Contents
SECTION I Conceptualization and Analysis of Chemical Processes
Chapter 1 Diagrams for Understanding Chemical Processes
1.1.1 Block Flow Process Diagram
1.1.2 Block Flow Plant Diagram
1.2 Process Flow Diagram (PFD)
1.2.4 Combining Topology, Stream Data, and Control Strategy to Give a PFD
1.3 Piping and Instrumentation Diagram (P&ID)
1.5 Three-Dimensional Representation of a Process
1.7 Operator and 3-D Immersive Training Simulators
1.7.1 Operator Training Simulators (OTS)
1.7.2 3-D Immersive Training Simulators (ITS)
1.7.3 Linking the ITS with an OTS
Chapter 2 The Structure and Synthesis of Process Flow Diagrams
2.1 Hierarchy of Process Design
2.2 Step 1—Batch versus Continuous Process
2.3 Step 2—The Input/Output Structure of the Process
2.3.2 The Input/Output Structure of the Process Flow Diagram
2.3.3 The Input/Output Structure and Other Features of the Generic Block Flow Process Diagram
2.3.4 Other Considerations for the Input/Output Structure of the Process Flowsheet
2.3.5 What Information Can Be Determined Using the Input/Output Diagram for a Process?
2.4 Step 3—The Recycle Structure of the Process
2.4.1 Efficiency of Raw Material Usage
2.4.2 Identification and Definition of the Recycle Structure of the Process
2.4.3 Other Issues Affecting the Recycle Structure That Lead to Process Alternatives
2.5 Step 4—General Structure of the Separation System
2.6 Step 5—Heat-Exchanger Network or Process Energy Recovery System
2.7 Information Required and Sources
3.1 Design Calculations for Batch Processes
3.2 Gantt Charts and Scheduling
3.3 Nonoverlapping Operations, Overlapping Operations, and Cycle Times
3.4 Flowshop and Jobshop Plants
3.5 Product and Intermediate Storage and Parallel Process Units
3.5.1 Product Storage for Single-Product Campaigns
3.6 Design of Equipment for Multiproduct Batch Processes
Chapter 4 Chemical Product Design
4.1 Strategies for Chemical Product Design
Chapter 5 Tracing Chemicals through the Process Flow Diagram
5.1 Guidelines and Tactics for Tracing Chemicals
5.2 Tracing Primary Paths Taken by Chemicals in a Chemical Process
5.3 Recycle and Bypass Streams
5.4 Tracing Nonreacting Chemicals
5.6 Written Process Description
Chapter 6 Understanding Process Conditions
6.1 Conditions of Special Concern for the Operation of Separation and Reactor Systems
6.2 Reasons for Operating at Conditions of Special Concern
6.3 Conditions of Special Concern for the Operation of Other Equipment
6.4 Analysis of Important Process Conditions
6.4.1 Evaluation of Reactor R-101
6.4.2 Evaluation of High-Pressure Phase Separator V-102
6.4.3 Evaluation of Large Temperature Driving Force in Exchanger E-101
6.4.4 Evaluation of Exchanger E-102
6.4.5 Pressure Control Valve on Stream 8
6.4.6 Pressure Control Valve on Stream from V-102 to V-103
SECTION II Engineering Economic Analysis of Chemical Processes
Chapter 7 Estimation of Capital Costs
7.1 Classifications of Capital Cost Estimates
7.2 Estimation of Purchased Equipment Costs
7.2.1 Effect of Capacity on Purchased Equipment Cost
7.2.2 Effect of Time on Purchased Equipment Cost
7.3 Estimating the Total Capital Cost of a Plant
7.3.2 Module Costing Technique
7.3.3 Bare Module Cost for Equipment at Base Conditions
7.3.4 Bare Module Cost for Non-Base-Case Conditions
7.3.6 Algorithm for Calculating Bare Module Costs
7.3.7 Grassroots (Green Field) and Total Module Costs
7.3.8 A Computer Program (CAPCOST) for Capital Cost Estimation Using the Equipment Module Approach
7.4 Estimation of Plant Costs Based on Capacity Information
Chapter 8 Estimation of Manufacturing Costs
8.1 Factors Affecting the Cost of Manufacturing a Chemical Product
8.3.1 Background Information on Utilities
8.3.2 Calculation of Utility Costs
8.5 Yearly Costs and Stream Factors
8.6 Estimating Utility Costs from the PFD
8.7 Cost of Treating Liquid and Solid Waste Streams
Chapter 9 Engineering Economic Analysis
9.1 Investments and the Time Value of Money
9.2 Different Types of Interest
9.2.3 Interest Rates Changing with Time
9.3 Time Basis for Compound Interest Calculations
9.3.1 Effective Annual Interest Rate
9.3.2 Continuously Compounded Interest
9.4.1 Discrete Cash Flow Diagram
9.4.2 Cumulative Cash Flow Diagram
9.5 Calculations from Cash Flow Diagrams
9.5.1 Annuities—A Uniform Series of Cash Transactions
9.7 Depreciation of Capital Investment
9.7.1 Fixed Capital, Working Capital, and Land
9.7.2 Different Types of Depreciation
9.7.3 Current Depreciation Method (2017): Modified Accelerated Cost Recovery System (MACRS)
9.8 Taxation, Cash Flow, and Profit
Chapter 10 Profitability Analysis
10.1 A Typical Cash Flow Diagram for a New Project
10.2 Profitability Criteria for Project Evaluation
10.2.1 Nondiscounted Profitability Criteria
10.2.2 Discounted Profitability Criteria
10.3 Comparing Several Large Projects: Incremental Economic Analysis
10.4 Establishing Acceptable Returns from Investments: The Concept of Risk
10.5 Evaluation of Equipment Alternatives
10.5.1 Equipment with the Same Expected Operating Lives
10.5.2 Equipment with Different Expected Operating Lives
10.6 Incremental Analysis for Retrofitting Facilities
10.6.1 Nondiscounted Methods for Incremental Analysis
10.6.2 Discounted Methods for Incremental Analysis
10.7 Evaluation of Risk in Evaluating Profitability
10.7.1 Forecasting Uncertainty in Chemical Processes
SECTION III Synthesis and Optimization of Chemical Processes
Chapter 11 Utilizing Experience-Based Principles to Confirm the Suitability of a Process Design
11.1 The Role of Experience in the Design Process
11.1.1 Introduction to Technical Heuristics and Shortcut Methods
11.1.2 Maximizing the Benefits Obtained from Experience
11.2 Presentation of Tables of Technical Heuristics and Guidelines
Chapter 12 Synthesis of the PFD from the Generic BFD
12.1 Information Needs and Sources
12.1.1 Interactions with Other Engineers and Scientists
12.3.1 General Guidelines for Choosing Separation Operations
12.3.2 Sequencing of Distillation Columns for Simple Distillation
12.3.3 Azeotropic Distillation
12.4 Reactor Feed Preparation and Separator Feed Preparation Sections
12.6 Environmental Control Section
12.7 Major Process Control Loops
12.9 Major Equipment Summary Table
Chapter 13 Synthesis of a Process Using a Simulator and Simulator Troubleshooting
13.1 The Structure of a Process Simulator
13.2 Information Required to Complete a Process Simulation: Input Data
13.2.1 Selection of Chemical Components
13.2.2 Selection of Physical Property Models
13.2.3 Selection and Input of Flowsheet Topology
13.2.4 Selection of Feed Stream Properties
13.2.5 Selection of Equipment Parameters
13.2.6 Selection of Output Display Options
13.2.7 Selection of Convergence Criteria and Running a Simulation
13.2.8 Common Errors in Using Simulators
13.4 Choosing Thermodynamic Models
13.4.1 Pure-Component Properties
13.4.4 Using Thermodynamic Models
13.5 Case Study: Toluene Hydrodealkylation Process
13.6 Electrolyte Systems Modeling
13.6.1 Fundamentals of Modeling Electrolyte Systems
13.7.2 Parameter Requirements for Solids Model
Calculation of Excess Gibbs Energy for Electrolyte Systems
Chapter 14 Process Optimization
14.1 Background Information on Optimization
14.1.2 Estimating Problem Difficulty
14.1.3 Top-Down and Bottom-Up Strategies
14.1.4 Communication of Optimization Results
14.2.3 Analysis of the Base Costs
14.2.4 Identifying and Prioritizing Key Decision Variables
14.3.2 Elimination of Unwanted Nonhazardous By-Products or Hazardous Waste Streams
14.3.3 Elimination and Rearrangement of Equipment
14.3.4 Alternative Separation Schemes and Reactor Configurations
14.4.1 Single-Variable Optimization: A Case Study on T-201, the DME Separation Column
14.4.3 Flowsheet Optimization Using Key Decision Variables
14.5 Lattice Search, Response Surface, and Mathematical Optimization Techniques
14.6 Process Flexibility and the Sensitivity of the Optimum
14.7 Optimization in Batch Systems
14.7.1 Problem of Scheduling Equipment
14.7.2 Problem of Optimum Cycle Time
15.2 Heat Integration and Network Design
15.3 Composite Temperature-Enthalpy Diagram
15.4 Composite Enthalpy Curves for Systems without a Pinch
15.5 Using the Composite Enthalpy Curve to Estimate Heat-Exchanger Surface Area
15.6 Effectiveness Factor (F) and the Number of Shells
15.7 Combining Costs to Give the EAOC for the Network
15.8.1 Materials of Construction and Operating Pressure Issues
15.8.2 Problems with Multiple Utilities
15.8.3 Handling Streams with Phase Changes
15.9 Heat-Exchanger Network Synthesis Analysis and Design (HENSAD) Program
Chapter 16 Advanced Topics Using Steady-State Simulators
16.1 Why the Need for Advanced Topics in Steady-State Simulation?
16.2.2 User Thermodynamic and Transport Models
16.3 Solution Strategy for Steady-State Simulations
16.3.1 Sequential Modular (SM)
16.3.3 Simultaneous Modular (SMod)
16.4 Studies with the Steady-State Simulation
16.5 Estimation of Physical Property Parameters
Chapter 17 Using Dynamic Simulators in Process Design
17.1 Why Is There a Need for Dynamic Simulation?
17.2 Setting Up a Dynamic Simulation
17.2.1 Step 1: Topological Change in the Steady-State Simulation
17.2.2 Step 2: Equipment Geometry and Size
17.2.3 Step 3: Additional Dynamic Data/Dynamic Specification
17.3 Dynamic Simulation Solution Methods
17.3.2 Solution of the DAE System
Chapter 18 Regulation and Control of Chemical Processes with Applications Using Commercial Software
18.1 A Simple Regulation Problem
18.2 The Characteristics of Regulating Valves
18.3 Regulating Flowrates and Pressures
18.4 The Measurement of Process Variables
18.5 Common Control Strategies Used in Chemical Processes
18.5.1 Feedback Control and Regulation
18.5.2 Feed-Forward Control and Regulation
18.5.3 Combination Feedback and Feed-Forward Control
18.6 Exchanging Heat and Work between Process and Utility Streams
18.6.1 Increasing the Pressure of a Process Stream and Regulating Its Flowrate
18.6.2 Exchanging Heat between Process Streams and Utilities
18.6.3 Exchanging Heat between Process Streams
18.8.1 Statistical Process Control (SPC)
18.9.1 The Cumene Reactor, R-801
18.9.2 A Basic Control System for a Binary Distillation Column
18.9.3 A More Sophisticated Control System for a Binary Distillation Column
18.10 Putting It All Together: The Operator Training Simulator (OTS)
SECTION IV Chemical Equipment Design and Performance Process Equipment Design and Performance
Chapter 19 Process Fluid Mechanics
19.1 Basic Relationships in Fluid Mechanics
19.1.2 Mechanical Energy Balance
19.3.1 Calculating Frictional Losses
19.4.1 Flow Past Submerged Objects
19.5 Performance of Fluid Flow Equipment
19.5.2 Net Positive Suction Head
19.5.5 Performance of the Feed Section to a Process
Chapter 20 Process Heat Transfer
20.1 Basic Heat-Exchanger Relationships
20.1.3 Streams with Phase Changes
20.1.4 Nonlinear Q versus T Curves
20.1.5 Overall Heat Transfer Coefficient, U, Varies along the Exchanger
20.2 Heat-Exchange Equipment Design and Characteristics
20.2.1 Shell-and-Tube Heat Exchangers
20.3 LMTD Correction Factor for Multiple Shell and Tube Passes
20.3.2 Basic Configuration of a Single-Shell-Pass, Double-Tube-Pass (1–2) Exchanger
20.3.3 Multiple Shell-and-Tube-Pass Exchangers
20.3.5 LMTD Correction and Phase Change
20.4 Overall Heat Transfer Coefficients—Resistances in Series
20.5 Estimation of Individual Heat Transfer Coefficients and Fouling Resistances
20.5.1 Heat Transfer Resistances Due to Fouling
20.5.2 Thermal Conductivities of Common Metals and Tube Properties
20.5.3 Correlations for Film Heat Transfer Coefficients
20.6.1 Rectangular Fin with Constant Thickness
20.6.2 Fin Efficiency for Other Fin Geometries
20.6.3 Total Heat Transfer Surface Effectiveness
20.7 Algorithm and Worked Examples for the Design of Heat Exchangers
20.7.1 Pressure Drop Considerations
20.8.1 What Variables to Specify in Performance Problems
20.8.2 Using Ratios to Determine Heat-Exchanger Performance
20.8.3 Worked Examples for Performance Problems
Appendix 20.A Heat-Exchanger Effectiveness Charts
Appendix 20.B Derivation of Fin Effectiveness for a Rectangular Fin
Chapter 21 Separation Equipment
21.1 Basic Relationships in Separations
21.1.3 Equilibrium Relationships
21.1.4 Mass Transfer Relationships
21.2.3 Dilute Solutions—The Kremser and Colburn Methods
21.3.4 Tray Tower or Packed Tower?
21.3.5 Performance of Packed and Tray Towers
21.4.2 Static and Pulsed Columns
21.5 Gas Permeation Membrane Separations
21.5.2 Models for Gas Permeation Membranes
22.1.3 Additional Mass Transfer Effects
22.2 Equipment Design for Nonisothermal Conditions
22.2.1 Nonisothermal Continuous Stirred Tank Reactor
22.2.2 Nonisothermal Plug Flow Reactor
22.3.1 Ratios for Simple Cases
23.2 Knockout Drums or Simple Phase Separators
23.2.1 Vapor-Liquid (V-L) Separation
23.2.2 Design of Vertical V-L Separators
23.2.3 Design of Horizontal V-L Separators
23.2.4 Mist Eliminators and Other Internals
23.2.5 Liquid-Liquid (L-L) Separation
23.3.1 Estimating Air Leaks into Vacuum Systems and the Load for Steam Ejectors
23.3.2 Single-Stage Steam Ejectors
23.3.3 Multistage Steam Ejectors
23.3.4 Performance of Steam Ejectors
Chapter 24 Process Troubleshooting and Debottlenecking
24.1.1 Elements of Problem-Solving Strategies
24.1.2 Application to Troubleshooting Problems
24.2 Troubleshooting Individual Units
24.2.1 Troubleshooting a Packed-Bed Absorber
24.2.2 Troubleshooting the Cumene Process Feed Section
24.3 Troubleshooting Multiple Units
24.3.1 Troubleshooting Off-Specification Acrylic Acid Product
24.3.2 Troubleshooting Steam Release in Cumene Reactor
24.4 A Process Troubleshooting Problem
SECTION V The Impact of Chemical Engineering Design on Society
Chapter 25 Ethics and Professionalism
25.1.5 Nonprofessional Responsibilities
25.1.10 Additional Ethics Heuristics
25.2 Professional Registration
25.2.2 Registered Professional Engineer
25.4 Business Codes of Conduct [14,15]
Chapter 26 Health, Safety, and the Environment
26.1.3 The Role of the Chemical Engineer
26.2.2 Environmental Protection Agency (EPA)
26.2.3 Nongovernmental Organizations
26.3.2 Pressure-Relief Systems
26.4.1 HAZOP (Hazard and Operability Study)
26.4.2 Dow Fire & Explosion Index and Chemical Exposure Index
26.5 Chemical Safety and Hazard Investigation Board
27.1 Environmental Regulations
27.2 Environmental Fate of Chemicals
27.4 Pollution Prevention during Process Design
27.5 Analysis of a PFD for Pollution Performance and Environmental Performance
27.6 An Example of the Economics of Pollution Prevention
SECTION VI Interpersonal and Communication Skills
28.1.1 Characteristics of Effective Groups
28.1.2 Assessing and Improving the Effectiveness of a Group
28.1.3 Organizational Behaviors and Strategies
28.3.1 When Groups Become Teams
28.3.2 Unique Characteristics of Teams
28.4.2 Overreliance on Team Members
Chapter 29 Written and Oral Communication
29.2.2 Transmittal Letters or Memos
29.2.3 Executive Summaries and Abstracts
29.2.4 Other Types of Written Communication
29.2.5 Exhibits (Figures and Tables)
29.2.8 WVU and Auburn University Guidelines for Written Design Reports
29.3.1 Formal Oral Presentations
29.3.4 WVU and Auburn University Oral Presentation Guidelines
29.4 Software and Author Responsibility
29.4.6 Colors and Exotic Features
29.4.7 Raw Output from Process Simulators
Chapter 30 A Report-Writing Case Study
30.1 The Assignment Memorandum
30.4.1 An Example of a Portion of a Student Written Report
30.4.2 An Example of an Improved Student Written Report
30.5 Checklist of Common Mistakes and Errors
30.5.1 Common Mistakes for Visual Aids
30.5.2 Common Mistakes for Written Text
Appendix A Cost Equations and Curves for the CAPCOST Program
A.2.1 Pressure Factors for Process Vessels
A.2.2 Pressure Factors for Other Process Equipment
A.3 Material Factors and Bare Module Factors
A.3.1 Bare Module and Material Factors for Heat Exchangers, Process Vessels, and Pumps
A.3.2 Bare Module and Material Factors for the Remaining Process Equipment
Appendix B Information for the Preliminary Design of Fifteen Chemical Processes
B.1 Dimethyl Ether (DME) Production, Unit 200
B.1.3 Simulation (CHEMCAD) Hints
B.2 Ethylbenzene Production, Unit 300
B.2.1 Process Description [1, 2]
B.2.3 Simulation (CHEMCAD) Hints
B.3 Styrene Production, Unit 400
B.3.1 Process Description [1, 2]
B.3.3 Simulation (CHEMCAD) Hints
B.4 Drying Oil Production, Unit 500
B.4.3 Simulation (CHEMCAD) Hints
B.5 Production of Maleic Anhydride from Benzene, Unit 600
B.5.3 Simulation (CHEMCAD) Hints
B.6 Ethylene Oxide Production, Unit 700
B.6.1 Process Description [1, 2]
B.6.3 Simulation (CHEMCAD) Hints
B.7 Formalin Production, Unit 800
B.7.1 Process Description [1, 2]
B.7.3 Simulation (CHEMCAD) Hints
B.8 Batch Production of L-Phenylalanine and L-Aspartic Acid, Unit 900
B.9 Acrylic Acid Production via The Catalytic Partial Oxidation of Propylene [1–5], Unit 1000
B.9.2 Reaction Kinetics and Reactor Configuration
B.9.3 Simulation (CHEMCAD) Hints
B.10 Production of Acetone via the Dehydrogenation of Isopropyl Alcohol (IPA) [1–4], Unit 1100
B.10.3 Simulation (CHEMCAD) Hints
B.11 Production of Heptenes from Propylene and Butenes [1], Unit 1200
B.11.3 Simulation (CHEMCAD) Hints
B.12 Design of a Shift Reactor Unit to Convert CO to CO2, Unit 1300
B.12.3 Simulation (Aspen Plus) Hints
B.13.2 Simulation (Aspen Plus) Hints
B.14 Design of a Claus Unit for the Conversion of H2S to Elemental Sulfur, Unit 1500
B.14.3 Simulation (Aspen Plus) Hints
B.15 Modeling a Downward-Flow, Oxygen-Blown, Entrained-Flow Gasifier, Unit 1600
B.15.3 Simulation (Aspen Plus) Hints
Project 1 Increasing the Production of 3-Chloro-1-Propene (Allyl Chloride) in Unit 600
C.1.2 Process Description of the Beaumont Allyl Chloride Facility
C.1.3 Specific Objectives of Assignment
C.1.4 Additional Background Information
C.1.5 Process Design Calculations
C.2.3 Problem-Solving Methodology
Project 3 Scale-Down of Phthalic Anhydride Production at TBWS Unit 700
C.3.2 Phthalic Anhydride Production
Project 4 The Design of a New 100,000-Metric-Tons-per-Year Phthalic Anhydride Production Facility
Project 5 Problems at the Cumene Production Facility, Unit 800
C.5.2 Cumene Production Reactions
C.5.4 Recent Problems in Unit 800
Calculations for Fuel Gas Exit Line for V-802
Project 6 Design of a New, 100,000-Metric-Tons-per-Year Cumene Production Facility