Chemical Engineering Design Project - A Case Study Approach Topics in Chemical Engineering;

383 Pages·1989·4.97 MB·English

by  Martyn S. Ray

Topics in Chemical Engineering
A series edited by R. Hughes, University of Salford, U.K.
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Volume 5 CONTROL OF LIQUID-LIQUID EXTRACTION
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Volume 6 CHEMICAL ENGINEERING DESIGN PROJECT
. .
. A Case Study Appidach
by M.S. Rayn and D.W. Johnston
. . . . . ,
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CHEMICAL ENGINEERING
DESIGN PROJECT

A Case Study Approach
By Martyn S. Ray
Curtin University of Technology, Western Australia
and
David W. Johnston
Shell Refining (Australia) Pty. Ltd., A
CUCEI
BIBLIOTECA CENTRAL
016722
No. DE ADQUISICION
FECHA ENTREGA
CLASIFIACION
0.
GORDON AND BREACH SCIENCE PUBLISHERS
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01989 by OPA (Amsterdam) B.V. All rights reserved. Published under
license by Gordon and Breach Science Publishers S.A.
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Library of Congress Cataloging-in-Publication Data
Ray, Martyn S., 1949-
Chemical engineering design project : a case study approach / by
Martin S. Ray and David W. Johnston.
P. cm. - (Topics in chemical engineering, ISSN 0277-5883 ;
v. 5)
Bibliography: p.
Includes index.
ISBN 2-88124713-X. -1SBN 2-88124-712-l (pbk.)
1. Chemical engineering-Case studies. 2. Nitric acid.
I. Johnston, David W., 1964 . II. Title. III. Series.
TP149.R35 1989
6606~20 89-2171
CIP
No part of this book may be reproduced or utilized in any form or by any
means, electronic or mechanical, including photocoping and recording,
or by any information storage or retrieval system, without permission in
writing from the publishers.
Printed in Great Britain by Bell and Bain Ltd., Glasgow
Contents

Introduction to the Series x111
Acknowledgements xiv
I About this Book - The Case Study Approach xv
II Advice to the Student xvii
III To the Lecturer xix
IV The Scope of Design Projects xxi
V Effective Communications xxii
VI Comments on the Case Study Approach xxiv
The Case Study - Summary for the Completed Project xxv
PART I PRELIMINARY DESIGN - TECHNICAL AND
ECONOMIC FEASIBILITY 1
CHAPTER 1 THE DESIGN PROBLEM 3
1.1 Initial Considerations and Specification 3
The Case Study - Summary for Part I 4
Feasibility Study and Initial Design Considerations
1.2 Case Study- Defining the Problem and Background
Information
Summary
1.2.1 Introduction
1.2.2 Properties and Uses
1.2.3 The Evolution of Nitric Acid Production
Processes 7
1.2.4 Ammonia Oxidation Chemistry 9
V
vi CONTENTS
CHAPTER 2 FEASIBILITY STUDY AND LITERATURE
SURVEY 12
2.1 Initial Feasibility Study 12
2.2 Presentation of Literature Surveys for Projects 15
2.3 Case Study- Feasibility Study (Market Assessment) 21
Summary 21
2.3.1 Introduction 22
2.3.2 The Domestic Scene 22
2.3.3 The Global Market 24
2.3.4 Market Analysis Discussion 24
2.3.5 Market Assessment Conclusions 27
2.4 Case Study - Literature Survey 28
Summary 28
2.4.1 Introduction 29
2.4.2 General Information 29
2.4.3 Process Technology 30
2.4.4 Cost Estimation 31
2.4.5 Market Data 32
2.4.6 Thermodynamic Data 33
2.5 Case Study - Bibliography 33
CHAPTER 3 PROCESS SELECTION 37
3.1 Process Selection - Considerations 37
3.2 Case Study - Process Selection 40
Summary 40
3.2.1 Introduction 41
3.2.2 Process Comparison 42
Factors Favouring the Dual-Pressure Process 45
Factors Favouring the Single-Pressure Process 46
Other Considerations 46
3.2.3 Process Selection Conclusions 47
CHAPTER 4 PROCESS DESCRIPTION AND EQUIPMENT
LIST 48
4.1 Introductory Notes 48
4.2 Case Study - Process Description 49
Summary 49
CONTENTS vii
4.2.1 Introduction 51
51
4.2.2 The Process
4.2.3 Requirements of Major Process Units 53
53
4.2.4 Mechanical Design Features of Major Units
59
4.2.5 Process Flow Diagram
4.2.6 Process Performance Assessment 59
CHAPTER 5 SITE CONSIDERATIONS 61
5.1 Site Selection 61
5.2 Plant Layout 64
5.3 Environmental Impact Analysis 66
5.3.1 General Considerations 67
5.3.2 EIA Policy and Scope 68
5.3.3 EIA Reports 69
5.3.4 Australia 72
5.3.5 United Kingdom 72
5.3.6 United States 73
5.4 Case Study - Site Considerations 75
Summary 75
5.4.1 Site Considerations - Introduction 76
5.4.2 Site Selection 76
5.4.3 Perth Metropolitan Region 76
5.4.4 Country Districts 81
5.4.5 Site Location Conclusions 82
5.4.6 Plant Layout 83
5.4.7 Environmental Impact Analysis 83
CHAPTER 6 ECONOMIC EVALUATION 87
6.1 Introductory Notes 87
6.2 Capital Cost Estimation 89
6.2.1 Cost of Equipment (Major Items) 89
6.2.2 Module Costs 92
6.2.3 Auxiliary Services 92
6.3 Operating Costs 92
6.4 Profitability Analysis 95
6.5 Case Study - Economic Evaluation 96
Summary 96
6.5.1 Introduction 97
Vlll CONTENTS
65.2 Capital Cost Estimation 98
(a) The Ratio Method 98
(b) The Factorial Method 99
(c) Capital Cost Conclusions 102
6.53 Investment Return 102
CHAPTER 7 MASS AND ENERGY BALANCES 106
7.1 Preparation of Mass and Energy Balances 106
7.2 Preliminary Equipment Design 109
7.3 Computer-Aided Design 109
7.4 Case Study - Mass and Energy Balances 115
Summary 115
7.4.1 Overall Process Mass Balance 116
7.4.2 Unit Mass and Energy Balances 119
7.4.2.1 Ammonia Vaporizer 119
7.4.2.2 Ammonia Superheater 120
7.4.2.3 Two-stage Air Compressor 121
7.4.2.4 Reactor Feed Mixer 122
7.4.2.5 Reactor 123
7.4.2.6 Steam Superheater 124
7.4.2.7 Waste-Heat Boiler 125
7.4.2.8 Platinum Filter 126
7.4.2.9 Tail-Gas Preheater 127
7.4.2.10 Oxidation Unit 128
7.4.2.11 Cooler/Condenser 129
7.4.2.12 Secondary Cooler 130
7.4.2.13 Absorber 131
7.4.2.14 Bleaching Column 132
7.4.2.15 Vapor/Liquid Separator 133
7.4.2.16 Tail-Gas Warmer 134
7.4.2.17 Refrigeration Unit 135
Comments 136
PART II DETAILED EQUIPMENT DESIGN 139
CHAPTER 8 THE DETAILED DESIGN STAGE 141
8.1 Detailed Equipment Design 141
8.1.1 Equipment Design - HELP! 142
CONTENTS ix
8.2 Additional Design Considerations 145
8.2.1 Energy Conservation 146
8.2.2 Process Control and Instrumentation 151
8.2.3 Safety, Loss Prevention and HAZOP 153
References 157
Case Study - Summary for Part II: Detailed Equipment
Design 160
Case Study-Amendments to Part I 160
CHAPTER 9 CASE STUDY - ABSORPTION COLUMN
DESIGN 162
Summary 162
9.1 introduction 163
9.2 The Design Method 164
9.2.1 The Mathematical Model 164
9.2.2 Sieve-Plate Hydraulic Design 165
9.2.3 Mechanical Design of Column 166
9.2.4 Process Control Scheme 167
9.3 Important Operating Considerations 167
9.4 Design Constraints 170
9.5 Absorption Column Specification 171
9.6 Sieve Tray Specifications 172
9.7 Process Control Scheme 175
9.8 Hazard and Operability Study 178
9.9 Discussion of Results 178
9.10 Assessment of the Design Method 187
9.1 i Revised Absorption Column Costing 187
9.12 Conclusions 188
References 188
CHAPTER 10 CASE STUDY - STEAM SUPERHEATER
DESIGN 190
Summary 190
10.1 Introduction 191
10.2 Summary of Design Method 192
10.2.1 The Kern Method 193
10.2.2 The Bell Method 195
10.2.3 Mechanical Sizing 196
X CONTENTS
10.3 Design Selection Factors 197
10.3.1 Exchanger Type 197
10.3.2 Choice of Flow Mode 198
10.3.3 Materials Selection 198
10.3.4 Shell and Tube Sizing 199
10.4 Design Specification 202
10.5 Process Control 202
10.6 Design Method Evaluation 204
10.7 Revised Cost Estimation 204
10.8 Conclusions 204
References 205
CHAPTER 11 CASE STUDY - BLEACHING-COLUMN
FEED PUMP SPECIFICATION 207
Summary 207
11.1 Introduction 207
11.2 Design Method 208
11.3 Pump Specification 211
11.4 Discussion 211
11.5 Conclusions 214
References 214
CHAPTER 12 CASE STUDY - NITRIC ACID STORAGE-
TANK DESIGN 215
Summary 215
12.1 Introduction 216
12.2 Design Method 217
12.3 Tank Specification 217
12.4 Conclusions 218
References 219
Final Comments 220
APPENDICES 223
Appendix A Data for Section 1.2 228
Appendix B Data for Section 2.3 229
Appendix C Data for Section 3.2 238
Appendix D Data for Section 4.2 246
Appendix E Data for Section 6.5 248
Appendix F Calculations for Section 7.4 255