Chemical Engineering Design

1323 Pages·2019·71.834 MB·English

by  Ray Sinnott, Gavin Towler

Chemical Engineering
Design
Coulson and Richardson’s Chemical
Engineering Series
Chemical Engineering
Design
Sixth Edition
Ray Sinnott
Gavin Towler
Butterworth-HeinemannisanimprintofElsevier
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In loving memory of
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Preface
Almosttenyearshavepassedsincethe5theditionofChemicalEngineering:Vol.6:Design.Whilethe
nature of chemical engineering design has not changed much, there have been several significant
changesindesigncodesandinthelegislativeenvironmentinwhichthechemicalandprocessindustries
operate, so an update is necessary and that provides an opportunity to make some other changes to
the book.
The feedback from many academics who use this book to teach design in the EU and Common-
wealth countries has been that they want to preserve the original format of Ray’s book, so I have
notbroughtoverallthechangesinchapterstructurefromthemostrecentU.S.edition.Ididfeelthat
twoareasdeservedsignificantexpansionthough:reactordesignandthetechnologyforfood,pharma-
ceutical and biological processes.
PrioreditionsofthebookhadasomewhatcursorytreatmentofreactordesigninSection10.13.This
hasbeenreplacedwithanewChapter15thatgivesabroadercoverageofreactortypes,reactordesign
methods and worked examples of how to size the more common types of reactor. My experience in
teachingdesignhasbeenthatstudentsoftenstruggletomaketheconnectionfromreactionengineering
fundamentalstoarealisticmechanicallayoutofareactor,sothenewchapterfocusesonthepractical
aspectsofreactorspecification.Inadditiontoreactorsizing,someguidanceisgivenonreactorscale-up
and important safetyconsiderations in reactor design.
AtNorthwestern,thereisastrongemphasisonbiochemicalengineering,andsowehaveworked
throughseveralofthebio/pharmadesignproblemsinAppendixE.Thispromptedmetoincreasethe
emphasisonbiologicalprocesses,designoffermentationreactorsandtheseparationsusedforproduct
recoveryandpurificationinthefood,pharmaceuticalandbiochemicalindustries:membranefiltration;
ion exchange; affinity chromatography and continuouschromatography.
Inadditiontothesemajor additions Iam pleased tosee thatmorevendorsofcommercial design
softwareareprovidingfreeorlow-costacademiclicenses,allowingmorestudentstogainexperience
withthetoolsthattheywilluseaftergraduation.Severalreaderspointedoutthatthe5theditiononly
usedAspenICARUS(nowAspenCapitalCostEstimator)forequipmentcosting.Thisneweditionalso
providesexamplesofhowtousetheCleopatraEnterprisesoftwarefromCostEngineering,andCost
Engineeringhasagreedtoprovidecertifiedacademicuserswithfreeaccesstotheircommercialcost
estimatingsoftwareforalimitedperiod.FormoredetailsonhowtoobtainanacademiclicenseofCle-
opatraEnterprise contact [email protected] use orcompanytrials please
contact [email protected].
Oneofthefactorsthatdelayedthisneweditionwasuncertaintyoverthegoverninglegislationand
engineeringstandardsintheUKafterBritain’splannedexitfromtheEuropeanUnion.Whilethatun-
certainty has not yet been resolved at the time of writing, it appears increasingly likely that the UK
chemical industry willcontinue torununder EU rules andstandards,soall the content onstandards
andlegislationhasbeenupdatedonthatassumption.Costdatahavealsobeenupdatedandrelevantnew
references added throughout the book.
Ray’sdeepindustrialexperienceandpragmaticapproachtofindingagooddesignleapoutofevery
pageofthisbook,andIhavetriedtomaintainthesamefocusonsimplepracticalguidancesupported
withlotsofworkedexamples.Thereisneverenoughspacetocoverallaspectsoftheunderlyingtheory
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xxviii Preface
indetail,soforthesethereaderisdirectedtothespecialisttextbooksandacademicworksthataddress
thefundamentalsmorethoroughly.AsIwroteinthe5thedition,Ray’sbookhasbeentremendously
valuabletomethroughoutmycareer.Iamdelightedtohavethisopportunitytorefreshthecontentand
keepthebookcurrentinthehopethatthenextgenerationofchemicalengineerswillfinditasusefulas
Idid.
Gavin Towler
Acknowledgements
As inmyprefacestothe earlier editions ofthisbook,Iwouldliketoacknowledge mydebttothose
colleagues and teachers who have assisted me in a varied career as a professional engineer. I would
particularly like to thank Professor J. F. Richardson for his help and encouragement with earlier
editionsofthisbook.Also, mywife, Muriel,forherhelpwiththetypescriptsoftheearlier editions.
Eur. Ing. R.K. Sinnott
Coed-y-bryn,Wales
IwouldliketothankthemanycolleaguesatHoneywellandelsewherewhohaveworkedwithme,
sharedtheirexperience,andtaughtmeallthatIknowaboutthedesign,operationandcontrolofchem-
icalplants.Iamalsoverygratefultomyacademiccolleagueswhocontinuetogivemetheopportunity
toteach occasionalclasses andpass onsomeofwhatIhavelearned,inparticularProfessor Iftekhar
Karimi atNationalUniversityofSingapore whohas been veryaccommodating ofmyunpredictable
travelschedule.Imustalsothankallthereaderswhohavesentmesuggestionsforimprovementsand
corrections to the book, most of which have been incorporated. After working on four editions, any
remainingerrorsareofcourseentirelymyfault.SteveMerken,NateMcFadden,KateyBirtcher,Sree-
jithViswanathan,StalinViswanathanandtherestoftheteamatElsevierhavedoneagreatjobpro-
ducingthisvolume.MyregularjobatHoneywellcontinuestokeepmebusyandIworkedonthisbook
ineveningsandweekends,soitwouldnothavebeenpossiblewithoutthelove,supportandunderstand-
ing ofmywife, Xiaona,and childrenMiranda andJames.
Gavin P.Towler
Inverness,Illinois
MaterialfromtheASMEBoilerandPressureVesselCodeisreproducedwithpermissionofASME
International,ThreeParkAvenue,NewYorkNY10016.MaterialfromtheAPIRecommendedPrac-
ticesisreproducedwithpermissionoftheAmericanPetroleumInstitute,1220LStreet,NWWashing-
ton,DC20005.MaterialfromBritishStandardsisreproducedbypermissionoftheBritishStandards
Institution, 389 Chiswick High Road, London, W4 4AL, United Kingdom. Complete copies of the
codes andstandards can be obtainedfrom these organizations.
WearegratefultoAspenTechnologyInc.,CostEngineeringandHoneywellInc.forpermissionto
includethescreenshotsthatweregeneratedusingtheirsoftwaretoillustratetheprocesssimulationand
costing examples. The material safety data sheet in Appendix I is reproduced with permission of
®
FischerScientificInc.AspenPlus ,AspenKbase,AspenCapitalCostEstimatorandallotherAspen-
TechproductnamesorlogosaretrademarksorregisteredtrademarksofAspenTechnologyInc.orits
subsidiaries in the United States and/or in other countries. All rights reserved. Cost Engineering has
agreedtoprovidecertifiedacademicuserswithfreeaccesstotheircommercialcostestimatingsoft-
ware,CleopatraEnterprise,foralimitedperiod.Formoredetailsonhowtoobtainanacademiclicense
of Cleopatra Enterprise contact [email protected]. For commercial use or company trials
pleasecontact [email protected].
xxix
xxx Acknowledgements
Thesupplementarymaterialcontainsimagesofprocessesandequipmentfrommanysources.We
wouldliketothankthefollowingcompaniesforpermissiontousetheseimages:Alfa-Laval,ANSYS,
Aspen Technology, Bete Nozzle, Bos-Hatten Inc., Chemineer, Dresser, Dresser-Rand, Enardo Inc.,
Honeywell, Komax Inc., Riggins Company, Tyco Flow Control Inc., United Valve Inc., UOP LLC,
and TheValve Manufacturer’s Association.
How to Use This Book
ThisbookhasbeenwrittenprimarilyforstudentsonundergraduatecoursesinChemicalEngineering
andhasparticularrelevancetotheirdesignprojects.Itshouldalsobeofinteresttonewgraduateswork-
inginindustrywhofindtheyneedtobroadentheirknowledgeofunitoperationsanddesign.Someof
theearlierchaptersofthebookcanalsobeusedinintroductorychemicalengineeringclassesandby
otherdisciplines in the chemical andprocessindustries.
AS A DESIGN COURSE TEXTBOOK
Chapters1to9and15coverthebasicmaterialforacourseonprocessdesignandincludeanexpla-
nationofthedesignmethod,includingconsiderationsofsafety,costing,andmaterialsselection.Chap-
ters2,3and8containalotofbackgroundmaterialthatshouldhavebeencoveredinearliercoursesand
canbequicklyskimmedasareminder.Iftimeisshort,Chapters4,6and9deservethemostemphasis.
Chapters10to13and15coverequipmentselectionanddesign,includingmechanicalaspectsofequip-
mentdesign.Theseimportantsubjectsareoftenneglectedinthechemicalengineeringcurriculum.The
equipmentchapterscanbeusedasthebasisforasecondcourseindesignorassupplementarymaterial
in aprocessdesign class.
AS AN INTRODUCTORY CHEMICAL ENGINEERING TEXTBOOK
ThematerialinChapters1,2,3and6doesnotrequireanypriorknowledgeofchemicalengineering
andcanbeusedasanintroductorycourseinchemicalengineering.MuchofthematerialinChapters7,
9,10and14couldalsobeusedinanintroductoryclass.Thereismuchtobesaidforintroducingdesign
atanearlypointinthechemicalengineeringcurriculum,asithelpsthestudentshaveabetterappre-
ciationofthepurposeoftheirotherrequiredclasses,andsetsthecontextfortherestofthesyllabus.
Studentsstartingchemicalengineeringtypicallyfindthepracticalapplicationsofthesubjectfarmore
fascinatingthanthedrymathematicstheyareusuallyfed.Anappreciationofeconomics,optimization
andequipmentdesigncandramaticallyimproveastudent’sperformanceinotherchemicalengineering
classes.Ifthebookisusedinanintroductoryclass,thenitcanbereferredtothroughoutthecurriculum
as aguide to design methods.
SUPPLEMENTARY MATERIAL
Many of the calculations described in the book can be performed using spreadsheets. Templates of
spreadsheet calculations and equipment specification sheets are available in Microsoft Excel format
online and can be downloadedfrom Elsevierdirect.com/companions.
Additionalsupplementarymaterial,includingMicrosoftPowerPointpresentationstosupportmost
of the chapters, can be downloaded from a restricted site for instructors Elsevierdirect.com/
companions.
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