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

1266 Pages·2007·23.26 MB·English

by  Gavin Towler

CHEMICAL ENGINEERING
DESIGN
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CHEMICAL ENGINEERING
DESIGN
Principles, Practice and
Economics of Plant and
Process Design
GAVIN TOWLER
RAY SINNOTT
AMSTERDAM (cid:127) BOSTON (cid:127) HEIDELBERG (cid:127) LONDON
NEW YORK (cid:127) OXFORD (cid:127) PARIS (cid:127) SAN DIEGO
SAN FRANCISCO (cid:127) SINGAPORE (cid:127) SYDNEY (cid:127) TOKYO
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PrintedintheUnitedStatesofAmerica
07 08 09 10 9 8 7 6 5 4 3 2 1
CoverDesign:JoeTenerelli
GavinTowleristheSeniorManagerofProcessDesign,ModelingandEquipmentatUOPLLC.
Hemanagestheareasofprocessdesignandoptimization,equipmentdesign,andphysicalandkinetic
modelingforUOPResearchandDevelopment.AsadjunctprofessoratNorthwesternUniversity,
heteachesthechemicalengineeringseniordesignclasses.HeisaCharteredEngineerandFellowof
theInstituteofChemicalEngineers.
RaySinnottbeganhiscareerindesignanddevelopmentwithseveralmajorcompanies,including
DuPontandJohnBrown.HelaterjoinedtheChemicalEngineeringDepartmentattheUniversityof
Wales,Swansea,UK,publishingthefirsteditionofChemicalEngineeringDesignin1983.Heisa
CharteredEngineer,Eur.Ing.andFellowoftheInstituteofChemicalEngineers.
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CONTENTS
PREFACE xv
HOWTOUSETHISBOOK xvii
ACKNOWLEDGMENTS xix
1
INTRODUCTION TO DESIGN 1
1.1. Introduction 2
1.2. NatureofDesign 2
1.3. TheAnatomyofaChemicalManufacturingProcess 8
1.4. TheOrganizationofaChemicalEngineeringProject 11
1.5. ProjectDocumentation 13
1.6. CodesandStandards 16
1.7. DesignFactors(DesignMargins) 17
1.8. SystemsofUnits 18
1.9. Optimization 19
1.10. References 44
1.11. Nomenclature 44
1.12. Problems 45
2
FUNDAMENTALS OF MATERIAL BALANCES 49
2.1. Introduction 50
2.2. TheEquivalenceofMassandEnergy 50
2.3. ConservationofMass 51
2.4. UnitsUsedtoExpressCompositions 51
2.5. Stoichiometry 52
2.6. ChoiceofSystemBoundary 53
2.7. ChoiceofBasisforCalculations 56
2.8. NumberofIndependentComponents 57
2.9. ConstraintsonFlowsandCompositions 58
2.10. GeneralAlgebraicMethod 59
vii
viii CONTENTS
2.11. TieComponents 60
2.12. ExcessReagent 62
2.13. Conversion,Selectivity,andYield 63
2.14. RecycleProcesses 68
2.15. Purge 70
2.16. Bypass 71
2.17. Unsteady-StateCalculations 72
2.18. GeneralProcedureforMaterial-BalanceProblems 74
2.19. References 75
2.20. Nomenclature 75
2.21. Problems 76
3
FUNDAMENTALS OF ENERGY BALANCES AND ENERGY
UTILIZATION 81
3.1. Introduction 82
3.2. ConservationofEnergy 82
3.3. FormsofEnergy(PerUnitMassofMaterial) 83
3.4. TheEnergyBalance 84
3.5. CalculationofSpecificEnthalpy 89
3.6. MeanHeatCapacities 90
3.7. TheEffectofPressureonHeatCapacity 92
3.8. EnthalpyofMixtures 94
3.9. Enthalpy-ConcentrationDiagrams 95
3.10. HeatsofReaction 98
3.11. StandardHeatsofFormation 101
3.12. HeatsofCombustion 102
3.13. CompressionandExpansionofGases 104
3.14. EnergyBalanceCalculations 112
3.15. UnsteadyStateEnergyBalances 113
3.16. EnergyRecovery 114
3.17. HeatExchangerNetworks 124
3.18. References 145
3.19. Nomenclature 146
3.20. Problems 150
4
FLOWSHEETING 153
4.1. Introduction 154
4.2. FlowsheetPresentation 155
4.3. ProcessSimulationPrograms 162
4.4. SpecificationofComponentsandPhysicalPropertyModels 165
CONTENTS ix
4.5. SimulationofUnitOperations 169
4.6. UserModels 204
4.7. FlowsheetswithRecycle 207
4.8. FlowsheetOptimization 219
4.9. DynamicSimulation 224
4.10. References 224
4.11. Nomenclature 225
4.12. Problems 226
5
PIPING AND INSTRUMENTATION 235
5.1. Introduction 236
5.2. ThePandIDiagram 236
5.3. ValveSelection 241
5.4. PumpsandCompressors 243
5.5. MechanicalDesignofPipingSystems 262
5.6. PipeSizeSelection 265
5.7. ControlandInstrumentation 275
5.8. TypicalControlSystems 277
5.9. Alarms,SafetyTrips,andInterlocks 285
5.10. ComputersinProcessControl 287
5.11. References 289
5.12. Nomenclature 291
5.13. Problems 293
6
COSTING AND PROJECT EVALUATION 297
6.1. Introduction 298
6.2. Costs,Revenues,andProfits 298
6.3. EstimatingCapitalCosts 306
6.4. EstimatingProductionCostsandRevenues 334
6.5. TaxesandDepreciation 352
6.6. ProjectFinancing 358
6.7. EconomicEvaluationofProjects 363
6.8. SensitivityAnalysis 380
6.9. ProjectPortfolioSelection 384
6.10. References 388
6.11. Nomenclature 390
6.12. Problems 392