Practical Process Design for Chemical Engineers

In-depth and practical textbook resource on chemical engineering processes, ranging from fundamentals to advanced aspects Practical Process Design for Chemical Engineers presents an extensive overview of the fundamental and advanced aspects of chemical engineering processes. Spanning 20 chapters, the book delves into various processes, equipment, and methodologies essential for modern chemical engineering, from basic principles to specific applications such as reactors, separations, and process integration. Each chapter systematically covers both theoretical concepts and practical applications, emphasizing process design, operational efficiency, environmental considerations, and safety. The book aims to equip chemical engineers with a robust toolkit for tackling diverse challenges in the industry, emphasizing innovation, sustainability, and the integration of new technologies. Unlike conventional texts that often focus primarily on established methods and theoretical fundamentals, this book actively explores innovative technologies and strategies to enhance efficiency and minimize environmental impact. Additionally, the book places significant emphasis on practical experience and real-world applications, imbuing readers not only with theoretical knowledge but also with practical skills and an understanding of industry trends. The book covers: Creativity, choice, and decision-making in chemical engineering, emphasizing the artistic and imaginative aspects of process design Solids processes such as size reduction, granulation, particle measurement and classification, and the conveyance of solids Principles and methods employed to mix diverse materials such as miscible and immiscible liquids, gases with liquids, and solids with liquids or gases Critical aspects of heat exchange in chemical processes, focusing on the heating, cooling, and phase changes of various substances Estimation of process engineering hours With detailed discussions on process intensification and the latest developments in solvent and reactor technologies, and a focus on modern, sustainable practices alongside traditional engineering concepts, this book serves as a vital resource for students and professionals seeking to polish and hone their knowledge and practice in chemical engineering design.

Table of Contents:
Preface xiv To Keith: Dedication and Foreword xv Acknowledgments xvii 1 A Plan for Process Design 1 1.1 Principles of Process Design 1 1.2 Operations and Equipment 2 2 Documentation and Communication 5 2.1 Basic Data 6 2.2 Process Flow Diagram (PFD) 6 2.3 Equipment List 9 2.4 Piping and Instrumentation Diagram (P&ID) 9 2.5 Equipment Data Sheets 12 2.6 Monitoring and Control Data Sheets 12 2.7 Functional Specification for Distributed Control System (DCS) 12 2.8 Scope of Work 12 2.9 Notes from Process Hazard Reviews 13 2.10 Input to Applications for Environmental Approval 13 2.11 Operating Instructions 13 2.12 Maintenance Instructions 13 2.13 Record of Design Calculations 14 2.14 People Communications 14 References 14 3 Introduction to Synthesis 17 3.1 Economic Basis of Synthesis 18 3.2 The Rate Concept 19 3.3 Achieving Driving Force: Some Patterns in Single-Stream Processes 22 3.4 Achieving Driving Force: Some Patterns in Two-Stream Processes 27 3.5 Summary of Synthesis 31 4 Experimentation and Modeling in Support of Design 33 4.1 A Systematic Review of Process Design 33 4.2 Pilot Plants and Scale-up 39 4.3 Mathematical Modeling 43 References 45 5 Operating Problems: Solution by Design 47 5.1 Buildup of Extraneous Substances 47 5.2 Corrosion 48 5.3 Erosion and Cavitation 49 5.4 Flashing and Phase Separation 50 5.5 Excessive Foaming and Entrainment 50 5.6 Interaction Between Units 51 5.7 Liquid Hammer and Vibrations 52 5.8 Restrictions in Piping Systems 53 5.9 Scaling and Fouling 54 5.10 Static Buildup 54 References 55 6 Process Monitoring and Control 57 6.1 Options for Measurement of Control Variables (CVs) 57 6.2 Combinations of Controllers for Specific Purposes 67 6.3 Causes of Non-Optimum Control 71 6.4 Programmable Controllers and Distributed Control Systems 74 7 Design for Safety and Health 77 7.1 Identification of Safety and Health Hazards 77 7.2 Process Design for Hazard Control: Equipment 79 7.3 Process Design for Hazard Control: Instrumentation 81 7.4 Process Reviews for Safety and Health 83 7.5 Training and Operating Procedures (PSM #3, #2) 85 7.6 Pre-Startup Safety and Health Review 86 References 86 8 Protecting the Environment 87 8.1 Consumption 88 8.2 Emission of Waste 92 References 103 9 Capital Cost Estimating and Economic Analysis 109 9.1 What Is an Estimate 109 9.2 Why Estimate 110 9.3 The What and Why of Economic Analysis 110 9.4 A Process Engineer’s Role in Estimating 111 9.5 Estimate Types and Methods 111 9.6 Detailed Capital Cost Estimates and Design/Build Projects 120 9.7 Hybrid Capital Cost Estimates 121 9.8 Estimate Summaries and Additional Factors 122 9.9 Economic Analysis 126 9.10 Risk Analysis of Project Economics 131 References 136 10 Project Management 139 10.1 Introduction 139 10.2 Comparison of Academic Versus Industry Project Environments 139 10.3 The Core Principles of Project Management 140 10.4 Phases of a Project 140 10.5 Business Phases of a Project 147 10.6 Engineering Project Phases 148 10.7 Project Initiation: Project Charter and Project Business Objectives 149 10.8 Project Initiation for Chemical Engineering Projects 150 10.9 Chemical Engineering Project Planning 151 References 163 11 Storage and Bulk Transport 165 11.1 Choose the Phase of the Material to be Stored 165 11.2 Choose the Volume of Storage Required 165 11.3 Choose a Design Pressure 166 11.4 Selecting a Tank Type 168 11.5 Storage of Gases 168 11.6 Storage of Liquids 169 11.7 Solid Storage 174 11.8 Bulk Shipping 174 References 177 12 In-Plant Transfer of Liquids and Liquid Mixtures with Gases and Solids 181 12.1 Flow of Liquids in Single Phase: Newtonian and Non-Newtonian 181 12.2 Two-Phase Flows 185 12.3 Liquid Movers – Dynamic 194 12.4 Liquid Movers – Positive Displacement and Other Pumps 201 12.5 Ancillary Equipment 205 References 211 13 Transfer of Gases: Compression and Vacuum 217 13.1 Compressible Flow 217 13.2 Gas Movers – General 221 13.3 Fans 222 13.4 Blowers 228 13.5 Compressors – Mechanical 230 13.6 Ejectors 235 13.7 Thermodynamics of Gas Compression 238 References 240 14 Formation and In-Plant Transfer of Solids 243 14.1 Solid’s Size Reduction 243 14.2 Cutting Mills 245 14.3 Formation of Granules 248 14.4 Measurement and Classification 251 14.5 In-Plant Transfer of Solids 252 14.6 In-Transit Storage 257 14.7 Solids Feeding 259 References 260 15 Heating, Cooling, and Change of Phase 263 15.1 Process Substances and Their Thermal Modifications 263 15.2 Heat Transfer Media 269 15.3 Insulation, Tracing, and Fouling 271 15.4 Shell-and-tube Heat Exchangers 271 15.5 Plate-and-frame and Other Heat Exchangers 272 15.6 Modeling, Control, and Design Tools 272 15.7 Thermal Integration and Pinch Technology 273 References 278 16 Mixing and Agitation 283 16.1 Mixing or Blending of Miscible Liquids 283 16.2 Blending Calculation 287 16.3 Immiscible Liquids 291 16.4 Gas and Liquid 293 16.5 Solid Particles in Liquid 295 16.6 Solid Particles with Solid Particles 298 16.7 Solid Particles and Gas 299 References 300 17 Mechanical Separations 303 17.1 Liquid–Liquid Separations 303 17.2 Solid–Solid Separations 306 17.3 Gas–Liquid Separations 309 17.4 Gas–Solid Separations 312 17.5 Liquid–Solid Separations 314 References 319 18 Molecular Separations 323 18.1 Separation of Permanent Gases 323 18.2 Separation of Gas–Vapor Mixtures 326 18.3 Separation of Vapor Mixtures 327 18.4 Separation of Liquid Mixtures 328 18.5 Separation of Liquid Solutions from Dissolved Solids 331 18.6 Separations: Solid–Solid, Dissolved Fluids from Solid 334 References 335 19 Chemical Reactions 341 19.1 Gas-Phase Reactions 342 19.2 Liquid-Phase Reactions 344 19.3 Gas–Liquid Reactions 349 19.4 Reaction of Immiscible Liquids 350 19.5 Fluid–Solid Reactions, Non-Catalytic 350 19.6 Solid-Catalyzed Reactions 351 19.7 Bio-Reactions 352 References 355 20 Process Intensification and Integration 359 20.1 Mixing and Comminution 359 20.2 Enhanced Energy 361 20.3 Solvent Development 364 20.4 Novel Reactors 367 20.5 Combined Operations 369 References 370 Index 373

About the Author :
Keith Marchildon P. Eng, PhD, was an engineer who made important and lasting contributions to Chemical Engineering in Canada. He pioneered the development of a number of chemical engineering refresher courses that have been offered outside of DuPont, locally and nationally, and was the author of several design handbook chapters published by Wiley. Keith served on the CCPE task force that defined the essential elements of the core knowledge of the Chemical Engineering Discipline that is used in assessing credentials of foreign-trained engineers. David Mody, P. Eng. brings a broad experience to the book through his industrial and academic experience. He worked as a design engineer with Fluor Corporation for 17 years in the Fluor/ DuPont corporate alliance group, followed by 13 years as the final year design instructor of Chemical Engineering at Queen’s University at Kingston.