Chemical Process Engineering: Volume 1 & Volume 2

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. 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 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. Cover Half-Title Page Series Page Title Page Copyright Page Companion Web Page Gratitude Dedication Contents 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 SECTION II – PROCESS SIMULATION INTRODUCTION Thermodynamics for Process Simulators UNISIM Design Software EXAMPLES AND SOLUTIONS References 2. Physical Property of Pure Components and Mixtures PURE COMPONENTS Density of Liquid Viscosity of Liquid Heat Capacity of Liquid Thermal Conductivity of Liquid Volumetric Expansion Rate Vapor Pressure Viscosity of Gas Thermal Conductivity of Gas Heat Capacity of Gases MIXTURES Surface Tensions Viscosity of Gas Mixture Enthalpy of Formation Enthalpy of Vaporization Gibbs Energy of Reaction Henry’s Law Constant for Gases in Water Coefficient of Thermal Expansion of Liquid DIFFUSION COEFFICIENTS Gas-Phase Diffusion Coefficients Liquid-Phase Diffusion Coefficients COMPRESSIBILITY Z-FACTOR SOLUBILITY AND ADSORPTION Solubility of Hydrocarbons in Water Solubility of Gases in Water Solubility of Sulfur and Nitrogen Compounds in Water Adsorption on Activated Carbon 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 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 References 5. Instrument Sizing INTRODUCTION Variable-Head Meters Macroscopic Mechanical Energy Balance Variable-Head Meters Orifice Sizing for Liquid and Gas Flows Orifice Sizing for Liquid Flows Orifice Sizing for Gas Flows Orifice Sizing for Gas Flow 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 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 Friction Losses Due to Flow Velocity Head Friction NET POSITIVE SUCTION HEAD (NPSH) AND PUMP SUCTION General Suction System Reductions in NPSHR Corrections to NPSHR for Hot Liquid Hydrocarbons and Water Charting NPSHR Values of Pumps Net Positive Suction Head (NPSH) Specific Speed “Type Specific Speed” Rotative Speed Pumping Systems and Performance 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 AFFINITY LAWS Pump Parameters Specific Speed, Flowrate and Power Required by a Pump Pump Sizing of Gas-Oil Debutanizer Unit CENTRIFUGAL PUMP EFFICIENCY 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 Amonton’s Law at Constant Volume Combined Boyle’s and Charles’ Laws Entropy Balance Method Isentropic Exponent Method 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 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 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 MACH NUMBER Specific Speed COMPRESSOR EQUATIONS IN SI UNITS Polytropic Compressor Adiabatic Compressor Efficiency Mass Flow Rate, w Mechanical Losses Estimating Compressor Horsepower Multistage Compressors Multicomponent Gas Streams 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 References Index Also of Interest Check out these other related titles from Scrivener Publishing Cover Half-Title Page Series Page Title Page Copyright Page Companion Web Page Gratitude Dedication Contents Preface Acknowledgments 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 8.6 The Effectiveness – NTU Method Example 8.4. Heating Water in a Counter-Current Flow Heat Exchanger Solution Example 8.5. LMTD and e-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 (Δpnoz) Total Shell-Side Pressure Drop, Δptotal 8.8 Heat Balance Heat Load or Duty 8.9 Transfer Area 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 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 Heat Transfer Coefficient for Water, hi Shell-Side Equivalent Tube Diameter [39] 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 8.16 Rapid Design Algorithms for Shell and Tube and Compact Heat Exchangers: Polley et al. [88] 8.17 Fluids in the Annulus of Tube-in-Pipe or Double Pipe Heat Exchanger, Forced Convection Finned Tube Exchangers Economics of Finned Tubes Low-Finned Tubes, 16 and 19 Fins/In. Finned Surface Heat Transfer 8.17.1 Pressure Drop Across Finned Tubes [166] 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 Tube-Side Heat Transfer and Pressure Drop 8.17.3 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 Conditions 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 Equations The Air Side Pressure Drop, Δpa (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 The Equations 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 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 (1-2 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 A Case Study: Kettle Reboiler Simulation Using UniSim STE Nozzle Data Process Data Appendix References Appendix A Heat Transfer 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 (Source: Seider 3rd ed. Wiley, 2009 [26]) Solution Example 9.4: Source - Manufacture of cellulose acetate fiber, by Robin Smith (Chemical Process Design and Integration, John Wiley, 2007 [34]) Stream Data Extraction Solution Heat Exchanger Area Targets Example 9.5. (Source: R. Smith, Chemical Process Design, McGraw-Hill, 1995 [20]) Solution Example 9.6 Solution HEN Simplification Heat Load Loops Example 9.7. Test Case 3, TC3 Linnhoff and Hindmarch [30] 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 ΔTmin Optimization Example 9.8. HEN for Maximum Energy Recovery (Warren D. Seider et al. [26]) 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). Solution Case study-2: Crude Preheat Train 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 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 [1] 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) Selected Portions of ASME Pressure Vessel Code, Quoted by Permission [1] 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 (Adapted after Ref. [41]) 10.18 Orifice Area Calculations [42] 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 .-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 [5] Example 10.12 SI Units Example 10.13 Solution Type 3 Integral Method [5] Example 10.14 [66] 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 Example 11.1 Solution Example 11.2 Solution Example 11.3 Solution Example 11.4 Solution Example 11.5 Solution Example 11.6 Solution Example 11.7 Solution Example 11.8 Solution Example 11.9 Solution Example 11.10 Solution Example 11.11 Solution Example 11.12 Solution Example 11.13 Solution Example 11.14 Solution Example 11.15 Solution 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 Example 12.1 Solution Example 12.2 Solution Example 12.3 Solution Example 12.4 Solution Example 12.5 Solution Example 12.6 Solution Example 12.7 Solution Example 12.8 Solution Example 12.9 Solution Example 12.10 Solution Nomenclature Carbon Tax 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 [10] 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 [15] Solution Notation References Further Reference Epilogue PROCESS SIMULATORS MS Excel Mathworks Matlab Process Simulators Chemstations Chemcad Aspen Hysys and Aspen Plus Specialized Software Computational Fluid Dynamics Good Habits for Process Simulation [3] Build a Simulation Model to Meet an Objective Identify the System or Process and Draw and Envelope Around It Imagine What is Going on Physically Translate the Physical Model to a Mathematical Model Know Your Components Know the Context of Your Feed Streams Know Your Components Boiling Points Keep Track of the Units of Measure in All Calculations Always Do a Simple Material and Energy Balance First Plot the Phase Envelope for Important Streams Caution in Using Process Simulators Conclusion References Index Also of Interest Check out these other related titles from Scrivener Publishing Books by the Same Authors Other Related Titles from Scrivener Publishing