(Ebook PDF) Process Equipment and Plant Design Principles and Practices 1st edition by Subhabrata Ray, Gargi Das ISBN 9780128148860 0128148861 full chapters

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ISBN 10:0128148861

ISBN 13:9780128148860

Author: Subhabrata Ray; Gargi Das

Process Equipment and Plant Design: Principles and Practices takes a holistic approach towards process design in the chemical engineering industry, dealing with the design of individual process equipment and its configuration as a complete functional system. Chapters cover typical heat and mass transfer systems and equipment included in a chemical engineering curriculum, such as heat exchangers, heat exchanger networks, evaporators, distillation, absorption, adsorption, reactors and more.

The authors expand on additional topics such as industrial cooling systems, extraction, and topics on process utilities, piping and hydraulics, including instrumentation and safety basics that supplement the equipment design procedure and help to arrive at a complete plant design. The chapters are arranged in sections pertaining to heat and mass transfer processes, reacting systems, plant hydraulics and process vessels, plant auxiliaries, and engineered safety as well as a separate chapter showcasing examples of process design in complete plants.

This comprehensive reference bridges the gap between industry and academia, while exploring best practices in design, including relevant theories in process design making this a valuable primer for fresh graduates and professionals working on design projects in the industry.

Table of Contents:

• I – Introduction to process design
• 1 – General aspects of process design
• 1.1 Process
• 1.2 Design problem and its documentation
• 1.3 The design process
• Qualitative considerations can be
• Quantitative considerations
• Optimum design
• Design steps
• 1.3.1 Deliverables
• 1.4 Organisation of the Book
• Further reading
• II – Heat transfer processes
• 2 – Heat transfer processes in industrial scale
• 2.1 Introduction
• 2.2 Exchanger types
• 2.2.1 Recuperator
• 2.2.2 Regenerator
• 2.2.3 Fluidised bed exchanger
• 2.2.4 Direct contact heat exchanger
• 2.3 Flow arrangement
• 2.3.1 Countercurrent flow exchanger
• 2.3.2 Co-current flow/parallel flow exchanger
• 2.3.3 Cross-flow exchanger
• 2.3.4 Split flow exchanger
• 2.3.5 Divided flow exchanger
• 2.3.6 Multipass exchanger
• 2.4 Exchanger selection
• 2.5 Heat exchanger design methodology
• Process and design specifications
• 2.6 Design overview for recuperators
• 2.6.1 Thermal design
• The effectiveness-NTU method
• 2.7 Estimation of overall design heat transfer coefficient
• Further reading
• 3 – Double pipe heat exchanger
• 3.1 Introduction
• 3.2 Design
• 3.2.1 Input data
• 3.2.2 Deliverables
• 3.2.3 Codes and standards
• 3.2.4 Guidelines to select inner and outer fluid
• 3.2.5 Design considerations
• 3.2.6 Thermal design
• 3.2.7 Hydraulic design
• 3.3 Series-parallel configuration of hairpins
• 3.4 Design illustration
• 3.4.1 Design steps
• 3.4.2 Design example
• References
• Further reading
• 4 – Shell and tube heat exchanger
• 4.1 Introduction
• 4.1.1 General description
• Shell
• Exchanger Head(s)
• Tubes
• Tube sheet
• Baffle
• Tie rods and spacers
• Impingement baffle
• Multipass exchanger
• Shell passes
• 4.1.2 Heat exchanger installations and commissioning
• 4.2 Codes and standards
• 4.3 Design considerations
• Process
• Mechanical
• 4.3.1 Input data for design
• 4.3.2 Design output
• Process design
• Mechanical details
• Fabrication details
• 4.4 Design – FT method
• 4.5 Pressure drop estimation
• 4.6 Mechanical detailing
• 4.6.1 Exchanger material
• 4.6.2 Tube length
• 4.6.3 Tube sheet details
• 4.6.4 Tube pass pattern
• 4.6.5 Finned tubes
• 4.6.6 Segmental baffles (transverse baffles in BIS code)
• 4.6.7 Tie rods
• 4.6.8 Impingement baffle
• 4.6.9 Shell dimensions
• 4.6.10 Channel and channel cover
• 4.6.11 Nozzles
• 4.6.12 Exchanger support
• 4.7 Design illustration
• Further reading
• 5 – Heat exchanger network analysis
• 5.1 Introduction
• 5.2 Energy-capital trade-off – two-stream problem
• 5.3 Multi-stream problem
• 5.3.1 Optimal ΔTmin
• 5.3.2 Practical values of ΔTmin
• 5.4 Pinch design analysis
• 5.4.1 Locating the pinch using the problem table algorithm
• 5.4.2 The pinch principle
• 5.4.3 Design strategy
• 5.4.4 Grid diagram
• Tick off heuristic
• 5.4.5 Stream splitting in network design
• 5.4.6 Network simplification: heat load loops and heat load paths
• 5.5 Targeting for multiple utilities
• 5.6 Design algorithm
• 5.7 Threshold problems
• 5.8 Data extraction
• 5.8.1 Composite curve for non-linear CP
• 5.8.2 Avoid mixing of streams at different temperatures
• 5.8.3 Use effective temperatures
• 5.8.4 True utility streams
• 5.9 Applications
• 5.10 Design illustration
• Composite curves
• Problem table algorithm
• Further reading
• 6 – Evaporators
• 6.1 Introduction
• 6.2 Components of an evaporation system
• 6.3 Evaporator types
• 6.3.1 Types of continuous evaporators
• Evaporators without heating surfaces
• 6.4 Evaporator performance
• 6.4.1 Multiple-effect evaporators
• Feeding arrangements
• Use of vapor as a “hot stream” in the plant
• 6.4.2 Vapor recompression
• 6.4.3 Heat recovery systems
• 6.4.4 Evaporator selection
• 6.5 Evaporator accessories
• 6.5.1 Condensers
• 6.5.2 Vent systems
• Salt removal
• 6.6 Evaporator design
• 6.6.1 Single-effect evaporation
• 6.6.2 Multiple effect evaporation
• Optimum number of effects in a multiple-effect system
• 6.6.3 Design data
• Elevation of boiling point (BPE)
• Boiling point elevation in multiple effect evaporators
• Enthalpy plots
• Tsteam & Tcon
• Steam pressure
• Pressure in the vapor space
• Influence of feed, steam and condensate temperature
• 6.6.4 Design algorithm for multiple-effect evaporator
• Design input
• Design objective
• Design deliverables
• Design algorithm
• 6.7 Design illustration
• Design example 1
• Process design deliverables
• Design example 2
• Deliverables
• Further reading
• 7 – Industrial cooling systems
• 7.1 Introduction
• 7.2 Cooling tower
• 7.2.1 Classification
• Classification by build
• Classification based on air draft
• Classification based on airflow pattern
• Classification based on the heat transfer method
• 7.2.2 Components of a typical cooling tower
• 7.2.3 Cooling tower parameters
• 7.2.4 Cooling water circuit in a process plant
• 7.2.5 Codes and standards
• 7.2.6 Thermal design
• 7.2.7 Notes on design and operation
• 7.3 Design illustration
• Summary of available data
• Tower selection
• Fill details
• Determination of operating L/G for the fill chosen
• Steps of calculation
• Fan power calculation
• Estimating head loss in the fill and water distributor level
• Estimating make up water (M) requirement
• Evaporation loss (E)
• Drift loss (D)
• Pump calculations
• Cooling tower sump
• Further reading
• III – Mass transfer processes
• 8 – Interphase mass transfer
• 8.1 Introduction
• 8.2 Processes and equipment
• 8.3 Process design and detailed design of the equipment
• 9 – Phase equilibria
• 9.1 Introduction
• 9.2 Representation of concentration
• 9.3 Representation of equilibrium
• 9.3.1 Graphical representation of equilibrium
• 9.3.2 Mathematical representation of equilibrium
• VLE: Distillation
• Solubility: absorption and stripping
• GSE and LSE: adsorption
• LLE: extraction
• Further reading
• 10 – Absorption and stripping
• 10.1 Introduction
• 10.2 Tray column
• 10.2.1 Graphical determination of the number of contacting stages
• Minimum required liquid flow rate (Lmin) in case of absorber for a given gas rate (G,G′)
• Approximations for low concentration system
• 10.2.2 Absorption factor
• 10.3 Packed column
• 10.3.1 Packed column design based on mass transfer coefficient
• 10.3.2 Driving force line
• 10.3.3 Overall mass transfer coefficient
• 10.3.4 Estimation of active bed height
• 10.3.5 Design based on liquid-phase resistance
• 10.3.6 Absorption accompanied by chemical reaction
• 10.4 Design illustration
• Driving force lines
• Estimating mass transfer coefficients
• Further reading
• 11 – Distillation
• 11.1 Introduction
• 11.2 Conceptual design
• 11.3 Detailed design
• 11.4 Fractionator
• 11.4.1 Process design of fractionating tower – equilibrium stage approach
• 11.4.2 Binary fractionation
• 11.4.3 Multicomponent distillation
• 11.5 Design illustration – fractionator
• 11.6 Flash distillation
• 11.6.1 Design equations
• 11.6.2 Design considerations
• 11.6.3 Design steps
• 11.7 Design illustration – flash distillation
• 11.8 Batch distillation
• 11.8.1 Design
• 11.8.2 Design deliverables
• 11.8.3 Design steps
• 11.9 Design illustration – batch distillation
• Further reading
• 12 – Adsorption
• 12.1 Introduction
• 12.1.1 Modes of operation
• Stagewise operation
• Continuous contact operation
• 12.1.2 Adsorption mechanisms
• 12.1.3 Adsorption equilibrium
• 12.2 Packed bed adsorption
• 12.2.1 Breakthrough curve, breakthrough point, and bed exhaustion
• 12.2.2 Desorption/regeneration
• Gas-phase adsorption
• Liquid-phase adsorption
• 12.2.3 Adsorbent aging
• 12.2.4 Bed design
• Rigorous methods
• Empirical or short-cut methods
• Pilot plant design
• Data/information required for design
• Operating parameters from pilot tests
• (a) Loading rate/filtration rate (LR) for liquid-phase applications
• (b) Superficial velocity (Us) for gas-phase applications
• (c) Empty bed contact time
• (d) Breakthrough time (tb)
• (e) Fraction of bed utilised (f)
• (f) Adsorbate loading (qs)
• Bed design
• Volume of fluid treated/change out period
• Pressure drop
• Bed configuration and mode of operation
• 12.3 Design illustration
• Further reading
• 13 – Extraction
• 13.1 Introduction
• 13.2 Extractor types and selection
• 13.2.1 Extractor types
• Stagewise contact
• Continuous contact
• 13.2.2 Contactor selection
• 13.3 Choice of solvent
• 13.4 Design of continuous countercurrent contactors
• Flooding
• 13.4.1 Calculation of the number of stages
• 13.4.2 Design parameters for extraction towers
• 13.5 Design of mixer-settler
• 13.5.1 Holding time
• 13.5.2 Power and mixing time
• 13.5.3 Scale-up
• 13.5.4 Flow mixers
• 13.6 Design illustrations
• Further reading
• 14 – Column and column internals for gas–liquid and vapour–liquid contacting
• 14.1 Introduction
• 14.2 Tray towers
• 14.2.1 Contacting trays
• Downcomer
• Outlet weir
• Liquid bypass baffles
• Bottom tray seal pan
• Weep holes
• Vapour disperser elements
• 14.2.2 Choice of tray type
• 14.2.3 Tray construction
• 14.2.4 Efficient operation of contacting tray
• 14.3 Tray design
• 14.3.1 Bubble cap tray design
• Tower diameter
• Check for entrainment
• Tray passes
• Outlet weir
• Height over weir
• Downcomer area
• Cap size
• Number of caps
• Area fractions over tray
• Liquid gradient across tray
• Tray pressure drop (htray, mm of liquid)
• Check for vapour distribution
• Vapour velocity and corrected ‘approach to flooding’
• Downcomer pressure drop (hdc,prdrop, mm of liquid)
• Downcomer backup (hL,dc, mm of liquid, for all cross-flow trays)
• Velocity and residence time in downcomer
• Downcomer throw over the weir
• System (foaming) factors (applicable for all cross-flow trays)
• Weep holes
• 14.3.2 Sieve tray design (cross-flow type – with downcomer)
• Steps of design
• 14.3.3 Valve tray design
• 14.4 Packed tower
• 14.4.1 Choice of packing
• Packing types and size
• 14.4.2 Liquid distribution
• Liquid distributor
• Redistributor and collector
• 14.4.3 Bed support
• 14.4.4 Flooding and pressure drop in randomly packed bed
• Bed diameter estimation based on flooding and pressure drop
• Pressure gradient
• Minimum wetting rate
• 14.5 Packed tower design
• 14.6 Chimney tray, reflux entry, feed tray and tower bottom
• 14.6.1 Chimney tray
• 14.6.2 Reflux entry arrangement on top tray
• 14.6.3 Feed tray
• 14.6.4 Tower bottom arrangement
• 14.7 Design illustration
• Further reading
• IV – Reacting systems
• 15 – Reactors and reactor design
• 15.1 Introduction
• 15.2 Design of reacting system
• 15.2.1 Reactor types
• 15.2.2 Rate and extent of reaction
• Rate-limiting step
• 15.3 Reactor design
• 15.3.1 Reaction/process conditions
• 15.3.2 Design deliverables
• Performance equation for idealized reactors
• 15.3.3 Scale-up
• 15.3.4 Bioreactors
• Sterilization
• 15.4 Design illustration
• Further reading
• V – Plant hydraulics and process vessels
• 16 – Plant hydraulics
• 16.1 Introduction
• 16.2 Pumps
• 16.2.1 Common pump types
• Centrifugal Pump
• Positive displacement pumps
• Reciprocating pumps
• Rotary pumps
• Diaphragm pump
• 16.2.2 Pump performance and hydraulics
• 16.2.3 Cavitation
• NPSH in centrifugal pump
• Liquid vapour pressure
• NPSH in reciprocating pumps
• 16.2.4 Characteristic curve for centrifugal pumps
• Q-H curve
• Pumps in series and parallel
• Q-SHP (or BHP) Curve
• Q-NPSHRCurve
• 16.2.5 System characteristic curve
• 16.2.6 Adjusting centrifugal pump performance
• 16.2.7 Characteristic curves for positive displacement pumps
• 16.2.8 Pump selection
• 16.2.9 Steps of design for a hydraulic circuit
• 16.3 Compressors
• 16.3.1 Compressor selection
• 16.3.2 Centrifugal compressor
• Characteristic curve
• 16.3.3 Compressor hydraulics
• Capacity and pressure ratio
• Power
• Head developed
• 16.3.4 Design/sizing
• 16.3.5 Capacity control
• 16.4 Piping
• 16.4.1 Piping codes
• 16.4.2 Pipe size
• 16.4.3 Piping services
• 16.4.4 Pipe rack
• 16.4.5 Pipe joints
• 16.4.6 Pipe fittings
• Pressure relief–safety devices
• Other fittings
• 16.4.7 Pressure drop in pipeline
• 16.4.8 Few typical process piping systems
• Purge out operation
• Vent and drain system
• Flushing connections
• Control valve installation
• Steam trap
• Good practices for piping layout
• 16.5 Hydraulic calculations
• Further reading
• 17 – Process vessels
• 17.1 Unfired pressure vessels
• 17.2 Vessel components and fixtures
• 17.3 Mechanical design
• 17.3.1 Design Parameters
• 17.3.2 Vessel sizing
• Vapour-liquid separator
• Separator with wire mesh mist eliminator (demister pad)
• Reflux drum
• Liquid-liquid separator
• 17.3.3 Nozzle dimensions and location
• 17.3.4 Manhole specifications
• 17.3.5 Wall thickness
• 17.4 Design illustrations
• Further reading
• VI – Plant auxiliaries
• 18 – Utility services in process plants
• 18.1 Introduction
• 18.2 Fuel systems
• 18.2.1 Fuel gas
• 18.2.2 Fuel oil
• 18.2.3 Design of fuel system
• 18.3 Electrical power
• 18.4 Steam
• 18.5 Compressed air
• 18.5.1 Air supply scheme
• 18.5.2 Design illustration – compressed air system
• 18.6 Inert gases
• 18.7 Water
• 18.8 Efficient use of utilities
• Further reading
• 19 – Plant instrumentation and control
• 19.1 Introduction
• 19.2 Control loop
• 19.2.1 Feeback and feedforward
• Selection–feedback versus feedforward
• 19.2.2 Characteristic features of a process being controlled
• 19.3 Analog signals–pneumatic and electronic
• 19.4 Control algorithms
• 19.4.1 P, PI and PID controllers
• Choice of P, PI, or PID controller
• 19.4.2 Few advanced configurations of controllers
• Cascade control
• Split range control
• 19.5 Measurement of process parameters
• 19.5.1 Temperature measurement
• Thermocouple versus RTD
• 19.5.2 Pressure measurement
• Measurement of differential pressure
• 19.5.3 Flow measurement
• 19.5.4 Level measurement
• 19.6 Control valves
• 19.6.1 Fail-open and fail-close valves
• 19.6.2 Valve size
• 19.7 Instrumentation for safety
• 19.8 Distributed control system (DCS)
• 19.9 Control schemes for common processes
• 19.9.1 Distillation control and instrumentation
• 19.9.2 CSTR instrumentation and control
• Further reading
• 20 – Engineered safety
• 20.1 Introduction
• 20.2 Hazardous area classification
• 20.3 Trips and alarms
• 20.4 Blowdown and flare
• 20.4.1 Blowdown
• 20.4.2 Safety and pressure relief valves
• 20.4.3 Flare system
• 20.5 HAZOP
• 21 – Process packages
• 21.1 Process package deliverables
• 21.2 Examples
• 21.2.1 Design illustration 1
• Design of 10,000 MT/Annum plant to manufacture Ethyl acetate from Ethanol
• 21.2.2 Design illustration 2
• Design of a facility for a refinery to treat 8000m3/d of wastewater
• Further reading

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