Introduction to Chemical Processes: Principles, Analysis, Synthesis

by Murphy, Regina

• ISBN13: 9780072849608
• ISBN10: 0072849606
• Edition: 1st
• Format: Hardcover
• Copyright: 2005-11-30
• Publisher: McGraw-Hill Education

Summary

Introduction to Chemical Processes: Principles, Analysis, Synthesis enhances student understanding of the connection between the chemistry and the process. Users will find strong coverage of chemistry, gain a solid understanding of what chemical processes do (convert raw materials into useful products using energy and other resources), and learn about the ways in which chemical engineers make decisions and balance constraints to come up with new processes and products. The author presents material and energy balances as tools to achieve a real goal: workable, economical, and safe chemical processes and products.Loaded with intriguing pedagogy, this text is essential to a students first course in Chemical Engineering.Additional resources intended to guide users are also available as package options, including the Engineering Equation Solver (EES) software, ChemSkill Builder and the well-known Perry's Chemical Engineering Handbook.

Table of Contents

Preface	xvi
List of Nomenclature	xxvi
List of Important Equations	xxix
Converting the Earth's Resources into Useful Products	1	(56)
Introduction	2	(1)
Raw Materials	3	(3)
Balanced Chemical Reaction Equations	6	(5)
Example 1.1 Balanced Chemical Reaction Equation: Nitric Acid Synthesis
Example 1.2 Balanced Chemical Reaction Equations: Adipic Acid Synthesis
Generation-Consumption Analysis	11	(7)
Example 1.3 Generation-Consumption Analysis: The LeBlanc Process
Example 1.4 Generation-Consumption Analysis: The Solvay Process
Example 1.5 Generation-Consumption Analysis: Ammonia Synthesis
A First Look at Material Balances and Process Economics	18	(39)
Mass, Moles, and Molar Mass	19	(1)
Atom Economy	20	(4)
Example 1.6 Atom Economy: LeBlanc versus Solvay
Example 1.7 Atom Economy: Improved Synthesis of 4-ADPA
Process Economy	24	(2)
Example 1.8 Process Economy: The Solvay Process
Process Capacities and Product Values	26	(1)
Case Study: Six-Carbon Chemistry	27	(10)
Summary	37	(2)
ChemiStory: Changing Salt into Soap	39	(1)
Quick Quiz Answers	40	(1)
References and Recommended Readings	41	(1)
Chapter 1 Problems	41	(16)
Process Flows: Variables, Diagrams, Balances	57	(112)
Introduction	58	(1)
Process Variables	59	(8)
A Brief Review of Dimensions and Units	59	(2)
Mass, Moles, and Composition	61	(2)
Temperature and Pressure	63	(1)
Volume, Density, and Concentration	64	(2)
Flowrates	66	(1)
Chemical Process Flow Sheets	67	(8)
Input-Output Flow Diagrams	68	(1)
Block Flow Diagrams	69	(2)
Process Flow Diagrams (PFD)	71	(3)
Modes of Process Operation	74	(1)
Process Flow Calculations	75	(29)
Definitions	76	(2)
Material Balance Equations	78	(3)
A Systematic Procedure for Process Flow Calculations	81	(1)
Helpful Hints for Process Flow Calculations	82	(2)
A Plethora of Problems	84	(20)
Example 2.1 Mixers: Battery Acid Production
Example 2.2 Reactors: Ammonia Synthesis
Example 2.3 Separators: Fruit Juice Concentration
Example 2.4 Splitters: Fruit Juice Processing
Example 2.5 Elements as Components: Ibuprofen Analysis
Example 2.6 Separation with Accumulation: Air Drying
Example 2.7 Reaction with Accumulation: Light from a Chip
Degree of Freedom Analysis	104	(8)
Example 2.8 DOF Analysis: Ammonia Synthesis
Example 2.9 DOF Analysis: Light from a Chip
Example 2.10 DOF Analysis: Battery Acid Production
Example 2.11 DOF Analysis: Eat Your Greens!
Process Flow Calculations with Multiple	112	(57)
Process Units	112	(9)
Example 2.12 Multiple Process Units: Toxin Accumulation
Example 2.13 Multiple Process Units: Adipic Acid Manufacture from Glucose
Synthesizing Block Flow Diagrams	121	(3)
Example 2.14 Synthesizing Block Flow Diagrams: Adipic Acid Process
The Art of Approximating	124	(1)
Degree of Freedom Analysis for Block Flow Diagrams with Multiple Process Units	125	(2)
Example 2.15 DOF Analysis: Adipic Acid Production
Case Study: Evolution of a Greener Process	127	(9)
Summary	136	(1)
ChemiStory: Guano and the Guns of August	137	(4)
Quick Quiz Answers	141	(1)
References and Recommended Readings	141	(1)
Chapter 2 Problems	142	(27)
Mathematical Analysis of Material Balance Equations and Process Flow Sheets	169	(94)
Introduction	170	(1)
The Material Balance Equation---Again	170	(30)
Conservation of Mass and the Material Balance Equation	171	(5)
Example 3.1 Decomposition Reactions
General Forms of the Differential Material Balance Equations	176	(6)
Example 3.2 Mass Balances: Sugar Dissolution
Example 3.3 Mass Balances: Glucose Consumption in a Fermentor
Example 3.4 Mole Balances: Manufacture of Urea
Example 3.5 Mole Balances: Urea Manufacture from Cheaper Reactants
Degree of Freedom Analysis	182	(4)
Example 3.6 DOF Analysis: Urea Synthesis from Cheaper Reactants
Example 3.7 Differential Material Balance Equation with Multiple Chemical Reactions at Steady State: Benzene into Catechol
General Forms of the Integral Material Balance Equations	186	(7)
Example 3.8 Integral Equation: Blending and Shipping
Example 3.9 Integral Equation with Unsteady Flow: Jammin' with Cherries
A Few More Problems	193	(7)
Example 3.10 Integral Equation with Unsteady Flow and Chemical Reaction: Controlled Drug Release
Example 3.11 Differential Equation with Unsteady Flow and Chemical Reaction: Glucose Utilization in a Fermentor
Linear Equations and Chemical Reactions (Optional Section)	200	(13)
Linear Equations, Linear Independence, Solution Existence, and Solution Uniqueness	201	(3)
Using Matrices to Balance Chemical Reactions	204	(3)
Example 3.12 Balancing Chemical Equations with Matrix Math: Adipic Acid
Using Matrices in Generation-Consumption Analysis	207	(3)
Example 3.13 Generation-Consumption Analysis Using Matrix Math: Nitric Acid Synthesis
Using Matrices to Find Linearly Independent Chemical Equations	210	(3)
Linear Models of Process Flow Sheets (Optional Section)	213	(1)
Linear Models of Single Process Units	214	(49)
Example 3.14 Linear Model of a Mixer: Sweet Mix
Example 3.15 Linear Model of a Splitter: Sweet Split
Example 3.16 Linear Model of a Reactor: Glucose-Fructose Isomerization
Example 3.17 Linear Model of a Reactor: Multiple Reactions
Example 3.18 Linear Model of a Separator: Sweet Solutions
Process Topology	226	(8)
Example 3.19 Linear Models with Multiple Process Units and Recycle: Taking an old Plant out of Mothballs
Case Study: Manufacture of Nylon-6,6	234	(10)
Summary	244	(2)
ChemiStory: Of Toothbrushes and Hosiery	246	(3)
Quick Quiz Answers	249	(1)
References & Recommended Reading	249	(1)
Chapter 3 Problems	249	(14)
Synthesis of Reactor Flow Sheets and Selection of Reactor Process Conditions	263	(102)
Introduction	264	(7)
Industrially Important Chemical Reactions	264	(2)
Heuristics for Selecting Chemical Reactions	266	(1)
A Brief Review: Generation-Consumption Analysis and Atom Economy	266	(3)
Example 4.1 Generation-Consumption and Atom Economy: Improved Synthesis of Ibuprofen
Reactor Design Variables	269	(2)
Reactor Material Balance Equations	271	(11)
Reactors with Known Reaction Stoichiometry	271	(7)
Example 4.2 Continuous-Flow Steady-State Reactor with Known Stoichiometry: Combustion of Natural Gas
Example 4.3 Batch Reactor with Known Reaction Stoichiometry: Ibuprofen Synthesis
Example 4.4 Semibatch Reactor with Known Reaction Stoichiometry: Ibuprofen Synthesis
Reactors with Unknown Reaction Stoichiometry	278	(4)
Example 4.5 Material Balance Equation with Elements: Combustion of Natural Gas
Example 4.6 Mass Rates of Reaction: Microbial Degradation of Soil Contaminants
Stream Composition and System Performance Specifications for Reactors	282	(22)
Stream Composition Specification: Excess and Limiting Reactants	284	(3)
Example 4.7 Excess Reactants: A Badly Maintained Furnace
System Performance Specification: Fractional Conversion	287	(3)
Example 4.8 Fractional Conversion: Ammonia Synthesis
Example 4.9 Effect of Conversion on Reactor Flows: Ammonia Synthesis
Fractional Conversion and Its Effect on Reactor Flow Sheet Synthesis: Recycle	290	(4)
Example 4.10 Low Conversion and Recycle: Ammonia Synthesis
Fractional Conversion and Its Effect on Reactor Flow Sheet Synthesis: Recycle and Purge	294	(4)
Example 4.11 Recycle with Purge: Ammonia Synthesis
System Performance Specifications: Selectivity and Yield	298	(6)
Example 4.12 Selectivity and Yield Definitions: Acetaldehyde Synthesis
Example 4.13 Using Selectivity in Process Flow Calculations: Acetaldehyde Synthesis
Why Reactors Aren't Perfect: Chemical Equilibrium and Chemical Kinetics	304	(61)
The Chemical Reaction Equilibrium Constant Ka	304	(3)
Example 4.14 Deriving Equations for Ka: Three Cases
Calculating Ka	307	(7)
Example 4.15 Calculating Ka: Ethyl Acetate Synthesis
Example 4.16 Chemical Equilibrium Considerations in Selection of Reaction Pathway: Safer Routes to Dimethyl Carbonate
Chemical Reaction Equilibrium and Reactor Performance	314	(9)
Example 4.17 Reactor Performance and Ka: Ammonia Synthesis
Example 4.18 Equilibrium Conversion as a Function of T and P: Ammonia Synthesis
Example 4.19 Multiple Chemical Equilibria and Reactor T: NOx Formation.
Chemical Reaction Kinetics and Reactor Performance (Optional Section)	323	(4)
Example 4.20 Reaction Kinetics and Reactor Performance: Vegetable Processing
Case Study: Hydrogen and Methanol	327	(8)
Summary	335	(2)
ChemiStory: Quit Bugging Me	337	(3)
Quick Quiz Answers	340	(1)
References and Recommended Readings	340	(1)
Chapter 4 Problems	341	(24)
Selection of Separation Technologies and Synthesis of Separation Flow Sheets	365	(130)
Introduction	366	(13)
Physical Property Differences: The Basis for All Separations	366	(1)
Example 5.1 Physical Property Differences: Separating Salt From Sugar
Mixtures and Phases	367	(2)
Classification of Separation Technologies	369	(4)
Heuristics for Selecting and Sequencing Separation Technologies	373	(6)
Example 5.2 Selection of Separation Technology: Separating Benzene from Toluene
Example 5.3 Selection of Separation Technology: Cleaning up Off-Gas from a Printing Press
Example 5.4 Sequencing of Separation Technologies: Aromatics and Acid
Separator Material Balance Equations	379	(7)
Example 5.5 Semibatch Mechanical Separation: Filtration of Beer Solids
Example 5.6 Rate-Based Separation: Membranes for Kidney Dialysis
Stream Composition and System Performance Specifications for Separators	386	(12)
Example 5.7 Defining Separator Performance Specifications: Separating Benzene from Toluene
Example 5.8 Purity and Recovery Specifications in Process Flow Calculations: Separating Benzene and Toluene
Example 5.9 Fractional Recovery in Rate-Based Separations: Membranes for Kidney Dialysis
Recycling in Separation Flow Sheets	394	(4)
Example 5.10 Separation with Recycle: Separating Sugar Isomers
Why Separators Aren't Perfect: Entrainment and Equilibrium	398	(5)
Entrainment: Incomplete Mechanical Separation	398	(3)
Example 5.11 Accounting for Entrainment: Coffee Making
Phase Equilibrium and the Equilibrium Stage	401	(2)
An Exhausting (but Not Exhaustive) Look at Phase Equilibrium	403	(20)
The Gibbs Phase Rule	404	(1)
Single-Component Phase Equilibrium	405	(3)
Multicomponent Phase Equilibrium	408	(15)
Example 5.12 Using Raoult's Law: Dew Point and Bubble Point Temperatures of Hexane-Heptane Mixtures
Equilibrium-Based Separations	423	(72)
Crystallization	425	(4)
Example 5.13 Process Flow Calculations with Liquid-Solid Equilibrium Data: Potassium Nitrate Crystallization
Example 5.14 Entrainment Effects in Equilibrium-Based Separations: Separation of Benzene and Naphthalene by Crystallization
Evaporation, Condensation, and Equilibrium Flash	429	(5)
Example 5.15 Process Flow Calculations with Raoult's Law: Dehumidification of Air by Condensation
Example 5.16 Process Flow Calculations with Raoult's Law: Equilibrium Flash of a Hexane/Heptane Mixture
Example 5.17 Vapor-Liquid Separations with Nonideal Solutions: Equilibrium Flash Separation of Ethanol-Water Mixture
Distillation (Optional)	434	(3)
Example 5.18 The Power of Multistaging: Distillation versus Equilibrium Flash for Hexane/Heptane Separation
Absorption, Adsorption, and Extraction	437	(9)
Example 5.19 Process Flow Calculations Using Gas-Liquid Equilibrium Data: Cleaning up Dirty Air by Absorption
Example 5.20 Process Flow Calculations Using Adsorption Isotherms: Monoclonal Antibody Purification
Example 5.21 Process Flow Calculations Using Liquid-Liquid Distribution Coefficients: Cleanup of Wastewater Stream by Solvent Extraction
Example 5.22 Process Flow Calculations Using Triangular Phase Diagrams: Separating Acetic Acid from Water
Multistaged Separations Using Material Separating Agents (Optional)	446	(5)
Example 5.23 The Power of Multistaging: Recovery of Acetic Acid from Wastewater
Case Study: Scrubbing Sour Gas	451	(6)
Summary	457	(1)
ChemiStory: How Sweet It Is	458	(3)
Quick Quiz Answers	461	(1)
References and Recommended Readings	462	(1)
Chapter 5 Problems	462	(33)
Process Energy Calculations and Synthesis of Safe and Efficient Energy Flow Sheets	495	(126)
Introduction	496	(8)
Energy Sources	496	(3)
Energy Distribution: Electricity, Heating Fluids, and Cooling Fluids	499	(1)
Energy Transfer Equipment	500	(2)
A Brief Review of Energy-Related Dimensions and Units	502	(2)
Process Energy Calculations: The Basics	504	(3)
The Energy Balance Equation	504	(1)
System Energy, Energy Flows, Specific Energy	505	(2)
Putting a Number on Energy: Energy Data and Model Equations	507	(14)
Two Forms of Energy: Kinetic and Potential	508	(3)
Example 6.1 Kinetic and Potential Energy: Toddler Troubles
Example 6.2 Change in Potential Energy: Snow Melt
Example 6.3 Change in Kinetic Energy of a Stream: Thomas Edison or Rube Goldberg?
A Third Kind of Energy and a Convenience Function: Internal Energy and Enthalpy	511	(1)
Using Tables and Graphs to Find U and H	512	(9)
Example 6.4 Using Steam Tables to Find H: Several Cases
Example 6.5 Using Steam Tables: Pumping Water, Compressing Steam
Example 6.6 Comparing Kinetic, Potential, and Internal Energy: Frequent Flyer
Example 6.7 Using Enthalpy-Composition Graphs: Ammonia-Water Mixtures
Using Model Equations to Find U and H	521	(15)
Example 6.8 Enthalpy Calculations: Enthalpy of Vaporization of Water at High Pressure
Example 6.9 Enthalpy Calculations: Enthalpy of Reaction at High Temperature
Minisummary	535	(1)
Energy Flows: Heat and Work	536	(2)
The Energy Balance Equation---Again	538	(2)
Process Energy Calculations	540	(20)
A Systematic Procedure for Process Energy Calculations	540	(1)
Helpful Hints for Process Energy Calculations	541	(1)
A Plethora of Problems	542	(18)
Example 6.10 Potential Energy into Work: Water over the Dam
Example 6.11 Integral Energy Balance with a Closed System: Unplugging the Frozen Pipes
Example 6.12 Temperature Change with Dissolution: Caustic Tank Safety
Example 6.13 Simultaneous Energy and Material Balances: Mel and Dan's Lemonade Stand
Example 6.14 Energy Balance with Equilibrium Flash: Separation of Hexane and Heptane
Example 6.15 Energy Balance with Chemical Reaction: Adiabatic Flame Temperature
Example 6.16 Energy Balance with Multiple Reactions: Synthesis of Acetaldehyde
Example 6.17 Unsteady-State Heat Loss: Cooling a Batch of Sterilized Broth
A Process Energy Sampler (Optional Section)	560	(61)
Work and the Engineering Bernoulli Equation	560	(3)
Example 6.18 The Engineering Bernoulli Equation: Sizing a Pump
Heat and the Synthesis of Heat Exchange Networks	563	(4)
Example 6.19 Heat Exchanger Sizing: Steam Heating of Methanol Vapor
Energy Conversion Processes	567	(12)
Example 6.20 Converting Reaction Energy to Heat: Furnace Efficiency
Example 6.21 Converting Reaction Energy to Work: Heat Engine Analysis
Example 6.22 Converting Reaction Energy to Work: Hydrogen Fuel Cells
Chemical Energy and Chemical Safety: Explosions	579	(5)
Example 6.23 Estimating Explosive Potential: Trinitrotoluene
Case Study: Energy Management in a Chemical Reactor	584	(5)
Summary	589	(2)
ChemiStory: Get the Lead Out!	591	(4)
Quick Quiz Answers	595	(1)
References and Recommended Readings	595	(1)
Chapter 6 Problems	596	(25)
Appendix A Mathematical Methods	621	(20)
Appendix B Physical Properties	641	(32)
Appendix C Answers to Select Problems	673	(8)
Glossary	681
Index	1