Principles of Chemical Engineering Practice

Description

Enables chemical engineering students to bridge theory and practice Integrating scientific principles with practical engineering experience, this text enables readers to master the fundamentals of chemical processing and apply their knowledge of such topics as material and energy balances, transport phenomena, reactor design, and separations across a broad range of chemical industries. The author skillfully guides readers step by step through the execution of both chemical process analysis and equipment design. Principles of Chemical Engineering Practice is divided into two sections: the Macroscopic View and the Microscopic View. The Macroscopic View examines equipment design and behavior from the vantage point of inlet and outlet conditions. The Microscopic View is focused on the equipment interior resulting from conditions prevailing at the equipment boundaries. As readers progress through the text, they'll learn to master such chemical engineering operations and equipment as: Separators to divide a mixture into parts with desirable concentrations Reactors to produce chemicals with needed properties Pressure changers to create favorable equilibrium and rate conditions Temperature changers and heat exchangers to regulate and change the temperature of process streams Throughout the book, the author sets forth examples that refer to a detailed simulation of a process for the manufacture of acrylic acid that provides a unifying thread for equipment sizing in context. The manufacture of hexyl glucoside provides a thread for process design and synthesis. Presenting basic thermodynamics, Principles of Chemical Engineering Practice enables students in chemical engineering and related disciplines to master and apply the fundamentals and to proceed to more advanced studies in chemical engineering. Cover......Page 1 Half-Title Page......Page 3 Principles Of Chemical Engineering Practice......Page 5 ISBN: 0-4705-3674-8......Page 6 Dedication......Page 7 Table of Contents......Page 9 Preface......Page 21 Part I: Macroscopic View......Page 25 1.1 Some Basic Concepts in Chemical Processing......Page 27 1.2 Acrylic Acid Production......Page 29 1.2.1 Catalysis......Page 31 1.2.2 Feed Section—Pumps and Compressors......Page 32 1.2.3 Reactor Section—Reactor, Heat Exchangers, and Gas Absorption......Page 36 1.2.4 Downstream Processing—Distillation and Extraction......Page 40 1.2.5 Storage......Page 43 1.2.7 Overview of Typical Process......Page 44 1.3 Biocatalytic Processes—Enzymatic Systems......Page 45 1.3.1 Biotransformation......Page 46 1.3.3 Alkyl Glucosides......Page 47 1.4 Basic Database......Page 48 Problems......Page 50 2.1 Chemical Processing Systems......Page 52 2.1.1 Input and Output Rates of Flow......Page 53 2.1.1.1 Some Equations of State......Page 55 Example 2.1.1.1-1: Calculate the Molar Volume of Methane at –250° F......Page 56 2.1.1.2 Mass Rate of Production......Page 60 2.2.1 Degrees of Freedom......Page 61 Example 2.2.1-1: Manufacture of Sugar......Page 63 Example 2.2.1-2: Air Separation Plant......Page 64 2.3 Steady-State Mass Balances with Single Chemical Reactions......Page 65 Example 2.3.1-1: Production of Formaldehyde......Page 66 Example 2.3.1-2: Manufacture of Nitroglycerin......Page 68 Example 2.4.1-1: Mass Balance on Acrylic Acid Reactor R-301......Page 70 Example 2.4.2-1: Independent Reactions in the Acrylic Acid System......Page 71 2.4.3 Construction of Independent Reactions......Page 72 Example 2.4.3-1: Independent Reactions in the Acrylic Acid System......Page 73 Problems......Page 74 3.1 Basic Thermodynamic Functions......Page 77 3.2.1 Gases—Departure Functions......Page 79 Example 3.2.1-2: Evaluation of an Enthalpy Change for Ethylene......Page 81 3.2.2 Liquids and Solids......Page 82 3.3.1 Ideal Gas Mixture......Page 83 3.3.4 Nonideal Liquid Solutions: Heat of Solution......Page 84 3.4 Energy Flows and the First Law......Page 86 3.4.1 Degrees of Freedom......Page 87 3.5.2 System Definition for Duty and Flow Rate Calculation......Page 88 Example 3.5.2-1: Calculation of Heat Duty and Stream Flow Rate for Exchanger E-309......Page 89 Example 3.5.3-1: Energy Balance on T-303 Extraction Unit. Feed Reference State......Page 90 Example 3.5.3-2: Calculation of Net Heat Duty for Distillation Tower T-304. Feed Reference State......Page 91 3.5.4.1 Mixing Two Liquid Streams at Different Temperatures and Concentrations......Page 92 Example 3.5.4.1-1: Dilution of an HCl Mixture......Page 93 3.6.1 Single Reaction-Ideal Solution......Page 94 3.6.1.1 Reference States for Reactive Systems—Standard Heat of Reaction......Page 95 Example 3.6.1.2-1 Energy Balances on Methanol Oxidation Reactor......Page 96 Example 3.6.3-1: Heat Duty for Acrylic Acid Reactor R-301......Page 98 Example 3.6.3-2: Feed Temperature Required in Methanol Synthesis......Page 100 3.7 Entropy Balances......Page 101 Example 3.7.2-1: Thermodynamic Models for Membrane Outlet Temperature......Page 102 3.7.3 The Availability and Lost Work......Page 104 3.7.4.1 Heat Exchanger with Saturated Heat Source......Page 105 3.7.4.2 Distillation......Page 106 Problems......Page 107 4.1 Momentum Balance......Page 110 Example 4.1-1: Force on a U-Bend......Page 111 4.2 Mechanical Energy Balance......Page 112 4.3.1.1 Flow in Pipes—The Friction Loss Factor......Page 113 Example 4.3.1.4-1: Power Required for P-301 A/B: Acrylic Acid Plant......Page 115 Example 4.3.1.4-2: NPSH Consideration in Pumping o-Dichlorobenzene from Temporary Storage to Process Storage......Page 117 Problems......Page 118 5.1 Mixing and Residence Time Distributions—Definitions......Page 119 Example 5.1-1: Production of n-Hexyl Glucoside—Residence Time and Reactor Volume......Page 120 5.2 Measurement and Interpretation of Residence Time Distributions......Page 121 5.3.1 Tank Dimensions and Impeller Specifications......Page 123 Example 5.3.1-1 Mixer Dimensions for T-303 Alternative Solution......Page 124 5.3.2.1 Power Requirements......Page 126 5.3.2.3 Liquid–Liquid Systems......Page 127 5.3.2.4 Solid Suspensions......Page 128 Example 5.3.2.4-1 Sizing of Hexyl Glucoside Slurry Adsorber......Page 129 Problems......Page 130 6.1 Phase Equilibrium: Single-Stage Separation Operations......Page 131 6.2.1.1 Gas Absorption and Stripping......Page 133 6.2.1.2 Flash Vaporization......Page 134 6.2.2 Vapor–Liquid Equilibrium......Page 135 6.2.2.1 Equation of State Method......Page 136 6.2.2.2 Activity Coefficient Method......Page 139 Example 6.2.2.3-1: Comparison of Several Methods for Obtaining the K Values for an Equimolar Mixture of Ethane, Propane, and n-Butane at –70° F and 300 psi......Page 149 6.2.3 Gas Absorption and Stripping......Page 150 6.2.3.1 Mass Balance–Constant Total Flows......Page 152 Example 6.2.3.2-1: Acetone Absorption......Page 154 Example 6.2.3.2-2: Determine the Solvent Requirements for Single- Stage Version of Tower 302: Off-Gas Absorber in Acrylic Acid Process......Page 156 6.3.1 Mass Balances......Page 157 6.3.4 Common Problem Specifications......Page 158 6.3.7 Solution for NV=NF = 0, P—Bubble-Point Temperature......Page 159 Example 6.3.7-2: Saturation Temperature for IPA–Water System......Page 160 Example 6.3.8-2: Calculate the Dew Point of an Equimolar Mixture of Propylene and Isobutane at 20 atm Assuming an Ideal Liquid and Application of the Peng–Robinson Equation of State for the Vapor......Page 161 Example 6.3.8-3: Repeat Example 6.3.8-2 but Use the DePriester Charts to Formulate the Equilibrium Relations......Page 163 6.3.9 Solution for T, P Specified: Isothermal Flash......Page 164 Example 6.3.9-2: Flash of the Extract from the Acid Extractor (Tower 303), Stream 13......Page 165 6.3.11 Sizing of Flash Drum......Page 167 Example 6.3.11-1: Size the Flash Drum for Example 6.3.9-1......Page 168 6.4.1 Equilibrium in Ternary Systems......Page 169 6.4.1.2 Data Collection and Representation......Page 170 6.4.2.1 Equipment......Page 171 6.4.2.3 Mass Balances......Page 172 Example 6.4.2.3-1: Extraction of HAc from Chloroform with Water......Page 173 Example 6.4.2.3-2: T-303 Acid Extractor—Solvent Flow for Single Equilibrium Stage......Page 174 6.5 Adsorption......Page 175 6.5.1 Adsorbents......Page 176 6.5.2 Gas Adsorption......Page 178 6.5.2.1 Equilibrium Relations for a Single Adsorbate......Page 180 6.5.3.2 Liquid Adsorption Operations......Page 181 6.6 Single-Phase Stirred Tank Reactors......Page 183 6.6.1.1 Liquid Phase Systems—Temperature Specified......Page 184 6.6.1.2 Gas Phase Systems—Temperature Specified......Page 185 Example 6.6.1.2-1: Multiple Second-Order Reactions and Sizing of R-301......Page 186 6.6.1.3 Selection of Reactor Temperature......Page 187 Example 6.6.1.3-1: Temperature Selection for Acrylic Acid Reactor......Page 188 Example 6.6.1.4-1: A Priori Calculation of Heat Load on Acrylic Acid Reactor R-301......Page 189 6.6.1.5 Autothermal Operation......Page 190 6.6.2.1 Mass Balance......Page 192 6.6.2.3 Some Background for Example 6.6.2.3-1......Page 193 Example 6.6.2.3-1: Production of L-Tyrosine-Feed Stock to L-Dopa Plant......Page 194 6.6.2.4 Gas Phase Reactions and Equation of State at Constant Volume......Page 196 Example 6.6.2.4-1: Reaction Order for Sulfuryl Chloride Oxidation......Page 197 6.7 Chemical Reaction Equilibrium......Page 198 Example 6.7-2: Check on Methanol Conversion to Formaldehyde......Page 200 Example 6.7-3: Phase Equilibrium with Chemical Reaction—Synthesis of Hexyl Glucoside......Page 202 Problems......Page 203 Part II: Microscopic View......Page 205 7.1 Absorption and Stripping......Page 207 7.1.1 Isothermal Binary Gas Absorption......Page 208 7.1.2 Countercurrent Cascade-Tray Tower......Page 209 7.1.3 Graphical Procedures for Single Components......Page 210 Example 7.1.3-1: Butane Recovery—Fixed Number of Stages......Page 214 7.1.4 Isothermal Liquid Stripping......Page 215 Example 7.1.4-1: Stripping of Acetone from Water......Page 217 7.1.5 Dilute Multicomponent Absorption and Stripping......Page 218 Example 7.1.5-1: Methane Purification......Page 219 7.1.6 Column Efficiency......Page 220 Example 7.1.7-1: Tower 303: Off-Gas Absorber in Acrylic Acid Process......Page 221 7.1.8 Heuristics for Absorption......Page 223 7.2.1 Construction of Distillation Operation......Page 224 7.2.2 Equipment for Distillation......Page 225 7.2.3 Application of Material and Energy Balances to Feed Tray......Page 227 7.2.4 Degrees of Freedom......Page 228 7.2.5 Material Balance for Enriching or Rectifying Section......Page 229 7.2.7 Intersection of Operating Lines......Page 230 Example 7.2.7-1: Operating Lines in Acetic Acid–Water Distillation......Page 231 7.2.8 Number of Stages......Page 232 7.2.9 High Purity Products......Page 234 Example 7.2.9-1: Stages Required for Acetic Acid–Water Distillation Using the Recursion Relations......Page 235 7.2.10.3 Reboiler......Page 236 7.2.11 Efficiency and Column Height......Page 237 7.2.12 Summary of Calculations and Setting Process Operating Conditions......Page 238 Example 7.2.12-2: Determine the Minimum Reflux Ratio for the Acetic Acid– Water Distillation......Page 239 7.2.13 Heuristics for Distillation Towers......Page 241 Example 7.2.13-1: Tower 305......Page 242 7.3.1 Multistage Cross-Flow Cascade......Page 245 7.3.2 Multistage Countercurrent Operation......Page 246 Example 7.3.2-1: Extraction of Acetone from MIBK with Water......Page 248 Example 7.3.2-2: T-303 Acid Extractor—Number of Equilibrium Stages and Solvent Flow Required......Page 253 7.3.3 Extraction Equipment......Page 256 Example 7.3.4-1: Height and Number of Trays on Tower 303 with Unagitated Sieve Tray Design......Page 257 7.3.6 Heuristics for Liquid–Liquid Extraction......Page 258 7.4.2 Comparisons with Plug Flow Reactor......Page 259 Example 7.4.3-1: Number of Stages for a Diels–Alder Reaction......Page 260 7.4.4.1 Single Reactions......Page 261 7.5 Staged Fixed-Bed Converters for Exothermic Gas Phase Reaction......Page 262 Example 7.5-1: Staged Fixed-Bed Converter for SO2 Oxidation......Page 264 Problems......Page 265 8: Microscopic Equations of Change......Page 267 8.1 Mass Flux: Average Velocities and Diffusion......Page 268 8.1.1 Mass Flow Rates Used in Material Balances......Page 269 8.1.2 Average Velocities and Diffusion Flows......Page 270 Example 8.1.3-1 Slip Velocity in Liquid–Liquid and Gas–Liquid Systems......Page 272 8.2 Momentum Flux: Stress Tensor......Page 273 8.3 Energy Flux: Conduction......Page 274 8.4.1 Mass Conservation......Page 275 8.4.3 Conservation of Energy......Page 276 8.5 Entropy Balance and Flux Expressions......Page 278 8.5.1.2 Homogeneous Reaction Kinetics......Page 279 8.5.1.3 Heterogeneous Catalytic Kinetics......Page 280 8.5.2 σ1: Vector Processes: Diffusion and Conduction......Page 284 8.5.4.2 Thermal Conductivities......Page 285 8.6 Turbulence......Page 289 8.6.1 Time-Averaged Mass Balance......Page 290 8.6.2.1 Empty Tubes......Page 291 8.6.2.3 Axial Dispersion......Page 292 8.7.1 Boundary Conditions......Page 293 8.7.2 Reduction to Scalar Equations: Laminar Flow in Tubes......Page 294 8.7.3 Introduction to Dimensionless Numbers and Characteristic Times......Page 296 8.7.4 Dual Geometry and Boundary Conditions for Fixed Beds......Page 298 Problems......Page 299 9.1.1 Slit Flow: Extrusion of Plastics Through Narrow Dies......Page 300 9.2.1 Axial Flow—Flow in Pipes and Tubes......Page 304 9.2.1.2 Pump Requirements......Page 305 Example 9.2.1.4-1: Application of Microscopic Mass Balance to Laminar Flow Reactor......Page 306 9.2.1.5 Wetted Wall Towers......Page 307 Example 9.2.1.5-1: Error in Film Thickness Approximation......Page 309 9.2.2.1 Couette Viscometer......Page 310 9.3.1 Creeping Flow Around a Solid Sphere......Page 311 9.4 Microfluidics—Gas Phase Systems......Page 313 9.4.1.1 Momentum and Mass Balances......Page 314 9.4.1.2 Mass Balance: Axial Velocity Distribution......Page 315 9.4.1.3 Pressure Distribution......Page 316 Problems......Page 318 10.1 Membranes......Page 320 10.1.1 Material Balance for Generic Membrane......Page 321 10.1.2 Gas Separations......Page 322 Example 10.1.2-1: Greenhouse Gas Removal from Power Station Flue Gas—Completely Mixed Membrane Model with No Sweep......Page 324 10.1.3 Liquid Separations—Reverse Osmosis......Page 325 Example 10.1.3-1: Regeneration of Pulping Feed Solution in Paper Production......Page 328 10.1.4 Porous Asymmetric and Composite Membranes—Overall Mass Transfer Coefficient......Page 329 10.2.1.1 Pore Diffusion......Page 331 10.2.1.2 Surface Diffusion......Page 332 10.2.3 Parallel Pore Model......Page 333 Example 10.2.3-1: Evaluation of Tortuosity in Parallel Pore Model for Honeycomb-Type Monolith Catalyst......Page 334 10.3.1 Effectiveness of a Single Closed Pore......Page 335 Example 10.3.1-1: Key Component Kinetics for SO2 Oxidation......Page 337 10.3.2 Effectiveness of Catalyst Particle......Page 338 10.4 Transient Adsorption by Porous Solid......Page 340 Example 10.4-1: The Recovery of Hexyl Glucoside......Page 341 10.5.1.1 Physical Absorption......Page 342 10.5.1.2 Chemical Absorption......Page 343 10.5.2 Laminar Flow in a Tube with Catalytic Walls......Page 344 Problems......Page 346 11: Energy Transfer Under Nonturbulent Conditions......Page 348 11.1 Conduction in Solids–Composite Walls......Page 349 Example 11.1-1: Insulated Firebox for Steam Reforming......Page 350 11.2.1 Temperature Rise due to Single Chemical Reaction......Page 351 11.2.2 Effectiveness Factor for Single Irreversible Reaction with Heat Effect......Page 352 11.3 Heat Transfer to Falling Film—Short Contact Times......Page 354 11.4 Moving Boundary Problem......Page 356 Example 11.4-1: Onset of Freezing in a Pipe......Page 357 Problems......Page 358 12.1.1 Film-Penetration Theory......Page 359 12.1.2 Penetration Theories......Page 361 12.2 Interphase Mass Transfer Coefficients—Controlling Resistances......Page 362 12.3.1 Measurement of Mass Transfer Coefficients......Page 363 12.3.2 Correlation of Mass Transfer Coefficients......Page 364 Example 12.3.2-1: Determination of Liquid Mass Transfer Coefficients in a Fixed Bed......Page 365 12.4.1.1 Ideal Case......Page 366 12.4.1.3 Gas Phase......Page 367 12.4.1.5 LDF (Linear Driving Force) Model......Page 368 12.5.1 Turbulent Flow in a Pipe with Catalytic Walls......Page 369 12.6 Particles, Drops, and Bubbles in Agitated Systems......Page 370 12.6.1 Slurry Adsorption—External Mass Transfer Control......Page 371 Example 12.6.1-1 Adsorption Time and Batch Integration in Continuous Processes......Page 372 12.7.1.1 Heuristics for Packed Towers......Page 373 12.7.2 Mass Transfer Correlations......Page 374 12.7.3 Mass Balances......Page 375 12.7.3.2 For the Gas......Page 376 12.7.3.3 Unreactive Case with Henry’s Law......Page 377 Example 12.7.3.3-1: Sulfur Dioxide Absorber......Page 379 12.8.1 Free Fluxes......Page 381 12.8.2.1 Diffusion Through a Stagnant Film: Absorption with Constant Flows......Page 382 Example 12.8.2.1-1: Height of Packed Bed in SO2 Absorption Using Method Suitable for Nonlinear Equilibrium Data......Page 383 12.8.2.3 Heterogeneous Chemical Reaction......Page 384 12.8.2.4 Kinetics Experiments......Page 385 12.8.3 Homogeneous Chemical Reaction......Page 386 12.8.3.1 Irreversible First-Order Kinetics......Page 387 12.8.3.3 Instantaneous Reactions......Page 388 Problems......Page 389 13: Interphase Momentum Transfer Under Turbulent Conditions......Page 391 13.1 Pressure Drop in Conduits and Fixed Beds......Page 392 13.1.1 Turbulent Flow of Gases in Pipelines......Page 393 Example 13.1.1.1-1: Pressure Drop and Pipe Size for Gas Supply Line......Page 394 13.1.1.2 Compressors......Page 396 13.1.2 Pressure Drop in Fixed Beds......Page 399 13.2 Flow Over Submerged Spheres......Page 400 13.2.2 Terminal Velocities in Newtonian Fluids: Solid Suspensions......Page 401 Example 13.2.2-1: Slurry Adsorption of Hexyl Glucoside......Page 402 13.2.3 Fluidization Velocities: Diameter of Fluidized Beds......Page 403 Example 13.2.3-1: Diameter of R-301 Reactor......Page 404 13.2.4 Flooding Velocity in Packed Towers: Tower Diameter and Pressure Drop......Page 405 Example 13.2.4-1: Sulfur Dioxide Absorber......Page 406 Problems......Page 407 14.1 Heat Transfer Coefficients—Analogy with Mass Transfer......Page 408 14.2 Heat Exchangers......Page 409 14.2.1 Double Pipe Exchangers......Page 411 Example 14.2.1-1 Cooling of HCl Product from Adiabatic Mixing......Page 413 14.2.2.1 Constant Wall Temperature......Page 414 Example 14.2.2.1-1: Exchanger 309—Solvent Endings......Page 416 14.3.1 Fixed-Bed Constant Wall Temperature One-Dimensional Model......Page 419 14.3.1.1 Bulk Phase Mass Balance (Molar Units)......Page 420 14.3.1.4 Bulk Phase Energy Balance......Page 421 14.3.2 Some Operational Considerations......Page 422 Problems......Page 423 15.1 Macroscopic Mass Balance......Page 424 15.2 Macroscopic Energy Balance......Page 425 15.3 Macroscopic Mechanical Energy Balance......Page 426 15.3.2 Steady-State Systems......Page 427 Problems......Page 428 Appendix A: Periodic Table......Page 429 Appendix B: Conversion Factors......Page 430 Appendix C: Partial Database for Acrylic Acid Process......Page 433 Appendix D: Some Mathematical Results......Page 438 Appendix E: Mass Balance in Cylindrical Coordinates and Laminar Flow in Z Direction......Page 442 Nomenclature......Page 443 References......Page 447 Index......Page 451 TrUe LiAr......Page 453