justifying reactors operating at temperature conditions of special concern, 153
for parallel and series reactions, 977–980
Selexol unit design. See CO2 and H2S removal from coal-derived syngas
Self-assessment, group effectiveness, 1178–1180
Self-confidence, in oral communications, 1209–1210
Semibatch processes, logic control in, 680–682
Semicolons, written report guidelines, 1203
decision variables and, 471–472, 487
steady-state simulators used in, 589
Sensitivity coefficient, quantifying risk, 315–318
Separate and purify, recycling unreacted raw materials, 71–73
in allyl chloride production, 1386, 1396–1397
distillation in. See Distillation
electrolyte applications, 428
formulating PFD for, 83
guidelines for choosing separation units, 374–376
McCabe-Thiele method for, 903–905
mist eliminators in V-L separation, 1040–1044
pollution prevention and, 1165
using alternative technologies for, 477–478
using mass separating agents, 876, 877
Separation basis, defined, 875–876
Separation equipment. See also Separators
condensers and reboilers, 923–926
distillation column performance, case study, 934–942
for gas permeation membrane separations, 947–950
performance of packed and tray towers, 933–934
for phase separation. See Knockout drums (phase separators)
tray towers. See Tray towers
Separations, basic relationships in
energy balances, 877
equilibrium relationships, 877–878
mass transfer relationships, 878–881
Separations, illustrative diagrams for
Kremser and Colburn methods for dilute solutions, 905–911
McCabe-Thiele diagram for distillation, 888–901
McCabe-Thiele diagram for mass separating agents, 903–905
McCabe-Thiele diagram for packed columns, 901–902
Separator block, in BFDs, 64–65
Separator feed preparation block, in BFDs, 64
Separators. See also Distillation
analyzing conditions of special concern for, 158–159, 164
decision variables in parametric optimization, 479
dynamic simulation of flash separators, 630–632
justifying conditions of special concern for, 150–154
optimization in batch systems and, 490–494
phase. See Knockout drums (phase separators)
Separators, synthesizing PFD from BFD
azeotropic distillation, 378–379
azeotropic distillation in binary systems, 379–382
azeotropic distillation in ternary systems, 382–388
gathering physical property data, 371
guidelines for choosing separation operations, 374–376
overview of, 374
Sequencing, batch process design and, 91
Sequential Function Chart (SFC), 680
Sequential modular (SM) approach, to steady-state simulation
accelerated successive substitution (relaxation) methods, 578
direct substitution algorithm, 578
dominant eigenvalue method (DEM), 578–579
equation-oriented (EO) approach vs., 585–586
Newton’s method, 579
optimization of flowsheet convergence and, 590–591
SMod approach as hybrid of SM and EO, 586–589
solving optimization problem using, 592–595
Wegstein’s method, 579
Series reactions, reaction kinetics, 977–980
dynamic simulation in, 619
split-range control system, 671–672
feedback control system and, 663–665
process control in dynamic simulation, 640, 644
SF (stream factors), in calculation of yearly costs, 237–238
Shell-and-tube (S-T) heat exchangers. See also Heat exchangers
concentration/temperature profiles in reactors, 987–989
design algorithm examples, 840–846
design for pressure drop, 837–838
effectiveness factor (F) and number of, 529–534
estimating EAOC for network, 534–536
estimating heat-exchanger network costs, 537–539
fixed tubesheet and floating tubesheet (head), 783–784
heat transfer coefficient for, 992–993
heat transfer design in, 990–991
LMTD. See LMTD correction factors
LMTD effectiveness charts, 861–864
matching volume and heat transfer area, 997–999
notations for, 781
overview of, 779
shell-and-tube partitions, 784–785
shell-side flow patterns, 785–788
tubesheet and tube configurations, 780, 782–784
Shell type, heuristics for S-T heat exchangers, 788–789
Shells, pressure vessel design for cylindrical, 1016–1021
Shewart charts, in statistical process control, 682
Shock wave, in explosions, 1144
Short-term exposure limit (STEL), air contaminant hazards, 1135
Shortcut methods, experience-based principles in process design, 348–349
Shortcut module, in distillation column design, 409
calculating flooding velocities, 915–916
prone to weeping, 913
for separation, 912
Signatures, for design meeting minutes, 1199
Simple distillation, PFD synthesis, 376–379
Simple phase separators. See Knockout drums (phase separators)
Simple savings, 248
Simplex-Nelder-Mead method, parametric optimization, 489
Simulated annealing method, parametric optimization, 489
common errors in using, 412–413
convergence criteria and running, 411–412
dynamic. See Dynamic simulators
immersive training simulators (ITS), 45–46
operator training simulators (OTS), 43–46
output display options, 411
training for emergencies, safety, and maintenance, 48
chemical components, 401
feed stream properties, 404–405
flowsheet topology, 404
physical property models, 401–404
avoid using raw output in reports, 1217–1218
dynamic. See Dynamic simulators
expert systems in, 402
and friction in groups, 1181
physical property databanks, 402
progress reports, 1199
steady-state. See Steady-state simulators
synthesis of PFD using. See Synthesis of PFD, using simulators
Simultaneous method, solutions to DAE systems, 634–635
Simultaneous modular (SMod) algorithm
process simulator, 400
for process simulators, 400
SM algorithm vs. See Sequential modular (SM) approach, to steady-state simulation
steady-state simulation, 586–589
Single-input-single-output (SISO) controllers, dynamic simulation, 640
number of potential recycle streams and, 75–76
in parametric optimization, 479
reactor design and, 373, 970–971
shifting equilibrium of reaction, 68
thermodynamic equilibrium and, 964
Single-product campaigns, product storage for, 106–108
Single-stage steam ejectors, 1051–1054
Single-variable example, of parametric optimization, 480–481
SISO (single-input-single-output) controllers, dynamic simulation, 640
Site plans, 32
capital cost for chemical plant, 182–183
capital cost for process equipment, 176–178
base-case ratio and equipment, 737
dimensions of standard pipes, 703–705
of droplet distribution in L-L separation, 1044–1045
of pressure vessels, 1023–1024
of vessel in dynamic simulation, 622–624
developing with multiple experiences/feedback, 6
ethical decisions and, 1105–1106
SL. See Straight-Line (SL) depreciation method
SLE (solid-liquid equilibrium), 441–443
Slide shows, oral presentation guidelines, 1211–1213
SM. See Sequential modular (SM) approach, to steady-state simulation
Societal impact, of chemical engineering, 1101–1102
SOCMA (Synthetic Organic Chemicals Manufacturers Association), 1143
author responsibility to know report, 1215–1218
PDMS, from Cadcentre, Inc., 41
virtual plant walkthrough, 34
Soilsorption coefficient, estimating fate of chemicals in environment, 1163
Solid-gas (adsorption), 903
Solid-liquid equilibrium (SLE), 441–443
Solid-liquid (leaching, washing, adsorption), 903
Solid-vapor equilibrium (SVE), 441–442
overview of, 440
parameter requirements, 442–444
chemical product design for new, 124
improving environment with green, 1164
minimizing pollution by recycling, 1165
Sour-water stripper (SWS), developing, 435–440
Source reduction regulation, Pollution Prevention Act, 1159–1160
SOYD (sum of the years digits) depreciation method, 270–273
feedback control system and, 663–665
process control in dynamic simulation, 640, 644
SPC (statistical process control), 682
Special process hazards factor, Dow Fire & Explosion Index, 1152
Speciality chemicals, 123, 124
using spell-checkers for written reports, 1215
in written design reports, 1202–1203
Split-range control system, 671–673
identifying recycle and bypass streams, 144–145
input for process simulation, 407
tracing chemical pathways in PFDs, 135–136
SQP (Successive Quadratic Programming), in flowsheet optimization, 590–592
Kern’s method for shell-side heat transfer, 810–813
layout patterns for tubes, 784
mechanical cleaning on shell side with, 783
ST (Structured Text), logic control, 680
Stack, in pressure-relief system, 1145
Stage cut, in gas permeation, 949
Staged separation, in dilution, 906–907
Staging, of compressors, 750–752
advantages/disadvantages of, 356
estimating plant cost for MOCs, 194–197
for pipes in extreme conditions, 703
temperature conditions of special concern for reactors/separators, 151
Standards for Steam Jet Vacuum Systems, 1050
Start-up procedures, developing with P&IDs, 31
Stationary head, fixed and floating tubesheet design, 783–784
Statistical process control (SPC), 682
Steady-state design, with OTS, 688
Steady-state material balance, maintaining process control, 656
accelerated successive substitution (or relaxation) methods, 578
direct substitution method, 578
dominant eigenvalue method (DEM), 578–579
dynamic simulation using topological changes from, 619–622
dynamic simulators compared to, 618
equation-oriented (EO) approach, 585–586
estimating physical property parameters, 601–604
need for, 562
Newton’s method, 579
operator training simulators (OTS) as, 43–45
optimizing cost function in flowsheet, 593–595
optimizing cost of syngas production, 595–600
overall heat transfer coefficient, 798–800
overview of, 562
sensitivity studies using, 589
SM approach to, 572–578, 580–585
solution strategy for, 571–572
user-added models (UAM) and, 562–563
user-added unit operation models (UAUOM), 563–564
user thermodynamic and transport models, 564–565
Wegstein’s method, 579
conditions of special concern for, 155
conventions for identifying in PFDs, 18
cost for high-pressure, 230–231
cost for low-pressure, 233–234
cost for medium-pressure, 231–233
cost of manufacturing (COM), 214, 241–242
cumene production facility problems, 1418
elevating condensers for high-pressure, 41
heuristics for physical properties and, 355
heuristics for piping and, 360
heuristics for refrigeration and, 367
heuristics for steam turbines, 358
input/output structure of process flowsheet for, 66–68
low-temperature heating via low-pressure, 389
recycling unwanted product and controlling, 77
regulation scheme for cumene reactor, 684–685
supply options for, 221
temperature conditions of special concern for, 152
troubleshooting cumene reactor, 1078–1081
utility costs for off-site, 222–223
in utility streams of PFDs, 62
air leaks into vacuum systems, and load for, 1050–1051
running columns at vacuum with, 925
modeling electrolyte systems, 434
STEL (short-term exposure limit), air contaminant hazards, 1135
Stoichiometric reactors, equipment parameters in PFD synthesis, 407
Stoichiometry, in process concept diagrams, 60–61
flow around submerged objects, 724
minimizing pollution during loading/unloading tanks, 1165–1166
for single-product campaigns, 106–108
Storage vessels, heuristics for, 359
Storming stage, in group evolution, 1184–1185
Straight fin thickness examples, 829
Straight-Line (SL) depreciation method
defined, 270
MACRS depreciation allowances using, 273–274
taxation, cash flow, and profit using, 276
Strategies for Creative Problem Solving (Fogler and LeBlanc), 1191
Strategies, for written communications, 1201–1202
Stream factors (SF), in calculation of yearly costs, 237–238
base-case ratios applied to properties of, 737
for cocurrent heat exchanger, 773–775
combining data to give PFD, 21–24
in countercurrent heat exchangers, 771–773
exchanging heat between, 674–679
feed streams. See Feed chemicals/feed streams
increasing pressure/regulating flowrate in, 674–676
input/output structure and, 60–61
with phase changes for HEN costs, 539–540
phase to be recycled, 77
recycle streams. See Recycle streams
recycling feed and product with/without purge stream, 73–75
regulating processes by manipulation of, 655
tactics for tracing chemicals, 135–136
tear streams. See Tear streams
utility streams. See Utility streams
waste streams. See Waste streams
Stress and strain relationships
cylindrical shell design for pressure vessel, 1016–1021
in pressure vessel design, 1016
Stress intensity factor, pressure vessel design, 1022
debottlenecking strategy for, 939–941
developing sour-water stripper (SWS), 435–440
in mass-exchange networks, 541–542
mass separating agents for, 903–904
obtaining height of packed column, 929
simulating, 411
in SM approach, 572
Stripping section, of distillation column, 890
Structural support diagrams, 32
Structure-mounted vertical arrangement, plant layout, 36
Structured packings, 928
Structured Text (ST), logic control, 680
Studies, steady-state simulation, 589
Study (Major Equipment or Factored), capital cost estimate of chemical plant, 172–174
Styrene, equilibrium control in, 67–68
major equipment summary, 1297–1298
making it greener, 1171
overview of, 1291
process description, 1291–1292
process flow diagram, 1293
references, 1299
simulation (CHEMCAD) hints, 1299
utility summary table, 1296
Submerged objects, frictional flow of fluid for, 723–728
Substitution of hazardous materials, inherently safe design, 1153
Successive Quadratic Programming (SQP)
case study. See Report-writing case study
in flowsheet optimization, 590–592
Successive Quadratic Programming (SQP), in flowsheet optimization, 590–592
Sulfur. See Claus unit design, converting H2S to elemental sulfur
Sum of the years digits (SOYD) depreciation method, 270–273
Summation equations, MESH, 435–440
Superfund Amendments and Reauthorization Act (SARA)
CERCLA amended by, 1161
overview of, 1141
Supply and demand, in chemical markets, 311–314
heuristics for liquid-liquid extraction, 365
modeling aqueous electrolyte system, 438–439
modeling distillation column for electrolyte systems, 449
modeling electrolyte systems, 434–435
in Onsager-Samaras Law, 434–435
Surge line, for centrifugal compressor, 749–750
Surge tanks, 687
Survival of personnel, inherently safe design, 1154
SVE (solid-vapor equilibrium), 441–442
Swing check valves, 706
for equations in reports, 1207–1208
process for troubleshooting, 1065–1066, 1069–1070
troubleshooting multiple units, 1076–1078
Synergy, group efficiency and, 1176–1178
Syngas, optimization study, 595–600
azeotropic distillation, 378–379
azeotropic distillation in binary systems, 379–382
azeotropic distillation in ternary systems, 382–388
environmental control section, 389
equipment summary table, 390–391
flow summary table, 390
guidelines for choosing separation operations, 374–376
information needs and sources, 370–371
overview of, 369
process control loops, 390
reactor and separator feed preparation, 388–389
recycle section, 389
Synthesis of PFD, using simulators
applying thermodynamic models, 424–426
building model of aqueous electrolyte, 435–440
calculating Gibbs free energy for electrolyte system, 445–447
chemical components, 401
chemical equilibrium in modeling electrolyte systems, 432
choosing thermodynamic models, 415–424
convergence criteria for simulation, 411–412
diffusion coefficient in modeling electrolyte systems, 433–434
electrolyte systems modeling, 428–435
feed stream properties, 404–405
flowsheet topology, 404
handling recycle streams, 413–415
heat capacity in modeling electrolyte systems, 431–432
information needed (input data), 401
modeling distillation column for electrolyte system, 447–519
molar volume in modeling electrolyte systems, 432
output display options, 411
parameters for solids model, 442–444
physical properties in solids modeling, 440–441
physical properties in thermodynamics, 416
physical property models, 401–404
structure of process simulator, 398–401
surface tension in modeling electrolyte systems, 434–435
thermal conductivity in modeling electrolyte systems, 433
toluene HDA case study, 426–428
viscosity in modeling electrolyte systems, 432–433
Synthesis pathways, in green chemistry, 1164
Synthetic Organic Chemicals Manufacturers Association (SOCMA), 1143
System curves, analyzing pump and, 743–749
T
T-Q diagrams. See Temperature-enthalpy (T-Q) diagrams
Table of contents, written report guidelines, 1204
common mistakes in presenting, 1227–1228
in design reports, 1200
learning software used for, 1217
written report guidelines, 1206–1207
TAMU (Texas A&M University), engineering ethics at, 1118
Tanks. See also Vessels
equipment cost data for, 1251
pressure factors for, 1266
purchase costs for, 1258
Task differentiation, in groups, 1176–1177
impact of tax rate on profit, 274–277
MACRS as current method of tax depreciation, 273–274
types of depreciation, 269–273
Teamwork. See also Groups
assessing group effectiveness, 1178–1180
essential to chemical engineering, 1175
misconceptions about, 1189
organizational behaviors and strategies, 1180–1184
task differentiation in, 1176–1177
unique characteristics of teams, 1187–1188
Teamwork and Project Management (Smith), 1191
Teamwork from Start to Finish (Rees), 1190
convergence methods, 580–585, 587–589
convergence methods, comparing performance of, 583
in sequential modular (SM) approach, 572, 575–578
solving problems with recycles, 400–401
advancing steady-state simulation with, 562
Tees, changing flow direction, 705
Temperature. See also Heat-exchanger networks (HENs)
composite temperature-enthalpy diagram, 523–529
in condensing heat transfer, 824–828
designing nonisothermal CSTRs, 980–984
effect of ambient conditions on dynamic models, 624
evaluating reactor process conditions, 158–164
impact on reaction rate, 162–163, 980
impacting bare module equipment costs, 190–192
justifying conditions of special concern in reactors/separators in PFD, 158–164
measuring process variables, 662
operating conditions of special concern for reactors/separators, 150–154
physical property variations with, 355
reactor design for PFD synthesis and, 372–373
reasons for multiple reactors, 76
regulating between process streams and utilities, 676–679
troubleshooting cumene reactor, 684–685
troubleshooting packed-bed absorber, 1071–1074
Temperature-enthalpy (T-Q) diagrams
analyzing reboiler performance after scale-down, 936–937
for condensers and reboilers, 923–924
for heat exchangers, 772–774, 776–778, 794
for phase changes, 775–776, 797–798
Tempered-water system, split-range control system, 671–672
Tensile strength, impact of temperature on, 151
of falling water drops in oils with different viscosity, 1045–1046
flow around submerged objects, 723–728
for water drops in air and oil, 1044–1045
dynamic simulation, 617
fires and explosions, 1143
optimization, 464
Ternary azeotropic distillation, 382–388
Texas A&M University (TAMU), engineering ethics at, 1118
The Team Handbook (Scholtes et al.), 1191
copper and its alloys used for high, 194
of metals and tubes in heat exchangers, 800–801
modeling aqueous electrolyte system, 438
modeling electrolyte systems, 433
physical property heuristics for, 355
solids modeling and, 442
using physical property data for PFD design, 371
Thermal insulation, heuristics for, 362
Thermal systems, cost of off-site, 223
Thermodynamic model solver, simulator features, 399
calibrating using scarce data, 422–423
enthalpy model, 416
estimating physical property parameters, 601–604
hybrid systems, 423
modeling distillation column for electrolyte system, 447–448
other models, 423
phase equilibrium model, 416–422
pure-component properties, 416
using, 424
validity of pressure-flow networks in dynamic simulation, 621–622
equilibrium in reactors and, 964–965
justifying conditions of special concern in reactors using PFD, 158–161
must have confidence in selected model for, 404
Thermosiphon reboilers, 40–41, 633, 779
Thesaurus, 1215
Threshold limit values (TLV), air contaminants standard, 1135
Tie line, TP-xy diagrams for V-L separations, 887
discounted profitability criteria, 291–293
evaluating profitability, 287
nondiscounted profitability, 287
Time value of money, investments and, 248–251, 259–261
Time-weighted average (TWA), air contaminant exposure, 1135
Tips for Teams (Fisher et al.), 1191
Titanium and its alloys, selecting materials of construction, 194–197
Title page, written report format, 1203
Title slide, oral presentation guidelines, 1212
TLV (threshold limit values), air contaminants standard, 1135
analyzing conditions of special concern in, 158–164
BFD for, 11
case study of simulating, 426–428
cost of manufacturing benzene via, 241–242
determining profit margin, 68–69
distillation column performance, case study, 934–942
distillation of benzene from, 14–15
estimating utility costs from PFDs, 238–240
evaluating high-pressure phase separator in, 164
feed purity and trace components in, 66
PFD for, 22
recycle and bypass streams, 142–145
specifying equipment parameters for, 409–411
tracing primary chemical pathways, 137–142
written process description of, 146–147
Top-down strategies, in optimization, 468
alternatives for separation and reactor configuration, 477–478
eliminating equipment, 475
eliminating unwanted by-products/waste streams, 473–475
introduction to, 473
rearranging equipment, 475–477
Topology. See Process topology
Torispherical (dished) heads, pressure vessels, 1022–1024
Torts, and chemical engineers, 1126
Total capital for depreciation, 269
Total module costs, vs. grassroots, 201–203
Total reflux, 897
capacities of process units in common usage, 356
equipment cost data for, 1251
heuristics for, 363
pressure factors in costs of, 1266
Toxic Release Inventory, 1141
Toxic Substances Control Act (TSCA), 1161
Trace contaminants, minimizing pollution, 1165
Tracing chemical pathways, in PFDs
guidelines and tactics, 135–136
recycle and bypass streams, 142–145
tracing nonreacting chemicals, 145
tracing primary paths taken by chemicals, 136–142
written process description, 146–147
Tracing chemical species, tactics for, 997
for emergencies, safety and maintenance, 48
immersive training simulators (ITS), 45
operator training simulators (OTS), 43–45
using P&IDs in operator, 31
Transfer units separation, 880–881, 929
Transient response, using dynamic simulation to study, 618
Transmittal letters, for written communications, 1198
building model of distillation column for electrolyte system, 448–449
Transport (pneumatic conveying) reactors, 1001
Trapezoidal method, dynamic simulation integrator algorithms, 636
choosing packed tower vs., 933
condensers and reboilers, 923–926
downcomers, 912
energy balances, 877
entrainment, 914
equilibrium relationships, 877–878
heuristics for distillation/gas absorption, 364
Kremser and Colburn methods for dilute solutions, 905–911
mass transfer relationships, 878–881
McCabe-Thiele method for distillation, 888–901
McCabe-Thiele method for mass separating agents, 903–905
McCabe-Thiele method for packed columns, 901–902
performance problems of, 933–934
vs. packed towers, 933
bare module cost for, 1270
bare module factors for, 1271
efficiency in distillation column, 920–922
equipment cost data for, 1251
material factors for, 1273
McCabe-Thiele method for distillation using, 903–905
pressure factors for, 1266
purchase costs for, 1257
Triangular fins, 831–832, 833–837
heat transfer coefficients for flow over tubes, 808
Kern’s method for shell-side heat transfer, 812–813
layout patterns for tubes, 784
Troubleshooting. See also Debottlenecking; Performance
applying to problems, 1069–1071
case studies involving multiple units, 1076–1081
cumene process feed section, 1074–1076
for an entire process, 1081–1085
fluid flow. See Fluid flow equipment, performance
packed-bed absorber, 1071–1074
performance. See Performance
problem-solving strategies, 1067–1069
steps in, 1066
TSCA (Toxic Substances Control Act), 1161
Tuning parameters, process control in dynamic simulation, 641–643
equipment cost data for, 1251
mechanical energy balance in piping systems, 700–703
pressure factors for, 1266
purchase costs for, 1254
utility costs for steam production, 228–234
falling-film condensation on cylinders, 825–828
film heat transfer coefficient inside tubes, 804–806
friction factors in compressible flow, 719–720
friction factors in incompressible flow, 712
frictional losses for, 709–711
Turbulent fluidized bed reactors, 1000–1001
TWA (time-weighted average), exposure to air contaminants, 1135
Two-phase model, bubbling fluidized beds, 999–1000, 1002
U
U-tubes, S-T heat exchanger design, 784, 789
UAMs. See User-added models (UAMs)
UEL (Upper explosive limit), 1144
UFL (Upper flammability limit), 1144
Uis (unlimited intermediate storage), in batch processing, 108
Unexpected behavior, in problem-solving, 1068–1069
UNIFAC model, 422
Unlimited intermediate storage (uis), in batch processing, 108
Unstable systems, dynamic modeling for, 619
Unwanted products, recycling, 77
Upper explosive limit (UEL), 1144
Upper flammability limit (UFL), 1144
U.S. Coast Guard, and transport of hazardous materials, 1141
user thermodynamic and transport models, 564–567
User-added unit operation models (UAUOM), steady-state simulation, 563–564
dynamic models for heaters and coolers, 625–627
heuristics for refrigeration and utility specifications, 367
sketching piping in 3-D plot plan, 41
background information on, 219–222
for cooling water tower, 221–225
formula for cost of manufacturing, 214–217
for hot circulating heat transfer fluids, 234
for optimization base case, 469
problems with multiple utilities, 539
in single-variable optimization, 480–481
in toluene HDA process, 241–242
in two-variable optimization, 483
Utility flowsheets, 32
for cocurrent heat exchanger, 773–775
conventions for identifying in PFDs, 18–20
in countercurrent heat exchangers, 771–773
cumene production facility problems, 1422
exchanging heat between process streams and, 676–678
exchanging heat/work between process streams and, 674–679
identifying on PFDs, 14–15, 62–63
mainpulating to regulate processes, 655
V
V-L. See Vapor-liquid (V-L) separation
Vacuum pumps, heuristics for, 361
conditions of special concerns for reactors/separators, 150
estimating air leaks for steam ejectors, 1050–1051
in single-stage steam ejectors, 1051–1052
analyzing conditions of special concern for pressure control, 164
binary distillation column case studies, 685–688
conditions of special concern for, 155–158
controlling processes with, 656
as final control in chemical process control loop, 29
input for process simulation, 407
minimizing pollution from leaking, 1166
regulating flowrate with, 655–656, 660–662, 674–676
regulating pressure with, 660–662, 674–676
relief or safety, 1145
split-range control system, 671–673
Vanes, of impeller for centrifugal pumps, 707
in condensing heat transfer, 824–828
damaging pumps, 706
justifying separator operations at conditions of special concern, 153–154
Vapor cloud explosions (VCEs), 1144–1145
Vapor fraction, and feed streams, 404–405
Vapor-liquid equilibrium (VLE)
air leaks into vacuum systems and, 1050–1051
estimating physical property parameters, 601–604
hybrid systems and, 423
justifying separator operations at conditions of special concern, 153–154
liquid-state activity-coefficient models, 419–423
modeling electrolyte systems with, 429–431
thermodynamic model solver and, 399
designing horizontal V-L separators, 1032–1036
designing V-L separators, 1029–1032
equilibrium relationships and, 878
flooding in mist eliminators, 1038–1040
flooding in mist eliminators, examples, 1040–1044
mass balances and, 877
McCabe-Thiele method for distillation and, 888–901
mist eliminators/other internals in, 1036–1037
in packed towers. See Packed towers
in tray towers. See Tray towers
Vapor pressure, impacting fate of chemicals in environment, 1162
bare module cost for, 1270
bare module factors for, 1271
equipment cost data for, 1251
material factors for, 1272–1273
pressure factors for, 1266
purchase costs for, 1253
in cascade regulation, 668–669
in combination feedback/feed-forward control, 667
control strategies for, 663
in dynamic simulation, 619
in feed-forward control and regulation, 663–665
in feedback control and regulation, 663–665
VB (Visual Basic), 563
VCEs (vapor cloud explosions), 1144–1145
flow around submerged objects and terminal, 723–728
friction factors in incompressible flow, 712–719
Kern’s method for shell-side heat transfer, 810
Velocity head, calculating frictional losses, 710
Venturi, measuring flowrate with, 731, 735
bare module and material factors for, 1267–1271
capacities of process units, 356
dynamic model of flash and, 632
dynamic simulation and size of, 622–624
equipment cost data for process, 1251
estimating plant cost for MOCs, 197–198
pressure. See Pressure vessels
pressure factors for process, 1264, 1266
purchase costs for, 1258
reaction. See Reaction vessels
sketches for successful project completion, 32
Videos, for oral presentations, 1211–1212
Virtual Plant Tour AVI file, for this book, 41–43
3-D immersive training simulators, 45
training for emergencies, safety and maintenance using, 48
viewing plant before construction, 33
calculating frictional losses, 709
of continuous fluid in L-L separation, 1045–1046
heat transfer coefficients for turbulent flow in tubes, 804–806
modeling electrolyte systems, 432–433
S-T heat exchanger heuristics, 789
content of, 1213
oral presentation guidelines, 1211–1212
report-writing and, 1224–1230, 1244–1245
Visual Basic (VB), 563
VLE. See Vapor-liquid equilibrium (VLE)
Voice, in oral presentations, 1214
Volatile organic compounds (VOCs), Clean Air Act Amendments, 1140–1141
Volume of catalyst, and heat transfer in S-T reactors, 997–999
Volute, and centrifugal pumps, 707
W
Waste disposal, utility costs for plant with multiple process units, 223
Waste heat boilers, 234, 823–824
Waste management, Pollution Prevention Act of 1990, 1159–1160
activated sludge in biological, 390
cost of treating liquid/solid, 240–241
eliminating unwanted hazardous by-products, 477–478
phthalic anhydride production design for new facility, 1412
separator design for PFD synthesis, 373–374, 376
Waste treatment, Pollution Prevention Act of 1990, 1160
cost of utilities for plant, 223
in green engineering, 1165
information in utility streams for, 18
maximum concentrations of discharges in, 1126
modeling electrolyte systems for, 428
for pollution prevention in styrene production, 1167
in process optimization, 471, 476
recycling of inerts in, 76
utility costs for, 223
environmental laws for, 1161
leaks in steam production requiring makeup, 228
minimize pollution by recycling, 1165
properties at different temperatures, 812
temperature conditions of special concern for, 151–152
utility costs for cooling tower, 214–217
utility costs for plant with multiple process units, 222
utility costs for steam production, 228–234
converting CO to CO2, 1352–1356
Weeping, bubble cap/valve trays and, 913
performance for tear stream convergence, 583
SM approach to steady-state simulation, 579–585
Weir height, estimating column pressure drop, 912, 922–923
Weirs, liquid level on tray maintained by, 912
Welded joints, cylindrical shell design for pressure vessel, 1016
Welds, connecting pipe with, 705
What-if technique, in Process Hazard Analysis, 1146
Work, and friction in groups, 1180
Worker Right to Know regulations, 1136–1138
Working capital, depreciation of, 269
Worst case scenario, risk assessment, 1133–1134
Writer’s block, causes of, 1201
executive summaries and abstracts, 1198–1199
exhibits (figures and tables), 1200
minutes from design meetings, 1199
performance evaluations, 1199
references, 1200
software and author responsibility, 1215–1218
strategies for writing, 1201–1202
transmittal letters or memos, 1198
university guidelines for written design reports, 1202–1209
Written process descriptions, 146–147
WVU and Auburn University, oral communication guidelines, 1212–1214
WVU and Auburn University, written report guidelines
grammar, punctuation, and spelling, 1202–1203
group reports, 1203
how engineering reports are used, 1208–1209
overview of, 1202
written communication, 1202–1209
Y
Yearly depreciation, 270
of equipment with different operating lives, 301, 303–304
estimating utility costs from PFDs, 239–240
stream factors in calculating, 237–238
Yearly savings, and pollution prevention, 1167–1168
Yield, of parallel and series reactions, 977–980
Z
brainstorming ideas in chemical product design, 128
new chemical products needed to prevent, 126
product manufacturing, 130–131
Zero wait (zw) batch process, 108