Details

Chemical Process Engineering Volume 1

Design, Analysis, Simulation, Integration, and Problem Solving with Microsoft Excel-UniSim Software for Chemical Engineers Computation, Physical Property, Fluid Flow, Equipment and Instrument Sizing
1. Aufl.

von: Rahmat Sotudeh-Gharebagh, A. Kayode Coker
204,99 €
Verlag:	Wiley
Format:	PDF
Veröffentl.:	21.03.2022
ISBN/EAN:	9781119510208
Sprache:	englisch
Anzahl Seiten:	544

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Beschreibungen

Titelbeschreibung

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.

Inhaltsverzeichnis

Preface xvii Acknowledgments xix About the Authors xxi 1 Computations with Excel Spreadsheet-UniSim Design Simulation 1 Section I - Numerical Analysis 1 Introduction 1 Excel Spreadsheet 1 Functions 2 Trendline Coefficients 2 Goal Seek 5 Solver 6 Linear Regression 7 Measuring Regression Quality 9 Multiple Regression 9 Polynomial Regression 11 Simultaneous Linear Equations 11 Nonlinear Equations 12 Interpolations 13 Integrations 14 The Trapezoidal Rule 14 Simpson’s 1/3 Rule 15 Simpson’s 3/8 Rule 15 Differential Equations 15 Nth Order Ordinary Differential Equations 15 Solution of First-Order Ordinary Differential Equations 15 Runge-Kutta Methods 16 Examples and Solutions 17 Section II – Process Simulation 28 Introduction 28 Thermodynamics for Process Simulators 29 UNISIM Design Software 30 Examples and Solutions 31 References 78 2 Physical Property of Pure Components and Mixtures 81 Pure Components 81 Density of Liquid 82 Viscosity of Liquid 83 Heat Capacity of Liquid 85 Thermal Conductivity of Liquid 87 Volumetric Expansion Rate 90 Vapor Pressure 91 Viscosity of Gas 93 Thermal Conductivity of Gas 94 Heat Capacity of Gases 95 Mixtures 97 Surface Tensions 98 Viscosity of Gas Mixture 99 Enthalpy of Formation 101 Enthalpy of Vaporization 103 Gibbs Energy of Reaction 105 Henry’s Law Constant for Gases in Water 107 Coefficient of Thermal Expansion of Liquid 108 Diffusion Coefficients 109 Gas-Phase Diffusion Coefficients 109 Liquid-Phase Diffusion Coefficients 110 Compressibility Z-factor 111 Solubility and Adsorption 116 Solubility of Hydrocarbons in Water 116 Solubility of Gases in Water 117 Solubility of Sulfur and Nitrogen Compounds in Water 118 Adsorption on Activated Carbon 119 References 119 3 Fluid Flow 121 Introduction 121 Flow of Fluids in Pipes 121 Equivalent Length of Various Fittings and Valves 123 Excess Head Loss 123 Pipe Reduction and Enlargement 124 Pressure Drop Calculations for Single-phase Incompressible Fluids 124 Friction Factor 127 Overall Pressure Drop 128 Nomenclature 130 Compressible Fluid Flow in Pipes 130 Maximum Flow and Pressure Drop 131 Critical or Sonic Flow and the Mach Number 131 Mach Number 132 Mathematical Model of Compressible Isothermal Flow 134 Flow Rate Through Pipeline 136 Pipeline Pressure Drop 138 Nomenclature 139 Subscripts 139 Two-phase Flow in Process Piping 139 Flow Patterns 140 Flow Regimes 142 Pressure Drop 142 Erosion-Corrosion 145 Nomenclature 145 Vapor-liquid Two-phase Vertical Downflow 146 The Equations 147 The Algorithm 147 Nomenclature 147 Line Sizes for Flashing Steam Condensate 148 The Equations 148 Nomenclature 149 Flow Through Packed Beds 150 The Equations 151 Nomenclature 152 Examples and Solutions 152 References 162 4 Equipment Sizing 165 Introduction 165 Sizing of Vertical and Horizontal Separators 166 Vertical Separators 166 Calculation Method for a Vertical Drum 168 Calculation Method for a Horizontal Drum 170 Liquid Holdup and Vapor Space Disengagement 171 Wire Mesh Pad 171 Standards for Horizontal Separators 172 Piping Requirements 172 Nomenclature 172 Sizing of Partly Filled Vessels and Tanks 173 The Equations 173 Nomenclature 175 Preliminary Vessel Design 176 Nomenclature 177 Cyclone Design 178 Introduction 178 Cyclone Design Procedure 178 The Equations 179 Saltation Velocity 180 Pressure Drop 181 Troubleshooting Cyclone Maloperations 182 Cyclone Collection Efficiency 182 Cyclone Design Factor 182 Cyclone Design Procedure 183 Nomenclature 183 Gas Dryer Design 184 The Equations 186 Pressure Drop 187 Desiccant Reactivation 188 Nomenclature 188 Examples and Solutions 189 References 194 5 Instrument Sizing 195 Introduction 195 Variable-Head Meters 195 Macroscopic Mechanical Energy Balance 196 Variable-Head Meters 196 Orifice Sizing for Liquid and Gas Flows 200 Orifice Sizing for Liquid Flows 201 Orifice Sizing for Gas Flows 202 Orifice Sizing for Liquid Flow 204 Orifice Sizing for Gas Flow 204 Types of Restriction Orifice Plates 205 Case Study 1 205 Nomenclature 212 Control Valve Sizing 221 Introduction 221 Control Valve Characteristics 223 Pressure Drop for Sizing 224 Choked Flow 224 Flashing and Cavitation 224 Control Valve Sizing for Liquid, Gas, Steam and Two-Phase Flows 225 Liquid Sizing 226 Gas Sizing 227 Critical Condition 227 Steam Sizing 227 Two-Phase Flow 228 Installation 229 Noise 229 Control Valve Sizing Criteria 230 Valve Sizing Criteria 230 Self-Acting Regulators 231 Types of Self-Acting Regulators 231 Case Study 2 233 Rules of Thumb 246 Nomenclature 246 References 247 6 Pumps and Compressors Sizing 249 Pumps 249 Introduction 249 Pumping of Liquids 249 Pump Design Standardization 252 Basic Parts of a Centrifugal Pump 253 Impellers 253 Casing 253 Shaft 254 Centrifugal Pump Selection 255 Single-Stage (Single Impeller) Pumps 256 Hydraulic Characteristics for Centrifugal Pumps 260 Friction Losses Due to Flow 269 Velocity Head 269 Friction 271 Net Positive Suction Head (npsh) and Pump Suction 271 General Suction System 277 Reductions in NPSHR 279 Corrections to NPSHR for Hot Liquid Hydrocarbons and Water 279 Charting NPSHR Values of Pumps 280 Net Positive Suction Head (NPSH) 280 Specific Speed 282 “Type Specific Speed” 285 Rotative Speed 286 Pumping Systems and Performance 286 System Head Using Two Different Pipe Sizes in Same Line 288 Power Requirements for Pumping Through Process Lines 291 Hydraulic Power 292 Relations Between Head, Horsepower, Capacity, Speed 293 Brake Horsepower (BHP) Input at Pump 293 Affinity Laws 296 Pump Parameters 298 Specific Speed, Flowrate and Power Required by a Pump 299 Pump Sizing of Gas-Oil 301 Debutanizer Unit 303 Centrifugal Pump Efficiency 306 Centrifugal Pump Specifications 311 Pump Specifications 311 Steps in Pump Sizing 312 Reciprocating Pumps 313 Significant Features in Reciprocating Pump Arrangements 314 Application 316 Performance 316 Discharge Flow Patterns 317 Horsepower 318 Pump Selection 318 Selection Rules-of-Thumb 318 A Case Study 321 Pump Simulation on a PFD 321 Variables Descriptions 322 Simulation Algorithm 322 Problem 323 Discussion 324 Pump Cavitation 332 Factors in Pump Selection 333 Compressors 334 Introduction 334 General Application Guide 334 Specification Guides 337 General Considerations for Any Type of Compressor Flow Conditions 337 Fluid Properties 338 Compressibility 338 Corrosive Nature 338 Moisture 339 Special Conditions 339 Specification Sheet 339 Performance Considerations 339 Cooling Water to Cylinder Jackets 339 Heat Rejected to Water 339 Drivers 340 Ideal Pressure – Volume Relationship 341 Actual Compressor Diagram 343 Deviations From Ideal Gas Laws: Compressibility 343 Adiabatic Calculations 346 Charles’ Law at Constant Pressure 346 Amonton’s Law at Constant Volume 346 Combined Boyle’s and Charles’ Laws 346 Entropy Balance Method 347 Isentropic Exponent Method 347 Compression Ratio 354 Horsepower 356 Single Stage 356 Theoretical Hp 356 Actual Brake Horsepower, Bhp 356 Actual Brake Horsepower, Bhp (Alternate Correction for Compressibility) 361 Temperature Rise – Adiabatic 363 Temperature Rise – Polytropic 365 A Case Study Using Unisim Design R460.1 Software for a Two–stage Compression 365 Case Study 2 365 Solution 365 1. Starting UniSim Design Software 366 2. Creating a New Simulation 366 Saving the Simulation 367 3. Adding Components to the Simulation 367 4. Selecting a Fluids Package 368 5. Select the Units for the Simulation 369 6. Enter Simulation Environment 369 Accidentally Closing the PFD 371 Object Palette 371 7. Adding Material Streams 371 8. Specifying Material Streams 372 9. Adding A Compressor 374 Specifications 381 Compression Process 385 Adiabatic 385 Isothermal 385 Polytropic 385 Efficiency 388 Head 390 Adiabatic Head Developed Per Single-stage Wheel 390 Polytropic Head 391 Polytropic 391 Brake Horsepower 393 Speed of Rotation 396 Temperature Rise During Compression 397 Sonic or Acoustic Velocity 399 Mach Number 402 Specific Speed 402 Compressor Equations in Si Units 403 Polytropic Compressor 405 Adiabatic Compressor 408 Efficiency 409 Mass Flow Rate, w 409 Mechanical Losses 410 Estimating Compressor Horsepower 411 Multistage Compressors 412 Multicomponent Gas Streams 414 Affinity Laws 422 Speed 423 Impeller Diameters (Similar) 423 Impeller Diameter (Changed) 424 Effect of Temperature 424 Affinity Law Performance 425 Troubleshooting of Centrifugal and Reciprocating Compressors 425 Nomenclature 429 Greek Symbols 431 Subscripts 432 Nomenclature 432 Subscripts 434 Greek Symbols 434 References 434 Pumps 434 Bibliography 435 References 435 Compressors 435 Bibliography 436 7 Mass Transfer 437 Introduction 437 Vapor Liquid Equilibrium 437 Bubble Point Calculation 441 Dew Point Calculation 442 Equilibrium Flash Composition 442 Fundamental 443 The Equations 444 The Algorithm 445 Nomenclature 446 Tower Sizing for Valve Trays 446 Introduction 446 The Equations 448 Nomenclature 452 Greek Letters 465 Packed Tower Design 466 Introduction 466 Pressure Drop 466 Flooding 466 Operating and Design Conditions 468 Design Equations 471 Packed Towers versus Trayed Towers 473 Economic Trade-Offs 473 Nomenclature 474 Greek Letters 474 Determination of Plates in Fractionating Columns By the Smoker Equations 474 Introduction 474 The Equations 474 Application to a Distillation Column 475 Rectifying Section: 475 Stripping Section: 476 Nomenclature 476 Multicomponent Distribution and Minimum Trays In Distillation Columns 477 Introduction 477 Key Components 477 Equations Surveyed 477 Fractionating Tray Stability Diagrams 479 Areas of Unacceptable Operation 479 Foaming 480 Flooding 480 Entrainment 480 Weeping/Dumping 480 Fractionation Problem Solving Considerations 481 Mathematical Modeling 481 The Fenske’s Method for Total Reflux 483 The Gilliland Method for Number of Equilibrium Stages 484 The Underwood Method 485 Equations for Describing Gilliland’s Graph 486 Kirkbride’s Feed Plate Location 487 Nomenclature 487 Greek Letters 488 Examples and Solutions 488 References 499 Index 501

Autorenportrait

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.

Back cover copy

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.