Plant Design and Economics for Chemical Engineers PDF
Preview Plant Design and Economics for Chemical Engineers
Plant Design and Economics for Chemical Engineers McGraw-Hill Chemical Engineering Series Editorial Advisory Board Eduardo D. Glandt, Dean, School of Engineering and Applied Science, University of Pennsylvania Michael T. Klein, Dean, School of Engineering, Rutgers University Thomas F. Edgar, Professor of Chemical Engineering, University of Texas at Austin Bailey and Ollis Marlin Biochemical Engineering Fundamentals Process Control: Designing Processes and Control Systems for Dynamic Performance Bennett and Myers Momentum, Heat and Mass Transfer McCabe, Smith, and Harriott Unit Operations of Chemical Engineering Coughanowr and LeBlanc Process Systems Analysis and Control Middleman and Hochberg Process Engineering Analysis in Semiconductor Device Davis and Davis Fabrication Fundamentals of Chemical Reaction Engineering Perry and Green de Nevers Perry's Chemical Engineers' Handbook Air Pollution Control Engineering Peters, Timmerhaus, and West de Nevers Plant Design and Economics for Chemical Engineers Fluid Mechanics for Chemical Engineers Reid, Prausnitz, and Poling Douglas Properties of Gases and Liquids Conceptual Design of Chemical Processes Smith, Van Ness, and Abbott Edgar, Himmelblau, and Lasdon Introduction to Chemical Engineering Thermodynamics Optimization of Chemical Processes Treybal Gates, Katzer, and Schuit Mass Transfer Operations Chemistry of Catalytic Processes King Separation Processes Luyben Process Modeling, Simulation, and Control for Chemical Engineers Plant Design and Economics for Chemical Engineers Fifth Edition Max S. Peters Klaus D. Timmerhaus Ronald E. West University of Colorado Mc Graw Boston Burr Ridge, IL Dubuque, IA Madison, Wl New York San Francisco St. Louis Bangkok Bogota Caracas Kuala Lumpur Lisbon London Madrid Mexico City Milan Montreal New Delhi Santiago Seoul Singapore Sydney Taipei Toronto McGraw-Hill Higher Education gr? A Division of The McGraw-Hill Companies PLANT DESIGN AND ECONOMICS FOR CHEMICAL ENGINEERS FIFTH EDITION Published by McGraw-Hill, a business unit of The McGraw-Hill Companies, Inc., 1221 Avenue of the Americas, New York, NY 10020. Copyright © 2003, 1991, 1980, 1968, 1958 by The McGraw-Hill Companies, Inc. All rights reserved. No part of this publication may be reproduced or distributed in any form or by any means, or stored in a database or retrieval system, without the prior written consent of The McGraw-Hill Companies, Inc., including, but not limited to, in any network or other electronic storage or transmission, or broadcast for distance learning. Some ancillaries, including electronic and print components, may not be available to customers outside the United States. This book is printed on acid-free paper. International 12 3 4567890 QPF/QPF 098765432 Domestic 1234567890 QPF/QPF 0987 6 5432 ISBN 0-07-239266-5 ISBN 0-07-119872-5 (ISE) Publisher: Elizabeth A. Jones Sponsoring editor: Suzanne Jeans Developmental editor; Kate Scheinman Marketing manager; Sarah Martin Senior project manager; Kay J. Brimeyer Production supervisor: Kara Kudronowicz Senior media project manager: Tammy Juran Coordinator of freelance design; Rick D. Noel Cover designer: John Rokusek/Rokusek Design Lead photo research coordinator: Carrie K. Burger Compositor; Interactive Composition Corporation Typeface: 10.5/12 Times Roman Printer: Quehecor World Fairfield, PA Library of Congress Cataloging-in-Publication Data Peters, Max Stone, I920-. Plant design and economics for chemical engineers. — 5th ed. / Max S . Peters, Klaus D. Timmerhaus, Ronald E. West. p. cm. — (McGraw-Hill chemical engineering series) Includes bibliographical references and index. ISBN 0-07-239266-5 (acid-free paper) 1. Chemical plants—Design and construction. I. Timmerhaus, Klaus D . II. West, Ronald E. (Ronald Emmett), 1933-. III. Title. IV. Series. TP155.5.P4 2003 660'.2S—dc21 2002032568 CIP INTERNATIONAL EDITION ISBN 0-07-119872-5 Copyright © 2003. Exclusive rights by The McGraw-Hill Companies, Inc., for manufacture and export. This book cannot be re-exported from the country to which it is sold by McGraw-Hill. The International Edition is not available in North America. www.mhhe.com ABOUT THE AUTHORS Max S. Peters is currently professor emeritus of chemical engineering and dean emeritus of engineering at the University of Colorado at Boulder. He received his B.S. and M.S. degrees in chemical engineering from Pennsylvania State University, worked for Hercules Power Company and Treyz Chemical Company, and returned to Penn State for his Ph.D. Subsequently he joined the faculty of the University of Illinois, and later he came to the University of Colorado as dean of the College of Engineering and Applied Science and professor of chemical engineering. He relinquished the position of dean in 1978 and became emeritus in 1987. Dr. Peters has served as president of the American Institute of Chemical Engineers, as a member of the board of directors for the Commission on Engineering Education, as chairman of the President's Committee on the National Medal of Science, and as chairman of the Colorado Environmental Commission. A fellow of the American Institute of Chemical Engineering, Dr. Peters is the recipient of the George Westing- house and Lamme Award of the American Society of Engineering Education, the Award of Merit of the American Association of Cost Engineers, and the Founders and W. K. Lewis Award of the American Institute of Chemical Engineers. He is a member of the National Academy of Engineering. Klaus D. Timmerhaus is currently President's Teaching Scholar at the University of Colorado at Boulder. He received his B.S., M.S., and Ph.D. degrees in chemical engi- neering from the University of Illinois. After serving as a process design engineer for Standard Oil of California Research Corporation, Dr. Timmerhaus joined the chemical engineering department of the University of Colorado, College of Engineering. He was subsequently appointed associate dean of the College of Engineering and director of the Engineering Research Center. This was followed by a term as chairman of the chemical engineering department. The author's extensive research publications have been primarily concerned with cryogenics, energy, and heat and mass transfer. He has edited 25 volumes of Advances in Cryogenic Engineering and coedited more than 30 volumes in the International Cryogenics Monograph Series. He is past president of the American Institute of Chemical Engineers, past presi- dent of the Society of Sigma Xi, and past president of the International Institute of Refrigeration; and he has held offices in the American Institute of Chemical Engineers (AIChE), the Cryogenic Engineering Conference, the International Cryocooler Con- ference, Society of Sigma Xi, American Astronautical Society, American Association for the Advancement of Science (AAAS), American Society for Engineering Educa- tion (ASEE)—Engineering Research Council, Accreditation Board for Engineering and Technology, and National Academy of Engineering. v vi About the Authors A fellow of AIChE and A A AS, Dr. Timmerhaus has received the ASEE George Westinghouse and Fred Merryfield Design Award, the AIChE Alpha Chi Sigma Award, the AIChE W. K. Lewis Award, the AIChE Founders Award, the SAE Ralph Teeter Award, the USNC/I1R W. T. Pentzer Award, NSF Distinguished Service Award, Uni- versity of Colorado Stearns Award, Colorado Professor of the Year Award, and Samuel C. Collins Award of the Cryogenic Engineering Conference. He is a member of the National Academy of Engineering and the Austrian Academy of Science. Ronald E. West is currently professor emeritus of chemical engineering after serv- ing for 38 years as a member of the faculty in the department of chemical engineering at the University of Colorado at Boulder. In that capacity, he directed both the under- graduate laboratory program and the senior plant design course for more than 25 years. He received his B.S., M.S., and Ph.D. degrees in chemical engineering from the University of Michigan. His professional work has been mainly in the areas of water pollution control and renewable energy technology. Dr. West is a member of the American Institute of Chemical Engineers and the American Solar Energy Society. CONTENTS Preface xv Developmen t of a Pollution Control System 42 Prologue xix Air Pollution Abatement 42 Water Pollution Abatement 47 Solid Waste Disposal 50 CHAPTER 1 Thermal Pollution Control 51 Introduction 1 Noise Control 52 Chemical Engineering Plant Design 1 Plant Location 52 General Overall Design Considerations 2 Factors Involved 53 Process Design Development 2 Selection of the Plant Site 56 Flowsheet Development 5 Plant Layout 56 Computer-Aided Design 6 Preparation of the Layout 57 Cost Estimation 6 Plant Operation and Control 57 Profitability Analysis of Investments 7 Instrumentation 57 Optimum Design 8 Maintenance 58 Practical Considerations in Design 11 Utilities 59 The Design Approach 12 Structural Design 60 Engineering Ethics in Design 13 Storage 60 Materials Handling 61 CHAPTER 2 Patent Considerations 62 General Design Considerations 15 Problems 62 Health and Safety Hazards 15 CHAPTER 3 Sources of Exposure 16 Process Design Development 67 Exposure Evaluation 18 Control of Exposure Hazards 20 Development of Design Database 67 Fire and Explosion Hazards 22 Literature Survey 68 Personnel Safety 2 7 Patent Search 69 Safety Regulations 27 Process Creation 69 Loss Prevention 29 Batch Versus Continuous Operation 70 HAZOP Study 29 Raw Materials and Product Fault-tree Analysis 35 Specifications 70 Failure Mode and Effect Analysis 36 Process Synthesis Steps 71 Safety Indexes 36 Process Design 72 Safety Audits 36 Types of Process Designs 74 Environmental Protection 40 Process Flow Diagrams 77 Environmental Regulations 41 Piping and Instrumentation Diagrams 79 vii viii Contents Vessel and Piping Layout Isometrics 80 Process Flowsheet 149 Equipment Design and Specifications 81 Reactors 149 Scale-up of Equipment in Design 81 Mass and Energy Balances 149 Safety Factors 81 Separation Trains 149 Equipment Specifications 84 Heat Exchange 150 Materials of Construction 86 Algorithmic Flowsheet Generation 158 The Preliminary Design—A Specific Example 87 Fundamentals of Algorithmic Process-Network Synthesis 159 Problem Statement 87 Application of Algorithmic Process-Network Literature Survey 87 Synthesis 165 Process Creation 88 Comparison of Hierarchical and Development of Conven tional Base-Case Design 90 Algorithmic Results 189 Economic Assessment of Base-Case Design 110 Genetic Algorithms 189 Assessment of Proposed Base-Case Design Modification 113 Future Approaches to Flowsheet Synthesis and Development 190 Summary 120 Software Use in Flowsheet Synthesis 190 Problems 121 Analysis and Evaluation of Flowsheets 190 CHAPTER 4 Criteria for Evaluating Designs 190 Flowsheet Synthesis and Summary 192 Development 125 Nomenclature 192 Greek Symbol 193 Flowsheet Synthesis and Development 126 Problems 193 General Procedure 126 Process Information 130 Background Information 130 CHAPTER 5 Molecular Path Synthesis 131 Software Use in Process Selecting a Process Pathway 132 Design 196 Production Mode 132 Software Structure 198 Recording Decisions 133 Chemical Property Estimation 198 Input/Output Structure 135 Process Equipment Models 201 Functions Diagram 137 Process Equipment Cost Estimation 202 Preprocessing 138 Process Economic Evaluation 203 Reactions 139 Heat Integration 203 Recycle 139 Process Control 203 By-products, Intermediates, and Wastes 139 Process Optimization 204 Separations 140 Software Capabilities 204 Operations Diagram 143 General-Type Software 205 Preprocessing 143 Software for Process Design 208 Reactors 143 Molecular Reaction Databases and Simulators 208 Separations Methods 144 Chemical Cost Databases 209 Heating and Cooling 145 Flowsheeting Software 209 Minimization of Processing 145 Unit Operations Simulators 211 Contents Piping System Design 214 Yard Improvements 246 Plant Layout 214 Service Facilities 246 Economic Evaluation 215 Health, Safety, and Environmental Functions 247 Software Selection 216 Land 248 Software Use 216 Engineering and Supervision 248 Physical Property Estimation Guidelines 217 Legal Expenses 248 Process Simulation Guidelines 217 Construction Expenses 248 Avoiding Pitfalls in Software Use 220 Contractor's Fee 249 Graphic Interface and Ease of Use 221 Contingencies 249 Thermodynamic Property Packages 222 Methods for Estimating Capital Investment Simulation Realism 222 Estimation of Revenue 258 Evaluation of Software Results 224 Estimation of Total Product Cost 259 Manufacturing Costs 262 CHAPTER 6 Variable Production Costs 262 Analysis of Cost Estimation 226 Plant Overhead Costs 270 General Expenses 270 Cash Flow for Industrial Operations 226 Gross Profit, Net Profit, and Cash Flow 271 Cash Plow 226 Cumulative Cash Position 228 Contingencies 272 Factors Affecting Investment and Summary 272 Production Costs 230 Nomenclature 274 Sources of Equipment 230 Greek Symbol 275 Price Fluctuations 230 Problems 275 Company Policies 230 Operating Time and Rate of Production 231 CHAPTER 7 Government Policies 232 Interest, Time Value of Money, Capital Investment 232 Taxes, and Fixed Charges 279 Fixed-Capital Investment 233 Working Capital 233 Interest 279 Simple Interest 280 Estimation of Capital Investment 233 Compound Interest 280 Types of Capital Cost Estimates 235 Nominal and Effective Interest Rates 281 Cost Indexes 236 Continuous Interest 283 Cost Components in Capital Investment 239 Cost of Capital 285 Purchased Equipment 241 Income Tax Effects 286 Estimating Equipment Costs by Scaling 242 Loan Payments 287 Purchased-Equipment Delivery 244 Time Value of Money 290 Purchased-Equipment Installation 244 Instrumentation and Controls 245 Cash Flow Patterns 292 Piping 245 Discrete Cash Flows 292 Electrical Systems 246 Continuous Cash Flows 294 Buildings 246 Compounding and Discounting Factors 297
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