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The leading integrated chemical process design guidenew coverage and more process designs More than ever, effective design is the focal point of sound chemical engineering. Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, presents design as a creative process that integrates both the big picture and the small details-and knows which to stress when, and why. Realistic from start to finish, this updated edition moves readers beyond classroom exercises into open-ended, real-world process problem solving. The authors introduce integrated techniques for every facet of the discipline, from finance to operations, new plant design to existing process optimization.This fourth edition adds new chapters introducing dynamic process simulation; advanced concepts in steady-state simulation; extensive coverage of thermodynamics packages for modeling processes containing electrolyte solutions and solids; and a concise introduction to logic control. "What You Have Learned" summaries have been added to each chapter, and the text's organization has been refined for greater clarity.Coverage IncludesConceptualization and analysis: flow diagrams, batch processing, tracing, process conditions, and product design strategies Economic analysis: capital and manufacturing costs, financial calculations, and profitability analysis Synthesis and optimization: principles, PFD synthesis, simulation techniques, top-down and bottom-up optimization, pinch technology, and software-based control Advanced steady-state simulation: goals, models, solution strategies, and sensitivity and optimization studies Dynamic simulation: goals, development, solution methods, algorithms, and solvers Performance analysis: I/O models, tools, performance curves, reactor performance, troubleshooting, and "debottlenecking" Societal impact: ethics, professionalism, health, safety, environmental issues, and green engineering Interpersonal and communication skills: improving teamwork and group effectivenessThis title draws on more than fifty years of innovative chemical engineering instruction at West Virginia University and the University of Nevada, Reno. It includes suggested curricula for single-semester and year-long design courses, case studies and practical design projects, current equipment cost data, and extensive preliminary design information that can be used as the starting point for more detailed analyses.About the CD-Rom and Web SiteThe CD contains the newest version of CAPCOST, a powerful tool for evaluating fixed capital investment, full process economics, and profitability. The heat exchanger network software, HENSAD, is also included. The CD also contains an additional appendix presenting preliminary design information for fifteen key chemical processes, including four new to this edition: shift reaction; acid-gas removal via physical solvent; H2S removal from a gas stream using the Claus process; and coal gasification. The CD also includes six additional projects, plus chapters on outcomes assessment, written and oral communications, and a written report case study. Sixty additional projects and twenty-four more problems are available at www.che.cemr.wvu.edu/publications/projects.
Contents
Material on the CD-ROM xix Preface xxiiiAbout the Authors xxviiList of Nomenclature xxixSection I: Conceptualization and Analysis of Chemical Processes 1Chapter 1: Diagrams for Understanding Chemical Processes 3What You Will Learn 31.1 Block Flow Diagram (BFD) 51.2 Process Flow Diagram (PFD) 81.3 Piping and Instrumentation Diagram (P&ID) 211.4 Additional Diagrams 261.5 Three-Dimensional Representation of a Process 271.6 The 3-D Plant Model 351.7 Operator and 3-D Immersive Training Simulators 371.8 Summary 43What You Should Have Learned 43References 44Short Answer Questions 44Problems 44Chapter 2: The Structure and Synthesis of Process Flow Diagrams 49What You Will Learn 492.1 Hierarchy of Process Design 492.2 Step 1-Batch versus Continuous Process 502.3 Step 2-The Input/Output Structure of the Process 542.4 Step 3-The Recycle Structure of the Process 642.5 Step 4-General Structure of the Separation System 782.6 Step 5-Heat-Exchanger Network or Process Energy Recovery System 782.7 Information Required and Sources 782.8 Summary 78What You Should Have Learned 80References 80Short Answer Questions 81Problems 81Chapter 3: Batch Processing 87What You Will Learn 873.1 Design Calculations for Batch Processes 873.2 Gantt Charts and Scheduling 933.3 Nonoverlapping Operations, Overlapping Operations, and Cycle Times 943.4 Flowshop and Jobshop Plants 973.5 Product and Intermediate Storage and Parallel Process Units 1023.6 Design of Equipment for Multiproduct Batch Processes 1073.7 Summary 109What You Should Have Learned 110References 110Short Answer Questions 110Problems 110Chapter 4: Chemical Product Design 115What You Will Learn 1154.1 Strategies for Chemical Product Design 1164.2 Needs 1174.3 Ideas 1194.4 Selection 1204.5 Manufacture 1224.6 Batch Processing 1234.7 Economic Considerations 1234.8 Summary 123What You Should Have Learned 124References 124Chapter 5: Tracing Chemicals through the Process Flow Diagram 125What You Will Learn 1255.1 Guidelines and Tactics for Tracing Chemicals 1255.2 Tracing Primary Paths Taken by Chemicals in a Chemical Process 1265.3 Recycle and Bypass Streams 1325.4 Tracing Nonreacting Chemicals 1355.5 Limitations 1355.6 Written Process Description 1365.7 Summary 137What You Should Have Learned 137Problems 138Chapter 6: Understanding Process Conditions 139What You Will Learn 1396.1 Conditions of Special Concern for the Operation of Separation and Reactor Systems 1406.2 Reasons for Operating at Conditions of Special Concern 1426.3 Conditions of Special Concern for the Operation of Other Equipment 1466.4 Analysis of Important Process Conditions 1506.5 Summary 157What You Should Have Learned 157References 158Short Answer Questions 158Problems 158Section II: Engineering Economic Analysis of Chemical Processes 161Chapter 7: Estimation of Capital Costs 163What You Will Learn 1637.1 Classifications of Capital Cost Estimates 1647.2 Estimation of Purchased Equipment Costs 1677.3 Estimating the Total Capital Cost of a Plant 1727.4 Summary 198What You Should Have Learned 198References 198Short Answer Questions 199Problems 200Chapter 8: Estimation of Manufacturing Costs 203What You Will Learn 2038.1 Factors Affecting the Cost of Manufacturing a Chemical Product 2038.2 Cost of Operating Labor 2088.3 Utility Costs 2098.4 Raw Material Costs 2238.5 Yearly Costs and Stream Factors 2258.6 Estimating Utility Costs from the PFD 2258.7 Cost of Treating Liquid and Solid Waste Streams 2288.8 Evaluation of Cost of Manufacture for the Production of Benzene via the Hydrodealkylation of Toluene 2288.9 Summary 229What You Should Have Learned 230References 230Short Answer Questions 230Problems 231Chapter 9: Engineering Economic Analysis 233What You Will Learn 2339.1 Investments and the Time Value of Money 2349.2 Different Types of Interest 2389.3 Time Basis for Compound Interest Calculations 2409.4 Cash Flow Diagrams 2419.5 Calculations from Cash Flow Diagrams 2459.6 Inflation 2509.7 Depreciation of Capital Investment 2539.8 Taxation, Cash Flow, and Profit 2599.9 Summary 262What You Should Have Learned 262References 262Short Answer Questions 263Problems 263Chapter 10: Profitability Analysis 269What You Will Learn 26910.1 A Typical Cash Flow Diagram for a New Project 26910.2 Profitability Criteria for Project Evaluation 27110.3 Comparing Several Large Projects: Incremental Economic Analysis 27910.4 Establishing Acceptable Returns from Investments: The Concept of Risk 28210.5 Evaluation of Equipment Alternatives 28310.6 Incremental Analysis for Retrofitting Facilities 28910.7 Evaluation of Risk in Evaluating Profitability 29310.8 Profit Margin Analysis 31010.9 Summary 311What You Should Have Learned 311References 312Short Answer Questions 312Problems 312Section III: Synthesis and Optimization of Chemical Processes 327Chapter 11: Utilizing Experience-Based Principles to Confirm the Suitability of a Process Design 331What You Will Learn 33111.1 The Role of Experience in the Design Process 33211.2 Presentation of Tables of Technical Heuristics and Guidelines 33511.3 Summary 338What You Should Have Learned 356References 356Problems 356Chapter 12: Synthesis of the PFD from the Generic BFD 357What You Will Learn 35712.1 Information Needs and Sources 35812.2 Reactor Section 36012.3 Separator Section 36212.4 Reactor Feed Preparation and Separator Feed Preparation Sections 37712.5 Recycle Section 37812.6 Environmental Control Section 37812.7 Major Process Control Loops 37912.8 Flow Summary Table 37912.9 Major Equipment Summary Table 38012.10 Summary 380What You Should Have Learned 380References 381Problems 382Chapter 13: Synthesis of a Process Using a Simulator and Simulator Troubleshooting 385What You Will Learn 38513.1 The Structure of a Process Simulator 38613.2 Information Required to Complete a Process Simulation: Input Data 38913.3 Handling Recycle Streams 40113.4 Choosing Thermodynamic Models 40313.5 Case Study: Toluene Hydrodealkylation Process 41413.6 Electrolyte Systems Modeling 41613.7 Solids Modeling 429What You Should Have Learned 434Appendix 13.1 Calculation of Excess Gibbs Energy for Electrolyte Systems 434Appendix 13.2 Steps to Build a Model of a Distillation Column for an Electrolyte System Using a Rate-Based Simulation with a Film Model for Mass Transfer, the Parameters Required at Each Stage, and Possible Sources of These Parameters 43713.8 Summary 440References 441Short Answer Questions 444Problems 444Chapter 14: Process Optimization 451What You Will Learn 45114.1 Background Information on Optimization 45114.2 Strategies 45714.3 Topological Optimization 46114.4 Parametric Optimization 46714.5 Lattice Search Techniques versus Response Surface Techniques 47814.6 Process Flexibility and the Sensitivity of the Optimum 47914.7 Optimization in Batch Systems 47914.8 Summary 487What You Should Have Learned 487References 487Short Answer Questions 488Problems 488Chapter 15: Pinch Technology 499What You Will Learn 49915.1 Introduction 49915.2 Heat Integration and Network Design 50015.3 Composite Temperature-Enthalpy Diagram 51415.4 Composite Enthalpy Curves for Systems without a Pinch 51615.5 Using the Composite Enthalpy Curve to Estimate Heat-Exchanger Surface Area 51715.6 Effectiveness Factor (F) and the Number of Shells 52115.7 Combining Costs to give the EAOC for the Network 52615.8 Other Considerations 52715.9 Heat-Exchanger Network Synthesis Analysis and Design (HENSAD) Program 53215.10 Mass-Exchange Networks 53215.11 Summary 541What You Should Have Learned 542References 542Short Answer Questions 543Problems 543Chapter 16: Advanced Topics Using Steady-State Simulators 551What You Will Learn 55116.1 Why the Need for Advanced Topics in Steady-State Simulation? 55216.2 User-Added Models 55216.3 Solution Strategy for Steady-State Simulations 56216.4 Studies with the Steady-State Simulation 58116.5 Estimation of Physical Property Parameters 58616.6 Summary 589What You Should Have Learned 590References 590Short Answer Questions 591Problems 592Chapter 17: Using Dynamic Simulators in Process Design 601What You Will Learn 60117.1 Why Is There a Need for Dynamic Simulation? 60217.2 Setting Up a Dynamic Simulation 60317.3 Dynamic Simulation Solution Methods 61817.4 Process Control 62417.5 Summary 632What You Should Have Learned 632References 633Short Answer Questions 633Problems 634Chapter 18: Regulation and Control of Chemical Processes with Applications Using Commercial Software 641What You Will Learn 64118.1 A Simple Regulation Problem 64218.2 The Characteristics of Regulating Valves 64318.3 Regulating Flowrates and Pressures 64618.4 The Measurement of Process Variables 64918.5 Common Control Strategies Used in Chemical Processes 64918.6 Exchanging Heat and Work between Process and Utility Streams 66018.7 Logic Control 66618.8 Advanced Process Control 66918.9 Case Studies 67018.10 Putting It All Together: The Operator Training Simulator (OTS) 67618.11 Summary 677What You Should Have Learned 677References 678Problems 678Section IV: Analysis Of Process Performance 683Chapter 19: Process Input/Output Models 685What You Will Learn 68519.1 Representation of Process Inputs and Outputs 68619.2 Analysis of the Effect of Process Inputs on Process Outputs 68919.3 A Process Example 69019.4 Summary 691What You Should Have Learned 692Problems 692Chapter 20: Tools for Evaluating Process Performance 693What You Will Learn 69320.1 Key Relationships 69320.2 Thinking with Equations 69420.3 Base-Case Ratios 69620.4 Analysis of Systems Using Controlling Resistances 69820.5 Graphical Representations 70020.6 Summary 704What You Should Have Learned 705References 705Problems 705Chapter 21: Performance Curves for Individual Unit Operations 707What You Will Learn 70721.1 Application to Heat Transfer 70921.2 Application to Fluid Flow 71421.3 Application to Separation Problems 72821.4 Summary 740What You Should Have Learned 741References 741Short Answer Questions 741Problems 743Chapter 22: Performance of Multiple Unit Operations 749What You Will Learn 74922.1 Analysis of a Reactor with Heat Transfer 74922.2 Performance of a Distillation Column 75422.3 Performance of a Heating Loop 75922.4 Performance of the Feed Section to a Process 76522.5 Summary 768What You Should Have Learned 769References 769Short Answer Questions 769Problems 769Chapter 23: Reactor Performance 785What You Will Learn 78523.1 Production of Desired Product 78623.2 Reaction Kinetics and Thermodynamics 78823.3 The Chemical Reactor 79123.4 Heat Transfer in the Chemical Reactor 79623.5 Reactor System Case Studies 79923.6 Summary 812What You Should Have Learned 813References 813Short Answer Questions 813Problems 814Chapter 24: Process Troubleshooting and Debottlenecking 819What You Will Learn 81924.1 Recommended Methodology 82124.2 Troubleshooting Individual Units 82524.3 Troubleshooting Multiple Units 83124.4 A Process Troubleshooting Problem 83624.5 Debottlenecking Problems 84024.6 Summary 841What You Should Have Learned 841References 841Problems 841Section V: The Impact of Chemical Engineering Design on Society 853Chapter 25: Ethics and Professionalism 855What You Will Learn 85525.1 Ethics 85625.2 Professional Registration 87425.3 Legal Liability 87925.4 Business Codes of Conduct 88025.5 Summary 881What You Should Have Learned 881References 882Problems 882Chapter 26: Health, Safety, and the Environment 885What You Will Learn 88526.1 Risk Assessment 88626.2 Regulations and Agencies 88826.3 Fires and Explosions 89826.4 Process Hazard Analysis 90026.5 Chemical Safety and Hazard Investigation Board 90926.6 Inherently Safe Design 90926.7 Summary 91026.8 Glossary 910What You Should Have Learned 912References 912Problems 913Chapter 27: Green Engineering 915What You Will Learn 91527.1 Environmental Regulations 91527.2 Environmental Fate of Chemicals 91627.3 Green Chemistry 91927.4 Pollution Prevention during Process Design 92027.5 Analysis of a PFD for Pollution Performance and Environmental Performance 92227.6 An Example of the Economics of Pollution Prevention 92327.7 Life Cycle Analysis 92427.8 Summary 926What You Should Have Learned 926References 926Problems 927Section VI: Interpersonal And Communication Skills 929Chapter28: Teamwork 931What You Will Learn 93128.1 Groups 93128.2 Group Evolution 94028.3 Teams and Teamwork 94328.4 Misconceptions 94528.5 Learning in Teams 94628.6 Other Reading 94728.7 Summary 948What You Should Have Learned 949References 949Problems 949Appendix A: Cost Equations and Curves for the CAPCOST Program 951A.1 Purchased Equipment Costs 951A.2 Pressure Factors 969A.3 Material Factors and Bare Module Factors 973References 982Index 983
