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.
