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

The new 4th edition of Seider’s Product and Process Design Principles: Synthesis, Analysis and Design covers content for process design courses in the chemical engineering curriculum, showing how process design and product design are inter-linked and why studying the two is important for modern applications. A principal objective of this new edition is to describe modern strategies for the design of chemical products and processes, with an emphasis on a systematic approach. This fourth edition presents two parallel tracks: (1) product design, and (2) process design, with an emphasis on process design. Process design instructors can show easily how product designs lead to new chemical processes. Alternatively, product design can be taught in a separate course subsequent to the process design course.

Table of Contents:
PART ONE INTRODUCTION TO PRODUCT AND PROCESS DESIGN 1 Chapter 1 Introduction to Chemical Product Design 3 1.0 Objectives 3 1.1 Introduction 3 1.2 The Diversity of Chemical Products 3 1.3 Product Design and Development 7 1.4 Summary 16 References 17 Exercises 17 Chapter 2 Introduction to Process Design 19 2.0 Objectives 19 2.1 Introduction 19 2.2 Experiments 21 2.3 Preliminary Process Synthesis 21 2.4 Next Process Design Tasks 40 2.5 Preliminary Flowsheet Mass Balances 41 2.6 Summary 45 References 45 Exercises 45 Chapter 3 Design Literature, Stimulating Innovation, Energy, Environment, Sustainability, Safety, Engineering Ethics 47 3.0 Objectives 47 3.1 Design Literature 47 3.2 Stimulating Invention and Innovation 50 3.3 Energy Sources 51 3.4 Environmental Protection 56 3.5 Sustainability 60 3.6 Safety Considerations 63 3.7 Engineering Ethics 70 3.8 Summary 73 References 73 Exercises 74 3S Supplement to Chapter 3—NSPE Code of Ethics (Online www.wiley.com/college/Seider) PART TWO DESIGN SYNTHESIS—PRODUCT AND PROCESSES 77 Chapter 4 Molecular and Mixture Design 79 4.0 Objectives 79 4.1 Introduction 79 4.2 Framework for Computer-Aided Molecular-Mixture Design 81 4.3 Case Studies 98 4.4 Summary 107 References 107 Exercises 108 Chapter 5 Design of Chemical Devices, Functional Products, and Formulated Products 110 5.0 Objectives 110 5.1 Introduction 110 5.2 Design of Chemical Devices and Functional Products 112 5.3 Design of Formulated Products 117 5.4 Design of Processes for B2C Products 123 5.5 Summary 126 References 127 Exercises 127 Chapter 6 Heuristics for Process Synthesis 132 6.0 Objectives 132 6.1 Introduction 133 6.2 Raw Materials and Chemical Reactions 133 6.3 Distribution of Chemicals 135 6.4 Separations 141 6.5 Heat Removal From and Addition to Reactors 145 6.6 Heat Exchangers and Furnaces 148 6.7 Pumping, Compression, Pressure Reduction, Vacuum, and Conveying of Solids 150 6.8 Changing the Particle Size of Solids and Size Separation of Particles 153 6.9 Removal of Particles From Gases and Liquids 154 6.10 Considerations that Apply to the Entire Flowsheet 154 6.11 Summary 155 References 159 Exercises 160 Chapter 7 Simulation to Assist in Process Creation 162 7.0 Objectives 162 7.1 Introduction 162 7.2 Principles of Process Simulation 163 7.3 Process Creation through Process Simulation 176 7.4 Case Studies 184 7.5 Principles of Batch Flowsheet Simulation 194 7.6 Summary 201 References 202 Exercises 202 Chapter 8 Synthesis of Networks Containing Reactors 209 8.0 Objectives 209 8.1 Introduction 209 8.2 Reactor Models in the Process Simulators 210 8.3 Reactor Network Design Using the Attainable Region 215 8.4 Reactor Design for Complex Configurations 220 8.5 Locating the Separation Section with Respect to the Reactor Section 224 8.6 Trade-Offs in Processes Involving Recycle 227 8.7 Optimal Reactor Conversion 228 8.8 Recycle to Extinction 229 8.9 Snowball Effects in the Control of Processes Involving Recycle 231 8.10 Summary 231 References 232 Exercises 232 Chapter 9 Synthesis of Separation Trains 234 9.0 Objectives 234 9.1 Introduction 234 9.2 Criteria for Selection of Separation Methods 241 9.3 Selection of Equipment 244 9.4 Sequencing of Ordinary Distillation Columns for the Separation of Nearly Ideal Liquid Mixtures 245 9.5 Sequencing of Operations for the Separation of Nonideal Liquid Mixtures 257 9.6 Separation Systems for Gas Mixtures 277 9.7 Separation Systems for Solid-Fluid Mixtures 279 9.8 Summary 280 References 280 Exercises 282 Chapter 10 Second-Law Analysis 287 10.0 Objectives 287 10.1 Introduction 287 10.2 The System and the Surroundings 289 10.3 Energy Transfer 289 10.4 Thermodynamic Properties 290 10.5 Equations for Second-Law Analysis 295 10.6 Examples of Lost-Work Calculations 297 10.7 Thermodynamic Efficiency 299 10.8 Causes of Lost Work 300 10.9 Three Examples of Second-Law Analysis 300 10.10 Summary 310 References 310 Exercises 310 Chapter 11 Heat and Power Integration 316 11.0 Objectives 316 11.1 Introduction 316 11.2 Minimum Utility Targets 319 11.3 Networks for Maximum Energy Recovery 325 11.4 Minimum Number of Heat Exchangers 329 11.5 Threshold Approach Temperature 334 11.6 Optimum Approach Temperature 336 11.7 Multiple Utilities 337 11.8 Heat-Integrated Reactors and Distillation Trains 342 11.9 Heat Engines and Heat Pumps 348 11.10 Summary 351 Heat Integration Software 351 References 352 Exercises 352 11S-1 Supplements to Chapter 11—MILP and MINLP Applications in HEN Synthesis (Online www.wiley.com/college/Seider) 11S-1.0 Objectives 11S-1.1 MER Targeting Using Linear Programming (LP) 11S-1.2 MER Design Using Mixed-Integer Linear Programming (MINLP) 11S-1.3 Superstructures for Minimization of Annual Costs 11S-1.4 Case Studies Case Study 11S-1.1 Optimal Heat-Integration for the ABCDE Process Case Study 11S-1.2 Optimal Heat-Integration for an Ethylene Plant 11S-1.5 Summary 11S-1.6 References 11S-2 Supplement to Chapter 11—Mass Integration (Online www.wiley.com/college/Seider) 11S-2.0 Objectives 11S-2.1 Introduction 11S-2.2 Minimum Mass-Separating Agent 11S-2.3 Mass Exchange Networks for Minimum External Area 11S-2.4 Minimum Number of Mass Exchangers 11S-2.5 Advanced Topics 11S-2.6 Summary 11S-2.7 References Chapter 12 Heat Exchanger Design 358 12.0 Objectives 358 12.1 Introduction 358 12.2 Equipment for Heat Exchange 363 12.3 Heat-Transfer Coefficients and Pressure Drop 375 12.4 Design of Shell-and-Tube Heat Exchangers 380 12.5 Summary 384 References 384 Exercises 384 Chapter 13 Separation Tower Design 386 13.0 Objectives 386 13.1 Operating Conditions 386 13.2 Fenske-Underwood-Gilliland (FUG) Shortcut Method for Ordinary Distillation 387 13.3 Kremser Shortcut Method for Absorption and Stripping 388 13.4 Rigorous Multicomponent, Multiequilibrium-Stage Methods with a Simulator 389 13.5 Plate Efficiency and HETP 391 13.6 Tower Diameter 392 13.7 Pressure Drop and Weeping 393 13.8 Summary 395 References 395 Exercises 396 Chapter 14 Pumps, Compressors, and Expanders 397 14.0 Objectives 397 14.1 Pumps 397 14.2 Compressors and Expanders 401 14.3 Summary 403 References 404 Exercises 404 Chapter 15 Chemical Reactor Design 405 15.0 Objectives 405 15.1 Introduction 405 15.2 Limiting Approximate Models for Tubular Reactors 405 15.3 The COMSOL CFD Package 407 15.4 CFD for Tubular Reactor Models 410 15.5 Nonisothermal Tubular Reactor Models 418 15.6 Mixing in Stirred-Tank Reactors 423 15.7 Summary 424 References 425 Exercises 425 Chapter 16 Cost Accounting and Capital Cost Estimation 426 16.0 Objectives 426 16.1 Accounting 426 16.2 Cost Indexes and Capital Investment 434 16.3 Capital Investment Costs 438 16.4 Estimation of the Total Capital Investment 444 16.5 Purchase Costs of the Most Widely Used Process Equipment 449 16.6 Purchase Costs of Other Chemical Processing Equipment 470 16.7 Equipment Costing Spreadsheet 486 16.8 Equipment Sizing and Capital Cost Estimation Using Aspen Process Economic Analyzer (APEA) 486 16.9 Summary 493 References 493 Exercises 494 Chapter 17 Annual Costs, Earnings, and Profitability Analysis 498 17.0 Objectives 498 17.1 Introduction 498 17.2 Annual Sales Revenues, Production Costs, and the Cost Sheet 499 17.3 Working Capital and Total Capital Investment 509 17.4 Approximate Profitability Measures 510 17.5 Time Value of Money 513 17.6 Cash Flow and Depreciation 520 17.7 Rigorous Profitability Measures 525 17.8 Profitability Analysis Spreadsheet 529 17.9 Summary 545 References 546 Exercises 546 PART THREE DESIGN ANALYSIS—PRODUCT AND PROCESS 551 Chapter 18 Six-Sigma Design Strategies 553 18.0 Objectives 553 18.1 Introduction 553 18.2 Six-Sigma Methodology in Product Design and Manufacturing 553 18.3 Example Applications 557 18.4 Summary 564 References 564 Exercises 565 18S Supplement to Chapter 18 (Online www.wiley.com/college/Seider) 18S.1 Penicillin Fermenter Model 18S.2 Reactive Extraction and Re-extraction Model References Chapter 19 Business Decision Making in Product Development 566 19.0 Objectives 566 19.1 Introduction 566 19.2 Economic Analysis 566 19.3 Make-or-Buy Decisions 570 19.4 Microeconomics of Product Development 572 19.5 Company and Societal Factors Affecting Product Development 573 19.6 Summary 574 References 575 Exercises 575 Chapter 20 Plantwide Controllability Assessment 576 20.0 Objectives 576 20.1 Introduction 576 20.2 Control System Configuration 579 20.3 Qualitative Plantwide Control System Synthesis 584 20.4 Summary 590 References 590 Exercises 591 20S Supplement to Chapter 20 (Online www.wiley.com/college/Seider) 20S.0 Objectives 20S.1 Generation of Linear Models in Standard Forms 20S.2 Quantitative Measures for Controllability and Resiliency 20S.3 Towards Automated Flowsheet C&R Diagnosis 20S.4 Control Loop Definition and Tuning 20S.5 Case Studies Case Study 20S.1 Exothermic Reactor Design for the Production of Propylene Glycol Case Study 20S.2 Two Alternative Heat Exchanger Networks Case Study 20S.3 Interaction of design and Control in the MCB Separation Process 20S.6 MATLAB for C&R Analysis 20S.7 Summary References Exercises Chapter 21 Design Optimization 597 21.0 Objectives 597 21.1 Introduction 597 21.2 General Formulation of the Optimization Problem 598 21.3 Classification of Optimization Problems 599 21.4 Linear Programming (LP) 601 21.5 Nonlinear Programming (NLP) with a Single Variable 603 21.6 Conditions for Nonlinear Programming (NLP) by Gradient Methods with Two or More Decision Variables 605 21.7 Optimization Algorithm 607 21.8 Flowsheet Optimizations—Case Studies 609 21.9 Summary 611 References 612 Exercises 612 Chapter 22 Optimal Design and Scheduling of Batch Processes 616 22.0 Objectives 616 22.1 Introduction 616 22.2 Design of Batch Process Units 617 22.3 Design of Reactor–Separator Processes 620 22.4 Design of Single-product Processing Sequences 622 22.5 Design on Multiproduct Processing Sequences 625 22.6 Summary 626 References 626 Exercises 627 PART FOUR DESIGN REPORTS—PRODUCT AND PROCESS 629 Chapter 23 Written Reports and Oral Presentations 631 23.0 Objectives 631 23.1 Contents of the Written Report 632 23.2 Preparation of the Written Report 636 23.3 Oral Design Presentations 638 23.4 Award Competition 641 23.5 Summary 641 References 641 PART FIVE CASE STUDIES—PRODUCT AND PROCESS DESIGNS 643 Chapter 24 Case Study 1—Home Hemodialysis Devices 645 24.0 Objectives 645 24.1 Hemodialysis Technology 645 24.2 Design Specifications of Home Hemodialysis Device 652 24.3 Summary 655 References 655 Bibliography Patents—Hemodialysis Devices—General 655 Patents—Hemodialysis Devices—Hollow-Fiber Membranes 656 Patents—Hemodialysis Devices—Dialysate Regeneration 656 Patents—Hemodialysis Devices—Alarms/User Interface 656 Exercises 656 Chapter 25 Case Study 2—High Throughput Screening Devices for Kinase Inhibitors 657 25.0 Objectives 657 25.1 Background Technology For High Throughput Screening of Kinase Inhibitors 657 25.2 Product Concept 665 25.3 Prototyping 669 25.4 Product Development 672 25.5 Summary 672 References 672 Patents 673 Exercises 673 Chapter 26 Case Study 3—Die Attach Adhesive: A Case Study of Product Development 674 26.0 Objectives 674 26.1 Background of Technology 674 26.2 Market Study 674 26.3 Product Design 677 26.4 Process Design 678 26.5 Prototyping 678 26.6 Estimation of Product Cost 679 26.7 Summary 680 References 680 Exercises 681 Chapter 27 Case Study 4—Ammonia Process 683 27.0 Objectives 683 27.1 Introduction 683 27.2 Initial Base Case Design 686 27.3 Design Refinement 692 Postscript 699 References 703 Exercises 703 APPENDICES I. Residue Curves for Heterogeneous Systems 704 II. Design Problem Statements by Area 705 III. Materials of Construction 709 INDICES Table of Acronyms 711 Author Index 719 Subject Index 725

About the Author :
Warren 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 has authored or coauthored over 110 journal articles and authored or edited seven books. He helped to organize the CACHE (Computer Aids for Chemical Engineering Education) Committee in 1969 and served as its chairman. Seider is a member of the Editorial Advisory Board of Computers and Chemical Engineering. Daniel R. Lewin is Professor of Chemical Engineering, the Churchill Family Chair, 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. He has authored or co-authored over 100 technical publications in the area of process systems engineering, as well as the first three editions of this textbook, and the multimedia CD that accompanies it. J. D. Seader is Professor Emeritus 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. In 2004, he received, with Professor Warren D. Seider, the Warren K. Lewis Award for Chemical Engineering Education from the AIChE. In 2008, his textbook, "Separation Process Principles" with co-author Ernest J. Henley, was cited as one of 30 ground-breaking books in the last 100 years of chemical engineering. Soemantri Widagdo is a retired R&D executive after a 15-year career at 3M. His last position was the R&D Head of 3M Southeast Asia. He received his B.S. degree in chemical engineering from Bandung Institute of Technology, Indonesia, and his M.Ch.E. and Ph.D. degrees from Stevens Institute of Technology. He has been involved in a variety of technology and product-development programs involving renewable energy, industrial and transportation applications, consumer office products, electrical and electronics applications, health care and dentistry, and display and graphics applications. He has authored and co-authored over 20 technical publications and two patents. Rafiqul Gani is Professor of System Design at the Department of Chemical & Biochemical Engineering, The Technical University of Denmark and the head and co-founder of the Computer Aided Product-Process Engineering Center (CAPEC). He received a B.S degree from the Bangladesh University of Engineering and Technology, and M.S., DIC and Ph.D. degrees from Imperial College, London. He has published more than 200 peer-reviewed journal articles and delivered over 300 lectures, seminars and plenary/keynote lectures at international conferences, institutions and companies all over the world. Professor Gani is currently (2014-2016) the president of the EFCE (European Federation of Chemical Engineering); a member of the Board of Trustees of the AIChE; a Fellow of the AIChE and also a Fellow of IChemE. Ka Ming Ng is Chair Professor of Chemical and Biomolecular Engineering at the Hong Kong University of Science and Technology. He obtained his B.S. degree from the University of Minnesota and his Ph.D. from the University of Houston. His research interests center on product conceptualization, process design and business development involving water, natural herbs, nanomaterials, and advanced materials. He is a fellow of the American Institute of Chemical Engineers where he received the Excellence in Process Development Research Award in 2002.