Martyn S. Ray Martyn, Martyn S. Ray, Martin G. Sneesby

Chemical Engineering Design Project

A Case Study Approach, Second Edition

• Gebundenes Buch

Produktbeschreibung

This new edition follows the original format, which combines a detailed case study - the production of phthalic anhydride - with practical advice and comprehensive background information. Guiding the reader through all major aspects of a chemical engineering design, the text includes both the initial technical and economic feasibility study as well as the detailed design stages. Each aspect of the design is illustrated with material from an award-winning student design project. The book embodies the "learning by doing" approach to design. The student is directed to appropriate information sources and is encouraged to make decisions at each stage of the design process rather than simply following a design method. Thoroughly revised, updated, and expanded, the accompanying text includes developments in important areas and many new references.

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Produktdetails

• Verlag: Routledge
• Revised
• Seitenzahl: 364
• Erscheinungstermin: 1. Oktober 1998
• Englisch
• Abmessung: 260mm x 183mm x 24mm
• Gewicht: 879g
• ISBN-13: 9789056991364
• ISBN-10: 9056991361
• Artikelnr.: 23443498

Autorenporträt

Martyn S. Ray is currently Associate Professor in Chemical Engineering at Curtin University of Technology, Western Australia, where he has taught the final year design class since 1985. He has industrial experience as a chemical engineer with BOC International (UK) Ltd and has held lecturing positions in the UK and the West Indies. He obtained his B.Sc. and Ph.D. in Chemical Engineering from the University of Surrey, UK and has published many papers and books. Martin G. Sneesby received a B.Eng. from Curtin University in 1991. He won awards for Curtin University's Most Promising Engineering Graduate and Best Design Project in Chemical Engineering. His final year design project then won the 1992 National CHEMECA Design Prize. After graduation he worked for Mobil Oil (Australia) in various roles, including Process Design Engineer, before returning to Curtin University to pursue a Ph.D.

Inhaltsangabe

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.