Chemical Engineering Design Project

Preface to Second Edition -- Acknowledgements -- Introduction -- I How to Use This Book -- (A) The Case Study Approach -- (B) A "Road Map" -- II Some Advice -- (A) General Advice to the Student -- (B) Advice from a Former Design Project Student -- (C) To the Lecturer -- (D) The Designer or Project Engineer -- III Presentation of Design Projects -- (A) Effective Communications -- (B) General Comments on Preparation of Literature Surveys -- IV Details of Particular Design Projects, and Information Sources -- (A) IChemE Design Projects -- Instructions for the IChemE Design Project, 1980 -- (B) Information Sources -- PART I Technical and Economic Feasibility Study -- Chapter 1 The Design Problem -- 1.1 Initial Considerations and Specification -- 1.1.1 The Feasibility Study -- 1.1.2 Time Management -- 1.1.3 Stages in a Design Problem -- 1.1.4 The Search for Information -- 1.1.5 Scope of the Project -- 1.1.6 Evaluating the Alternatives - Making Decisions -- Some Questions to Ask for the Chemical to be Produced -- Further Reading -- Case Study: Production of Phthalic Anhydride -- Overall Summary for the Technical and Economic Feasibility Study -- 1.2 Case Study - Defining the Problem and Background Information -- Summary -- 1.2.1 Background and Objectives -- 1.2.2 Chemical Structure and Physical Properties -- 1.2.3 Applications and Uses -- 1.2.4 Basic Chemistry -- 1.2.5 Evaluation of Alternative Processing Schemes -- 1.2.6 Conclusions -- 1.2.7 Recommendations -- Chapter 2 Feasibility Study and Market Survey -- 2.1 Initial Feasibility Study -- 2.2 Preliminary Market Survey /Economic Analysis References -- 2.3 Information Sources -- 2.4 Evaluation of Available Literature -- 2.5 Considerations for Literature Surveys References -- 2.6 Case Study - Feasibility Study and Market Assessment -- Summary -- 2.6.1 Market Assessment -- 2.6.1.1 Production: Worldwide -- 2.6.1.2 Production: Regional -- 2.6.1.3 Production: National -- 2.6.2 Current and Future Prices -- 2.6.3 Demand -- 2.6.4 Australian Imports and Exports -- 2.6.5 Plant Capacity -- 2.6.6 Product Value and Operating Costs -- 2.6.6.1 Capital Costs -- 2.6.6.2 Operating Costs -- 2.6.6.3 Approximate Selling Price -- 2.6.7 Conclusions -- 2.6.8 Recommendations -- Chapter 3 Process Selection, Process Description and Equipment List -- 3.1 Process Selection Considerations -- 3.1.1 Flow Diagrams - PFD and P&ID -- 3.1.2 The Reactor -- 3.1.3 Product Purity -- 3.1.4 Process Conditions -- 3.1.5 Process Data -- 3.1.6 Energy Efficiency -- 3.1.7 Factors in Process Evaluation and Selection -- 3.1.8 Choices and Compromises -- 3.1.9 The Optimum Design -- 3.1.10 Process Control and Instrumentation References -- 3.2 Process Description -- 3.3 Preparing the Equipment List -- 3.4 Rules of Thumb -- 3.5 Safety Considerations and Preliminary HAZOP Study References -- 3.6 Case Study - Process Selection and Equipment List -- Summary -- 3.6.1 Trends in Phthalic Anhydride Processing -- 3.6.2 Raw Material -- 3.6.3 Process Configurations -- 3.6.4 Detailed Process Description -- 3.6.5 Advantages of the LAR Process -- 3.6.6 Advantages of the LEVH Process -- 3.6.7 Process Selection -- 3.6.8 Initial Equipment Design -- 3.6.9 Equipment List -- 3.6.10 Conclusions -- 3.6.11 Recommendations -- Appendix A: Preliminary Equipment Specifications -- Chapter 4 Site Considerations: Site Selection and Plant Layout -- 4.1 Site Selection /Location -- 4.1.1 Local Industrial Areas -- 4.1.2 Some Important Factors -- 4.1.3 Prioritizing the Factors References -- 4.2 Plant Layout -- 4.2.1 Plant Layout Strategies -- 4.2.2 Factors Influencing Plant Layout References -- 4.3 Case Study - Site Considerations: Site Selection and Plant Layout -- Summary -- 4.3.1 Background and Objectives -- 4.3.2 Potential Sites -- 4.3.2.1 Kemerton -- 4.3.2.2 Geraldton -- 4.3.2.3 Karratha -- 4.3.2.4 Kwinana -- 4.3.3 Preferred Site and Layout -- 4.3.4 Conclusions -- 4.3.5 Recommendations -- Chapter 5 Environmental Considerations -- 5.1 Environmental Impact Assessment -- 5.2 General Considerations -- 5.3 El A Policy and Scope -- 5.4 El A Reports -- 5.5 Australia -- 5.6 United Kingdom -- 5.7 United States -- 5.8 ISO-14000 -- 5.9 Legislation References -- 5.10 Case Study - Environmental Considerations -- Summary -- 5.10.1 Purpose -- 5.10.2 Airborne Emissions -- 5.10.3 Waterborne Emissions -- 5.10.4 Solid Waste -- 5.10.5 Process Hazards -- 5.10.6 Accidental Spills and Tank Breaches -- 5.10.7 Personnel Safety Precautions and Procedures -- 5.10.8 Conclusions -- 5.10.9 Recommendations -- Chapter 6 Economic Evaluation -- 6.1 Introductory Notes -- 6.2 Capital Cost Estimation -- 6.2.1 Cost of Equipment (Major Items) -- (I) Cost Correlations (II) Factored Estimate Method -- 6.2.2 Module Costs -- 6.2.3 Auxiliary Services -- 6.3 Operating Costs - Fixed and Variable -- 6.3.1 Depreciation -- 6.4 Profitability Analysis -- 6.4.1 The Payback Period -- 6.4.2 Return on Investment (ROI) -- 6.4.3 Evaluating Different Scenarios -- 6.4.4 Economic Evaluation and Analysis -- 6.4.5 Evaluating Different Projects: Use of DCF and NPV The Engineers' Approach to Economic Evaluation The Final Word? -- References -- 6.5 Case Study - Economic Evaluation -- Summary -- 6.5.1 Background and Objectives -- 6.5.2 Equipment Costs -- 6.5.3 Installed Plant Cost by Lang Factor -- 6.5.4 Installed Plant Cost from Recent Plant Construction Data -- 6.5.5 Production Costs -- 6.5.6 Profitability Analysis -- 6.5.7 Conclusions -- 6.5.8 Recommendations -- Process Control -- Safety, Health and the Environment (including Loss Prevention and HAZOP) -- 8.4 Case Study - Energy Integration, Piping Specifications, Process Control and the P&ID -- Summary -- 8.4.1 Energy Management and Integration -- 8.4.2 Plant Piping Specifications -- 8.4.3 Control and Instrumentation -- 8.4.4 The Piping and Instrumentation Diagram (P&ID) -- 8.4.5 Conclusions -- 8.4.6 Recommendations -- References for Case Study Sections in Chapters 1 to 8 -- Comments -- References -- PART II: Detailed Equipment Design -- Chapter 9 The Detailed Design Stage -- 9.1 Detailed Equipment Design -- 9.1.1 Equipment Design - HELP!!! -- How to Begin to Design an Item of Equipment -- 9.2 Standards and Codes -- 9.3 Additional Design Considerations -- References -- Some General Textbooks -- Design Books -- Chapter 10 Case Study - Phthalic Anhydride Reactor Design -- Overall Summary -- Updated Material and Energy Balance for the Phthalic -- Anhydride Reactor (R101) -- Engineering Specification Sheet for the Reactor (R101) -- Schematic Drawing of the Reactor (R101) -- Part I Chemical Engineering Design -- 10.1 Overall Design Strategy -- 10.2 Design Basis -- 10.3 Design Parameters -- 10.4 Design Criteria -- 10.5 Chemical Engineering Design Methods -- 10.5.1 Catalyst Properties -- 10.5.2 Kinetics -- Chapter 7 Mass and Energy Balances -- 7.1 Preparation of Mass and Energy Balances References -- 7.2 Preliminary Equipment Design References -- 7.3 Computer-Aided Design -- What design work is there left to do now that we have simulation packages? -- References -- 7.4 Case Study - Mass and Energy Balances, and Utilities -- Summary -- 7.4.1 Scope and Objectives -- 7.4.2 Mass Balances -- 7.4.3 Energy Balances -- 7.4.4 Optimisation of Mass and Energy Balances -- 7.4.5 Utilities -- 7.4.6 Conclusions -- 7.4.7 Recommendations -- Chapter 8 Additional Design Considerations -- 8.1 Energy Integration and Conservation -- 8.2 Process Control, Instrumentation and Alarms -- 8.3 Safety, Health and the Environment References -- Energy Conservation -- 10.5.3 Reactor Simulation -- 10.5.4 Heat Transfer -- 10.5.5 Pressure Drop -- 10.6 Detailed Design -- 10.6.1 Reactor Configuration -- 10.6.2 Coolant -- 10.6.3 Computer Model -- 10.6.4 Shell Configuration -- 10.6.5 Salt Cooler -- 10.6.6 Salt Circulation Pump -- 10.7 Chemical Engineering Design Specification -- 10.7.1 Reactor Specification -- 10.7.2 Salt Cooler Specification -- 10.7.3 Salt Circulation Pump Specification -- Part II Mechanical Engineering Design -- 10.8 Mechanical Engineering Design Parameters -- 10.9 Mechanical Engineering Design Methods -- 10.9.1 Shell Design -- 10.9.2 Supports and Foundations -- 10.10 Materials of Construction -- 10.11 Pressure Vessel Design (AS1210) -- 10.12 Insulation -- 10.13 Supports and Foundations -- 10.14 Costing -- 10.15 Engineering Specification Specification Sheets Engineering Drawings -- Part III Operational Considerations -- 10.16 HAZOP Analysis -- 10.17 Process Hazards -- 10.18 Safety -- 10.19 Operability -- 10.20 Environmental Considerations -- 10.21 Control and Instrumentation -- 10.22 Operating Considerations -- 10.22.1 Operation Under Normal Conditions -- 10.22.2 Commissioning -- 10.22.3 Shut-Down -- 10.22.4 Start-Up -- 10.22.5 Regular Maintenance -- Part IV Conclusions, Recommendations and References -- 10.23 Conclusions -- Chemical Engineering Design -- Mechanical Engineering Design -- Operational Considerations -- 10.24 Recommendations -- 10.25 References -- Appendix B. Calculations for Phthalic Anhydride Reactor Design B.l Reactions -- B.2 Derivation of Simulation Model Equations B.3 Tube-Side Heat Transfer Coefficient B.4 Shell-Side Heat Transfer Coefficient B.5 Overall Heat Transfer Coefficient (Clean) -- B.6 Tube Count B.7 Tube-Side Pressure Drop B.8 Shell-Side Pressure Drop B.9 Salt Cooler Design B.10 Shell Design (AS1210) -- B.ll Tube-Plate Design -- B.12 Vessel Openings -- B.13 Protective Devices (AS1210) -- B.14 Insulation -- B.l 5 Supports -- B.16 Foundation -- Appendix C. FORTRAN Program for Phthalic Anhydride Reactor Simulation -- Appendix D. Hazard and Operability Studies for Phthalic Anhydride Reactor -- Chapter 11 Case Study - Phthalic Anhydride After-Cooler Design -- Overall Summary -- Updated Material and Energy Balance for the After-Cooler (E105) -- Engineering Specification Sheet for the After-Cooler (E105) -- Schematic Drawing of the After-Cooler -- Part I Chemical Engineering Design -- 11.1 General Design Considerations -- 11.2 Design Strategy and Criteria -- 11.3 Preliminary Design Decisions -- 11.3.1 Condenser Type -- 11.3.2 Coolant -- 11.4 Chemical Engineering Design Methods -- 11.4.1 Heat Transfer Coefficient -- 11.4.2 After-Cooler Simulation -- 11.4.3 Pressure Drop -- 11.5 Detailed Design -- 11.5.1 General Considerations -- 11.5.2 Simulation Results -- 11.5.3 Vessel Configuration -- 11.6 Chemical Engineering Design Specification -- Part II Mechanical Engineering Design -- 11.7 Mechanical Engineering Design Requirements -- 11.8 Materials of Construction -- 11.9 Vessel Dimensions -- 11.10 Insulation -- 11.11 Supports and Foundation -- 11.12 Costing -- 11.13 Engineering Specification Part III Operational Considerations -- 11.14 HAZOP Analysis -- 11.15 Process Hazards -- 11.16 Safety -- 11.17 Operability -- 11.18 Environmental Considerations -- 11.19 Control and Instrumentation -- 11.20 Operating Considerations -- 11.20.1 Operation Under Normal Conditions -- 11.20.2 Commissioning -- 11.20.3 Shut-Down and Start-Up -- 11.20.4 Regular Maintenance -- Part IV Conclusions, Recommendations and References -- 11.21 Conclusions -- Chemical Engineering Design Mechanical Engineering Design Operational Considerations -- 11.22 Recommendations -- 11.23 References -- Appendix E. Calculations for Phthalic Anhydride After-Cooler Design -- E.l Provisional After-Cooler Design -- E.2 Shell-Side Cross-Flow Area -- E.3 Pressure Drops -- E.4 Mechanical Design -- E.5 Supports -- E.6 Foundation -- Appendix F. FORTRAN Program for Phthalic Anhydride -- After-Cooler Simulation -- Appendix G. Hazard and Operability Study for Phthalic Anhydride -- After-Cooler (Tables G.l to G.5) -- Final Comments -- INDEX.