Chemical Engineering Design Principles, Practice and Economics of Plant and Process Design.

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1 INTRODUCTION TO DESIGN Page 1

1.1. Introduction Page 2
1.2. Nature of Design Page 2
1.3. The Anatomy of a Chemical Manufacturing Process Page 8
1.4. The Organization of a Chemical Engineering Project Page 11
1.5. Project Documentation Page 13
1.6. Codes and Standards Page 16
1.7. Design Factors (Design Margins) Page 17
1.8. Systems of Units Page 18
1.9. Optimization Page 19
1.10. References Page 44
1.11. Nomenclature Page 44
1.12. Problems Page 45

2 FUNDAMENTALS OF MATERIAL BALANCES Page 49

2.1. Introduction Page 50
2.2. The Equivalence of Mass and Energy Page 50
2.3. Conservation of Mass Page 51
2.4. Units Used to Express Compositions Page 51
2.5. Stoichiometry Page 52
2.6. Choice of System Boundary Page 53
2.7. Choice of Basis for Calculations Page 56
2.8. Number of Independent Components Page 57
2.9. Constraints on Flows and Compositions Page 58
2.10. General Algebraic Method Page 59
2.11. Tie Components Page 60
2.12. Excess Reagent Page 62
2.13. Conversion, Selectivity, and Yield Page 63
2.14. Recycle Processes Page 68
2.15. Purge Page 70
2.16. Bypass Page 71
2.17. Unsteady-State Calculations Page 72
2.18. General Procedure for Material-Balance Problems Page 74
2.19. References Page 75
2.20. Nomenclature Page 75
2.21. Problems Page 76

3 FUNDAMENTALS OF ENERGY BALANCES AND ENERGY UTILIZATION Page 81

3.1. Introduction Page 82
3.2. Conservation of Energy Page 82
3.3. Forms of Energy (Per Unit Mass of Material) Page 83
3.4. The Energy Balance Page 84
3.5. Calculation of Specific Enthalpy Page 89
3.6. Mean Heat Capacities Page 90
3.7. The Effect of Pressure on Heat Capacity Page 92
3.8. Enthalpy of Mixtures Page 94
3.9. Enthalpy-Concentration Diagrams Page 95
3.10. Heats of Reaction Page 98
3.11. Standard Heats of Formation Page 101
3.12. Heats of Combustion Page 102
3.13. Compression and Expansion of Gases Page 104
3.14. Energy Balance Calculations Page 112
3.15. Unsteady State Energy Balances Page 113
3.16. Energy Recovery Page 114
3.17. Heat Exchanger Networks Page 124
3.18. References Page 145
3.19. Nomenclature Page 146
3.20. Problems Page 150

4 FLOWSHEETING Page 153

4.1. Introduction Page 154
4.2. Flowsheet Presentation Page 155
4.3. Process Simulation Programs Page 162
4.4. Specification of Components and Physical Property Models Page 165
4.5. Simulation of Unit Operations Page 169
4.6. User Models Page 204
4.7. Flowsheets with Recycle Page 207
4.8. Flowsheet Optimization Page 219
4.9. Dynamic Simulation Page 224
4.10. References Page 224
4.11. Nomenclature Page 225
4.12. Problems Page 226

5 PIPING AND INSTRUMENTATION Page 235

5.1. Introduction Page 236
5.2. The P and I Diagram Page 236
5.3. Valve Selection Page 241
5.4. Pumps and Compressors Page 243
5.5. Mechanical Design of Piping Systems Page 262
5.6. Pipe Size Selection Page 265
5.7. Control and Instrumentation Page 275
5.8. Typical Control Systems Page 277
5.9. Alarms, Safety Trips, and Interlocks Page 285
5.10. Computers in Process Control Page 287
5.11. References Page 289
5.12. Nomenclature Page 291
5.13. Problems Page 293

6 COSTING AND PROJECT EVALUATION Page 297

6.1. Introduction Page 298
6.2. Costs, Revenues, and Profits Page 298
6.3. Estimating Capital Costs Page 306
6.4. Estimating Production Costs and Revenues Page 334
6.5. Taxes and Depreciation Page 352
6.6. Project Financing Page 358
6.7. Economic Evaluation of Projects Page 363
6.8. Sensitivity Analysis Page 380
6.9. Project Portfolio Selection Page 384
6.10. References Page 388
6.11. Nomenclature Page 390
6.12. Problems Page 392

7 MATERIALS OF CONSTRUCTION Page 397

7.1. Introduction Page 398
7.2. Material Properties Page 398
7.3. Mechanical Properties Page 399
7.4. Corrosion Resistance Page 402
7.5. Selection for Corrosion Resistance Page 407
7.6. Material Costs Page 408
7.7. Contamination Page 409
7.8. Commonly Used Materials of Construction Page 410
7.9. Plastics as Materials of Construction for Chemical Plants Page 417
7.10. Ceramic Materials (Silicate Materials) Page 419
7.11. Carbon Page 421
7.12. Protective Coatings Page 421
7.13. Design for Corrosion Resistance Page 421
7.14. References Page 422
7.15. Nomenclature Page 424
7.16. Problems Page 424

8 DESIGN INFORMATION AND DATA Page 427

8.1. Introduction Page 428
8.2. Sources of Information on Manufacturing Processes Page 428
8.3. General Sources of Physical Properties Page 430
8.4. Accuracy Required of Engineering Data Page 432
8.5. Prediction of Physical Properties Page 433
8.6. Density Page 434
8.7. Viscosity Page 436
8.8. Thermal Conductivity Page 440
8.9. Specific Heat Capacity Page 442
8.10. Enthalpy of Vaporization (Latent Heat) Page 449
8.11. Vapor Pressure Page 451
8.12. Diffusion Coefficients (Diffusivities) Page 452
8.13. Surface Tension Page 455
8.14. Critical Constants Page 457
8.15. Enthalpy of Reaction and Enthalpy of Formation Page 460
8.16. Phase Equilibrium Data Page 460
8.17. References Page 472
8.18. Nomenclature Page 477
8.19. Problems Page 479

9 SAFETY AND LOSS PREVENTION Page 481

9.1. Introduction Page 482
9.2. Materials Hazards Page 486
9.3. Process Hazards Page 493
9.4. Analysis of Product and Process Safety Page 502
9.5. Failure-Mode Effect Analysis Page 503
9.6. Safety Indices Page 506
9.7. Hazard and Operability Studies Page 517
9.8. Quantitative Hazard Analysis Page 526
9.9. Safety Checklists Page 531
9.10. References Page 534
9.11. Nomenclature Page 538
9.12. Problems Page 538

10 EQUIPMENT SELECTION, SPECIFICATION, AND DESIGN Page 541

10.1. Introduction Page 542
10.2. Separation Processes Page 543
10.3. Solid-Solid Separations Page 543
10.4. Liquid-Solid (Solid-Liquid) Separators Page 550
10.5. Separation of Dissolved Solids Page 577
10.6. Liquid-Liquid Separation Page 582
10.7. Separation of Dissolved Liquids Page 590
10.8. Gas-Solid Separations (Gas Cleaning) Page 591
10.9. Gas-Liquid Separators Page 603
10.10. Crushing and Grinding (Comminution) Equipment Page 609
10.11. Mixing Equipment Page 609
10.12. Transport and Storage of Materials Page 620
10.13. Reactors Page 626
10.14. References Page 630
10.15. Nomenclature Page 635
10.16. Problems Page 637

11 SEPARATION COLUMNS (DISTILLATION, ABSORPTION, AND EXTRACTION) Page 641

11.1. Introduction Page 642
11.2. Continuous Distillation: Process Description Page 642
11.3. Continuous Distillation: Basic Principles Page 645
11.4. Design Variables in Distillation Page 650
11.5. Design Methods for Binary Systems Page 652
11.6. Multicomponent Distillation: General Considerations Page 665
11.7. Multicomponent Distillation: Shortcut Methods for Stage and Reflux Requirements Page 667
11.8. Multicomponent Systems: Rigorous Solution Procedures (Computer Methods) Page 693
11.9. Other Distillation Systems Page 697
11.10. Plate Efficiency Page 698
11.10.1. Prediction of Plate Efficiency Pg 720 - 722
11.10.2. OConnells Correlation Pg 722 - 724
11.10.3. Van Winkles Correlation Pg 724 - 725
11.10.4. AIChE Method Pg 725 - 729
11.10.5. Entrainment Pg 729 - 729
11.11. Approximate Column Sizing Pg 729 - 730 Page 708
Plate Spacing
Column Diameter
11.12. Plate Contactors Pg 730 - 737 Page 709
1. Sieve Plate (Perforated Plate)
2. Bubble-Cap Plates
3. Valve Plates (Floating Cap Plates)
Liquid Flow Pattern
11.12.1. Selection of Plate Type Pg 733 - 734
11.12.2. Plate Construction Pg 734 - 737
Sectional Construction
Stacked Plates (Cartridge Plates)
Downcomers
Side Stream and Feed Points
Structural Design
11.13. Plate Hydraulic Design Pg 737 - 762 Page 716
Operating Range
11.13.1. Plate-Design Procedure Pg 740 - 740
11.13.2. Plate Areas Pg 740 - 740
11.13.3. Diameter Pg 741 - 742
11.13.4. Liquid-Flow Arrangement Pg 742 - 742
11.13.5. Entrainment Pg 742 - 743
11.13.6. Weep Point Pg 743 - 745
11.13.7. Weir Liquid Crest Pg 745 - 745
11.13.8. Weir Dimensions Pg 746 - 747
Weir Height
Inlet Weirs
Weir Length
11.13.9. Perforated Area Pg 747 - 747
11.13.10. Hole Size Pg 747 - 748
11.13.11. Hole Pitch Pg 748 - 748
11.13.12. Hydraulic Gradient Pg 749 - 749
11.13.13. Liquid Throw Pg 749 - 749
11.13.14. Plate Pressure Drop Pg 749 - 751
Dry Plate Drop
Residual Head
Total Drop
11.13.15. Downcomer Design [Backup] Pg 751 - 762
Froth Height Pg 752 - 752
Downcomer Residence Time Pg 752 - 753
 Example 11.11 Pg 753 - 758
Flow Rates Pg 753 - 753
Physical Properties Pg 753 - 754
Column Diameter Pg 754 - 755
Liquid Flow Pattern Pg 755 - 755
Provisional Plate Design Pg 755 - 756
Check Weeping Pg 756 - 756
Plate Pressure Drop Pg 756 - 757
Downcomer Liquid Backup Pg 757 - 757
Check Entrainment Pg 757 - 757
Trial Layout Pg 758 - 758
Perforated Area Pg 758 - 758
Number of Holes Pg 758 - 758
Plate Specification Pg 758 - 758
Example 11.12 Pg 759 - 761
Example 11.13 Pg 761 - 761
11.14. Packed Columns Page 741
11.15. Column Auxiliaries Page 771
11.16. Solvent Extraction (Liquid-Liquid Extraction) Page 772
11.17. References Page 779
11.18. Nomenclature Page 784
11.19. Problems Page 789

12 HEAT TRANSFER EQUIPMENT Page 793

12.1. Introduction Page 794
12.2. Basic Design Procedure and Theory Page 795
12.3. Overall Heat Transfer Coefficient Page 796
12.4. Fouling Factors (Dirt Factors) Page 798
12.5. Shell and Tube Exchangers: Construction Details Page 801
12.6. Mean Temperature Difference (Temperature Driving Force) Page 815
12.7. Shell and Tube Exchangers: General Design Considerations Page 820
12.8. Tube-Side Heat Transfer Coefficient and Pressure Drop (Single Phase) Page 823
12.9. Shell-Side Heat Transfer and Pressure Drop (Single Phase) Page 829
12.10. Condensers Page 870
12.11. Reboilers and Vaporizers Page 890
12.12. Plate Heat Exchangers Page 918
12.13. Direct-Contact Heat Exchangers Page 929
12.14. Finned Tubes Page 930
12.15. Double-Pipe Heat Exchangers Page 931
12.16. Air-Cooled Exchangers Page 932
12.17. Fired Heaters (Furnaces and Boilers) Page 932
12.18. Heat Transfer to Vessels Page 938
12.19. References Page 945
12.20. Nomenclature Page 951
12.21. Problems Page 957

13 MECHANICAL DESIGN OF PROCESS EQUIPMENT Page 961

13.1. Introduction Page 962
13.2. Pressure Vessel Codes and Standards Page 963
13.3. Fundamental Principles and Equations Page 966
13.4. General Design Considerations: Pressure Vessels Page 980
13.5. The Design of Thin-Walled Vessels Under Internal Pressure Page 986
13.6. Compensation for Openings and Branches Page 993
13.7. Design of Vessels Subject to External Pressure Page 995
13.8. Design of Vessels Subject to Combined Loading Page 999
13.9. Vessel Supports Page 1013
13.10. Bolted Flanged Joints Page 1020
13.11. Heat Exchanger Tube Plates Page 1028
13.12. Welded-Joint Design Page 1031
13.13. Fatigue Assessment of Vessels Page 1033
13.14. Pressure Tests Page 1034
13.15. High-Pressure Vessels Page 1035
13.16. Liquid Storage Tanks Page 1038
13.17. Pressure-Relief Devices Page 1038
13.18. References Page 1053
13.19. Nomenclature Page 1056
13.18. Problems Page 1060

14 GENERAL SITE CONSIDERATIONS Page 1065

14.1. Introduction Page 1066
14.2. Plant Location and Site Selection Page 1066
14.3. Site Layout Page 1068
14.4. Plant Layout Page 1069
14.5. Utilities Page 1074
14.6. Environmental Considerations Page 1076
14.7. References Page 1086

APPENDIX Page 1089

A Graphical Symbols for Piping Systems and Plant Page 1089
B Corrosion Chart Page 1099
C Physical Property Data Bank Page 1119
D Conversion Factors for Some Common SI Units Page 1141
E Design Projects I Page 1145
F Design Projects II Page 1165
G Equipment Specification (Data) Sheets Page 1193
H Typical Shell and Tube Heat Exchanger Tube-Sheet Layouts Page 1207
I Material Safety Data Sheet Page 1213
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