Chemical Engineering Design (eBook)

Front Cover 1
Chemical Engineering Design 4
Copyright Page 5
Dedication Page 6
Contents 8
Preface 16
How to Use this Book 18
Acknowledgments 20
Chapter 1: Introduction to Design 22
1.1. Introduction 23
1.2. Nature of Design 23
1.3. The Anatomy of a Chemical Manufacturing Process 29
1.4. The Organization of a Chemical Engineering Project 32
1.5. Project Documentation 34
1.6. Codes and Standards 37
1.7. Design Factors (Design Margins) 38
1.8. Systems of Units 39
1.9. Optimization 40
1.10. References 65
1.11. Nomenclature 65
1.12. Problems 66
Chapter 2: Fundamentals of Material Balances 70
2.1. Introduction 71
2.2. The Equivalence of Mass and Energy 71
2.3. Conservation of Mass 72
2.4. Units Used to Express Compositions 72
2.5. Stoichiometry 73
2.6. Choice of System Boundary 74
2.7. Choice of Basis for Calculations 77
2.8. Number of Independent Components 78
2.9. Constraints on Flows and Compositions 79
2.10. General Algebraic Method 80
2.11. Tie Components 81
2.12. Excess Reagent 83
2.13. Conversion, Selectivity, and Yield 84
2.14. Recycle Processes 89
2.15. Purge 91
2.16. Bypass 92
2.17. Unsteady-State Calculations 93
2.18. General Procedure for Material-Balance Problems 95
2.19. References 96
2.20. Nomenclature 96
2.21. Problems 97
Chapter 3: Fundamentals of Energy Balances and Energy Utilization 102
3.1. Introduction 103
3.2. Conservation of Energy 103
3.3. Forms of Energy (Per Unit Mass of Material) 104
3.4. The Energy Balance 105
3.5. Calculation of Specific Enthalpy 110
3.6. Mean Heat Capacities 111
3.7. The Effect of Pressure on Heat Capacity 113
3.8. Enthalpy of Mixtures 115
3.9. Enthalpy-Concentration Diagrams 116
3.10. Heats of Reaction 119
3.11. Standard Heats of Formation 122
3.12. Heats of Combustion 123
3.13. Compression and Expansion of Gases 125
3.14. Energy Balance Calculations 133
3.15. Unsteady State Energy Balances 134
3.16. Energy Recovery 135
3.17. Heat Exchanger Networks 145
3.18. References 166
3.19. Nomenclature 167
3.20. Problems 171
Chapter 4: Flowsheeting 174
4.1. Introduction 175
4.2. Flowsheet Presentation 176
4.3. Process Simulation Programs 183
4.4. Specification of Components and Physical Property Models 186
4.5. Simulation of Unit Operations 190
4.6. User Models 225
4.7. Flowsheets with Recycle 228
4.8. Flowsheet Optimization 240
4.9. Dynamic Simulation 245
4.10. References 245
4.11. Nomenclature 246
4.12. Problems 247
Chapter 5: Piping and Instrumentation 256
5.1. Introduction 257
5.2. The P and I Diagram 257
5.3. Valve Selection 262
5.4. Pumps and Compressors 264
5.5. Mechanical Design of Piping Systems 283
5.6. Pipe Size Selection 286
5.7. Control and Instrumentation 296
5.8. Typical Control Systems 298
5.9. Alarms, Safety Trips, and Interlocks 306
5.10. Computers in Process Control 308
5.11. References 310
5.12. Nomenclature 312
5.13. Problems 314
Chapter 6: Costing and Project Evaluation 318
6.1. Introduction 319
6.2. Costs, Revenues, and Profits 319
6.3. Estimating Capital Costs 327
6.4. Estimating Production Costs and Revenues 355
6.5. Taxes and Depreciation 373
6.6. Project Financing 379
6.7. Economic Evaluation of Projects 384
6.8. Sensitivity Analysis 401
6.9. Project Portfolio Selection 405
6.10. References 409
6.11. Nomenclature 411
6.12. Problems 413
Chapter 7: Materials of Construction 418
7.1. Introduction 419
7.2. Material Properties 419
7.3. Mechanical Properties 420
7.4. Corrosion Resistance 423
7.5. Selection for Corrosion Resistance 428
7.6. Material Costs 429
7.7. Contamination 430
7.8. Commonly Used Materials of Construction 431
7.9. Plastics as Materials of Construction for Chemical Plants 438
7.10. Ceramic Materials (Silicate Materials) 440
7.11. Carbon 442
7.12. Protective Coatings 442
7.13. Design for Corrosion Resistance 442
7.14. References 443
7.15. Nomenclature 445
7.16. Problems 445
Chapter 8: Design Information and Data 448
8.1. Introduction 449
8.2. Sources of Information on Manufacturing Processes 449
8.3. General Sources of Physical Properties 451
8.4. Accuracy Required of Engineering Data 453
8.5. Prediction of Physical Properties 454
8.6. Density 455
8.7. Viscosity 457
8.8. Thermal Conductivity 461
8.9. Specific Heat Capacity 463
8.10. Enthalpy of Vaporization (Latent Heat) 470
8.11. Vapor Pressure 472
8.12. Diffusion Coefficients (Diffusivities) 473
8.13. Surface Tension 476
8.14. Critical Constants 478
8.15. Enthalpy of Reaction and Enthalpy of Formation 481
8.16. Phase Equilibrium Data 481
8.17. References 493
8.18. Nomenclature 498
8.19. Problems 500
Chapter 9: Safety and Loss Prevention 502
9.1. Introduction 503
9.2. Materials Hazards 507
9.3. Process Hazards 514
9.4. Analysis of Product and Process Safety 523
9.5. Failure-Mode Effect Analysis 524
9.6. Safety Indices 527
9.7. Hazard and Operability Studies 538
9.8. Quantitative Hazard Analysis 547
9.9. Safety Checklists 552
9.10. References 555
9.11. Nomenclature 559
9.12. Problems 559
Chapter 10: Equipment Selection, Specification, and Design 562
10.1. Introduction 563
10.2. Separation Processes 564
10.3. Solid-Solid Separations 564
10.4. Liquid-Solid (Solid-Liquid) Separators 571
10.5. Separation of Dissolved Solids 598
10.6. Liquid-Liquid Separation 603
10.7. Separation of Dissolved Liquids 611
10.8. Gas-Solid Separations (Gas Cleaning) 612
10.9. Gas-Liquid Separators 624
10.10. Crushing and Grinding (Comminution) Equipment 630
10.11. Mixing Equipment 630
10.12. Transport and Storage of Materials 641
10.13. Reactors 647
10.14. References 651
10.15. Nomenclature 656
10.16. Problems 658
Chapter 11: Separation Columns (Distillation, Absorption, and Extraction) 662
11.1. Introduction 663
11.2. Continuous Distillation: Process Description 663
11.3. Continuous Distillation: Basic Principles 666
11.4. Design Variables in Distillation 671
11.5. Design Methods for Binary Systems 673
11.6. Multicomponent Distillation: General Considerations 686
11.7. Multicomponent Distillation: Shortcut Methods for Stage and Reflux Requirements 688
11.8. Multicomponent Systems: Rigorous Solution Procedures (Complex Methods) 714
11.9. Other Distillation Systems 718
11.10. Plate Efficiency 719
11.11. Approximate Column Sizing 729
11.12. Plate Contactors 730
11.13. Plate Hydraulic Design 737
11.14. Packed Columns 762
11.15. Column Auxiliaries 792
11.16. Solvent Extraction (Liquid-Liquid Extraction) 793
11.17. References 800
11.18. Nomenclature 805
11.19. Problems 810
Chapter 12: Heat Transfer Equipment 814
12.1. Introduction 815
12.2. Basic Design Procedure and Theory 816
12.3. Overall Heat Transfer Coefficient 817
12.4. Fouling Factors (Dirt Factors) 819
12.5. Shell and Tube Exchangers: Construction Details 822
12.6. Mean Temperature Difference (Temperature Driving Force) 836
12.7. Shell and Tube Exchangers: General Design Considerations 841
12.8. Tube-Side Heat Transfer Coefficient and Pressure Drop (Single Phase) 844
12.9. Shell-Side Heat Transfer and Pressure Drop (Single Phase) 850
12.10. Condensers 891
12.11. Reboilers and Vaporizers 911
12.12. Plate Heat Exchangers 939
12.13. Direct-Contact Heat Exchangers 950
12.14. Finned Tubes 951
12.15. Double-Pipe Heat Exchangers 952
12.16. Air-Cooled Exchangers 953
12.17. Fired Heaters (Furnaces and Boilers) 953
12.18. Heat Transfer to Vessels 959
12.19. References 966
12.20. Nomenclature 972
12.21. Problems 978
Chapter 13: Mechanical Design of Process Equipment 982
13.1. Introduction 983
13.2. Pressure Vessel Codes and Standards 984
13.3. Fundamental Principles and Equations 987
13.4. General Design Considerations: Pressure Vessels 1001
13.5. The Design of Thin-Walled Vessels Under Internal Pressure 1007
13.6. Compensation for Openings and Branches 1014
13.7. Design of Vessels Subject to External Pressure 1016
13.8. Design of Vessels Subject to Combined Loading 1020
13.9. Vessel Supports 1034
13.10. Bolted Flanged Joints 1041
13.11. Heat Exchanger Tube Plates 1049
13.12. Welded-Joint Design 1052
13.13. Fatigue Assessment of Vessels 1054
13.14. Pressure Tests 1055
13.15. High-Pressure Vessels 1056
13.16. Liquid Storage Tanks 1059
13.17. Pressure-Relief Devices 1059
13.18. References 1074
13.19. Nomenclature 1077
13.20. Problems 1081
Chapter 14: General Site Considerations 1086
14.1. Introduction 1087
14.2. Plant Location and Site Selection 1087
14.3. Site Layout 1089
14.4. Plant Layout 1090
14.5. Utilities 1095
14.6. Environmental Considerations 1097
14.7. References 1107
Appendix 1110
A Graphical Symbols for Piping Systems and Plant 1110
B Corrosion Chart 1120
C Physical Property Data Bank 1140
D Conversion Factors for Some Common SI Units 1162
E Design Projects I 1166
F Design Projects II 1186
G Equipment Specification (Data) Sheets 1214
H Typical Shell and Tube Heat Exchanger Tube-Sheet Layouts 1228
I Material Safety Data Sheet 1234
Index 1242