Chemical process design and integration /
Robin Smith.
- xxiii, 687 pages : illustrations ; 29 cm.
Includes bibliographical references and index.
CONTENTS Preface Acknowledgements Nomenclature Chapter 1 The Nature of Chemical Process Design and Integration 1.1 Chemical Products 1.2 Formulation of Design Problems 1.3 Chemical Process Design and Integration 1.4 The Hierarchy of Chemical Process Design and Integration 1.5 Continuous and Batch Processes 1.6 New Design and Retrofit 1.7 Approaches to Chemical Process Design and Integration 1.8 Process Control 1.9 The Nature of Chemical Process Design and Integration - Summary 1.10 References Chapter 2 Process Economics 2.1 The Role of Process Economics 2.2 Simple Economic Criteria 2.3 Capital Cost for New Design 2.4 Capital Cost for Retrofit 2.5 Annualized Capital Cost 2.6 Operating Cost 2.7 Project Cash Flow and Economic Evaluation 2.8 Investment Criteria 2.9 Economic Evaluation - Summary 2.10 Exercises 2.11 References Chapter 3 Optimization 3.1 Objective Functions 3.2 Single Variable Optimization 3.3 Multivariable Optimization 3.4 Constrained Optimization 3.5 Linear Programming 3.6 Non-linear Programming 3.7 Profile Optimization 3.8 Structural Optimization 3.9 Solution of Equations Using Optimization 3.10 The Search for Global Optimality 3.11 Optimization - Summary 3.12 Exercises 3.13 References Chapter 4 Phase Equilibrium and Thermodynamic Properties 4.1 Equations of State 4.2 Phase Equilibrium for Single Components 4.3 Fugacity and Phase Equilibrium 4.4 Vapor-liquid Equilibrium 4.5 Vapor-liquid Equilibrium Based on Activity Coefficient Models 4.6 Vapor-liquid Equilibrium Based on Equations of State 4.7 Calculation of Vapor-liquid Equilibrium 4.8 Liquid-liquid Equilibrium 4.9 Liquid-liquid Equilibrium Activity Coefficient Models 4.10 Calculation of Liquid-liquid Equilibrium 4.11 Calculation of Enthalpy 4.12 Calculation of Entropy 4.13 Phase Equilibrium and Thermodynamic Properties - Summary 4.14 Exercises 4.15 References Chapter 5 Choice of Reactor I - Reactor Performance 5.1 Reaction Paths 5.2 Types of Reaction Systems 5.3 Measures of Reactor Performance 5.4 Rate of Reaction 5.5 Idealized Reactor Models 5.6 Choice of Idealized Reactor Model 5.7 Choice of Reactor Performance 5.8 Choice of Reactor Performance - Summary 5.9 Exercises 5.10 References Chapter 6 Choice of Reactor II - Reactor Conditions 6.1 Reaction Equilibrium 6.2 Reactor Temperature 6.3 Reactor Pressure 6.4 Reactor Phase 6.5 Reactor Concentration 6.6 Biochemical Reactions 6.7 Catalysts 6.8 Choice of Reactor Conditions - Summary 6.9 Exercises 6.10 References Chapter 7 Choice of Reactor III - Reactor Configuration 7.1 Temperature Control 7.2 Catalyst Deactivation 7.3 Gas-liquid and Liquid-liquid Reactors 7.4 Reactor Configuration 7.5 Reactor Configuration for Heterogeneous Solid-catalyzed Reactions 7.6 Reactor Configuration from Optimization of a Superstructure 7.7 Choice of Reactor Configuration - Summary 7.8 Exercises 7.9 References Chapter 8 Choice of Separator for Heterogeneous Mixtures 8.1 Homogeneous and Heterogeneous Separation 8.2 Settling and Sedimentation 8.3 Inertial and Centrifugal Separation 8.4 Electrostatic Precipitation 8.5 Filtration 8.6 Scrubbing 8.7 Flotation 8.8 Drying 8.9 Separation of Heterogeneous Mixtures - Summary 8.10 Exercises 8.11 References Chapter 9 Choice of Separator for Homogeneous Fluid Mixtures I - Distillation 9.1 Single Stage Separation 9.2 Distillation 9.3 Binary Distillation 9.4 Total and Minimum Reflux Conditions for Multicomponent Mixtures 9.5 Finite Reflux Conditions for Multicomponent Mixtures 9.6 Choice of Operating Conditions 9.7 Limitations of Distillation 9.8 Separation of Homogeneous Fluid Mixtures by Distillation - Summary 9.9 Exercises 9.10 References Chapter 10 Choice of Separator for Homogeneous Fluid Mixtures II - Other Methods 10.1 Absorption 10.2 Liquid-liquid Extraction 10.3 Adsorption 10.4 Membranes 10.5 Crystallization 10.6 Evaporation 10.7 Separation of Homogeneous Fluid Mixtures by Other Methods - Summary 10.8 Exercises 10.9 References Chapter 11 Distillation Sequencing 11.1 Distillation Sequencing Using Simple Columns 11.2 Practical Constraints Restricting Options 11.3 Choice of Sequence for Simple Non-integrated Distillation Columns 11.4 Distillation Sequencing Using Columns with More than Two Products 11.5 Distillation Sequencing Using Thermal Coupling 11.6 Retrofit of Distillation Sequences 11.7 Crude Oil Distillation 11.8 Distillation Sequencing Based on Optimization of a Superstructure 11.9 Distillation Sequencing - Summary 11.10 Exercises 11.11 References Chapter 12 Distillation Sequencing for Azeotropic Distillation 12.1 Azeotropic Systems 12.2 Change in Pressure 12.3 Representation of Azeotropic Distillation 12.4 Distillation at Total Reflux Conditions 12.5 Distillation at Minimum Reflux Conditions 12.6 Distillation at Finite Reflux Conditions 12.7 Distillation Sequencing Using an Entrainer 12.8 Heterogeneous Azeotropic Distillation 12.9 Entrainer Selection 12.10 Multicomponent Systems 12.11 Trade-offs in Azeotropic Distillation 12.12 Membrane Separation 12.13 Distillation Sequencing for Azeotropic Distillation - Summary 12.14 Exercises 12.15 References Chapter 13 Reaction, Separation and Recycle Systems for Continuous Processes 13.1 The Function of Process Recycles 13.2 Recycles With Purges 13.3 Pumping and Compression 13.4 Simulation of Recycles 13.5 The Process Yield 13.6 Optimization of Reactor Conversion 13.7 Optimization of Processes Involving a Purge 13.8 Hybrid Reaction and Separation 13.9 Feed, Product and Intermediate Storage 13.10 Reaction and Separation Systems for Continuous Processes - Summary 13.11 Exercises 13.12 References Chapter 14 Reaction, Separation and Recycle Systems for Batch Processes 14.1 Batch Processes 14.2 Batch Reactors 14.3 Batch Separation Processes 14.4 Gantt Charts 14.5 Production Schedules for Single Products 14.6 Production Schedules for Multiple Products 14.7 Equipment Cleaning and Material Transfer 14.8 Synthesis of Reaction and Separation Systems for Batch Processes 14.9 Optimization of Batch Processes 14.10 Storage in Batch Processes 14.11 Reaction-Separation Systems for Batch Processes - Summary 14.12 Exercises 14.13 References Chapter 15 Heat Exchanger Networks I - Heat Transfer Equipment 15.1 Overall Heat Transfer Coefficients 15.2 Heat Transfer Coefficients and Pressure Drops in Shell-and-tube Heat Exchangers 15.3 Temperature Difference in Shell-and-tube Heat Exchangers 15.4 Allocation of Fluids in Shell-and-tube Heat Exchangers 15.5 Extended Surface Tubes 15.6 Condensers 15.7 Reboilers 15.8 Other Types of Heat Exchanger Equipment 15.9 Heat Exchanger Equipment - Summary 15.10 Exercises 15.11 References Chapter 16 Heat Exchanger Networks II - Energy Targets 16.1 Composite Curves 16.2 The Heat Recovery Pinch 16.3 Threshold Problems 16.4 The Problem Table Algorithm 16.5 Non-global Minimum Temperature Differences 16.6 Process Constraints 16.7 Utility Selection 16.8 Furnaces 16.9 Cogeneration (Combined Heat and Power Generation) 16.10 Integration of Heat Pumps 16.11 Heat Exchanger Network and Utilities Energy Targets - Summary 16.12 Exercises 16.13 References Chapter 17 Heat Exchanger Networks II - Capital and Total Cost Targets 17.1 Number of Heat Exchange Units 17.2 Heat Exchange Area Targets 17.3 Number of Shells Target 17.4 Capital Cost Targets 17.5 Total Cost Targets 17.6 Heat Exchanger Network and Utilities Capital and Total Costs - Summary 17.7 Exercises 17.8 References Chapter 18 Heat Exchanger Networks III - Network Design 18.1 The Pinch Design Method 18.2 Design for Threshold Problems 18.3 Stream Splitting 18.4 Design for Multiple Pinches 18.5 Remaining Problem Analysis 18.6 Network Optimization 18.7 Heat Exchanger Network Design Based on the Optimization of a Superstructure 18.8 Heat Exchanger Network Retrofit 18.9 Addition of New Heat Transfer Area in Retrofit 18.10 Heat Exchanger Network Design - Summary 18.11 Exercises 18.12 References Chapter 19 Heat Exchanger Networks IV - Stream Data 19.1 Process Changes for Heat Integration 19.2 The Trade-offs Between Process Changes, Utility Selection, 19.3 Data Extraction 19.4 Heat Exchanger Network Stream Data - Summary 19.5 Exercises 19.6 Reference Chapter 20 Heat Integration of Reactors 20.1 The Heat Integration Characteristics of Reactors 20.2 Appropriate Placement of Reactors 20.3 Use of the Grand Composite Curve for Heat Integration of Reactors 20.4 Evolving Reactor Design to Improve Heat Integration 20.5 Heat Integration of Reactors - Summary 20.6 References Chapter 21 Heat Integration of Distillation 21.1 The Heat Integration Characteristics of Distillation 21.2 Appropriate Placement of Distillation 21.3 Use of the Grand Composite Curve for Heat Integration of Distillation 21.4 Evolving the Design of Simple Distillation Columns to Improve Heat Integration 21.5 Heat Pumping in Distillation 21.6 Capital Cost Considerations for the Integration of Distillation 21.7 Heat Integration Characteristics of Distillation Sequences 21.8 Heat Integrated Distillation Sequences Based on Optimization of a Superstructure 21.9 Heat Integration of Distillation Columns - Summary 21.10 Exercises 21.11 References Chapter 22 Heat Integration of Evaporators and Dryers 22.1 The Heat Integration Characteristics of Evaporators 22.2 Appropriate Placement of Evaporators 22.3 Evolving Evaporator Design to Improve Heat Integration 22.4 The Heat Integration Characteristics of Dryers 22.5 Evolving Dryer Design to Improve Heat Integration 22.6 A Case Study 22.7 Heat Integration of Evaporators and Dryers - Summary 22.8 Exercises 22.9 References Chapter 23 Steam Systems and Cogeneration 23.1 Boiler Feedwater Treatment 23.2 Steam Boilers 23.3 Steam Turbines 23.4 Gas Turbines 23.5 Steam System Configuration 23.6 Steam and Power Balances 23.7 Site Composite Curves 23.8 Cogeneration Targets 23.9 Optimizing Steam Levels 23.10 Site Power-to-Heat Ratio 23.11 Optimizing Steam Systems 23.12 Steam Costs 23.13 Choice of Driver 23.14 Steam Systems and Cogeneration - Summary 23.15 Exercises 23.16 References Chapter 24 Cooling and Refrigeration Systems 24.1 Cooling Systems 24.2 Recirculating Cooling Water Systems 24.3 Targeting Minimum Cooling Water Flowrate 24.4 Design of Cooling Water Networks 24.5 Retrofit of Cooling Water Systems 24.6 Refrigeration Cycles 24.7 Process Expanders 24.8 Choice of Refrigerant for Compression Refrigeration 24.9 Targeting Refrigeration Power for Compression Refrigeration 24.10 Heat Integration of Compression Refrigeration Processes 24.11 Mixed Refrigerants for Compression Refrigeration 24.12 Absorption Refrigeration 24.13 Indirect Refrigeration 24.14 Cooling and Refrigeration Systems - Summary 24.15 Exercises 24.16 References Chapter 25 Environmental Design for Atmospheric Emissions
25.1 Atmospheric Pollution 25.2 Sources of Atmospheric Pollution 25.3 Control of Solid Particulate Emissions to Atmosphere 25.4 Control of VOC Emissions 25.5 Control of Sulfur Emissions 25.6 Control of Oxides of Nitrogen 25.7 Control of Combustion Emissions 25.8 Atmospheric Dispersion 25.9 Environmental Design for Atmospheric Emissions - Summary 25.10 Exercises 25.11 References Chapter 26 Water System Design 26.1 Aqueous Contamination 26.2 Primary Treatment Processes 26.3 Biological Treatment Processes 26.4 Tertiary Treatment Processes 26.5 Water Use 26.6 Targeting Maximum Water Re-use for Single Contaminants 26.7 Design for Maximum Water Re-use for Single Contaminants 26.8 Targeting and Design for Maximum Water Re-use Based on Optimization of Superstructure 26.9 Process Changes for Reduced Water Consumption 26.10 Targeting Minimum Wastewater Treatment Flowrate for Single Contaminants 26.11 Design for Minimum Wastewater Treatment Flowrate for Single Contaminants 26.12 Regeneration of Wastewater 26.13 Targeting and Design for Effluent Treatment and Regeneration Based Optimization of a Superstructure 26.14 Data Extraction 26.15 Water System Design - Summary 26.16 Exercises 26.17 References Chapter 27 Inherent Safety 27.1 Fire 27.2 Explosion 27.3 Toxic Release 27.4 Intensification of Hazardous Materials 27.5 Attenuation of Hazardous Materials 27.6 Quantitative Measures of Inherent Safety 27.7 Inherent Safety - Summary 27.8 Exercises 27.9 References Chapter 28 Waste Minimization 28.1 Minimization of Waste from Reactors 28.2 Minimization of Waste from the Separation and Recycle System 28.3 Minimization of Waste from Process Operations 28.4 Minimization of Utility Waste 28.5 Trading Off Waste Minimization Options 28.6 Life-Cycle Analysis 28.7 Waste Minimization in Practice 28.8 Waste Minimization - Summary 28.9 Exercises 28.10 References Chapter 29 Overall Strategy for Chemical Process Design and Integration 29.1 The Objectives 29.2 The Hierarchy 29.3 The Final Design Appendix A Annualization of Capital Cost Appendix B Gas Compression B.1 Reciprocating Compressors B.2 Centrifugal Compressors Appendix C Heat Transfer Coefficients and Pressure Drop in Shell-and-Tube Heat Exchangers C.1 Pressure Drop and Heat Transfer Correlations for the Tube-side C.2 Pressure Drop and Heat Transfer Correlations for the Shell-side C.3 References Appendix D Maximum Thermal Effectiveness for 1-2 Shell-and-Tube Heat Exchangers Appendix E Expression for the Minimum Number of 1-2 Shell-and-Tube Heat Exchangers for a Given Unit Appendix F Algorithm for the Heat Exchange Area Target Appendix G Algorithm for the Number-of-Shells Target G.1 Minimum Area Target for Networks of 1-2 Shells G.2 References Appendix H Algorithm for Heat Exchanger Capital Cost Target