Analysis, Synthesis, and Design of Chemical Processes

An integrative approach to continuous improvement in chemical engineering.Process design skills are the focal point of sound chemical engineering. In this second edition of "Analysis, Synthesis, and Design of Chemical Processes," the authors present design as a creative process that integrates the big picture and the small details-and relies on knowing which to stress, and why. These techniques are applied to every aspect of the discipline, from the conceptual design of a plant to improving an existing process, and more."Analysis, Synthesis, and Design of Chemical Processes" moves chemical engineering students beyond neatly delineated classroom exercises and into the world of solving the open-ended process problems they will see in practice. The authors accomplish this by emphasizing design synthesis of the entire process--from equipment sizing to optimization, from finances to operation. Coverage includes: Evolution and generation of different process configurationsEstimating capital,investment, manufacturing costs, and other economic factorsSynthesis and optimization of chemical processesPerformance analysis of existing processes and equipment Environmental concerns, green engineering, engineering ethics, and health and safetyWritten and oral communications and teamwork"Analysis, Synthesis, and Design of Chemical Processes" represents over 30 years of chemical engineering teaching at West Virginia University. Included are suggested curricula for both single-semester and year-long design courses, case studies and design projects with practical applications, and appendices with current equipment cost data andpreliminary design information for four chemical processes.About the CD-ROMThe CD-ROM contains a heavily revised version of CAPCOST, now in the form of a spreadsheet template, which is used for evaluating fixed capital investme

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 last thirty years and is still evolving, it is fair to say that the current program has gelled over the last fifteen 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 grass-roots 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 they apply. In the second edition, we have rearranged material from the first edition and have added several new chapters. The new material includes the following: Chapter 0, titled Outcomes assessment, addresses the subject from both student and faculty perspectives, including the relationship to the ABET EC 2000 criteria for accreditation of engineering programs in the United States. The material in Chapter 1 on process diagrams has been expanded to include some preliminary plant layout information. The topology of the chemical plant is introduced with the help of three-dimensional graphics tools. A digital "movie" is included on the CD accompanying the book, which gives a "virtual plant tour" of a simple chemical process. Material on the structure, synthesis, and conceptual design of chemical processes is added to the new Chapter 2. The hierarchical approach to conceptual design is presented with several examples. The chapter on capital cost estimation (new Chapter 5) has been revised, and new capital cost estimates for process equipment are presented (in Appendix A) which are based on an extensive survey of equipment manufacturers carried out during 2001. The CAPCOST program for estimating the fixed capital cost of building a new chemical plant has been revised extensively. The program is now written in the form of a Microsoft? Excel? template. The new capital costs from Chapter 5 and Appendix A are included. In addition, a full financial analysis, including operating costs, raw material costs, cash flow diagrams, and a Monte Carlo simulation feature, is included. Detailed calculations on how to estimate utility costs are included in the new Chapter 6 (old Chapter 3). Raw material costs and fuel cost