Chemical process design and integration / Robin Smith.

Includes bibliographical references and index.

CONTENTS
Preface
Acknowledgements
Nomenclature
Chapter 1 The Nature of Chemical Process Design and Integration
1.1 Chemical Products
1.2 Formulation of Design Problems
1.3 Chemical Process Design and Integration
1.4 The Hierarchy of Chemical Process Design and Integration
1.5 Continuous and Batch Processes
1.6 New Design and Retrofit
1.7 Approaches to Chemical Process Design and Integration
1.8 Process Control
1.9 The Nature of Chemical Process Design and Integration - Summary
1.10 References
Chapter 2 Process Economics
2.1 The Role of Process Economics
2.2 Simple Economic Criteria
2.3 Capital Cost for New Design
2.4 Capital Cost for Retrofit
2.5 Annualized Capital Cost
2.6 Operating Cost
2.7 Project Cash Flow and Economic Evaluation
2.8 Investment Criteria
2.9 Economic Evaluation - Summary
2.10 Exercises
2.11 References
Chapter 3 Optimization
3.1 Objective Functions
3.2 Single Variable Optimization
3.3 Multivariable Optimization
3.4 Constrained Optimization
3.5 Linear Programming
3.6 Non-linear Programming
3.7 Profile Optimization
3.8 Structural Optimization
3.9 Solution of Equations Using Optimization
3.10 The Search for Global Optimality
3.11 Optimization - Summary
3.12 Exercises
3.13 References
Chapter 4 Phase Equilibrium and Thermodynamic Properties
4.1 Equations of State
4.2 Phase Equilibrium for Single Components
4.3 Fugacity and Phase Equilibrium
4.4 Vapor-liquid Equilibrium
4.5 Vapor-liquid Equilibrium Based on Activity Coefficient Models
4.6 Vapor-liquid Equilibrium Based on Equations of State
4.7 Calculation of Vapor-liquid Equilibrium
4.8 Liquid-liquid Equilibrium
4.9 Liquid-liquid Equilibrium Activity Coefficient Models
4.10 Calculation of Liquid-liquid Equilibrium
4.11 Calculation of Enthalpy
4.12 Calculation of Entropy
4.13 Phase Equilibrium and Thermodynamic Properties - Summary
4.14 Exercises
4.15 References
Chapter 5 Choice of Reactor I - Reactor Performance
5.1 Reaction Paths
5.2 Types of Reaction Systems
5.3 Measures of Reactor Performance
5.4 Rate of Reaction
5.5 Idealized Reactor Models
5.6 Choice of Idealized Reactor Model
5.7 Choice of Reactor Performance
5.8 Choice of Reactor Performance - Summary
5.9 Exercises
5.10 References
Chapter 6 Choice of Reactor II - Reactor Conditions
6.1 Reaction Equilibrium
6.2 Reactor Temperature
6.3 Reactor Pressure
6.4 Reactor Phase
6.5 Reactor Concentration
6.6 Biochemical Reactions
6.7 Catalysts
6.8 Choice of Reactor Conditions - Summary
6.9 Exercises
6.10 References
Chapter 7 Choice of Reactor III - Reactor Configuration
7.1 Temperature Control
7.2 Catalyst Deactivation
7.3 Gas-liquid and Liquid-liquid Reactors
7.4 Reactor Configuration
7.5 Reactor Configuration for Heterogeneous Solid-catalyzed Reactions
7.6 Reactor Configuration from Optimization of a Superstructure
7.7 Choice of Reactor Configuration - Summary
7.8 Exercises
7.9 References
Chapter 8 Choice of Separator for Heterogeneous Mixtures
8.1 Homogeneous and Heterogeneous Separation
8.2 Settling and Sedimentation
8.3 Inertial and Centrifugal Separation
8.4 Electrostatic Precipitation
8.5 Filtration
8.6 Scrubbing
8.7 Flotation
8.8 Drying
8.9 Separation of Heterogeneous Mixtures - Summary
8.10 Exercises
8.11 References
Chapter 9 Choice of Separator for Homogeneous Fluid Mixtures I - Distillation
9.1 Single Stage Separation
9.2 Distillation
9.3 Binary Distillation
9.4 Total and Minimum Reflux Conditions for Multicomponent Mixtures
9.5 Finite Reflux Conditions for Multicomponent Mixtures
9.6 Choice of Operating Conditions
9.7 Limitations of Distillation
9.8 Separation of Homogeneous Fluid Mixtures by Distillation - Summary
9.9 Exercises
9.10 References
Chapter 10 Choice of Separator for Homogeneous Fluid Mixtures II - Other Methods
10.1 Absorption
10.2 Liquid-liquid Extraction
10.3 Adsorption
10.4 Membranes
10.5 Crystallization
10.6 Evaporation
10.7 Separation of Homogeneous Fluid Mixtures by Other Methods - Summary
10.8 Exercises
10.9 References
Chapter 11 Distillation Sequencing
11.1 Distillation Sequencing Using Simple Columns
11.2 Practical Constraints Restricting Options
11.3 Choice of Sequence for Simple Non-integrated Distillation Columns
11.4 Distillation Sequencing Using Columns with More than Two Products
11.5 Distillation Sequencing Using Thermal Coupling
11.6 Retrofit of Distillation Sequences
11.7 Crude Oil Distillation
11.8 Distillation Sequencing Based on Optimization of a Superstructure
11.9 Distillation Sequencing - Summary
11.10 Exercises
11.11 References
Chapter 12 Distillation Sequencing for Azeotropic Distillation
12.1 Azeotropic Systems
12.2 Change in Pressure
12.3 Representation of Azeotropic Distillation
12.4 Distillation at Total Reflux Conditions
12.5 Distillation at Minimum Reflux Conditions
12.6 Distillation at Finite Reflux Conditions
12.7 Distillation Sequencing Using an Entrainer
12.8 Heterogeneous Azeotropic Distillation
12.9 Entrainer Selection
12.10 Multicomponent Systems
12.11 Trade-offs in Azeotropic Distillation
12.12 Membrane Separation
12.13 Distillation Sequencing for Azeotropic Distillation - Summary
12.14 Exercises
12.15 References
Chapter 13 Reaction, Separation and Recycle Systems for Continuous Processes
13.1 The Function of Process Recycles
13.2 Recycles With Purges
13.3 Pumping and Compression
13.4 Simulation of Recycles
13.5 The Process Yield
13.6 Optimization of Reactor Conversion
13.7 Optimization of Processes Involving a Purge
13.8 Hybrid Reaction and Separation
13.9 Feed, Product and Intermediate Storage
13.10 Reaction and Separation Systems for Continuous Processes - Summary
13.11 Exercises
13.12 References
Chapter 14 Reaction, Separation and Recycle Systems for Batch Processes
14.1 Batch Processes
14.2 Batch Reactors
14.3 Batch Separation Processes
14.4 Gantt Charts
14.5 Production Schedules for Single Products
14.6 Production Schedules for Multiple Products
14.7 Equipment Cleaning and Material Transfer
14.8 Synthesis of Reaction and Separation Systems for Batch Processes
14.9 Optimization of Batch Processes
14.10 Storage in Batch Processes
14.11 Reaction-Separation Systems for Batch Processes - Summary
14.12 Exercises
14.13 References
Chapter 15 Heat Exchanger Networks I - Heat Transfer Equipment
15.1 Overall Heat Transfer Coefficients
15.2 Heat Transfer Coefficients and Pressure Drops in Shell-and-tube Heat Exchangers
15.3 Temperature Difference in Shell-and-tube Heat Exchangers
15.4 Allocation of Fluids in Shell-and-tube Heat Exchangers
15.5 Extended Surface Tubes
15.6 Condensers
15.7 Reboilers
15.8 Other Types of Heat Exchanger Equipment
15.9 Heat Exchanger Equipment - Summary
15.10 Exercises
15.11 References
Chapter 16 Heat Exchanger Networks II - Energy Targets
16.1 Composite Curves
16.2 The Heat Recovery Pinch
16.3 Threshold Problems
16.4 The Problem Table Algorithm
16.5 Non-global Minimum Temperature Differences
16.6 Process Constraints
16.7 Utility Selection
16.8 Furnaces
16.9 Cogeneration (Combined Heat and Power Generation)
16.10 Integration of Heat Pumps
16.11 Heat Exchanger Network and Utilities Energy Targets - Summary
16.12 Exercises
16.13 References
Chapter 17 Heat Exchanger Networks II - Capital and Total Cost Targets
17.1 Number of Heat Exchange Units
17.2 Heat Exchange Area Targets
17.3 Number of Shells Target
17.4 Capital Cost Targets
17.5 Total Cost Targets
17.6 Heat Exchanger Network and Utilities Capital and Total Costs - Summary
17.7 Exercises
17.8 References
Chapter 18 Heat Exchanger Networks III - Network Design
18.1 The Pinch Design Method
18.2 Design for Threshold Problems
18.3 Stream Splitting
18.4 Design for Multiple Pinches
18.5 Remaining Problem Analysis
18.6 Network Optimization
18.7 Heat Exchanger Network Design Based on the Optimization of a Superstructure
18.8 Heat Exchanger Network Retrofit
18.9 Addition of New Heat Transfer Area in Retrofit
18.10 Heat Exchanger Network Design - Summary
18.11 Exercises
18.12 References
Chapter 19 Heat Exchanger Networks IV - Stream Data
19.1 Process Changes for Heat Integration
19.2 The Trade-offs Between Process Changes, Utility Selection,
19.3 Data Extraction
19.4 Heat Exchanger Network Stream Data - Summary
19.5 Exercises
19.6 Reference
Chapter 20 Heat Integration of Reactors
20.1 The Heat Integration Characteristics of Reactors
20.2 Appropriate Placement of Reactors
20.3 Use of the Grand Composite Curve for Heat Integration of Reactors
20.4 Evolving Reactor Design to Improve Heat Integration
20.5 Heat Integration of Reactors - Summary
20.6 References
Chapter 21 Heat Integration of Distillation
21.1 The Heat Integration Characteristics of Distillation
21.2 Appropriate Placement of Distillation
21.3 Use of the Grand Composite Curve for Heat Integration of Distillation
21.4 Evolving the Design of Simple Distillation Columns to Improve Heat Integration
21.5 Heat Pumping in Distillation
21.6 Capital Cost Considerations for the Integration of Distillation
21.7 Heat Integration Characteristics of Distillation Sequences
21.8 Heat Integrated Distillation Sequences Based on Optimization of a Superstructure
21.9 Heat Integration of Distillation Columns - Summary
21.10 Exercises
21.11 References
Chapter 22 Heat Integration of Evaporators and Dryers
22.1 The Heat Integration Characteristics of Evaporators
22.2 Appropriate Placement of Evaporators
22.3 Evolving Evaporator Design to Improve Heat Integration
22.4 The Heat Integration Characteristics of Dryers
22.5 Evolving Dryer Design to Improve Heat Integration
22.6 A Case Study
22.7 Heat Integration of Evaporators and Dryers - Summary
22.8 Exercises
22.9 References
Chapter 23 Steam Systems and Cogeneration
23.1 Boiler Feedwater Treatment
23.2 Steam Boilers
23.3 Steam Turbines
23.4 Gas Turbines
23.5 Steam System Configuration
23.6 Steam and Power Balances
23.7 Site Composite Curves
23.8 Cogeneration Targets
23.9 Optimizing Steam Levels
23.10 Site Power-to-Heat Ratio
23.11 Optimizing Steam Systems
23.12 Steam Costs
23.13 Choice of Driver
23.14 Steam Systems and Cogeneration - Summary
23.15 Exercises
23.16 References
Chapter 24 Cooling and Refrigeration Systems
24.1 Cooling Systems
24.2 Recirculating Cooling Water Systems
24.3 Targeting Minimum Cooling Water Flowrate
24.4 Design of Cooling Water Networks
24.5 Retrofit of Cooling Water Systems
24.6 Refrigeration Cycles
24.7 Process Expanders
24.8 Choice of Refrigerant for Compression Refrigeration
24.9 Targeting Refrigeration Power for Compression Refrigeration
24.10 Heat Integration of Compression Refrigeration Processes
24.11 Mixed Refrigerants for Compression Refrigeration
24.12 Absorption Refrigeration
24.13 Indirect Refrigeration
24.14 Cooling and Refrigeration Systems - Summary
24.15 Exercises
24.16 References
Chapter 25 Environmental Design for Atmospheric Emissions

25.1 Atmospheric Pollution
25.2 Sources of Atmospheric Pollution
25.3 Control of Solid Particulate Emissions to Atmosphere
25.4 Control of VOC Emissions
25.5 Control of Sulfur Emissions
25.6 Control of Oxides of Nitrogen
25.7 Control of Combustion Emissions
25.8 Atmospheric Dispersion
25.9 Environmental Design for Atmospheric Emissions - Summary
25.10 Exercises
25.11 References
Chapter 26 Water System Design
26.1 Aqueous Contamination
26.2 Primary Treatment Processes
26.3 Biological Treatment Processes
26.4 Tertiary Treatment Processes
26.5 Water Use
26.6 Targeting Maximum Water Re-use for Single Contaminants
26.7 Design for Maximum Water Re-use for Single Contaminants
26.8 Targeting and Design for Maximum Water Re-use Based on Optimization of Superstructure
26.9 Process Changes for Reduced Water Consumption
26.10 Targeting Minimum Wastewater Treatment Flowrate for Single Contaminants
26.11 Design for Minimum Wastewater Treatment Flowrate for Single Contaminants
26.12 Regeneration of Wastewater
26.13 Targeting and Design for Effluent Treatment and Regeneration Based Optimization of a Superstructure
26.14 Data Extraction
26.15 Water System Design - Summary
26.16 Exercises
26.17 References
Chapter 27 Inherent Safety
27.1 Fire
27.2 Explosion
27.3 Toxic Release
27.4 Intensification of Hazardous Materials
27.5 Attenuation of Hazardous Materials
27.6 Quantitative Measures of Inherent Safety
27.7 Inherent Safety - Summary
27.8 Exercises
27.9 References
Chapter 28 Waste Minimization
28.1 Minimization of Waste from Reactors
28.2 Minimization of Waste from the Separation and Recycle System
28.3 Minimization of Waste from Process Operations
28.4 Minimization of Utility Waste
28.5 Trading Off Waste Minimization Options
28.6 Life-Cycle Analysis
28.7 Waste Minimization in Practice
28.8 Waste Minimization - Summary
28.9 Exercises
28.10 References
Chapter 29 Overall Strategy for Chemical Process Design and Integration
29.1 The Objectives
29.2 The Hierarchy
29.3 The Final Design
Appendix A Annualization of Capital Cost
Appendix B Gas Compression
B.1 Reciprocating Compressors
B.2 Centrifugal Compressors
Appendix C Heat Transfer Coefficients and Pressure Drop in Shell-and-Tube Heat Exchangers
C.1 Pressure Drop and Heat Transfer Correlations for the Tube-side
C.2 Pressure Drop and Heat Transfer Correlations for the Shell-side
C.3 References
Appendix D Maximum Thermal Effectiveness for 1-2 Shell-and-Tube Heat
Exchangers
Appendix E Expression for the Minimum Number of 1-2 Shell-and-Tube
Heat Exchangers for a Given Unit
Appendix F Algorithm for the Heat Exchange Area Target
Appendix G Algorithm for the Number-of-Shells Target
G.1 Minimum Area Target for Networks of 1-2 Shells
G.2 References
Appendix H Algorithm for Heat Exchanger Capital Cost Target