Book description
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.
Table of contents
- Title Page
- Copyright Page
- Contents
- Material on the CD-ROM
- Preface
- About the Authors
- List of Nomenclature
-
Section I. Conceptualization and Analysis of Chemical Processes
-
Chapter 1. Diagrams for Understanding Chemical Processes
- 1.1. Block Flow Diagram (BFD)
- 1.2. Process Flow Diagram (PFD)
- 1.3. Piping and Instrumentation Diagram (P&ID)
- 1.4. Additional Diagrams
- 1.5. Three-Dimensional Representation of a Process
- 1.6. The 3-D Plant Model
- 1.7. Operator and 3-D Immersive Training Simulators
- 1.8. Summary
- References
- Short Answer Questions
- Problems
-
Chapter 2. The Structure and Synthesis of Process Flow Diagrams
- 2.1. Hierarchy of Process Design
- 2.2. Step 1—Batch Versus Continuous Process
- 2.3. Step 2—The Input/Output Structure of the Process
- 2.4. Step 3—The Recycle Structure of the Process
- 2.5. Step 4—General Structure of the Separation System
- 2.6. Step 5—Heat-Exchanger Network or Process Energy Recovery System
- 2.7. Information Required and Sources
- 2.8. Summary
- References
- Short Answer Questions
- Problems
-
Chapter 3. Batch Processing
- 3.1. Design Calculations for Batch Processes
- 3.2. Gantt Charts and Scheduling
- 3.3. Nonoverlapping Operations, Overlapping Operations, and Cycle Times
- 3.4. Flowshop and Jobshop Plants
- 3.5. Product and Intermediate Storage and Parallel Process Units
- 3.6. Design of Equipment for Multiproduct Batch Processes
- 3.7. Summary
- References
- Short Answer Questions
- Problems
- Chapter 4. Chemical Product Design
- Chapter 5. Tracing Chemicals through the Process Flow Diagram
-
Chapter 6. Understanding Process Conditions
- 6.1. Conditions of Special Concern for the Operation of Separation and Reactor Systems
- 6.2. Reasons for Operating at Conditions of Special Concern
- 6.3. Conditions of Special Concern for the Operation of Other Equipment
- 6.4. Analysis of Important Process Conditions
- 6.5. Summary
- References
- Short Answer Questions
- Problems
-
Chapter 1. Diagrams for Understanding Chemical Processes
-
Section II. Engineering Economic Analysis of Chemical Processes
- Chapter 7. Estimation of Capital Costs
-
Chapter 8. Estimation of Manufacturing Costs
- 8.1. Factors Affecting the Cost of Manufacturing a Chemical Product
- 8.2. Cost of Operating Labor
- 8.3. Utility Costs
- 8.4. Raw Material Costs
- 8.5. Yearly Costs and Stream Factors
- 8.6. Estimating Utility Costs from the PFD
- 8.7. Cost of Treating Liquid and Solid Waste Streams
- 8.8. Evaluation of Cost of Manufacture for the Production of Benzene Via the Hydrodealkylation of Toluene
- 8.9. Summary
- References
- Short Answer Questions
- Problems
-
Chapter 9. Engineering Economic Analysis
- 9.1. Investments and the Time Value of Money
- 9.2. Different Types of Interest
- 9.3. Time Basis for Compound Interest Calculations
- 9.4. Cash Flow Diagrams
- 9.5. Calculations from Cash Flow Diagrams
- 9.6. Inflation
- 9.7. Depreciation of Capital Investment
- 9.8. Taxation, Cash Flow, and Profit
- 9.9. Summary
- References
- Short Answer Questions
- Problems
-
Chapter 10. Profitability Analysis
- 10.1. A Typical Cash Flow Diagram for a New Project
- 10.2. Profitability Criteria for Project Evaluation
- 10.3. Comparing Several Large Projects: Incremental Economic Analysis
- 10.4. Establishing Acceptable Returns from Investments: The Concept of Risk
- 10.5. Evaluation of Equipment Alternatives
- 10.6. Incremental Analysis for Retrofitting Facilities
- 10.7. Evaluation of Risk in Evaluating Profitability
- 10.8. Profit Margin Analysis
- 10.9. Summary
- References
- Short Answer Questions
- Problems
-
Section III. Synthesis and Optimization of Chemical Processes
- Chapter 11. Utilizing Experience-Based Principles to Confirm the Suitability of a Process Design
-
Chapter 12. Synthesis of the PFD from the Generic BFD
- 12.1. Information Needs and Sources
- 12.2. Reactor Section
- 12.3. Separator Section
- 12.4. Reactor Feed Preparation and Separator Feed Preparation Sections
- 12.5. Recycle Section
- 12.6. Environmental Control Section
- 12.7. Major Process Control Loops
- 12.8. Flow Summary Table
- 12.9. Major Equipment Summary Table
- 12.10. Summary
- References
- General Reference
- Problems
-
Chapter 13. Synthesis of a Process Using a Simulator and Simulator Troubleshooting
- 13.1. The Structure of a Process Simulator
- 13.2. Information Required to Complete a Process Simulation: Input Data
- 13.3. Handling Recycle Streams
- 13.4. Choosing Thermodynamic Models
- 13.5. Case Study: Toluene Hydrodealkylation Process
- 13.6. Electrolyte Systems Modeling
- 13.7. Solids Modeling
- Appendix 13.1. Calculation of Excess Gibbs Energy for Electrolyte Systems
- 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
- 13.8. Summary
- References
- Short Answer Questions
- Problems
-
Chapter 14. Process Optimization
- 14.1. Background Information on Optimization
- 14.2. Strategies
- 14.3. Topological Optimization
- 14.4. Parametric Optimization
- 14.5. Lattice Search Techniques versus Response Surface Techniques
- 14.6. Process Flexibility and the Sensitivity of the Optimum
- 14.7. Optimization in Batch Systems
- 14.8. Summary
- References
- Short Answer Questions
- Problems
-
Chapter 15. Pinch Technology
- 15.1. Introduction
- 15.2. Heat Integration and Network Design
- 15.3. Composite Temperature-Enthalpy Diagram
- 15.4. Composite Enthalpy Curves for Systems without a Pinch
- 15.5. Using the Composite Enthalpy Curve to Estimate Heat-Exchanger Surface Area
- 15.6. Effectiveness Factor (F) and the Number of Shells
- 15.7. Combining Costs to Give the Eaoc for the Network
- 15.8. Other Considerations
- 15.9. Heat-Exchanger Network Synthesis Analysis and Design (HENSAD) Program
- 15.10. Mass-Exchange Networks
- 15.11. Summary
- References
- Short Answer Questions
- Problems
- Chapter 16. Advanced Topics Using Steady-State Simulators
- Chapter 17. Using Dynamic Simulators in Process Design
-
Chapter 18. Regulation and Control of Chemical Processes with Applications Using Commercial Software
- 18.1. A Simple Regulation Problem
- 18.2. The Characteristics of Regulating Valves
- 18.3. Regulating Flowrates and Pressures
- 18.4. The Measurement of Process Variables
- 18.5. Common Control Strategies Used in Chemical Processes
- 18.6. Exchanging Heat and Work Between Process and Utility Streams
- 18.7. Logic Control
- 18.8. Advanced Process Control
- 18.9. Case Studies
- 18.10. Putting it all Together: The Operator Training Simulator (OTS)
- 18.11. Summary
- References
- Problems
- Section IV. Analysis of Process Performance
-
Section V. The Impact of Chemical Engineering Design on Society
- Chapter 25. Ethics and Professionalism
- Chapter 26. Health, Safety, and the Environment
-
Chapter 27. Green Engineering
- 27.1. Environmental Regulations
- 27.2. Environmental Fate of Chemicals
- 27.3. Green Chemistry
- 27.4. Pollution Prevention During Process Design
- 27.5. Analysis of a PFD for Pollution Performance and Environmental Performance
- 27.6. An Example of the Economics of Pollution Prevention
- 27.7. Life Cycle Analysis
- 27.8. Summary
- References
- Problems
- Section VI. Interpersonal and Communication Skills
- Appendix A. Cost Equations and Curves for the CAPCOST Program
- Index
- Chapter 0. Outcomes Assessment
- Chapter 29. Written and Oral Communication
- Chapter 30. A Report-Writing Case Study
-
Appendix B. Information for the Preliminary Design of Fifteen Chemical Processes
- B.1. Dimethyl Ether (DME) Production, Unit 200
- B.2. Ethylbenzene Production, Unit 300
- B.3. Styrene Production, Unit 400
- B.4. Drying Oil Production, Unit 500
- B.5. Production Of Maleic Anhydride From Benzene, Unit 600
- B.6. Ethylene Oxide Production, Unit 700
- B.7. Formalin Production, Unit 800
- B.8. Batch Production Of L-Phenylalanine And L-Aspartic Acid, Unit 900
- B.9. Acrylic Acid Production Via The Catalytic Partial Oxidation Of Propylene [1, 2, 3, 4, 5], Unit 1000
- B.10. Production Of Acetone Via The Dehydrogenation Of Isopropyl Alcohol (IPA) [1, 2, 3, 4], Unit 1100
- B.11. Production Of Heptenes From Propylene And Butenes [1], Unit 1200
- B.12. Design of a Shift Reactor Unit to Convert Co To Co2, Unit 1300
- B.13. Design of a Dual-Stage Selexol Unit to Remove CO2 And H2S From Coal-Derived Synthesis Gas, Unit 1400
- B.14. Design of a Claus Unit For the Conversion of H2s to Elemental Sulfur, Unit 1500
- B.15. Modeling a Downward-Flow, Oxygen-Blown, Entrained-Flow Gasifier, Unit 1600
-
Appendix C. Design Projects
- Project 1. Increasing the Production of 3-Chloro-1-Propene (Allyl Chloride) in Unit 600
- PROJECT 2. Design and Optimization of a New 20,000-Metric-Tons-per-Year Facility to Produce Allyl Chloride at La Nueva Cantina, Mexico
- PROJECT 3. Scale-Down of Phthalic Anhydride Production at TBWS Unit 700
- PROJECT 4. The Design of a New 100,000-Metric-Tons-per-Year Phthalic Anhydride Production Facility
- PROJECT 5. Problems at the Cumene Production Facility, Unit 800
- PROJECT 6. Design of a New, 100,000-Metric-Tons-per-Year Cumene Production Facility
- Where are the Companion Content Files?
Product information
- Title: Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition
- Author(s):
- Release date: June 2012
- Publisher(s): Pearson
- ISBN: 9780132618724
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