Process Technology: An Introduction

597 Pages·2022·40.508 MB·English

by  André B. de Haan, Johan T. Padding

AndréB.deHaan,JohanT.Padding
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André B. de Haan, Johan T. Padding
Process
Technology
An Introduction
2nd Edition
Authors
Prof.Dr.Ir.AndréB.deHaan
DepartmentofChemicalEngineering
DelftUniversityofTechnology
SectionTransportPhenomena
VanderMaasweg9
2629HZDelft
Netherlands
Prof.Dr.JohanT.Padding
FacultyofMechanical,MaritimeandMaterialsEngineering
DelftUniversityofTechnology
Leeghwaterstraat39
2628CBDelft
Netherlands
ISBN978-3-11-071243-8
e-ISBN(PDF)978-3-11-071244-5
e-ISBN(EPUB)978-3-11-071246-9
LibraryofCongressControlNumber:2021951791
BibliographicinformationpublishedbytheDeutscheNationalbibliothek
TheDeutscheNationalbibliothekliststhispublicationintheDeutscheNationalbibliografie;
detailedbibliographicdataareavailableontheInternetathttp://dnb.dnb.de.
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Preface
Multidisciplinarycooperation isoneof the key contributorsto successful innovation
andprojectexecutionwithinthecurrentandfutureprocessindustry.Themainchal-
lengewithinmultidisciplinaryteamsiscommunication,whichwillbemuchmoreef-
fective whenpossessingbasic understandingofeachother’s discipline. It isexactly
thisreason, enhancing the understanding of processtechnology by those without a
background in (bio)chemical process engineering, that has motivated us to create
thesecondeditionofthisbook.Thefirsteditionservedasthebasisfortheindustrial
course“IntroductionintotheWorldofProcessTechnology,”whichhasbeengivenfor
manyyearswithinmultiplemultinationalcompanies.Participantsincludedchemists
(organic/catalytic/bio/physical/analytical), material technologists, economists, ac-
countants, lawyers and many others working in a position where cooperation and
communication with (bio)chemical process engineers was an essential part of their
job.Since2020thecoursehasbeenrevivedandisnowprovidedas“ProcessTechnol-
ogyforNon-processTechnologists”bytheTUDelftProcess&ProductTechnologyIn-
stitute(www.tudelft.nl/Pro2Tech).Besides small revisions/correctionsthroughout all
chaptersandanupdateofreferencesforfurtherreading,thissecondeditionnowin-
cludeselectrochemicalconversion,amorecompleteoverviewofcomputationalfluid
dynamicsapproachesandmorebackgroundoneconomicevaluationofprojects.
The main objective of this book is to provide a general overview of chemical
and biochemical process and product technology. It focuses on the structure and
development of production processes, main technological operations and the most
importantaspectsofproductandprocessdevelopment,includingeconomics.Forthe
technological operations, the emphasis is on their operating principles, reasons for
applicationandavailableindustrialequipment.Designcalculationsandmathematics
havebeenkepttoaminimumrequiredtounderstandwhyprocesstechnologistsand
engineersneedcertaininformation.Alltopicsareextensivelyillustratedbyrepresen-
tativeexamples.
Thebookisorganizedintosevendistinctparts.Anintroductiontothestructure
ofthechemicalindustryand(bio)chemicalprocessesistreatedinChapters1and2.
Chapters3–5dealwith(bio)chemicalreactionengineeringandreactortechnology.
The most frequently applied molecular separation techniques such as distillation,
extraction, absorption, stripping, adsorption and ion exchange are discussed in
Chapters6–9.Thepartonmechanicalseparationtechnologypresentsanoverview
of the most important techniques for separating heterogeneous mixtures in Chap-
ters10–12.Technologiesrelevantforparticlesandfinalproductmanufacturingare
treatedinChapters13–15.Chapters16–18dealwiththedevelopment,scale-up,de-
sign,engineeringandsafetyofprocesses.Thebookconcludeswiththreeappendi-
ces in which major industrial processes for the production of base chemicals,
polymersandfinechemicalsaredescribed.Itshouldbenotedbythereaderthatthe
appendicesonlyrepresentasmallselectionofthenumerousindustrialprocessesin
https://doi.org/10.1515/9783110712445-202
VI Preface
operation and that the described processes have been selected with a bias on the
companies where the course was lectured. For further reading, an extensive list of
referencebooksisprovided.
AndréB.deHaan
JohanT.Padding
Contents
Preface V
1 Thechemicalindustry 1
1.1 Introduction 1
1.2 Generalcharacteristicsofthechemicalindustrysegments 3
1.3 Majorrawmaterials 5
1.4 Productionstructureofthechemicalindustry 6
2 Thestructureofchemicalandbiochemicalprocesssystems 11
2.1 Structureofchemicalandbiochemicalprocesses 11
2.2 Characteristicsofproductionprocesses 12
2.2.1 Batchproductiontechnology 12
2.2.2 Continuousprocesses 13
2.3 Unitoperations 15
2.3.1 Reactors 16
2.3.2 Recovery,purificationandfractionationtechnologies 18
2.3.3 Productfinishingoperations 20
2.3.4 Otherimportantprocessunits 22
2.4 Processsynthesis 24
3 Principlesofchemicalreactionengineering 27
3.1 Introduction 27
3.2 Classificationofreactions 28
3.3 Rateofchemicalreactions 29
3.3.1 Effectofconcentration 29
3.3.2 Effectoftemperature 30
3.3.3 Chemicalequilibria 31
3.4 Catalysis 33
3.4.1 Homogeneouscatalysis 33
3.4.2 Heterogeneouscatalysis 35
3.5 Conversion,selectivtityandyield 37
3.5.1 Conversion 37
3.5.2 Selectivityandyield 38
3.5.3 Multistepreactions 39
3.6 Basicdesignequationsformodelreactors 41
3.6.1 Molarbalances 41
3.6.2 Theidealbatchreactor 42
3.6.3 Thecontinuousidealstirredtankreactor 44
3.6.4 Idealcontinuousplugflowreactor 45
3.6.5 Cascadeofcontinuousidealstirredtanksreactors 47
VIII Contents
3.7 Heateffectsinmodelreactors 48
3.7.1 Generalheatbalance 48
3.7.2 Heatbalanceinacontinuousidealstirredtankreactor 49
3.7.3 Heatbalanceinabatchreactor 50
4 Chemicalreactorsandtheirindustrialapplications 53
4.1 Introduction 53
4.1.1 Classificationofreactors 53
4.1.2 Influenceofheatofreactiononreactortype 53
4.2 Stirredtankreactors 54
4.2.1 Description 54
4.2.2 Batchstirredtankreactors 55
4.2.3 Continuousstirredtanks 57
4.2.4 Cascadeofstirredtanks 60
4.3 Tubularreactors 61
4.3.1 Introduction 61
4.3.2 Gas-phasereactors 62
4.3.3 Liquid-phasereactors 64
4.4 Loopreactors 65
4.4.1 Continuousloopreactors 66
4.4.2 Bussloopreactor 66
4.5 Bubblecolumns 68
4.6 Fixedandmovingbedreactors 70
4.6.1 Fixedbedreactors 70
4.6.2 Adiabaticfixedbedreactors 71
4.6.3 Fixedbedreactorswithsupplyorremoval
ofheat 72
4.6.4 Movingbedreactors 74
4.7 Fluidizedbedreactors 75
4.7.1 Thefluidizationprinciple 76
4.7.2 Fluidizationpropertiesoftypicalbedsolids 78
4.7.3 Applications 78
4.8 Electrochemicalreactors 82
4.8.1 Basicelementsofanelectrochemicalreactor 82
4.8.2 Designofanelectrochemicalreactor 83
4.8.3 Applications 85
5 Biochemicalreactiontechnology 87
5.1 Characteristicsofbiochemicalprocesses 87
5.1.1 Fermentation 88
5.1.2 Enzymaticconversions 93
5.2 Biochemicalreactionengineering 96
Contents IX
5.2.1 Principles 96
5.2.2 Kineticsofbiochemicalreactions 96
5.2.3 Basicreactoroperations 100
5.3 Industrialbioreactors 102
5.3.1 Classification 102
5.3.2 Bioreactorswithmechanicalmixing 103
5.3.3 Bioreactorswithpneumaticmixing 104
5.3.4 Bioreactorsforimmobilizedenzymesandcells 106
6 Evaporativeseparations 109
6.1 Evaporativeseparation 109
6.1.1 Introduction 109
6.1.2 Vapor-liquidequilibria 110
6.1.3 Separationbysingle-stagepartialevaporation 113
6.2 Multistagedistillation 115
6.2.1 Distillationcascades 115
6.2.2 Columndistillation 116
6.2.3 Feasibledistillationconditions 118
6.2.4 Basicdesigncalculations 119
6.2.5 Energyrequirements 122
6.2.6 Batchdistillation 123
6.2.7 Continuousseparationofmultipleproducts 125
6.2.8 Enhanceddistillationtechniques 125
6.3 Distillationequipment 127
6.3.1 Basicfunctions 127
6.3.2 Traycolumns 128
6.3.3 Packedcolumns 132
6.3.4 Criteriaforcolumnselection 137
6.4 Polymerdevolatilization 137
6.4.1 Introduction 137
6.4.2 Basicmechanisms 138
6.4.3 Multistageoperationanddevolatilizationaids 140
6.4.4 Devolatilizationequipment 141
7 Extractionandleaching 147
7.1 Liquid-liquidextraction 147
7.1.1 Introduction 147
7.1.2 Liquid-liquidequilibria 149
7.1.3 Solventselection 151
7.1.4 Extractionschemes 152
7.2 Industrialliquid-liquidextractors 154
7.2.1 Mixersettlers 154