Handbook of Batch Process Design

332 Pages·1997·18.163 MB·English

by  P. N. Sharratt (auth.), P. N. Sharratt (eds.)

Handbook of Batch Process Design
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Handbook of
Batch Process Design
Edited by
P.N. SHARRATT
Department of Chemical Engineering
UMIST
Manchester, UK
lOJ
BLACKIE ACADEMIC & PROFESSIONAL
An Imprint of Chapman & Hall
London· Weinheim . New York· Tokyo· Melbourne· Madras
Published by Blackie Academic and Professional,
an imprint of Chapman & Hall, 2-6 Boundary Row, London SEt 8HN, UK
Chapman & Hall, 2-6 Boundary Row, London SEI 8HN, UK
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Chapman & Hall India, R. Seshadri, 32 Second Main Road, CIT East, Madras
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First edition 1997
CD 1997 Chapman & Hall
Softcover reprint of the hardcover 1s t edition 1997
Typeset in IOjl2pt Times by Academic & Technical Typesetting, Bristol
ISBN-13: 978-94-010-7150-5 e-ISBN-13: 978-94-009-1455-1
DOl: 10.1007/978-94-009-1455-1
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Contents
List of contributors xi
Preface xiii
Acknowledgements xiv
1 Chemicals manufacture by batch processes 1
P.N. SHARRATT
1.1 Introduction I
1.2 Industrial background 2
1.2.1 Definitions 2
1.2.2 Product life cycles and regulatory influences 5
1.3 Reasons for the use of batch processing 7
1.4 Batch process design for fine and speciality chemical production 8
1.4.1 Process chemistry 9
1.4.2 Process design l3
1.4.3 Unit operations 17
1.4.4 Process operation and control 18
1.4.5 Health, safety and environmental issues during operation 20
1.5 Plant design 21
1.6 Summary 22
References 22
2 Scheduling and simulation of batch processes 24
G.V. REKLAITIS, 1. PEKNY and G.S. 10GLEKAR
2.1 Introduction 24
2.2 Batch process features 24
2.3 The scheduling problem 29
2.3.1 General features 29
2.3.2 Generic solution approaches 31
2.3.3 Uniform discretization scheduling approach 35
2.3.4 Requirements for implementation 38
2.4 Batch process simulation 40
2.4.1 The role of simulation 40
2.4.2 Simulation model features 41
2.4.3 Elements of combined simulation 41
2.4.4 Limitations of discrete simulation languages 48
2.4.5 Features of a process-oriented combined simulator 50
2.5 Design implications 57
References 58
vi CONTENTS
3 Solvents in chemicals production 61
M. SHEEHAN
3.1 Introduction 61
3.2 Solvent properties 62
3.2.1 Chemical properties 62
3.2.2 Physical properties 63
3.3 Solubility 71
3.3.1 Non-specific intermolecular forces 72
3.3.2 Specific intermolecular forces 74
3.3.3 Energy of solvation 75
3.3.4 Selective solvation 76
3.3.5 Solvent mixtures 76
3.3.6 Supercritical solvents 77
3.4 Solvent effects on reactions 77
3.4.1 Rules of thumb - Hughes-Ingold rules 78
3.4.2 The transition state approach 79
3.4.3 Solvation dynamics 81
3.4.4 Reaction examples 82
3.4.5 Heterogeneous reactions 87
3.5 Solvent recovery 90
3.5.1 Origin of solvent wastes 90
3.5.2 Designing for recovery 91
3.5.3 Separation of solvents from gaseous wastes 94
3.5.4 Separation of solvents as liquid 95
3.6 Solvent destruction 101
3.6.1 Non-biological treatment 101
3.6.2 Biological treatment 102
3.7 Conclusion 104
3.8 Nomenclature 105
References 105
4 Agitation 107
K.J. CARPENTER
4.1 Agitator selection 107
4.1.1 Agitator duties 107
4.1.2 Agitator types 108
4.2 Calculation of agitator power, discharge flow and mixing time 114
4.2.1 Typical power levels 114
4.2.2 Calculation of power 114
4.2.3 Discharge flow 115
4.2.4 Mixing time 116
4.3 Power and circulation in non-Newtonian fluids 117
4.3.\ Calculation of power 117
4.3.2 Circulation 118
4.4 Design to disperse solid particles 119
4.4.1 Disperse sinking particles 119
4.4.2 Draw down floating particles 120
4.5 Design for two or more liquid phases 121
4.5.\ Miscibility 121
4.5.2 Phase continuity and phase inversion 123
4.5.3 Phase distribution - the just dispersed condition 125
4.5.4 Drop sizes 127
4.5.5 Mass transfer 129
CONTENTS vii
4.6 Design for dispersing gas 130
4.6.1 Sparged gas 130
4.6.2 Sparged with surface incorporation 131
4.6.3 Specialized gas-inducing impellers 131
4.6.4 Mass transfer 131
4.7 Design for heat transfer 132
4.7.1 Heat transfer surfaces 132
4.7.2 Service side heat transfer coefficient 133
4.7.3 Process side heat transfer coefficient 135
4.7.4 Wall resistance 136
4.8 Nomenclature 136
References 137
5 Mixing and the selectivity of fast chemical reactions 139
J.R. BOURNE
5.1 The problem 139
5.2 Mixing mechanisms and modelling 141
5.2.1 Semi-batch reactor: micromixing 141
5.2.2 Extensions 144
5.3 Applications 145
5.3.1 Model reactions 145
5.3.2 Characterization of mixers 147
5.3.3 Scale-up principles 148
5.4 Extensions 149
5.5 Concluding remarks 149
5.6 Nomenclature 150
References 150
6 Batch filtration of solid-liquid suspensions 153
A.RUSHTON
6.1 Introduction 153
6.2 Filtration ptocess fundamentals 155
6.2.1 Flow of fluids in filtration 155
6.2.2 Quantitative relationship for cake filtration 157
6.2.3 Laboratory tests and filter media in cake filtration 159
6.2.4 Application of basic relationships to centrifugal filters 165
6.2.5 Filter cake washing 166
6.2.6 Filter cake dewatering 168
6.2.7 Clarification filtration processes 169
6.2.8 Laboratory tests and filter media in clarification processes 171
6.2.9 Membrane filtration principles 174
6.3 Batch operated filtration machinery 177
6.3.1 Pressure-vacuum filters 177
6.3.2 Centrifugal filters 185
6.3.3 Membrane filters 186
6.4 Nomenclature 189
References 190
7 Design and engineering of a batch plant 193
M.J. MAYES
7.1 Introduction 193
7.2 Project definition 193
7.3 Project strategy 194
viii CONTENTS
7.4 Project organization 195
7.5 'Fast track' projects 198
7.5.1 Techniques 198
7.5.2 Problems 201
7.6 Regulations and other controls 202
7.6.1 Hazard and operability (HAZOP) studies 202
7.6.2 Environmental impact studies 204
7.6.3 Fire and explosion hazards 204
7.6.4 Construction safety 205
7.7 Design techniques 205
7.7.1 Case study - design for ease of construction 207
7.8 Layout considerations 208
7.8.1 Case study - layout 210
7.9 Plant relocation/reuse of existing equipment 212
7.9.1 Case study - plant relocation 217
7.10 Modular plant 217
8 Control 219
P.E. SAWYER
8.1 Introduction 219
8.2 Control of continuous processes 220
8.3 Control of batch processes 220
8.3.1 A simple example 220
8.3.2 Multiproduct, multistream and multipurpose operations 223
8.4 Batch control systems - structure and functions 225
8.4.1 Models and terminology - the SP88 standard 225
8.4.2 Models for batch processing 226
8.5 Computer control 235
8.5.1 Introduction 235
8.5.2 Systems architecture - hardware and software 236
8.5.3 Choosing an architecture 237
8.5.4 Hardware 238
8.5.5 Software 243
8.6 Procedural control 243
8.6.1 Introduction 243
8.6.2 Identifying procedures 244
8.6.3 Specifying procedures 244
8.7 Acknowledgements 251
References 251
9 Hazards from chemical reactions and flammable materials in
batch reactor operations 253
R. ROGERS
9.1 Introduction 253
9.2 Hazard identification 254
9.2.1 The defined procedure 255
9.3 Chemical reaction hazards 257
9.3.1 Thermal explosions 259
9.3.2 Characterization of the desired reaction 262
9.3.3 Characterization of exothermic decomposition reactions 263
9.3.4 Selection of safety measures 267
CONTENTS ix
9.4 Fire and explosion hazards 270
9.4.1 Flammability characteristics of materials 271
9.4.2 Sources of ignition 280
9.4.3 Assessment of hazards and definition of appropriate safety measures 283
9.4 Conclusions 287
References
10 Environmental protection and waste minimization 289
C. JONES
10.1 Introduction 289
10.2 Batch reactor waste minimization 291
10.2.1 Process chemistry 291
10.2.2 Heat effects 291
10.2.3 Mixing and contacting pattern 292
10.3 Equipment for the production of solid products 292
10.3.1 Crystallization processes 294
10.3.2 Precipitation processes 294
10.3.3 Solid-liquid separation 294
10.3.4 Batch drying 300
10.4 Fugitive and other minor emissions 301
10.5 Cleaning wastes 303
10.6 Waste treatment and solvent management 304
10.7 Environmental protection 305
10.8 Conclusions 306
References
11 Future developments in batch process design and technology 308
P.N. SHARRATT
11.1 Influences for and against change 308
11.2 New technologies 309
11.2.1 New or enhanced unit operations 309
11.2.2 New plant designs 310
11.2.3 Process intensification 311
II. 3 New processes 312
11.4 New design methods 312
11.5 New skill requirements 313
References 313
Index 315
List of contributors
J. Bourne Vine House, Ankerdine Road, Cothridge,
Worcester WR6 5LU, UK
K.J. Carpenter Process Technology Department, Zeneca pic,
Huddersfield Works, Huddersfield
HD2 IFF, UK
G.S. Joglekar Batch Process Technologies, 1291E
Cumberland Ave., PO Box 2001,
W. Lafayette, IN 47906, USA
C. Jones Fluor Daniel Limited, Process Department,
Fluor Daniel Centre, Camberley, Surrey
GU15 3YL, UK
J. Mayes Simon Carves, Sim-Chem House,
PO Box 17, Cheadle Hume, Cheshire
SK8 5BR, UK
J. Pekny School of Chemical Engineering, Chemical
Engineering Building, Purdue University,
West Lafayette, IN 47907, USA
G.V. Reklaitis School for Chemical Engineering, Chemical
Engineering Building, Purdue University,
West Lafayette, IN 47907, USA
R. Rogers Imburex GmbH, Wilhelmstrasse 2, 59067
Hamm, Germany
A. Rushton Department of Chemical Engineering,
UMIST, PO Box 88, Manchester M60 lQD,
UK
P. Sawyer PES Associates, 44 High Street,
Chippenham, Wiltshire SN14 8LP, UK