Chemical Process Engineering Volume 1 E-Book

Rahmat Sotudeh-Gharebagh

• Herausgeber: John Wiley & Sons
• Kategorie: Fachliteratur
• Sprache: Englisch

Seitenzahl: 686

Veröffentlichungsjahr: 2022

Beschreibung

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.

Leseprobe

Table of Contents

Cover

Title Page

Copyright

Companion Web Page

Gratitude

Preface

Acknowledgments

About the Authors

1 Computations with Excel Spreadsheet-UniSim Design Simulation

SECTION I - NUMERICAL ANALYSIS

INTRODUCTION

SOLVER

LINEAR REGRESSION

MULTIPLE REGRESSION

POLYNOMIAL REGRESSION

SIMULTANEOUS LINEAR EQUATIONS

NONLINEAR EQUATIONS

INTERPOLATIONS

INTEGRATIONS

DIFFERENTIAL EQUATIONS

EXAMPLES AND SOLUTIONS

SECTION II – PROCESS SIMULATION

INTRODUCTION

EXAMPLES AND SOLUTIONS

References

2 Physical Property of Pure Components and Mixtures

PURE COMPONENTS

MIXTURES

DIFFUSION COEFFICIENTS

COMPRESSIBILITY Z-FACTOR

SOLUBILITY AND ADSORPTION

References

3 Fluid Flow

INTRODUCTION

EQUIVALENT LENGTH OF VARIOUS FITTINGS AND VALVES

PRESSURE DROP CALCULATIONS FOR SINGLE-PHASE INCOMPRESSIBLE FLUIDS

COMPRESSIBLE FLUID FLOW IN PIPES

TWO-PHASE FLOW IN PROCESS PIPING

VAPOR-LIQUID TWO-PHASE VERTICAL DOWNFLOW

LINE SIZES FOR FLASHING STEAM CONDENSATE

FLOW THROUGH PACKED BEDS

EXAMPLES AND SOLUTIONS

References

4 Equipment Sizing

INTRODUCTION

SIZING OF VERTICAL AND HORIZONTAL SEPARATORS

SIZING OF PARTLY FILLED VESSELS AND TANKS

PRELIMINARY VESSEL DESIGN

CYCLONE DESIGN

GAS DRYER DESIGN

EXAMPLES AND SOLUTIONS

References

5 Instrument Sizing

INTRODUCTION

CONTROL VALVE SIZING

References

6 Pumps and Compressors Sizing

PUMPS

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

Charting NPSHR Values of Pumps

Net Positive Suction Head (NPSH)

Specific Speed

Rotative Speed

Pumping Systems and Performance

POWER REQUIREMENTS FOR PUMPING THROUGH PROCESS LINES

Hydraulic Power

AFFINITY LAWS

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

Variables Descriptions

SIMULATION ALGORITHM

Problem

Discussion

Pump Cavitation

Factors in Pump Selection

COMPRESSORS

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

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 [9]

Amonton’s Law at Constant Volume [9]

Combined Boyle’s and Charles’ Laws

Entropy Balance Method [7]

Isentropic Exponent Method [7]

COMPRESSION RATIO

Horsepower

Single Stage

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

Solution

Accidentally Closing the PFD

Object Palette

Specifications

COMPRESSION PROCESS

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 [35]

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

Bibliography

7 Mass Transfer

INTRODUCTION

VAPOR LIQUID EQUILIBRIUM

BUBBLE POINT CALCULATION

DEW POINT CALCULATION

EQUILIBRIUM FLASH COMPOSITION

Nomenclature

TOWER SIZING FOR VALVE TRAYS

PACKED TOWER DESIGN

DETERMINATION OF PLATES IN FRACTIONATING COLUMNS BY THE SMOKER EQUATIONS

MULTICOMPONENT DISTRIBUTION AND MINIMUM TRAYS IN DISTILLATION COLUMNS

EXAMPLES AND SOLUTIONS

References

Index

Also of Interest

End User License Agreement

List of Tables

Chapter 1

Table 1.1 Selected basic functions of Excel spreadsheet [2, 5].

Table 1.2 Selected applied functions of Excel spreadsheet for design and simulat...

Table 1.3 Syntax for finding trendline coefficients [7].

Table 1.4 Input data for liquid mixing experiment.

Table 1.5 Input data for fluid flow experiments.

Table 1.6 xy data for polynomial approximation.

Table 1.7 Blend specifications.

Table 1.8 Design and reaction data for continuous stirred tanks.

Table 1.9 Flow gas data at various temperatures.

Table 1.10 Kinetic and concentration data for the batch reactor.

Table 1.11 Benefits of using process simulators for engineers and scientists.

Table 1.12 List of mostly used chemical process simulators.

Table 1.13 Good simulation practice.

Chapter 2

Table 2.1 The temperature range for the surface tension.

Table 2.2 Calculation of specific gravity of natural gas.

Chapter 3

Table 3.1 Values of K1 and K∞ for the two-K method for pipe fittings. Source: H...

Table 3.2 Excess head loss “K” correlation due to changes in pipe size [1].

Table 3.3 Equivalent roughness of various surfaces (Source [6]).

Table 3.4 Recommended fluid velocity and maximum ΔP for carbon steel vapor lines...

Table 3.5 Approximate k values for some common gases (68°F, 14.7 psia).

Table 3.6 Friction factors for total turbulence in new commercial steel pipes.

Table 3.7 Characteristic linear Velocities of two-phase flow regimes.

Table 3.8 Characteristic linear velocities of two-phase flow regimes [26].

Chapter 4

Table 4.1 Design criteria for Reflux Distillate Accumulators.

Table 4.2 Operator factors for external units.

Table 4.3 Head blank diameter factor (H.Fac).

Table 4.4 Effect of variables on Cyclone Performance.

Table 4.5 Cyclone operational and design data.

Table 4.6 Dryer operational data.

Chapter 5

Table 5.1 Flow coefficients for control valves.

Table 5.2 Correction factors for control valve flow coefficient.

Table 5.3 Cv table for quick opening trim.

Table 5.4 Cv table for linear trim.

Chapter 6

Table 6.1 General types or classification of pumps.

Table 6.2 Approximate capacity-head ranges for centrifugal pumps.

Table 6.3 Effects of fluid density on head.

Table 6.4 Basic parts of a centrifugal pump.

Table 6.5 Pump selection guide.

Table 6.6 Troubleshooting centrifugal pumps.

Table 6.7 Pump installation check list [30].

Table 6.8 General compression and vacuum limits.

Table 6.9 Comparison of performance for propane.

Table 6.10 Compressibility Factors, Z.

Table 6.11 Approximate ratio of specific heats (“k” values) for various gases.

Table 6.11a Constants for molal heat capacity.

Table 6.12 Properties of the gas mixture.

Table 6.13 Polytropic efficiencies for various types of machines.

Table 6.14 Approximate mechanical losses as a percentage of a gas power requirem...

Table 6.15 Properties of the gas mixture.

Table 6.16 Probable causes of reciprocating compressor trouble.

Table 6.17 Probable causes of centrifugal compressor trouble.

Chapter 7

Table 7.1 Ways to produce two-phase mixture [1].

Table 7.2 Equilibrium flash criteria.

Table 7.3 Values of G and H for each tray spacing.

Table 7.4 Recommended values for foam factor and residence time.

Table 7.5 Tower diameter versus cross sectional areas.

Table 7.6 Downcomer dimensions.

Table 7.7 Downcomer dimensions.

Table 7.8 Downcomer dimensions.

Table 7.9 Tower diameter versus cross sectional areas.

Table 7.10 Determining number of passes.

Table 7.11 Pressure-drop correlations for packed towers. Source: van Winkle [17]...

Table 7.12 Generalized pressure drop rules. Source: Branan [25].

Table 7.13 Packing factors (Source: Eckert [26]).

Table 7.14 Constants for each pressure drop correlation. Source: Blackwell [13].

Table 7.15 Composition of feed.

Table 7.16 Feed composition to a natural gas liquefaction plant.

Table 7.17 Bubble and dew point temperatures.

Table 7.18 Constants for each pressure drop correlation.

Guide

Cover

Table of Contents

Title Page

Copyright

Companion Web Page

Gratitude

Preface

Acknowledgments

About the Authors

Begin Reading

Index

Also of Interest

End User License Agreement

Pages

ix

ii

iii

iv

v

vii

xvii

xviii

xix

xxi

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

60

61

62

63

64

65

66

67

68

69

70

71

72

73

74

75

76

77

78

79

81

82

83

84

85

86

87

88

89

90

91

92

93

94

95

96

97

98

99

100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

119

120

121

122

123

124

125

126

127

128

129

130

131

132

133

134

135

136

137

138

139

140

141

142

143

144

145

146

147

148

149

150

151

152

153

154

155

156

157

158

159

160

161

162

163

165

166

167

168

169

170

171

172

173

174

175

176

177

178

179

180

181

182

183

184

185

186

187

188

189

190

191

192

193

194

195

196

197

198

199

200

201

202

203

204

205

206

207

208

209

210

211

212

213

214

215

216

217

218

219

220

221

222

223

224

225

226

227

228

229

230

231

232

233

234

235

236

237

238

239

240

241

242

243

244

245

246

247

249

250

251

252

253

254

255

256

257

258

259

260

261

262

263

264

265

266

267

268

269

270

271

272

273

274

275

276

277

278

279

280

281

282

283

284

285

286

287

288

289

290

291

292

293

294

295

296

297

298

299

300

301

302

303

304

305

306

307

308

309

310

311

312

313

314

315

316

317

318

319

320

321

322

323

324

325

326

327

328

329

330

331

332

333

334

335

336

337

338

339

340

341

342

343

344

345

346

347

348

349

350

351

352

353

354

355

356

357

358

359

360

361

362

363

364

365

366

367

368

369

370

371

372

373

374

375

376

377

378

379

380

381

382

383

384

385

386

387

388

389

390

391

392

393

394

395

396

397

398

399

400

401

402

403

404

405

406

407

408

409

410

411

412

413

414

415

416

417

418

419

420

421

422

423

424

425

426

427

428

429

430

431

432

433

434

435

436

437

438

439

440

441

442

443

444

445

446

447

448

449

450

451

452

453

454

455

456

457

458

459

460

461

462

463

464

465

466

467

468

469

470

471

472

473

474

475

476

477

478

479

480

481

482

483

484

485

486

487

488

489

490

491

492

493

494

495

496

497

498

499

500

501

502

503

505

506

507

508

Scrivener Publishing

100 Cummings Center, Suite 541J

Beverly, MA 01915-6106

Publishers at Scrivener

Martin Scrivener ([email protected])

Phillip Carmical ([email protected])

Volume 1

Chemical Process Engineering

Design, Analysis, Simulation and Integration, and Problem Solving With Microsoft Excel – UniSim Design Software

Computation, Physical Property, Fluid Flow, Equipment & Instrument Sizing, Pumps & Compressors, Mass Transfer

A. Kayode Coker

and

Rahmat Sotudeh-Gharebagh

This edition first published 2022 by John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, USA and Scrivener Publishing LLC, 100 Cummings Center, Suite 541J, Beverly, MA 01915, USA

© 2022 Scrivener Publishing LLC

For more information about Scrivener publications please visit www.scrivenerpublishing.com.

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, except as permitted by law. Advice on how to obtain permission to reuse material from this title is available at http://www.wiley.com/go/permissions.

Wiley Global Headquarters

111 River Street, Hoboken, NJ 07030, USA

For details of our global editorial offices, customer services, and more information about Wiley products visit us at www.wiley.com.

Limit of Liability/Disclaimer of Warranty

While the publisher and authors have used their best efforts in preparing this work, they make no representations or warranties with respect to the accuracy or completeness of the contents of this work and specifically disclaim all warranties, including without limitation any implied warranties of merchant-ability or fitness for a particular purpose. No warranty may be created or extended by sales representatives, written sales materials, or promotional statements for this work. The fact that an organization, website, or product is referred to in this work as a citation and/or potential source of further information does not mean that the publisher and authors endorse the information or services the organization, website, or product may provide or recommendations it may make. This work is sold with the understanding that the publisher is not engaged in rendering professional services. The advice and strategies contained herein may not be suitable for your situation. You should consult with a specialist where appropriate. Neither the publisher nor authors shall be liable for any loss of profit or any other commercial damages, including but not limited to special, incidental, consequential, or other damages. Further, readers should be aware that websites listed in this work may have changed or disappeared between when this work was written and when it is read.

Library of Congress Cataloging-in-Publication Data

ISBN 9781119510185

Cover image: Chemical Plant - Slidezero | Dreamstime.com

Cover background: Flowing Image - Mikhail Sheleh | Dreamstime.com

Cover design by Kris Hackerott

Set in size of 11pt and Minion Pro by Manila Typesetting Company, Makati, Philippines

Printed in the USA

10 9 8 7 6 5 4 3 2 1

Companion Web Page

This 2-volume set includes access to its companion web page, from which can be downloaded useful software, spreadsheets, and other value-added products related to the books. To access it, follow the instructions below:

Go to

https://scrivenerpublishing.com/coker_volume_one/

Enter your email in the username field

Enter “Refining” in the password field

Gratitude

To the Almighty father for providing us with the abundance of nature, so that human beings can further develop and make use of the many things in nature for our well-being and for the world.

To all process/chemical engineers worldwide utilizing this abundance of nature for the good of mankind.

Keep the heart of your thoughts pure, by so doing you will bring peace and be happy

To honour God in all things and to perform everything solely to the glory of God

Abd-ru-shin (In the Light of Truth)

A. Kayode Coker

Dedication

“I am always obliged to a person who has taught me a single word.”

In memory of my late father and to my respected family for their endless support

To engineers and scientists for their commitment to inclusion and sustainability

R. Sotudeh-Gharebagh

Preface

An increased use of computational resources by engineers has greatly expedited the design of equipment and process plants in refining, and the chemical process industries. In addition, the availability of commercial and open source process simulation packages, and spreadsheets has drastically reduced the requirement of programming with high-level languages, such as BASIC, C, C++, COBOL, Java, FORTRAN and Pascal. Situations may arise where a simulation package is not readily available, too expensive or of a limited scope, in this case, hands-on tools; e.g. spreadsheets could be used to review other alternatives or develop specific programs. Furthermore, the simulation packages can be integrated with spreadsheets to enlarge their scope to equipment and process design due to the infrastructure they provide on component databases, physical property estimations and unit operations.

A text-book, including the theory with equations, tables, and figures and the use of advanced tools is not readily available to the process designer. Our aim in preparing this text is to present theory, along with Excel spreadsheet and UniSim Design software programs for solving a wide range of design problems. The book will, therefore, benefit chemical/process engineers, students, technologists and practitioners in the petroleum, petrochemical, pharmaceutical, biochemical and fine chemical industries. The structured approaches are provided that can be used to solve a wide range of process engineering problems and thus analyze and simulate process equipment regularly.

The process design concepts, guidelines; codes and standards are clearly important, and several excellent books and references are available to address these issues and will be cited in the book where applicable. However, these two volume-sets are unique in that to date no textbook on chemical process design and simulation has been published, which provides adequate information (theory, equations, figures, tables and programs) to enable the reader to perform robust calculations using Excel spreadsheet - UniSim Design software program. The better use of these tools in the special format shapes the core of the book as:

– Microsoft Excel

®

is part of the Microsoft Office. It is widely recognized as the most versatile spreadsheet for problem solving, which enables a chemical engineer to make computation and visualizations in an easiest way possible. Process engineers can use Excel spreadsheet for equipment and process design, modeling, simulation and optimization. Data bases and pivot tables can be easily designed with Excel spreadsheet to ease making calculations, understanding technical reports, and preparing charts and figures.

– The new improved UniSim R480 Design of Honeywell, is a smart and intuitive software; it creates thermodynamics and unit operation steady-state and dynamic models. Process simulation is a tool used to design a new process, an existing process or debottleneck, monitor process conditions, troubleshoot current operations to compare theoretical results, optimize process conditions for enhanced throughput, and to reduce energy yields, and emissions.

The contents of this book have been formed over many years through the concentrated research and industrial efforts of the authors. Furthermore, to assist the user and to demonstrate the validity of the methods, worked examples and case studies of practical relevance using the Excel spreadsheet and UniSim Design software programs are provided throughout the text, and the source files are provided at the publisher website. In this way, the students, and engineers can save time by using hands-on tools to ease the calculation and concentrate in understanding the fundamentals of the phenomena occurring in the process design sequences. These two volumes are fully extended version of the original title: Fortran Programs for Chemical Process Design, Analysis and Simulation by A. Kayode Coker. In these volumes, we have provided examples in both Imperial and SI units, but we have intentionally kept most examples in Imperial units based on the following reasons:

a) All problems solved in UniSim Design can be easily converted to any units of measurement and it makes no difference which unit is used.

b) The use of both units is very useful from instructional viewpoint as students need to have some sort of practice with both units as the Imperial unit is still used in some countries.

However, since all problems are carefully solved in Excel, the conversion is then easy, and we have also provided a conversion table to assist readers in their calculations.

The book is primarily intended to serve senior students, early career engineers, university professors and practitioners, especially in the process, chemical, petrochemical, biochemical, mechanical, mining and metallurgical industries. However, other engineers, consultants, technicians and scientists concerned with various aspects of industrial design, and scale-up may also find it useful. It can be considered as a textbook to process design for senior and graduate students as well as a hands-on document for engineers at the entry level and practitioners. The content of this book can also be taught in intensive workshops in process industries.

Acknowledgments

RSG wishes to express his profound gratitude to his students for reading the chapters and checking the programs. Further, he wishes to thank his current and former graduate students, Ms. Aghasi, Ms. Bakhshi and Messrs. Jabbari, Ahmadi, Moshiri, Khodabendehlou for checking the chapters and programs. Special credits are also extended to Professor Jamal Chaouki from Polytechnique de Montreal for hosting RSG for his sabbatical leave upon the completion of the book beside the main activity planned for sababtical. AKC expresses his gratitude to Ahmed Mutawa, formerly of SASREF for developing the conversion table software for the book. Thank you, Ahmed.

Wherever it is required, permissions have been obtained to reproduce the works published by some organizations and companies. We acknowledge and thank the American Institute of Chemical Engineers, the Institution of Chemical Engineers (U.K.), Chemical Engineering (Mc-Graw Hill), Oil & Gas Journal, Tubular Exchanger Manufacturers’ Association, American Petroleum Institute, John Wiley & Sons, Nutter Engineering, and many other organizations that provided materials for this book. We express our gratitude to Honeywell Process Solutions for granting permission to incorporate the use of UniSim Design software simulation and many suites of software programs in the book.

We wish to express our thanks to the Wiley-Scrivener team: Kris Hackerott- Graphics Designer, Bryan Aubrey – Copy editor, Myrna Ting – Typesetter and her colleagues. We are truly grateful for your professionalism, assistance and help in the production of this volume. Finally, very special thanks to Phil Carmical of Scrivener publishing company for his advice and helpful suggestions during the production of this volume.

Finally, we should emphasize that process design is a creative, dynamic and challenging activity and for this reason, the design books like this one need continuous improvement with current digitalization outlook and abundant access to computation resources. We would appreciate and welcome any comments, suggestions, or feedback that you may have on this volume.

A. Kayode Coker (www.akctechnology.com)

A. K.C. TECHNOLOGY, U.K.

Rahmat Sotudeh-Gharebagh ([email protected]) College of Engineering, University of Tehran, Iran

About the Authors

A. Kayode Coker PhD