Chemical Process Engineering Volume 1

Chemical Process Engineering Volume 1
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CHEMICAL PROCESS ENGINEERING [b]Written by two of the most prolific and respected chemical engineers in the world, this groundbreaking 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. This first new volume in a 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, professors, scientists 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 text 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 Excel spreadsheets and UniSim simulation software. Written by two industry and university’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.

Оглавление

A. Kayode Coker. Chemical Process Engineering Volume 1

Table of Contents

List of Tables

List of Illustrations

Guide

Pages

Chemical Process Engineering. Design, Analysis, Simulation and Integration, and Problem Solving With Microsoft Excel – UniSim Design Software

Companion Web Page

Gratitude

Dedication

Preface

Acknowledgments

About the Authors

1. Computations with Excel Spreadsheet-UniSim Design Simulation

SECTION I - NUMERICAL ANALYSIS. INTRODUCTION. Excel Spreadsheet

Functions

Trendline Coefficients

Goal Seek

SOLVER

LINEAR REGRESSION

Measuring Regression Quality

MULTIPLE REGRESSION

POLYNOMIAL REGRESSION

SIMULTANEOUS LINEAR EQUATIONS

NONLINEAR EQUATIONS

INTERPOLATIONS

INTEGRATIONS

The Trapezoidal Rule

Simpson’s 1/3 Rule

Simpson’s 3/8 Rule

DIFFERENTIAL EQUATIONS

Nth Order Ordinary Differential Equations

Solution of First-Order Ordinary Differential Equations

Runge-Kutta Methods

EXAMPLES AND SOLUTIONS. Example 1.1

Solution

Example 1.2

Solution

Example 1.3

Solution

Example 1.4

Solution

Example 1.5

Solution

Example 1.6

Solution

Example 1.7

Solution

Example 1.8

Solution

SECTION II – PROCESS SIMULATION. INTRODUCTION

Thermodynamics for Process Simulators

UNISIM Design Software

EXAMPLES AND SOLUTIONS. Example 1.9

Solution

Example 1.10

Solution

Example 1.11

Solution

Example 1.12

Solution

Example 1.13

Solution

Example 1.14

Solution

References

2. Physical Property of Pure Components and Mixtures

PURE COMPONENTS

Density of Liquid

Example 2.1

Solution

Viscosity of Liquid

Example 2.2

Solution

Heat Capacity of Liquid

Example 2.3

Solution

Thermal Conductivity of Liquid

Example 2.4

Solution

Volumetric Expansion Rate

Example 2.5

Solution

Vapor Pressure

Example 2.6

Solution

Viscosity of Gas

Example 2.7

Solution

Thermal Conductivity of Gas

Example 2.8

Solution

Heat Capacity of Gases

Example 2.9

Solution

MIXTURES

Surface Tensions

Example 2.10

Solution

Viscosity of Gas Mixture

Example 2.11

Solution

Enthalpy of Formation

Example 2.12

Solution

Enthalpy of Vaporization

Example 2.13

Solution

Gibbs Energy of Reaction

Example 2.14

Solution

Henry’s Law Constant for Gases in Water

Example 2.15

Solution

Coefficient of Thermal Expansion of Liquid

Example 2.16

Solution

DIFFUSION COEFFICIENTS

Gas-Phase Diffusion Coefficients

Example 2.17

Solution

Liquid-Phase Diffusion Coefficients

Example 2.18

Solution

COMPRESSIBILITY Z-FACTOR

Example 2.19

Solution

SOLUBILITY AND ADSORPTION

Solubility of Hydrocarbons in Water

Example 2.20

Solution

Solubility of Gases in Water

Example 2.21

Solution

Solubility of Sulfur and Nitrogen Compounds in Water

Example 2.22

Solution

Adsorption on Activated Carbon

Example 2.23

Solution

References

3. Fluid Flow. INTRODUCTION

FLOW OF FLUIDS IN PIPES

EQUIVALENT LENGTH OF VARIOUS FITTINGS AND VALVES

Excess Head Loss

Pipe Reduction and Enlargement

PRESSURE DROP CALCULATIONS FOR SINGLE-PHASE INCOMPRESSIBLE FLUIDS

Friction Factor

Overall Pressure Drop

Nomenclature

COMPRESSIBLE FLUID FLOW IN PIPES

Maximum Flow and Pressure Drop

Critical or Sonic Flow and the Mach Number

Mach Number

Mathematical Model of Compressible Isothermal Flow

Flow Rate Through Pipeline

Pipeline Pressure Drop

Nomenclature

Subscripts

TWO-PHASE FLOW IN PROCESS PIPING

Flow Patterns

Flow Regimes

Pressure Drop

Erosion-Corrosion

Nomenclature

VAPOR-LIQUID TWO-PHASE VERTICAL DOWNFLOW

The Equations

The Algorithm

Nomenclature

LINE SIZES FOR FLASHING STEAM CONDENSATE

The Equations

Nomenclature

FLOW THROUGH PACKED BEDS

The Equations

Nomenclature

EXAMPLES AND SOLUTIONS. Example 3.1

Solution

Example 3.2

Solution

Example 3.3

Solution

Solution - UniSim Design Software Simulator

Basis Environment:

Simulation Environment

Example 3.4

Solution

Example 3.5

Solution

Example 3.6

Solution

Example 3.7

Solution

Example 3.8

Solution

Example 3.9

Solution-Excel

Solution-UniSim Design Software

Basis Environment:

Simulation Environment

References

4. Equipment Sizing. INTRODUCTION

SIZING OF VERTICAL AND HORIZONTAL SEPARATORS. Vertical Separators

Calculation Method for a Vertical Drum

Calculation Method for a Horizontal Drum

Liquid Holdup and Vapor Space Disengagement

Wire Mesh Pad

Standards for Horizontal Separators

Piping Requirements

Nomenclature

SIZING OF PARTLY FILLED VESSELS AND TANKS

The Equations

Nomenclature

PRELIMINARY VESSEL DESIGN

Nomenclature

CYCLONE DESIGN. Introduction

Cyclone Design Procedure

The Equations

Saltation Velocity

Pressure Drop

Troubleshooting Cyclone Maloperations

Cyclone Collection Efficiency

Cyclone Design Factor

Cyclone Design Procedure

Nomenclature

GAS DRYER DESIGN

The Equations

Pressure Drop

Desiccant Reactivation

Nomenclature

EXAMPLES AND SOLUTIONS. Example 4.1

Solution

Example 4.2

Solution

Example 4.3

Solution

Example 4.4

Solution

Example 4.5

Solution

References

5. Instrument Sizing. INTRODUCTION

Variable-Head Meters

Macroscopic Mechanical Energy Balance

Variable-Head Meters

Example 5.1 Orifice Meter Sizing

Solution

Orifice Sizing for Liquid and Gas Flows

Orifice Sizing for Liquid Flows

Orifice Sizing for Gas Flows

Example 5.2. Orifice Sizing for Liquid Flow

Orifice Sizing for Gas Flow

Solution

Types of Restriction Orifice Plates

Case Study 1

Nomenclature

CONTROL VALVE SIZING. Introduction

Control Valve Characteristics

Pressure Drop for Sizing

Choked Flow

Flashing and Cavitation

Control Valve Sizing for Liquid, Gas, Steam and Two-Phase Flows

Liquid Sizing

Gas Sizing

Critical Condition

Steam Sizing

Two-Phase Flow

Installation

Noise

Control Valve Sizing Criteria

Valve Sizing Criteria

Self-Acting Regulators

Types of Self-Acting Regulators

Example 5.3

Solution

Case Study 2

Rules of Thumb

Nomenclature

References

6. Pumps and Compressors Sizing. PUMPS. INTRODUCTION. Pumping of Liquids

Pump Design Standardization

Basic Parts of a Centrifugal Pump

Impellers

Casing

Shaft

CENTRIFUGAL PUMP SELECTION

Single-Stage (Single Impeller) Pumps

Hydraulic Characteristics for Centrifugal Pumps

Example 6.1: Liquid Heads

Friction Losses Due to Flow

Velocity Head

Friction

NET POSITIVE SUCTION HEAD (NPSH) AND PUMP SUCTION

General Suction System

Reductions in NPSHR

Example 6.2. Corrections to NPSHR for Hot Liquid Hydrocarbons and Water

Charting NPSHR Values of Pumps

Net Positive Suction Head (NPSH)

Specific Speed

Example 6.3 “Type Specific Speed”

Rotative Speed

Pumping Systems and Performance

Example 6.4. System Head Using Two Different Pipe Sizes in Same Line

POWER REQUIREMENTS FOR PUMPING THROUGH PROCESS LINES

Hydraulic Power

Relations Between Head, Horsepower, Capacity, Speed. Brake Horsepower (BHP) Input at Pump

Example 6.5

Solution

AFFINITY LAWS

Example 6.6. Pump Parameters

Solution

Example 6.7. Specific Speed, Flowrate and Power Required by a Pump

Solution

Example 6.8. Pump Sizing of Gas-Oil

Solution

Example 6.9. Debutanizer Unit

Solution

CENTRIFUGAL PUMP EFFICIENCY

Example 6.10

Solution

Centrifugal Pump Specifications

Pump Specifications (Figures 6.43a and b)

Steps in Pump Sizing

Reciprocating Pumps

Significant Features in Reciprocating Pump Arrangements

Application

Performance

Discharge Flow Patterns

HORSEPOWER

Pump Selection

Selection Rules-of-Thumb

A CASE STUDY. Pump Simulation on a PFD

Variables Descriptions

SIMULATION ALGORITHM

Problem

Discussion

Pump Cavitation

Factors in Pump Selection

COMPRESSORS. INTRODUCTION

General Application Guide

Specification Guides

GENERAL CONSIDERATIONS FOR ANY TYPE OF COMPRESSOR FLOW CONDITIONS

Fluid Properties

Compressibility

Corrosive Nature

Moisture

Special Conditions

Specification Sheet

PERFORMANCE CONSIDERATIONS. Cooling Water to Cylinder Jackets

Heat Rejected to Water

Drivers

Ideal Pressure – Volume Relationship

Actual Compressor Diagram

DEVIATIONS FROM IDEAL GAS LAWS: COMPRESSIBILITY

Adiabatic Calculations

Charles’ Law at Constant Pressure [9]

Amonton’s Law at Constant Volume [9]

Combined Boyle’s and Charles’ Laws

Entropy Balance Method [7]

Isentropic Exponent Method [7]

COMPRESSION RATIO

Horsepower

Single Stage. Theoretical Hp

Actual Brake Horsepower, Bhp

Actual Brake Horsepower, Bhp (Alternate Correction for Compressibility)

Temperature Rise – Adiabatic

Temperature Rise – Polytropic

A CASE STUDY USING UNISIM DESIGN R460.1 SOFTWARE FOR A TWO–STAGE COMPRESSION. CASE STUDY 2

Solution

1. Starting UniSim Design Software

2. Creating a New Simulation

Saving the Simulation

3. Adding Components to the Simulation

4. Selecting a Fluids Package

5. Select the Units for the Simulation

6. Enter Simulation Environment

Accidentally Closing the PFD

Object Palette

7. Adding Material Streams

8. Specifying Material Streams

9. Adding A Compressor

Specifications

COMPRESSION PROCESS

Adiabatic

Isothermal

Polytropic

Efficiency

Head

ADIABATIC HEAD DEVELOPED PER SINGLE-STAGE WHEEL

Polytropic Head

Polytropic

Brake Horsepower

Speed of Rotation

TEMPERATURE RISE DURING COMPRESSION

Sonic or Acoustic Velocity

Example 6.12

Solution

MACH NUMBER [35]

Specific Speed

COMPRESSOR EQUATIONS IN SI UNITS

Polytropic Compressor

Adiabatic Compressor

Efficiency

Mass Flow Rate, w

Mechanical Losses

Estimating Compressor Horsepower

Multistage Compressors

Example 6.13

Solution

Multicomponent Gas Streams

Example 6.14

Solution

AFFINITY LAWS

Speed

Impeller Diameters (Similar)

Impeller Diameter (Changed)

Effect of Temperature

AFFINITY LAW PERFORMANCE

TROUBLESHOOTING OF CENTRIFUGAL AND RECIPROCATING COMPRESSORS

NOMENCLATURE

Greek Symbols

Subscripts

Nomenclature

Subscripts

Greek Symbols

References. Pumps

Bibliography

References. Compressors

Bibliography

7. Mass Transfer. INTRODUCTION

VAPOR LIQUID EQUILIBRIUM

BUBBLE POINT CALCULATION

DEW POINT CALCULATION

EQUILIBRIUM FLASH COMPOSITION

Fundamental

The Equations

The Algorithm

Nomenclature

TOWER SIZING FOR VALVE TRAYS. Introduction

The Equations

Nomenclature

Greek Letters

PACKED TOWER DESIGN. Introduction

Pressure Drop

Flooding

Operating and Design Conditions

Design Equations

Packed Towers versus Trayed Towers

Economic Trade-Offs

Nomenclature

Greek Letters

DETERMINATION OF PLATES IN FRACTIONATING COLUMNS BY THE SMOKER EQUATIONS. Introduction

The Equations

Application to a Distillation Column

Rectifying Section:

Stripping Section:

Nomenclature

MULTICOMPONENT DISTRIBUTION AND MINIMUM TRAYS IN DISTILLATION COLUMNS. Introduction

Key Components

Equations Surveyed

Fractionating Tray Stability Diagrams

Areas of Unacceptable Operation

Foaming

Flooding

Entrainment

Weeping/Dumping

Fractionation Problem Solving Considerations

Mathematical Modeling

The Fenske’s Method for Total Reflux

The Gilliland Method for Number of Equilibrium Stages

The Underwood Method

Equations for Describing Gilliland’s Graph

Kirkbride’s Feed Plate Location

Nomenclature

Greek Letters

EXAMPLES AND SOLUTIONS. Example 7.1

Solution

Example 7.2

Solution

Example 7.3

Solution

Example 7.4

Solution

Example 7.5

Solution

Tray Geometry

Example 7.6

Solution

Example 7.7

Solution

Example 7.8

Solution

References

Index

Also of Interest

WILEY END USER LICENSE AGREEMENT

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Phillip Carmical (pcarmical@scrivenerpublishing.com)

A. Kayode Coker

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