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Chemical Process Engineering Volume 2

Design, Analysis, Simulation, Integration, and Problem Solving with Microsoft Excel-UniSim Software for Chemical Engineers, Heat Transfer and Integration, Process Safety, Chemical Kinetics and Reactor Design, Engineering Economics, Optimization
By A. Kayode Coker and Rahmat Sotudeh-Gharebagh
Copyright: 2022   |   Status: Published
ISBN: 9781119853992  |  Hardcover  |  
891 pages
Price: $329 USD
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One Line Description
Written by one of the most prolific and respected chemical engineers in the world and his co-author, also a well-known and respected engineer, this two-volume set is the “new standard” in the industry, offering engineers and students alike the most up-do-date, comprehensive, and state-of-the-art coverage of processes and best practices in the field today.

Audience
Petroleum, chemical, and process engineers, petroleum and chemical engineering students, engineers and technicians working in petroleum refining, other engineers and technicians in the oil and gas industry, and engineers working towards Professional Engineering qualifications

Description
This new two-volume set explores and describes integrating new tools for engineering education and practice for better utilization of the existing knowledge on process design. Useful not only for students, university professors, and practitioners, especially process, chemical, mechanical and metallurgical engineers, it is also a valuable reference for other engineers, consultants, technicians and scientists concerned about various aspects of industrial design.

The text can be considered as a complementary to process design for senior and graduate students as well as a hands-on reference work or refresher for engineers at entry level. The contents of the book can also be taught in intensive workshops in the oil, gas, petrochemical, biochemical and process industries.

The book provides a detailed description and hands-on experience on process design in chemical engineering, and it is an integrated text that focuses on practical design with new tools, such as Microsoft Excel spreadsheets and UniSim simulation software.

Written by two of the industry’s most trustworthy and well-known authors, this book is the new standard in chemical, biochemical, pharmaceutical, petrochemical and petroleum refining. Covering design, analysis, simulation, integration, and, perhaps most importantly, the practical application of Microsoft Excel-UniSim software, this is the most comprehensive and up-to-date coverage of all of the latest developments in the industry. It is a must-have for any engineer or student’s library.

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Author / Editor Details
A. Kayode Coker, PhD, is an engineering consultant for AKC Technology, an honorary research fellow at the University of Wolverhampton, UK, a former engineering coordinator at Saudi Aramco Shell Refinery Company, and chairman of the Department of Chemical Engineering Technology at Jubail Industrial College, Saudi Arabia. He has been a chartered chemical engineer for more than 30 years. He is a fellow of the Institution of Chemical Engineers, UK, and a senior member of the American Institute of Chemical Engineers. He holds a BSc honors degree in chemical engineering, a master of science degree in process analysis and development and PhD in chemical engineering, all from Aston University, Birmingham, UK, and a Teacher’s Certificate in Education at the University of London, UK. He has directed and conducted short courses extensively throughout the world and has been a lecturer at the university level. His articles have been published in several international journals. He is an author of seven books in chemical engineering, a contributor to the Encyclopedia of Chemical Processing and Design, Vol 61 and a certified train-the-mentor trainer. He is also a technical report assessor and interviewer for chartered chemical engineers (IChemE) in the U.K. He is a member of the International Biographical Centre in Cambridge, UK, is in “Leading Engineers of the World for 2008.” He is also a member of “International Who’s Who of ProfessionalsTM” and “Madison Who’s Who in the U.S.”

Rahmat Sotudeh–Gharebaagh, PhD, is a full professor of chemical engineering at the University of Tehran. He teaches process modeling and simulation, transport phenomena, plant design and economics and soft skills. His research interests include computer-aided process design and simulation, fluidization, and engineering education. He holds a BEng degree in chemical engineering from Iran’s Sharif University of Technology, plus a MSc and a PhD in fluidization engineering from Canada’s Polytechnique. He has been an invited Professor at Qatar University and Polytechnique de Montréal. Professor Sotudeh has more than 300 publications in major international journals and conferences, plus four books and four book chapters. He is the co-founder and editor-in-chief of the journal, Chemical Product and Process Modeling, a member of the Iranian Elite Foundation, and an official expert (OE) on the oil industry with the Iranian Official Expert Organization.

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Table of Contents
Preface
Acknowledgements
About the Authors
8. Heat Transfer
Introduction
8.1 Types of Heat Transfer Equipment Terminology
8.2 Details of Exchange Equipment Assembly and Arrangement
Construction Codes
Thermal Rating Standards
Details of Stationary Heads
Exchanger Shell Types
8.3 Factors Affection Shell Selection
8.4 Common Combinations of Shell and Tube Heat Exchangers
AES
BEM
AEP
CFU
AKT
AJW
8.5 Thermal Design
8.5.1 Temperature Difference: Two Fluid Transfer
8.5.2 Mean Temperature Difference or Log Mean Temperature Difference
8.5.3 Log Mean Temperature Difference Correction Factor, F
8.5.4 Correction for Multipass Flow through Heat Exchangers
Example 8.1. Calculation of LMTD and Correction
Example 8.2. Calculate the LMTD
Solution
Example 8.3. Heating of Glycerin in a Multipass Heat Exchanger
Solution 604
8.6 The Effectiveness – NTU Method
Example 8.4. Heating Water in a Counter-Current Flow Heat Exchanger
Solution
Example 8.5. LMTD and ε-NTU Methods
Solution
Example 8.6
Solution
8.7 Pressure Drop, Δp
8.7.1 Frictional Pressure Drop
8.7.2 Factors Affecting Pressure Drop (Δp)
Tube-Side Pressure Drop, Δpf
Shell-Side Pressure Drop Δpf
Shell Nozzle Pressure Drop (∆pnoz)
Total Shell-Side Pressure Drop, ∆ptotal
8.8 Heat Balance 629 Heat Load or Duty
8.9 Transfer Area 630 Over Surface and Over Design
8.10 Fouling of Tube Surface
8.10.1 Prevention and Control of Gas-Side Fouling
8.11 Exchanger Design 640 Overall Heat Transfer Coefficients for Plain or Bare Tubes
Example 8.7. Calculation of Overall Heat Transfer Coefficient from Individual Components
8.12 Approximate Values for Overall Heat Transfer Coefficients
Simplified Equations
8.12.1 Film Coefficients with Fluids Outside Tubes Forced Convection
Viscosity Correction Factor (μ/μw)0.14
Heat Transfer Coefficient for Water, hi
Shell-Side Equivalent Tube Diameter
Shell-Side Velocities
8.13 Design and Rating of Heat Exchangers
Rating of a Shell and Tube Heat Exchanger
8.13.1 Design of a Heat Exchanger
8.13.2 Design Procedure for Forced Convection Heat Transfer in Exchanger Design 8.13.3 Design Programs for a Shell and Tube Heat Exchanger
Example 8.8. Convention Heat Transfer Exchanger Design
8.14 Shell and Tube Heat Exchanger Design Procedure (SI Units)
Tubes
Tube-Side Pass Partition Plate
8.14.1 Calculations of Tube-Side Heat Transfer Coefficient
Example 8.9. Design of a Shell and Tube Heat Exchanger (SI Units) Kern’s Method Solution
8.14.2 Pressure Drop for Plain Tube Exchangers
Total Tube-Side Pressure Drop
Tube-Side Condensation Pressure Drop
Shell Side
A Case Study Using UniSim Shell-Tube Exchanger (STE) Modeler
Solution
8.15 Bell-Delaware Method
Overall Heat Transfer Coefficient, U
Shell-Side Pressure (Δp)
Tube Pattern
Accuracy of Correlations Between Kern’s Method and the Bell-Delaware Method Specification Process Data Sheet, Design and Construction of Heat Exchangers Rapid Design Algorithms for Shell and Tube and Compact Heat Exchangers: Polley et al.
8.17 Fluids in the Annulus of Tube-in-Pipe or Double Pipe Heat Exchanger, Forced Convection
Finned Tube Exchangers
Low-Finned Tubes, 16 and 19 Fins/In.
Finned Surface Heat Transfer
8.17.1 Pressure Drop Across Finned Tubes
Design for Heat Transfer Coefficients by Forced Convection Using Radial Low-Fin Tubes in Heat Exchanger Bundles
8.17.2 Pressure Drop in Exchanger Shells Using Bundles of Low-Fin Tubes
8.17.3 Tube-Side Heat Transfer and Pressure Drop
Double Pipe Finned Tube Heat Exchangers
Finned Side Heat Transfer
Tube Wall Resistance
Tube-Side Heat Transfer and Pressure Drop
Fouling Factor
Finned Side Pressure Drop
8.17.4 Design Equations for the Rating of a Double Pipe Heat Exchanger
Process Condition Required
Inner Pipe
Annulus
Vapor Service
Shell-Side Bare Tube
Shell Side (Finned Tube)
Annulus
8.17.5 Calculation of the Pressure Drop
Effect of Pressure Drop (Δp) on the Original Design
Nomenclature:
Example 8.9
Solution
Heat Balance
Pressure Drop Calculations
Tube Side
Tube-Side Δp
Shell-Side Δp
8.18 Plate and Frame Heat Exchangers
Selection
8.19 Air-Cooled Heat Exchangers
8.19.1 Induced Draft
8.19.2 Forced Draft
General Application
Advantages – Air-Cooled Heat Exchangers
Disadvantages
Mean Temperature Difference
8.19.3 Design Procedure for Approximation
8.19.4 Tube-Side Fluid Temperature Control
8.19.5 Rating Method for Air-Cooler Exchangers
The Air Side Pressure Drop, ∆pa (inch H2O)
Example 8.10
Solution
8.19.6 Operations of Air-Cooled Heat Exchangers
8.19.7 Monitoring of Air-Cooled Heat Exchangers
8.20 Spiral Heat Exchangers
8.21 Spiral Coils in Vessels
8.22 Heat-Loss Tracing for Process Piping
Example 8.11
Solution
In SI Units
8.23 Boiling and Vaporization
8.23.1 Boiling
8.23.2 Vaporization
8.23.3 Vaporization During Flow
8.24 Heating Media
Heat Fux Limit
8.25 Batch Heating and Cooling of Fluids
Batch Heating: Internal Coil: Isothermal Heating Medium
Example
8.12. Batch Heating: Internal Coil Isothermal Heating Medium
Solution
Batch Reactor Heating and Cooling Temperature Prediction
Example 8.13: Batch Reactor Heating and Cooling Temperature Prediction
Solution
Batch Cooling: Internal Coil Isothermal Cooling Medium
Example 8.14 Batch Cooling: Internal Coil, Isothermal Cooling Medium
Solution
Batch Heating: Non-Isothermal Heating Medium
Example 8.15: Batch Heating with Non-Isothermal Heating Medium
Solution
Batch Cooling: Non-Isothermal Cooling Medium
Example 8.16: Batch Cooling Non-Isothermal Cooling Medium
Solution
Batch Heating: External Heat Exchanger, Isothermal Heating Medium
Example 8.17: Batch Heating: External Heat Exchanger Isothermal Heating Medium Solution
Batch Cooling: External Heat Exchanger, Isothermal Cooling Medium
Example 8.18: Batch Cooling: External Heat Exchanger, Isothermal Cooling Medium Solution
Batch Cooling: External Heat Exchanger (Counter-Current Flow), Non-isothermal
Cooling Medium
Example 8.19: Batch Cooling: External Heat Exchanger (Counter-Current Flow),
Non-Isothermal Cooling Medium
Solution
Batch Heating: External Heat Exchanger and Non-Isothermal Heating Medium Example 8.20: Batch Heating: External Heat Exchanger and Non-Isothermal Heating Medium
Solution
Batch Heating: External Heat Exchanger (1-2 Multipass Heat Exchangers),
Non-Isothermal Heating Medium
Example 8.21: External Heat Exchanger 2 Multipass Heat Exchangers),
Non-Isothermal Heating Medium
Solution
Batch Cooling: External Heat Exchanger (1-2 Multipass), Non-Isothermal Cooling Medium
Example 8.22: External Heat Exchanger (1-2 Multipass), Non-Isothermal Cooling Medium
Solution
Batch Heating and Cooling: External Heat Exchanger (2-4 Multipass Heat Exchangers
Non-Isothermal Heating Medium)
Batch Heating and Cooling: External Heat Exchanger (2-4 Multipass Heat Exchangers Non-Isothermal Cooling Medium)
Example 8.23: External Heat Exchanger (2-4 Multipass Exchanger), Non-Isothermal Heating Medium
Example 8.24: External Heat Exchanger (2-4 Multipass Heat Exchangers),
Non-Isothermal Cooling Medium
Heat Exchanger Design with Computers
Functionality
Physical Properties
UniSim Heat Exchanger Model Formulations
Case Study: Kettle Reboiler Simulation Using UniSim STE
Nozzle Data
Process Data
References
9. Process Integration and Heat Exchanger Network
Introduction
Application of Process Integration
Pinch Technology
Heat Exchanger Network Design
Energy and Capital Targeting and Optimization
Optimization Variables
Optimization of the Use of Utilities (Utility Placement)
Heat Exchanger Network Revamp
Heat Recovery Problem Identification
The Temperature-Enthalpy Diagram (T-H)
Energy Targets
Construction of Composite Curves
Heat Recovery for Multiple Systems
Example 9.1. Setting Energy Targets and Heat Exchanger Network
Solution
The Heat Recovery Pinch and Its Significance
The Significance of the Pinch
The Plus-Minus Principle for Process Modifications
A Targeting Procedure: The Problem Table Algorithm
The Grand Composite Curve
Placing Utilities Using the Grand Composite Curve
Stream Matching at the Pinch
The Pinch Design Approach to Inventing a Network
Heat Exchanger Network Design (HEN)
The Design Grid
Network Design Above the Pinch
The Intermediate Temperatures in the Streams are:
Network Design Below the Pinch
The Intermediate Temperatures in the Streams are:
Above the Pinch
Below the Pinch
Example 9.2
Solution
Design for Threshold Problems
Stream Splitting
Advantages and Disadvantages of Stream Splitting
Example 9.3
Solution
Example 9.4
Stream Data Extraction
Solution
Heat Exchanger Area Targets
Example 9.5
Solution
Example 9.6
Solution
HEN Simplification
Heat Load Loops
Example 9.7. Test Case 3, TC3 Linnhoff and Hindmarch
Solution
Heat Load Paths
Number of Shells Target
Implications for HEN Design
Capital Cost Targets
Capital Cost
Network Capital Cost (CC)
Total Cost Targeting
Energy Targeting
Supertargeting or ∆Tmin Optimization
Example 9.8. HEN for Maximum Energy Recovery
Solution
Summary: New Heat Exchanger Network Design
Targeting and Design for Constrained Matches
Process Constraints
Targeting for Constraints
Heat Engines and Heat Pumps for Optimum Integration
Principle of Operation
Heat Pump Evaluation
Application of a Heat Pump
Appropriate Integration of Heat Engines
Opportunities for Placement of Heat Engines
Appropriate Integration of Heat Pumps
Opportunities for Placement of Heat Pumps
Appropriate Placement of Compression and Expansion in Heat Recovery Systems Pressure Drop and Heat Transfer in Process Integration
Total Site Analysis
Applications of Process Integration
Hydrogen Pinch Studies
Oxygen Pinch
Carbon Dioxide (CO2) Management
Mass and Water Pinch
Site-Wide Integration
Flue Gas Emissions
Pitfalls in Process Integration
Pinch to Target CO2 Emissions
Pinch Technology in Petroleum and Chemical Industries
Conclusions
Industrial Applications: Case Studies
Case study-1: (From Gary Smith and Ajit Patel, The Chemical Engineer, p. 26,
November 1987)
Case study-2: Crude Preheat Train
Introduction
Process Description
Solution
Above the Pinch
Below the Pinch
Case Study-3: Network for Aromatics Plant (G. T. Polley, and M.H. Panjeh Shahi,
Trans. Inst. ChemE., Vol. 69, Part A, November 1991)
Introduction
Process Description
Stream Data Extraction
Solution
Glossary of Terms
Summary and Heuristics
Heuristics
Nomenclature
References
Bibliography
10. Process Safety and Pressure-Relieving Devices
Introduction
10.1 Types of Positive Pressure-Relieving Devices
(See Manufacturers’ Catalogs for Design Details)
Pressure Relief Valve
Pilot-Operated Safety Valves
10.2 Types of Valves/Relief Devices
Conventional Safety Relief Valve
Balanced Safety Relief Valve
Special Valves
10.3 Rupture Disk
Example 10.1
Hypothetical Vessel Design, Carbon Steel Grade A-285, Gr C
10.4 Design Pressure of a Vessel
10.5 Materials of Construction
Safety and Relief Valves; Pressure-Vacuum Relief Values
10.6 Rupture Disks
General Code Requirements
Relief Mechanisms
Reclosing Devices, Spring Loaded
Non-Reclosing Pressure-Relieving Devices
Pressure Settings and Design Basis
10.7 Unfired Pressure Vessels Only, But Not Fired or Unfired Steam Boilers External Fire or Heat Exposure Only and Process Relief
10.8 Relieving Capacity of Combinations of Safety Relief Valves and Rupture Disks
or Non-Reclosure Devices (Reference ASME Code, Par. UG-127, U-132)
Primary Relief
Selected Portions of ASME Pressure Vessel Code, Quoted by Permission
10.9 Establishing Relieving or Set Pressures
Safety and Safety Relief Valves for Steam Service
10.10 Selection and Application
10.11 Capacity Requirements Evaluation for Process Operation (Non-Fire) Installation
10.12 Selection Features: Safety, Safety Relief Valves, and Rupture Disks
10.13 Calculations of Relieving Areas: Safety and Relief Valves
10.14 Standard Pressure Relief Valves Relief Area Discharge Openings
10.15 Sizing Safety Relief Type Devices for Required Flow Area at Time of Relief
10.16 Effects of Two-Phase Vapor-Liquid Mixture on Relief Valve Capacity
10.17 Sizing for Gases or Vapors or Liquids for Conventional Valves with Constant Backpressure Only
Procedure
Establish Critical Flow for Gases and Vapors
Example 10.2
Flow through Sharp Edged Vent Orifice
10.18 Orifice Area Calculations
10.19 Sizing Valves for Liquid Relief: Pressure Relief Valves Requiring Capacity Certification [5d]
10.20 Sizing Valves for Liquid Relief: Pressure Relief Valves Not Requiring Capacity Certification [5d]
10.21 Reaction Forces
Example 10.3
Solution
Example 10.4
Solution
10.22 Calculations of Orifice Flow Area using Pressure-Relieving Balanced Bellows Valves, with Variable or Constant Back Pressure
10.23 Sizing Valves for Liquid Expansion (Hydraulic Expansion of Liquid-Filled Systems/Equipment/Piping)
10.24 Sizing Valves for Subcritical Flow: Gas or Vapor but not Steam [5d]
10.25 Emergency Pressure Relief: Fires and Explosions Rupture Disks
10.26 External Fires
10.27 Set Pressures for External Fires
10.28 Heat Absorbed
The Severe Case
10.29 Surface Area Exposed to Fire
10.30 Relief Capacity for Fire Exposure
10.31 Code Requirements for External Fire Conditions
10.32 Design Procedure
Example 10.5
Solution
10.33 Runaway Reactions: DIERS
10.34 Hazard Evaluation in the Chemical Process Industries
10.35 Hazard Assessment Procedures
10.36 Exotherms
10.37 Accumulation
10.38 Thermal Runaway Chemical Reaction Hazards
10.39 Heat Consumed Heating the Vessel. The φ-Factor
10.40 Onset Temperature
10.41 Time-to-Maximum Rate
10.42 Maximum Reaction Temperature
10.43 Vent Sizing Package (VSP)
10.44 Vent Sizing Package 2TM (VSP2TM)
10.45 Advanced Reactive System Screening Tool (ARSST)
10.46 Two-Phase Flow Relief Sizing for Runaway Reaction
10.47 Runaway Reactions
10.48 Vapor Pressure Systems
10.49 Gassy Systems
10.50 Hybrid Systems
10.51 Simplified Nomograph Method
10.52 Vent Sizing Methods
10.53 Vapor Pressure Systems
10.54 Fauske’s Method
10.55 Gassy Systems
10.56 Homogeneous Two-Phase Venting Until Disengagement
10.57 Two-Phase Flow Through an Orifice
10.58 Conditions of Use
10.59 Discharge System
Design of the Vent Pipe
10.60 Safe Discharge
10.61 Direct Discharge to the Atmosphere
Example 10.6
Tempered Reaction
Solution
Example 10.7
Solution
Example 10.8
Solution
Example 10.9
Solution
10.62 DIERS Final Reports
10.63 Sizing for Two-Phase Fluids
Step 1. Calculate the Saturated Omega Parameter, ωs
Step 2. Determine the Subcooling Region
Step 3. Determine if the Flow is Critical or Subcritical
Step 4. Calculate the Mass Flux
Step 5. Calculate the Required Area of the PRV
SI Units
Example 10.10
Solution
Example 10.11
Solution
Type 2. (Omega Method): Sizing for Two-Phase Flashing Flow with a Noncondensable Gas Through a Pressure Relief Valve
Example 10.12
SI Units
Example 10.13
Solution
Type 3 Integral Method
Example 10.14
Solution
Glossary
Acronyms and Abbreviations
Nomenclature
Subscripts
Greek Symbols
References
Listing of Final Reports from the DIERS Research Program (Design Institute
for Emergency Relief Systems)
Project Manual
Technology Summary
Sm 540 All/Large-Scale Experimental Data and Analysis
Bench-Scale Apparatus Design and Test Results
11. Chemical Kinetics and Reactor Design
INTRODUCTION
INDUSTRIAL REACTION PROCESSES
Conventional Reactors
Membrane Reactors
Spherical Reactors
Bioreactors
CHEMICAL REACTIONS
Conversion Type
Equilibrium Type
Kinetic Type
IDEAL REACTORS
Conversion Reactor
Adiabatic Flame Temperature
Heats of Reaction
Equilibrium Reactor
Gibbs Reactor
CSTR Reactor
PFR Reactor
NON-IDEAL REACTORS
Modular Analysis
Multiscale Analysis
BIOCHEMICAL REACTIONS
Models of Enzyme Kinetics
Constant Volume Batch Reactor
CHEMICAL REACTION HAZARDS INCIDENTS
Reactive Hazards Incidents
Chemical Reactivity Worksheet (CRW)
Protective Measures for Runaway Reactions
PROBLEMS AND SOLUTIONS
References
12. Engineering Economics
INTRODUCTION
GROSS PROFIT ANALYSIS
CAPITAL COST ESTIMATION
Equipment/Plant Cost Estimations by Capacity Exponents
Factored Cost Estimate
Functional-Unit Estimate
Percentage of Delivered Equipment Cost
PROJECT EVALUATION
Cash Flow
Cumulated Cash Flow
Return on Investment (ROI)
Payback Period (PBP)
Present Worth (or Present Value)
Net Present Value (NPV)
Discounted Cash Flow Rate of Return (DCFRR)
Net Return Rate (NRR)
Depreciation
Double Declining Balance (DDB) Depreciation
Capitalized Cost
Average Rate of Return (ARR)
Present Value Ratio (Present Worth Ratio)
Profitability
ECONOMIC ANALYSIS
Inflation
EXAMPLES AND SOLUTIONS
Nomenclature
References
13. Optimization in Chemical/Petroleum Engineering
Optimal Operating Conditions of a Boiler
Optimum Distillation Reflux
Features of Optimization Problems
Objective Functions for Reactors
Linear Programming (LP) For Blending
LP Software
The Excel Solver
Problem Solution
Example 13.1
Solution
Example 13.2
Solution
Example 13.3
Solution
A Case Study: Optimum Reactor Temperature
Solution
Optimization of Product Blending Using Linear Programming
Introduction
Blending Processes
Non-Linear Octane Blending Formula
Gasoline Blending
Gasoline blending Example – 3 Blend stocks, 2 Specifications
Non-Linear Programming
Example 13.4
Solution
Mathematical Formulation
Problem Solution
Example 13.5
Solution
A Case Study
Solution
Notation
References
Further Reference
Index
Epilogue

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