Process Plant Design
Description
Process Plant Design is a practical guide to chemical engineering process plant design, particularly in relation to design projects, giving an up-to-date approach to the structure of process design projects as practiced industrially and exploring the wider issues of process design in terms of the services (utilities) required to make a practical process design function.
The text allows chemical engineering students to gain an understanding of reliability, maintainability, and availability in relation to the subject, enabling them to specify with confidence the use of standby equipment, redundancy, reliability required of safety equipment, required availability to meet production targets, and the use of storage to achieve the required process availability.
To aid in reader comprehension, Process Plant Design features worked examples within the text and exercises at the end of some chapters with solutions available via supporting website.
Written by a renowned author with a proven track record in textbooks for chemical engineering students, Process Plant Design contains information on:
Chemical process projects, development of process design concepts, heating and cooling utilities, and waste treatment systems
Piping and instrumentation diagram (P&ID) development, I.E. The most important document in the industrial practice of chemical engineering that must be developed for all design projects
Flow rate and inventory control, degrees of freedom, control of process operations, and overall process control
Piping and pressure relief, process operations, construction, mechanical design, site layout, and process layout
Process Plant Design is a highly valuable resource on the subject for final year undergraduate students, as well as practicing chemical engineers working in engineering, procurement, and construction. The text is also useful for industrial disciplines related to chemical engineering working in engineering, procurement, and construction of chemical processes.
<b>Thorough treatment of process plant layout providing a systematic approach to the synthesis of control systems for overall processes</b>
Process Plant Design is a practical guide to chemical engineering process plant design, particularly in relation to design projects, giving an up-to-date approach to the structure of process design projects as practiced industrially and exploring the wider issues of process design in terms of the services (utilities) required to make a practical process design function.
The text allows chemical engineering students to gain an understanding of reliability, maintainability, and availability in relation to the subject, enabling them to specify with confidence the use of standby equipment, redundancy, reliability required of safety equipment, required availability to meet production targets, and the use of storage to achieve the required process availability.
To aid in reader comprehension, <i>Process Plant Design</i> features worked examples within the text and exercises at the end of some chapters with solutions available via supporting website.
Written by a renowned author with a proven track record in textbooks for chemical engineering students, <i>Process Plant Design</i> contains information on:
<ul><li>Chemical process projects, development of process design concepts, heating and cooling utilities, and waste treatment systems</li><li>Piping and instrumentation diagram (P&ID) development, I.E. The most important document in the industrial practice of chemical engineering that must be developed for all design projects</li><li>Flow rate and inventory control, degrees of freedom, control of process operations, and overall process control</li><li>Piping and pressure relief, process operations, construction, mechanical design, site layout, and process layout</li></ul><i>Process Plant Design</i> is a highly valuable resource on the subject for final year undergraduate students, as well as practicing chemical engineers working in engineering, procurement, and construction. The text is also useful for industrial disciplines related to chemical engineering working in engineering, procurement, and construction of chemical processes.
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Person
<b>Professor Robin Smith</b> is Head of the Centre for Process Integration within the School of Chemical Engineering and Analytical Science at the University of Manchester, UK. He is also Chief Executive Officer of Process Integration Limited, which provides software and consultancy to chemical, oil, gas, and petroleum industries. He has extensive industrial experience with Rohm & Haas in process investigation, production, and process design, as well as acting extensively as a consultant in process integration projects.
Content
Preface
Acknowledgements
Nomenclature
Chapter 1 Execution of Chemical Process Projects
1.1 The Process Design Problem
1.2 Continuous and Batch Processes
1.3 New Design and Retrofit
1.4 Hazard Management in Process Design
1.5 Project Phases
1.6 Chemical Process Projects - Summary
References
Chapter 2 Process Economics
2.1 Capital Cost Estimates
2.2 Class 5 Capital Cost Estimates
2.3 Class 4 Capital Cost Estimates
2.4 Class 3 to Class 1 Capital Cost Estimates
2.5 Capital Cost for Retrofit
2.6 Annulalized Capital Cost
2.7 Operating Cost
2.8 Economic Evaluation
2.9 Investment Criteria
2.10 Process Economics - Summary
2.11 Exercises
References
Chapter 3 Development of Process Design Concepts
3.1 Formulation of Design Problems
3.2 Evaluation of Design Performance
3.3 Optimization of Performance
3.4 Approaches to the Development of Design Concepts
3.5 Screening of Design Options
3.6 Influencing the Design as the Project Progresses
3.7 Development of Process Design Concepts - Summary
References
Chapter 4 Heating Utilities
4.1 Process Heating and Cooling
4.2 Steam Heating
4.3 Water Treatment for Steam Generation
4.4 Steam Generation from the Combustion of Fuels
4.5 Steam Generation from Electrical Energy
4.6 Gas Turbines
4.7 Steam Turbines
4.8 Steam Distribution
4.9 Steam Heating Limits
4.10 Fired Heaters
4.11 Other Heat Carriers
4.12 Heating Utilities - Summary
4.13 Exercises
References
Chapter 5 Cooling Utilities
5.1 Waste Heat Steam Generation
5.2 Once Through Cooling Water Systems
5.3 Recirculating Cooling Water Systems
5.4 Air Coolers
5.5 Refrigeration
5.6 Choice of Single Component Refrigerant for Compression Refrigeration
5.7 Mixed Refrigerants for Compression Refrigeration
5.8 Absorption Refrigeration
5.9 Indirect Refrigeration
5.10 Cooling Utilities - Summary
5.11 Exercises
References
Chapter 6 Waste Treatment
6.1 Aqueous Emissions
6.2 Primary Wastewater Treatment Processes
6.3 Biological Wastewater Treatment Processes
6.4 Tertiary Wastewater Treatment Processes
6.5 Atmospheric Emissions
6.6 Treatment of Solid Particulate Emissions to Atmosphere
6.7 Treatment of VOC Emissions to Atmosphere
6.8 Treatment of Sulfur Emissions to Atmosphere
6.9 Treatment of Oxides of Nitrogen Emissions to Atmosphere
6.10 Treatment of Combustion Emissions to Atmosphere
6.11 Atmospheric Dispersion
6.12 Waste Treatment - Summary
6.13 Exercises
References
Chapter 7 Reliability, Maintainability and Availability Concepts
7.1 Reliability, Maintainability and Availability
7.2 Reliability
7.3 Repairable and Non-repairable Systems
7.4 Reliability Data
7.5 Maintainability
7.6 Availability
7.7 Process Shutdown for Maintenance
7.8 Reliability, Maintainability and Availability - Summary
7.9 Exercises
References
Chapter 8 Reliability, Maintainability and Availability of Process Systems
8.1 System Representation
8.2 Reliability of Series Systems
8.3 Reliability of Parallel Systems
8.4 Availability of Parallel Systems
8.5 Availability of Series Systems
8.6 Redundancy
8.7 k-out-of-n Systems
8.8 Common Mode Failure
8.9 Capacity
8.10 Reliability, Availability and Capacity
8.11 Monte Carlo Simulation
8.12 Reliability, Maintainability and Availability of Process Systems - Summary
8.13 Exercises
References
Chapter 9 Storage Tanks
9.1 Feed, Intermediate and Product Storage
9.2 Intermediate (Buffer) Storage and Process Availability
9.3 Optimization of Intermediate Storage
9.4 Storage Tanks - Summary
9.5 Exercises
References
Chapter 10 Process Control Concepts
10.1 Control Objectives
10.2 The Control Loop
10.3 Measurement
10.4 Control Signals
10.5 The Controller
10.6 Final Control Element
10.7 Feedback Control
10.8 Cascade Control
10.9 Split Range Control
10.10 Limit and Selector
10.11 Feedforward Control
10.12 Ratio Control
10.13 Computer Control Systems
10.14 Digital Control
10.15 Safety Instrumented Systems
10.16 Alarms and Trips
10.17 Representation of Control Systems
10.18 Process Control Concepts - Summary
10.19 Exercises
References
Chapter 11 Process Control - Flowrate and Inventory Control
11.1 Flowrate Control
11.2 Inventory Control of Individual Operations
11.3 Inventory Control of Series Systems
11.4 Inventory Control of Recycle Systems
11.5 Flowrate and Inventory Control - Summary
11.6 Exercises
References
Chapter 12 Process Control - Degrees of Freedom
12.1 Degrees of Freedom and Process Control
12.2 Control Degrees of Freedom for Individual Operations
12.3 Individual Single Phase Operations
12.4 Heat Transfer Operations With No Phase Change
12.5 Pumps and Compressors
12.6 Equilibrated Multiphase Operations
12.7 Control Degrees of Freedom for Overall Processes
12.8 Degrees of Freedom - Summary
12.9 Exercises
References
Chapter 13 Process Control - Control of Process Operations
13.1 Pump Control
13.2 Compressor Control
13.3 Heat Exchanger Control
13.4 Furnace Control
13.5 Flash Drum Control
13.6 Absorber and Stripper Control
13.7 Distillation Control
13.8 Reactor Control
13.9 Control of Process Operations - Summary
13.10 Exercises
References
Chapter 14 Process Control - Overall Process Control
14.1 Illustrative Example of Overall Process Control Systems
14.2 Synthesis of Overall Process Control Schemes
14.3 Procedure for the Synthesis of Overall Process Control Schemes
14.4 Evolution of the Control Design
14.5 Process Dynamics
14.6 Overall Process Control - Summary
14.7 Exercises
References
Chapter 15 Piping and Instrumentation Diagrams - Piping and Pressure Relief
15.1 Piping and Instrumentation Diagrams
15.2 Piping Systems
15.3 Pressure Relief
15.4 Relief Device Arrangements
15.5 Reliability of Pressure Relief Devices
15.6 Location of Relief Devices
15.7 P&ID Piping and Pressure Relief - Summary
15.8 Exercises
References
Chapter 16 Piping and Instrumentation Diagrams - Process Operations
16.1 Pumps
16.2 Compressors
16.3 Heat Exchangers
16.4 Distillation
16.5 Liquid Storage
16.6 P&ID Process Operations - Summary
16.7 Exercises
References
Chapter 17 Piping and Instrumentation Diagrams - Construction
17.1 Development of Piping and Instrumentation Diagrams
17.2 A Case Study
17.3 P&ID Construction - Summary
References
Chapter 18 Materials of Construction
18.1 Mechanical Properties
18.2 Corrosion
18.3 Corrosion Allowance
18.4 Commonly Used Materials of Construction
18.5 Criteria for Selection of Materials of Construction
18.6 Materials of Construction - Summary
References
Chapter 19 Mechanical Design
19.1 Stress, Strain and Deformation
19.2 Combined Stresses
19.3 Spherical Vessels Under Internal Pressure
19.4 Cylindrical Vessels Under Internal Pressure
19.5 Design of Heads for Cylindrical Vessels Under Internal Pressure
19.6 Design of Vertical Cylindrical Pressure Vessels Under Internal Pressure
19.7 Design of Horizontal Cylindrical Pressure Vessels Under Internal Pressure
19.8 Buckling of Cylindrical Vessels Due to External Pressure and Axial Compression
19.9 Welded and Bolted Joints
19.10 Opening Reinforcements
19.11 Vessel Supports
19.12 Design of Flat-bottomed Cylindrical Vessels
19.13 Shell-and-tube Heat Exchangers
19.14 Mechanical Design - Summary
19.15 Exercises
References
Chapter 20 Process Plant Layout - Site Layout
20.1 Site, Process and Equipment Layout
20.2 Separation Distances
20.3 Separation for Vapor Cloud Explosions
20.4 Separation for Toxic Emissions
20.5 Site Access
20.6 Site Topology, Groundwater and Drainage
20.7 Geotechnical Engineering
20.8 Atmospheric Discharges
20.9 Wind Direction
20.10 Utilities
20.11 Process Units
20.12 Control Room
20.13 Ancillary Buildings
20.14 Pipe Racks
20.15 Constraints on Site Layout
20.16 The Final Site Layout
20.17 Site Layout ? Summary
References
Chapter 21 Process Plant Layout - Process Layout
21.1 Process Access
21.2 Process Structures
21.3 Hazards
21.4 Preliminary Process Layout
21.5 Example - Preliminary Process Layout
21.6 Process Layout - Summary
21.7 Exercises
References
Appendix A - Weibull Reliability Function
Appendix B - MTTF for the Weibull Distribution
Appendix C - Reliability of Cold Standby Systems
Appendix D - Corrosion Resistance Table
Appendix E - Moment of Inertia and Bending Stress for Common Beam Cross Sections
E.1 Solid Rectangular Cross Section
E.2 Hollow Rectangular Cross Section
F.3 Solid Circular Cylinder
F.4 Hollow Circular Cross Section
F.5 Approximate Expressions for Thin-Walled Cylinders
Appendix F - First Moment of Area and Shear Stress for Common Beam Cross Sections
F.1 Solid Rectangular Cross Section
F.2 Hollow Rectangular Cross Section
F.3 Solid Circular Cross Section
F.3 Hollow Circular Cross Sections
Appendix G - Principal Stresses
Appendix H - Dimensions and Weights of Carbon Steel Pipes
Appendix I - Bending Stress on Horizontal Cylindrical Vessels Resulting from the Hydraulic Head
Appendix J - Equivalent Cylinder Approximation