Table Of ContentPlant Design and Economics
for
Chemical Engineers
McGraw-Hill Chemical Engineering Series
Editorial Advisory Board
Eduardo D. Glandt, Dean, School of Engineering and Applied Science, University of Pennsylvania
Michael T. Klein, Dean, School of Engineering, Rutgers University
Thomas F. Edgar, Professor of Chemical Engineering, University of Texas at Austin
Bailey and Ollis Marlin
Biochemical Engineering Fundamentals Process Control: Designing Processes and Control
Systems for Dynamic Performance
Bennett and Myers
Momentum, Heat and Mass Transfer McCabe, Smith, and Harriott
Unit Operations of Chemical Engineering
Coughanowr and LeBlanc
Process Systems Analysis and Control Middleman and Hochberg
Process Engineering Analysis in Semiconductor Device
Davis and Davis
Fabrication
Fundamentals of Chemical Reaction Engineering
Perry and Green
de Nevers
Perry's Chemical Engineers' Handbook
Air Pollution Control Engineering
Peters, Timmerhaus, and West
de Nevers
Plant Design and Economics for Chemical Engineers
Fluid Mechanics for Chemical Engineers
Reid, Prausnitz, and Poling
Douglas
Properties of Gases and Liquids
Conceptual Design of Chemical Processes
Smith, Van Ness, and Abbott
Edgar, Himmelblau, and Lasdon
Introduction to Chemical Engineering Thermodynamics
Optimization of Chemical Processes
Treybal
Gates, Katzer, and Schuit
Mass Transfer Operations
Chemistry of Catalytic Processes
King
Separation Processes
Luyben
Process Modeling, Simulation, and Control
for Chemical Engineers
Plant Design and Economics
for Chemical Engineers
Fifth Edition
Max S. Peters
Klaus D. Timmerhaus
Ronald E. West
University of Colorado
Mc
Graw
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PLANT DESIGN AND ECONOMICS FOR CHEMICAL ENGINEERS
FIFTH EDITION
Published by McGraw-Hill, a business unit of The McGraw-Hill Companies, Inc., 1221 Avenue of the Americas, New York,
NY 10020. Copyright © 2003, 1991, 1980, 1968, 1958 by The McGraw-Hill Companies, Inc. All rights reserved. No part of this
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This book is printed on acid-free paper.
International 12 3 4567890 QPF/QPF 098765432
Domestic 1234567890 QPF/QPF 0987 6 5432
ISBN 0-07-239266-5
ISBN 0-07-119872-5 (ISE)
Publisher: Elizabeth A. Jones
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Library of Congress Cataloging-in-Publication Data
Peters, Max Stone, I920-.
Plant design and economics for chemical engineers. — 5th ed. / Max S . Peters, Klaus D.
Timmerhaus, Ronald E. West.
p. cm. — (McGraw-Hill chemical engineering series)
Includes bibliographical references and index.
ISBN 0-07-239266-5 (acid-free paper)
1. Chemical plants—Design and construction. I. Timmerhaus, Klaus D . II. West, Ronald E.
(Ronald Emmett), 1933-. III. Title. IV. Series.
TP155.5.P4 2003
660'.2S—dc21 2002032568
CIP
INTERNATIONAL EDITION ISBN 0-07-119872-5
Copyright © 2003. Exclusive rights by The McGraw-Hill Companies, Inc., for manufacture and
export. This book cannot be re-exported from the country to which it is sold by McGraw-Hill.
The International Edition is not available in North America.
www.mhhe.com
ABOUT THE AUTHORS
Max S. Peters is currently professor emeritus of chemical engineering and dean
emeritus of engineering at the University of Colorado at Boulder. He received his B.S.
and M.S. degrees in chemical engineering from Pennsylvania State University, worked
for Hercules Power Company and Treyz Chemical Company, and returned to Penn
State for his Ph.D. Subsequently he joined the faculty of the University of Illinois, and
later he came to the University of Colorado as dean of the College of Engineering and
Applied Science and professor of chemical engineering. He relinquished the position
of dean in 1978 and became emeritus in 1987.
Dr. Peters has served as president of the American Institute of Chemical Engineers,
as a member of the board of directors for the Commission on Engineering Education,
as chairman of the President's Committee on the National Medal of Science, and
as chairman of the Colorado Environmental Commission. A fellow of the American
Institute of Chemical Engineering, Dr. Peters is the recipient of the George Westing-
house and Lamme Award of the American Society of Engineering Education, the
Award of Merit of the American Association of Cost Engineers, and the Founders and
W. K. Lewis Award of the American Institute of Chemical Engineers. He is a member
of the National Academy of Engineering.
Klaus D. Timmerhaus is currently President's Teaching Scholar at the University of
Colorado at Boulder. He received his B.S., M.S., and Ph.D. degrees in chemical engi-
neering from the University of Illinois. After serving as a process design engineer for
Standard Oil of California Research Corporation, Dr. Timmerhaus joined the chemical
engineering department of the University of Colorado, College of Engineering. He
was subsequently appointed associate dean of the College of Engineering and director
of the Engineering Research Center. This was followed by a term as chairman of the
chemical engineering department. The author's extensive research publications have
been primarily concerned with cryogenics, energy, and heat and mass transfer. He has
edited 25 volumes of Advances in Cryogenic Engineering and coedited more than 30
volumes in the International Cryogenics Monograph Series.
He is past president of the American Institute of Chemical Engineers, past presi-
dent of the Society of Sigma Xi, and past president of the International Institute of
Refrigeration; and he has held offices in the American Institute of Chemical Engineers
(AIChE), the Cryogenic Engineering Conference, the International Cryocooler Con-
ference, Society of Sigma Xi, American Astronautical Society, American Association
for the Advancement of Science (AAAS), American Society for Engineering Educa-
tion (ASEE)—Engineering Research Council, Accreditation Board for Engineering
and Technology, and National Academy of Engineering.
v
vi About the Authors
A fellow of AIChE and A A AS, Dr. Timmerhaus has received the ASEE George
Westinghouse and Fred Merryfield Design Award, the AIChE Alpha Chi Sigma Award,
the AIChE W. K. Lewis Award, the AIChE Founders Award, the SAE Ralph Teeter
Award, the USNC/I1R W. T. Pentzer Award, NSF Distinguished Service Award, Uni-
versity of Colorado Stearns Award, Colorado Professor of the Year Award, and Samuel
C. Collins Award of the Cryogenic Engineering Conference. He is a member of the
National Academy of Engineering and the Austrian Academy of Science.
Ronald E. West is currently professor emeritus of chemical engineering after serv-
ing for 38 years as a member of the faculty in the department of chemical engineering
at the University of Colorado at Boulder. In that capacity, he directed both the under-
graduate laboratory program and the senior plant design course for more than 25 years.
He received his B.S., M.S., and Ph.D. degrees in chemical engineering from the
University of Michigan. His professional work has been mainly in the areas of water
pollution control and renewable energy technology. Dr. West is a member of the
American Institute of Chemical Engineers and the American Solar Energy Society.
CONTENTS
Preface xv Developmen t of a Pollution Control System 42
Prologue xix
Air Pollution Abatement 42
Water Pollution Abatement 47
Solid Waste Disposal 50
CHAPTER 1
Thermal Pollution Control 51
Introduction 1
Noise Control 52
Chemical Engineering Plant Design 1 Plant Location 52
General Overall Design Considerations 2 Factors Involved 53
Process Design Development 2 Selection of the Plant Site 56
Flowsheet Development 5 Plant Layout 56
Computer-Aided Design 6 Preparation of the Layout 57
Cost Estimation 6 Plant Operation and Control 57
Profitability Analysis of Investments 7 Instrumentation 57
Optimum Design 8 Maintenance 58
Practical Considerations in Design 11 Utilities 59
The Design Approach 12 Structural Design 60
Engineering Ethics in Design 13 Storage 60
Materials Handling 61
CHAPTER 2 Patent Considerations 62
General Design Considerations 15 Problems 62
Health and Safety Hazards 15
CHAPTER 3
Sources of Exposure 16
Process Design Development 67
Exposure Evaluation 18
Control of Exposure Hazards 20 Development of Design Database 67
Fire and Explosion Hazards 22 Literature Survey 68
Personnel Safety 2 7 Patent Search 69
Safety Regulations 27 Process Creation 69
Loss Prevention 29 Batch Versus Continuous Operation 70
HAZOP Study 29 Raw Materials and Product
Fault-tree Analysis 35 Specifications 70
Failure Mode and Effect Analysis 36 Process Synthesis Steps 71
Safety Indexes 36 Process Design 72
Safety Audits 36 Types of Process Designs 74
Environmental Protection 40 Process Flow Diagrams 77
Environmental Regulations 41 Piping and Instrumentation Diagrams 79
vii
viii Contents
Vessel and Piping Layout Isometrics 80 Process Flowsheet 149
Equipment Design and Specifications 81 Reactors 149
Scale-up of Equipment in Design 81 Mass and Energy Balances 149
Safety Factors 81 Separation Trains 149
Equipment Specifications 84 Heat Exchange 150
Materials of Construction 86 Algorithmic Flowsheet Generation 158
The Preliminary Design—A Specific Example 87 Fundamentals of Algorithmic Process-Network
Synthesis 159
Problem Statement 87
Application of Algorithmic Process-Network
Literature Survey 87
Synthesis 165
Process Creation 88
Comparison of Hierarchical and
Development of Conven tional Base-Case Design 90
Algorithmic Results 189
Economic Assessment of Base-Case Design 110
Genetic Algorithms 189
Assessment of Proposed Base-Case Design
Modification 113 Future Approaches to Flowsheet Synthesis
and Development 190
Summary 120
Software Use in Flowsheet Synthesis 190
Problems 121
Analysis and Evaluation of Flowsheets 190
CHAPTER 4 Criteria for Evaluating Designs 190
Flowsheet Synthesis and Summary 192
Development 125 Nomenclature 192
Greek Symbol 193
Flowsheet Synthesis and Development 126
Problems 193
General Procedure 126
Process Information 130
Background Information 130 CHAPTER 5
Molecular Path Synthesis 131 Software Use in Process
Selecting a Process Pathway 132 Design 196
Production Mode 132
Software Structure 198
Recording Decisions 133
Chemical Property Estimation 198
Input/Output Structure 135
Process Equipment Models 201
Functions Diagram 137 Process Equipment Cost Estimation 202
Preprocessing 138 Process Economic Evaluation 203
Reactions 139 Heat Integration 203
Recycle 139 Process Control 203
By-products, Intermediates, and Wastes 139 Process Optimization 204
Separations 140 Software Capabilities 204
Operations Diagram 143 General-Type Software 205
Preprocessing 143 Software for Process Design 208
Reactors 143 Molecular Reaction Databases and Simulators 208
Separations Methods 144 Chemical Cost Databases 209
Heating and Cooling 145 Flowsheeting Software 209
Minimization of Processing 145 Unit Operations Simulators 211
Contents
Piping System Design 214 Yard Improvements 246
Plant Layout 214 Service Facilities 246
Economic Evaluation 215 Health, Safety, and Environmental
Functions 247
Software Selection 216
Land 248
Software Use 216
Engineering and Supervision 248
Physical Property Estimation Guidelines 217
Legal Expenses 248
Process Simulation Guidelines 217
Construction Expenses 248
Avoiding Pitfalls in Software Use 220
Contractor's Fee 249
Graphic Interface and Ease of Use 221
Contingencies 249
Thermodynamic Property Packages 222
Methods for Estimating Capital Investment
Simulation Realism 222
Estimation of Revenue 258
Evaluation of Software Results 224
Estimation of Total Product Cost 259
Manufacturing Costs 262
CHAPTER 6
Variable Production Costs 262
Analysis of Cost Estimation 226 Plant Overhead Costs 270
General Expenses 270
Cash Flow for Industrial Operations 226
Gross Profit, Net Profit, and Cash Flow 271
Cash Plow 226
Cumulative Cash Position 228 Contingencies 272
Factors Affecting Investment and Summary 272
Production Costs 230 Nomenclature 274
Sources of Equipment 230 Greek Symbol 275
Price Fluctuations 230 Problems 275
Company Policies 230
Operating Time and Rate of Production 231
CHAPTER 7
Government Policies 232
Interest, Time Value of Money,
Capital Investment 232
Taxes, and Fixed Charges 279
Fixed-Capital Investment 233
Working Capital 233 Interest 279
Simple Interest 280
Estimation of Capital Investment 233
Compound Interest 280
Types of Capital Cost Estimates 235
Nominal and Effective Interest Rates 281
Cost Indexes 236
Continuous Interest 283
Cost Components in Capital Investment 239
Cost of Capital 285
Purchased Equipment 241
Income Tax Effects 286
Estimating Equipment Costs by Scaling 242
Loan Payments 287
Purchased-Equipment Delivery 244
Time Value of Money 290
Purchased-Equipment Installation 244
Instrumentation and Controls 245 Cash Flow Patterns 292
Piping 245 Discrete Cash Flows 292
Electrical Systems 246 Continuous Cash Flows 294
Buildings 246 Compounding and Discounting Factors 297
