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. Cover Half Title Practical Process Design for Chemical Engineers Copyright Contents Preface To Keith: Dedication and Foreword Acknowledgments 1. A Plan for Process Design 1.1 Principles of Process Design 1.2 Operations and Equipment 2. Documentation and Communication 2.1 Basic Data 2.2 Process Flow Diagram (PFD) 2.2.1 PFD for Batch Processes 2.3 Equipment List 2.4 Piping and Instrumentation Diagram (P&ID) 2.5 Equipment Data Sheets 2.6 Monitoring and Control Data Sheets 2.7 Functional Specification for Distributed Control System (DCS) 2.8 Scope of Work 2.9 Notes from Process Hazard Reviews 2.10 Input to Applications for Environmental Approval 2.11 Operating Instructions 2.12 Maintenance Instructions 2.13 Record of Design Calculations 2.14 People Communications References 3. Introduction to Synthesis 3.1 Economic Basis of Synthesis 3.2 The Rate Concept 3.3 Achieving Driving Force: Some Patterns in Single‐Stream Processes 3.4 Achieving Driving Force: Some Patterns in Two‐Stream Processes 3.5 Summary of Synthesis 4. Experimentation and Modeling in Support of Design 4.1 A Systematic Review of Process Design 4.1.1 Momentum Transfer Considerations (see also Chapter 12) 4.1.2 Heat (or Energy) Transfer Considerations (see also Chapter 14) 4.1.3 Mass Transfer Considerations (see also Chapters 17 and 20) 4.2 Pilot Plants and Scale‐up 4.2.1 Size and Cost of Pilot Plants 4.2.2 Equipment and Piping 4.2.3 Scale Considerations for Heat Transfer and for Flow Regime 4.3 Mathematical Modeling References 5. Operating Problems: Solution by Design 5.1 Buildup of Extraneous Substances 5.2 Corrosion 5.3 Erosion and Cavitation 5.4 Flashing and Phase Separation 5.5 Excessive Foaming and Entrainment 5.6 Interaction Between Units 5.7 Liquid Hammer and Vibrations 5.8 Restrictions in Piping Systems 5.9 Scaling and Fouling 5.10 Static Buildup References 6. Process Monitoring and Control 6.1 Options for Measurement of Control Variables (CVs) 6.1.1 Temperature 6.1.2 Flow 6.1.3 Level 6.1.4 Pressure 6.1.5 Concentration 6.2 Combinations of Controllers for Specific Purposes 6.3 Causes of Non‐Optimum Control 6.4 Programmable Controllers and Distributed Control Systems 7. Design for Safety and Health 7.1 Identification of Safety and Health Hazards 7.2 Process Design for Hazard Control: Equipment 7.3 Process Design for Hazard Control: Instrumentation 7.4 Process Reviews for Safety and Health 7.5 Training and Operating Procedures (PSM #3, #2) 7.6 Pre‐Startup Safety and Health Review References 8. Protecting the Environment 8.1 Consumption 8.1.1 Raw Materials 8.1.2 Consumption of Water 8.1.3 Consumption of Energy 8.2 Emission of Waste 8.2.1 Dealing with Liquid Waste 8.2.1.1 Biological Treatment of Wastewater 8.2.1.2 Other Treatments of Wastewater 8.2.2 Dealing with Gaseous Waste 8.2.2.1 Thermal Oxidation and Thermal Catalytic Oxidation 8.2.2.2 Other Treatments for Waste Gases 8.2.3 Nitrogen Oxides (NOx) 8.2.4 Fugitive Emissions 8.2.5 Odors 8.2.6 Greenhouse Gases 8.2.6.1 Carbon Dioxide 8.2.6.2 Alternative Sources of Energy 8.2.7 Auditing and Regulation of Greenhouse Gases (GHG) 8.2.8 Handling of Solid Waste References 9. Capital Cost Estimating and Economic Analysis 9.1 What Is an Estimate 9.2 Why Estimate 9.3 The What and Why of Economic Analysis 9.4 A Process Engineer's Role in Estimating 9.5 Estimate Types and Methods 9.5.1 Order of Magnitude 9.5.2 Licensor Estimate 9.5.3 Capacity Factored Estimate 9.5.4 Factored Equipment Estimate (FEE) 9.5.4.1 Obtaining Equipment Prices 9.5.4.2 Cost Indexes – Timing Is Important 9.5.4.3 Lang Factor Estimates 9.5.4.4 Guthrie Method 9.6 Detailed Capital Cost Estimates and Design/Build Projects 9.7 Hybrid Capital Cost Estimates 9.8 Estimate Summaries and Additional Factors 9.8.1 Grass Roots Factor 9.8.2 Allowance and Contingency – Estimating the Unknowns 9.8.2.1 Escalation 9.8.2.2 Allowance – Probability 1, but Unknown Costs 9.8.2.3 Contingency – Probability