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| موضوع: كتاب Product and Process Design Principles السبت 15 مايو 2021, 2:15 am | |
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أخوانى فى الله أحضرت لكم كتاب Product and Process Design Principles Synthesis, Analysis, and Evaluation Second Edition Warren D. Seider Department of Chemical and Biomolecular Engineering University of Pennsylvania J. D. Seader Department of Chemical and Fuels Engineering University of Utah Daniel R. Lewin Department of Chemical Engineering
و المحتوى كما يلي :
Contents 2.1 Introduction 43 Pharmaceutical Product Design 44 2.2 Property Estimation Methods 45 Computer Data Banks 45 Property Estimation 46 Polymer Property Estimation 47 Microsimulation 48 2.3 Optimization to Locate Molecular Structure 49 Polymer Design 50 Refrigerant Design 52 Solvent Design 56 Solutes for Hand Warmers 60 2.4 Summary 60 References 60 Exercises 61 Part One PRODUCT AND PROCESS INVENTIONHEURISTICS AND ANALYSIS 1. The Design Process 3 1.0 Objectives 3 1.1 Design Opportunities 3 Design Team 5 1.2 Steps in Product and Process Design 5 Create and Assess Primitive Problem 8 Find Chemicals or Chemical Mixtures Having Desired Properties and Performance 15 Process Creation 16 Development of Base Case Process 16 Detailed Process Synthesis Using Algorithmic Methods 18 Plantwide Controllability Assessment 18 Detailed Design, Equipment Sizing, and Optimization—Configured Product Design 19 Written Design Report and Oral Presentation 20 Plant Design, Construction, Startup, and Operation 20 Summary 21 1.3 Environmental Protection 21 Environmental Issues 21 Environmental Factors in Process Design 23 Environmental Design Problems 26 1.4 Safety Considerations 27 Safety Issues 28 Design Approaches Toward Safe Chemical Plants 30 1.5 Engineering Ethics 31 1.6 Role of Computers 37 Spreadsheets 39 Mathematical Packages 39 Process Simulators 39 Computational Guidelines 40 1.7 Summary 40 References 41 3. Process Creation 62 3.0 Objectives 62 3.1 Introduction 62 3.2 Preliminary Database Creation 62 Thermophysical Property Data 63 Environmental and Safety Data 67 Chemical Prices 67 Summary 68 3.3 Experiments 68 3.4 Preliminary Process Synthesis 68 Chemical State 69 Process Operations 70 Synthesis Steps 72 Continuous or Batch Processing 73 Example of Process Synthesis: Manufacture of Vinyl Chloride 73 Synthesis Tree 84 Heuristics 85 Example of Process Synthesis: Manufacture of Tissue Plasminogen Activator (tPA) 85 Synthesis Tree 95 Algorithmic Methods 96 3.5 Development of the Base-Case Design 96 Flow Diagrams 96 Process Integration 102 Detailed Database 102 Pilot-Plant Testing 103 Process Simulation 104 3.6 Summary 104 References 104 Exercises 105 2. Molecular Structure Design 42 2.0 Objectives 42 XllContents xiii 4. Simulation to Assist in Process Creation 106 4.0 Objectives 106 4.1 Introduction 107 4.2 Principles of Steady-State Flowsheet Simulation 108 Process and Simulation Flowsheets 108 Unit Subroutines 119 Calculation Order 123 Recycle 125 Recycle Convergence Methods 133 Flash with Recycle Problem 135 Flash Vessel Control 136 Equation-Oriented Architectures 136 4.3 Synthesis of the Toluene Hydrodealkylation Process 136 Process Simulation 140 4.4 Steady-State Simulation of the Monochlorobenzene Separation Process 142 Use of Process Simulators 144 4.5 Principles of Batch Flowsheet Simulation 145 Process and Simulation Flowsheets 145 Equipment Models 145 4.6 Summary 154 References 154 Exercises 155 5.8 Changing the Particle Size of Solids and Size Separation of Particles 191 5.9 Removal of Particles from Gases and Liquids 193 5.10 Summary 193 References 198 Exercises 198 Part Two DETAILED PROCESS SYNTHESISALGORITHMIC METHODS 6. Reactor Design and Reactor Network Synthesis 205 6.0 Objectives 205 6.1 Reactor Models 205 Reaction Stoichiometry 206 Extent of Reaction 206 Equilibrium 207 Kinetics 210 Ideal Kinetic Reaction Models—CSTRs and PFRs 211 6.2 Reactor Design for Complex Configurations 214 6.3 Reactor Network Design Using the Attainable Region 220 Construction of the Attainable Region 222 The Principle of Reaction Invariants 226 6.4 Summary 229 References 229 Exercises 230 5. Heuristics for Process Synthesis 161 5.0 Objectives 161 5.1 Introduction 162 5.2 Raw Materials and Chemical Reactions 163 5.3 Distribution of Chemicals 165 Inert Species 166 Purge Streams 168 Recycle to Extinction 171 Selectivity 172 Reactive Separations 173 Optimal Conversion 175 5.4 Separations 175 Separations Involving Liquid and Vapor Mixtures 175 Separations Involving Solid Particles 177 5.5 Heat Removal from and Addition to Reactors 179 Heat Removal from Exothermic Reactors 179 Heat Addition to Endothermic Reactors 182 5.6 Heat Exchangers and Furnaces 183 5.7 Pumping, Compression, Pressure Reduction, Vacuum, and Conveying of Solids 185 Increasing the Pressure 186 Decreasing the Pressure 188 Pumping a Liquid or Compressing a Gas 189 Vacuum 190 Conveying Granular Solids 190 Changing the Pressure of Granular Solids 191 7. Synthesis of Separation Trains 231 7.0 Objectives 231 7.1 Introduction 231 Feed Separation System 232 Phase Separation of Reactor Effluent 232 Industrial Separation Operations 238 7.2 Criteria for Selection of Separation Methods 241 Phase Condition of the Feed as a Criterion 242 Separation Factor as a Criterion 242 Reason for the Separation as a Criterion 246 7.3 Selection of Equipment 246 Absorption, Stripping, and Distillation 246 Liquid-Liquid Extraction 247 Membrane Separation 247 Adsorption 247 Leaching 247 Crystallization 247 Drying 248 7.4 Sequencing of Ordinary Distillation Columns for the Separation of Nearly Ideal Fluid Mixtures 248 Column Pressure and Type of Condenser 248 Number of Sequences of Ordinary Distillation Columns 249xiv Contents Heuristics for Determining Favorable Sequences 251 Marginal Vapor Rate Method 253 Complex and Thermally Coupled Distillation Columns 255 7.5 Sequencing of Operations for the Separation of Nonideal Fluid Mixtures 258 Azeotropy 259 Residue Curves 263 Simple Distillation Boundaries 266 Distillation Towers 266 Distillation Lines 267 Computing Azeotropes for Multicomponent Mixtures 269 Distillation-Line Boundaries and Feasible Product Compositions 269 Heterogeneous Distillation 271 Multiple Steady States 275 Pressure-Swing Distillation 277 Membranes, Adsorbers, and Auxiliary Separators 279 Reactive Distillation 279 Separation Train Synthesis 282 7.6 Separation Systems for Gas Mixtures 288 Membrane Separation by Gas Permeation 289 Adsorption 290 Absorption 291 Partial Condensation and Cryogenic Distillation 291 7.7 Separation Sequencing for Solid-Fluid Systems 291 7.8 Summary 294 References 294 Exercises 295 9.3 Energy Transfer CD-9-7 9.4 Thermodynamic Properties CD-9-9 Typical Entropy Changes CD-9-11 Thermodynamic Availability CD-9-13 Typical Availability Changes CD-9-15 9.5 Equations for Second-Law Analysis CD-9-20 9.6 Examples of Lost-Work Calculations CD-9-25 9.7 Thermodynamic Efficiency CD-9-30 9.8 Causes of Lost Work CD-9-33 9.9 Three Examples of Second-Law Analysis CD-9-34 9.10 Summary CD-9-52 References CD-9-52 Exercises CD-9-53 10. Heat and Power Integration 302 10.0 Objectives 302 10.1 Introduction 303 10.2 Minimum Utility Targets 306 Temperature-Interval (TI) Method 307 Composite Curve Method 310 Linear Programming Method 312 10.3 Networks for Maximum Energy Recovery 316 Stream Matching at the Pinch 316 Mixed-Integer Linear Programming 320 10.4 Minimum Number of Heat Exchangers 326 Reducing the Number of Heat Exchangers— Breaking Heat Loops 326 Reducing the Number of Heat Exchangers— Stream Splitting 330 10.5 Threshold Approach Temperature 333 10.6 Optimum Approach Temperature 335 10.7 Superstructures for Minimization of Annual Costs 338 8. Reactor-Separator-Recycle Networks (CD-ROM) 300, CD-8-1 8.0 Objectives 300, CD-8-1 8.1 Introduction CD-8-2 8.2 Locating the Separation Section with Respect to the Reactor Section CD-8-3 8.3 Tradeoffs in Processes Involving Recycle CD-8-11 8.4 Optimal Reactor Conversion CD-8-13 8.5 Recycle to Extinction CD-8-17 8.6 Snowball Effects in the Control of Processes Involving Recycle CD-8-23 8.7 Summary CD-8-23 References CD-8-24 Exercises CD-8-24 10.8 Multiple Utilities 341 Designing HENs Assisted by the Grand Composite Curve 342 10.9 Heat-Integrated Distillation Trains 346 Impact of Operating Pressure 346 Multiple-Effect Distillation 349 Heat Pumping, Vapor Recompression, and Reboiler Flashing 350 10.10 Heat Engines and Heat Pumps 352 Positioning Heat Engines and Heat Pumps 355 Optimal Design 357 10.11 Summary 360 Heat Integration Software 361 References 361 Exercises 361 9. Second-Law Analysis (CD-ROM) 301 9.0 Objectives 301, CD-9-1 9.1 Introduction CD-9-3 9.2 The System and the Surroundings CD-9-5 11. Mass Integration 367 11.0 Objectives 367 11.1 Introduction 367Contents xv 11.2 Minimum Mass-Separating Agent 369 Approach to Phase Equilibrium 370 Concentration-Interval (Cl ) Method 370 Composite-Curve Method 374 11.3 Mass Exchange Networks for Minimum External MSA 377 Stream Matching at the Pinch 377 Stream Splitting at the Pinch 378 11.4 Minimum Number of Mass Exchangers 380 Reducing the Number of Mass Exchangers— Breaking Mass Loops 380 11.5 Advanced Topics 381 11.6 Summary 381 References 382 Exercises 382 12. Optimal Design and Scheduling of Batch Processes 384 12.0 Objectives 384 12.1 Introduction 384 12.2 Design of Batch Process Units 386 Batch Processing 386 Fed-Batch Processing 387 Batch-Product Removal 389 12.3 Design of Reactor-Separator Processes 391 12.4 Design of Single Product Processing Sequences 395 Batch Cycle Times 395 Intermediate Storage 398 Batch Size 398 12.5 Design of Multiproduct Processing Sequences 399 Scheduling and Designing Multiproduct Plants 399 12.6 Summary 401 References 401 Exercises 401 Furnaces 424 Temperature-Driving Forces in Shell-and-Tube Heat Exchangers 424 13.3 Heat Transfer Coefficients and Pressure Drop 428 Estimation of Overall Heat Transfer Coefficients 430 Estimation of Individual Heat Transfer Coefficients and Frictional Pressure Drop 430 Turbulent Flow in Straight, Smooth Ducts, Pipes, and Tubes of Circular Cross Section 432 Turbulent Flow in the Annular Region between Straight, Smooth, Concentric Pipes of Circular Cross Section 433 Turbulent Flow on the Shell Side of Shell-andTube Heat Exchangers 434 Heat Transfer Coefficients for Laminar-Flow, Condensation, Boiling, and Compact Heat Exchangers 436 13.4 Design of Shell-and-Tube Heat Exchangers 436 13.5 Summary 439 References 441 Exercises 441 14. Separation Tower Design 443 14.0 Objectives 443 14.1 Operating Conditions 443 14.2 Fenske-Underwood-Gilliland (FUG) Shortcut Method for Ordinary Distillation 445 14.3 Kemser Shortcut Method for Absorption and Stripping 446 14.4 Rigorous Multicomponent, Multi-EquilibriumStage Methods with a Simulator 449 14.5 Plate Efficiency and HETP 451 14.6 Tower Diameter 453 Tray Towers 453 Packed Towers 454 14.7 Pressure Drop and Weeping 455 14.8 Summary 458 References 458 Exercises 459 Part Three DETAILED DESIGN, EQUIPMENT SIZING, AND OPTIMIZATION—CONFIGURED PRODUCT DESIGN 15. Pumps, Compressors, and Expanders 460 15.0 Objectives 460 13. Heat Exchanger Design 405 15.1 Pumps 460 13.0 Objectives 405 13.1 Introduction 405 Heat Duty 406 Heat Transfer Media 407 Temperature-Driving Force for Heat Transfer 410 Pressure Drop 413 13.2 Equipment for Heat Exchange 414 Double-Pipe Heat Exchangers 414 Shell-and-Tube Heat Exchangers 415 Air-Cooled Heat Exchangers 421 Compact Heat Exchangers 422 Centrifugal Pumps 461 Positive-Displacement Pumps 464 Pump Models in Simulators 466 15.2 Compressors and Expanders 467 Centrifugal Compressors 467 Positive-Displacement Compressors 468 Expanders 469 Compressor and Expander Models in Simulators 470 15.3 Summary 471 References 471 Exercises 471xvi Contents 16. Cost Accounting and Capital Cost Estimation 472 16.0 Objectives 472 16.1 Accounting 473 Debits and Credits 473 The Annual Report 474 The Balance Sheet 474 The Income Statement 477 The Cash Flow Statement 478 Financial Ratio Analysis 479 Cost Accounting 481 16.2 Cost Indexes and Capital Investment for Commodity Chemicals 483 Cost Indexes 483 Commodity Chemicals 485 Economy of Scale and the Six-Tenths Factor 486 Typical Plant Capacities and Capital Investments for Commodity Chemicals 487 16.3 Capital Investment Costs 488 Direct Materials and Labor (M&L) 490 Indirect Costs 491 Other Investment Costs 493 Example of an Estimate of Capital Investment 496 16.4 Estimation of the Total Capital Investment 497 Method 1. Order-of-Magnitude Estimate (Based on the Method of Hill, 1956) 498 Method 2. Study Estimate (Based on the Overall Factor Method of Lang, 1947a,b, 1948) 500 Method 3. Preliminary Estimate (Based on the Individual Factors Method of Guthrie, 1969, 1974) 503 16.5 Purchase Costs of the Most Widely Used Process Equipment 505 Pumps and Electric Motors 506 Pump and Motor Purchase Costs 508 Fans, Blowers, and Compressors 514 Heat Exchangers 522 Fired Heaters 525 Pressure Vessels and Towers for Distillation, Absorption, and Stripping 527 16.6 Purchase Costs of Other Chemical Processing Equipment 536 Adsorption Equipment 536 Agitators (Propellers and Turbines) 537 Autoclaves 537 Crystallizers 538 Drivers Other than Electric Motors 538 Dryers 538 Dust Collectors 539 Evaporators 540 Fired Heaters for Specific Purposes 540 Liquid-Liquid Extractors 541 Membrane Separations 542 Mixers for Powders, Pastes, and Doughs 542 Power Recovery 542 Screens 542 Size Enlargement 543 Size Reduction Equipment 543 Solid-Liquid Separation Equipment (Thickeners, Clarifiers, Filters, Centrifuges, and Expression) 544 Solids Handling Systems 547 Storage Tanks and Vessels 549 Vacuum Systems 550 Wastewater Treatment 557 16.7 Equipment Cost Estimation Using the Aspen Icarus Process Evaluator (IPE) (CD-ROM) 557, CD-16.7-1 16.8 Summary 557 References 558 Exercises 558 17. Annual Costs, Earnings, and Profitability Analysis 563 17.0 Objectives 563 17.1 Introduction 564 17.2 Annual Sales Revenues, Production Costs, and the Cost Sheet 565 Sales Revenue 565 Feedstocks 565 Utilities 567 Labor-Related Operations, O 574 Maintenance, M 575 Operating Overhead 576 Property Taxes and Insurance 576 Depreciation, D 577 Cost of Manufacture, COM 577 Total Production Cost, C 577 Pretax (Gross) Earnings and After-Tax (Net) Earnings (Profit) 579 17.3 Working Capital and Total Capital Investment 580 17.4 Approximate Profitability Measures 581 Return on Investment (ROI) 581 Payback Period (PBP) 582 Venture Profit (VP) 583 Annualized Cost (CA) 584 Product Selling Price for Profitability 585 17.5 Time Value of Money 585 Compound Interest 586 Nominal and Effective Interest Rates 588 Continuous Compounding of Interest 589 Annuities 590 Present Worth of an Annuity 594 Comparing Alternative Equipment Purchases 595Contents xvii 19.4 Hand Warmer 659 GRABBER MYCOAL Hand Warmer 660 Zap Pak Heat Pack 660 19.5 Multilayer Polymer Mirrors 662 19.6 CVD of Polysilicon in IC Manufacture 663 Initial Dissociation 663 19.7 Germ-Killing Surfaces 667 19.8 Insect Repelling Wristband 667 19.9 Automotive Fuel Cell 668 19.10 Environmentally Safe Refrigerants 671 19.11 Summary 672 References 673 17.6 Cash Flow and Depreciation 597 Depreciation 598 Depletion 604 17.7 Rigorous Profitability Measures 606 Net Present Value (NPV) 606 Investor’s Rate of Return (IRR or DCFRR) 607 Inflation 609 17.8 Profitability Analysis Spreadsheet (CD-ROM) 611, CD-17.8-1 General Instructions For Use of Profitability Analysis- l .O.xls, CD-17.8-1 17.9 Summary 611 References 611 Exercises 611 Exercises 674 18. Optimization of Process Flowsheets 616 18.0 Objectives 616 18.1 Introduction 616 18.2 General Formulation of the Optimization Problem 617 Objective Function and Decision Variables 618 Equality Constraints 618 Inequality Constraints 619 Lower and Upper Bounds 619 18.3 Classification of Optimization Problems 619 18.4 Linear Programming (LP) 623 18.5 Nonlinear Programming (NLP) with a Single Variable 626 Golden-Section Search 626 18.6 Conditions for Nonlinear Programming (NLP) by Gradient Methods with Two or More Decision Variables 630 General Formulation 630 Stationary Conditions 631 Solution of the Stationary Equations 631 18.7 Optimization Algorithm 632 Repeated Simulation 634 Infeasible Path Approach 634 Compromise Approach 635 Practical Aspects of Flowsheet Optimization 635 18.8 Flowsheet Optimization—Case Studies 636 18.9 Summary 640 References 640 Part Four PLANTWIDE CONTROLLABILITY ASSESSMENT 20. The Interaction of Process Design and Process Control 679 20.0 Objectives 679 20.1 Introduction 679 20.2 Control System Configuration 684 Classification of Process Variables 684 Selection of Controlled (Output) Variables 685 Selection of Manipulated Variables 685 Selection of Measured Variables 685 Degree-of-Freedom Analysis 686 20.3 Qualitative Plantwide Control System Synthesis 692 20.4 Summary 702 References 702 Exercises 702 21. Flowsheet Controllability Analysis 705 21.0 Objectives 705 21.1 Generation of Linear Models in Standard Forms 706 21.2 Quantitative Measures for Controllability and Resiliency 710 Steady-State RGA (Bristol, 1966) 710 Properties of the Steady-State RGA 712 Dynamic RGA (McAvoy, 1983) 712 The RGA as a Measure of Process Sensitivity to Uncertainty 718 Using the Disturbance Cost to Assess Resiliency to Disturbances 719 21.3 Toward Automated Flowsheet C&R Diagnosis 723 Shortcut C&R Diagnosis 723 Generating Low-Order Dynamic Models 724 Steady-State Gain Matrix, t? 724 Dynamics Matrix, vjjc{5 } 724 Exercises 640 19. Product Design 644 19.0 Objectives 644 19.1 Steps in Designing Industrial and Consumer Products 644 Six Sigma in Product Design and Manufacturing 646 19.2 Hemodialysis Device 650 19.3 Solar Desalination Unit 656xviii Contents 21.4 Controller Loop Definition and Tuning 732 Definition of PID Control Loop 732 Controller Tuning 733 Model-Based Pi-Controller Tuning 734 21.5 Case Studies 736 Written Handout 776 Evaluation of the Oral Presentation 776 Videotapes and DVDs 778 22.3 Award Competition 778 22.4 Summary 779 Case Study 21.1 Exothermic Reactor Design References 779 for the Production of Propylene Glycol (Example 21.1 Revisited) 736 Case Study 21.2 Two Alternative Heat-Exchanger Networks (Examples 20.1 and 20.5 Revisited) 741 Case Study 21.3 Interaction of Design and Control in the MCB Separation Process 747 21.6 MATLAB for C&R Analysis 755 21.7 Summary 757 References 759 APPENDIXES I. Residue Curves for Heterogeneous Systems 781 II. Design Problem Statements (CD-ROM) 782, CD-A-II-1 Exercises 759 A-II.O A-II.l A-II.2 A-H.3 A-H.4 A-H.5 A-II.6 Polymers CD-A-II-41 A-II.7 Environmental-Air Quality CD-A-II-48 A-II.8 Environmental-Water Treatment CD-A-II-63 A-II.9 Environmental-Soil Treatment CD-A-II-67 A-II.10 Environmental-Miscellaneous CD-A-II-71 Contents and Introduction CD-A-II-1 Petrochemicals CD-A-II-6 Petroleum Products CD-A-II-26 Gas Manufacture CD-A-II-27 Foods CD-A-II-35 Pharmaceuticals CD-A-II-38 Part Five DESIGN REPORT 22. Written Reports and Oral Presentations 765 22.0 Objectives 765 22.1 Contents of the Written Report 766 Opening Sections of the Report 766 Remaining Sections of the Process Design Report 767 Remaining Sections of the Product Design Report 767 Preparation of the Written Report 772 Sample Design Reports 775 22.2 Oral Design Presentation 776 Typical Presentation 776 Media for the Presentation 776 Rehearsing the Presentation 776 III. Materials of Construction 785 NAME INDEX 787 SUBJECT INDEX 791 CONTENTS INTRODUCTION 1 PREPARING AN ASPEN PLUS SIMULATION FOR ASPEN IPE 2 Additional Mixture Properties 3 INVESTMENT ANALYSIS USING ASPEN IPE 3 DEPROPANIZER 3 Initial Setup 3 Mapping Process Simulation Units into Aspen IPE 8 Standard Basis 17 Equipment Costing 19 Total Permanent Investment 25 Adding Equipment 25 Applying Alternative Utilities 34 MONOCHLOROBENZENE SEPARATION PROCESS 37 Initial Setup 37 Mapping Process Simulation Units to Aspen IPE 39 Standard Basis 45 Equipment Costing 45 Total Permanent Investment 50 ASPEN IPE FOLDERS AND FILES 51 REFERENCES 51 APPENDIX I - DEPROPANIZER – ASPEN PLUS REPORT 52 APPENDIX II - DESIGN CRITERIA SPECIFICATIONS 58 APPENDIX III - ASPEN IPE CAPITAL ESTIMATE REPORT FOR THE 61 DEPROPANIZER APPENDIX IV - ASPEN IPE CAPITAL ESTIMATE REPORT FOR THE 70 MONOCHLOROBENZENE SEPARATION PROCESS Subject Index Page Number Definitions Page numbers in textbook Page numbers in Chapter 8.pdf on CD-ROM Page numbers in Chapter 9.pdf on CD-ROM Page numbers in Section 16-7.pdf on CD-ROM Page numbers in Section 17.8.pdf on CD-ROM Page numbers in Design Problem Statements.pdf on CD-ROM Page numbers in GAMS.pdf on CD-ROM Page numbers in Aspen 1PE Course Notes.pdf on CD-ROM Refers to the multimeda ASPEN menu on the CD-ROM Refers to the multimeda HYSYS menu on the CD-ROM 1 , 2, . . . CD-8-1, 2, ... CD-9-1, 2, ... CD-16.7-1, 2, .. . CD-17.8-1, 2, .. . CD-A.11-1, 2, ... CD-G-1, 2, . .. CD-IPE-1, 2, .. . CD-ASPEN CD-HYSYS Refers to the Aspen Eng. Suite folder on the CD-ROM Refers to the HYSYS folder on the CD-ROM Refers to the MATLAB folder on the CD-ROM CD-AES CD-HYSYS folder CD-MATLAB folder results forms flash vessel simulation, CD-ASPEN sensitivity analysis propylene-glycol CSTR, CD-ASPEN simulation flowsheet MCB separation process, CD-ASPEN tear streams, 128-132, CD-ASPEN unit subroutines, 119-123 Aspen Technology, Inc., 38, 106 Assets, 474-477 Attainable region, 220-229 maleic anhydride mfg., 224-226 methane reforming, 227-229 AUT097, 38 AUTOCAD, 97 Auxiliary facilities, 489 Auxiliary studies, 12 Award competition, 778-779 Azeotrope binary maximum boiling, 260, 262 minimum boiling, 259-261 fixed point, 262, 264 heterogeneous, 263, 271-272 multicomponent, 269 pinch point, 262 reactive, 281-282 Azeotropic distillation heterogeneous, 271-276 multiple steady states, 275-276 ABACUS, 136 Aspen IPE, 557, CD-16.7, CD-IPE-1 Accounting, 473-482 Acetaldehyde from acetic acid design problem, CD-A-II-10 to 11 Activity coefficients DECHEMA database, 64 NRTL, 64 UNIFAC, CD-ASPEN UNIQUAC, 64 Wilson, 64 Adiabatic reaction temperature, 179 AEROTRAN, 437 Alitame sweetener mfg. design problem, CD-A-II-37 to 38 Allyl chloride reactions, 172-173 Ammonia process, 156-157, 168-170, 198 Synthesis reactor network, 218-220, CD-ASPEN, CD-HYSYS TVA reactor, 181-182 Ammonia separation process simulation, CD-ASPEN, CD-HYSYS Amortization, 477 Annual report, 474 Annuities (see Time value of money) Argon recovery process costing exercise, 560-561 Aromatics separation sequence exercise, 296 Artificial kidney, 650 ASPEN DYNAMICS, 38, 680 (see also Aspen Engineering Suite) Aspen IPE, 557, CD-16.7, CD-IPE (see also Aspen Engineering Suite) Aspen Engineering Suite, 38 AEROTRAN, 437 ASPEN DYNAMICS, 38, 680 to 78 ASPEN PINCH, 38, 361 ASPEN PLUS (see ASPEN PLUS) ASPEN SPLIT, 38, 284 BATCH PLUS (see BATCH PLUS) B-JAC, 437-438 HETRAN, 437-438 TEAMS, 437 ASPEN PLUS, 38, 106, CD-ASPEN backup files (.bkp), CD-AES batch distillation BATCHFRAC, 390-391, CD-ASPEN calculation sequence, 123-132 calculator, CD-ASPEN design specifications, 122-123, CD-ASPEN equation-oriented simulation, 136 flowsheet, 110, 117, 127 drawing, CD-ASPEN heat streams, CD-ASPEN inline FORTRAN, CD-ASPEN input forms, CD-ASPEN flash vessel simulation, CD-ASPEN input summary, CD-ASPEN (see also program) intro, case study—flash simul., 135-136, 155 main window, CD-ASPEN nested recycle loops, 128-132, CD-ASPEN optimization (see Flowsheet optimization) paragraphs, 120, CD-ASPEN PFD, CD-ASPEN program, 121, CD-ASPEN output history file, CD-ASPEN report file, CD-ASPEN Balance sheet, 474-477 Bare-module costs, 488-490 Base case design, 16-18, 96-104 detailed database, 102-103 791792 Subject Index Base case design (Continued ) flow diagrams block flow diagram, 96-97 P&ID, 101 process flow diagram (PFD), 97-101 pilot plant testing, 103-104 process integration, 102 (see also Heat int. & mass int.) process simulation, 104 (see also Process simulation) Basic chemicals, 1-2, 17 BATCH PLUS, 38, 145-154, CD-ASPEN equipment models, 145-149 Gantt chart, 154 recipe, 152 tPA process simulation, 150-154 Batch process units batch product removal, 389-391 (see also Batch product-removal proc.) batch size, 145, 386, 396, 398 batch time, 145, 386, 396 exothermic batch reactor, 386-387 fed batch, 387-389 size factor, 386 Batch processing (see scheduling batch processes) favorable conditions, 385-386 multiproduct sequences, 399-401 reactor-separator processes, 391-395 single product sequences, 395-398 Batch size, 145, 386, 396, 398 Batch time, 145, 386, 396 minimum, 387 BATCHFRAC, 390-391, CD-ASPEN Batch product-removal process, 385 batch distillation, 389-391 BATCHFRAC, 390-391, CD-ASPEN Battery limits, 489 Bidirectional information flow, 121-122 Bioconcentration factor (BCF), 58 B-JAC, 437^438 Blowers, 467, 518-519 Boiling heat transfer (see Heat exchangers) film boiling, 411 nucleate boiling, 411 Book value, 476-477 Bottleneck, 150, 154, 396 Butadiene to n-butyraldehyde and n-butanol design problem, CD-A-II-12 to 13 Butenes recovery system example separation sequence, 238-241 Marshall and Swift, 483^185 Nelson-Farrar, 484-485 direct permanent investment, 483, 488, 493 economy of scale, 486^187 equations, 505-506 blowers, 518-519 compressors, 520-522 electric motors, 509-511 fans, 515-517 fired heaters (furnaces), 525-526 heat exchangers, 522-525 other equipment (Table 16.32), 553-556 packings, 533-534 plates (trays), 532 pressure vessels and towers, 527-531 pumps, 508, 511-512 estimating methods, 497 definitive estimate, Aspen IPE, 497^198, 557, CD-16.7-1 to 13 order-of-magnitude estimate, 497-500 preliminary estimate, Guthrie, 497, 503-505 study estimate, Lang, 497, 500-502 installation costs table of components, 488 total bare-module investment, 488, 493 total capital investment, 483, 493, 580 total depreciable capital, 487^188, 493 total permanent investment, 483, 488, 493 Aspen IPE, CD-16.7-7, 12 Guthrie method, 503-505 Lang factor method, 500-502 working capital, 483, 488, 493, 496, 580-581 Capitalized cost, 596-597 Carbon dioxide fixation by microalgae design problem, CD-A-II-60 to 61 Cash flow, 478, 564, 597-598 investment costs, 597-598 MACRS tax basis for depreciation (see depreciation) production schedule, 598 table of cash flows, 608 Cash flow statement, 478^179 Catalytic converter, 171, CD-A-II-53 to 55 Cavett process, simulation exercise, 155-156 Center for Chemical Process Safety, 19, 27 CEP Software Directory, 37 Cheese whey to lactic acid design problem, CD-A-II-79 to 80 CHEMCAD, 38, 106 unit subroutines, 115 Chemical equilibrium (see Chemical reactors) Chemical Marketing Reporter, 67, 76, 567 Chemical reactors batch reactor optimization, 386-387 chemical equilibrium calculations equilibrium constant method, 207-209, CD-ASPEN, CD-HYSYS free-energy minimization method, 207-210, CD-ASPEN, CD-HYSYS complex configurations external heat exchange reactor, 181-182, 214-216 heat-exchanger reactor, 214-215 hot/cold shot reactor, 180-181, 214, 216 use of a diluent, 180-181, 214-215 control. & resil. (C&R) analysis, 736-741 CSTR control configuration, 688-689 CSTR model ASPEN RCSTR, 211, CD-ASPEN HYSYS CSTR, 211, 740-741, CD-HYSYS linear model formulation, 708-709 model formulation, 211 dynamic simulation, 740-741 equilibrium model ASPEN REQUIL, CD-ASPEN ASPEN RGIBBS, CD-ASPEN HYSYS Equilibrium Reactor, CD-HYSYS HYSYS Gibbs Reactor , CD-HYSYS extent of reaction, 206-207 fed-batch reactor optimization, 387-389 fractional conversion, 206-207 heuristics for reactor design, 172-175, 179-183 Aspen IPE, CD-16.7-5 to 6, CD-IPE-19 to 25 bare-module cost, 488^190 bare-module factors, 492 direct labor, 490^191 direct materials, 490^191 indirect costs, 491-492 materials factor, misc. equipment, 536 other investment costs allocated costs for utilities, 488, 493-494 catalyst, 488, 493 contingencies, 488, 493^194 contractor’s fee, 493^194 land, 488, 495 royalties, 488, 495 service facilities, 488, 493^194 site factors, 495^196 site preparation, 488, 493 spares, 488, 493 startup, 488, 495 storage tanks, 488, 493 surge vessels, 488, 493 working capital, 483, 488, 493, 496, 580-581 pressure factor, 524 purchase-cost charts blowers, 519 compressors, 521 double-pipe heat exchangers, 524 electric motors, 510 external gear pumps, 512 fans, 516 indirect-fired heaters (furnaces), 526 pressure vessels and towers, 528 radial centrifugal pumps, 509 reciprocating plunger pumps, 513 shell-and-tube heat exchangers, 523 six-tenths factor, 486^4-87 C4 byproduct upgrade design problem, CD-A-II-16 to 17 Calculation order, 123-124 Campaign time—batch, 394-395 Capital cost, 483 Aspen IPE—Icarus method, 497^198, 557, CD-16.7, CD-IPE cost indices Chemical Engineering, 483—485 Engineering News-Record, 484^185Subject Index 793 CVD of polysilicon in IC mfg., 663-667 Cycle time—batch processes, 150, 396-398 Cyclohexane from benzene, CD-9-45 to 51 key reactant, 206 kinetic models, 210 models, 205-206 multiple reactions, 206 multiple steady states, 217 networks attainable region, 220-229 bypass fractions, 218-220 reaction invariants, 226-229 optimal reaction rate trajectory, 216-220, CD-ASPEN, CD-HYSYS PFR model ASPEN RPLUG, CD-ASPEN HYSYS PFR, CD-HYSYS model formulation, 211-213 reaction kinetics Langmuir-Hinshelwood model, 210 power-law model, 210 reaction stoichiometry, 206 stoichiometric model ASPEN RSTOIC subroutine, CD-ASPEN HYSYS Conversion Reactor, CD-HYSYS Chemical state, 69-70 Chemicals, 485 bulk, 3-4, 485 commodity fine, 485 , 3—4, 485—486 CHEMSEP specialty, 3—4, 56, 485 separations software, 39 ChemStations, 38, 106 Chlorinated hydrocarbon sepn. sequencing exercise, 296 Combined cycle power generation design problem, CD-A-II-72 to 74 Combined feed, CD-8-2 Compact Commodity heat chemicals exchangers , 3,,4422 , 485—486 Compressors, 467, 514-515, 520 —424 -521, CD-ASPEN, CD-HYSYS brake horsepower, 470 centrifugal heuristics for , 467 equipment —468 selection, 185-187, 189, 514-515 isentropic efficiency, 470 isentropic horsepower, 470 purchase positive-displacement cost, 520-522 , 468—469 Computers guidelines for design, 40 mathematical packages, 39 process simulators, 38, 39—40 programs used in design, 38-39 spreadsheets, 39 table of useful software, 38-39 Condensing heat transfer, 436 Construction, 20 Consumer configured products , 20 , 3—4, 16-17, 20 Contingency, 483 Continuous processing, 150, 384-386 Control action direct acting, 732-733 reverse acting, 732-733 Control blocks, 122-123, CD-ASPEN (see also design specifications) Control variables selection of (see manipulated variables) Control, and resil. (C&R) analysis CSTRs in series, 736-741 heat exchanger networks, 741-747 heat-integrated distillation, 725-732 MCB separation process, 747-755 shortcut, 723-724 Controllability definition, 679 Controlled variables selection of, 685 Controller tuning definitions, 732-733 model-based tuning, 733-735 examples, 735-736,CD-HYSYS Cost Coolants accounting , 407—409 , 481 Cost charts (see Capital —482 cost) Cost equations (see Capital cost) Cost estimation (see Cap. cost & profit, anal.) Cost indices (see Capital cost) Cost of manufacturing, 477 Cost of sales, 477 Cost sheet, 564, 566 cost of manufacture (COM), 566, 574, 577 cost of sales (total production cost), 577 depreciation (see Depreciation) feedstocks, 565-567 Chemical Market Reporter, 567 transfer price, 567 fixed costs, 577, CD-17.8-7 to 8 general expenses, 577 maintenance materials and services, 575 overhead, 575 salaries and benefits, 575 wages and benefits, 575 operating factor, 565, 567, 598 operating overhead, 576 operations control laboratory, 575 operators, number of, 574 salaries and benefits, supervisory, 575 supplies and services, 575 technical assistance, 575 wages and benefits, labor, 574 property insurance, 576-577 property taxes, 576-577 total production cost (C), 577 utilities (see utilities) variable costs, CD-17.8-7 Cracking products separation sequencing exercise, 296 Credits Cumene , 473 mfg—.,474 CD-8-4 to 10 exercise, CD-8-24 to 26 Database chemical prices, 67 DECHEMA, 64 detailed, 102-103 environmental data, 67 preliminary, 62-68 safety data, 67 thermophysical properties, 63-67 (see also Physical properties) toxic chemical data, 67 vapor-liquid equilibria, 63-67 (see also Physical properties) DDT, 23, 33 Debits, 473-474 Decanter control loop pairings exercise, 760 DECHEMA database, 64 Degrees of freedom, 119-120, 686 analysis, 686-691 Delay times, 725 Depletion, 478, 604-605 Depreciation, 477, 577 book depreciation, 599 book value, 599 market value, 599 replacement value, 599 Depreciation methods declining balance, 599-600 double-declining balance, 599-600 MACRS, 602-604 straight-line, 598 sum-of-the-years-digits, 601-602 Depropanizer distillation ASPEN DISTL simulation, CD-ASPEN ASPEN DSTWU design calc., CD-ASPEN ASPEN RADFRAC simulation, CD-IPE-52 to 57, CD-ASPEN HYSYS Column simulation, CD-HYSYS Desalination (see Solar desalination unit) Design problem statements, 782-783, CD-A-II environmental, CD-A-II-48 to 80 environmental —air quality, CD-A-II-48 to 63 carbon dioxide fixation by microalgae, CD-A-II-60 to 61 desulfuriz. of diesel oil—biocatalytic, CD-A-II-50 to 51 HFC recovery and purification, CD-A-II- 58 to 60 hydrogen mfg., CD-A-II-61 to 63 R134a refrigerant mfg., CD-A-II-48 to 50 smog control, CD-A-II-53 to 55 sulfur recovery from natural gas, CD-A-II-51 to 52 vol. org. compound (VOC) abatement, CD-A-II-57 zero emissions, CD-A-II-56 to 57794 Subject Index Design problem statements (Continued ) environmental —miscellaneous cheese whey to lactic acid, CD-A-II-79 to petroleum products, CD-A-II-26 to 27 methyl-tert-butyl-ether mfg., CD-A-II-26 Distillation boundaries, 266 Distillation lines, 267-268 distillation line boundaries, 269-271 Distillation towers azeotropic (see Azeotropic distillation) batch (see BATCH FRAC and MULTIBATCHDS) condenser, 248-249 control configurations, 690-691, 713-715 diameter packed towers, 454-455 tray towers, 453^154 dividing-wall columns, 257-258 ease of separation index (ESI), 255-256 equipment sizing ASPEN PLUS RADFRAC, CD-ASPEN HYSYS.Plant, CD-HYSYS feasible product compositions, 269-270 Fenske-Underwood-Gilliland (FUG) method, 445^146 flooding velocity of Fair, 453^454 flooding velocity of Leva, 454-455 Gilliland correlation, 446 heat pumping, 350-352 HETP, 451-452 heuristics for equipment design, 175 material balance lines, 269-270 minimum equilibrium stages, Fenske, 445 minimum reflux, Underwood, 445 multipass trays, 456 number of stages, 446 plate efficiency, 451-452 pressure drop, tray, 455-456 pressure, operating, 248-249, 443-444 purchase cost, 527-536 residue-curve maps, 263-266 residue curves, 263-266 (see also Residue curves) rigorous models, 449-450 side streams, 255-257 video lab tower and industrial complex, CD-ASPEN, CD-HYSYS weeping, sieve trays, 456 Distillation trains direct sequence, 252 heat integrated (see Heat-integrated distillation and Multiple-effect distillation) indirect sequence, 252 number of sequences, 250-251 ordinary distillation, 249-255 Petlyuk towers, 255-258 prefractionator, 255-257 reboiler liquid flashing, 350-352, CD-9-43 to 45 side stream rectifier, 255-256 side stream stripper, 255-256 vapor recompression, 350-352 Distribution of chemicals, 73, 78-79, 165-175 excess reactant, 165-166 heat addition, 182-183 heat removal, 179-181 to 27 80 pharmaceuticals, CD-A-II-39 to 42 novobiocin mfg., CD-A-II-40 to 41 penicillin mfg., CD-A-II-39 to 40 tissue plasminogen activator (tPA) mfg., CD-A-II-38 to 39 polymers, CD-A-II-41 to 48 PHBV-copolymer mfg., CD-A-II-44 polyvinyl acetate mfg., CD-A-II-41 to 43 rapamycin-coated stents mfg., CD-A-II-46 to 47 styrene from butadiene, CD-A-II-43 xantham biopolymer mfg., CD-A-II-44 to 46 primitive, 8 Design report—oral, 776-778 DVDs, 778 evaluation of presentation, 777-778 media for presentation computer projection software, 776 overhead projector, 776 preparation of exhibits, 777 rehearsing the presentation, 777 typical presentation, 776 video tapes, 778 written handout, 777 Design report—written, 766-775 page format, 774-775 preparation, 772-775 preparation coordination of design team, 772 editing, 774 milestones, 773 project notebook, 772-773 word processing, 774 sample design reports, 775 sections—template process design, 766-771 product design, 771-772 specification sheets, 769 Design specifications, 122-123, CD-ASPEN (see also Control blocks) Design stages, 680 Design steps, 6, 7, 202, 402, 676, 764 Design team, 5, 772 Desulfurization of diesel oil —biocatalytic design problem, CD-A-II-50 to 51 Di (3-pentyl) malate—batch process design problem, CD-A-II-6 to 9 Dialysis device, 8, 9-10 (also see Hemodialysis device) Diesel fuel production—low sulfur design problem, CD-A-II-74 to 76 Di-tertiary-butyl-peroxide mfg., 284-288, CD-A-II-18 to 19 Direct costs, 481 Disprop. of toluene to benzene, CD-9-2 to 5 DISTIL, 284 Distillation near-isothermal process, 155-156 combined cycle power generation, CD-A-II-72 to 74 diesel fuel production—low sulfur, CD-A-II-74 to 76 ethanol manufacture, CD-A-II-80 fuel cell—fuel processor, CD-A-II-71 to 72 waste fuel upgrading, CD-A-II-76 to 78 environmental —soil treatment, CD-A-H-67 to 71 phytoremediation of lead-contam. sites, CD-A-II-67 to 69 soil remediation and reclamation, CD-A-II-69 to 71 environmental —water treatment, CD-A-II-63 to 67 effluent remediation from wafer mfg., CD-A-II-63 to 64 germanium from opt. fiber mfg. effluents, CD-A-II-64 to 65 solvent waste recovery, CD-A-II-66 to 67 foods, CD-A-II-35 to 38 alitame sweetener mfg., CD-A-II-37 to 38 monosodium glutamate mfg., CD-A-II-35 to 37 polysaccharides from microalgae, CD-A-II-37 industrial gases, CD-A-II-27 to 35 krypton and xenon from air, CD-A-II-32 to 33 nitrogen production, CD-A-II-30 to 32 nitrogen production—ultra-pure, CD-A-II-29 to 30 nitrogen rejection from natural gas, CD-A-II-27 to 28 oxygen mfg.—ultra-pure, CD-A-II-33 to 35 origin, 783-784, CD-A-II-4 to 5 petrochemicals, CD-A-II-6 to 25 acetaldehyde from acetic acid, CD-A-II-10 to 11 butadiene to n-butyrald., n-butanol, CD-A-II-12 to 13 C4 byproduct upgrade, CD-A-II-16 to 17 di (3-pentyl) malate—batch process, CD-A-II-6 to 9 di-tertiary-butyl-peroxide mfg., 284-288, CD-A-n-18 to 19 ethylene and acetic acid from ethane, CD-A-II-14 to 15 ethylene from ethane, CD-A-II-11 to 12 hydrogen peroxide mfg., CD-A-II-17 to 18 methylmethacryl. from methacrylic acid, CD-A-II-14 methylmethacrylate from propyne, CD-A-II-15 to 16 PM acetate manufacture, CD-A-D-23 to 25 propoxylated ethylenediamine mfg., CD-A-II-25 vinyl acetate mfg., CD-A-II-20 to 23Subject Index 795 inert species, 166-168 purge streams, 168-171 reactive distillation, 173-175 recycle to extinction, 171-172 selectivity, 172-173 Disturbance cost (DC) CSTRs in series, 738 definition, 719-720 heat exchanger networks, 741-745 heat integrated distillation, 730 interpretation, 720 MATLAB script, 756-757 MCB separation process, 751-753 Mystery process, 722-723 Shell process, 720-722 Di-tertiary-butyl-peroxide mfg. design problem, CD-A-II-18 to 19 pressure swing distillation, 284-288, 299 Dominant-eigenvalue method, 135 Dowtherm, 407^409 Dynamic simulation ASPEN DYNAMICS (see Aspen Engineering Suite) HYSYS.Plant, CD-HYSYS CSTRs in series, 740-741 heat exchanger network, 745-747 heat-integrated distillation, 730-732 MCB separation process, 753-755 toxic metals and minerals, 23 toxic wastes, 22 mass integration, 367-383 ozone, 53-55, 671 refrigerant design, 52-56, 671-672, CD-A-II-48 to 50 toxic chem. release inventory (TRI), 56, 67 toxicity measure, 58 Equation of state Peng-Robinson (PR), 64 Soave-Redlich-Kwong (SRK), 64-67 Equation-oriented simulation, 136 Equipment design heuristics and methods absorbers, 291, 444 shortcut (Kremser) method, 446-448 adsorption, 245, 290 azeotropic distillation, 258-276, 451 compressors, 186, 187, 470—471 conveyors, 190 crystallization, 245, 292-293 distillation, 243, 248-249, 443^146, 451-458 rigorous shortcut (method FUG) method , 449—451 , 445 distillation sequences, 249-258—446 evaporators, 177-178, 292 extraction expanders,, liquid 188, 470 -liquid —471 , 243-244 extractive distillation, 244 furnaces, 183, 185, 424 membranes heat exchangers , 245 ,-184 246 , 185 , 289 , 407 -290—414, 424-439 phase separation, 232-238 pipe lines, 187 pressure-recovery turbines, 188 pressure-swing distillation, 277-279 reactive pumps, 460 distillation —461, 466 , 279-282, 451 reactor networks, 220-229 reactors, 165, 166, 172, 180, 182, 205-220 strippers, 444 supercritical shortcut (Kremser extraction ) method , 246 , 446—448 vacuum systems, 190, 444 Equipment purchase costs absorbers (see Pressure vessels) adsorbents, 553 adsorbers, 536-537 agitators (propellers and turbines), 537, 553 autoclaves (agitated reactor), 537, 553 bins (for solid particles), 547, 555 blowers, 518-519 centrifuges, 555 clarifiers, 555 classifiers, 555 compressors, 520-522 conveyors (for solid particles), 547-548, 555 crushers, grinders, mills, 543-544, 555 crystallizers, 538, 553 cyclone separators, 539-540, 553 distillation (see Pressure vessels) drives (other than electric motors), 538, 553 dryers, 538-539, 553 dust collectors, 539-540, 553 elevators (for solid particles), 548, 555 evaporators, 540, 553 expanders, gas (power recovery), 542, 554 expression, 555 extractors, liquid-liquid, 541, 554 fans, 515-517 filters, 555 fired heaters, 525-527, 540, 554 flash drums (see Pressure vessels) heat exchangers air-cooled fin-fan, 554 compact units, 554 double-pipe, 524-525 packings, 533-536 plates, 532-533 shell-and-tube, 522-524 hydroclones, 555 liquid-liquid extraction, 541, 554 membrane separations, 542, 554 mixers for liquids (see Pressure vessels) mixers for powders, pastes, doughs, 542, 554 motors, electric, 509-511 power-recovery turbine (liquid), 542, 554 pressure vessels and towers, 527-532 pumps, liquid centrifugal, 508-509 gear, 511-512 reciprocating, 511-513 reactors (see Pressure vessels) reflux drums (see Pressure vessels) screens (for particle-size separation), 542-543, 554 settlers and decanters (see Pressure vessels) size enlargement of solids, 543, 554 size reduction of solids, 543-544, 555 solid-liquid separators, 544-546, 555 solids-handling systems, 547-549, 555 storage tanks, 549-550, 556 strippers (see Pressure vessels) tanks (see Storage tanks) thickeners, 555 vacuum systems, 550-552, 556 wastewater treatment, 556, 557 Equipment selection heuristics absorbers, 246-247 adsorbers, 247, 279 blowers, 186, 514-515 compressors, 186, 189, 467^169, 514-515 conveyors, 190 crushers and grinders, 192, 543-544 crystallizers, 177, 247-248 distillation, 246-247 dryers, 178, 179, 248 expanders, 188, 469 extraction, Liquid-liquid, 247 fans, 186, 514-515 filters, 178 furnaces, 183, 424 heat exchangers, 183, 185, 414-424 leaching, 247 membranes, 247, 279 Earnings after-tax (net), 579 depreciation (see Depreciation) income tax, 579 pretax, 579 sales revenue, 565 total production cost (C), 566, 577 Effluent remediation from wafer mfg. design problem, CD-A-II-63 to 64 Encyclopedias, 11 Environment aqueous waste removal, 369 bioconcentration factor (BCF), 58 data, 67 design problems, 26-27, CD-A-II-48 to 80 air quality, 26-27, CD-A-II-48 to 63 soil treatment, 26-27, CD-A-II-67 to 71 water treatment, 26-27, CD-A-II-63 to 67 factors in design avoiding nonroutine events, 24 dilute streams, 25 electrolytes, 25-26 intangible costs, 25 materials characterization, 24 reaction pathways, 23-24 reducing and reusing wastes, 24 regulations, 25 global warming potential (GWP), 671 H2S from tail gas, 371-374, 378-381 hazardous air pollutants (HAP) list, 56 issues bioaccumulated chemicals, 23 burning fossil fuels, 22796 Subject Index Fuel cell automotive, 669-670 fuel processor design problem, CD-A-II-71 to 72 Future worth, F, 587 FEMLAB, 20, 38, 644 Fifo-Lifo, 482 Fifteen percent rule, 13 Financial ratio analysis acid-test ratio, 480 current ratio, 479 equity ratio, 480 operating margin, 480 profit margin, 481 return on equity (ROE), 480 return on total assets (ROA), 480 Fin-fan heat exchanger, 422 video, CD-ASPEN, CD-HYSYS Fixed costs, 577, CD-17.8-7 to 8 Flammability limits, 28-29, CD-A-II-32 to 33 Flash point, 58 Flash vessels, CD-ASPEN, CD-HYSYS ASPEN PLUS FLASH2 subroutine, CD-ASPEN introductory case study, CD-ASPEN control configurations, 689-690 equipment sizing, 750 HYSYS Separator model, CD-HYSYS video, CD-ASPEN, CD-HYSYS Flash with recycle process, 135-136, 155 Flooding velocity, 453-455 Flow diagrams block flow diagram (BFD), 96-97 piping and instrumentation diagram (P&ID), 101 process flow diagram (PFD), 97-101 process flowsheet, 109 simulation flowsheet, 109-113 Flowsheet (see Flow diagrams) Flowsheet optimization ASPEN PLUS, CD-ASPEN discrete changes, 636 distil, tower with sidedraws, 637-639 ASPEN PLUS, CD-ASPEN HYSYS.Plant, CD-HYSYS ethyl chloride manufacture HYSYS.Plant, 636-637, CD-HYSYS heat exch. min. temp. app. exercise, 641 HYSYS.Plant, CD-HYSYS Petlyuk distillation exercise, 641-642 propylene-propane dist. exercise, 641-642 simulation design specs. convert to equalities, 636 successive quadratic prog, (see Optimization) with recycle loops compromise algorithm, 635 infeasible path algorithms, 633-635 NLP with tear equations, 633 repeated simulation, 632 sensitivity analysis, 632 FLOWTRAN, 508 FLUENT, 20 Equipment selection heuristics (Continued ) particle removal from fluids, 193 particle-size enlargement, 192 particle-size separation, 192 pressure-recovery turbines, 188 pumps, 187, 189, 461^166, 506-507, 512-514 separation of liquid mixtures, 175, 242 separation of slurries, 242 separation of vapor mixtures, 175, 242 solids-handling systems, 547-549 strippers, 246-247 vacuum systems, 190, 550-552 Equipment sizing Aspen IPE—Icarus method, CD-16.7-4 to 5 (see also Capital cost) chemical reactors (see Chemical reactors) compressors (see Compressors) distillation towers ASPEN PLUS RADFRAC, CD-ASPEN HYSYS.Plant, CD-HYSYS heat exchangers (see Heat exchangers) other equipment, 536-557 pumps (see Pumps) turbines (see Turbines) Estimation of capital cost (see Capital cost) Ethanol dehydration process, 271-275 Ethanol manufacture design problem, CD-A-II-80 Ethics ABET, 31-32 AIChE Code, 32 case studies Ethics Center, 33 Engineers’ Creed, 31 Global ethics, 33, 36-37 NSPE Code, 31-36 Ethyl chloride manufacture maximizing venture profit, 636-637, CD-ASPEN, CD-HYSYS simulation, CD-ASPEN, CD-HYSYS Ethylene and acetic acid from ethane design problem, CD-A-II-14 to 15 Ethylene carbonate manufact., 164-165 Ethylene from ethane design problem, CD-A-II-11 to 12 Ethylene glycol manufacture, 163-165, 198 Ethylene separation process, 353-354, 359-360 Ethyl-tertiary-butyl-ether mfg. exercise, 198 Exergy, CD-9-15 Expanders (see Turbines) Experiments, 68 Extent of reaction, 206-207 Externally defined variables disturbances, 686 GAMS batch reactor-separator optimization, 395 compilation, CD-G-2 to 3 debugging, CD-G-17 to 19 debugging compilation errors, CD-G-17 to 18 execution errors, CD-G-18 to 19 documentation, CD-G-7 execution, CD-G-3 initialization, CD-G-9 input file, CD-G-3 to 7,10,11,14 format, CD-G-16 linear program (LP) HEN minimum utilities, CD-G-3 to 4,10 mixed-integer lin. prog. (MIP) HEN stream matching, CD-G-13 to 14 nonlinear program (NLP) HEN superstructure opt., CD-G-10 to 11 polymer design, 51-52 statements bounds and initial conditions, CD-G-9 data (scalars, params, tables), CD-G-15 equation declaration, CD-G-5 equation definition, CD-G-5 to 6 model declaration, CD-G-6 set declarations, CD-G-12 to 15 solve, CD-G-6 variable declaration, CD-G-5 variable display, CD-G-8 variable redeclaration, CD-G-8 Gantt chart, 154, 396-397, 399, 400 Germ killing surfaces, 667 Germanium from optical fiber mfg. effluents design problem, CD-A-II-64 to 65 Golden section search, 626-630 gPROMS, 136 Grass-roots plant, 489, CD-IPE-18 Group contribution methods polymers, 47, 50-52 refrigerants, 54-55 solvents, 57-59 Handbooks, 11-12 Handwarmer Grabber Mycoal handwarmer, 660 solutes for handwarmers, 60, 660-662 Zap Pak heat pack, 660-661 HAZOP analysis, 19, 31 Heat and power integration ethylene separation process, 353-355, 359-360 heat engine positioning, 355-356 heat pump positioning, 355-357 optimization methods, 357-358 typical process (ABCDE), 352-353, 358-35' Heat engines, 356, CD-9-62 Fabricated process equipment, 489 Fans, 186, 467, 515-517 Fed-batch processing, 384-385, 387-389 Feedstock costs, 565-567Subject Index 797 Heat exchangers B-JAC, 437-439 (see also HETRAN, TEAMS, and AEROTRAN) boiling, 411 cocurrent flow, 410 cooling curves, 406^109, 412^413 (see also Max. energy recovery (MER)) countercurrent flow, 410 crossflow, 410 equipment air-cooled, 421^122 compact, 422^424 double-pipe, 414^415 fin-fan, 421-422 kettle reboiler, 421 shell-and-tube, 415^421 heat transfer coefficients estimation, 430-436 typical, 431 heat transfer media, 409 heating curves, 406-409, 412^413 (see also Max. energy recovery (MER)) heuristics for equipment design, 183-185, 416, 421-422, 424 minimum temperature approach, 410 crossover, 412^113 one-sided, 406 purchase pressure drop cost,, 522 413-^525 414, 430—435 simulator models, CD-ASPEN, CD-HYSYS steel pipe data, 416 temperature driving force, 410, 424-429 tube data, 419 video, CD-ASPEN, CD-HYSYS Heat exchanger networks (HENs) (see Heat integration) control configurations, 681, 686-687 control. & resil. (C&R) analysis, 741-747 Heat-integrated distillation trains, 346-352 (see also Multiple-effect distillation) control. & resil. (C&R) analysis, 725-732 dynamic simulation—HYSYS.Plant, 730-732 heat pumping, 350-352 pressure effect, 346-349 reboiler flashing, 350-352, CD-9-43 to 45 (see also Distillation trains) T-Q diagram, 346-349 vapor recompression, 350-352 Heat integration annualized cost minimum Chen approximation, CD-G-10 nonlinear program (NLP), 339-341 superstructures, 339 auxiliary heat exchangers, 303 composite curve (see Maximum energy recovery (MER)) controllability of HENs control structure, 686-687, 741-745 control. & resil. (C&R) analysis, 741-747 controller tuning, 745-747 dynamic simulation, 746-747 distillation trains (see Heat integ. dist. trains) grand composite curve design for multiple utilities, 342-346 interior heat exchangers, 303 lost work, 305 minimum heat exchangers breaking heat loops, 327-330 definition, 326-327 minimum utilities (see Maximum energy recovery (MER)) multiple utilities, 341-346 optim. temperature approach, 335-338 software, 361 stream splitting, 330-333 styrene process exercise, 364-366, CD-HYSYS Heat pump, 350-352, 357 Heat streams, CD-ASPEN Heat transfer media, 409 HEATX, 437, CD-ASPEN Hemodialysis device C-DAK 4000 artificial kidney, 650 design basis, 651 design model, 654-655 mass-transfer coefficients, 652-653 pressure drop, 653-654 primitive design problem, 8, 9-10 Heterogeneous azeotropic distillation, 271-276 HETRAN, 437-438 (see also Aspen Engineering Suite) HFC recovery and purification design problem, CD-A-II-58 to 60 HX-NET, 361 Hydrogen mfg. automobile power train, 669 design problem, CD-A-II-61 to 63 Hydrogen peroxide mfg. design problem, CD-A-II-17 to 18 Hyprotech, 106, 284 HYSYS.Plant bidirectional information flow, 121-122 case study (see also dynamic simulation), CD-HYSYS data recorder, CD-HYSYS databook, CD-HYSYS dynamic simulation binary distillation tower, CD-HYSYS CSTRs in series, 739-741 heat exchanger networks, 746-747 heat integ. distillation towers, 730-732 MCB separation process, 753-755 steps, CD-HYSYS HYSYS case files, CD-HYSYS folder object palette, CD-HYSYS optimization (see Flowsheet optimization) PFD view, CD-HYSYS physical properties define property prediction pkg., CD-HYSYS PID controller model installation, CD-HYSYS loop definition, CD-HYSYS property view, CD-HYSYS reaction package, CD-HYSYS recycle convergence Recycle procedure, CD-HYSYS reverse information flow, 121-122 spreadsheet, CD-HYSYS subflowsheets, CD-HYSYS unit subroutines, CD-HYSYS workbook view,CD-HYSYS Heuristics compression, 185-187 conveying of solids, 190-191 crushing and grinding, 191-192 cyclones, 193 distribution of chemicals, 165-175 enlargement of particles, 192 equipment design (see Equipment design heuristics) expanders and turbines, 188 heat addition to reactors diabatic operation, 182-183 excess reactant, 182-183 hotshots, 182-183 inert diluent, 182-183 interheaters, 182-183 heat exchangers and furnaces, 183-185 heat removal from reactors cold shots, 180-181 diabatic operation, 181-182 excess reactant, 180 inert diluent, 180 intercoolers, 182 pumping, 187-188,189 raw materials, 163-165 screening, 192 separations involving solids, 177-179 separation of liquid and vapor mixtures, 175-176 table of, 193-197 vacuum systems, 190 HEXTRAN, 361 Idea generation, 8, 645 Income statement, 477^178 Indexes, 12 Indirect costs (overhead), 481 Industrial chemicals, 4, 16-17, 18, 20 Industrial consultants, 783-784 Inflation, 609-610 Insect repelling wrist band, 667-668 Installation costs (see Capital cost) Intelligen, Inc., 39, 145 Interest compound interest, 586-587 cost of capital, 564 interest rate, 564 simple interest, 587 Intermediate storage, 398 Inventory, 482 Investment costs (see Capital cost) Ionic liquids, 43-44 Isentropic efficiency, 470798 Subject Index Kirk-Othmer Encyclopedia, 11 Krypton and xenon from air design problem, CD-A-II-32 to 33 pinch decomposition, 309 transshipment model, 320-323 targets, 306-316 temperature-interval method, 307-310, 314-316 interval heat balances, 307-310 threshold approach temp., 312, 333-335 MAYFLOWER, 284 Measured variables selection of, 685-686 Methane reforming attainable region, 227-229 recycle to extinction, CD-8-20 to 23 Methanol dehydration (distil.) dynamic simulation HYSYS.Plant, 730-731, CD-HYSYS multiple-effect distillation energy requirements, 681-682 Methylmethacrylate from methacrylic acid design problem, CD-A-II-14 Methylmethacrylate from propyne design problem, CD-A-II-15 to 16 Methyl-tert-butyl-ether mfg., 167-168 design problem, CD-A-II-26 to 27 Microsimulation Minimum mass separating , 48—49 agents, 369-376 approach to phase equilibrium, 370 composite-curve method, 374-376 mass exchange curves, 375 rich and lean curves, 375 composite-interval method, 370-374 interval mass balances, 372-374 pinch, 373-374 pinch compositions, 373-374 stream matching, 377-380 at pinch, 377-378 pinch decomposition, 374 stream splitting, 378-380 stream splitting at pinch, 378-380 threshold approach to phase equil., 381 Minnesota Mining & Manufacturing (3M), 1 fifteen percent rule, 13 process innovation tech, centers, 13 stretch goals, 13 tech forum, 13 Mixed-integer nonlinear prog., 55, 59, 163, 339, 623 Mixers, 114-115 Molecular dynamics, 48-49 Molecular structure design, 15-16, 42-61 ionic liquids, 43-44 microsimulation, 48-49 molecular dynamics, 48-49 Monte-Carlo methods, 49 optimization (see also optimization), 49-60 polymer design, 50-52 refrigerant design, 52-56, 671-672, CD-A-II-48 to 50, 58 to 60 solvent design, 56-60 pharmaceutical product design, 44-45 polymer property estimation, 47-48, 50-52 (see also physical properties) solutes for handwarmers, 60, 660-662 Monochlorobenzene separation process Aspen IPE equip, sizes and costs, CD-16.7-10 to 13 ASPEN PLUS history file, CD-ASPEN ASPEN PLUS program, CD-ASPEN ASPEN PLUS report file, CD-ASPEN ASPEN PLUS sim. flowsheet, 144 control. & resil. (C&R) analysis, 747-755 dynamic simulation HYSYS.Plant, 753-755 process flowsheet, 143 profitability analysis, CD-17.8-9 to 25 simulation, 142-144 Monosodium glutamate mfg. design problem, CD-A-II-35 to 37 Monte-Carlo methods, 49 MSDS (Material Safety Data Sheet), 31, 63, 163 MULTIBATCHDS multicomponent batch dist., 39 Multilayer polymer mirrors, 662-663 Multiple-effect distillation, 349-350, 681-682, 725-732 control. & resil. (C&R) analysis, 725-730 exercise, 761 feed splitting (FS), 349-350, 681-682, 725-732 HYSYS.Plant dynamic simulation, 730-731 light split/forward (LSF), 349-350, 681-682, 725-732 light split/reverse (LSR), 349-350, 681-682, 725-732 HYSYS.Plant dynamic simulation, 730-731 PRO/II simulation results, 726 SIMULINK flowsheets, 728 Multiproduct batch plants, 399-401 Multipurpose batch plants, 399 Lang factors, 500-502 Lennard-Jones pair potential, 48-49 Liabilities, 474-477 Linear process model state-space representation, 706 transfer function representation, 707 variable scaling, 709 Linearization method analytical, 707, 708-709 Linear programming (LP) (see Optimization) Lost work (see second-law analyis) Low-order dynamic models steady-state gains, 724 time constants and delays, 724-725 Maleic anhydride mfg. attainable region, 224-225 Manipulated variables selection of, 685 Manufacturing process, 16, 644-645 Marketing studies, 12 Mass exchangers, 367-369, 377 Mass integration, 367-383 annualized cost minimum, 369 energy separating agent (ESA), 367, 368 H2S from tail gas, 371-374, 378-381 mass separating agent (MSA) (see Minimum mass separating agent) mass separating agent (MSA), 367, 368 external, 368 process, 368 minimum mass exchangers, 369, 380-381 breaking mass loops, 380-381 multiple solutes, 381 exercise, 383 optim. approach to phase equilibrium, 381 Material safety data sheets (MSDS), 31, 63, 163 Materials factor, misc. equipment, 536 Materials of construction, 509, 524, 531, 785-786 Nested recycle loops, 128-132, CD-ASPEN Net worth, 474-477 Newton-Raphson method, 133-134, 631-632 Nitrogen production design problem, CD-A-II-30 to 32 Nitrogen production—ultra-pure design problem, CD-A-II-29 to 30 Nitrogen rejection from natural gas design problem, CD-A-II-27 to 28 Nonlinear programming (NLP) (see Optimization) Novobiocin mfg. design problem, CD-A-II-40 to 41 MATLAB finite-element toolbox, 20, 644 for control. & resil. (C&R) anal., 755-757,CD MATLAB folder Maximum energy recovery (MER) graphical displays composite curves, 310-312 cooling curves, 312, 314-315 heating curves, 311, 314-315 linear programming, 312-314 min. temperature approach, 307 (see also Heat exchangers) pinch distillation analogy, 310 pinch temperatures, 309 stream matching at pinch, 316-320 mixed-integer linear program, 320-325 Off-site facilities, 489 On-site facilities, 489 Operating factor, 565, 567, 598 Operation, 20 Operational constraints examples, 684Subject Index 799 PFD (see Process flow diagram) P&ID diagram, 101 Par value, 477 Patents, 5, 8, 12-14, 20, 74, 86, 258, 645, Optimal control problem, 385, 386 minimum batch time, 387 penicillin mfg. fed-batch process, 388-389 Pontryagin maximum principle, 389 reactor-separator processes, 391-395 Optimization classification, 619-623 constrained, 619 constraints, 618-619 decision variables, 618 distillation towers (see Flowsheet optimization) flowsheet (see Flowsheet optimization) formulation, 617-619 GAMS (see GAMS) Golden-Section search, 626-630 heat exchanger design, 628-629 Himmelblau’s function, 621-622 Karush-Kuhn-Tucker (KKT) conditions, 631 Lagrangian, 631 linear program (LP) minimum utilities, 312-314 linear programming, 623-626 mixed-integer lin. prog. (MILP) stream matching, 320-326 molecular structure design, 49-60 nonlinear programming (NLP), 626-632 decision variables, 618 degrees of freedom, 617 equality constraints, 618 general formulation, 617-619, 630 gradient methods, 630-632 HEN superstructure opt., 338-341 inequality constraints, 619 Karesh-Kuhn-Tucker conds., 631 Lagrangian, 631 objective function, 618 stationarity conditions, 631 objective function, 618 optimal batch time, 384, 388-389 optimal multiproduct batch plant, 399^101 optimal solution local, 619 global, 619 process flowsheets (see also Flowsheet optim. ) quadratic programming (QP), 632 reactor conversion, 391-395, CD-8-13 to 17 simplex method, 625 stationarity conditions, 631-632 successive linear programming (SLP), 623 successive quad. prog. (SQP) quadratic program (QP), 632 solution of stationarity conds., 631-632 unidirectional search, 632 unconstrained, 619 Overhead (indirect costs), 481 Oxygen mfg.—ultra-pure design problem, CD-A-II-33 to 35 Ozone, 53, 671, CD-A-II-48 to 50, 58 to 60 Ozone deletion potential (ODP), 55, 671 water absorption, 47^18, 50-52 refrigerants, 54-55 ozone depletion potential, 55, 671 residue-curve maps, CD-ASPEN (see also Residue curves) solvents, 57-59 solubility parameters, 57-58 thermophysical prop, diags., CD-ASPEN Phytoremediation of lead-contam. sites design problem, CD-A-II-67 to 69 PID Controller Tuning (see controller tuning) Pilot plant, 103-104 Pipe (steel) data, 416 Pipeline models, 114-115 Plantwide control synthesis acyclic process, 693-695 qualitative examples, 693-702 qualitative steps, 692-693 reactor-flash-recycle process, 695-698 vinyl chloride process, 699-702 PM Acetate manufacture design problem, CD-A-II-23 to 25 Polymer design, 50-52 Polysaccharides from microalgae design problem, CD-A-II-37 Polysilicon CVD CVD, 663-664 mass balances, 665 momentum balances, 664 silane reactions and rates, 663-664 Polyvinyl acetate mfg. design problem, CD-A-II-41 to 43 Present worth, P, 587 Pressure-swing distillation, 277-279, 284-288, 299, CD-A-II-18 to 19 PRO/II, 38,106, 726 unit subroutines, 115 Process creation, 16, 62-105 Process flow diagram (PFD), 97-101 AUTOCAD, 97 equipment summary table, 99, 101 processing units, 97, 99 stream information, 97, 100 utilities, 99, 100 VISIO, 97 Process flowsheet, 109 Process integration, 102 Process machinery, 489 Process simulation, 104 Process simulation—batch BATCH PLUS sim.—tPA cultivators, 150-154 exercise, 159-160 bottleneck, 150, 154 distillation BATCHFRAC, 390-391 equipment models, 145, 147-149 BATCH PLUS, 147-148 SUPERPRO DESIGNER—procedures, 148-149 Gantt chart, 154 660 Peng-Robinson equation of state, 64 Penicillin mfg. design problem, CD-A-II-39 to 40 fed-batch process optimal control problem, 388-389 Perpetuities, 596 Pharmaceutical products, 14-15 clinical trials, 14 design genetically-engineered drugs, 45 synthetic chemical drugs, 44 design problem novobiocin mfg., CD-A-II-40 to 41 penicillin mfg., CD-A-II-39 to 40 tissue plasminogen activator (tPA) mfg., CD-A-II-38 to 39 discovery, 14 FDA approval, 15 penicillin mfg. fed-batch process, 388-389 preclinical development, 14 process simulation tPA process, 150-154,159-160 process synthesis, 85-96 (see also Tissue plasmin. activ. proc.) Phase envelope, 64-67, CD-ASPEN Phase equilibria bin. phase diags.-Txy, xy, etc., 64-65, 260-263, CD-ASPEN Phase equilibria calculation, CD-ASPEN PHBV-copolymer mfg. design problem, CD-A-I1-44 Physical properties ASPEN data regression equilibrium data, 64-65, CD-ASPEN ASPEN PLUS option sets, CD-ASPEN ASPEN PLUS property meth., CD-ASPEN bin. phase diags.-Txy, xy, etc., 64-65, 260-263, CD-ASPEN data banks, 45^16, CD-ASPEN estimation methods, 45^17, CD-ASPEN group contribution methods, 47-59 (see also group Contribution methods) microsimulation molecular dynamics, 48^19 Monte Carlo methods, 49 param. estim.-pure species ASPEN PLUS, CD-ASPEN phase envelopes ASPEN PLUS, 64-67, CD-ASPEN phase equilibria, CD-ASPEN calculations, CD-ASPEN polymers density
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