Product and Process Design Principles: Synthesis, Analysis, and Evaluation

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. PRODUCT AND PROCESS INVENTION - HEURISTICS AND ANALYSIS.1. The Design Process.1.0 Objectives.1.1 Design Opportunities.1.2 Steps in Product Process Design.1.3 Environmental Protection.1.4 Safety Considerations.1.5 Engineering Ethics.1.6 Role of Computers.1.7 Summary.2. Molecular Structure Design.2.0 Objectives.2.1 Introduction.2.2 Property Estimation Methods.2.3 Optimization to Locate Molecular Structure.2.4 Summary.3. Process Creation.3.0 Objectives.3.1 Introduction.3.2 Preliminary Database Creation.3.3 Experiments.3.4 Preliminary Process Synthesis.3.5 Development of the Base-case Deign.3.6 Summary.4. Simulation to Assist in Process Creation.4.0 Objectives.4.1 Introduction.4.2 Principles of Steady-state Flowsheet Simulation.4.3 Synthesis of the Toluene Hydrodealkylation Process.4.4 Steady-state Simulation of the Monochlorobenzene Separation Process.4.5 Principles of Batch Flowsheet Simulation.4.6 Summary.5. Heuristics for Process Synthesis.5.0 Objectives.5.1 Introduction.5.2 Raw Materials and Chemical Reactions.5.3 Distribution of Chemicals.5.4 Separation.5.5 Heat Removal From and Addition to Reactors.5.6 Heat Exchangers and Furnaces.5.7 Pumping, Compression, Pressure Reduction, Vacuum, and Conveying of Solids.5.8 Changing the Particle Size of Solids and Size Separation of Particles.5.9 Removal of Particles from Gases and Liquids.5.10 Summary.PART TWO. DETAILED PROCESS SYNTHESIS - ALGORITHMIC METHODS.6. Reactor Design and Reactor Network Synthesis.6.0 Objectives.6.1 Reactor Models.6.2 Reactor Design for Complex Configurations.6.3 Reactor Network Design Using the Attainable Region.6.4 Summary.7. Synthesis of Separation Trains.7.0 Objectives.7.1 Introduction.7.2 Criteria for Selection of Separation Methods.7.3 Selection of Equipment.7.4 Sequencing of Ordinary Distillation for the Separation of Nearly Ideal Fluid Mixtures.7.5 Sequencing of Operations for the Separation of Nonideal Fluid Mixtures.7.6 Separation Systems for Gas Mixtures.7.7 Separation Sequencing for Solid-Fluid Systems.7.8 Summary.8. Reactor-Separator-Recycle Networks (CD-ROM).8.0 Objectives.8.1 Introduction.8.2 Locating the Separation Section with Respect to the Reactor Section.8.3 Tradeoffs in Processes Involving Recycle.8.4 Optimal Reactor Conversion.8.5 Recycle to Extinction.8.6 Snowball Effects in the Control of Processes Involving recycle.9. Second Law Analysis (CD-ROM).9.0 Objectives.9.1 Introduction.9.2 The System and the Surroundings.9.3 Energy Transfer.9.4 Thermodynamic Properties.9.5 Equations for Second Law Analysis.9.6 Examples of Lost-Work Calculations.9.7 Thermodynamic Efficiency.9.8 Causes of Lost Work.9.9 Three Examples of Second Law Analysis.9.10 Summary.10. Heat and Power Integration.10.0 Objectives.10.1 Introduction.10.2 Minimum Utility Targets.10.3 Networks for Maximum Energy Recovery.10.4 Minimum Number of Heat Exchangers.10.5 Threshold Approach Temperature.10.6 Optimum Approach Temperature.10.7 Superstructures for Minimization of Annual Costs.10.8 Multiple Utilities.10.9 Heat-integrated Distillation Trains.10.10 Heat Engines and Heat Pumps.10.11 Summary.11. Mass Integration.11.0 Objectives.11.1 Introduction.11.2 Minimum Mass Separating Agent.11.3 Mass Exchange Networks for Minimum External MSA.11.4 Minimum Number of Mass Exchangers.11.5 Advanced Topics.11.6 Summary.12. Optimal Design and Scheduling of Batch Processes.12.0 Objectives.12.1 Introduction.12.2 Design of Batch Process Units.12.3 Design of Reactor-separator Processes.12.4 Design of Single Product Processing Sequences.12.5 Design of Multi-Product Processing Sequencing.12.6 Summary.PART THREE. DETAILED DESIGN, EQUIPMENT SIZING,AND OPTIMIZATION - CONFIGURED PRODUCT DESIGN.13. Heat Exchanger Design.13.0 Objectives.13.1 Introduction.13.2 Equipment for Heat Exchange.13.3 Heat Transfer Coefficients and Pressure Drop.13.4 Design of Shell-and-Tube Heat Exchangers.13.5 Summary.14. Multisage and Packed Tower Design.14.0 Objectives.14.1 Operating Conditions.14.2 Fenske-Underwood-Gilliland (FUG) Shortcut Method for Ordinary Distillation.14.3 Kremer Shortcut Method for Absorption and Stripping.14.4 Rigorous Multicomponent, Multi-Equilibrium-Stage Methods with a Simulator.14.5 Plate Efficiency and HETP.14.6 Tower Diameter.14.7 Pressure Drop and Weeping.14.8 Summary.15. Pumps, Compressors, and Expanders.15.0 Objectives.15.1 Pumps.15.2 Compressors and Expanders.15.3 Summary.16. Cost Accounting and Capital Cost Estimation.16.0 Objectives.16.1 Accounting.16.2 Cost Indexes and Capital Investment for Commodity Chemicals.16.3 Capital Investment Costs.16.4 Estimation of the Total Capital Investment.16.5 Purchase Costs of the Most Widely Used Process Equipment.16.6 Purchase Costs of Other Chemical Processing Equipment.16.7 Equipment Cost Estimation Using the Icarus Process Evaluator (IPE) (CD-ROM).16.8 Summary.17. Annual Costs, Earnings, and Profitability Analysis.17.0 Objectives.17.1 Introduction.17.2 Annual Sales Revenues, Production Costs, and the Cost Sheet.17.3 Working Capital and Total Capital Investment.17.4 Approximate Profitability Measures.17.5 Time Value of Money.17.6 Cash Flow and Depreciation.17.7 Rigorous Profitability Measures.17.8 Profitability Analysis Using the Icarus Process Evaluator (IPE) (CD-ROM).17.9 Summary.18. Optimization of Process Flowsheets.18.0 Objectives.18.1 Introduction.18.2 General Formulation of the Optimization Problem.18.3 Classification of Optimization Problems.18.4 Linear Programming (LP).18.5 Nonlinear Programming (NLP) with a Single Variable.18.6 Conditions for Nonlinear Programming (NLP) by Gradient Methods with Two or More Decision Variables.18.7 Optimization Algorithm.18.8 Flowsheet Optimization - Case Studies.18.9 Summary.19. Product Design.19.0 Objectives.19.1 Steps in Designing Industrial and Consumer Products.19.2 Hemodialysis Device.19.3 Solar Desalination Unit.19.4 Hand Warmer.19.5 Multi-layer Polymer Mirrors.19.6 Silicon Coated Chips.19.7 Germ Killing Surfaces.19.8 Insect Repelling Wrist Band.19.9 Automotive Fuel Cell.19.10 Environmentally Safe Refrigerants.19.11 Summary.PART FOUR. PLANTWIDE CONTROLLABILITY ASSESSMENT.20. The Interaction of Process Design and Process Control.20.0 Objectives.20.1 Introduction.20.2 Control System Configuration.20.3 Qualitative Plantwide Control System Synthesis.20.4 Summary.21. Flowsheet Controllability Analysis.21.0 Objectives.21.1 Generation of Linear Models in Standard Forms.21.2 Quantitative Measures for Controllability and Resiliency.21.3 Toward Automated Flowsheet C&R Diagnosis.21.4 Control Loop Definition and Tuning.21.5 Case Studies.21.6 MATLAB for C&R Analysis.21.7 Summary.PART FIVE. DESIGN REPORT.22. Written Reports and Oral Presentations.22.0 Objectives.22.1 Contents of the Written Reports.22.2 Oral Design Presentation.22.3 Award Competition.22.4 Summary.Appendix I. Residue Curves for Heterogeneous Systems.Appendix II. Design Problem Statements (CD-ROM).Appendix III. Materials of Construction.Name Index.Subject Index.

About the Author :
Wareen D. Seider is Professor of Chemical Engineering at the University of Pennsylvania. He received a B.S. degree from the Polytechnic Institute of Brooklyn and M.S. and Ph.D. degrees from the University of Michigan. Seider has contributed to the fields of process analysis, simulation, design, and control. He co-authored FLOWTRAN. Simulation -An Introduction in 1974 and has coauthored the design course at Penn for over 20 years involving projects provided by many practicing engineers in the Philadelphia area. He has authored or coauthored over 80 journal articles and authored or edited six books. J.D. Seader is Professor of Chemical Engineering at the University of Utah. He received B.S. and M.S. degrees from the University of California at Berkeley and a Ph.D. from the University of Wisconsin. From 1952 to 1959, he designed processes for Chevron Research and directed the development of one of the first computer-aided process design programs. From 1959 to 1965, he conducted rocket engine research for Rocketdyne on all of the engines that took astronauts to the moon. Before joining the faculty at the University of Utah in 1966, Saeder was a professor at the University of Idaho. He is the author or coauthor of 109 technical articles, seven books, and four patents. Daniel R. Lewin is Professor of Chemical Engineering and the director of the Process Systems Engineering (PSE) research group at the Technion, the Israel Institute of Technology. He received his B.Sc. from the University of Edinburgh and his D.Sc. from the Technion. His research focuses on the interaction of Process design and process control and operations, with emphasis on model-based methods. He has authored and coauthored over 90 Technical publications in the area of process systems engineering, as well as the first edition of this textbook, and the multimedia CD that accompanies it.