Contents
Preface
About the Authors
List of Nomenclature
SECTION 1 CONCEPTUALIZATION AND ANALYSIS OF CHEMICAL
PROCESSES
Chapter 1 Diagrams for Understanding Chemical Processes
1.1 Block Flow Diagram (BFD)
1.1.1 Block Flow Process Diagram
1.1.2 Block Flow Plant Diagram
1.2 Process Flow Diagram (PFD)
1.2.1 Process Topology
1.2.2 Stream Information
1.2.3 Equipment Information
1.2.4 Combining Topology, Stream Data, and Control Strategy to Give a
PFD
1.3 Piping and Instrumentation Diagram (P&ID)
1.4 Additional Diagrams
1.5 3-Dimensional Representation of a Process
1.6 The 3-D Plant Model
1.7 Summary
References
Problems
Chapter 2 The Structure and Synthesis of Process Flow Diagrams

2.1 Introduction
2.2 Step 1 - Batch vs. Continuous Process
2.3 Step 2 - The Input-Output Structure of the Process
2.3.1 Process Concept Diagram
2.3.2 The Input-Output Structure of the Process Flow Diagram
2.3.3 The Input-Output Structure and Other Features of the Generic Block
Flow Process Diagram
2.3.4 Other Considerations for the Input-Output Structure of the
Process Flowsheet
2.3.5 What Information Can Be Determined Using the Input-Output
Diagram for a Process?
2.4 Step 3 - The Recycle Structure of the Process
2.4.1 Efficiency of Raw Material Usage
2.4.2 Identification and Definition of the Recycle Structure of the
Process
2.4.3 Other Issues Affecting the Recycle Structure That Lead to
Process Alternatives
2.5 Step 4 - General Structure of the Separation System
2.6 Step 5 - Heat-Exchanger Network or Process Energy Recovery
System
2.7 Information Required and Sources
2.8 Summary
References
Problems
Chapter 3 Batch Processing
3.1 Design Calculations for Batch Processes
3.2 Gantt Charts and Scheduling
3.3 Non-Overlapping, Overlapping operations, and Cycle times
3.4 Multiproduct and Multipurpose Plants
3.4.1 Multipurpose (Flowshop) Plants
3.4.2 Multiproduct (Jobshop) Plants
3.5 Product and Intermediate Storage and Parallel Process Units
3.5.1 Product storage for single product campaigns
3.5.2 Intermediate Storage
3.5.3 Parallel Processing Units
3.6 Design of Equipment for Multiproduct Batch Processes
3.7 Summary
References
Problems
Chapter 4 Chemical Product Design
4.1 Strategies for Chemical Product
4.2 Needs
4.3 Ideas
4.4 Selection
4.5 Manufacture
4.6 Batch Processing
4.7 Economic Considerations
4.8 Summary
References
Chapter 5 Tracing Chemicals through the Process Flow Diagram
5.1 Guidelines and Tactics for Tracing Chemicals
5.2 Tracing Primary Paths Taken by Chemicals in a Chemical Process
5.3 Recycle and Bypass Streams
5.4 Tracing Nonreacting Chemicals
5.5 Limitations 111
5.6 Written Process Description
5.7 Summary
Problems

Chapter 6 Understanding Process Conditions
6.1 Conditions of Special Concern for the Operation of Separation and
Reactor Systems
6.1.1 Pressure
6.1.2 Temperature
6.2 Reasons for Operating at Conditions of Special Concern
6.3 Conditions of Special Concern for the Operation of Other Equipment
6.4 Analysis of Important Process Conditions
6.4.1 Evaluation of Reactor R-101
6.4.2 Evaluation of High-Pressure Phase Separator V-101
6.4.3 Evaluation of Large Temperature Driving Force in Exchanger E-101
6.4.4 Evaluation of Exchanger E-102
6.4.5 Pressure Control Valve on Stream 8
6.4.6 Pressure Control Valve on Stream from V-102 to V-103
6.5 Summary
References
Problems
SECTION 2 ENGINEERING ECONOMIC ANALYSIS OF CHEMICAL
PROCESSES
Chapter 7 Estimation of Capital Costs
7.1 Classifications of Capital Cost Estimates
7.2 Estimation of Purchased Equipment Costs
7.2.1 Effect of Capacity on Purchased Equipment Cost
7.2.2 Effect of Time on Purchased Equipment Cost
7.3 Estimating the Total Capital Cost of a Plant
7.3.1 Lang Factor Technique
7.3.2 Module Costing Technique
7.3.3 Bare Module Cost for Equipment at Base Conditions
7.3.4 Bare Module Cost for Nonbase Case Conditions
7.3.5 Combination of Pressure and MOC Information to Give the
Bare Module Factor, FBM, and Bare Module Cost, CBM
7.3.6 Algorithm for Calculating Bare Module Costs
7.3.7 Grass Roots and Total Module Costs
7.3.8 A Computer Program (CAPCOST©) for Capital Cost
Estimation Using the Equipment Module Approach
7.4 Summary
References
Problems

Chapter 8 Estimation of Manufacturing Costs
8.1 Factors Affecting the Cost of Manufacturing a Chemical Product
8.2 Cost of Operating Labor
8.3 Utility Costs
8.3.1 Background Information on Utilities
8.3.2 Calculation of Utility Costs
8.4 Raw Material Costs
8.5 Yearly Costs and Stream Factors
8.6 Estimating Utility Costs from the PFD
8.7 Cost of Treating Liquid and Solid Waste Streams
8.8 Evaluation of Cost of Manufacture for the Production of Benzene via the
Hydrodealkylation of Toluene
8.9 Summary
References
Problems
Chapter 9 Engineering Economic Analysis
9.1 Investments and the Time Value of Money
9.2 Different Types of Interest
9.2.1 Simple Interest
9.2.2 Compound Interest
9.2.3 Interest Rates Changing with Time
9.3 Time Basis for Compound Interest Calculations
9.3.1 Effective Annual Interest Rate
9.3.2 Continuously Compounded Interest
9.4 Cash Flow Diagrams
9.4.1 Discrete Cash Flow Diagram
9.4.2 Cumulative Cash Flow Diagram
9.5 Calculations from Cash Flow Diagrams
9.5.1 Annuities; A Uniform Series of Cash Transactions
9.5.2 Discount Factors
9.6 Inflation
9.7 Depreciation of Capital Investment
9.7.1 Fixed Capital, Working Capital, and Land
9.7.2 Different Types of Depreciation
9.7.3 Current Depreciation Method; Modified Accelerated Cost
Recovery System (MACRS)
9.8 Taxation, Cash Flow, and Profit
9.9 Summary
References
Problems
Chapter 10 Profitability Analysis
10.1 A Typical Cash Flow Diagram for a New Project
10.2 Profitability Criteria for Project Evaluation
10.2.1 Nondiscounted Profitability Criteria
10.2.2 Discounted Profitability Criteria
10.3 Comparing Several Large Projects; Incremental Economic
Analysis
10.4 Establishing Acceptable Returns from Investments; The Concept of
Risk
10.5 Evaluation of Equipment Alternatives
10.5.1 Equipment with the Same Expected Operating Lives
10.5.2 Equipment with Different Expected Operating Lives
10.6 Incremental Analysis for Retrofitting Facilities
10.6.1 Nondiscounted Methods for Incremental Analysis
10.6.2 Discounted Methods for Incremental Analysis
10.7 Evaluation of Risk in Evaluating Profitability
10.7.1 Forecasting Uncertainty in Chemical Processes
10.7.2 Quantifying Risk
10.8 Profit Margin Analysis
10.9 Summary
References
Problems
SECTION 3 SYNTHESIS AND OPTIMIZATION OF CHEMICAL
PROCESSES
Chapter 11 Utilizing Experience-Based Principles to Confirm the Suitability of a Process
Design
11.1 The Role of Experience in the Design Process
11.1.1 Introduction to Technical Heuristics and Short-Cut Methods
11.1.2 Maximizing the Benefits Obtained from Experience
11.2 Presentation of Tables of Technical Heuristics and Guidelines
11.3 Summary
References
Problems

Chapter 12 Synthesis of the PFD from the Generic BFD
12.1 Information Needs and Sources
12.1.1 Interactions with Other Engineers and Scientists
12.1.2 Reaction Kinetics Data
12.1.3 Physical Property Data
12.2 Reactor Section
12.3 Separator Section
12.3.1 General Guidelines for Choosing Separation Operations
12.3.2 Sequencing of Distillation Columns for Simple Distillation
12.3.3 Azeotropic Distillation
12.4 Reactor Feed Preparation and Separator Feed Preparation Sections
12.5 Recycle Section
12.6 Environmental Control Section
12.7 Major Process Control Loops
12.8 Flow Summary Table
12.9 Major Equipment Summary Table
12.10 Summary
References
Problems
Chapter 13 Synthesis of a Process Using a Simulator and Simulator Troubleshooting
13.1 The Structure of a Process Simulator
13.2 Information Required to Complete a Process Simulation - Input Data
13.2.1 Selection of Chemical Components
13.2.2 Selection of Physical Property Model(s)
13.2.3 Input the Topology of the Flowsheet
13.2.4 Select Feed Stream Properties
13.2.5 Select Equipment Parameters
13.2.6 Selection of Output Display Options
13.2.7 Selection of Convergence Criteria and Running a Simulation
13.3 Handling Recycle Streams
13.4 Choosing Thermodynamic Models
13.4.1 Pure-Component Properties
13.4.2 Enthalpy
13.4.3 Phase Equilibria
13.4.4 Using Thermodynamic Models
13.5 Case Study; Toluene Hydrodealkylation Process
13.6 Summary
References
Problems
Chapter 14 Process Optimization
14.1 Background Information on Optimization
14.1.1 Common Misconceptions
14.1.2 Estimating Problem Difficulty
14.1.3 Top-down/Bottom-up Strategies
14.1.4 Communication of Optimization Results
14.2 Strategies
14.2.1 Base Case
14.2.2 Objective Functions
14.2.3 Analysis of the Base Costs
14.2.4 Identifying and Prioritizing Key Decision Variables
14.3 Topological Optimization
14.3.1 Introduction
14.3.2 Elimination of Unwanted Nonhazardous By-products or
Hazardous Waste Streams
14.3.3 Elimination and Rearrangement of Equipment
14.3.4 Alternative Separation Schemes and Reactor Configurations
14.4 Parametric Optimization
14.4.1 Single Variable Optimization: A Case Study on T-201, the
DME Separation Column
14.4.2 Two-Variable Optimization: The Effect of Pressure and Reflux
Ratio on T-201, the DME Separation Column
14.4.3 Flowsheet Optimization Using Key Decision Variables
14.5 Lattice Search Techniques vs. Experimental Design
14.6 Process Flexibility and the Sensitivity of the Optimum
14.7 Optimization in Batch Systems
14.7.1 Problem of Scheduling Equipment
14.7.2 Problem of Optimum Cycle Time
14.8 Summary
References
Problems
Chapter 15 Pinch Technology
15.1 Introduction
15.2 Heat Integration and Network Design
15.3 Composite Temperature Enthalpy Diagram
15.4 Composite Enthalpy Curves for Systems without a Pinch
15.5 Using the Composite Enthalpy Curve to Estimate Heat Exchanger
Surface Area
15.6 Effectiveness Factor (F) and the Number of Shells
15.7 Combining Costs to Give the EAOC for the Network
15.8 Other Considerations
15.8.1 Materials of Construction and Operating Pressure Issues
15.8.2 Problems with Multiple Utilities
15.8.3 Handling Streams with Phase Changes
15.9 Heat Exchanger Network Synthesis Analysis and Design (HENSAD)
Program
15.10 Mass-Exchange Networks
15.11 Summary
References
Problems
SECTION 4 ANALYSIS OF PROCESS PERFORMANCE
Chapter 16 Process Input/Output Models
16.1 Representation of Process Inputs and Outputs
16.2 Analysis of the Effect of Process Inputs on Process Outputs
16.3 A Process Example
16.4 Summary
Problems
Chapter 17 Tools for Evaluating Process Performance
17.1 Key Relationships
17.2 Thinking with Equations
17.2.1 GENI
17.2.2 Predicting Trends
17.3 Base Case Ratios
17.4 Analysis of Systems Using Controlling Resistances
17.5 Graphical Representations
17.5.1 The Moody Diagram for Friction Factors
17.5.2 The System Curve for Frictional Losses
17.5.3 The T-Q Diagram for Heat Exchangers
17.6 Summary
Reference
Problems

Chapter 18 Performance Curves for Individual Unit Operations
18.1 Applications to Heat Transfer
18.2 Application to Fluid Flow
18.2.1 Pump and System Curves
18.2.2 Regulating Flowrates
18.2.3 Reciprocating or Positive Displacement Pumps
18.2.4 Net Positive Suction Head
18.2.5 Compressors
18.3 Application to Separation Problems
18.3.1 Separations with Mass Separating Agents
18.3.2 Distillation
18.4 Summary
Reference
Problems
Chapter 19 Performance of Multiple Unit Operations
19.1 Analysis of a Reactor with Heat Transfer
19.2 Performance of a Distillation Column
19.3 Performance of a Heating Loop
19.4 Performance of the Feed Section to a Process
19.5 Summary
References
Problems
Chapter 20 Reactor Performance
20.1 Production of Desired Product
20.2 Reaction Kinetics and Thermodynamics
20.2.1 Reaction Kinetics
20.2.2 Thermodynamic Limitations
20.3 The Chemical Reactor
20.4 Heat Transfer in the Chemical Reactor
20.5 Reactor System Case Studies
20.5.1 Replacement of Catalytic Reactor in Benzene Process
20.5.2 Replacement of Cumene Catalyst
20.5.3 Increasing Acetone Production
20.6 Summary
References
Problems
Chapter 21 Regulating Process Conditions
21.1 A Simple Regulation Problem
21.2 The Characteristics of Regulating Valves
21.3 Regulating Flowrates and Pressures
21.4 The Measurement of Process Variables
21.5 Common Control Strategies Used in Chemical Processes
21.5.1 Feedback Control/Regulation
21.5.2 Feedforward Control/Regulation
21.5.3 Combination Feedback/Feedforward Control
21.5.4 Cascade Regulation
21.6 Exchanging Heat and Work between Process and Utility Streams
21.6.1 Increasing the Pressure of a Process Stream and Regulating
Its Flowrate
21.6.2 Exchanging Heat between Process Streams and Utilities
21.6.3 Exchanging Heat between Process Streams
21.7 Case Studies
21.7.1 The Cumene Reactor, R-801
21.7.2 A Basic Control System for a Binary Distillation Column
21.7.3 A More Sophisticated Control System for a Binary Distillation
Column
21.8 Summary
References
Problems
Chapter 22 Process Troubleshooting and Debottlenecking
22.1 Recommended Methodology
22.1.1 Elements of Problem-Solving Strategies
22.1.2 Application to Troubleshooting Problems
22.2 Troubleshooting Individual Units
22.2.1 Troubleshooting a Packed Bed Absorber
22.2.2 Troubleshooting the Cumene Process Feed Section
22.3 Troubleshooting Multiple Units
22.3.1 Troubleshooting Off-Specification Acrylic Acid Product
22.3.2 Troubleshooting Steam Release in Cumene Reactor
22.4 A Process Troubleshooting Problem
22.5 Debottlenecking Problems
22.6 Summary
References
Problems
SECTION 5 THE IMPACT OF CHEMICAL ENGINEERING DESIGN
ON SOCIETY
Chapter 23 Ethics and Professionalism
23.1 Ethics
23.1.1 Moral Autonomy
23.1.2 Rehearsal
23.1.3 Reflection in Action
23.1.4 Mobile Truth
23.1.5 Nonprofessional Responsibilities
23.1.6 Duties and Obligations
23.1.7 Codes of Ethics
23.1.8 Whistleblowing
23.1.9 Ethical Dilemmas
23.1.10 Additional Ethics Heuristics
23.1.11 Other Resources
23.2 Professional Registration
23.2.1 Engineer-in-Training
23.2.2 Registered Professional Engineer
23.3 Legal Liability
23.4 Business Codes of Conduct
References
Problems
Chapter 24 Health, Safety, and the Environment
24.1 Risk Assessment
24.1.1 Accident Statistics
24.1.2 Worst-Case Scenarios
24.1.3 The Role of the Chemical Engineer
24.2 Regulations and Agencies
24.2.1 OSHA and NIOSH
24.2.2 Environmental Protection Agency
24.2.3 Non-Governmental Organizations
24.3 Fires and Explosions
24.3.1 Terminology
24.3.2 Pressure Relief Systems
24.4 Process Hazard Analysis
24.4.1 HAZOP
24.4.2 Dow Fire & Explosion Index and Chemical Exposure
Index
24.5 Chemical Safety and Hazard Investigation Board
24.6 Inherently Safe Design
24.7 Summary
24.8 Glossary
References
Problems
Chapter 25 Green Engineering
25.1 Environmental Regulations
25.2 Environmental Fate of Chemicals
25.3 Green Chemistry
25.4 Pollution Prevention during Process Design
25.5 Analysis of a PFD for Pollution Performance and Environmental
Performance
25.6 An Example of the Economics of Pollution Prevention
25.7 Life-Cycle Analysis
25.8 Summary
References
Problems
SECTION 6 INTERPERSONAL AND COMMUNICATION SKILLS
Chapter 26 Teamwork
26.1 Groups
26.1.1 Characteristics of Effective Groups
26.1.2 Assessing and Improving the Effectiveness of a Group
26.1.3 Organizational Behaviors and Strategies
26.2 Group Evolution
26.2.1 Forming
26.2.2 Storming
26.2.3 Norming
26.2.4 Performing
26.3 Teams and Teamwork
26.3.1 When Groups Become Teams
26.3.2 Unique Characteristics of Teams
26.4 Misconceptions
26.4.1 Team Exams
26.4.2 Over-Reliance on Team Members
26.5 Learning in Teams
26.6 Other Reading
26.7 Summary
References
Problems
Appendix A Cost Equations and Curves for the CAPCOST© Program
A.1 Purchased Equipment Costs
A.2 Pressure Factors
A.2.1 Pressure Factors for Process Vessels
A.2.2 Pressure Factors for Other Process Equipment
A.3 Material Factors and Bare Module Factors
A.3.1 Bare Module and Material Factors for Heat Exchangers, Process
Vessels, and Pumps
A.3.2 Bare Module and Material Factors for the Remaining Process
Equipment
References
Appendix B Information for the Preliminary Design of Eleven Chemical Processes
Project B.1 - DME Production Unit 200
B.1.1 Process Description
B.1.2 Reaction Kinetics
B.1.3 Simulation (CHEMCAD) Hints
B.1.4 References
Project B.2 - Ethyl Benzene Production Unit 300
B.2.1 Process Description
B.2.2 Reaction Kinetics
B.2.3 Simulation (Chemcad) Hints
B.2.4 References
Project B.3 - Styrene Production Unit 400
B.3.1 Process Description
B.3.2 Reaction Kinetics
B.3.3 Simulation (Chemcad) Hints
B.3.4 References
Project B.4 - Drying Oil Production Unit 500
B.4.1 Process Description
B.4.2 Reaction Kinetics
B.4.3 Simulation (Chemcad) Hints
B.4.4 References
Project B.5 - Production of Maleic Anhydride from Benzene Unit 600
B.5.1 Process Description
B.5.2 Reaction Kinetics
B.5.3 Simulation (Chemcad) Hints
B.5.4 References
Project B.6 - Ethylene Oxide Production Unit 700
B.6.1 Process Description
B.6.2 Reaction Kinetics
B.6.3 Simulation (Chemcad) Hints
B.6.4 References
Project B.7 - Formalin Production Unit 800
B.7.1 Process Description
B.7.2 Reaction Kinetics
B.7.3 Simulation (Chemcad) Hints
B.7.4 References
Project B.8 - Batch Manufacture of Amino Acids Unit 900
B.8.1 Process Description
B.8.2 Reaction Kinetics
B.8.3 Simulation (Chemcad) Hints
B.8.4 References
Project B.9 / Acrylic Acid Production Unit 1000
B.9.1 Process Description
B.9.2 Reaction Kinetics
B.9.3 Simulation (Chemcad) Hints
B.9.4 References
Project B.10 - Acetone Production Unit 1100
B.10.1 Process Description
B.10.2 Reaction Kinetics
B.10.3 Simulation (Chemcad) Hints
B.10.4 References
Project B.11 / Production of Heptenes Unit 200
B.11.1 Process Description
B.11.2 Reaction Kinetics
B.11.3 Simulation (Chemcad) Hints
B.11.4 References
Index