Process Design Principles: Synthesis, Analysis, and Evaluation

by Warren D. Seider; J. D. Seader; Daniel R. Lewin

• ISBN13: 9780471243120
• ISBN10: 0471243124
• Edition: 1st
• Format: Hardcover
• Copyright: 1998-08-01
• Publisher: WILEY

Summary

One of the most important objective in this text describes the strategies and approaches for the design of chemical processes. It covers economic (optimization) and environmental issues. The latest design strategies are described, most of which have been improved significantly with the advent of computers, mathematical programming methods, and artificial intelligence. Various methods are utilized to perform the extensive calculations and provide graphical results that are visualized easily, including the usage of computer programs for simulation and design optimization.

Table of Contents

Part One PROCESS INVENTION---HEURISTICS AND ANALYSIS
The Design Process	3	(29)
Objectives	3	(1)
Primitive Design problems	3	(3)
Typical Primitive Design problem	5	(1)
Process Design Team	5	(1)
Industrial Consultants	5	(1)
Steps in Designing and Retrofitting Chemical Processes	6	(7)
Assess Primitive Problem	6	(2)
Survey Literature	8	(2)
Process Creation	10	(1)
Development of Base Case	10	(1)
Detailed Process Synthesis Using Algorithmic Methods	11	(1)
Plantwide Controllability Assessment	11	(1)
Detailed Design, Equipment Sizing and Cost Estimation, Profitability Analysis, and Optimization	12	(1)
Written process Design Report and Oral Presentation	12	(1)
Final Design, Construction, Start-up, and Operation	12	(1)
Summary	13	(1)
Environmental Protection	13	(6)
Environmental Issues	13	(2)
Environmental Factors in Process Design	15	(3)
Environmental Design Problems	18	(1)
Safety Considerations	19	(4)
Safety Issues	19	(3)
Design Approaches Toward Safe Chemical Plants	22	(1)
Engineering Ethics	23	(4)
Role of Computers	27	(3)
Spreadsheets	28	(1)
Mathematical Packages	28	(1)
Process Simulators	28	(2)
Computational Guidelines	30	(1)
Summary	30	(2)
References	31	(1)
Process Creation	32	(32)
Objectives	32	(1)
Introduction	32	(1)
Preliminary Database Creation	32	(6)
Thermophysical Property Data	33	(4)
Environmental and Safety Data	37	(1)
Chemical Prices	37	(1)
Summary	38	(1)
Experiments	38	(1)
Preliminary Process Synthesis	38	(19)
Continuous or Batch Processing	39	(2)
Chemical State	41	(1)
Process Operations	42	(2)
Synthesis Steps	44	(1)
Example of Process Synthesis: Manufacture of Vinyl Chloride	45	(11)
Synthesis Tree	56	(1)
Heuristics	56	(1)
Algorithmic Methods	57	(1)
Development of the Base-Case Design	57	(5)
Detailed process Flowsheet	57	(3)
Process Integration	60	(1)
Detailed Database	60	(1)
Pilot-Plant Testing	61	(1)
Process Simulation	62	(1)
Summary	62	(2)
References	62	(1)
Exercises	63	(1)
Simulation to Assist in Process Creation	64	(48)
Objectives	64	(1)
Introduction	65	(1)
Principles of Flowsheet Simulation	66	(32)
Process and Simulation Flowsheets	66	(11)
Unit Subroutines	77	(2)
Calculation Order	79	(1)
Recycle	79	(8)
Recycle Convergence Methods	87	(2)
Flash with Recycle Problem	89	(1)
Degrees of Freedom	90	(1)
Control Blocks---Design Specifications	91	(3)
Flash Vessel Control	94	(1)
Bidirectional Information Flow (HYSYS)	94	(4)
Synthesis of the Toluene Hydrodealkylation Process	98	(6)
Process Simulation	101	(3)
Simulation of the Monochlorobenzene Separation Process	104	(2)
Use of Process Simulators	105	(1)
Summary	106	(6)
References	107	(1)
Exercises	107	(5)
Heuristics for Process Synthesis	112	(29)
Objectives	112	(1)
Introduction	113	(1)
Raw Materials and Chemical Reactions	114	(2)
Distribution of Chemicals	116	(10)
Inert Species	117	(2)
Purge Streams	119	(3)
Recycle to Extinction	122	(1)
Selectivity	123	(2)
Reactive Separations	125	(1)
Separations	126	(2)
Heat Removal from and Addition to Reactors	128	(4)
Heat Removal from Exothermic Reactors	128	(3)
Heat Addition to Endothermic Reactors	131	(1)
Pumping and Compression	132	(2)
Summary	134	(7)
References	134	(1)
Exercises	135	(6)
Part Two DETAILED PROCESS SYNTHESIS---ALGORITHMIC METHODS
Synthesis of Separation Trains	141	(66)
Objectives	141	(1)
Introduction	141	(4)
Criteria for Selection of Separation Methods	145	(3)
Selection of Equipment	148	(2)
Sequencing of Ordinary Distillation Columns	150	(6)
Sequencing of General Vapor-Liquid Separation Processes	156	(14)
Sequencing of Azeotropic Distillation Columns	170	(24)
Azeotropy and Polyazeotropy	170	(5)
Residue Curves	175	(3)
Distillation Towers	178	(10)
Separation Train Synthesis	188	(6)
Separation Systems for Gas Mixtures	194	(5)
Membrane Separation by Gas Permeation	197	(1)
Adsorption	197	(1)
Absorption	198	(1)
Partial Condensation and Cryogenic Distillation	199	(1)
Separation Sequencing for Solid-Fluid Systems	199	(2)
Summary	201	(6)
References	201	(1)
Exercises	202	(5)
Second Law Analysis	207	(36)
Objectives	207	(1)
Introduction	207	(3)
The System and the Surroundings	210	(2)
Energy Transfer	212	(1)
Thermodynamic Properties	213	(2)
Equations for Second Law Analysis	215	(4)
Examples of Lost-Work Calculations	219	(3)
Thermodynamic Efficiency	222	(1)
Causes of Lost Work	223	(1)
Three Examples of Second Law Analysis	224	(13)
Summary	237	(6)
References	237	(1)
Exercises	238	(5)
Heat and Power Integration	243	(60)
Objectives	243	(1)
Introduction	244	(3)
Heat Integration Software	247	(1)
Minimizing Utilities in Heat Integration	247	(9)
Temperature-Interval Method	248	(3)
Using Graphical Displays	251	(3)
Linear Programming Method	254	(2)
Stream Matching at Minimum Utilities	256	(11)
Stream Matching at the Pinch	256	(7)
Stream Matching Using a Mixed-Integer Linear Program	263	(4)
Minimum Number of Heat Exchangers---Breaking Heat Loops	267	(4)
Optimum Approach Temperature	271	(3)
Superstructures for Minimization of Annualized Cost	274	(5)
Heat-Integrated Distillation Trains	279	(7)
Effect of Pressure on Heat Integration	279	(2)
Multiple-Effect Distillation	281	(3)
Heat Pumping, Vapor Recompression, and Reboiler Flashing	284	(1)
Superstructures for Minimization of Annualized Cost	284	(2)
Heat Engines and Heat Pumps	286	(9)
Positioning Heat Engines and Heat Pumps	289	(3)
Optimal Design	292	(3)
Summary	295	(8)
References	295	(1)
Exercises	296	(7)
Part Three DETAILED DESIGN, EQUIPMENT SIZING, ECONOMICS, AND OPTIMIZATION
Heat Exchanger Design	303	(35)
Objectives	303	(1)
Introduction	303	(9)
Heat Duty	303	(2)
Heat Transfer Media	305	(3)
Temperature-Driving Force for Heat Transfer	308	(4)
Pressure Drop	312	(1)
Equipment for Heat Exchange	312	(14)
Double-Pipe Heat Exchangers	312	(2)
Shell-and-Tube Heat Exchangers	314	(5)
Air-Cooled Heat Exchangers	319	(1)
Compact Heat Exchangers	320	(1)
Temperature-Driving Forces in Shell-and-Tube Heat Exchangers	321	(5)
Heat Transfer Coefficients and Pressure Drop	326	(7)
Estimation of Overall Heat Transfer Coefficients	327	(1)
Estimation of Individual Heat Transfer Coefficients and Frictional Pressure Drop	327	(2)
Turbulent Flow in Straight, Smooth Ducts, Pipes, and Tubes of Circular Cross Section	329	(2)
Turbulent Flow in the Annular Region Between Straight, Smooth, Concentric Pipes of Circular Cross Section	331	(1)
Turbulent Flow on the Shell Side of Shell-and-Tube Heat Exchangers	331	(1)
Heat Transfer Coefficients for Laminar-Flow, Condensation, Boiling, and Compact Heat Exchangers	332	(1)
Design of Shell-and-Tube Heat Exchangers	333	(2)
Summary	335	(3)
References	335	(1)
Exercises	336	(2)
Capital Cost Estimation	338	(36)
Objectives	338	(1)
Introduction	338	(1)
Cost Charts	339	(9)
Cost Indices	342	(1)
Installation Costs	342	(2)
Materials and Pressure Considerations	344	(1)
Equipment Sizes	344	(1)
Other Investment Costs	345	(3)
Lang Factor Method	348	(1)
Equations	348	(3)
Heat Exchangers	348	(1)
Cylindrical Process Vessels	349	(1)
Trays	349	(1)
Blowers and Compressors	349	(2)
Aspen Plus	351	(17)
Project Dates	353	(1)
Equipment Lists	353	(3)
Equipment Size and Cost Specifications	356	(5)
Remaining Investment Costs	361	(2)
Cost Indices	363	(1)
Results	364	(4)
Detailed Cost Estimation	368	(1)
Summary	369	(5)
References	369	(1)
Exercises	370	(4)
Profitability Analysis	374	(42)
Objectives	374	(1)
Introduction	374	(1)
Cost Sheet	375	(3)
Total Capital Investment and Approximate Profitability Measures	378	(6)
Working Capital	378	(1)
Approximate Profitability Measures	378	(6)
Time Value of Money	384	(7)
Compound Interest	384	(2)
Annuities	386	(2)
Comparison of Equipment Purchases	388	(3)
Cash Flow	391	(5)
Depreciation	392	(1)
Profitability Measures	393	(1)
Net Present Value	393	(1)
Investor's Rate of Return	394	(2)
Aspen Plus	396	(12)
Cost Sheet	396	(5)
Working Capital	401	(1)
Profitability Measures	401	(3)
Results	404	(4)
Detailed Cost Estimation	408	(1)
Summary	408	(8)
References	409	(1)
Exercises	409	(7)
Optimization of Process Flowsheets	416	(23)
Objectives	416	(1)
Introduction	416	(1)
Nonlinear Program	417	(2)
Objective Function	417	(1)
Equality Constraints	418	(1)
Inequality Constraints	418	(1)
General Formulation	419	(1)
Optimization Algorithm	419	(4)
Repeated Simulation	421	(1)
Infeasible Path Approach	421	(1)
Compromise Approach	422	(1)
Practical Aspects of Flowsheet Optimization	422	(1)
Flowsheet Optimizations---Case Studies	423	(2)
Aspen Plus	425	(8)
Entering the NLP	425	(1)
Adjusting the Simulation Flowsheet	426	(7)
Summary	433	(6)
References	433	(1)
Exercises	433	(6)
Part Four PLANTWIDE CONTROLLABILITY ASSESSMENT
Interaction of Process Design and Process Control	439	(18)
Objectives	439	(1)
Introduction	439	(5)
Control System Configuration	444	(5)
Classification of Process Variables	444	(2)
Degrees-of-Freedom Analysis	446	(3)
Qualitative Plantwide Control System Synthesis	449	(5)
Summary	454	(3)
References	456	(1)
Exercises	456	(1)
Flowsheet Controllability Analysis	457	(43)
Objectives	457	(1)
Quantitative Measures for Controllability and Resiliency	458	(13)
Relative-Gain Array (RGA)	459	(8)
Disturbance Cost and Disturbance Condition Number	467	(4)
Toward Automated Flowsheet C & R Diagnosis	471	(9)
Short-Cut C & R Diagnosis	471	(1)
Generating Low-Order Dynamic Models	472	(2)
Tutorial: C & R Analysis for Heat-Integrated Distillation Columns	474	(6)
Case Studies	480	(13)
MATLAB for C & R Analysis	493	(3)
Summary	496	(4)
References	496	(1)
Exercises	497	(3)
Dynamic Simulation of Process Flowsheets	500	(37)
Objectives	500	(1)
Fundamental Concepts in Dynamic Simulation	500	(1)
Dynamic Simulation Using HYSYS	501	(1)
Control-Loop Definition	502	(2)
Controller Tuning Methods	504	(5)
On-Line PI Controller Tuning	504	(1)
Model-Based PI Controller Tuning	505	(4)
Tutorial Exercise: Control of a Binary Distillation Column	509	(13)
Case Studies	522	(10)
Summary	532	(5)
References	532	(1)
Exercises	532	(5)
Part Five DESIGN REPORT
Written Process Design Report and Oral Presentation	537	(278)
Objectives	537	(1)
Written Report	538	(8)
Sections of the Report	538	(5)
Preparation of the Written Report	543	(1)
Page Format	544	(1)
Sample Design Reports	545	(1)
Oral Design Presentation	546	(3)
Typical Presentation	546	(1)
Media for the Presentation	546	(1)
Rehearsing the Presentation	547	(1)
Written Handout	547	(1)
Evaluation of the Oral Presentation	547	(2)
Videotapes	549	(1)
Award Competition	549	(1)
Summary	549	(2)
References	549	(2)
APPENDIXES
I. ASPEN PLUS in Process Design	551	(30)
A-I.1 ASPEN PLUS Input Forms	551	(2)
A-I.2 Drawing an ASPEN PLUS Flowsheet	553	(1)
A-I.3 ASPEN PLUS Paragraphs	553	(1)
A-I.4 Nested Recycle Loops	554	(3)
A-I.5 Design Specifications	557	(2)
A-I.6 Inline FORTRAN	559	(6)
A-I.7 Case Study: Monochlorobenzene Separation Process	565	(1)
ASPEN PLUS Simulation Flowsheet and Input	565	(1)
Interpretation of Program Output	565	(16)
II. HYSYS in Process Design	581	(49)
A-II.1 The HYSYS Modeling Environment	581	(3)
A-II.2 Steady-State Simulation	584	(1)
Acyclic Processes	584	(21)
Processes Involving Recycle	605	(4)
Subflowsheets	609	(1)
Multistage Separation Using the Column Subflowsheet	609	(9)
Optimization	618	(9)
A-II.3 Case Study	627	(2)
References	629	(1)
III Phase Equilibria and Process Unit Models	630	(50)
A-III.1 Phase Equilibria	630	(1)
A-III.2 Flash Vessels	630	(12)
A-III.3 Pumps	642	(2)
A-III.4 Compressors and Expanders	644	(2)
A-III.5 Heat Exchangers	646	(1)
Heat Requirement Models	647	(1)
Shell-and-Tube Heat Exchangers	647	(4)
A-III.6 Chemical Reactors	651	(1)
Stoichiometric Reactor Models	652	(2)
Equilibrium Reactor Models	654	(1)
Kinetic Reactor Models	655	(11)
A-III.7 Separators	666	(1)
Split-Fraction (Black Box) Models	667	(1)
Distillation: Fenske (Winn)-Underwood-Gilliland Shortcut Design	667	(5)
Distillation: Edmister Approximate Group Method	672	(1)
Distillation: Rigorous Simulation Using the Unabridged MESH Equations	673	(6)
References	679	(1)
IV. Physical Property Estimation, Solids Handling, and Electrolytes	680	(42)
A-IV.1 Physical Property Estimation	680	(1)
Data Banks	680	(1)
Property Estimation	681	(5)
ASPEN PLUS	686	(4)
Estimating Parameters for Pure Species	690	(2)
Selection of Property Estimation Methods and Property Data Regression	692	(6)
A-IV.2 Nonconventional Components and Substreams	698	(2)
Substreams	700	(2)
Stream Classes	702	(1)
A-IV.3 Solids handling	703	(6)
A-IV.4 Electrolytes	709	(1)
Chemical and Phase Equilibrium	709	(7)
Electrolytes in Process Simulators	716	(4)
References	720	(2)
V. Residue Curves for Heterogeneous Systems	722	(1)
VI. Successive Quadratic Programming	723	(3)
A-VI.1 NLP and Stationarity Conditions	723	(1)
A-VI.2 Solution of the Stationarity Equations	724	(1)
References	725	(1)
VII. General Algebraic Modeling Systems (GAMS)	726	(14)
A-VII.1 Input File	727	(1)
Statements	728	(2)
A-VII.2 Expanded Features: Documentation, Variable Redeclaration, and Display	730	(4)
A-VII.3 Expanded Features: Sets, Tables, Parameters and Scalars, and Equation Grouping	734	(3)
A-VII.4 Debugging	737	(2)
References	739	(1)
VIII. Design Problem Statements	740	(38)
A-VIII.0 Contents and Introduction	740	(2)
A-VIII.1 Petrochemicals	742	(6)
A-VIII.2 Petroleum Products	748	(1)
A-VIII.3 Gas Manufacture	749	(3)
A-VIII.4 Foods	752	(2)
A-VIII.5 Pharmaceuticals	754	(1)
A-VIII.6 Polymers	755	(3)
A-VIII.7 Environmental---Air Quality	758	(9)
A-VIII.8 Environmental---Water Treatment	767	(4)
A-VIII.9 Environmental---Soil Treatment	771	(3)
A-VIII.10 Environmental---Miscellaneous	774	(4)
IX. Dynamic Simulation Using DYNAPLUS	778	(17)
A-IX.1 Introduction	778	(1)
A-IX.2 Procedure for Dynamic Simulation	779	(1)
A-IX.3 Control-Loop Definition in DYNAPLUS	779	(1)
A-IX.4 Tutorial Exercise: Control of a Binary Distillation Column	780	(11)
A-IX.5 Dynamic Simulation of the MCB Separation Process	791	(4)
X. Heuristics for Process Equipment Design	795	(13)
Compressors and Vacuum Pumps	795	(1)
Conveyors for Particulate Solids	796	(1)
Cooling Towers	796	(1)
Crystallization from Solution	797	(1)
Disintegration	797	(1)
Distillation and Gas Absorption	798	(1)
Drivers and Power Recovery Equipment	799	(1)
Drying of Solids	799	(1)
Evaporators	800	(1)
Extraction, Liquid-Liquid	800	(1)
Filtration	801	(1)
Fluidization of Particles with Gases	801	(1)
Heat Exchangers	802	(1)
Insulation	802	(1)
Mixing and Agitation	803	(1)
Particle Size Enlargement	803	(1)
Piping	804	(1)
Pumps	804	(1)
Reactors	804	(1)
Refrigeration	805	(1)
Size Separation of Particles	805	(1)
Utilities: Common Specifications	806	(1)
Vessels (Drums)	806	(1)
Vessels (Pressure)	806	(1)
Vessels (Storage Tanks)	807	(1)
XI. Materials of Construction	808	(2)
XII. Generation of Linear Models in Standard Forms	810	(5)
Author Index	815	(2)
Subject Index	817