A principal objective of this textbook and accompanying CD-ROM, referred to here as courseware, is to describe modern strategies for the design of chemical products and processes. Since the early 1960s, the emphasis in undergraduate education has been on the engineering sciences. In recent years, however, more scientific approaches to product and process design have been developed, and the need to teach students these approaches has be-come widely recognized. Consequently, this courseware has been developed to help students and practitioners better utilize the modern approaches to process design and the growing im¬portance of the design by chemical engineers of new products that require the selection of an appropriate chemical or chemical mixture or involve chemical reactions and/or the separa¬tion of chemical mixtures. Like workers in thermodynamics; momentum, heat, and mass transfer; and chemical reaction kinetics, product and process designers apply the principles of mathematics, chemistry, physics, and biology. Designers, however, utilize these princi¬ples, and those established by engineering scientists, to create chemical products and processes that satisfy societal needs while returning a profit. In so doing, designers empha¬size the methods of synthesis and optimization in the face of uncertainties, often utilizing the results of analysis and experimentation prepared in cooperation with engineering scientists.
In this courseware, the latest design strategies are described, most of which have been improved significantly with the advent of computers, numerical mathematical program¬ming methods, and artificial intelligence. Since most curricula place little emphasis on de-sign strategies prior to design courses, this courseware is intended to provide a smooth transition for students and engineers who are called upon to design creative new products and processes.
The first edition of this textbook focused on the design of commodity chemical processes. While this material has been updated and augmented to include recent developments, the second edition, with a new title, broadens this focus to include the design of chemical prod¬ucts. Strategies for product design have been added for both configured industrial and con¬sumer products. Also, numerous examples of the process design of specialty chemicals are included based on batch, rather than continuous, processing. In addition, the second edition has expanded coverage on the design of process units, the estimation of capital costs, prof¬itability analysis, and optimization. Of particular note is the addition of more than 100 equa¬tions for the estimation of purchase costs for most kinds of process equipment.
This courseware is intended for seniors and graduate students, most of whom have solved a few open-ended problems but have not received instruction in a systematic approach to product and process design. To guide this instruction, the subject matter is presented in five parts. As discussed in Chapter 1, Figure 1.2 shows how these parts relate to the entire design process and to each other. All of the parts are presented at the senior level.
In this second edition, the scope of Part One is broadened to include the idea-generation stage in designing new chemical products, and the search for chemicals or chemical mixtures that have the desired properties and performance. When a process is required to produce the chemicals, the steps in process design are covered, expanded beyond those presented in the first edition. When configured industrial or consumer products are needed, with or without a new chemical process, the steps in detailed product design are covered with many examples in Part Three. Because many specialty chemicals are manufactured in small quantities, the second edition has been expanded to include the design of batch processes.
For process design, the coverage is similar to that in the first edition, but expanded to in¬clude new methods and more coverage of solids processing. The emphasis throughout the text, and especially in Part One, on process invention, and Part Two, on detailed process syn¬thesis, is on the steps in process creation and the development of a base-case design(s). For the former, methods of preparing the synthesis tree of alternative flowsheets are covered. Then, for the most promising flowsheets, a base-case design(s) is developed, including a de-tailed process flow diagram, with material and energy balances. The base-case design(s) then enters the detailed design stage, in which the equipment is sized, cost estimates are obtained, a profitability analysis is completed, and optimization is carried out, as discussed in Part Three.
Throughout this courseware, various methods are utilized to perform the extensive calcu¬lations and provide graphical results that are visualized easily, including the use of computer programs for simulation and design optimization. The use of these programs is an important attribute of this courseware. We believe that our approach is an improvement over an alter-native approach that introduces the strategies of process synthesis without computer methods, emphasizing heuristics and back-of-the-envelope calculations. We favor a blend of heuristics and analysis using the computer. Since the 1970s, many faculty have begun to augment the heuristic approach with an introduction to the analysis of prospective flowsheets using simulators, such as ASPEN PLUS, HYSYS.Plant, PRO/II, CHEMCAD, FLOW¬TRAN, BATCH PLUS, and SUPERPRO DESIGNER. Today, most schools use one of these simulators, but often without adequate teaching materials. Consequently, the challenge for us, in the preparation of this courseware, has been to find the proper blend of modern compu¬tational approaches with simple heuristics.
In the chapters on the design of commodity chemical processes, emphasis is placed on the synthesis of processes that operate at steady state and present no unusual control problems. For these processes, dynamic simulators, such as ASPEN DYNAMICS and HYSYS.Plant, are useful for studying startup, shutdown, upsets, and the performance of alternative control sys¬tems. Dynamic analysis often suggests designs that are easier to implement and control. As processes become more integrated, to achieve more economical operation, their responses to disturbances and setpoint changes become more closely related to the design integration, and consequently, the need to assess their controllability gains importance. To introduce several methods, Part Four is intended for readers who have studied linear control theory for single-input, single-output (SISO) controllers (usually in a first course in process control). Emphasis is placed on the methods for assessing the controllability of processes designed to operate at a steady state, with the consideration of frequency-dependent measures only when necessary. Control systems are designed for the most promising processes, and the ability of the processes to reject typical disturbances is evaluated using dynamic simulation. In summary, Part Four is intended to show that, to achieve more profitable designs, it is important to consider plantwide control during process design. This is accomplished, qualitatively and then quantitatively, using the simpler strategies for multiple-input, multiple-output (MIMO) control.
In this courseware, the latest design strategies are described, most of which have been improved significantly with the advent of computers, numerical mathematical program¬ming methods, and artificial intelligence. Since most curricula place little emphasis on de-sign strategies prior to design courses, this courseware is intended to provide a smooth transition for students and engineers who are called upon to design creative new products and processes.
The first edition of this textbook focused on the design of commodity chemical processes. While this material has been updated and augmented to include recent developments, the second edition, with a new title, broadens this focus to include the design of chemical prod¬ucts. Strategies for product design have been added for both configured industrial and con¬sumer products. Also, numerous examples of the process design of specialty chemicals are included based on batch, rather than continuous, processing. In addition, the second edition has expanded coverage on the design of process units, the estimation of capital costs, prof¬itability analysis, and optimization. Of particular note is the addition of more than 100 equa¬tions for the estimation of purchase costs for most kinds of process equipment.
This courseware is intended for seniors and graduate students, most of whom have solved a few open-ended problems but have not received instruction in a systematic approach to product and process design. To guide this instruction, the subject matter is presented in five parts. As discussed in Chapter 1, Figure 1.2 shows how these parts relate to the entire design process and to each other. All of the parts are presented at the senior level.
In this second edition, the scope of Part One is broadened to include the idea-generation stage in designing new chemical products, and the search for chemicals or chemical mixtures that have the desired properties and performance. When a process is required to produce the chemicals, the steps in process design are covered, expanded beyond those presented in the first edition. When configured industrial or consumer products are needed, with or without a new chemical process, the steps in detailed product design are covered with many examples in Part Three. Because many specialty chemicals are manufactured in small quantities, the second edition has been expanded to include the design of batch processes.
For process design, the coverage is similar to that in the first edition, but expanded to in¬clude new methods and more coverage of solids processing. The emphasis throughout the text, and especially in Part One, on process invention, and Part Two, on detailed process syn¬thesis, is on the steps in process creation and the development of a base-case design(s). For the former, methods of preparing the synthesis tree of alternative flowsheets are covered. Then, for the most promising flowsheets, a base-case design(s) is developed, including a de-tailed process flow diagram, with material and energy balances. The base-case design(s) then enters the detailed design stage, in which the equipment is sized, cost estimates are obtained, a profitability analysis is completed, and optimization is carried out, as discussed in Part Three.
Throughout this courseware, various methods are utilized to perform the extensive calcu¬lations and provide graphical results that are visualized easily, including the use of computer programs for simulation and design optimization. The use of these programs is an important attribute of this courseware. We believe that our approach is an improvement over an alter-native approach that introduces the strategies of process synthesis without computer methods, emphasizing heuristics and back-of-the-envelope calculations. We favor a blend of heuristics and analysis using the computer. Since the 1970s, many faculty have begun to augment the heuristic approach with an introduction to the analysis of prospective flowsheets using simulators, such as ASPEN PLUS, HYSYS.Plant, PRO/II, CHEMCAD, FLOW¬TRAN, BATCH PLUS, and SUPERPRO DESIGNER. Today, most schools use one of these simulators, but often without adequate teaching materials. Consequently, the challenge for us, in the preparation of this courseware, has been to find the proper blend of modern compu¬tational approaches with simple heuristics.
In the chapters on the design of commodity chemical processes, emphasis is placed on the synthesis of processes that operate at steady state and present no unusual control problems. For these processes, dynamic simulators, such as ASPEN DYNAMICS and HYSYS.Plant, are useful for studying startup, shutdown, upsets, and the performance of alternative control sys¬tems. Dynamic analysis often suggests designs that are easier to implement and control. As processes become more integrated, to achieve more economical operation, their responses to disturbances and setpoint changes become more closely related to the design integration, and consequently, the need to assess their controllability gains importance. To introduce several methods, Part Four is intended for readers who have studied linear control theory for single-input, single-output (SISO) controllers (usually in a first course in process control). Emphasis is placed on the methods for assessing the controllability of processes designed to operate at a steady state, with the consideration of frequency-dependent measures only when necessary. Control systems are designed for the most promising processes, and the ability of the processes to reject typical disturbances is evaluated using dynamic simulation. In summary, Part Four is intended to show that, to achieve more profitable designs, it is important to consider plantwide control during process design. This is accomplished, qualitatively and then quantitatively, using the simpler strategies for multiple-input, multiple-output (MIMO) control.
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