Analysis, Synthesis, and Design of Chemical Processes

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

• ISBN13: 9780135705650
• ISBN10: 0135705657
• Edition: Disk
• Format: Hardcover
• Copyright: 1997-11-01
• Publisher: Pearson College Div

Summary

For upper-level undergraduate chemical engineering courses in Chemical Engineering Process Design, an A.B.E.T. requirement.Designed to help chemical engineering students make the transition from solving well-posed problems in a specific subject to integrating and applying all the knowledge they have gained to solving open-ended process problems. It is intended to help students hone their design skills through process design, rather than plant design and move them toward becoming practicing engineers. In that way, the book takes a systems- oriented approach, rather than to simply provide a compendium of design information.

Table of Contents

Preface	xvii	(4)
List of Nomenclature	xxi
SECTION 0 CHEMICAL PROCESS DIAGRAMS	1	(38)
Chapter 1 Essential Flow Diagrams for Understanding Processes	5	(34)
1.1 Block Flow Diagrams (BFD)	7	(2)
1.1.1 Block Flow Process Diagram	7	(2)
1.1.2 Block Flow Plant Diagrams	9	(1)
1.2 Process Flow Diagrams (PFD)	9	(17)
1.2.1 Process Topology	12	(5)
1.2.2 Stream Information	17	(2)
1.2.3 Equipment Information	19	(3)
1.2.4 Combining Topology, Stream Data, and Control Strategy to Give a PFD	22	(4)
1.3 Piping and Instrumentation Diagram (P&ID)	26	(6)
1.4 Additional Diagrams	32	(1)
1.5 Summary	33	(1)
References	33	(1)
Problems	34	(5)
SECTION 1 ENGINEERING ECONOMIC ANALYSIS OF CHEMICAL PROCESSES	39	(138)
Chapter 2 Estimation of Capital Costs	41	(36)
2.1 Classifications of Capital Cost Estimates	41	(5)
2.2 Estimating Purchased Equipment Costs	46	(6)
2.2.1 Effect of Capacity on Purchased Equipment Cost	46	(3)
2.2.2 Effect of Time on Purchased Equipment Cost	49	(3)
2.3 Estimating the Total Capital Cost of a Plant	52	(20)
2.3.1 Bare Module Cost for Equipment at Base Conditions	57	(5)
2.3.2 Bare Module Cost for Non-Base Case Conditions	62	(5)
2.3.3 Grass Roots and Total Module Costs	67	(3)
2.3.4 A Computer Program [CAPCOSTXXX] for Capital Cost Estimation Using the Equipment Module Approach	70	(2)
2.4 Summary	72	(1)
References	73	(1)
Problems	73	(4)
Chapter 3 Estimation of Manufacturing Costs	77	(22)
3.1 Factors Affecting the Cost of Manufacturing a Chemical Product	77	(5)
3.2 Cost of Operating Labor	82	(3)
3.3 Utility Costs	85	(6)
3.4 Raw Material Costs	91	(1)
3.5 Yearly Costs and Stream Factors	92	(1)
3.6 Estimating Utility Costs from the PFD	93	(3)
3.7 Cost of Treating Liquid and Solid Waste Streams	96	(1)
3.8 Evaluation of Cost of Manufacture for the Production of Benzene via the Hydrodealkylation of Toluene	96	(1)
3.9 Summary	97	(1)
References	97	(1)
Problems	98	(1)
Chapter 4 Engineering Economic Analysis	99	(37)
4.1 Investments and the Time Value of Money	100	(4)
4.2 Different Types of Interest	104	(2)
4.2.1 Simple Interest	104	(1)
4.2.2 Compound Interest	105	(1)
4.2.3 Interest Rates Changing with Time	106	(1)
4.3 Time Basis for Compound Interest Calculations	106	(2)
4.3.1 Effective Annual Interest Rate	107	(1)
4.3.2 Continuously Compounded Interest	107	(1)
4.4 Cash Flow Diagrams	108	(4)
4.4.1 Discrete Cash Flow Diagram	109	(2)
4.4.2 Cumulative Cash Flow Diagram	111	(1)
4.5 Calculations from Cash Flow Diagrams	112	(6)
4.5.1 Annuities--A Uniform Series of Cash Transactions	114	(1)
4.5.2 Discount Factors	114	(4)
4.6 Inflation	118	(3)
4.7 Depreciation of Capital Investment	121	(5)
4.7.1 Fixed Capital, Working Capital, and Land	121	(1)
4.7.2 Different Types of Depreciation	122	(4)
4.8 Tazation, Cash Flow, and Profit	126	(3)
4.9 Summary	129	(1)
Problems	129	(7)
Chapter 5 Profitability Analysis	136	(41)
5.1 A Typical Cash Flow Diagram for a New Project	136	(2)
5.2 Profitability Criteria for Project Evaluation	138	(9)
5.2.1 Nondiscounted Profitability Criteria	139	(2)
5.2.2 Discounted Profitability Criteria	141	(6)
5.3 Comparing Several Large Projects--Incremental Economic Analysis	147	(3)
5.4 Establishing Acceptable Returns from Investments: The Concept of Risk	150	(1)
5.5 Evaluation of Equipment Alternatives	151	(8)
5.5.1 Equipment with the Same Expected Operating Lives	152	(1)
5.5.2 Equipment with Different Expected Operating Lives	152	(7)
5.6 Incremental Analysis for Retrofitting Facilities	159	(5)
5.6.1 Nondiscounted Methods for Incremental Analysis	159	(3)
5.6.2 Discounted Methods for Incremental Analysis	162	(2)
5.7 Profit Margin Analysis	164	(1)
5.8 Summary	165	(1)
Problems	165	(12)
SECTION 2 TECHNICAL ANALYSIS OF A CHEMICAL PROCESS	177	(82)
Chapter 6 Structure of Chemical Process Flow Diagrams	179	(11)
6.1 The Input-Output Structure of a Flow Diagram	179	(5)
6.2 The Generic Block Flow Process Diagram	184	(2)
6.3 Categorizing Equipment into Generic Function Blocks	186	(2)
6.4 Summary	188	(1)
Problems	188	(2)
Chapter 7 Tracing Chemicals through the Process Flow Diagram	190	(17)
7.1 Guidelines and Tactics for Tracing Chemicals	190	(1)
7.2 Tracing Primary Paths Taken by Chemicals in a Chemical Process	191	(8)
7.3 Recycle and Bypass Streams	199	(4)
7.4 Tracing Non-Reacting Chemicals	203	(1)
7.5 Limitations	204	(1)
7.6 Written Process Description	204	(2)
7.7 Summary	206	(1)
Problems	206	(1)
Chapter 8 Understanding Process Conditions	207	(25)
8.1 Conditions of Special Concern for the Operation of Separation and Reactor Systems	208	(2)
8.1.1 Pressure	208	(1)
8.1.2 Temperature	209	(1)
8.2 Reasons for Operating at Conditions of Special Concern	210	(5)
8.3 Conditions of Special Concern for the Operation of Other Equipment	215	(4)
8.4 Analysis of Important Process Conditions	219	(8)
8.4.1 Evaluation of Reactor R-101	219	(7)
8.4.2 Evaluation of High-Pressure Phase Separator V-101	226	(1)
8.4.3 Evaluation of Large Temperature Driving Force in Exchanger E-101	227	(1)
8.4.4 Evaluation of Exchanger E-102	227	(1)
8.4.5 Pressure Control Value on Stream 8	227	(1)
8.4.6 Pressure Control Value on Stream from V-101 to V-103	227	(1)
8.5 Summary	227	(1)
References	228	(1)
Problems	228	(4)
Chapter 9 Utilizing Experience-Based Principles to Confirm the Suitability of a Process Design	232	(27)
9.1 The Role of Experience in the Design Process	233	(4)
9.1.1 Introduction to Technical Heuristics and Short-Cut Methods	234	(1)
9.1.2 Maximizing the Benefits Obtained from Experience	235	(2)
9.2 Presentation of Tables of Technical Heuristics and Guidelines	237	(21)
9.3 Summary	258	(1)
References	258	(1)
Problems	258	(1)
SECTION 3 ANALYSIS OF SYSTEM PERFORMANCE	259	(204)
Chapter 10 Process Input/Output Models	263	(9)
10.1 Representation of Process Inputs and Outputs	264	(3)
10.2 Analysis of the Effect of Process Inputs on Process Outputs	267	(2)
10.3 A Process Example	269	(2)
10.4 Summary	271	(1)
Problems	271	(1)
Chapter 11 Tools for Evaluating System Performance	272	(16)
11.1 Key Relationships	272	(2)
11.2 Thinking with Equations	274	(2)
11.2.1 GENI	274	(1)
11.2.2 Predicting Trends	274	(2)
11.3 Base Case Ratios	276	(2)
11.4 Analysis of Systems Using Controlling Resistances	278	(2)
11.5 Graphical Representations	280	(6)
11.5.1 The Moody Diagram for Friction Factors	281	(1)
11.5.2 The System Curve for Frictional Losses	281	(2)
11.5.3 The T-Q Diagram for Heat Exchangers	283	(3)
11.6 Summary	286	(1)
References	286	(1)
Problems	286	(2)
Chapter 12 Performance Curves for Individual Unit Operations	288	(45)
12.1 Applications to Heat Transfer	290	(6)
12.2 Applications to Fluid Flow	296	(16)
12.2.1 Pump and System Curves	296	(7)
12.2.2 Regulating Flowrates	303	(2)
12.2.3 Reciprocating or Positive Displacement Pumps	305	(1)
12.2.4 Net Positive Suction Head	306	(4)
12.2.5 Compressors	310	(2)
12.3 Application to Separation Problems	312	(14)
12.3.1 Separations with Mass Separating Agents	312	(5)
12.3.2 Distillation	317	(9)
12.4 Summary	326	(1)
References	326	(1)
Problems	326	(7)
Chapter 13 Performance of Multiple Unit Operations	333	(27)
13.1 Analysis of a Reactor with Heat Transfer	333	(5)
13.2 Performance of a Distillation Column	338	(7)
13.3 Performance of a Heating Loop	345	(7)
13.4 Performance of the Feed Section to a Process	352	(3)
13.5 Summary	355	(1)
References	356	(1)
Problems	356	(4)
Chapter 14 Reactor Performance	360	(36)
14.1 Production of Desired Product	362	(2)
14.2 Reaction Kinetics and Thermodynamics	364	(3)
14.2.1 Reaction Kinetics	364	(2)
14.2.2 Thermodynamic Limitations	366	(1)
14.3 The Chemical Reactor	367	(5)
14.4 Heat Transfer in the Chemical Reactor	372	(4)
14.5 Reactor System Case Studies	376	(16)
14.5.1 Replacement of Catalytic Reactor in Benzene Process	377	(5)
14.5.2 Replacement of Cumene Catalyst	382	(5)
14.5.3 Increasing Acetone Production	387	(5)
14.6 Summary	392	(1)
References	392	(1)
Problems	392	(4)
Chapter 15 Regulating Process Conditions	396	(36)
15.1 A Simple Regulation Problem	397	(2)
15.2 The Characteristics of Regulating Valves	399	(2)
15.3 Regulating Flowrates and Pressures	401	(3)
15.4 The Measurement of Process Variables	404	(1)
15.5 Common Control Strategies Used in Chemical Processes	405	(7)
15.5.1 Feedback Control/Regulation	405	(1)
15.5.2 Feedforward Control/Regulation	406	(4)
15.5.3 Combination Feedback/Feedforward Control	410	(1)
15.5.4 Cascade Regulation	411	(1)
15.6 Exchanging Heat and Work between Process and Utility Streams	412	(8)
15.6.1 Increasing the Pressure of a Process Stream and Regulating Its Flowrate	413	(2)
15.6.2 Exchanging Heat between Process Streams and Utilities	415	(5)
15.6.3 Exchanging Heat Between Process Streams	420	(1)
15.7 Case Studies	420	(6)
15.7.1 The Cumene Reactor R-701	420	(2)
15.7.2 A Basic Control System for a Binary Distillation Column	422	(3)
15.7.3 A More Sophisticated Control System for a Binary Distillation Column	425	(1)
15.8 Summary	426	(1)
References	427	(1)
Problems	427	(5)
Chapter 16 Process Troubleshooting and Debottlenecking	432	(31)
16.1 Recommended Methodology	434	(5)
16.1.1 Elements of Problem-Solving Strategies	434	(3)
16.1.2 Application to Troubleshooting Problems	437	(2)
16.2 Troubleshooting Individual Units	439	(7)
16.2.1 Troubleshooting a Packed Bed Absorber	439	(4)
16.2.2 Troubleshooting the Cumene Process Feed Section	443	(3)
16.3 Troubleshooting Multiple Units	446	(6)
16.3.1 Troubleshooting Off-Specification Acrylic Acid Product	446	(2)
16.3.2 Troubleshooting Steam Release in Cumene Reactor	448	(4)
16.4 A Process Troubleshooting Problem	452	(5)
16.5 Debottlenecking Problems	457	(1)
16.6 Summary	458	(1)
References	458	(1)
Problems	458	(5)
SECTION 4 SYNTHESIS AND OPTIMIZATION OF A PROCESS FLOW DIAGRAM	463	(96)
Chapter 17 Synthesis of the PFD from the Generio BFD	465	(13)
17.1 Information Needs and Sources	466	(2)
17.1.1 Interactions with Other Engineers and Scientists	466	(1)
17.1.2 Reaction Kinetics Data	466	(1)
17.1.3 Physical Property Data	467	(1)
17.2 Reactor Section	468	(2)
17.3 Separator Section	470	(3)
17.4 Reactor Feed Preparation and Separator Feed Preparation Sections	473	(1)
17.5 Recycle Section	474	(1)
17.6 Environmental Control Section	474	(1)
17.7 Major Process Control Loops	475	(1)
17.8 Flow Summary Table	475	(1)
17.9 Major Equipment Summary Table	475	(1)
17.10 Summary	476	(1)
References	476	(1)
Problems	477	(1)
Chapter 18 Synthesis of a Process Using a Simulator and Simulator Troubleshooting	478	(31)
18.1 The Structure of a Process Simulator	479	(4)
18.2 Information Required to Complete a Process Simulation--Input Data	483	(12)
18.2.1 Selection of Chemical Components	483	(1)
18.2.2 Selection of Thermodynamic Model(s)	483	(2)
18.2.3 Input the Topology of the Flowsheet	485	(1)
18.2.4 Select Feed Stream Properties	485	(1)
18.2.5 Select Equipment Parameters	486	(8)
18.2.6 Selection of Output Display Options	494	(1)
18.2.7 Selection of Convergence Criteria and Running Simulation	494	(1)
18.3 Handling Recycle Streams	495	(2)
18.4 Thermodynamic Models	497	(6)
18.4.1 Physical Properties	498	(1)
18.4.2 Enthalpy	498	(1)
18.4.3 Phase Equilibria	499	(2)
18.4.4 Using Thermodynamic Models	501	(2)
18.5 Case Study--Toluene Hydrodealkylation Process	503	(3)
18.6 Summary	506	(1)
References	506	(1)
Problems	507	(2)
Chapter 19 Process Optimization	509	(50)
19.1 Background Information on Optimization	509	(6)
19.1.1 Common Misconceptions	511	(2)
19.1.2 Estimating Problem Difficulty	513	(1)
19.1.3 Top-down/Bottom-up Strategies	514	(1)
19.1.4 Communication of Optimization Results	515	(1)
19.2 Strategies	515	(5)
19.2.1 Base Case	515	(2)
19.2.2 Objective Functions	517	(1)
19.2.3 Analysis of the Base Costs	518	(1)
19.2.4 Identifying and Prioritizing Key Decision Variables	519	(1)
19.3 Topological Optimization	520	(20)
19.3.1 Introduction	520	(1)
19.3.2 Elimination of Unwanted Non-Hazardous By-products or Hazardous Waste Streams	521	(2)
19.3.3 Elimination and Rearrangement of Equipment	523	(3)
19.3.4 Alternative Separation Schemes and Reactor Configurations	526	(2)
19.3.5 Improvements in Heat Integration	528	(12)
19.4 Parametric Optimization	540	(12)
19.4.1 Single Variable Optimization: A Case Study on T-201, the DME Separation Column	541	(3)
19.4.2 Two-Variable Optimization: The Effect of Pressure and Reflux Ratio on T-201, the DME Separation Column	544	(3)
19.4.3 Flowsheet Optimization Using Key Decision Variables	547	(5)
19.5 Lattice Search Techniques vs. Experimental Design	552	(1)
19.6 Process Flexibility and the Sensitivity of the Optimum	553	(1)
19.7 Summary	554	(1)
References	554	(1)
Problems	555	(4)
SECTION 5 THE PROFESSIONAL ENGINEER, THE ENVIRONMENT, AND COMMUNICATIONS	559	(120)
Chapter 20 Ethics and Professionalism	561	(31)
20.1 Ethics	562	(21)
20.1.1 Moral Autonomy	563	(1)
20.1.2 Rehearsal	564	(1)
20.1.3 Reflection in Action	565	(1)
20.1.4 Mobile Truth	566	(2)
20.1.5 Nonprofessional Responsibilities	568	(1)
20.1.6 Duties and Obligations	569	(1)
20.1.7 Codes of Ethics	570	(3)
20.1.8 Whistleblowing	573	(8)
20.1.9 Ethical Dilemmas	581	(1)
20.1.10 Additional Ethics Heuristics	582	(1)
20.2 Professional Registration	583	(3)
20.2.1 Engineer-in-Training	584	(1)
20.2.2 Registered Professional Engineer	585	(1)
20.3 Legal Liability	586	(1)
20.4 Business Codes of Conduct	587	(2)
References	589	(1)
Problems	590	(2)
Chapter 21 Health, Safety, and the Environment	592	(30)
21.1 Risk Assessment	593	(3)
21.1.1 Accident Statistics	593	(1)
21.1.2 Worst Case Scenarios	594	(1)
21.1.3 The Role of the Chemical Engineer	595	(1)
21.2 Regulations and Agencies	596	(15)
21.2.1 OSHA and NIOSH	596	(10)
21.2.2 Environmental Protection Agency (EPA)	606	(4)
21.2.3 Nongovernmental Organizations	610	(1)
21.3 Fires and Explosions	611	(2)
21.3.1 Terminology	611	(2)
21.3.2 Pressure Relief Systems	613	(1)
21.4 HAZOP	613	(2)
21.5 Inherently Safe Design	615	(1)
21.6 Pollution Prevention	616	(1)
21.7 Life-Cycle Analysis	617	(1)
21.8 Summary	618	(1)
21.9 Glossary	618	(2)
References	620	(1)
Problems	621	(1)
Chapter 22 Written and Oral Communications	622	(28)
22.1 Audience Analysis	623	(1)
22.2 Written Communication	624	(12)
22.2.1 Design Reports	625	(1)
22.2.2 Transmittal Letters or Memos	626	(1)
22.2.3 Executive Summaries and Abstracts	626	(1)
22.2.4 Other Types of Written Communication	627	(1)
22.2.5 Exhibits (Figures and Tables)	628	(1)
22.2.6 References	629	(1)
22.2.7 Strategies for Writing	629	(2)
22.2.8 WVU Guidelines for Written Design Report	631	(5)
22.3 Oral Communications	636	(7)
22.3.1 Formal Oral Presentations	638	(1)
22.3.2 Briefings	638	(1)
22.3.3 Visual Aids	639	(1)
22.3.4 WVU Oral Presentation Guidelines	640	(3)
22.4 Software and Author Responsibility	643	(5)
22.4.1 Spell Checkers	644	(1)
22.4.2 Thesaurus	644	(1)
22.4.3 Grammar Checkers	644	(1)
22.4.4 Graphs	645	(1)
22.4.5 Tables	646	(1)
22.4.6 Colors and Exotic Features	646	(1)
22.4.7 Raw Output from Process Simulators	647	(1)
22.5 Summary	648	(1)
References	648	(1)
Problems	648	(2)
Chapter 23 A Report Writing Case Study	650	(29)
23.1 Assignment Memorandum	650	(2)
23.2 Response Memorandum	652	(2)
23.3 Visual Aids	654	(6)
23.4 Example Reports	660	(16)
23.4.1 An Example of a Portion of a Student Report	661	(3)
23.4.2 An Example of an Improved Student Written Report	664	(12)
23.5 Checklist of Common Mistakes and Errors	676	(3)
23.5.1 Common Mistakes for Visual Aids	676	(1)
23.5.2 Common Mistakes for Written Text	677	(2)
APPENDICES	679	(130)
Appendix A Cost Equations and Curves for the CAPCOST(XXX) Program	679	(29)
A.1 Heat Exchangers	680	(2)
A.2 Process Vessels and Internals	682	(3)
A.2.1 Horizontal and Vertical Process Vessels	682	(2)
A.2.2 Process Vessel Internals	684	(1)
A.3 Pumps with Electric Drives	685	(1)
A.4 Fans with Electric Drives	686	(1)
A.5 Compressors and Blowers without Drives	687	(1)
A.6 Drives for Compressors and Blowers	688	(1)
A.7 Power Recovery Equipment	688	(1)
A.8 Fired Heaters and Furnaces	688	(3)
A.9 Vaporizers and Evaporators	691	(17)
Appendix B Information for the Preliminary Design of Four Chemical Processes	708	(39)
B.1 Production of Dimethyl Ether (DME) via the Dehydration of Methanol	709	(7)
B.2 Acrylic Acid Production via the Catalytic Partial Oxidation of Propylene	716	(12)
B.3 Production of Acetone via the Dehydrogenation of Isopropyl Alcohol (IPA)	728	(8)
B.4 Production of Heptenes from Propylene and Butenes	736	(11)
Appendix C Design Projects	747	(62)
Project 1: Increasing the Production of 3-Chloro-1-Propene (Allyl Chloride) in Unit 600	749	(15)
Project 2: Design and Optimization of a New 20,000 Metric Tons per Year Facility to Produce Allyl Chloride at La Nueva Cantina, Mexico	764	(8)
Project 3: Scale-Down of Phthalic Anhydride Production at TBWS Unit 700	772	(12)
Project 4: The Design of a New, 100,000 Metric Tons per Year, Phthalic Anhydride Production Facility	784	(5)
Project 5: Problems at the Cumene Production Facility, Unit 800	789	(15)
Project 6: Design of a New, 100,000 Metric Tons per Year Cumene Production Facility	804	(5)
Index	809