Analysis, Synthesis and Design of Chemical Processes

by Turton, Richard; Bailie, Richard C.; Whiting, Wallace B.; Shaeiwitz, Joseph A.

• ISBN13: 9780135129661
• ISBN10: 0135129664
• Edition: 3rd
• Format: Hardcover
• Copyright: 2008-12-24
• Publisher: Prentice Hall

Summary

More than ever, effective design is the focal point of sound chemical engineering. Analysis, Synthesis, and Design of Chemical Processes, Third 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 book 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 optimisation. This fully updated Third Edition presents entirely new problems at the end of every chapter. It also adds extensive coverage of batch process design, including realistic examples of equipment sizing for batch sequencing; batch scheduling for multi-product plants; improving production via intermediate storage and parallel equipment; and new optimisation techniques specifically for batch processes. Coverage includes bull; Conceptualising and analysing chemical process: flow diagrams, tracing, process conditions, and more bull; Chemical process economics: analysing capital and manufacturing costs, and predicting or assessing profitability bull; Synthesizing and optimising chemical processing: experience-based principles, BFD/PFD, simulations, and more bull; Analysing process performance via I/O models, performance curves, and other tools bull; Process troubleshooting and 'debottlenecking' bull; Chemical engineering design and society: ethics, professionalism, health, safety, and new 'green engineering' techniques bull; Participating successfully in chemical engineering design teams Analysis, Synthesis, and Design of Chemical Processes, Third Edition draws on nearly 35 years of innovative chemical engineering instruction at West Virginia University.

Author Biography

Richard Turton, P.E., has taught the senior design course at West Virginia University for the past 22 years. Previously, he spent five years in the design and construction industry.

Richard C. Bailie, professor emeritus at WVU, taught chemical engineering design for more than 20 years, and has ten years of additional experience in process evaluation, pilot plant operation, plant start-up, and industrial consulting.

Wallace B. Whiting, P.E., professor emeritus at the University of Nevada, Reno, has practiced and taught chemical process design for more than 24 years.

Joseph A. Shaeiwitz has been involved in WVU’s senior design sequence and unique sophomore- and junior-level integrated design projects for 20 years.

Table of Contents

Material on the CD-ROM	p. xix
Preface	p. xxiii
About the Authors	p. xxvii
List of Nomenclature	p. xxix
Conceptualization and Analysis of Chemical Processes	p. 1
Diagrams for Understanding Chemical Processes	p. 5
Block Flow Diagrams (BFDs)	p. 7
Process Flow Diagram (PFD)	p. 9
Piping and Instrumentation Diagram (P&ID)	p. 26
Additional Diagrams	p. 32
Three-Dimensional Representation of a Process	p. 33
The 3-D Plant Model	p. 42
Summary	p. 44
References	p. 45
Short Answer Questions	p. 45
Problems	p. 46
The Structure and Synthesis of Process Flow Diagrams	p. 51
Hierarchy of Process Design	p. 51
Step 1-Batch versus Continuous Process	p. 52
Step 2-The Input/Output Structure of the Process	p. 57
Step 3-The Recycle Structure of the Process	p. 68
Step 4-General Structure of the Separation System	p. 84
Step 5-Heat-Exchanger Network or Process Energy Recovery System	p. 84
Information Required and Sources	p. 84
Summary	p. 84
References	p. 86
Short Answer Questions	p. 88
Problems	p. 88
Batch Processing	p. 93
Design Calculations for Batch Processes	p. 93
Gantt Charts and Scheduling	p. 100
Nonoverlapping, Overlapping Operations, and Cycle Times	p. 101
Flowshop and Jobshop Plants	p. 104
Product and Intermediate Storage and Parallel Process Units	p. 110
Design of Equipment for Multiproduct Batch Processes	p. 116
Summary	p. 119
References	p. 119
Short Answer Questions	p. 119
Problems	p. 120
Chemical Product Design	p. 123
Strategies for Chemical Product Design	p. 124
Needs	p. 126
Ideas	p. 128
Selection	p. 129
Manufacture	p. 131
Batch Processing	p. 132
Economic Considerations	p. 132
Summary	p. 133
References	p. 133
Tracing Chemicals through the Process Flow Diagram	p. 135
Guidelines and Tactics for Tracing Chemicals	p. 135
Tracing Primary Paths Taken by Chemicals in a Chemical Process	p. 136
Recycle and Bypass Streams	p. 142
Tracing Nonreacting Chemicals	p. 146
Limitations	p. 147
Written Process Description	p. 147
Summary	p. 149
Problems	p. 149
Understanding Process Conditions	p. 151
Conditions of Special Concern for the Operation of Separation and Reactor Systems	p. 152
Reasons for Operating at Conditions of Special Concern	p. 154
Conditions of Special Concern for the Operation of Other Equipment	p. 159
Analysis of Important Process Conditions	p. 163
Summary	p. 171
References	p. 172
Short Answer Questions	p. 172
Problems	p. 172
Engineering Economic Analysis of Chemical Processes	p. 175
Estimation of Capital Costs	p. 177
Classifications of Capital Cost Estimates	p. 177
Estimation of Purchased Equipment Costs	p. 181
Estimating the Total Capital Cost of a Plant	p. 187
Summary	p. 215
References	p. 215
Short Answer Questions	p. 216
Problems	p. 216
Estimation of Manufacturing Costs	p. 221
Factors Affecting the Cost of Manufacturing a Chemical Product	p. 221
Cost of Operating Labor	p. 226
Utility Costs	p. 228
Raw Material Costs	p. 244
Yearly Costs and Stream Factors	p. 246
Estimating Utility Costs from the PFD	p. 247
Cost of Treating Liquid and Solid Waste Streams	p. 250
Evaluation of Cost of Manufacture for the Production
Table of Contents provided by Publisher. All Rights Reserved.

Excerpts

Preface Preface This book represents the culmination of many years of teaching experience in the senior design course at West Virginia University (WVU) and University of Nevada, Reno. Although the program at WVU has evolved over the past 30 years and is still evolving, it is fair to say that the current program has gelled over the past 20 years as a concerted effort by the authors to integrate design throughout the undergraduate curriculum in chemical engineering. We view design as the focal point of chemical engineering practice. Far more than the development of a set of specifications for a new chemical plant, design is the creative activity through which engineers continuously improve the operations of facilities to create products that enhance the quality of life. Whether developing the grassroots plant, proposing and guiding process modifications, or troubleshooting and implementing operational strategies for existing equipment, engineering design requires a broad spectrum of knowledge and intellectual skills to be able to analyze the big picture and the minute details and, most important, to know when to concentrate on each. Our vehicle for helping students develop and hone their design skills is process design rather than plant design, covering synthesis of the entire chemical process through topics relating to the preliminary sizing of equipment, flowsheet optimization, economic evaluation of projects, and the operation of chemical processes. The purpose of this text is to assist chemical engineering students in making the transition from solving well-posed problems in a specific subject to integrating all the knowledge that they have gained in their undergraduate education and applying this information to solving open-ended process problems. Many of the nuts-and-bolts issues regarding plant design (for example, what schedule pipe to use for a given stream or what corrosion allowance to use for a vessel in a certain service) are not covered. Although such issues are clearly important to the practicing engineer, several excellent handbooks and textbooks are available to address such problems, and these are cited in the text where applicable. In the third edition, we have rearranged some of the material from previous editions, added a new chapter on batch processing and a section on optimization of batch processes, and supplied new problems for all of the quantitative chapters. We continue to emphasize the importance of understanding, analyzing, and synthesizing chemical processes and process flow diagrams. To this end, we have expanded Appendix B to include an additional seven preliminary designs of chemical processes. The CAPCOST program for preliminary evaluation of fixed capital investment and profitability analysis has been expanded to include more equipment. Finally, the chapters on outcomes assessment, written and oral communications, and a written report case study have been moved to the CD accompanying the text. The arrangement of chapters into the six sections of the book is similar to that adopted in the second edition. These sections are as follows. Section 1Conceptualization and Analysis of Chemical Processes Section 2Engineering Economic Analysis of Chemical Processes Section 3Synthesis and Optimization of Chemical Processes Section 4Analysis of Process Performance Section 5The Impact of Chemical Engineering Design on Society Section 6 Interpersonal and Communication Skills In Section 1, the student is introduced first to the principal diagrams that are used to describe a chemical process. Next, the evolution and generation of different process configurations are covered. Key concepts used in evaluating batch processes are included in the new Chapter 3, and the chapter on product design has been moved to Chapter 4. Finally, the analysis of existing processes is covered. In Section 2, the information needed to assess the economic feasibility of a process is covered. This includes the estimation of fixed capital investment and manufacturing costs, the concepts of the time value of money and financial calculations, and finally the combination of these costs into profitability measures for the process. Section 3 covers the synthesis of a chemical process. The minimum information required to simulate a process is given, as are the basics of using a process simulator. The choice of the appropriate thermodynamic model to use in a simulation is covered, and the choice of separation operations is covered. In addition, process optimization (including an introduction to optimization of batch processes) and heat integration techniques are covered in this section. In Section 4, the analysis of the performance of existing processes and equipment is covered. The material in Section 4 is substantially different from that found in most textbooks. We consider equipment that is already built and operating and analyze how the operation can be changed, how an operating problem may be solved, and how to analyze what has occurred in the process to cause an observed change. In Section 5, the impact of chemical engineering design on society is covered. The role of the professional engineer in society is addressed. Separate chapters addressing ethics and professionalism, health, safety, and the environment, and green engineering are included. In Section 6, the interpersonal skills required by the engineer to function as part of a team and to communicate both orally and in written form are covered (both in the text and on the CD). An entire chapter (on the CD) is devoted to addressing some of the common mistakes that students make in written reports. Finally, three appendices are included. Appendix A gives a series of cost charts for equipment. This information is embedded in the CAPCOST program for evaluating fixed capital investments and process economics. Appendix B gives the preliminary design information for 11 chemical processes: dimethyl ether, ethylbenzene, styrene, drying oil, maleic anhydride, ethylene oxide, formalin, batch manufacture of amino acids, acrylic acid, acetone, and heptenes production. This information is used in many of the end-of-chapter problems in the book. These processes can also be used as the starting point for more detailed analysesfor example, optimization studies. Other projects, detailed in Appendix C, are included on the CD accompanying this book. The reader (faculty and students) is also referred to our Web site at che.cemr.wvu.edu/publications/projects/, where a variety of design projects for sophomore- through senior-level chemical engineering courses is provided. There is also a link to another Web site that contains environmentally related design projects. For a one-semester design course, we recommend including the following core: Section 1Chapters 1 through 6 Section 3Chapters 11, 12, and 13 Section 5Chapters 23 and 24 For programs in which engineering economics is not a prerequisite to the design course, Section 2 (Chapters 710) should also be included. If students have previously covered engineering economics, Chapters 14 and 15 covering optimization and pinch technology could be substituted. For the second term of a two-term sequence, we recommend Chapters 16 through 20 (and Chapters 14 and 15 if not included in the first design course) plus design projects. If time permits, we also recommend Chapter 21 (Regulating Process Conditions) and Chapter 22 (Process Troubleshooting) because these tend to solidify as well as extend the concepts of Chapters 16 through 20, that is, what an entry-level process engineer will encounter in the first few years of employment at a chemical process facility. For an environmental emphasis, Chap