Analysis, Synthesis, and Design of Chemical Processes, Global Edition

The Leading Integrated Chemical Process Design Guide: With Extensive Coverage of Equipment Design and Other Key Topics More than ever, effective design is the focal point of sound chemical engineering. Analysis, Synthesis, and Design of Chemical Processes, Fifth Edition, presents design as a creative process that integrates the big-picture and small details, and knows which to stress when and why. Realistic from start to finish, it moves readers beyond classroom exercises into open-ended, real-world problem solving. The authors introduce up-to-date, integrated techniques ranging from finance to operations, and new plant design to existing process optimization. The fifth edition includes updated safety and ethics resources and economic factors indices, as well as an extensive, new section focused on process equipment design and performance, covering equipment design for common unit operations, such as fluid flow, heat transfer, separations, reactors, and more. - Conceptualization and analysis: process diagrams, configurations, batch processing, product design, and analyzing existing processes - Economic analysis: estimating fixed capital investment and manufacturing costs, measuring process profitability, and more - Synthesis and optimization: process simulation, thermodynamic models, separation operations, heat integration, steady-state and dynamic process simulators, and process regulation - Chemical equipment design and performance: a full section of expanded and revamped coverage of designing process equipment and evaluating the performance of current equipment - Advanced steady-state simulation: goals, models, solution strategies, and sensitivity and optimization results - Dynamic simulation: goals, development, solution methods, algorithms, and solvers - Societal impacts: ethics, professionalism, health, safety, environmental issues, and green engineering - Interpersonal and communication skills: working in teams, communicating effectively, and writing better reports This text draws on a combined 55 years of innovative instruction at West Virginia University (WVU) and the University of Nevada, Reno. It includes suggested curricula for one- and two-semester design courses, case studies, projects, equipment cost data, and extensive preliminary design information for jump-starting more detailed analyses.

Richard Turton, P.E., has taught the design and design-related courses at West Virginia University for the past 32 years. Prior to this, he spent five years in the design and construction industry. His main interests are design education and process systems modeling. Joseph A. Shaeiwitz taught design and design-related classes at West Virginia University for more than 25 years. He now teaches design at Auburn University. His interests include design education and outcomes assessment. Debangsu Bhattacharyya has more than ten years' experience in a large petroleum refinery. While in the refinery, he worked in process operations, plant start-up, large-scale process simulation, and process control. His main research interests are in process modeling, dynamic simulation, state estimation, sensor placement, and advanced process control. Wallace B. Whiting, P.E., is professor emeritus at University of Nevada, Reno. He has been involved in the practice and teaching of chemical process design for more than 24 years.

Preface xxv About the Authors xxix List of Nomenclature xxxi Chapter 0: Outcomes Assessment 1 0.1 Student Self-Assessment 2 0.2 Assessment by Faculty 4 0.3 Summary 6 References 6 Section I: Conceptualization and Analysis of Chemical Processes 7 Chapter 1: Diagrams for Understanding Chemical Processes 9 1.1 Block Flow Diagram (BFD) 11 1.2 Process Flow Diagram (PFD) 14 1.3 Piping and Instrumentation Diagram (P&ID) 27 1.4 Additional Diagrams 32 1.5 Three-Dimensional Representation of a Process 34 1.6 The 3-D Plant Model 41 1.7 Operator and 3-D Immersive Training Simulators 43 1.8 Summary 48 References 49 Short Answer Questions 49 Problems 50 Chapter 2: The Structure and Synthesis of Process Flow Diagrams 55 2.1 Hierarchy of Process Design 55 2.2 Step 1-Batch versus Continuous Process 56 2.3 Step 2-The Input/Output Structure of the Process 60 2.4 Step 3-The Recycle Structure of the Process 70 2.5 Step 4-General Structure of the Separation System 83 2.6 Step 5-Heat-Exchanger Network or Process Energy Recovery System 83 2.7 Information Required and Sources 83 2.8 Summary 83 References 85 Short Answer Questions 86 Problems 86 Chapter 3: Batch Processing 91 3.1 Design Calculations for Batch Processes 91 3.2 Gantt Charts and Scheduling 97 3.3 Nonoverlapping Operations, Overlapping Operations, and Cycle Times 98 3.4 Flowshop and Jobshop Plants 101 3.5 Product and Intermediate Storage and Parallel Process Units 106 3.6 Design of Equipment for Multiproduct Batch Processes 111 3.7 Summary 113 References 114 Short Answer Questions 114 Problems 114 Chapter 4: Chemical Product Design 123 4.1 Strategies for Chemical Product Design 124 4.2 Needs 125 4.3 Ideas 127 4.4 Selection 128 4.5 Manufacture 130 4.6 Batch Processing 131 4.7 Economic Considerations 131 4.8 Summary 132 References 132 Chapter 5: Tracing Chemicals through the Process Flow Diagram 135 5.1 Guidelines and Tactics for Tracing Chemicals 135 5.2 Tracing Primary Paths Taken by Chemicals in a Chemical Process 136 5.3 Recycle and Bypass Streams 142 5.4 Tracing Nonreacting Chemicals 145 5.5 Limitations 145 5.6 Written Process Description 146 5.7 Summary 147 Problems 147 Chapter 6: Understanding Process Conditions 149 6.1 Conditions of Special Concern for the Operation of Separation and Reactor Systems 150 6.2 Reasons for Operating at Conditions of Special Concern 152 6.3 Conditions of Special Concern for the Operation of Other Equipment 155 6.4 Analysis of Important Process Conditions 158 6.5 Summary 165 References 165 Short Answer Questions 165 Problems 166 Section II: Engineering Economic Analysis of Chemical Processes 169 Chapter 7: Estimation of Capital Costs 171 7.1 Classifications of Capital Cost Estimates 172 7.2 Estimation of Purchased Equipment Costs 175 7.3 Estimating the Total Capital Cost of a Plant 182 7.4 Estimation of Plant Costs Based on Capacity Information 206 7.5 Summary 208 References 208 Short Answer Questions 209 Problems 210 Chapter 8: Estimation of Manufacturing Costs 213 8.1 Factors Affecting the Cost of Manufacturing a Chemical Product 213 8.2 Cost of Operating Labor 218 8.3 Utility Costs 219 8.4 Raw Material Costs 234 8.5 Yearly Costs and Stream Factors 237 8.6 Estimating Utility Costs from the PFD 238 8.7 Cost of Treating Liquid and Solid Waste Streams 240 8.8 Evaluation of Cost of Manufacture for the Production of Benzene via the Hydrodealkylation of Toluene 241 8.9 Summary 242 References 243 Short Answer Questions 243 Problems 244 Chapter 9: Engineering Economic Analysis 247 9.1 Investments and the Time Value of Money 248 9.2 Different Types of Interest 251 9.3 Time Basis for Compound Interest Calculations 254 9.4 Cash Flow Diagrams 255 9.5 Calculations from Cash Flow Diagrams 259 9.6 Inflation 266 9.7 Depreciation of Capital Investment 268 9.8 Taxation, Cash Flow, and Profit 274 9.9 Summary 277 References 277 Short Answer Questions 278 Problems 278 Chapter 10: Profitability Analysis 285 10.1 A Typical Cash Flow Diagram for a New Project 285 10.2 Profitability Criteria for Project Evaluation 287 10.3 Comparing Several Large Projects: Incremental Economic Analysis 295 10.4 Establishing Acceptable Returns from Investments: The Concept of Risk 298 10.5 Evaluation of Equipment Alternatives 299 10.6 Incremental Analysis for Retrofitting Facilities 305 10.7 Evaluation of Risk in Evaluating Profitability 309 10.8 Profit Margin Analysis 325 10.9 Summary 326 References 327 Short Answer Questions 327 Problems 328 Section III: Synthesis and Optimization of Chemical Processes 343 Chapter 11: Utilizing Experience-Based Principles to Confirm the Suitability of a Process Design 347 11.1 The Role of Experience in the Design Process 348 11.2 Presentation of Tables of Technical Heuristics and Guidelines 351 11.3 Summary 354 List of Informational Tables 354 References 368 Problems 368 Chapter 12: Synthesis of the PFD from the Generic BFD 369 12.1 Information Needs and Sources 370 12.2 Reactor Section 372 12.3 Separator Section 373 12.4 Reactor Feed Preparation and Separator Feed Preparation Sections 388 12.5 Recycle Section 389 12.6 Environmental Control Section 389 12.7 Major Process Control Loops 390 12.8 Flow Summary Table 390 12.9 Major Equipment Summary Table 390 12.10 Summary 391 References 391 General Reference 392 Problems 392 Chapter 13: Synthesis of a Process Using a Simulator and Simulator Troubleshooting 397 13.1 The Structure of a Process Simulator 398 13.2 Information Required to Complete a Process Simulation: Input Data 401 13.3 Handling Recycle Streams 413 13.4 Choosing Thermodynamic Models 415 13.5 Case Study: Toluene Hydrodealkylation Process 426 13.6 Electrolyte Systems Modeling 428 13.7 Solids Modeling 440 Appendix 13.1 445 Appendix 13.2 447 13.8 Summary 450 References 451 Short Answer Questions 454 Problems 455 Chapter 14: Process Optimization 463 14.1 Background Information on Optimization 463 14.2 Strategies 469 14.3 Topological Optimization 473 14.4 Parametric Optimization 479 14.5 Lattice Search, Response Surface, and Mathematical Optimization Techniques 489 14.6 Process Flexibility and the Sensitivity of the Optimum 489 14.7 Optimization in Batch Systems 490 14.8 Summary 497 References 498 Short Answer Questions 498 Problems 498 Chapter 15: Pinch Technology 509 15.1 Introduction 509 15.2 Heat Integration and Network Design 510 15.3 Composite Temperature-Enthalpy Diagram 523 15.4 Composite Enthalpy Curves for Systems without a Pinch 524 15.5 Using the Composite Enthalpy Curve to Estimate Heat-Exchanger Surface Area 525 15.6 Effectiveness Factor (F) and the Number of Shells 529 15.7 Combining Costs to Give the EAOC for the Network 534 15.8 Other Considerations 536 15.9 Heat-Exchanger Network Synthesis Analysis and Design (HENSAD) Program 540 15.10 Mass-Exchange Networks 541 15.11 Summary 550 References 550 Short Answer Questions 551 Problems 552 Chapter 16: Advanced Topics Using Steady-State Simulators 561 16.1 Why the Need for Advanced Topics in Steady-State Simulation? 562 16.2 User-Added Models 562 16.3 Solution Strategy for Steady-State Simulations 571 16.4 Studies with the Steady-State Simulation 589 16.5 Estimation of Physical Property Parameters 601 16.6 Summary 605 References 605 Short Answer Questions 607 Problems 607 Chapter 17: Using Dynamic Simulators in Process Design 617 17.1 Why Is There a Need for Dynamic Simulation? 618 17.2 Setting Up a Dynamic Simulation 619 17.3 Dynamic Simulation Solution Methods 633 17.4 Process Control 639 17.5 Summary 647 References 647 Short Answer Questions 648 Problems 649 Chapter 18: Regulation and Control of Chemical Processes with Applications Using Commercial Software 655 18.1 A Simple Regulation Problem 656 18.2 The Characteristics of Regulating Valves 657 18.3 Regulating Flowrates and Pressures 660 18.4 The Measurement of Process Variables 662 18.5 Common Control Strategies Used in Chemical Processes 663 18.6 Exchanging Heat and Work between Process and Utility Streams 674 18.7 Logic Control 680 18.8 Advanced Process Control 682 18.9 Case Studies 683 18.10 Putting It All Together: The Operator Training Simulator (OTS) 688 18.11 Summary 689 References 690 Problems 690 Section IV: Chemical Equipment Design and Performance Process Equipment Design and Performance 695 Chapter 19: Process Fluid Mechanics 697 19.1 Basic Relationships in Fluid Mechanics 697 19.2 Fluid Flow Equipment 703 19.3 Frictional Pipe Flow 709 19.4 Other Flow Situations 723 19.5 Performance of Fluid Flow Equipment 736 References 755 Short Answer Questions 756 Problems 757 Chapter 20: Process Heat Transfer 771 20.1 Basic Heat-Exchanger Relationships 771 20.2 Heat-Exchange Equipment Design and Characteristics 779 20.3 LMTD Correction Factor for Multiple Shell and Tube Passes 789 20.4 Overall Heat Transfer Coefficients-Resistances in Series 798 20.5 Estimation of Individual Heat Transfer Coefficients and Fouling Resistances 800 20.6 Extended Surfaces 828 20.7 Algorithm and Worked Examples for the Design of Heat Exchangers 837 20.8 Performance Problems 846 References 859 Appendix 20.A Heat-Exchanger Effectiveness Charts 861 Appendix 20.B Derivation of Fin Effectiveness for a Rectangular Fin 864 Short Answer Questions 866 Problems 866 Chapter 21: Separation Equipment 875 21.1 Basic Relationships in Separations 876 21.2 Illustrative Diagrams 883 21.3 Equipment 911 21.4 Extraction Equipment 942 21.5 Gas Permeation Membrane Separations 947 References 951 Short Answer Questions 952 Problems 954 Chapter 22: Reactors 961 22.1 Basic Relationships 962 22.2 Equipment Design for Nonisothermal Conditions 980 22.3 Performance Problems 1003 Chapter 23: Other Equipment 1015 23.1 Pressure Vessels 1016 23.2 Knockout Drums or Simple Phase Separators 1024 23.3 Steam Ejectors 1049 References 1058 Short Answer Questions 1059 Problems 1060 Chapter 24: Process Troubleshooting and Debottlenecking 1065 24.1 Recommended Methodology 1067 24.2 Troubleshooting Individual Units 1071 24.3 Troubleshooting Multiple Units 1076 24.4 A Process Troubleshooting Problem 1081 24.5 Debottlenecking Problems 1085 24.6 Summary 1091 References 1091 Problems 1091 Section V: The Impact of Chemical Engineering Design on Society 1101 Chapter 25: Ethics and Professionalism 1103 25.1 Ethics 1104 25.2 Professional Registration 1121 25.3 Legal Liability [13] 1125 25.4 Business Codes of Conduct [14, 15] 1126 25.5 Summary 1127 References 1128 Problems 1129 Chapter 26: Health, Safety, and the Environment 1131 26.1 Risk Assessment 1131 26.2 Regulations and Agencies 1134 26.3 Fires and Explosions 1143 26.4 Process Hazard Analysis 1145 26.5 Chemical Safety and Hazard Investigation Board 1153 26.6 Inherently Safe Design 1153 26.7 Summary 1154 26.8 Glossary 1154 References 1156 Problems 1157 Chapter 27: Green Engineering 1159 27.1 Environmental Regulations 1159 27.2 Environmental Fate of Chemicals 1160 27.3 Green Chemistry 1163 27.4 Pollution Prevention during Process Design 1164 27.5 Analysis of a PFD for Pollution Performance and Environmental Performance 1166 27.6 An Example of the Economics of Pollution Prevention 1167 27.7 Life Cycle Analysis 1168 27.8 Summary 1169 Section VI: Interpersonal and Communication Skills 1173 Chapter 28: Teamwork 1175 28.1 Groups 1175 28.2 Group Evolution 1184 28.3 Teams and Teamwork 1186 28.4 Misconceptions 1189 28.5 Learning in Teams 1189 28.6 Other Reading 1190 28.7 Summary 1191 References 1192 Problems 1192 Chapter 29: Written and Oral Communication 1195 29.1 Audience Analysis 1196 29.2 Written Communication 1196 29.3 Oral Communication 1209 29.4 Software and Author Responsibility 1215 29.5 Summary 1218 References 1218 Problems 1219 Chapter 30: A Report-Writing Case Study 1221 30.1 The Assignment Memorandum 1221 30.2 Response Memorandum 1222 30.3 Visual Aids 1224 30.4 Example Reports 1230 30.5 Checklist of Common Mistakes and Errors 1244 Appendix A: Cost Equations and Curves for the CAPCOST Program 1247 A.1 Purchased Equipment Costs 1247 A.2 Pressure Factors 1264 A.3 Material Factors and Bare Module Factors 1267 References 1275 Appendix B: Information for the Preliminary Design of Fifteen Chemical Processes 1277 B.1 Dimethyl Ether (DME) Production, Unit 200 1278 B.2 Ethylbenzene Production, Unit 300 1283 B.3 Styrene Production, Unit 400 1291 B.4 Drying Oil Production, Unit 500 1299 B.5 Production of Maleic Anhydride from Benzene, Unit 600 1305 B.6 Ethylene Oxide Production, Unit 700 1311 B.7 Formalin Production, Unit 800 1317 B.8 Batch Production of L-Phenylalanine and L-Aspartic Acid, Unit 900 1323 B.9 Acrylic Acid Production via the Catalytic Partial Oxidation of Propylene [1-5], Unit 1000 1329 B.10 Production of Acetone via the Dehydrogenation of Isopropyl Alcohol (IPA) [1-4], Unit 1100 1338 B.11 Production of Heptenes from Propylene and Butenes [1], Unit 1200 1344 B.12 Design of a Shift Reactor Unit to Convert CO to CO2, Unit 1300 1352 B.13 Design of a Dual-Stage Selexol Unit to Remove CO2 and H2S From B.14 Design of a Claus Unit for the Conversion of H2S to Elemental Sulfur, Unit 1500 1363 B.15 Modeling a Downward-Flow, Oxygen-Blown, Entrained-Flow Gasifier, Unit 1600 1371 Appendix C: Design Projects 1379 Project 1 Increasing the Production of 3-Chloro-1-Propene (Allyl Chloride) in Unit 600 1381 Project 2 Design and Optimization of a New 20,000-Metric-Tons-per-Year Facility to Produce Allyl Chloride at La Nueva Cantina, Mexico 1394 Project 4 The Design of a New 100,000-Metric-Tons-per-Year Phthalic Anhydride Production Facility 1412 Project 5 Problems at the Cumene Production Facility, Unit 800 1417 Project 6 Design of a New, 100,000-Metric-Tons-per-Year Cumene Production Facility 1430 Index 1433