Analysis, Synthesis and Design of Chemical Processes: Pearson New International Edition
Pearson Education Limited
978-1-292-02567-4 (ISBN)
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Material on the CD-ROM xixPreface xxiii
About the Authors xxvii
List of Nomenclature xxix
Section I: Conceptualization and Analysis of Chemical Processes 1
Chapter 1: Diagrams for Understanding Chemical Processes 3
What You Will Learn 3
1.1 Block Flow Diagram (BFD) 5
1.2 Process Flow Diagram (PFD) 8
1.3 Piping and Instrumentation Diagram (P&ID) 21
1.4 Additional Diagrams 26
1.5 Three-Dimensional Representation of a Process 27
1.6 The 3-D Plant Model 35
1.7 Operator and 3-D Immersive Training Simulators 37
1.8 Summary 43
What You Should Have Learned 43
References 44
Short Answer Questions 44
Problems 44
Chapter 2: The Structure and Synthesis of Process Flow Diagrams 49
What You Will Learn 49
2.1 Hierarchy of Process Design 49
2.2 Step 1-Batch versus Continuous Process 50
2.3 Step 2-The Input/Output Structure of the Process 54
2.4 Step 3-The Recycle Structure of the Process 64
2.5 Step 4-General Structure of the Separation System 78
2.6 Step 5-Heat-Exchanger Network or Process Energy Recovery System 78
2.7 Information Required and Sources 78
2.8 Summary 78
What You Should Have Learned 80
References 80
Short Answer Questions 81
Problems 81
Chapter 3: Batch Processing 87
What You Will Learn 87
3.1 Design Calculations for Batch Processes 87
3.2 Gantt Charts and Scheduling 93
3.3 Nonoverlapping Operations, Overlapping Operations, and Cycle Times 94
3.4 Flowshop and Jobshop Plants 97
3.5 Product and Intermediate Storage and Parallel Process Units 102
3.6 Design of Equipment for Multiproduct Batch Processes 107
3.7 Summary 109
What You Should Have Learned 110
References 110
Short Answer Questions 110
Problems 110
Chapter 4: Chemical Product Design 115
What You Will Learn 115
4.1 Strategies for Chemical Product Design 116
4.2 Needs 117
4.3 Ideas 119
4.4 Selection 120
4.5 Manufacture 122
4.6 Batch Processing 123
4.7 Economic Considerations 123
4.8 Summary 123
What You Should Have Learned 124
References 124
Chapter 5: Tracing Chemicals through the Process Flow Diagram 125
What You Will Learn 125
5.1 Guidelines and Tactics for Tracing Chemicals 125
5.2 Tracing Primary Paths Taken by Chemicals in a Chemical Process 126
5.3 Recycle and Bypass Streams 132
5.4 Tracing Nonreacting Chemicals 135
5.5 Limitations 135
5.6 Written Process Description 136
5.7 Summary 137
What You Should Have Learned 137
Problems 138
Chapter 6: Understanding Process Conditions 139
What You Will Learn 139
6.1 Conditions of Special Concern for the Operation of Separation and Reactor Systems 140
6.2 Reasons for Operating at Conditions of Special Concern 142
6.3 Conditions of Special Concern for the Operation of Other Equipment 146
6.4 Analysis of Important Process Conditions 150
6.5 Summary 157
What You Should Have Learned 157
References 158
Short Answer Questions 158
Problems 158
Section II: Engineering Economic Analysis of Chemical Processes 161
Chapter 7: Estimation of Capital Costs 163
What You Will Learn 163
7.1 Classifications of Capital Cost Estimates 164
7.2 Estimation of Purchased Equipment Costs 167
7.3 Estimating the Total Capital Cost of a Plant 172
7.4 Summary 198
What You Should Have Learned 198
References 198
Short Answer Questions 199
Problems 200
Chapter 8: Estimation of Manufacturing Costs 203
What You Will Learn 203
8.1 Factors Affecting the Cost of Manufacturing a Chemical Product 203
8.2 Cost of Operating Labor 208
8.3 Utility Costs 209
8.4 Raw Material Costs 223
8.5 Yearly Costs and Stream Factors 225
8.6 Estimating Utility Costs from the PFD 225
8.7 Cost of Treating Liquid and Solid Waste Streams 228
8.8 Evaluation of Cost of Manufacture for the Production of Benzene via the Hydrodealkylation of Toluene 228
8.9 Summary 229
What You Should Have Learned 230
References 230
Short Answer Questions 230
Problems 231
Chapter 9: Engineering Economic Analysis 233
What You Will Learn 233
9.1 Investments and the Time Value of Money 234
9.2 Different Types of Interest 238
9.3 Time Basis for Compound Interest Calculations 240
9.4 Cash Flow Diagrams 241
9.5 Calculations from Cash Flow Diagrams 245
9.6 Inflation 250
9.7 Depreciation of Capital Investment 253
9.8 Taxation, Cash Flow, and Profit 259
9.9 Summary 262
What You Should Have Learned 262
References 262
Short Answer Questions 263
Problems 263
Chapter 10: Profitability Analysis 269
What You Will Learn 269
10.1 A Typical Cash Flow Diagram for a New Project 269
10.2 Profitability Criteria for Project Evaluation 271
10.3 Comparing Several Large Projects: Incremental Economic Analysis 279
10.4 Establishing Acceptable Returns from Investments: The Concept of Risk 282
10.5 Evaluation of Equipment Alternatives 283
10.6 Incremental Analysis for Retrofitting Facilities 289
10.7 Evaluation of Risk in Evaluating Profitability 293
10.8 Profit Margin Analysis 310
10.9 Summary 311
What You Should Have Learned 311
References 312
Short Answer Questions 312
Problems 312
Section III: Synthesis and Optimization of Chemical Processes 327
Chapter 11: Utilizing Experience-Based Principles to Confirm the Suitability of a Process Design 331
What You Will Learn 331
11.1 The Role of Experience in the Design Process 332
11.2 Presentation of Tables of Technical Heuristics and Guidelines 335
11.3 Summary 338
What You Should Have Learned 356
References 356
Problems 356
Chapter 12: Synthesis of the PFD from the Generic BFD 357
What You Will Learn 357
12.1 Information Needs and Sources 358
12.2 Reactor Section 360
12.3 Separator Section 362
12.4 Reactor Feed Preparation and Separator Feed Preparation Sections 377
12.5 Recycle Section 378
12.6 Environmental Control Section 378
12.7 Major Process Control Loops 379
12.8 Flow Summary Table 379
12.9 Major Equipment Summary Table 380
12.10 Summary 380
What You Should Have Learned 380
References 381
Problems 382
Chapter 13: Synthesis of a Process Using a Simulator and Simulator Troubleshooting 385
What You Will Learn 385
13.1 The Structure of a Process Simulator 386
13.2 Information Required to Complete a Process Simulation: Input Data 389
13.3 Handling Recycle Streams 401
13.4 Choosing Thermodynamic Models 403
13.5 Case Study: Toluene Hydrodealkylation Process 414
13.6 Electrolyte Systems Modeling 416
13.7 Solids Modeling 429
What You Should Have Learned 434
Appendix 13.1 Calculation of Excess Gibbs Energy for Electrolyte Systems 434
Appendix 13.2 Steps to Build a Model of a Distillation Column for an Electrolyte System Using a Rate-Based Simulation with a Film Model for Mass Transfer, the Parameters Required at Each Stage, and Possible Sources of These Parameters 437
13.8 Summary 440
References 441
Short Answer Questions 444
Problems 444
Chapter 14: Process Optimization 451
What You Will Learn 451
14.1 Background Information on Optimization 451
14.2 Strategies 457
14.3 Topological Optimization 461
14.4 Parametric Optimization 467
14.5 Lattice Search Techniques versus Response Surface Techniques 478
14.6 Process Flexibility and the Sensitivity of the Optimum 479
14.7 Optimization in Batch Systems 479
14.8 Summary 487
What You Should Have Learned 487
References 487
Short Answer Questions 488
Problems 488
Chapter 15: Pinch Technology 499
What You Will Learn 499
15.1 Introduction 499
15.2 Heat Integration and Network Design 500
15.3 Composite Temperature-Enthalpy Diagram 514
15.4 Composite Enthalpy Curves for Systems without a Pinch 516
15.5 Using the Composite Enthalpy Curve to Estimate Heat-Exchanger Surface Area 517
15.6 Effectiveness Factor (F) and the Number of Shells 521
15.7 Combining Costs to give the EAOC for the Network 526
15.8 Other Considerations 527
15.9 Heat-Exchanger Network Synthesis Analysis and Design (HENSAD) Program 532
15.10 Mass-Exchange Networks 532
15.11 Summary 541
What You Should Have Learned 542
References 542
Short Answer Questions 543
Problems 543
Chapter 16: Regulation and Control of Chemical Processes with Applications Using Commercial Software 641
What You Will Learn 641
16.1 A Simple Regulation Problem 642
16.2 The Characteristics of Regulating Valves 643
16.3 Regulating Flowrates and Pressures 646
16.4 The Measurement of Process Variables 649
16.5 Common Control Strategies Used in Chemical Processes 649
16.6 Exchanging Heat and Work between Process and Utility Streams 660
16.7 Logic Control 666
16.8 Advanced Process Control 669
16.9 Case Studies 670
16.10 Putting It All Together: The Operator Training Simulator (OTS) 676
16.11 Summary 677
What You Should Have Learned 677
References 678
Problems 678
Section IV: Analysis Of Process Performance 683
Chapter 17: Process Input/Output Models 685
What You Will Learn 685
17.1 Representation of Process Inputs and Outputs 686
17.2 Analysis of the Effect of Process Inputs on Process Outputs 689
17.3 A Process Example 690
17.4 Summary 691
Wat You Should Have Learned 692
Problems 692
Chapter 18: Tools for Evaluating Process Performance 693
What You Will Learn 693
18.1 Key Relationships 693
18.2 Thinking with Equations 694
18.3 Base-Case Ratios 696
18.4 Analysis of Systems Using Controlling Resistances 698
18.5 Graphical Representations 700
18.6 Summary 704
What You Should Have Learned 705
References 705
Problems 705
Chapter 19: Performance Curves for Individual Unit Operations 707
What You Will Learn 707
19.1 Application to Heat Transfer 709
19.2 Application to Fluid Flow 714
19.3 Application to Separation Problems 728
19.4 Summary 740
What You Should Have Learned 741
References 741
Short Answer Questions 741
Problems 743
Chapter 20: Performance of Multiple Unit Operations 749
What You Will Learn 749
20.1 Analysis of a Reactor with Heat Transfer 749
20.2 Performance of a Distillation Column 754
20.3 Performance of a Heating Loop 759
20.4 Performance of the Feed Section to a Process 765
20.5 Summary 768
What You Should Have Learned 769
References 769
Short Answer Questions 769
Problems 769
Chapter 21: Reactor Performance 785
What You Will Learn 785
21.1 Production of Desired Product 786
21.2 Reaction Kinetics and Thermodynamics 788
21.3 The Chemical Reactor 791
21.4 Heat Transfer in the Chemical Reactor 796
21.5 Reactor System Case Studies 799
21.6 Summary 812
What You Should Have Learned 813
References 813
Short Answer Questions 813
Problems 814
Chapter 22: Process Troubleshooting and Debottlenecking 819
What You Will Learn 819
22.1 Recommended Methodology 821
22.2 Troubleshooting Individual Units 825
22.3 Troubleshooting Multiple Units 831
22.4 A Process Troubleshooting Problem 836
22.5 Debottlenecking Problems 840
22.6 Summary 841
What You Should Have Learned 841
References 841
Problems 841
Section V: The Impact of Chemical Engineering Design on Society 853
Chapter 23: Ethics and Professionalism 855
What You Will Learn 855
23.1 Ethics 856
23.2 Professional Registration 874
23.3 Legal Liability 879
23.4 Business Codes of Conduct 880
23.5 Summary 881
What You Should Have Learned 881
References 882
Problems 882
Chapter 24: Health, Safety, and the Environment 885
What You Will Learn 885
24.1 Risk Assessment 886
24.2 Regulations and Agencies 888
24.3 Fires and Explosions 898
24.4 Process Hazard Analysis 900
24.5 Chemical Safety and Hazard Investigation Board 909
24.6 Inherently Safe Design 909
24.7 Summary 910
24.8 Glossary 910
What You Should Have Learned 912
References 912
Problems 913
Chapter 25: Green Engineering 915
What You Will Learn 915
25.1 Environmental Regulations 915
25.2 Environmental Fate of Chemicals 916
25.3 Green Chemistry 919
25.4 Pollution Prevention during Process Design 920
25.5 Analysis of a PFD for Pollution Performance and Environmental Performance 922
25.6 An Example of the Economics of Pollution Prevention 923
25.7 Life Cycle Analysis 924
25.8 Summary 926
What You Should Have Learned 926
References 926
Problems 927
Section VI: Interpersonal And Communication Skills 929
Chapter 26: Teamwork 931
What You Will Learn 931
26.1 Groups 931
26.2 Group Evolution 940
26.3 Teams and Teamwork 943
26.4 Misconceptions 945
26.5 Learning in Teams 946
26.6 Other Reading 947
26.7 Summary 948
What You Should Have Learned 949
References 949
Problems 949
Appendix A: Cost Equations and Curves for the CAPCOST Program 951
A.1 Purchased Equipment Costs 951
A.2 Pressure Factors 969
A.3 Material Factors and Bare Module Factors 973
References 982
Index 983
| Erscheint lt. Verlag | 2.8.2013 |
|---|---|
| Verlagsort | Harlow |
| Sprache | englisch |
| Maße | 216 x 276 mm |
| Themenwelt | Technik ► Umwelttechnik / Biotechnologie |
| ISBN-10 | 1-292-02567-0 / 1292025670 |
| ISBN-13 | 978-1-292-02567-4 / 9781292025674 |
| Zustand | Neuware |
| Informationen gemäß Produktsicherheitsverordnung (GPSR) | |
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