Chemical Engineering Design, Fourth Edition: Chemical Engineering Volume 6

1055 Pages·2005·7.01 MB·English

by  R K Sinnott

Coulson & Richardson’s
CHEMICAL ENGINEERING
VOLUME 6
Coulson & Richardson’s Chemical Engineering
Chemical Engineering, Volume 1, Sixth edition
Fluid Flow, Heat Transfer and Mass Transfer
J. M. Coulson and J. F. Richardson
with J. R. Backhurst and J. H. Harker
Chemical Engineering, Volume 2, Fifth edition
Particle Technology and Separation Processes
J. F. Richardson and J. H. Harker
with J. R. Backhurst
Chemical Engineering, Volume 3, Third edition
Chemical & Biochemical Reactors & Process Control
Edited by J. F. Richardson and D. G. Peacock
Chemical Engineering, Second edition
Solutions to the Problems in Volume 1
J. R. Backhurst and J. H. Harker with J. F. Richardson
Chemical Engineering, Solutions to the Problems
in Volumes 2 and 3
J. R. Backhurst and J. H. Harker with J. F. Richardson
Chemical Engineering, Volume 6, Fourth edition
Chemical Engineering Design
R. K. Sinnott
Coulson & Richardson’s
CHEMICAL ENGINEERING
VOLUME 6
FOURTH EDITION
Chemical Engineering Design
R. K. SINNOTT
AMSTERDAM ž BOSTON ž HEIDELBERG ž LONDON ž NEWYORK ž OXFORD
PARIS ž SANDIEGO ž SANFRANCISCO ž SINGAPORE ž SYDNEY ž TOKYO
ElsevierButterworth-Heinemann
LinacreHouse,JordanHill,OxfordOX28DP
30CorporateDrive,MA01803
Firstpublished1983
Secondedition1993
Reprintedwithcorrections1994
Reprintedwithrevisions1996
Thirdedition1999
Reprinted2001,2003
Fourthedition2005
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Contents
PREFACETOFOURTHEDITION xvii
PREFACETOTHIRDEDITION xx
PREFACETOSECONDEDITION xxi
PREFACETOFIRSTEDITION xxiii
SERIESEDITOR’SPREFACE xxiv
ACKNOWLEDGEMENT xxv
1 Introduction to Design 1
1.1 Introduction 1
1.2 Natureofdesign 1
1.2.1 Thedesignobjective(theneed) 3
1.2.2 Datacollection 3
1.2.3 Generationofpossibledesignsolutions 3
1.2.4 Selection 4
1.3 Theanatomyofachemicalmanufacturingprocess 5
1.3.1 Continuousandbatchprocesses 7
1.4 Theorganisationofachemicalengineeringproject 7
1.5 Projectdocumentation 10
1.6 Codesandstandards 12
1.7 Factorsofsafety(designfactors) 13
1.8 Systemsofunits 14
1.9 Degreesoffreedomanddesignvariables.Themathematicalrepresentation
ofthedesignproblem 15
1.9.1 Informationflowanddesignvariables 15
1.9.2 Selectionofdesignvariables 19
1.9.3 Informationflowandthestructureofdesignproblems 20
1.10 Optimisation 24
1.10.1 Generalprocedure 25
1.10.2 Simplemodels 25
1.10.3 Multiplevariableproblems 27
1.10.4 Linearprogramming 29
1.10.5 Dynamicprogramming 29
1.10.6 Optimisationofbatchandsemicontinuousprocesses 29
1.11 References 30
1.12 Nomenclature 31
1.13 Problems 32
2 Fundamentals of Material Balances 34
2.1 Introduction 34
2.2 Theequivalenceofmassandenergy 34
2.3 Conservationofmass 34
2.4 Unitsusedtoexpresscompositions 35
2.5 Stoichiometry 36
v
vi CONTENTS
2.6 Choiceofsystemboundary 37
2.7 Choiceofbasisforcalculations 40
2.8 Numberofindependentcomponents 40
2.9 Constraintsonflowsandcompositions 41
2.10 Generalalgebraicmethod 42
2.11 Tiecomponents 44
2.12 Excessreagent 46
2.13 Conversionandyield 47
2.14 Recycleprocesses 50
2.15 Purge 52
2.16 By-pass 53
2.17 Unsteady-statecalculations 54
2.18 Generalprocedureformaterial-balanceproblems 56
2.19 References(FurtherReading) 57
2.20 Nomenclature 57
2.21 Problems 57
3 Fundamentals of Energy Balances (and Energy Utilisation) 60
3.1 Introduction 60
3.2 Conservationofenergy 60
3.3 Formsofenergy(perunitmassofmaterial) 61
3.3.1 Potentialenergy 61
3.3.2 Kineticenergy 61
3.3.3 Internalenergy 61
3.3.4 Work 61
3.3.5 Heat 62
3.3.6 Electricalenergy 62
3.4 Theenergybalance 62
3.5 Calculationofspecificenthalpy 67
3.6 Meanheatcapacities 68
3.7 Theeffectofpressureonheatcapacity 70
3.8 Enthalpyofmixtures 71
3.8.1 Integralheatsofsolution 72
3.9 Enthalpy-concentrationdiagrams 73
3.10 Heatsofreaction 75
3.10.1 Effectofpressureonheatsofreaction 77
3.11 Standardheatsofformation 79
3.12 Heatsofcombustion 80
3.13 Compressionandexpansionofgases 81
3.13.1 Mollierdiagrams 82
3.13.2 Polytropiccompressionandexpansion 84
3.13.3 Multistagecompressors 90
3.13.4 Electricaldrives 93
3.14 Energybalancecalculations 93
3.15 Unsteadystateenergybalances 99
3.16 Energyrecovery 101
3.16.1 Heatexchange 101
3.16.2 Heat-exchangernetworks 101
3.16.3 Waste-heatboilers 102
3.16.4 High-temperaturereactors 103
3.16.5 Low-gradefuels 105
3.16.6 High-pressureprocessstreams 107
3.16.7 Heatpumps 110
3.17 Processintegrationandpinchtechnology 111
3.17.1 Pinchtechnology 111
3.17.2 Theproblemtablemethod 115
3.17.3 Theheatexchangernetwork 117
3.17.4 Minimumnumberofexchangers 121
3.17.5 Thresholdproblems 123
CONTENTS vii
3.17.6 Multiplepinchesandmultipleutilities 124
3.17.7 Processintegration:integrationofotherprocessoperations 124
3.18 References 127
3.19 Nomenclature 128
3.20 Problems 130
4 Flow-sheeting 133
4.1 Introduction 133
4.2 Flow-sheetpresentation 133
4.2.1 Blockdiagrams 134
4.2.2 Pictorialrepresentation 134
4.2.3 Presentationofstreamflow-rates 134
4.2.4 Informationtobeincluded 135
4.2.5 Layout 139
4.2.6 Precisionofdata 139
4.2.7 Basisofthecalculation 140
4.2.8 Batchprocesses 140
4.2.9 Services(utilities) 140
4.2.10 Equipmentidentification 140
4.2.11 Computeraideddrafting 140
4.3 Manualflow-sheetcalculations 141
4.3.1 Basisfortheflow-sheetcalculations 142
4.3.2 Flow-sheetcalculationsonindividualunits 143
4.4 Computer-aidedflow-sheeting 168
4.5 Fullsteady-statesimulationprograms 168
4.5.1 Informationflowdiagrams 171
4.6 Manualcalculationswithrecyclestreams 172
4.6.1 Thesplit-fractionconcept 172
4.6.2 Illustrationofthemethod 176
4.6.3 Guiderulesforestimatingsplit-fractioncoefficients 185
4.7 References 187
4.8 Nomenclature 188
4.9 Problems 188
5 Piping and Instrumentation 194
5.1 Introduction 194
5.2 ThePandIdiagram 194
5.2.1 Symbolsandlayout 195
5.2.2 Basicsymbols 195
5.3 Valveselection 197
5.4 Pumps 199
5.4.1 Pumpselection 199
5.4.2 Pressuredropinpipelines 201
5.4.3 Powerrequirementsforpumpingliquids 206
5.4.4 Characteristiccurvesforcentrifugalpumps 208
5.4.5 Systemcurve(operatingline) 210
5.4.6 Netpositivesuctionhead(NPSH) 212
5.4.7 Pumpandothershaftseals 213
5.5 Mechanicaldesignofpipingsystems 216
5.5.1 Wallthickness:pipeschedule 216
5.5.2 Pipesupports 217
5.5.3 Pipefittings 217
5.5.4 Pipestressing 217
5.5.5 Layoutanddesign 218
5.6 Pipesizeselection 218
5.7 Controlandinstrumentation 227
5.7.1 Instruments 227
5.7.2 Instrumentationandcontrolobjectives 227
5.7.3 Automatic-controlschemes 228
viii CONTENTS
5.8 Typicalcontrolsystems 229
5.8.1 Levelcontrol 229
5.8.2 Pressurecontrol 229
5.8.3 Flowcontrol 229
5.8.4 Heatexchangers 230
5.8.5 Cascadecontrol 231
5.8.6 Ratiocontrol 231
5.8.7 Distillationcolumncontrol 231
5.8.8 Reactorcontrol 233
5.9 Alarmsandsafetytrips,andinterlocks 235
5.10 Computersandmicroprocessorsinprocesscontrol 236
5.11 References 238
5.12 Nomenclature 239
5.13 Problems 240
6 Costing and Project Evaluation 243
6.1 Introduction 243
6.2 Accuracyandpurposeofcapitalcostestimates 243
6.3 Fixedandworkingcapital 244
6.4 Costescalation(inflation) 245
6.5 Rapidcapitalcostestimatingmethods 247
6.5.1 Historicalcosts 247
6.5.2 Stepcountingmethods 249
6.6 Thefactorialmethodofcostestimation 250
6.6.1 Langfactors 251
6.6.2 Detailedfactorialestimates 251
6.7 Estimationofpurchasedequipmentcosts 253
6.8 Summaryofthefactorialmethod 260
6.9 Operatingcosts 260
6.9.1 Estimationofoperatingcosts 261
6.10 Economicevaluationofprojects 270
6.10.1 Cashflowandcash-flowdiagrams 270
6.10.2 Taxanddepreciation 272
6.10.3 Discountedcashflow(timevalueofmoney) 272
6.10.4 Rateofreturncalculations 273
6.10.5 Discountedcash-flowrateofreturn(DCFRR) 273
6.10.6 Pay-backtime 274
6.10.7 Allowingforinflation 274
6.10.8 Sensitivityanalysis 274
6.10.9 Summary 275
6.11 Computermethodsforcostingandprojectevaluation 278
6.12 References 279
6.13 Nomenclature 279
6.14 Problems 280
7 Materials of Construction 284
7.1 Introduction 284
7.2 Materialproperties 284
7.3 Mechanicalproperties 285
7.3.1 Tensilestrength 285
7.3.2 Stiffness 285
7.3.3 Toughness 286
7.3.4 Hardness 286
7.3.5 Fatigue 286
7.3.6 Creep 287
7.3.7 Effectoftemperatureonthemechanicalproperties 287
7.4 Corrosionresistance 287
7.4.1 Uniformcorrosion 288
7.4.2 Galvaniccorrosion 289
CONTENTS ix
7.4.3 Pitting 290
7.4.4 Intergranularcorrosion 290
7.4.5 Effectofstress 290
7.4.6 Erosion-corrosion 291
7.4.7 High-temperatureoxidation 291
7.4.8 Hydrogenembrittlement 292
7.5 Selectionforcorrosionresistance 292
7.6 Materialcosts 293
7.7 Contamination 294
7.7.1 Surfacefinish 295
7.8 Commonlyusedmaterialsofconstruction 295
7.8.1 Ironandsteel 295
7.8.2 Stainlesssteel 296
7.8.3 Nickel 298
7.8.4 Monel 299
7.8.5 Inconel 299
7.8.6 TheHastelloys 299
7.8.7 Copperandcopperalloys 299
7.8.8 Aluminiumanditsalloys 299
7.8.9 Lead 300
7.8.10 Titanium 300
7.8.11 Tantalum 300
7.8.12 Zirconium 300
7.8.13 Silver 301
7.8.14 Gold 301
7.8.15 Platinum 301
7.9 Plasticsasmaterialsofconstructionforchemicalplant 301
7.9.1 Poly-vinylchloride(PVC) 302
7.9.2 Polyolefines 302
7.9.3 Polytetrafluroethylene(PTFE) 302
7.9.4 Polyvinylidenefluoride(PVDF) 302
7.9.5 Glass-fibrereinforcedplastics(GRP) 302
7.9.6 Rubber 303
7.10 Ceramicmaterials(silicatematerials) 303
7.10.1 Glass 304
7.10.2 Stoneware 304
7.10.3 Acid-resistantbricksandtiles 304
7.10.4 Refractorymaterials(refractories) 304
7.11 Carbon 305
7.12 Protectivecoatings 305
7.13 Designforcorrosionresistance 305
7.14 References 305
7.15 Nomenclature 307
7.16 Problems 307
8 Design Information and Data 309
8.1 Introduction 309
8.2 Sourcesofinformationonmanufacturingprocesses 309
8.3 Generalsourcesofphysicalproperties 311
8.4 Accuracyrequiredofengineeringdata 312
8.5 Predictionofphysicalproperties 313
8.6 Density 314
8.6.1 Liquids 314
8.6.2 Gasandvapourdensity(specificvolume) 315
8.7 Viscosity 316
8.7.1 Liquids 316
8.7.2 Gases 320
8.8 Thermalconductivity 320
8.8.1 Solids 320
8.8.2 Liquids 321