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, and Chemical Kinetics
, by Coker, A. Kayode; Sotudeh-Gharebagh, Rahmat
- ISBN: 9781119853992 | 1119853990
- Cover: Hardcover
- Copyright: 7/20/2022
CHEMICAL PROCESS ENGINEERING
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.
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.
Preface xxi
Acknowledgments xxiii
About the Authors xxv
8 Heat Transfer 505
INTRODUCTION 505
8.1 TYPES OF HEAT TRANSFER EQUIPMENT TERMINOLOGY 506
8.2 DETAILS OF EXCHANGE EQUIPMENT 507
Assembly and Arrangement 507
CONSTRUCTION CODES 508
THERMAL RATING STANDARDS 513
DETAILS OF STATIONARY HEADS 513
EXCHANGER SHELL TYPES 524
8.3 FACTORS AFFECTION SHELL SELECTION 528
8.4 COMMON COMBINATIONS OF SHELL AND TUBE HEAT EXCHANGERS 528
AES 528
BEM 530
AEP 540
CFU 541
AKT 543
AJW 546
8.5 THERMAL DESIGN 547
8.5.1 Temperature Difference: Two Fluid Transfer 581
8.5.2 Mean Temperature Difference or Log Mean Temperature Difference 583
8.5.3 Log Mean Temperature Difference Correction Factor, F 593
8.5.4 Correction for Multipass Flow through Heat Exchangers 596
Example 8.1. Calculation of LMTD and Correction 603
Example 8.2. Calculate the LMTD 608
Solution 608
Example 8.3. Heating of Glycerin in a Multipass Heat Exchanger 610
Solution 610
8.6 THE EFFECTIVENESS – NTU METHOD 612
Example 8.4. Heating Water in a Counter-Current Flow Heat Exchanger 616
Solution 616
Example 8.5. LMTD and ε-NTU Methods 618
Solution 618
Example 8.6 620
Solution 620
8.7 PRESSURE DROP, Δp 621
8.7.1 Frictional Pressure Drop 626
8.7.2 Factors Affecting Pressure Drop (Δp) 630
TUBE-SIDE PRESSURE DROP, Δpf 631
SHELL-SIDE PRESSURE DROP Δpf 632
SHELL NOZZLE PRESSURE DROP (Δpnoz) 633
TOTAL SHELL-SIDE PRESSURE DROP, Δptotal 634
8.8 HEAT BALANCE 635
HEAT LOAD OR DUTY 636
8.9 TRANSFER AREA 636
OVER SURFACE AND OVER DESIGN 636
8.10 FOULING OF TUBE SURFACE 636
8.10.1 Prevention and Control of Gas-Side Fouling 643
8.11 EXCHANGER DESIGN 643
Overall Heat Transfer Coefficients for Plain or Bare Tubes 643
Example 8.7. Calculation of Overall Heat Transfer Coefficient from Individual Components 646
8.12 APPROXIMATE VALUES FOR OVERALL HEAT TRANSFER COEFFICIENTS 647
SIMPLIFIED EQUATIONS 662
8.12.1 Film Coefficients with Fluids Outside Tubes Forced Convection 668
VISCOSITY CORRECTION FACTOR (μ/μW)0.14 670
HEAT TRANSFER COEFFICIENT FOR WATER, hi 670
SHELL-SIDE EQUIVALENT TUBE DIAMETER 672
SHELL-SIDE VELOCITIES 680
8.13 DESIGN AND RATING OF HEAT EXCHANGERS 681
RATING OF A SHELL AND TUBE HEAT EXCHANGER 681
8.13.1 Design of a Heat Exchanger 685
8.13.2 Design Procedure for Forced Convection Heat Transfer in Exchanger Design 686
8.13.3 Design Programs for a Shell and Tube Heat Exchanger 689
Example 8.8. Convention Heat Transfer Exchanger Design 691
8.14 SHELL AND TUBE HEAT EXCHANGER DESIGN PROCEDURE (SI UNITS) 702
TUBES 703
TUBE-SIDE PASS PARTITION PLATE 704
8.14.1 Calculations of Tube-Side Heat Transfer Coefficient 704
Example 8.9. Design of a Shell and Tube Heat Exchanger (SI Units) Kern’s Method 707
Solution 707
8.14.2 Pressure Drop for Plain Tube Exchangers 716
TOTAL TUBE-SIDE PRESSURE DROP 718
TUBE-SIDE CONDENSATION PRESSURE DROP 718
SHELL SIDE 718
A CASE STUDY USING UNISIM SHELL-TUBE EXCHANGER (STE) MODELER 718
Solution 719
8.15 BELL-DELAWARE METHOD 734
OVERALL HEAT TRANSFER COEFFICIENT, U 736
SHELL-SIDE PRESSURE (Δp) 736
TUBE PATTERN 739
Accuracy of Correlations Between Kern’s Method and the Bell-Delaware Method 740
Specification Process Data Sheet, Design and Construction of Heat Exchangers 741
8.16 RAPID DESIGN ALGORITHMS FOR SHELL AND TUBE AND COMPACT HEAT EXCHANGERS: POLLEY et al. 742
8.17 FLUIDS IN THE ANNULUS OF TUBE-IN-PIPE OR DOUBLE PIPE HEAT EXCHANGER, FORCED CONVECTION 744
FINNED TUBE EXCHANGERS 745
ECONOMICS OF FINNED TUBES 745
LOW-FINNED TUBES, 16 AND 19 FINS/IN. 750
FINNED SURFACE HEAT TRANSFER 751
8.17.1 Pressure Drop Across Finned Tubes 751
DESIGN FOR HEAT TRANSFER COEFFICIENTS BY FORCED CONVECTION USING RADIAL LOW-FIN TUBES IN HEAT EXCHANGER BUNDLES 751
8.17.2 Pressure Drop in Exchanger Shells Using Bundles of Low-Fin Tubes 753
TUBE-SIDE HEAT TRANSFER AND PRESSURE DROP 755
8.17.3 Double Pipe Finned Tube Heat Exchangers 755
FINNED SIDE HEAT TRANSFER 757
TUBE WALL RESISTANCE 763
TUBE-SIDE HEAT TRANSFER AND PRESSURE DROP 763
FOULING FACTOR 763
FINNED SIDE PRESSURE DROP 764
8.17.4 Design Equations for the Rating of a Double Pipe Heat Exchanger 765
Process Conditions Required 765
Inner Pipe 766
Annulus 767
Vapor Service 768
SHELL-SIDE BARE TUBE 768
SHELL SIDE (FINNED TUBE) 769
Annulus 771
8.17.5 CALCULATION OF THE PRESSURE DROP 771
EFFECT OF PRESSURE DROP (Δp) ON THE ORIGINAL DESIGN 772
NOMENCLATURE 773
Example 8.9 774
Solution 775
HEAT BALANCE 775
PRESSURE DROP CALCULATIONS 781
Tube Side 781
Tube-Side Δp 781
Shell-Side Δp 782
8.18 PLATE AND FRAME HEAT EXCHANGERS 784
Selection 788
8.19 AIR-COOLED HEAT EXCHANGERS 788
8.19.1 Induced Draft 790
8.19.2 Forced Draft 791
GENERAL APPLICATION 796
Advantages – Air-Cooled Heat Exchangers 798
Disadvantages 799
Mean Temperature Difference 801
8.19.3 Design Procedure for Approximation 801
8.19.4 Tube-Side Fluid Temperature Control 809
8.19.5 Rating Method for Air-Cooler Exchangers 811
THE AIR SIDE PRESSURE DROP, Δpa (INCH H2O) 816
Example 8.10 817
Solution 817
8.19.6 Operations of Air-Cooled Heat Exchangers 818
8.19.7 Monitoring of Air-Cooled Heat Exchangers 819
8.20 SPIRAL HEAT EXCHANGERS 819
8.21 SPIRAL COILS IN VESSELS 821
8.22 HEAT-LOSS TRACING FOR PROCESS PIPING 821
Example 8.11 826
Solution 826
IN SI UNITS 827
8.23 BOILING AND VAPORIZATION 833
8.23.1 Boiling 833
8.23.2 Vaporization 837
8.23.3 Vaporization During Flow 837
8.24 HEATING MEDIA 837
Heat Fux Limit 840
8.25 BATCH HEATING AND COOLING OF FLUIDS 840
BATCH HEATING: INTERNAL COIL: ISOTHERMAL HEATING MEDIUM 840
Example 8.12. Batch Heating: Internal Coil Isothermal Heating Medium 842
Solution 842
BATCH REACTOR HEATING AND COOLING TEMPERATURE PREDICTION 842
Example 8.13: Batch Reactor Heating and Cooling Temperature Prediction 843
Solution 843
BATCH COOLING: INTERNAL COIL ISOTHERMAL COOLING MEDIUM 844
Example 8.14 Batch Cooling: Internal Coil, Isothermal Cooling Medium 845
Solution 845
BATCH HEATING: NON-ISOTHERMAL HEATING MEDIUM 846
Example 8.15: Batch Heating with Non-Isothermal Heating Medium 847
Solution 848
BATCH COOLING: NON-ISOTHERMAL COOLING MEDIUM 849
Example 8.16: Batch Cooling Non-Isothermal Cooling Medium 849
Solution 849
BATCH HEATING: EXTERNAL HEAT EXCHANGER, ISOTHERMAL HEATING MEDIUM 850
Example 8.17: Batch Heating: External Heat Exchanger Isothermal Heating Medium 853
Solution 853
BATCH COOLING: EXTERNAL HEAT EXCHANGER, ISOTHERMAL COOLING MEDIUM 854
Example 8.18: Batch Cooling: External Heat Exchanger, Isothermal Cooling Medium 854
Solution 855
BATCH COOLING: EXTERNAL HEAT EXCHANGER (COUNTER-CURRENT FLOW), NON-ISOTHERMAL COOLING MEDIUM 856
Example 8.19: Batch Cooling: External Heat Exchanger (Counter-Current Flow), Non-Isothermal Cooling Medium 856
Solution 856
BATCH HEATING: EXTERNAL HEAT EXCHANGER AND NON-ISOTHERMAL HEATING MEDIUM 857
Example 8.20: Batch Heating: External Heat Exchanger and Non-Isothermal Heating Medium 858
Solution 858
BATCH HEATING: EXTERNAL HEAT EXCHANGER (1-2 MULTIPASS HEAT EXCHANGERS), NON-ISOTHERMAL HEATING MEDIUM 859
Example 8.21: External Heat Exchanger (1-2 Multipass Heat Exchangers), Non-Isothermal Heating Medium 861
Solution 861
BATCH COOLING: EXTERNAL HEAT EXCHANGER (1-2 MULTIPASS), NON-ISOTHERMAL COOLING MEDIUM 863
Example 8.22: External Heat Exchanger (1-2 Multipass), Non-Isothermal Cooling Medium 863
Solution 864
BATCH HEATING AND COOLING: EXTERNAL HEAT EXCHANGER (2-4 MULTIPASS HEAT EXCHANGERS NON-ISOTHERMAL HEATING MEDIUM) 865
BATCH HEATING AND COOLING: EXTERNAL HEAT EXCHANGER (2-4 MULTIPASS HEAT EXCHANGERS NON-ISOTHERMAL COOLING MEDIUM) 866
Example 8.23: External Heat Exchanger (2-4 Multipass Exchanger), Non-Isothermal Heating Medium 866
Example 8.24: External Heat Exchanger (2-4 Multipass Heat Exchangers), Non-Isothermal Cooling Medium 867
HEAT EXCHANGER DESIGN WITH COMPUTERS 868
FUNCTIONALITY 869
PHYSICAL PROPERTIES 870
UNISIM HEAT EXCHANGER MODEL FORMULATIONS 870
A CASE STUDY: KETTLE REBOILER SIMULATION USING UNISIM STE 871
NOZZLE DATA 875
PROCESS DATA 877
REFERENCES 894
APPENDIX A 898
HEAT TRANSFER 898
9 Process Integration and Heat Exchanger Network 947
INTRODUCTION 947
APPLICATION OF PROCESS INTEGRATION 953
PINCH TECHNOLOGY 953
HEAT EXCHANGER NETWORK DESIGN 954
Energy and Capital Targeting and Optimization 957
OPTIMIZATION VARIABLES 957
OPTIMIZATION OF THE USE OF UTILITIES (UTILITY PLACEMENT) 959
HEAT EXCHANGER NETWORK REVAMP 960
HEAT RECOVERY PROBLEM IDENTIFICATION 960
THE TEMPERATURE-ENTHALPY DIAGRAM (T-H) 961
ENERGY TARGETS 963
Construction of Composite Curves 963
HEAT RECOVERY FOR MULTIPLE SYSTEMS 964
Example 9.1. Setting Energy Targets and Heat Exchanger Network 964
Solution 965
THE HEAT RECOVERY PINCH AND ITS SIGNIFICANCE 969
THE SIGNIFICANCE OF THE PINCH 970
THE PLUS-MINUS PRINCIPLE FOR PROCESS MODIFICATIONS 972
A TARGETING PROCEDURE: THE PROBLEM TABLE ALGORITHM 973
THE GRAND COMPOSITE CURVE 975
PLACING UTILITIES USING THE GRAND COMPOSITE CURVE 978
STREAM MATCHING AT THE PINCH 979
THE PINCH DESIGN APPROACH TO INVENTING A NETWORK 981
HEAT EXCHANGER NETWORK DESIGN (HEN) 981
The Design Grid 981
NETWORK DESIGN ABOVE THE PINCH 984
THE INTERMEDIATE TEMPERATURES IN THE STREAMS ARE: 986
NETWORK DESIGN BELOW THE PINCH 986
THE INTERMEDIATE TEMPERATURES IN THE STREAMS ARE: 987
ABOVE THE PINCH 987
BELOW THE PINCH 988
EXAMPLE 9.2 988
SOLUTION 989
DESIGN FOR THRESHOLD PROBLEMS 991
STREAM SPLITTING 993
ADVANTAGES AND DISADVANTAGES OF STREAM SPLITTING 994
EXAMPLE 9.3 994
SOLUTION 994
EXAMPLE 9.4 1002
STREAM DATA EXTRACTION 1003
SOLUTION 1003
HEAT EXCHANGER AREA TARGETS 1005
EXAMPLE 9.5 1010
SOLUTION 1010
EXAMPLE 9.6 1017
SOLUTION 1017
HEN SIMPLIFICATION 1018
HEAT LOAD LOOPS 1018
EXAMPLE 9.7. TEST CASE 3, TC3 LINNHOFF AND HINDMARCH 1019
SOLUTION 1019
HEAT LOAD PATHS 1024
NUMBER OF SHELLS TARGET 1025
IMPLICATIONS FOR HEN DESIGN 1027
CAPITAL COST TARGETS 1027
CAPITAL COST 1028
NETWORK CAPITAL COST (CC) 1028
TOTAL COST TARGETING 1028
ENERGY TARGETING 1029
SUPERTARGETING OR ΔTmin OPTIMIZATION 1030
EXAMPLE 9.8. HEN FOR MAXIMUM ENERGY RECOVERY 1030
SOLUTION 1030
SUMMARY: NEW HEAT EXCHANGER NETWORK DESIGN 1032
TARGETING AND DESIGN FOR CONSTRAINED MATCHES 1033
Process Constraints 1033
TARGETING FOR CONSTRAINTS 1033
HEAT ENGINES AND HEAT PUMPS FOR OPTIMUM INTEGRATION 1034
PRINCIPLE OF OPERATION 1034
HEAT PUMP EVALUATION 1036
APPLICATION OF A HEAT PUMP 1037
APPROPRIATE INTEGRATION OF HEAT ENGINES 1037
OPPORTUNITIES FOR PLACEMENT OF HEAT ENGINES 1038
APPROPRIATE INTEGRATION OF HEAT PUMPS 1038
OPPORTUNITIES FOR PLACEMENT OF HEAT PUMPS 1039
APPROPRIATE PLACEMENT OF COMPRESSION AND EXPANSION IN HEAT RECOVERY SYSTEMS 1040
PRESSURE DROP AND HEAT TRANSFER IN PROCESS INTEGRATION 1040
TOTAL SITE ANALYSIS 1040
APPLICATIONS OF PROCESS INTEGRATION 1045
Hydrogen Pinch Studies 1045
OXYGEN PINCH 1047
CARBON DIOXIDE (CO2) MANAGEMENT 1047
MASS AND WATER PINCH 1048
SITE-WIDE INTEGRATION 1049
FLUE GAS EMISSIONS 1050
PITFALLS IN PROCESS INTEGRATION 1053
PINCH TO TARGET CO2 EMISSIONS 1053
PINCH TECHNOLOGY IN PETROLEUM AND CHEMICAL INDUSTRIES 1055
CONCLUSIONS 1056
INDUSTRIAL APPLICATIONS: CASE STUDIES 1059
Case Study-1: (From Gary Smith And Ajit Patel, The Chemical Engineer, P. 26, November 1987) 1059
SOLUTION 1060
Case Study-2: Crude Preheat Train 1067
Introduction 1067
Process Description 1073
Solution 1073
Above the Pinch 1076
Below the Pinch 1076
CASE STUDY-3: NETWORK FOR AROMATICS PLANT (G. T. POLLEY, AND M.H. PANJEH SHAHI, TRANS. INST. CHEME., VOL. 69, PART A, NOVEMBER 1991) 1081
Introduction 1081
Process Description 1081
STREAM DATA EXTRACTION 1081
SOLUTION 1082
GLOSSARY OF TERMS 1082
SUMMARY AND HEURISTICS 1086
HEURISTICS 1086
NOMENCLATURE 1087
REFERENCES 1087
BIBLIOGRAPHY 1091
10 Process Safety and Pressure-Relieving Devices 1093
INTRODUCTION 1093
10.1 TYPES OF POSITIVE PRESSURE-RELIEVING DEVICES 1094
(See Manufacturers’ Catalogs for Design Details) 1094
Pressure Relief Valve 1094
Pilot-Operated Safety Valves 1096
10.2 TYPES OF VALVES/RELIEF DEVICES 1096
Conventional Safety Relief Valve 1096
Balanced Safety Relief Valve 1097
Special Valves 1097
10.3 RUPTURE DISK 1098
EXAMPLE 10.1 1101
Hypothetical Vessel Design, Carbon Steel Grade A-285, Gr C 1101
10.4 DESIGN PRESSURE OF A VESSEL 1107
10.5 MATERIALS OF CONSTRUCTION 1107
Safety and Relief Valves; Pressure-Vacuum Relief Values 1107
10.6 RUPTURE DISKS 1108
GENERAL CODE REQUIREMENTS 1109
RELIEF MECHANISMS 1109
Reclosing Devices, Spring Loaded 1109
NON-RECLOSING PRESSURE-RELIEVING DEVICES 1110
PRESSURE SETTINGS AND DESIGN BASIS 1110
10.7 UNFIRED PRESSURE VESSELS ONLY, BUT NOT FIRED OR UNFIRED STEAM BOILERS 1110
EXTERNAL FIRE OR HEAT EXPOSURE ONLY AND PROCESS RELIEF 1112
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) 1113
Primary Relief 1113
Selected Portions of ASME Pressure Vessel Code, Quoted by Permission 1117
10.9 ESTABLISHING RELIEVING OR SET PRESSURES 1120
SAFETY AND SAFETY RELIEF VALVES FOR STEAM SERVICE 1120
10.10 SELECTION AND APPLICATION 1121
10.11 CAPACITY REQUIREMENTS EVALUATION FOR PROCESS OPERATION (NON-FIRE) 1121
INSTALLATION 1125
10.12 SELECTION FEATURES: SAFETY, SAFETY RELIEF VALVES, AND RUPTURE DISKS 1134
10.13 CALCULATIONS OF RELIEVING AREAS: SAFETY AND RELIEF VALVES 1136
10.14 STANDARD PRESSURE RELIEF VALVES RELIEF AREA DISCHARGE OPENINGS 1136
10.15 SIZING SAFETY RELIEF TYPE DEVICES FOR REQUIRED FLOW AREA AT TIME OF RELIEF 1137
10.16 EFFECTS OF TWO-PHASE VAPOR-LIQUID MIXTURE ON RELIEF VALVE CAPACITY 1137
10.17 SIZING FOR GASES OR VAPORS OR LIQUIDS FOR CONVENTIONAL VALVES WITH CONSTANT BACKPRESSURE ONLY 1137
PROCEDURE 1141
ESTABLISH CRITICAL FLOW FOR GASES AND VAPORS 1141
EXAMPLE 10.2 1144
Flow through Sharp Edged Vent Orifice 1144
10.18 ORIFICE AREA CALCULATIONS 1144
10.19 SIZING VALVES FOR LIQUID RELIEF: PRESSURE RELIEF VALVES REQUIRING CAPACITY CERTIFICATION [5d] 1148
10.20 SIZING VALVES FOR LIQUID RELIEF: PRESSURE RELIEF VALVES NOT REQUIRING CAPACITY CERTIFICATION [5d] 1149
10.21 REACTION FORCES 1152
EXAMPLE 10.3 1154
SOLUTION 1154
EXAMPLE 10.4 1156
SOLUTION 1156
10.22 CALCULATIONS OF ORIFICE FLOW AREA USING PRESSURE-RELIEVING BALANCED BELLOWS VALVES, WITH VARIABLE OR CONSTANT BACK PRESSURE 1158
10.23 SIZING VALVES FOR LIQUID EXPANSION (HYDRAULIC EXPANSION OF LIQUID-FILLED SYSTEMS/EQUIPMENT/PIPING) 1163
10.24 SIZING VALVES FOR SUBCRITICAL FLOW: GAS OR VAPOR BUT NOT STEAM [5D] 1168
10.25 EMERGENCY PRESSURE RELIEF: FIRES AND EXPLOSIONS RUPTURE DISKS 1171
10.26 EXTERNAL FIRES 1171
10.27 SET PRESSURES FOR EXTERNAL FIRES 1171
10.28 HEAT ABSORBED 1172
THE SEVERE CASE 1172
10.29 SURFACE AREA EXPOSED TO FIRE 1173
10.30 RELIEF CAPACITY FOR FIRE EXPOSURE 1175
10.31 CODE REQUIREMENTS FOR EXTERNAL FIRE CONDITIONS 1175
10.32 DESIGN PROCEDURE 1175
EXAMPLE 10.5 1176
SOLUTION 1176
10.33 RUNAWAY REACTIONS: DIERS 1179
10.34 HAZARD EVALUATION IN THE CHEMICAL PROCESS INDUSTRIES 1180
10.35 HAZARD ASSESSMENT PROCEDURES 1181
10.36 EXOTHERMS 1182
10.37 ACCUMULATION 1182
10.38 THERMAL RUNAWAY CHEMICAL REACTION HAZARDS 1183
10.39 HEAT CONSUMED HEATING THE VESSEL. THE Φ-FACTOR 1183
10.40 ONSET TEMPERATURE 1185
10.41 TIME-TO-MAXIMUM RATE 1185
10.42 MAXIMUM REACTION TEMPERATURE 1185
10.43 VENT SIZING PACKAGE (VSP) 1186
10.44 VENT SIZING PACKAGE 2TM (VSP2TM) 1189
10.45 ADVANCED REACTIVE SYSTEM SCREENING TOOL (ARSST) 1191
10.46 TWO-PHASE FLOW RELIEF SIZING FOR RUNAWAY REACTION 1191
10.47 RUNAWAY REACTIONS 1192
10.48 VAPOR PRESSURE SYSTEMS 1192
10.49 GASSY SYSTEMS 1192
10.50 HYBRID SYSTEMS 1193
10.51 SIMPLIFIED NOMOGRAPH METHOD 1193
10.52 VENT SIZING METHODS 1199
10.53 VAPOR PRESSURE SYSTEMS 1199
10.54 FAUSKE’S METHOD 1201
10.55 GASSY SYSTEMS 1202
10.56 HOMOGENEOUS TWO-PHASE VENTING UNTIL DISENGAGEMENT 1203
10.57 TWO-PHASE FLOW THROUGH AN ORIFICE 1204
10.58 CONDITIONS OF USE 1205
10.59 DISCHARGE SYSTEM 1206
Design of the Vent Pipe 1206
10.60 SAFE DISCHARGE 1206
10.61 DIRECT DISCHARGE TO THE ATMOSPHERE 1206
EXAMPLE 10.6 1207
Tempered Reaction 1207
SOLUTION 1207
EXAMPLE 10.7 1209
SOLUTION 1209
EXAMPLE 10.8 1210
SOLUTION 1210
EXAMPLE 10.9 1211
SOLUTION 1212
10.62 DIERS FINAL REPORTS 1215
10.63 SIZING FOR TWO-PHASE FLUIDS 1215
Step 1. Calculate the Saturated Omega Parameter, ωs 1215
Step 2. Determine the Subcooling Region 1216
Step 3. Determine if the Flow is Critical or Subcritical 1217
Step 4. Calculate the Mass Flux 1217
Step 5. Calculate the Required Area of the PRV 1218
SI UNITS 1218
EXAMPLE 10.10 1219
SOLUTION 1220
EXAMPLE 10.11 1222
SOLUTION 1222
TYPE 2. (OMEGA METHOD): SIZING FOR TWO-PHASE FLASHING FLOW WITH A NONCONDENSABLE GAS THROUGH A PRESSURE RELIEF VALVE 1226
EXAMPLE 10.12 1230
SI UNITS 1232
EXAMPLE 10.13 1235
SOLUTION 1235
TYPE 3 INTEGRAL METHOD 1237
EXAMPLE 10.14 1238
SOLUTION 1238
GLOSSARY 1239
ACRONYMS AND ABBREVIATIONS 1245
NOMENCLATURE 1246
Subscripts 1249
Greek Symbols 1249
REFERENCES 1249
LISTING OF FINAL REPORTS FROM THE DIERS RESEARCH PROGRAM (DESIGN INSTITUTE FOR EMERGENCY RELIEF SYSTEMS) 1249
PROJECT MANUAL 1249
TECHNOLOGY SUMMARY 1249
SM 540 ALL/LARGE-SCALE EXPERIMENTAL DATA AND ANALYSIS 1250
BENCH-SCALE APPARATUS DESIGN AND TEST RESULTS 1250
11 Chemical Kinetics and Reactor Design 1253
INTRODUCTION 1253
INDUSTRIAL REACTION PROCESSES 1255
Conventional Reactors 1255
Membrane Reactors 1259
Spherical Reactors 1261
Bioreactors 1262
CHEMICAL REACTIONS 1265
Conversion Type 1265
Equilibrium Type 1265
Kinetic Type 1266
IDEAL REACTORS 1268
Conversion Reactor 1269
Adiabatic Flame Temperature 1269
Heats of Reaction 1270
Equilibrium Reactor 1271
Gibbs Reactor 1272
CSTR Reactor 1272
PFR Reactor 1272
NON-IDEAL REACTORS 1272
Modular Analysis 1272
Multiscale Analysis 1273
BIOCHEMICAL REACTIONS 1275
Models of Enzyme Kinetics 1275
Constant Volume Batch Reactor 1277
CHEMICAL REACTION HAZARDS INCIDENTS 1278
Reactive Hazards Incidents 1278
Chemical Reactivity Worksheet (CRW) 1280
Protective Measures for Runaway Reactions 1280
PROBLEMS AND SOLUTIONS 1288
REFERENCES 1331
12 Engineering Economics 1335
INTRODUCTION 1335
GROSS PROFIT ANALYSIS 1335
CAPITAL COST ESTIMATION 1337
Equipment/Plant Cost Estimations by Capacity Exponents 1339
Factored Cost Estimate 1342
Functional-Unit Estimate 1342
Percentage of Delivered Equipment Cost 1342
PROJECT EVALUATION 1342
Cash Flow 1343
Cumulated Cash Flow 1343
Return on Investment (ROI) 1343
Payback Period (PBP) 1344
Present Worth (or Present Value) 1344
Net Present Value (NPV) 1344
Discounted Cash Flow Rate of Return (DCFRR) 1346
Net Return Rate (NRR) 1346
Depreciation 1346
Double Declining Balance (DDB) Depreciation 1347
Capitalized Cost 1347
Average Rate of Return (ARR) 1348
Present Value Ratio (Present Worth Ratio) 1348
Profitability 1348
ECONOMIC ANALYSIS 1349
Inflation 1351
EXAMPLES AND SOLUTIONS 1351
Nomenclature 1360
CARBON TAX 1362
References 1362
13 Optimization in Chemical/Petroleum Engineering 1363
OPTIMAL OPERATING CONDITIONS OF A BOILER 1364
OPTIMUM DISTILLATION REFLUX 1366
FEATURES OF OPTIMIZATION PROBLEMS 1366
Objective Functions for Reactors 1367
LINEAR PROGRAMMING (LP) FOR BLENDING 1369
LP SOFTWARE 1371
THE EXCEL SOLVER 1372
PROBLEM SOLUTION 1373
Example 13.1 1375
Solution 1375
Example 13.2 1375
Solution 1377
Example 13.3 1377
Solution 1378
A CASE STUDY: OPTIMUM REACTOR TEMPERATURE 1379
Solution 1380
Optimization of Product Blending Using Linear Programming 1384
INTRODUCTION 1384
BLENDING PROCESSES 1386
NON-LINEAR OCTANE BLENDING FORMULA 1387
GASOLINE BLENDING 1388
Gasoline Blending Example – 3 Blend Stocks, 2 Specifications 1388
Non-Linear Programming 1389
Example 13.4 1391
SOLUTION 1391
MATHEMATICAL FORMULATION 1393
Problem Solution 1394
Example 13.5 1394
Solution 1394
Ethyl Corporation Model 1394
A CASE STUDY 1396
Solution 1397
NOTATION 1402
REFERENCES 1403
FURTHER REFERENCE 1403
Epilogue 1405
Index 1415
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