Chemical Process deals with the design and integration of chemical processes, emphasizing the conceptual issues that are fundamental to the creation of the process.

Chemical Process deals with the design of utility systems so that the interactions between processes and the utility system and interactions between different processes through the utility system can be exploited to maximize the performance of the site as a whole.

Chemical Process is intended to provide a practical guide to chemical process design and integration for undergraduate and postgraduate students of chemical engineering, practicing process designers and chemical engineers and applied chemists working in process development. Examples have been included throughout the text. Most of these examples do not require specialist software and can be performed on spreadsheet software.

Exercises have been added at the end of each chapter to allow the reader to practice the calculation procedures.

Contents

1. The Nature of Chemical Process Design and Integration
   • Chemical Products
   • Formulation of the Design Problem
   • Chemical Process Design and Integration
   • The Hierarchy of Chemical Process Design and Integration
   • Continuous and Batch Processes
   • New Design and Retrofit
   • Approaches to Chemical Process Design and Integration
   • Process Control
   • The Nature of Chemical Process Design and Integration – Summary

2. Process Economics
   • The Role of Process Economics
   • Capital Cost for New Design
   • Capital Cost for Retrofit
   • Annualized Capital Cost
   • Operating Cost
   • Simple Economic Criteria
   • Project Cash Flow and Economic Evaluation
   • Investment Criteria
   • Process Economics – Summary

3. Optimization
   • Objective Functions
   • Single-variable Optimization
   • Multivariable Optimization
   • Constrained Optimization
   • Linear Programming
   • Nonlinear Programming
   • Profile Optimization
   • Structural Optimization
   • Solution of Equations using Optimization
   • The Search for Global Optimality
   • Summary – Optimization

4. Thermodynamic Properties and Phase Equilibrium
   • Equations of State
   • Phase Equilibrium for Single Components
   • Fugacity and Phase Equilibrium
   • Vapor–Liquid Equilibrium
   • Vapor–Liquid Equilibrium Based on Activity Coefficient Models
   • Vapor–Liquid Equilibrium Based on Equations of State
   • Calculation of Vapor–Liquid Equilibrium
   • Liquid–Liquid Equilibrium
   • Liquid–Liquid Equilibrium Activity Coefficient Models
   • Calculation of Liquid–Liquid Equilibrium
   • Calculation of Enthalpy
   • Calculation of Entropy
   • Phase Equilibrium and Thermodynamic Properties – Summary

5. Choice of Reactor I – Reactor Performance
   • Reaction Path
   • Types of Reaction Systems
   • Reactor Performance
   • Rate of Reaction
   • Idealized Reactor Models
   • Choice of Idealized Reactor Model
   • Choice of Reactor Performance
   • Choice of Reactor Performance – Summary

6. Choice of Reactor II – Reactor Conditions
   • Reaction Equilibrium
   • Reactor Temperature
   • Reactor Pressure
   • Reactor Phase
   • Reactor Concentration
   • Biochemical Reactions
   • Catalysts
   • Choice of Reactor Conditions – Summary

7. Choice of Reactor III – Reactor Configuration
   • Temperature Control
   • Catalyst Degradation
   • Gas–Liquid and Liquid–Liquid Reactors
   • Reactor Configuration
   • Reactor Configuration for Heterogeneous Solid-Catalyzed Reactions
   • Reactor Configuration from Optimization of a Superstructure
   • Choice of Reactor Configuration – Summary

8. Choice of Separator for Heterogeneous Mixtures
   • Homogeneous and Heterogeneous Separation
   • Settling and Sedimentation
   • Inertial and Centrifugal Separation
   • Electrostatic Precipitation
   • Filtration
   • Scrubbing
   • Flotation
   • Drying
   • Separation of Heterogeneous Mixtures – Summary

9. Choice of Separator for Homogeneous Fluid Mixtures I – Distillation
   • Single-Stage Separation
   • Distillation
   • Binary Distillation
   • Total and Minimum Reflux Conditions for Multicomponent Mixtures
   • Finite Reflux Conditions for Multicomponent Mixtures
   • Choice of Operating Conditions
   • Limitations of Distillation
   • Separation of Homogeneous Fluid Mixtures by Distillation – Summary

10. Choice of Separator for Homogeneous Fluid Mixtures II – Other Methods
    • Absorption and Stripping
    • Liquid–Liquid Extraction
    • Adsorption
    • Membranes
    • Crystallization
    • Evaporation
    • Separation of Homogeneous Fluid Mixtures by Other Methods – Summary

11. Distillation Sequencing
    • Distillation Sequencing Using Simple Columns
    • Practical Constraints Restricting Options
    • Choice of Sequence for Simple Nonintegrated Distillation Columns
    • Distillation Sequencing Using Columns With More Than Two Products
    • Distillation Sequencing Using Thermal Coupling
    • Retrofit of Distillation Sequences
    • Crude Oil Distillation
    • Distillation Sequencing Using Optimization of a Superstructure
    • Distillation Sequencing – Summary

12. Distillation Sequencing for Azeotropic Distillation
    • Azeotropic Systems
    • Change in Pressure
    • Representation of Azeotropic Distillation
    • Distillation at Total Reflux Conditions
    • Distillation at Minimum Reflux Conditions
    • Distillation at Finite Reflux Conditions
    • Distillation Sequencing Using an Entrainer
    • Heterogeneous Azeotropic Distillation
    • Entrainer Selection
    • Trade-offs in Azeotropic Distillation
    • Multicomponent Systems
    • Membrane Separation
    • Distillation Sequencing for Azeotropic Distillation – Summary

13. Reaction, Separation and Recycle Systems for Continuous Processes
    • The Function of Process Recycles
    • Recycles with Purges
    • Pumping and Compression
    • Simulation of Recycles
    • The Process Yield
    • Optimization of Reactor Conversion
    • Optimization of Processes Involving a Purge
    • Hybrid Reaction and Separation
    • Feed, Product and Intermediate Storage
    • Reaction, Separation and Recycle Systems for Continuous Processes – Summary

14. Reaction, Separation and Recycle Systems for Batch Processes
    • Batch Processes
    • Batch Reactors
    • Batch Separation Processes
    • Gantt Charts
    • Production Schedules for Single Products
    • Production Schedules for Multiple Products
    • Equipment Cleaning and Material Transfer
    • Synthesis of Reaction and Separation Systems for Batch Processes
    • Optimization of Batch Processes
    • Storage in Batch Processes
    • Reaction and Separation Systems for Batch Processes – Summary

15. Heat Exchanger Networks I – Heat Transfer Equipment
    • Overall Heat Transfer Coefficients
    • Heat Transfer Coefficients and Pressure Drops for Shell-and-Tube Heat Exchangers
    • Temperature Differences in Shell-and-Tube Heat Exchangers
    • Allocation of Fluids in Shell-and-Tube Heat Exchangers
    • Extended Surface Tubes
    • Retrofit of Heat Exchangers
    • Condensers
    • Reboilers and Vaporizers
    • Other Types of Heat Exchange Equipment
    • Fired Heaters
    • Heat Transfer Equipment – Summary

16. Heat Exchanger Networks II – Energy Targets
    • Composite Curves
    • The Heat Recovery Pinch
    • Threshold Problems
    • The Problem Table Algorithm
    • Nonglobal Minimum Temperature Differences
    • Process Constraints
    • Utility Selection
    • Furnaces
    • Cogeneration (Combined Heat and Power Generation)
    • Integration Of Heat Pumps
    • Heat Exchanger Network Energy Targets – Summary

17. Heat Exchanger Networks III – Capital and Total Cost Targets
    • Number of Heat Exchange Units
    • Heat Exchange Area Targets
    • Number-of-shells Target
    • Capital Cost Targets
    • Total Cost Targets
    • Heat Exchanger Network and Utilities Capital and Total Costs – Summary

18. Heat Exchanger Networks IV – Network Design
    • The Pinch Design Method
    • Design for Threshold Problems
    • Stream Splitting
    • Design for Multiple Pinches
    • Remaining Problem Analysis
    • Network Optimization
    • The Superstructure Approach to Heat Exchanger Network Design
    • Retrofit of Heat Exchanger Networks
    • Addition of New Heat Transfer Area in Retrofit
    • Heat Exchanger Network Design – Summary

19. Heat Exchanger Networks V – Stream Data
    • Process Changes for Heat Integration
    • The Trade-Offs Between Process Changes, Utility Selection, Energy Cost and Capital Cost
    • Data Extraction
    • Heat Exchanger Network Stream Data – Summary

20. Heat Integration of Reactors
    • The Heat Integration Characteristics of Reactors
    • Appropriate Placement of Reactors
    • Use of the Grand Composite Curve for Heat Integration of Reactors
    • Evolving Reactor Design to Improve Heat Integratio
    • Heat Integration of Reactors – Summary

21. Heat Integration of Distillation Columns
    • The Heat Integration Characteristics of Distillation
    • The Appropriate Placement of Distillation
    • Use of the Grand Composite Curve for Heat Integration of Distillation
    • Evolving the Design of Simple Distillation Columns to Improve Heat Integration
    • Heat Pumping in Distillation
    • Capital Cost Considerations
    • Heat Integration Characteristics of Distillation Sequences
    • Heat-integrated Distillation Sequences Based on the Optimization of a Superstructure
    • Heat Integration of Distillation Columns – Summary

22. Heat Integration of Evaporators and Dryers
    • The Heat Integration Characteristics of Evaporators
    • Appropriate Placement of Evaporators
    • Evolving Evaporator Design to Improve Heat Integration
    • The Heat Integration Characteristics of Dryers
    • Evolving Dryer Design to Improve Heat Integration
    • Heat Integration of Evaporators and Dryers – Summary

23. Steam Systems and Cogeneration
    • Boiler Feedwater Treatment
    • Steam Boilers
    • Steam Turbines
    • Gas Turbines
    • Steam System Configuration
    • Steam and Power Balances
    • Site Composite Curves
    • Cogeneration Targets
    • Optimization of Steam Levels
    • Site Power-to-heat Ratio
    • Optimizing Steam Systems
    • Steam Costs
    • Choice of Driver
    • Steam Systems and Cogeneration – Summary

24. Cooling and Refrigeration Systems
    • Cooling Systems
    • Recirculating Cooling Water Systems
    • Targeting Minimum Cooling Water Flowrate
    • Design of Cooling Water Networks
    • Retrofit of Cooling Water Systems
    • Refrigeration Cycles
    • Process Expanders
    • Choice of Refrigerant for Compression Refrigeration
    • Targeting Refrigeration Power for Compression Refrigeration
    • Heat Integration of Compression Refrigeration Processes
    • Mixed Refrigerants for Compression Refrigeration
    • Absorption Refrigeration
    • Indirect Refrigeration
    • Cooling Water and Refrigeration Systems – Summary

25. Environmental Design for Atmospheric Emissions
    • Atmospheric Pollution
    • Sources of Atmospheric Pollution
    • Control of Solid Particulate Emissions to Atmosphere
    • Control of VOC Emissions to Atmosphere
    • Control of Sulfur Emissions
    • Control of Oxides of Nitrogen Emissions
    • Control of Combustion Emissions
    • Atmospheric Dispersion
    • Environmental Design for Atmospheric Emissions – Summary

26. Water System Design
    • Aqueous Contamination
    • Primary Treatment Processes
    • Biological Treatment Processes
    • Tertiary Treatment Processes
    • Water Use
    • Targeting Maximum Water Reuse for Single Contaminants
    • Design for Maximum Water Reuse for Single Contaminants
    • Targeting and Design for Maximum Water Reuse Based on Optimization of a Superstructure
    • Process Changes for Reduced Water Consumption
    • Targeting Minimum Wastewater Treatment Flowrate for Single Contaminants
    • Design for Minimum Wastewater Treatment Flowrate for Single Contaminants
    • Regeneration of Wastewater
    • Targeting and Design for Effluent Treatment and Regeneration Based on Optimization of a Superstructure
    • Data Extraction
    • Water System Design – Summary

27. Inherent Safety
    • Fire
    • Explosion
    • Toxic Release
    • Intensification of Hazardous Materials
    • Attenuation of Hazardous Materials
    • Quantitative Measures of Inherent Safety
    • Inherent Safety – Summary

28. Clean Process Technology
    • Sources of Waste from Chemical Production
    • Clean Process Technology for Chemical Reactors
    • Clean Process Technology for Separation and Recycle Systems
    • Clean Process Technology for Process Operations
    • Clean Process Technology for Utility Systems
    • Trading off Clean Process Technology Options
    • Life Cycle Analysis
    • Clean Process Technology – Summary

29. Overall Strategy for Chemical Process Design and Integration
    • Objectives
    • The Hierarchy
    • The Final Design

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