Analysis, Synthesis, and Design of Chemical Processes (International Series in the Physical and Chemical Engineering Sciences)

The Leading Integrated Chemical Process Design Guide: With Extensive Coverage of Equipment Design and Other Key Topics More than ever, effective design is the focal point of sound chemical engineering. Analysis, Synthesis, and Design of Chemical Processes, Fifth Edition, presents design as a creative process that integrates the big-picture and small details, and knows which to stress when and why. Realistic from start to finish, it moves readers beyond classroom exercises into open-ended, real-world problem solving. The authors introduce up-to-date, integrated techniques ranging from finance to operations, and new plant design to existing process optimization. The fifth edition includes updated safety and ethics resources and economic factors indices, as well as an extensive, new section focused on process equipment design and performance, covering equipment design for common unit operations, such as fluid flow, heat transfer, separations, reactors, and more. Conceptualization and analysis: process diagrams, configurations, batch processing, product design, and analyzing existing processes Economic analysis: estimating fixed capital investment and manufacturing costs, measuring process profitability, and more Synthesis and optimization: process simulation, thermodynamic models, separation operations, heat integration, steady-state and dynamic process simulators, and process regulation Chemical equipment design and performance: a full section of expanded and revamped coverage of designing process equipment and evaluating the performance of current equipment Advanced steady-state simulation: goals, models, solution strategies, and sensitivity and optimization results Dynamic simulation: goals, development, solution methods, algorithms, and solvers Societal impacts: ethics, professionalism, health, safety, environmental issues, and green engineering Interpersonal and communication skills: working in teams, communicating effectively, and writing better reports This text draws on a combined 55 years of innovative instruction at West Virginia University (WVU) and the University of Nevada, Reno. It includes suggested curricula for one- and two-semester design courses, case studies, projects, equipment cost data, and extensive preliminary design information for jump-starting more detailed analyses. Cover......Page 0 About This E-Book......Page 2 Title Page......Page 3 Copyright Page......Page 4 Dedication Page......Page 5 Contents......Page 6 Preface......Page 26 About the Authors......Page 31 List of Nomenclature......Page 32 Chapter 0 Outcomes Assessment......Page 42 SECTION I Conceptualization and Analysis of Chemical Processes......Page 49 Chapter 1 Diagrams for Understanding Chemical Processes......Page 52 Chapter 2 The Structure and Synthesis of Process Flow Diagrams......Page 90 Chapter 3 Batch Processing......Page 130 Chapter 4 Chemical Product Design......Page 155 Chapter 5 Tracing Chemicals through the Process Flow Diagram......Page 168 Chapter 6 Understanding Process Conditions......Page 182 SECTION II Engineering Economic Analysis of Chemical Processes......Page 204 Chapter 7 Estimation of Capital Costs......Page 206 Chapter 8 Estimation of Manufacturing Costs......Page 236 Chapter 9 Engineering Economic Analysis......Page 272 Chapter 10 Profitability Analysis......Page 313 SECTION III Synthesis and Optimization of Chemical Processes......Page 360 Chapter 11 Utilizing Experience-Based Principles to Confirm the Suitability of a Process Design......Page 363 Chapter 12 Synthesis of the PFD from the Generic BFD......Page 386 Chapter 13 Synthesis of a Process Using a Simulator and Simulator Troubleshooting......Page 418 Chapter 14 Process Optimization......Page 500 Chapter 15 Pinch Technology......Page 541 Chapter 16 Advanced Topics Using Steady-State Simulators......Page 583 Chapter 17 Using Dynamic Simulators in Process Design......Page 625 Chapter 18 Regulation and Control of Chemical Processes with Applications Using Commercial Software......Page 669 SECTION IV Chemical Equipment Design and Performance Process Equipment Design and Performance......Page 714 Chapter 19 Process Fluid Mechanics......Page 716 Chapter 20 Process Heat Transfer......Page 776 Chapter 21 Separation Equipment......Page 865 Chapter 22 Reactors......Page 966 Chapter 23 Other Equipment......Page 1028 Chapter 24 Process Troubleshooting and Debottlenecking......Page 1086 SECTION V The Impact of Chemical Engineering Design on Society......Page 1129 Chapter 25 Ethics and Professionalism......Page 1131 Chapter 26 Health, Safety, and the Environment......Page 1164 Chapter 27 Green Engineering......Page 1191 SECTION VI Interpersonal and Communication Skills......Page 1208 Chapter 28 Teamwork......Page 1209 Chapter 29 Written and Oral Communication......Page 1232 Chapter 30 A Report-Writing Case Study......Page 1265 Appendix A Cost Equations and Curves for the CAPCOST Program......Page 1283 Appendix B Information for the Preliminary Design of Fifteen Chemical Processes......Page 1311 Appendix C Design Projects......Page 1404 Project 1 Increasing the Production of 3-Chloro-1-Propene (Allyl Chloride) in Unit 600......Page 1406 Project 2 Design and Optimization of a New 20,000-Metric-Tons-per-Year Facility to Produce Allyl Chloride at La Nueva Cantina, Mexico......Page 1419 Project 3 Scale-Down of Phthalic Anhydride Production at TBWS Unit 700......Page 1423 Project 4 The Design of a New 100,000-Metric-Tons-per-Year Phthalic Anhydride Production Facility......Page 1430 Project 5 Problems at the Cumene Production Facility, Unit 800......Page 1434 Project 6 Design of a New, 100,000-Metric-Tons-per-Year Cumene Production Facility......Page 1443 Index......Page 1446 Credits......Page 1549 Cover 1 About This E-Book 2 Title Page 3 Copyright Page 4 Dedication Page 5 Contents 6 Preface 26 About the Authors 31 List of Nomenclature 32 Chapter 0 Outcomes Assessment 42 SECTION I Conceptualization and Analysis of Chemical Processes 49 Chapter 1 Diagrams for Understanding Chemical Processes 52 Chapter 2 The Structure and Synthesis of Process Flow Diagrams 90 Chapter 3 Batch Processing 130 Chapter 4 Chemical Product Design 155 Chapter 5 Tracing Chemicals through the Process Flow Diagram 168 Chapter 6 Understanding Process Conditions 182 SECTION II Engineering Economic Analysis of Chemical Processes 204 Chapter 7 Estimation of Capital Costs 206 Chapter 8 Estimation of Manufacturing Costs 236 Chapter 9 Engineering Economic Analysis 272 Chapter 10 Profitability Analysis 313 SECTION III Synthesis and Optimization of Chemical Processes 360 Chapter 11 Utilizing Experience-Based Principles to Confirm the Suitability of a Process Design 363 Chapter 12 Synthesis of the PFD from the Generic BFD 386 Chapter 13 Synthesis of a Process Using a Simulator and Simulator Troubleshooting 418 Chapter 14 Process Optimization 500 Chapter 15 Pinch Technology 541 Chapter 16 Advanced Topics Using Steady-State Simulators 583 Chapter 17 Using Dynamic Simulators in Process Design 625 Chapter 18 Regulation and Control of Chemical Processes with Applications Using Commercial Software 669 SECTION IV Chemical Equipment Design and Performance Process Equipment Design and Performance 714 Chapter 19 Process Fluid Mechanics 716 Chapter 20 Process Heat Transfer 776 Chapter 21 Separation Equipment 865 Chapter 22 Reactors 966 Chapter 23 Other Equipment 1028 Chapter 24 Process Troubleshooting and Debottlenecking 1086 SECTION V The Impact of Chemical Engineering Design on Society 1129 Chapter 25 Ethics and Professionalism 1131 Chapter 26 Health, Safety, and the Environment 1164 Chapter 27 Green Engineering 1191 SECTION VI Interpersonal and Communication Skills 1208 Chapter 28 Teamwork 1209 Chapter 29 Written and Oral Communication 1232 Chapter 30 A Report-Writing Case Study 1265 Appendix A Cost Equations and Curves for the CAPCOST Program 1283 Appendix B Information for the Preliminary Design of Fifteen Chemical Processes 1311 Appendix C Design Projects 1404 Project 1 Increasing the Production of 3-Chloro-1-Propene (Allyl Chloride) in Unit 600 1406 Project 2 Design and Optimization of a New 20,000-Metric-Tons-per-Year Facility to Produce Allyl Chloride at La Nueva Cantina, Mexico 1419 Project 3 Scale-Down of Phthalic Anhydride Production at TBWS Unit 700 1423 Project 4 The Design of a New 100,000-Metric-Tons-per-Year Phthalic Anhydride Production Facility 1430 Project 5 Problems at the Cumene Production Facility, Unit 800 1434 Project 6 Design of a New, 100,000-Metric-Tons-per-Year Cumene Production Facility 1443 Index 1446 Credits 1549