Process Intensification: Faster, Better, Cheaper

Description

Process Intensification: Faster, Better, Cheaper presents basic concepts and applications of process intensification (PI) and links their common effects across processes. It defines two fundamental parameters, PI factor, and Cost Impact (CI) factor, and uses these to analyze various applications where Process Intensification has been carried out. Process Intensification principles have, in the past, been applied to diverse fields, ranging from biodiesel production to offshore processing, and this book unifies these aspects to identify the common factors that drive process enhancements. Each chapter investigates a specific application, discusses the key PI principles, and includes problem sets and examples. The book also provides case studies and realworld examples throughout the chapters. Features • Explores Cost Impact of Process Intensification, and their relative magnitudes, as a universal metric. • Covers a range of industrial applications, including heat and mass transfer, atomization and comminution, and enhanced oil recovery. • Discusses the application of Process Intensification for clean coal technology and environmental remediation. • Includes end-of-chapter problems, examples, and case studies. The book is intended for senior undergraduate chemical and mechanical engineering students taking courses in Process Design, Process Optimization, Process Synthesis, and Process Intensification. Instructors will be able to utilize a Solutions Manual and Lecture Slides for their course. The eBook+ version includes the following enhancements Open-ended essay questions to encourage conceptual thinking and apply new information. Pop-up explanations of selected concepts and terms throughout the chapters Interactive definition flashcards that summarize key takeaways at the end of the chapter. Quizzes within chapters to help readers refresh their knowledge. Cover Half Title Title Page Copyright Page Dedication Contents Preface Chapter 1: What is Process Intensification? 1.1. Process 1.2. Intensification 1.3. Process Intensification Exercise Questions References Chapter 2: PIF/CIF Case Studies 2.1. The Cookie Factory 2.2. Tolerancing of Critical Dimensions in a Hard Disk Drive 2.3. Microcontamination Control 2.4. Call Centers: The Business Case for Offshoring 2.5. Clean Coal Technology Exercise Questions References Chapter 3: Common Process Intensification Parameters 3.1. Temperature 3.2. Pressure 3.3. Time Exercise Questions References Chapter 4: Process Intensification Driven by External Fields Exercise References Chapter 5: Acoustic Intensification of Processes—Mechanisms Involved 5.1. Surface Cleaning 5.2. Heat Transfer Enhancement in Furnace Tubes 5.3. Degradation of Methyl Violet 5.4. Sono-Fragmentation of Coal 5.5. Destratification 5.6. Effervescent Atomization 5.7. Coal Beneficiation Exercise Questions References Chapter 6: Process Intensification Fields: Case Studies 6.1. Microwave 6.1.1. Heating and Drying 6.1.2. Applications in Food Industry 6.1.3. Waste Treatment under Microwave Irradiation 6.1.4. Pyrolysis of Biomass Waste 6.2. Laser 6.2.1. Surface Hardening 6.2.2. Surface Cleaning 6.2.3. Ablation 6.3. Thermophoresis 6.3.1. Bulb Blackening 6.3.2. Hot Corrosion 6.3.3. Particle Thermophoresis 6.4. Electrophoresis 6.4.1. Biomolecular Separations 6.4.2. Transport in Microchannels 6.4.3. Electrostatic Precipitator 6.5. Magnetophoresis 6.5.1. Separation 6.5.2. Mixing 6.5.3. Trapping 6.6. Acoustophoresis 6.6.1. Continuous Flow Concentration of Cells and Particles 6.6.2. Filtration/Removal of Suspended Particles 6.6.3. Particle Separation, Mixing, and Focusing Exercise Questions References Chapter 7: Acoustic Fields Coupled to Liquids: Basics and Some Applications 7.1. Destratification/Mixing 7.2. Effervescent Atomization 7.3. Nanoparticle Synthesis 7.3.1. Bottom-Up Methods 7.3.2. Top-Down Methods Exercise Questions References Chapter 8: Intensification of Transport Phenomena and Chemical Reactions 8.1. Heat Transfer 8.1.1. Surface Roughness 8.1.2. Flow Disruptions 8.1.3. Channel Curvature 8.1.4. Re-Entrant Obstructions 8.1.5. Secondary Flows 8.1.6, Out-of-Plane Mixing 8.1.7. Fluid Additives 8.1.8. Vibration 8.1.9. Electrostatic Fields 8.1.10. Flow Pulsation 8.1.11. Variable Roughness Structures 8.1.12. Acoustic Enhancement 8.2. Mass Transfer (Without Chemical Reaction) 8.3. Chemical Reactions 8.4. Mass Transfer (With Chemical Reaction) Exercise Questions References Chapter 9: Intensification of Heat Transfer: Case Studies 9.1. Heat Transfer in Furnace Tubes 9.2. Heat Transfer in Tank with Side Heaters 9.2.1. Quiescent Conditions 9.2.2. Flow Conditions 9.3. Nanofluids Exercise References Chapter 10: Mass Transfer Rate Enhancement: Case Study 10.1. Acoustic Intensification of Dye Uptake by Leather 10.2. Acoustic Intensification of Gas-Liquid Mass Transfer Exercise References Chapter 11: Pollution Abatement and Microcontamination Control: Case Study 11.1. Methyl Violet Degradation 11.2. Component Surface Cleaning in Microelectronics Manufacturing 11.2.1. Spray Cleaning 11.2.2. Spin-Rinse-Dryer Cleaning 11.2.3. Vapor Degreasing 11.2.4. Chemical Cleaning 11.2.5. Solvent Cleaning 11.2.6. Mechanical Agitation Cleaning (Undulation and Sparging) 11.2.7. Manual Cleaning (Swabbing and Wiping) 11.2.8. Specialty Cleaning (Plasma, UV, and UV/Ozone, CO2 Snow Supercritical Fluid, etc.) 11.2.9. Supercritical Fluid Cleaning 11.2.10. CO2 Snow Cleaning 11.2.11. Ultrasonic Cleaning 11.2.12. Component Cleaning in the HDD Industry Exercise Questions References Chapter 12: Formulation of Nanoemulsion: Case Study 12.1. Formulation Process 12.2. Ultrasound Application 12.3. Experimental Setup and Procedure 12.4. Results and Discussion 12.4.1. Emulsion Droplet Size Distribution 12.4.2. Stability Analysis References Chapter 13: Enhanced Oil Recovery: Case Study 13.1. Experimental Setup and Methodology 13.2. Results and Discussion Exercise References Chapter 14: In Conclusion References Index