Plant Design and Economics for Chemical Engineers

by Peters, Max; Timmerhaus, Klaus; West, Ronald

• ISBN13: 9780072392661
• ISBN10: 0072392665
• Edition: 5th
• Format: Hardcover
• Copyright: 2002-12-09
• Publisher: McGraw-Hill Education

Summary

The fifth edition of Plant Design and Economics for Chemical Engineers is a major revision of the popular fourth edition. There are new chapters on process synthesis, computer-aided design, and design of chemical reactors. A traditionally strong feature of the text, economic analysis, has been revamped and updated. Another strength, equipment sizing and cost estimation, is updated and expanded as well. These improvements also reflect changes in equipment availability. The numerous real examples throughout the book include computer or hand solutions, and often both. There is a new increased emphasis on computer use in design, economic evaluation, and optimization. Concepts, strategies, and approaches to computer use are featured. These concepts are not tied to particular software programs and therefore apply to wide a range of applications software, of both current and future release. This widely used text is now more useful than ever, providing a '¬Sone-stop'¬ basic guide to chemical process design and evaluation.

Table of Contents

Preface	xv
Prologue	xix
Introduction	1	(14)
Chemical Engineering Plant Design	1	(1)
General Overall Design Considerations	2	(9)
Process Design Development	2	(3)
Flowsheet Development	5	(1)
Computer-Aided Design	6	(1)
Cost Estimation	6	(1)
Profitability Analysis of Investments	7	(1)
Optimum Design	8	(3)
Practical Considerations in Design	11	(2)
The Design Approach	12	(1)
Engineering Ethics in Design	13	(2)
General Design Considerations	15	(52)
Health and Safety Hazards	15	(14)
Sources of Exposure	16	(2)
Exposure Evaluation	18	(2)
Control of Exposure Hazards	20	(2)
Fire and Explosion Hazards	22	(5)
Personnel Safety	27	(1)
Safety Regulations	27	(2)
Loss Prevention	29	(11)
HAZOP Study	29	(6)
Fault-tree Analysis	35	(1)
Failure Mode and Effect Analysis	36	(1)
Safety Indexes	36	(1)
Safety Audits	36	(4)
Environmental Protection	40	(12)
Environmental Regulations	41	(1)
Development of a Pollution Control System	42	(1)
Air Pollution Abatement	42	(5)
Water Pollution Abatement	47	(3)
Solid Waste Disposal	50	(1)
Thermal Pollution Control	51	(1)
Noise Control	52	(1)
Plant Location	52	(4)
Factors Involved	53	(3)
Selection of the Plant Site	56	(1)
Plant Layout	56	(1)
Preparation of the Layout	57	(1)
Plant Operation and Control	57	(5)
Instrumentation	57	(1)
Maintenance	58	(1)
Utilities	59	(1)
Structural Design	60	(1)
Storage	60	(1)
Materials Handling	61	(1)
Patent Considerations	62	(1)
Problems	62	(5)
Process Design Development	67	(58)
Development of Design Database	67	(2)
Literature Survey	68	(1)
Patent Search	69	(1)
Process Creation	69	(3)
Batch Versus Continuous Operation	70	(1)
Raw Materials and Product Specifications	70	(1)
Process Synthesis Steps	71	(1)
Process Design	72	(5)
Types of Process Designs	74	(3)
Process Flow Diagrams	77	(2)
Piping and Instrumentation Diagrams	79	(1)
Vessel and Piping Layout Isometrics	80	(1)
Equipment Design and Specifications	81	(6)
Scale-up of Equipment in Design	81	(1)
Safety Factors	81	(3)
Equipment Specifications	84	(2)
Materials of Construction	86	(1)
The Preliminary Design---A Specific Example	87	(33)
Problem Statement	87	(1)
Literature Survey	87	(1)
Process Creation	88	(2)
Development of Conventional Base-Case Design	90	(20)
Economic Assessment of Base-Case Design	110	(3)
Assessment of Proposed Base-Case Design Modification	113	(7)
Summary	120	(1)
Problems	121	(4)
Flowsheet Synthesis and Development	125	(71)
Flowsheet Synthesis and Development	126	(4)
General Procedure	126	(4)
Process Information	130	(5)
Background Information	130	(1)
Molecular Path Synthesis	131	(1)
Selecting a Process Pathway	132	(1)
Production Mode	132	(1)
Recording Decisions	133	(2)
Input/Output Structure	135	(2)
Functions Diagram	137	(6)
Preprocessing	138	(1)
Reactions	139	(1)
Recycle	139	(1)
By-products, Intermediates, and Wastes	139	(1)
Separations	140	(3)
Operations Diagram	143	(6)
Preprocessing	143	(1)
Reactors	143	(1)
Separations Methods	144	(1)
Heating and Cooling	145	(1)
Minimization of Processing	145	(4)
Process Flowsheet	149	(9)
Reactors	149	(1)
Mass and Energy Balances	149	(1)
Separation Trains	149	(1)
Heat Exchange	150	(8)
Algorithmic Flowsheet Generation	158	(31)
Fundamentals of Algorithmic Process-Network Synthesis	159	(6)
Application of Algorithmic Process-Network Synthesis	165	(24)
Comparison of Hierarchical and Algorithmic Results	189	(1)
Genetic Algorithms	189	(1)
Future Approaches to Flowsheet Synthesis and Development	190	(1)
Software Use in Flowsheet Synthesis	190	(1)
Analysis and Evaluation of Flowsheets	190	(2)
Criteria for Evaluating Designs	190	(2)
Summary	192	(1)
Nomenclature	192	(1)
Greek Symbol	193	(1)
Problems	193	(3)
Software Use in Process Design	196	(30)
Software Structure	198	(6)
Chemical Property Estimation	198	(3)
Process Equipment Models	201	(1)
Process Equipment Cost Estimation	202	(1)
Process Economic Evaluation	203	(1)
Heat Integration	203	(1)
Process Control	203	(1)
Process Optimization	204	(1)
Software Capabilities	204	(4)
General-Type Software	205	(3)
Software for Process Design	208	(8)
Molecular Reaction Databases and Simulators	208	(1)
Chemical Cost Databases	209	(1)
Flowsheeting Software	209	(2)
Unit Operations Simulators	211	(3)
Piping System Design	214	(1)
Plant Layout	214	(1)
Economic Evaluation	215	(1)
Software Selection	216	(1)
Software Use	216	(4)
Physical Property Estimation Guidelines	217	(1)
Process Simulation Guidelines	217	(3)
Avoiding Pitfalls in Software Use	220	(4)
Graphic Interface and Ease of Use	221	(1)
Thermodynamic Property Packages	222	(1)
Simulation Realism	222	(2)
Evaluation of Software Results	224	(2)
Analysis of Cost Estimation	226	(53)
Cash Flow for Industrial Operations	226	(4)
Cash Flow	226	(2)
Cumulative Cash Position	228	(2)
Factors Affecting Investment and Production Costs	230	(2)
Sources of Equipment	230	(1)
Price Fluctuations	230	(1)
Company Policies	230	(1)
Operating Time and Rate of Production	231	(1)
Government Policies	232	(1)
Capital Investment	232	(1)
Fixed-Capital Investment	233	(1)
Working Capital	233	(1)
Estimation of Capital Investment	233	(3)
Types of Capital Cost Estimates	235	(1)
Cost Indexes	236	(3)
Cost Components in Capital Investment	239	(10)
Purchased Equipment	241	(1)
Estimating Equipment Costs by Scaling	242	(2)
Purchased-Equipment Delivery	244	(1)
Purchased-Equipment Installation	244	(1)
Instrumentation and Controls	245	(1)
Piping	245	(1)
Electrical Systems	246	(1)
Buildings	246	(1)
Yard Improvements	246	(1)
Service Facilities	246	(1)
Health, Safety, and Environmental Functions	247	(1)
Land	248	(1)
Engineering and Supervision	248	(1)
Legal Expenses	248	(1)
Construction Expenses	248	(1)
Contractor's Fee	249	(1)
Contingencies	249	(1)
Methods for Estimating Capital Investment	249	(9)
Estimation of Revenue	258	(1)
Estimation of Total Product Cost	259	(12)
Manufacturing Costs	262	(1)
Variable Production Costs	262	(8)
Plant Overhead Costs	270	(1)
General Expenses	270	(1)
Gross Profit, Net Profit, and Cash Flow	271	(1)
Contingencies	272	(1)
Summary	272	(2)
Nomenclature	274	(1)
Greek Symbol	275	(1)
Problems	275	(4)
Interest, Time Value of Money, Taxes, and Fixed Charges	279	(40)
Interest	279	(6)
Simple Interest	280	(1)
Compound Interest	280	(1)
Nominal and Effective Interest Rates	281	(2)
Continuous Interest	283	(2)
Cost of Capital	285	(5)
Income Tax Effects	286	(1)
Loan Payments	287	(3)
Time Value of Money	290	(2)
Cash Flow Patterns	292	(5)
Discrete Cash Flows	292	(2)
Continuous Cash Flows	294	(3)
Compounding and Discounting Factors	297	(6)
Income Taxes	303	(4)
Federal Income Taxes	304	(1)
Taxable Income	304	(1)
Capital Gains Tax	305	(1)
Losses	306	(1)
Other Federal Taxes	306	(1)
State Taxes	306	(1)
Nonincome Taxes	306	(1)
Fixed Charges	307	(8)
Depreciation	307	(1)
Depreciation and Income Tax	308	(1)
Depreciable Investments	309	(1)
Current Value	309	(1)
Salvage Value	309	(1)
Recovery Period	309	(1)
Methods for Calculating Depreciation	310	(3)
Insurance	313	(1)
Self-insurance	314	(1)
Nomenclature	315	(1)
Greek Symbol	316	(1)
Problems	316	(3)
Profitability, Alternative Investments, and Replacements	319	(39)
Profitability Standards	320	(2)
Cost of Capital	320	(1)
Minimum Acceptable Rate of Return	321	(1)
Methods for Calculating Profitability	322	(18)
Methods That Do Not Consider the Time Value of Money	322	(5)
Methods That Consider the Time Value of Money	327	(3)
Selecting a Profitability Method	330	(5)
Effect of Inflation on Profitability Analysis	335	(5)
Start-up Costs	340	(1)
Spreadsheet for Economic Evaluation Calculations	340	(1)
Alternative Investments	340	(8)
Alternatives When an Investment Must Be Made	342	(4)
Analysis with Small Investment Increments	346	(2)
Replacements	348	(4)
Methods of Profitability Evaluation for Replacements	349	(1)
Typical Example of Replacement Policy	349	(1)
Book Values and Unamortized Values	350	(1)
Investment on Which the Replacement Comparison Is Based	350	(2)
Practical Factors in Alternative-Investment and Replacement Analysis	352	(1)
Nomenclature	352	(1)
Greek Symbol	353	(1)
Problems	353	(5)
Optimum Design and Design Strategy	358	(82)
Defining the Optimization Problem	359	(2)
Selecting an Objective Function	361	(2)
Structural Optimization	361	(1)
Parametric Optimization	362	(1)
Variable Screening and Selection	363	(1)
Suboptimization	363	(1)
Practical and Intangible Considerations	364	(1)
Programming Optimization Problems	364	(15)
Linear Programming	367	(3)
Generalization of Strategy for Linear Programming	370	(2)
Simultaneous Equations	372	(1)
Nonlinear Programming	373	(4)
Dynamic Programming	377	(2)
Optimization Solution Methodologies	379	(11)
Procedure with One Variable	380	(1)
Procedure with Two or More Variables	381	(3)
Breakeven Chart for Optimum Analysis of Production	384	(1)
Experimental Design and Analysis of Process Simulations	384	(2)
Algorithm Solutions to Optimization Problems	386	(4)
Optimization Applications	390	(43)
Optimization Application: Optimum Production Rates in Plant Operation	390	(4)
Optimization Application: Cyclic Operations	394	(7)
Optimization Application: Economic Pipe Diameter	401	(5)
Optimization Application: Cooling Water Flow Rate	406	(3)
Optimization Application: Distillation Reflux Ratio	409	(5)
Optimization Application: Pinch Technology Analysis	414	(19)
Nomenclature	433	(2)
Greek Symbols	435	(1)
Problems	435	(5)
Materials and Fabrication Selection	440	(29)
Factors Contributing to Corrosion	440	(3)
Combating Corrosion	443	(1)
Properties of Materials	444	(13)
Ferrous Metals and Alloys	444	(6)
Nonferrous Metals and Alloys	450	(1)
Inorganic Nonmetals	451	(1)
Organic Nonmetals	452	(3)
Low- and High-Temperature Materials	455	(2)
Gasket Materials	457	(1)
Tabulated Data for Selecting Materials of Construction	457	(1)
Selection of Materials	457	(8)
Economics Involved in Selection	464	(1)
Fabrication of Equipment	465	(2)
Methods of Fabrication	466	(1)
Problems	467	(2)
Written and Oral Design Reports	469	(16)
Written Reports	470	(11)
Organization of a Written Report	470	(3)
Preparing the Report	473	(1)
Presenting the Results	474	(6)
Comments on Common Errors	480	(1)
Checklist for the Final Report	481	(1)
Oral Reports	481	(3)
Organization and Presentation of an Oral Design Report	482	(2)
Problems	484	(1)
Materials-Handling Equipment---Design and Costs	485	(107)
Basic Concepts of Fluid Transport	485	(12)
Newtonian Fluids	486	(2)
Non-Newtonian and Bingham Fluids	488	(1)
Vacuum Flow	489	(2)
Frictional Losses Encountered in Pipelines	491	(1)
Power Requirements for Transport of Liquids and Gases	492	(5)
Piping in Fluid Transport Processes	497	(11)
Selection of Piping Materials	497	(2)
Design of Piping Systems	499	(3)
Costs for Piping and Piping System Auxiliaries	502	(6)
Pumping of Fluids	508	(12)
Selection of Pumps	508	(7)
Design Procedures for Pumps	515	(1)
Costs for Pumps and Motors	516	(4)
Compression and Expansion of Fluids	520	(16)
Selection of Compressors	520	(3)
Selection of Fans and Blowers	523	(1)
Selection of Vacuum System Equipment	524	(1)
Selection of Turbines, Expanders, and Other Drivers	525	(2)
Design Procedures for Compressors	527	(2)
Design Procedures for Turbines and Expanders	529	(2)
Costs for Compressors, Fans, Blowers, and Expanders	531	(5)
Agitation and Mixing of Fluids	536	(13)
Selection of Agitators and Mixers	536	(3)
Design Procedures for Agitators and Mixers	539	(5)
Costs for Agitators and Mixers	544	(5)
Flow Measurement of Fluids	549	(3)
Storage and Containment of Fluids	552	(8)
Design Procedures for Pressure Vessels	553	(1)
Costs for Tanks, Pressure Vessels, and Storage Equipment	553	(7)
Transport of Solids	560	(12)
Selection of Solids Transport Equipment	561	(4)
General Design Procedures for Solids Transport Equipment	565	(7)
Costs for Solids Transport Equipment	572	(1)
Handling of Solids	572	(15)
Selection of Solids-Handling Equipment	577	(3)
General Design Procedures for Solids-Handling Equipment	580	(2)
Costs for Solids-Handling Equipment	582	(5)
Nomenclature	587	(2)
Greek Symbols	589	(1)
Problems	589	(3)
Reactor Equipment---Design and Costs	592	(50)
Reactor Principles	594	(11)
Reactor Types	596	(1)
Space Velocity and Space Time	597	(1)
Batch Reactors	597	(1)
Tubular Plug-Flow Reactors	598	(1)
Back-Mix Reactors	599	(1)
Nonideality of Reactors	599	(1)
Accounting for Reactor Nonideality	600	(1)
Residence Time Distribution	600	(1)
Nonideal Reactor Emulation Using Ideal Reactor Combinations	601	(1)
Recycle Reactors	602	(3)
Development of Chemical Reaction Rate Expressions	605	(8)
Types of Reactions	606	(7)
Reaction and Reactor Performance	613	(3)
Parallel Reactions	613	(1)
Series Reactions	614	(1)
Systems of Identical Multiple Reactors	614	(2)
Reactor and Catalyst Equipment	616	(18)
Selection of Catalyst	616	(1)
Types of Reactors	617	(4)
Selection of Reactors	621	(1)
Design of Reactor Systems	622	(4)
Reactor Design Procedure	626	(1)
Software	626	(1)
Costs for Reactor Equipment	627	(7)
Summary	634	(1)
Nomenclature	635	(2)
Greek Symbols	636	(1)
Problems	637	(5)
Heat-Transfer Equipment---Design and Costs	642	(112)
Basic Theory of Heat Transfer in Exchangers	643	(13)
Steady-State Heat-Transfer Considerations	644	(8)
Alternative Approaches to Heat Exchanger Performance	652	(4)
Determination of Heat-Transfer Coefficients	656	(8)
Film Coefficients for Fluids Flowing Inside of Pipes and Tubes (No Phase Change)	657	(2)
Film Coefficients for Fluids Flowing Outside of Pipes and Tubes (No Phase Change)	659	(2)
Film Coefficients and Overall Coefficients for Various Heat-Transfer Situations	661	(3)
Determination of Pressure Drop in Heat Exchangers	664	(5)
Tube-Side Pressure Drop	664	(1)
Shell-Side Pressure Drop	665	(4)
Selection of Heat Exchanger Type	669	(25)
Key Heat Exchanger Types Available	670	(6)
Preliminary Selection of Heat Exchanger Types	676	(1)
Costs of Heat Exchangers	676	(18)
Design of Key Heat Exchanger Types	694	(44)
Double-Pipe and Multiple Double-Pipe Exchangers	696	(6)
Shell-and-Tube Exchangers	702	(22)
Plate Exchangers	724	(5)
Compact Exchangers	729	(4)
Air-Cooled Exchangers	733	(1)
Condensers	734	(3)
Evaporators	737	(1)
Optimum Design of Heat Exchangers	738	(6)
General Case	739	(5)
General Methods for Design of Heat Exchangers	744	(1)
Nomenclature	745	(4)
Greek Symbols	748	(1)
Problems	749	(5)
Separation Equipment---Design and Costs	754	(123)
Selection of Suitable Separation Processes	755	(14)
Guidelines for the Separation Process Selection	757	(12)
Equipment Design and Costs for Separating Homogeneous Mixtures	769	(1)
Separation by Distillation	769	(28)
Distillation Design Procedures for Columns with Sieve Trays	769	(14)
Distillation Design Procedures for Columns with Random Packing	783	(4)
Distillation Design Procedures for Columns with Structured Packing	787	(1)
Rating of Distillation Equipment	788	(1)
Rigorous Design Methods for Multicomponent Distillation	788	(1)
Design Procedures for Other Distillation Processes	789	(3)
Equipment Costs for Tray and Packed Columns	792	(5)
Separation by Absorption and Stripping	797	(7)
Design Procedures for Trayed Columns Separating Dilute Solutes	799	(3)
Design Procedures for Packed Columns Separating Dilute Solutes	802	(1)
Design Procedures for Packed Columns Separating Concentrated Solutes	803	(1)
Separation by Extraction	804	(10)
Equipment Selection for Liquid/Liquid Extraction	804	(2)
Design Procedures for Liquid/Liquid Extraction	806	(8)
Equipment Costs for Liquid/Liquid Extraction Equipment	814	(1)
Separation Using Membranes	814	(10)
Selection of Membrane Types	814	(1)
General Design Concepts for Membrane Separation	815	(5)
General Design Procedures for Membrane Separation	820	(4)
Range of Costs for Several Membrane Systems	824	(1)
Separation by Adsorption	824	(13)
Selection of Sorbent for Separation by Adsorption	825	(2)
Basic Adsorption Cycles	827	(2)
Selection of Appropriate Adsorption Cycle	829	(1)
General Design Concepts for Separation by Adsorption	830	(7)
Costs for Adsorption Equipment	837	(1)
Equipment Design and Costs for Separating Heterogeneous Mixtures	837	(2)
Separation by Drying	839	(12)
Equipment Selection for Drying Solids	839	(3)
General Design Procedures for Drying	842	(3)
Costs for Typical Dryers	845	(6)
Separation by Filtration	851	(18)
Selection of Filtration Equipment	851	(3)
General Design Procedures for Separation by Filtration	854	(9)
Costs for Filtration and Other Solids Separation Equipment	863	(6)
Nomenclature	869	(4)
Greek Symbols	872	(1)
Problems	873	(4)
Appendix A: The International System (SI) of Units	877	(13)
Appendix B: Auxiliary, Utility, and Instrumentation Cost Data	890	(9)
Appendix C: Design Problems	899	(48)
Appendix D: Tables of Physical Properties and Constants	947	(19)
Appendix E: Heuristics for Process Equipment Design	966	(8)
Appendix F: Software Useful for Design	974	(2)
Author Index	976	(3)
Subject Index	979