Description

Appropriate for all courses in chemical engineering process design.

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Analysis, Synthesis and Design of Chemical Processes, Second Edition 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, finances to operation. Drawing on over 30 years of teaching chemical engineering process design, they present design as a creative process that integrates the big picture with the small details, and relies on knowing which to stress, and why. They show students how to apply key process design techniques to every aspect of the discipline, from the conceptual design of a plant to improving an existing process. This edition has been updated throughout, and contains extensive new coverage of environmental, health, and safety issues, green engineering, and engineering ethics. Coverage also includes: evolution and generation of multiple process configurations; estimating capital investment, manufacturing cost, and other economic factors; synthesis and optimization of chemical processes; performance analysis of existing processes and equipment; and more. The authors provide 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 and preliminary design information for four chemical processes. The accompanying CD-ROM contains powerful tools for helping students master chemical process design, including a thoroughly revised version of CAPCOST for evaluating fixed capital investments and full process economics; HENSAD for planning temperatures and heat exchange; a virtual plant tour of a simple chemical process; and additional student design projects.

Features

• NEW - New and in-depth coverage of environmental, health, and safety issues, green engineering, and engineering ethics.

  • Helps students understand their responsibilities as chemical engineers in the broader society.

• NEW - Thoroughly updated version of CAPCOST-A powerful spreadsheet template for evaluating fixed capital investments and full process economics.

  • Gives students a powerful tool for estimating and costing virtually any chemical process.

• Synthesis of the entire chemical design process-Covers the preliminary sizing of equipment, flowsheet optimization, economic evaluation of projects, the operation of chemical processes, and more.

  • Helps students become effective in the critical early stages of chemical engineering design.

• In-depth insight into the philosophy of process design-Illuminates the professional engineers approach to process design through a case study manufacturing process (toluene into benzene) which continues throughout the entire book.

  • Gives students insight into the entire process of chemical design, so they can contribute to any phase of the process.

• Exceptional relevance-Focuses on the aspects of design that will be most relevant to chemical engineers across a broad array of job assignments.

  • Helps students prepare for the realities of chemical engineering practice.

• Detailed principle diagrams-Presents and explains the principle diagrams utilized by chemical engineers, including the Process Flow Diagram (PFD).

  • Exposes students to the essential tools of the trade.

• Practical insight and rules of thumb-Explains how and why the operating conditions in a process are chosen, and includes basic rules of thumb for preliminary process design.

  • Helps students gain insight into chemical process design that typically takes years to learn through workplace trial and error.

• Performance optimization techniques-Demonstrates how to analyze, evaluate, modify, and troubleshoot system and process performance.

  • Helps students improve the performance of existing processes.

• Process simulation-Shows how to simulate processes and work with process simulators.

  • Helps students anticipate the growing importance of process simulation in the chemical engineering profession.

• Powerful tools on CD-ROM-Includes a thoroughly revised version of CAPCOST for evaluating fixed capital investments and full process economics. Additional software tools include a virtual plant tour, multiple student design projects, and HENSAD, an application which enables students to construct temperature interval, cascade, and temperature-enthalpy diagrams; estimate optimal approach temperatures; and design heat exchanger networks.

  • Gives students a broad range of valuable tools they will be able to use both in the course of their studies and as members of the profession.

• Design projects, suggested curricula, and other resources for students and faculty-Provides suggested curricula for both single-semester and year-long design courses; case studies and design projects with practical applications; and appendices with updated equipment cost data and preliminary design information for four chemical processes.

  • Helps faculty structure and customize courses for maximum student benefit.

New to this Edition

• New and in-depth coverage of environmental, health, and safety issues, green engineering, and engineering ethics.

  • Helps students understand their responsibilities as chemical engineers in the broader society.

• Thoroughly updated version of CAPCOST-A powerful spreadsheet template for evaluating fixed capital investments and full process economics.

  • Gives students a powerful tool for estimating and costing virtually any chemical process.

Table of Contents

(NOTE: Each chapter concludes with a Summary.)
Preface.
List of Nomenclature.
0. Outcomes Assessment.

For Students. For Faculty.

SECTION 1. CONCEPTUALIZATION AND ANALYSIS OF CHEMICAL PROCESSES.

1. Diagrams for Understanding Chemical Processes.
Block Flow Diagram (BFD). Process Flow Diagram (PFD). Piping and Instrumentation Diagram (P&ID). Additional Diagrams. 3-Dimensional Representation of a Process. The 3-D Plant Model.2. The Structure and Synthesis of Process Flow Diagrams.
Introduction. Step 1-Batch vs. Continuous Process. Step 2-The Input-Output Structure of the Process. Step 3-The Recycle Structure of the Process. Step 4-General Structure of the Separation System. Step 5-Heat-Exchanger Network or Process Energy Recovery System. Information Required and Sources.3. Tracing Chemicals through the Process Flow Diagram.
Guidelines and Tactics for Tracing Chemicals. Tracing Primary Paths Taken by Chemicals in a Chemical Process. Recycle and Bypass Streams. Tracing Nonreacting Chemicals. Limitations. Written Process Description.4. Understanding Process Conditions.
Conditions of Special Concern for the Operation of Separation and Reactor Systems. Reasons for Operating at Conditions of Special Concern. Conditions of Special Concern for the Operation of Other Equipment. Analysis of Important Process Conditions.

SECTION 2. ENGINEERING ECONOMIC ANALYSIS OF CHEMICAL PROCESSES.

5. Estimation of Capital Costs.
Classifications of Capital Cost Estimates. Estimation of Purchased Equipment Costs. Estimating the Total Capital Cost of a Plant.6. Estimation of Manufacturing Costs.
Factors Affecting the Cost of Manufacturing a Chemical Product. Cost of Operating Labor. Utility Costs. Raw Material Costs. Yearly Costs and Stream Factors. Estimating Utility Costs from the PFD. Cost of Treating Liquid and Solid Waste Streams. Evaluation of Cost of Manufacture for the Production of Benzene via the Hydrodealkylation of Toluene.7. Engineering Economic Analysis.
Investments and the Time Value of Money. Different Types of Interest. Time Basis for Compound Interest Calculations. Cash Flow Diagrams. Calculations from Cash Flow Diagrams. Inflation. Depreciation of Capital Investment. Taxation, Cash Flow, and Profit.8. Profitability Analysis.
A Typical Cash Flow Diagram for a New Project. Profitability Criteria for Project Evaluation. Comparing Several Large Projects-Incremental Economic Analysis. Establishing Acceptable Returns from Investments-The Concept of Risk. Evaluation of Equipment Alternatives. Incremental Analysis for Retrofitting Facilities. Evaluation of Risk in Evaluating Profitability. Profit Margin Analysis.

SECTION 3. SYNTHESIS AND OPTIMIZATION OF CHEMICAL PROCESSES.

9. Utilizing Experience-Based Principles to Confirm the Suitability of a Process Design.

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The Role of Experience in the Design Process. Presentation of Tables of Technical Heuristics and Guidelines.10. Synthesis of the PFD from the Generic BFD.

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Information Needs and Sources. Reactor Section. Separator Section. Reactor Feed Preparation and Separator Feed Preparation Sections. Recycle Section. Environmental Control Section. Major Process Control Loops. Flow Summary Table. Major Equipment Summary Table.11. Synthesis of a Process Using a Simulator and Simulator Troubleshooting.
The Structure of a Process Simulator. Information Required to Complete a Process Simulation-Input Data. Handling Recycle Streams. Choosing Thermodynamic Models. Case Study-Toluene Hydrodealkylation Process.12. Process Optimization.
Background Information on Optimization. Strategies. Topological Optimization. Parametric Optimization. Lattice Search Techniques vs. Experimental Design. Process Flexibility and the Sensitivity of the Optimum.13. Pinch Technology.
Introduction. Heat Integration and Network Design. Composite Temperature Enthalpy Diagram. Composite Enthalpy Curves for Systems without a Pinch. Using the Composite Enthalpy Curve to Estimate Heat Exchanger Surface Area. Effectiveness Factor (F) and the Number of Shells. Combining Costs to Give the EAOC for the Network. Other Considerations. Heat Exchanger Network Synthesis Analysis and Design (HENSAD) Program. Mass-Exchange Networks.

SECTION 4. ANALYSIS OF PROCESS PERFORMANCE.

14. Process Input/Output Models.
Representation of Process Inputs and Outputs. Analysis of the Effect of Process Inputs on Process Outputs. A Process Example.15. Tools for Evaluating Process Performance.
Key Relationships. Thinking with Equations. Base Case Ratios. Analysis of Systems Using Controlling Resistances. Graphical Representations.16. Performance Curves for Individual Unit Operations.
Applications to Heat Transfer. Application to Fluid Flow. Application to Separation Problems.17. Performance of Multiple Unit Operations.
Analysis of a Reactor with Heat Transfer. Performance of a Distillation Column. Performance of a Heating Loop. Performance of the Feed Section to a Process.18. Reactor Performance.
Production of Desired Product. Reaction Kinetics and Thermodynamics. The Chemical Reactor. Heat Transfer in the Chemical Reactor. Reactor System Case Studies.19. Regulating Process Conditions.
A Simple Regulation Problem. The Characteristics of Regulating Valves. Regulating Flowrates and Pressures. The Measurement of Process Variables. Common Control Strategies Used in Chemical Processes. Exchanging Heat and Work between Process and Utility Streams. Case Studies.20. Process Troubleshooting and Debottlenecking.
Recommended Methodology. Troubleshooting Individual Units. Troubleshooting Multiple Units. A Process Troubleshooting Problem. Debottlenecking Problems.

SECTION 5. THE IMPACT OF CHEMICAL ENGINEERING DESIGN ON SOCIETY.

21. Ethics and Professionalism.
Ethics. Professional Registration. Legal Liability. Business Codes of Conduct.22. Health, Safety, and the Environment.

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Risk Assessment. Regulations and Agencies. Fires and Explosions. Process Hazard Analysis. Chemical Safety and Hazard Investigation Board. Inherently Safe Design. Glossary.23. Green Engineering.
Environmental Regulations. Environmental Fate of Chemicals. Green Chemistry. Pollution Prevention during Process Design. Analysis of a PFD for Pollution Performance and Environmental Performance. An Example of the Economics of Pollution Prevention. Life-Cycle Analysis.24. Chemical Product Design.
Strategies for Chemical Product Design. Needs. Ideas. Selection. Manufacture. Batch Processing. Economic Considerations.

SECTION 6. INTERPERSONAL AND COMMUNICATION SKILLS.

25. Teamwork.
Groups. Group Evolution. Teams and Teamwork. Misconceptions. Learning in Teams. Other Reading.26. Written and Oral Communications.
Audience Analysis. Written Communication. Oral Communications. Software and Author Responsibility.27. A Report Writing Case Study.

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The Assignment Memorandum. Response Memorandum. Visual Aids. Example Reports. Checklist of Common Mistakes and Errors.Appendix A. Cost Equations and Curves for the CAPCOST Program.
Purchased Equipment Costs. Pressure Factors. Material Factors and Bare Module Factors.Appendix B. Information for the Preliminary Design of Four Chemical Processes.
Production of Dimethyl Ether (DME) via the Dehydration of Methanol. Acrylic Acid Production via the Catalytic Partial Oxidation of Propylene. Production of Acetone via the Dehydrogenation of Isopropyl Alcohol (IPA). Production of Heptenes from Propylene and Butenes.Appendix C. Design Projects (on companion CD-ROM).

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Project 1. Increasing the Production of 3-Chloro-1-Propene (Allyl Chloride) in Unit 600. Project 2. Design and Optimization of a New 20,000 Metric Tons per Year Facility to Produce Allyl Chloride at La Nueva Cantina, Mexico. Project 3. Scale-Down of Phthalic Anhydride Production at TBWS Unit 700. Project 4. The Design of a New, 100,000 Metric Tons per Year, Phthalic Anhydride Production Facility. Project 5. Problems at the Cumene Production Facility, Unit 800. Project 6. Design of a New, 100,000 Metric Tons per Year, Cumene Production Facility.Index.

Back Cover

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 configurations
• Estimating capital investment, manufacturing costs, and other economic factors
• Synthesis and optimization of chemical processes
• Performance analysis of existing processes and equipment
• Environmental concerns, green engineering, engineering ethics, and health and safety
• Written 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 and preliminary design information for four chemical processes.

About the CD-ROM

The CD-ROM contains a heavily revised version of CAPCOST, now in the form of a spreadsheet template, which is used for evaluating fixed capital investments and full process economics. The HENSAD application allows the user to construct temperature interval, cascade, and temperature-enthalpy diagrams; estimate the optimal approach temperature; and design heat exchanger networks. Also included are a virtual plant tour of a simple chemical process and additional student design projects.

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Author

Richard Turton, P.E., has taught the senior design course at WVU for the past 16 years. Prior to this, he spent 5 years in the design and construction industry. His main interests are in design education and fluid bed coating and particulate processing.

Richard C. Bailie has over 10 years of experience in process evaluation, pilot plant operation, plant start-up, and industrial consulting. He also ran his own chemical company. He is a professor emeritus at WVU, having taught chemical engineering design for over 20 years.

Wallace B. Whiting, P.E., is currently professor and chair of chemical engineering at the University of Nevada, Reno. He has been involved in the practice and teaching of chemical process design for 22 years.

Joseph A. Shaeiwitz has been involved in the senior design sequence and the unique sophomore- and junior-level integrated design projects at WVU for 14 years. His interests include design education and outcomes assessment.