Analysis, Synthesis and Design of Chemical Processes: International Edition

The leading integrated chemical process design guide: Now with extensive new coverage and more process designs   More than ever, effective design is the focal point of sound chemical engineering. Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, presents design as a creative process that integrates both the big picture and the small details–and knows which to stress when, and why. Realistic from start to finish, this updated edition moves readers beyond classroom exercises into open-ended, real-world process problem solving. The authors introduce integrated techniques for every facet of the discipline, from finance to operations, new plant design to existing process optimization.   This fourth edition adds new chapters introducing dynamic process simulation; advanced concepts in steady-state simulation; extensive coverage of thermodynamics packages for modeling processes containing electrolyte solutions and solids; and a concise introduction to logic control. “What You Have Learned” summaries have been added to each chapter, and the text’s organization has been refined for greater clarity.   Coverage Includes Conceptualization and analysis: flow diagrams, batch processing, tracing, process conditions, and product design strategies Economic analysis: capital and manufacturing costs, financial calculations, and profitability analysis Synthesis and optimization: principles, PFD synthesis, simulation techniques, top-down and bottom-up optimization, pinch technology, and software-based control Advanced steady-state simulation: goals, models, solution strategies, and sensitivity and optimization studies Dynamic simulation: goals, development, solution methods, algorithms, and solvers Performance analysis: I/O models, tools, performance curves, reactor performance, troubleshooting, and “debottlenecking” Societal impact: ethics, professionalism, health, safety, environmental issues, and green engineering Interpersonal and communication skills: improving teamwork and group effectiveness   This title draws on more than fifty years of innovative chemical engineering instruction at West Virginia University and the University of Nevada, Reno. It includes suggested curricula for single-semester and year-long design courses, case studies and practical design projects, current equipment cost data, and extensive preliminary design information that can be used as the starting point for more detailed analyses.   About the CD-Rom and Web Site The CD contains the newest version of CAPCOST, a powerful tool for evaluating fixed capital investment, full process economics, and profitability. The heat exchanger network software, HENSAD, is also included. The CD also contains an additional appendix presenting preliminary design information for fifteen key chemical processes, including four new to this edition: shift reaction; acid-gas removal via physical solvent; H2S removal from a gas stream using the Claus process; and coal gasification. The CD also includes six additional projects, plus chapters on outcomes assessment, written and oral communications, and a written report case study. Sixty additional projects and twenty-four more problems are available at www.che.cemr.wvu.edu/publications/projects.

Table of Contents:
Material on the CD-ROM          xix Preface          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: Advanced Topics Using Steady-State Simulators           551 What You Will Learn   551 16.1 Why the Need for Advanced Topics in Steady-State Simulation?   552 16.2 User-Added Models   552 16.3 Solution Strategy for Steady-State Simulations   562 16.4 Studies with the Steady-State Simulation   581 16.5 Estimation of Physical Property Parameters   586 16.6 Summary   589 What You Should Have Learned   590 References   590 Short Answer Questions   591 Problems   592   Chapter 17: Using Dynamic Simulators in Process Design          601 What You Will Learn   601 17.1 Why Is There a Need for Dynamic Simulation?   602 17.2 Setting Up a Dynamic Simulation   603 17.3 Dynamic Simulation Solution Methods   618 17.4 Process Control   624 17.5 Summary   632 What You Should Have Learned   632 References   633 Short Answer Questions   633 Problems   634   Chapter 18: Regulation and Control of Chemical Processes with Applications Using Commercial Software          641 What You Will Learn   641 18.1 A Simple Regulation Problem   642 18.2 The Characteristics of Regulating Valves   643 18.3 Regulating Flowrates and Pressures   646 18.4 The Measurement of Process Variables   649 18.5 Common Control Strategies Used in Chemical Processes   649 18.6 Exchanging Heat and Work between Process and Utility Streams   660 18.7 Logic Control   666 18.8 Advanced Process Control   669 18.9 Case Studies   670 18.10 Putting It All Together: The Operator Training Simulator (OTS)   676 18.11 Summary 677 What You Should Have Learned   677 References   678 Problems   678   Section IV: Analysis Of Process Performance          683 Chapter 19: Process Input/Output Models          685 What You Will Learn   685 19.1 Representation of Process Inputs and Outputs   686 19.2 Analysis of the Effect of Process Inputs on Process Outputs   689 19.3 A Process Example   690 19.4 Summary   691 What You Should Have Learned   692 Problems   692   Chapter 20: Tools for Evaluating Process Performance         693 What You Will Learn   693 20.1 Key Relationships   693 20.2 Thinking with Equations   694 20.3 Base-Case Ratios   696 20.4 Analysis of Systems Using Controlling Resistances   698 20.5 Graphical Representations   700 20.6 Summary   704 What You Should Have Learned   705 References   705 Problems   705   Chapter 21: Performance Curves for Individual Unit Operations            707 What You Will Learn   707 21.1 Application to Heat Transfer   709 21.2 Application to Fluid Flow   714 21.3 Application to Separation Problems   728 21.4 Summary   740 What You Should Have Learned   741 References   741 Short Answer Questions   741 Problems   743   Chapter 22: Performance of Multiple Unit Operations           749 What You Will Learn   749 22.1 Analysis of a Reactor with Heat Transfer   749 22.2 Performance of a Distillation Column   754 22.3 Performance of a Heating Loop   759 22.4 Performance of the Feed Section to a Process   765 22.5 Summary   768 What You Should Have Learned   769 References   769 Short Answer Questions   769 Problems   769   Chapter 23: Reactor Performance          785 What You Will Learn   785 23.1 Production of Desired Product   786 23.2 Reaction Kinetics and Thermodynamics   788 23.3 The Chemical Reactor   791 23.4 Heat Transfer in the Chemical Reactor   796 23.5 Reactor System Case Studies   799 23.6 Summary   812 What You Should Have Learned   813 References   813 Short Answer Questions   813 Problems   814   Chapter 24: Process Troubleshooting and Debottlenecking           819 What You Will Learn   819 24.1 Recommended Methodology   821 24.2 Troubleshooting Individual Units   825 24.3 Troubleshooting Multiple Units   831 24.4 A Process Troubleshooting Problem   836 24.5 Debottlenecking Problems   840 24.6 Summary   841 What You Should Have Learned   841 References   841 Problems   841   Section V: The Impact of Chemical Engineering Design on Society            853 Chapter 25: Ethics and Professionalism             855 What You Will Learn   855 25.1 Ethics   856 25.2 Professional Registration   874 25.3 Legal Liability   879 25.4 Business Codes of Conduct   880 25.5 Summary   881 What You Should Have Learned   881 References   882 Problems   882   Chapter 26: Health, Safety, and the Environment           885 What You Will Learn   885 26.1 Risk Assessment   886 26.2 Regulations and Agencies   888 26.3 Fires and Explosions 898 26.4 Process Hazard Analysis   900 26.5 Chemical Safety and Hazard Investigation Board   909 26.6 Inherently Safe Design   909 26.7 Summary   910 26.8 Glossary   910 What You Should Have Learned   912 References   912 Problems   913   Chapter 27: Green Engineering             915 What You Will Learn   915 27.1 Environmental Regulations   915 27.2 Environmental Fate of Chemicals   916 27.3 Green Chemistry   919 27.4 Pollution Prevention during Process Design   920 27.5 Analysis of a PFD for Pollution Performance and Environmental Performance   922 27.6 An Example of the Economics of Pollution Prevention   923 27.7 Life Cycle Analysis   924 27.8 Summary   926 What You Should Have Learned   926 References   926 Problems   927   Section VI: Interpersonal And Communication Skills             929 Chapter 28: Teamwork           931 What You Will Learn   931 28.1 Groups   931 28.2 Group Evolution   940 28.3 Teams and Teamwork   943 28.4 Misconceptions   945 28.5 Learning in Teams   946 28.6 Other Reading   947 28.7 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  

About the Author :
Richard Turton is professor of chemical engineering and professor in the Statler College of Engineering and Mineral Resources at West Virginia University. He has taught WVU’s senior design course for more than twenty-five years.   Richard C. Bailie, professor emeritus at WVU, taught chemical engineering design for more than twenty years. He has extensive experience in process evaluation, pilot plant operation, and plant startup.   Wallace B. Whiting, professor emeritus at the University of Nevada, Reno, has practiced and taught chemical process design for more than twenty-four years.   Joseph A. Shaeiwitz has been involved in WVU’s senior design sequence and sophomore- and junior-level integrated design projects for twenty years.   Debangsu Bhattacharyya, associate professor in the department of chemical engineering at WVU, has worked in computer-aided simulation, design, construction, and in the operation of a large petroleum refinery for more than ten years.