Integrated Design and Simulation of Chemical Processes (eBook)

Cover 1
Contents 10
Preface 6
Acknowledgments 8
Nomenclature 16
Chapter 1. Integrated Process Design 18
1.1 Introduction 19
1.2 Sustainable Development 23
1.3 Process Design 24
1.4 Systems Engineering 28
1.5 Integrated Process Design 32
1.6 Production-Integrated Environmental Protection 39
1.7 Summary 46
1.8 References 47
Part I: Process 48
Chapter 2. Introduction in Process Simulation 50
2.1 Computer Simulation in Process Engineering 51
2.2 Steps in a Simulation Approach 58
2.3 Architecture of Flowsheeting Software 63
2.4 Integration of Simulation Tools 67
2.5 Selection of Simulation Software 72
2.6 Summary 74
2.7 References 75
Chapter 3. Steady State Flowsheeting 76
3.1 Fundamentals of Steady State Flowsheeting 77
3.2 Degrees of Freedom Analysis 98
3.3 Methodology in Sequential-modular Flowsheeting 113
3.4 Results 122
3.5 Analysis Tools 123
3.6 Optimisation 124
3.7 Summary 128
3.8 References 129
Chapter 4. Dynamic Simulation 130
4.1 Transition from Steady State to Dynamic Simulation 131
4.2 Dynamic Flowsheeting 134
4.3 Numerical Problems in Dynamic Simulation 136
4.4 Dynamic Flash 138
4.5 Dynamic Distillation Column 142
4.6 Dynamic Simulation of Chemical Reactors 146
4.7 Process Control Tools 148
4.8 Further Reading 150
4.9 References 151
Part II: Thermodynamic Methods 152
Chapter 5. Computational Methods in Thermodynamics 154
5.1 PVT Behaviour of Fluids 155
5.2 Fundamentals of Thermodynamics 159
5.3 Fugacity 172
5.4 Equations of State 180
5.5 Generalised Computational Methods Using PVT Relationship 188
5.6 Summary 196
5.7 References 197
Chapter 6. Phase Equilibria 198
6.1 Computation of Vapour-Liquid Equilibrium 199
6.2 Models for Liquid Activity 209
6.3 The Regression of Parameters in Thermodynamic Models 219
6.4 Special Topics in Phase Equilibrium 229
6.5 Further Reading 242
6.6 References 242
Part III: Process Synthesis 244
Chapter 7. Process Synthesis by Hierarchical Approach 246
7.1 Introduction 247
7.2 Outline of the Hierarchical Approach 251
7.3 Data and Requirements 253
7.4 Input/Output Analysis 255
7.5 Reactor Design and Recycle Structure 265
7.6 General Structure of the Separation System 272
7.7 Vapour Recovery and Gas Separation Systems 281
7.8 Liquid Separation System 288
7.9 Separation of Zeotropic Mixtures by Distillation 297
7.10 Enhanced Distillation 306
7.11 Alternatives to Distillation 308
7.12 Reactive Distillation 309
7.13 Economic Potential after Separations 311
7.14 Summary 313
7.15 References 314
Chapter 8. Synthesis of Reaction Systems 316
8.1 Chemical Reaction Network 317
8.2 Chemical Equilibrium 324
8.3 Reactors for Homogeneous Systems 327
8.4 Reactors for Heterogeneous Systems 336
8.5 Thermal Design Issues 339
8.6 Selection of Chemical Reactors 348
8.7 Synthesis of Chemical Reactor Networks 357
8.8 Further Reading 366
8.9 References 366
Chapter 9. Synthesis of Azeotropic Separation Systems 368
9.1 Graphical Representations for Ternary Mixtures 369
9.2 Homogeneous Azeotropic Distillation 380
9.3 Heterogeneous Azeotropic Distillation 394
9.4 Combined Processes 399
9.5 Design Issues 401
9.6 Further Reading 405
9.7 Summary 406
9.8 References 407
Part IV: Process Integration 408
Chapter 10. Pinch Point Analysis 410
10.1 Introduction 411
10.2 Targets for Energy Recovery 416
10.3 Placement of Utilities 428
10.4 Design of the Heat Exchanger Network 432
10.5 Mathematical Programming 445
10.6 Design Evolution 446
10.7 Extensions of the Pinch Principle 447
10.8 Summary of Pinch Point Analysis 449
10.9 References 450
Chapter 11. Practical Energy Integration 452
11.1 Heat and Power Integration 453
11.2 Distillation Systems 460
11.3 The Integration of Chemical Reactors 476
11.4 Total Site Integration 477
11.5 Summary 479
11.6 References 479
Chapter 12. Controllability Analysis 480
12.1 Introduction 481
12.2 Modelling of Dynamic Systems 482
12.3 Controllability Analysis of SISO Systems 489
12.4 Controllability Analysis of MIMO Systems 500
12.5 Decentralized Control 506
12.6 References 517
Chapter 13. Integration of Design and Control 518
13.1 Introduction 519
13.2 Steady State Design and Controllability 520
13.3 Dynamic Effects in Recycle Systems 522
13.4 Control of Component Inventory 530
13.5 Steady State Nonlinear Effects of Material Recycle 539
13.6 Dynamic Effects of Energy Recycle 550
13.7 Plantwide Control Procedure 554
13.8 Integrating Plantwide Control in Hierarchical Conceptual Design 560
13.9 Summary 569
13.10 References 571
Part V: Design Project 572
Chapter 14. Process Design Project 574
14.1 Scope 575
14.2 Organisation 577
14.3 Process Integration Courses 578
14.4 Process Integration Project 580
14.5 Plant Design Project 581
14.6 References 587
Chapter 15. Economic Evaluation of Projects 588
15.1 Introduction 589
15.2 Basic Concepts 590
15.3 Time-Value of Money 595
15.4 Capital Costs 600
15.5 Operating Costs 608
15.6 Profitability Analysis 612
15.7 Further Reading 621
15.8 References 621
Chapter 16. Equipment Selection and Design 622
16.1 Reactors 623
16.2 Separators 629
16.3 Heat Exchangers Design 642
16.4 Transport of Fluids 653
16.5 References 655
Chapter 17. Case Studies 656
17.1 Design and Simulation of HDA Plant 657
17.2 Dynamic Simulation of the HDA Plant 668
17.3 Control of Impurities in a Complex Plant 675
17.4 References 690
Appendices 692
A. Estimation of Basic Equipment Cost 694
B. Cost of Utilities 700
C. Materials of Construction 702
D. Saturated Steam Properties 705
E. Vapour Pressures of Some Hydrocarbon 706
F. Vapour Pressures of Some Organic Components 707
G. Conversion Factors 708
Index 710