Analysis, Synthesis, and Design of Chemical Processes, Global Edition

Richard Turton, P.E., has taught the design and design-related courses at West Virginia University for the past 32 years. Prior to this, he spent five years in the design and construction industry. His main interests are design education and process systems modeling.  Joseph A. Shaeiwitz taught design and design-related classes at West Virginia University for more than 25 years. He now teaches design at Auburn University. His interests include design education and outcomes assessment.  Debangsu Bhattacharyya has more than ten years’ experience in a large petroleum refinery. While in the refinery, he worked in process operations, plant start-up, large-scale process simulation, and process control. His main research interests are in process modeling, dynamic simulation, state estimation, sensor placement, and advanced process control.  Wallace B. Whiting, P.E., is professor emeritus at University of Nevada, Reno. He has been involved in the practice and teaching of chemical process design for more than 24 years.

• Preface xxvAbout the Authors xxixList of Nomenclature xxxi  Chapter 0: Outcomes Assessment 10.1 Student Self-Assessment 20.2 Assessment by Faculty 40.3 Summary 6References 6   Section I: Conceptualization and Analysis of Chemical Processes 7  Chapter 1: Diagrams for Understanding Chemical Processes 9 1.1 Block Flow Diagram (BFD) 111.2 Process Flow Diagram (PFD) 141.3 Piping and Instrumentation Diagram (P&ID) 271.4 Additional Diagrams 321.5 Three-Dimensional Representation of a Process 341.6 The 3-D Plant Model 411.7 Operator and 3-D Immersive Training Simulators 431.8 Summary 48References 49Short Answer Questions 49Problems 50  Chapter 2: The Structure and Synthesis of Process Flow Diagrams 552.1 Hierarchy of Process Design 552.2 Step 1—Batch versus Continuous Process 562.3 Step 2—The Input/Output Structure of the Process 602.4 Step 3—The Recycle Structure of the Process 702.5 Step 4—General Structure of the Separation System 832.6 Step 5—Heat-Exchanger Network or Process Energy Recovery System 832.7 Information Required and Sources 832.8 Summary 83References 85Short Answer Questions 86Problems 86  Chapter 3: Batch Processing 913.1 Design Calculations for Batch Processes 913.2 Gantt Charts and Scheduling 973.3 Nonoverlapping Operations, Overlapping Operations, and Cycle Times 983.4 Flowshop and Jobshop Plants 1013.5 Product and Intermediate Storage and Parallel Process Units 1063.6 Design of Equipment for Multiproduct Batch Processes 1113.7 Summary 113References 114Short Answer Questions 114Problems 114  Chapter 4: Chemical Product Design 1234.1 Strategies for Chemical Product Design 1244.2 Needs 1254.3 Ideas 1274.4 Selection 1284.5 Manufacture 1304.6 Batch Processing 1314.7 Economic Considerations 1314.8 Summary 132References 132  Chapter 5: Tracing Chemicals through the Process Flow Diagram 1355.1 Guidelines and Tactics for Tracing Chemicals 1355.2 Tracing Primary Paths Taken by Chemicals in a Chemical Process 1365.3 Recycle and Bypass Streams 1425.4 Tracing Nonreacting Chemicals 1455.5 Limitations 1455.6 Written Process Description 1465.7 Summary 147Problems 147  Chapter 6: Understanding Process Conditions 1496.1 Conditions of Special Concern for the Operation of Separation and Reactor Systems 1506.2 Reasons for Operating at Conditions of Special Concern 1526.3 Conditions of Special Concern for the Operation of Other Equipment 1556.4 Analysis of Important Process Conditions 1586.5 Summary 165References 165Short Answer Questions 165Problems 166   Section II: Engineering Economic Analysis of Chemical Processes 169  Chapter 7: Estimation of Capital Costs 171 7.1 Classifications of Capital Cost Estimates 1727.2 Estimation of Purchased Equipment Costs 1757.3 Estimating the Total Capital Cost of a Plant 1827.4 Estimation of Plant Costs Based on Capacity Information 2067.5 Summary 208References 208Short Answer Questions 209Problems 210  Chapter 8: Estimation of Manufacturing Costs 2138.1 Factors Affecting the Cost of Manufacturing a Chemical Product 2138.2 Cost of Operating Labor 2188.3 Utility Costs 2198.4 Raw Material Costs 2348.5 Yearly Costs and Stream Factors 2378.6 Estimating Utility Costs from the PFD 2388.7 Cost of Treating Liquid and Solid Waste Streams 2408.8 Evaluation of Cost of Manufacture for the Production of Benzene via the Hydrodealkylation of Toluene 2418.9 Summary 242References 243Short Answer Questions 243Problems 244  Chapter 9: Engineering Economic Analysis 2479.1 Investments and the Time Value of Money 2489.2 Different Types of Interest 2519.3 Time Basis for Compound Interest Calculations 2549.4 Cash Flow Diagrams 2559.5 Calculations from Cash Flow Diagrams 2599.6 Inflation 2669.7 Depreciation of Capital Investment 2689.8 Taxation, Cash Flow, and Profit 2749.9 Summary 277References 277Short Answer Questions 278Problems 278  Chapter 10: Profitability Analysis 28510.1 A Typical Cash Flow Diagram for a New Project 28510.2 Profitability Criteria for Project Evaluation 28710.3 Comparing Several Large Projects: Incremental Economic Analysis 29510.4 Establishing Acceptable Returns from Investments: The Concept of Risk 29810.5 Evaluation of Equipment Alternatives 29910.6 Incremental Analysis for Retrofitting Facilities 30510.7 Evaluation of Risk in Evaluating Profitability 30910.8 Profit Margin Analysis 32510.9 Summary 326References 327Short Answer Questions 327Problems 328   Section III: Synthesis and Optimization of Chemical Processes 343  Chapter 11: Utilizing Experience-Based Principles to Confirm the Suitability of a Process Design 347 11.1 The Role of Experience in the Design Process 34811.2 Presentation of Tables of Technical Heuristics and Guidelines 35111.3 Summary 354List of Informational Tables 354References 368Problems 368  Chapter 12: Synthesis of the PFD from the Generic BFD 36912.1 Information Needs and Sources 37012.2 Reactor Section 37212.3 Separator Section 37312.4 Reactor Feed Preparation and Separator Feed Preparation Sections 38812.5 Recycle Section 38912.6 Environmental Control Section 38912.7 Major Process Control Loops 39012.8 Flow Summary Table 39012.9 Major Equipment Summary Table 39012.10 Summary 391References 391General Reference 392Problems 392  Chapter 13: Synthesis of a Process Using a Simulator and Simulator Troubleshooting 39713.1 The Structure of a Process Simulator 39813.2 Information Required to Complete a Process Simulation: Input Data 40113.3 Handling Recycle Streams 41313.4 Choosing Thermodynamic Models 41513.5 Case Study: Toluene Hydrodealkylation Process 42613.6 Electrolyte Systems Modeling 42813.7 Solids Modeling 440Appendix 13.1 445Appendix 13.2 44713.8 Summary 450References 451Short Answer Questions 454Problems 455  Chapter 14: Process Optimization 46314.1 Background Information on Optimization 46314.2 Strategies 46914.3 Topological Optimization 47314.4 Parametric Optimization 47914.5 Lattice Search, Response Surface, and Mathematical Optimization Techniques 48914.6 Process Flexibility and the Sensitivity of the Optimum 48914.7 Optimization in Batch Systems 49014.8 Summary 497References 498Short Answer Questions 498Problems 498  Chapter 15: Pinch Technology 50915.1 Introduction 50915.2 Heat Integration and Network Design 51015.3 Composite Temperature-Enthalpy Diagram 52315.4 Composite Enthalpy Curves for Systems without a Pinch 52415.5 Using the Composite Enthalpy Curve to Estimate Heat-Exchanger Surface Area 52515.6 Effectiveness Factor (F) and the Number of Shells 52915.7 Combining Costs to Give the EAOC for the Network 53415.8 Other Considerations 53615.9 Heat-Exchanger Network Synthesis Analysis and Design (HENSAD) Program 54015.10 Mass-Exchange Networks 54115.11 Summary 550References 550Short Answer Questions 551Problems 552  Chapter 16: Advanced Topics Using Steady-State Simulators 56116.1 Why the Need for Advanced Topics in Steady-State Simulation? 56216.2 User-Added Models 56216.3 Solution Strategy for Steady-State Simulations 57116.4 Studies with the Steady-State Simulation 58916.5 Estimation of Physical Property Parameters 60116.6 Summary 605References 605Short Answer Questions 607Problems 607  Chapter 17: Using Dynamic Simulators in Process Design 61717.1 Why Is There a Need for Dynamic Simulation? 61817.2 Setting Up a Dynamic Simulation 61917.3 Dynamic Simulation Solution Methods 63317.4 Process Control 63917.5 Summary 647References 647Short Answer Questions 648Problems 649  Chapter 18: Regulation and Control of Chemical Processes with Applications Using Commercial Software 65518.1 A Simple Regulation Problem 65618.2 The Characteristics of Regulating Valves 65718.3 Regulating Flowrates and Pressures 66018.4 The Measurement of Process Variables 66218.5 Common Control Strategies Used in Chemical Processes 66318.6 Exchanging Heat and Work between Process and Utility Streams 67418.7 Logic Control 68018.8 Advanced Process Control 68218.9 Case Studies 68318.10 Putting It All Together: The Operator Training Simulator (OTS) 68818.11 Summary 689References 690Problems 690   Section IV: Chemical Equipment Design and Performance Process Equipment Design and Performance 695  Chapter 19: Process Fluid Mechanics 697 19.1 Basic Relationships in Fluid Mechanics 69719.2 Fluid Flow Equipment 70319.3 Frictional Pipe Flow 70919.4 Other Flow Situations 72319.5 Performance of Fluid Flow Equipment 736References 755Short Answer Questions 756Problems 757  Chapter 20: Process Heat Transfer 77120.1 Basic Heat-Exchanger Relationships 77120.2 Heat-Exchange Equipment Design and Characteristics 77920.3 LMTD Correction Factor for Multiple Shell and Tube Passes 78920.4 Overall Heat Transfer Coefficients—Resistances in Series 79820.5 Estimation of Individual Heat Transfer Coefficients and Fouling Resistances 80020.6 Extended Surfaces 82820.7 Algorithm and Worked Examples for the Design of Heat Exchangers 83720.8 Performance Problems 846References 859Appendix 20.A Heat-Exchanger Effectiveness Charts 861Appendix 20.B Derivation of Fin Effectiveness for a Rectangular Fin 864Short Answer Questions 866Problems 866  Chapter 21: Separation Equipment 87521.1 Basic Relationships in Separations 87621.2 Illustrative Diagrams 88321.3 Equipment 91121.4 Extraction Equipment 94221.5 Gas Permeation Membrane Separations 947References 951Short Answer Questions 952Problems 954  Chapter 22: Reactors 96122.1 Basic Relationships 96222.2 Equipment Design for Nonisothermal Conditions 98022.3 Performance Problems 1003  Chapter 23: Other Equipment 101523.1 Pressure Vessels 101623.2 Knockout Drums or Simple Phase Separators 102423.3 Steam Ejectors 1049References 1058Short Answer Questions 1059Problems 1060  Chapter 24: Process Troubleshooting and Debottlenecking 106524.1 Recommended Methodology 106724.2 Troubleshooting Individual Units 107124.3 Troubleshooting Multiple Units 107624.4 A Process Troubleshooting Problem 108124.5 Debottlenecking Problems 108524.6 Summary 1091References 1091Problems 1091   Section V: The Impact of Chemical Engineering Design on Society 1101  Chapter 25: Ethics and Professionalism 1103 25.1 Ethics 110425.2 Professional Registration 112125.3 Legal Liability [13] 112525.4 Business Codes of Conduct [14, 15] 112625.5 Summary 1127References 1128Problems 1129  Chapter 26: Health, Safety, and the Environment 113126.1 Risk Assessment 113126.2 Regulations and Agencies 113426.3 Fires and Explosions 114326.4 Process Hazard Analysis 114526.5 Chemical Safety and Hazard Investigation Board 115326.6 Inherently Safe Design 115326.7 Summary 115426.8 Glossary 1154References 1156Problems 1157  Chapter 27: Green Engineering 115927.1 Environmental Regulations 115927.2 Environmental Fate of Chemicals 116027.3 Green Chemistry 116327.4 Pollution Prevention during Process Design 116427.5 Analysis of a PFD for Pollution Performance and Environmental Performance 116627.6 An Example of the Economics of Pollution Prevention 116727.7 Life Cycle Analysis 116827.8 Summary 1169   Section VI: Interpersonal and Communication Skills 1173  Chapter 28: Teamwork 1175 28.1 Groups 117528.2 Group Evolution 118428.3 Teams and Teamwork 118628.4 Misconceptions 118928.5 Learning in Teams 118928.6 Other Reading 119028.7 Summary 1191References 1192Problems 1192  Chapter 29: Written and Oral Communication 119529.1 Audience Analysis 119629.2 Written Communication 119629.3 Oral Communication 120929.4 Software and Author Responsibility 121529.5 Summary 1218References 1218Problems 1219  Chapter 30: A Report-Writing Case Study 122130.1 The Assignment Memorandum 122130.2 Response Memorandum 122230.3 Visual Aids 122430.4 Example Reports 123030.5 Checklist of Common Mistakes and Errors 1244  Appendix A: Cost Equations and Curves for the CAPCOST Program 1247A.1 Purchased Equipment Costs 1247A.2 Pressure Factors 1264A.3 Material Factors and Bare Module Factors 1267References 1275  Appendix B: Information for the Preliminary Design of Fifteen Chemical Processes 1277B.1 Dimethyl Ether (DME) Production, Unit 200 1278B.2 Ethylbenzene Production, Unit 300 1283B.3 Styrene Production, Unit 400 1291B.4 Drying Oil Production, Unit 500 1299B.5 Production of Maleic Anhydride from Benzene, Unit 600 1305B.6 Ethylene Oxide Production, Unit 700 1311B.7 Formalin Production, Unit 800 1317B.8 Batch Production of L-Phenylalanine and L-Aspartic Acid, Unit 900 1323B.9 Acrylic Acid Production via the Catalytic Partial Oxidation of Propylene [1–5], Unit 1000 1329B.10 Production of Acetone via the Dehydrogenation of Isopropyl Alcohol (IPA) [1–4], Unit 1100 1338B.11 Production of Heptenes from Propylene and Butenes [1], Unit 1200 1344B.12 Design of a Shift Reactor Unit to Convert CO to CO2, Unit 1300 1352B.13 Design of a Dual-Stage Selexol Unit to Remove CO2 and H2S FromB.14 Design of a Claus Unit for the Conversion of H2S to Elemental Sulfur, Unit 1500 1363B.15 Modeling a Downward-Flow, Oxygen-Blown, Entrained-Flow Gasifier, Unit 1600 1371  Appendix C: Design Projects 1379Project 1 Increasing the Production of 3-Chloro-1-Propene (Allyl Chloride) in Unit 600 1381Project 2 Design and Optimization of a New 20,000-Metric-Tons-per-Year Facility to Produce Allyl Chloride at La Nueva Cantina, Mexico 1394Project 4 The Design of a New 100,000-Metric-Tons-per-Year Phthalic Anhydride Production Facility 1412Project 5 Problems at the Cumene Production Facility, Unit 800 1417Project 6 Design of a New, 100,000-Metric-Tons-per-Year Cumene Production Facility 1430  Index 1433