Chemical

Engineering
Design
and Economics

Principles, Practice

of Plant and Process

Design

Second Edition

Gavin Towler

Ray Sinnott

AMSTERDAM

NEW YORK

BOSTON

SAN FRANCISCO

ELSEVIER

OXFORD

HEIDELBERG

PARIS

SINGAPORE

LONDON

SAN DIEGO

SYDNEY

TOKYO

Bulterworth-Heinemann is an imprint of Elsevier

Contents
Preface to the Second Edition

xi

How to Use This Book

xiii

Acknowledgments

PART 1

xv

PROCESS DESIGN

CHAPTER 1
1.1

Introduction to

Design

Introduction

1.2 Nature of Design

1.3

The

Organization

3
of

Chemical

Engineering Project

1.4 Project Documentation

12

1.5

Codes and Standards

18

1.6

Design

1.7

Systems

Factors

20

(Design Margins)

of Units

20

1.8 Product Design

22

References

31

Nomenclature

31

Problems

31

CHAPTER 2

Process Flowsheet

33

Development

2.1 Introduction

33

2.2 Flowsheet Presentation

2.3 The Anatomy of

34

Chemical

Manufacturing

Process

45

2.4 Selection, Modification, and Improvement of Commercially-Proven Processes... 57

2.5 Revamps of Existing Plants

64

2.6 Synthesis of Novel Flowsheets

78

2.7 PFD Review

2.8 Overall Procedure for Flowsheet Development

CHAPTER 3
3.1

References

Nomenclature

Problems

Utilities and

Energy Efficient Design

Introduction

10
10

3.2 Utilities

10

3.3 Energy Recovery

11

3.4 Waste Stream Combustion

12

3.5 Heat-exchanger Networks

12

3.6 Energy

Management

in

Unsteady

Processes

14

iv

Contents

CHAPTER 4

References

155

Nomenclature

157

Problems

158

Process Simulation

161

4.1 Introduction

161

4.2 Process Simulation Programs

162

4.3

165

Specification

of

Components

4.4 Selection of Physical Property Models

169

4.5 Simulation of Unit Operations

184

4.6 User Models

219

4.7 Flowsheets With Recycle

223

4.8 Flowsheet Optimization

236

4.9

239

CHAPTER 5
5.1

Simulation

Dynamic

References

239

Nomenclature

241

Problems

243

Instrumentation and Process Control

251

Introduction

5.2 The P&I

251

Diagram

252

5.3 Process Instrumentation and Control

257

5.4 Conventional Control Schemes

261

5.5 Alarms,

270

Safety Trips,

and Interlocks

5.6 Batch Process Control

272

5.7

272

CHAPTER 6
6.1

Computer

Control

Systems

References

275

Problems

276

Materials of Construction
Introduction

6.2 Material

279
280

Properties

6.3 Mechanical

279

Properties

280

6.4 Corrosion Resistance

283

6.5 Selection for Corrosion Resistance

288

6.6 Material Costs

289

6.7

Contamination

290

6.8

Commonly Used Materials of Construction

291

6.9 Plastics

as

Materials of Construction for Chemical Plant

6.10 Ceramic Materials

6.11

(Silicate Materials)

Carbon

6.12 Protective

297
300
301

Coatings

302

Contents

6.13

CHAPTER 7
7.1

Design for Corrosion

302

Nomenclature

304

Problems

304

Capital Cost Estimating

307

Introduction

307

Components

7.3

Accuracy

of

and

7.4 Order of

7.6

302

Resistance

References

7.2

7.5

Capital

Purpose

Magnitude

308

Cost
of

Capital

Cost Estimates

Estimating

Purchased

Estimating

Installed Costs: The Factorial Method

Equipment

Costs

Estimating

7.10

Computer

7.11

Validity

CHAPTER 8

320
328
335
338

7.8 Location Factors

Offsite

311
312

Estimates

7.7 Cost Escalation

7.9

Costs

Capital

Tools for Cost

Estimating

of Cost Estimates

340
341
348

References

349

Nomenclature

350

Problems

352

Estimating Revenues

and Production Costs

355

8.1 Introduction

355

8.2 Costs, Revenues, and Profits

356

8.3 Product and Raw Material Prices

360

8.4 Estimating Variable Production Costs

373

Fixed Production Costs

8.5

Estimating
8.6 Summarizing Revenues

CHAPTER 9
9.1

376
380

References

385

Nomenclature

385

Problems

385

Economic Evaluation of Projects

389
389

Introduction

9.2 Cash Flows

9.3

and Production Costs

during

Project

Project Financing

389
393

9.4 Taxes and Depreciation

398

9.5 Simple Methods for Economic Analysis

403

9.6 Present Value Methods

406

9.7 Annualized Cost Methods

411

vi

Contents

9.8

Sensitivity Analysis

414

9.9 Project Portfolio Selection

421

References

426

Nomenclature

426

Problems

427

CHAPTER 10 Safety and Loss Prevention

431

10.1 Introduction

431

10.2 Materials Hazards

436

10.3 Process Hazards

443

10.4 Analysis of Product and Process

10.5 Failure-Mode Effect

Safety

Analysis

10.6 Safety Indices

10.7 Hazard and

450
454
456

Operability

Studies

467

10.8 Quantitative Hazard Analysis

475

10.9 Pressure Relief

481

References

496

Nomenclature

501

Problems

502

CHAPTER 11 General Site Considerations

11.1

Introduction

505
505

11.2 Plant Location and Site Selection

505

11.3 Site Layout

508

11.4 Plant Layout

509

11.5 Environmental Considerations

513

References

CHAPTER 12 Optimization

522

in

Design

525

12.1 Introduction

525

12.2 The Design Objective

526

12.3 Constraints and Degrees of Freedom

527

12.4 Trade-Offs

530

12.5 Problem Decomposition

12.6 Optimization of

Single

531
Decision Variable

12.7 Search Methods

12.8 Optimization of Two
12.9 Linear Programming

532
533

or

More Decision Variables

536
539

Contents

vii

12.10 Nonlinear Programming

540

12.11 Mixed Integer Programming

542

12.12

Optimization in Industrial Practice

544

References

549

Nomenclature

549

Problems

551

PART 2

PLANT DESIGN

CHAPTER 13 Equipment Selection, Specification, and Design

13.1

557
557

Introduction

13.2 Sources of Equipment Design Information

558

13.3 Guide

560

Selection and

Equipment

to

Design

References

562

CHAPTER 14 Design of Pressure Vessels

563

14.1 Introduction

563

14.2 Pressure Vessel Codes and Standards

565

14.3 Fundamentals of Strength of Materials

567

14.4 General Design Considerations for Pressure Vessels

570

14.5 The Design of Thin-Walled Vessels Under Internal Pressure

575

14.6 Compensation for

584

Openings

and Branches

14.7 Design of Vessels Subject

to External

14.8 Design of Vessels Subject

to

Pressure

Combined

Loading

584
585
598

14.9 Vessel Supports

14.10 Bolted Flanged Joints

606

14.11 Welded Joint Design

615

14.12 Fatigue Assessment of Vessels

617

14.13 Pressure Tests

618

14.14 High-Pressure Vessels

618

14.15

621

Liquid Storage

Tanks

References

622

Nomenclature

624

Problems

627

CHAPTER 15 Design

631

of Reactors and Mixers

631

15.1 Introduction
15.2 Reactor

Design:

General Procedure

15.3 Sources of Reaction

Engineering

Data

632

641

viii

Contents

15.4 Choice of Reaction Conditions

653

15.5

660

Mixing

15.6 Heating and Cooling of

Reacting Systems

669

15.7 Multiphase Reactors

678

15.8 Reactor Design for Catalytic Processes

689

15.9 Design of Bioreactors

712

15.10 Multifunctional Batch Reactors

733

15.11 Computer Simulation of Reactors

735

15.12 Determining Actual Reactor Performance

738

15.13

Safety

740

15.14

Capital

Considerations in Reactor

Design

Cost of Reactors

744

References

744

Nomenclature

747

Problems

750

CHAPTER 16 Separation

of Fluids

753

16.1 Introduction

753

16.2 Gas-Gas Separations

754

16.3 Gas-Liquid Separators

768

16.4 Liquid-Liquid Separation

773

16.5 Separation of Dissolved Components

780

References

801

Nomenclature

803

Problems

805

CHAPTER 17 Separation Columns (Distillation, Absorption, and Extraction)

807

17.1 Introduction

807

17.2 Continuous Distillation: Process

17.3 Continuous Distillation: Basic

17.4

Design Variables

Description

808

Principles

811

in Distillation

816

17.5

Design Methods for Binary Systems

Multicomponent Distillation: General Considerations
17.7 Multicomponent Distillation: Shortcut Methods for Stage and
Requirements
17.8 Multicomponent Distillation: Rigorous Solution Procedures

817

17.6

824
Reflux

833

(Computer Methods)

839

17.9 Other Distillation Processes

841

17.10 Plate Efficiency

843

17.11

853

Approximate Column Sizing

Contents

854

17.12 Plate Contactors

17.13 Plate Hydraulic

ix

863

Design

17.14 Packed Columns

886

17.15 Column Auxiliaries

916

17.16 Solvent Extraction (Liquid-Liquid Extraction)

917

17.17 Capital Cost of Separation Columns

923

References

924

Nomenclature

928

Problems

932

CHAPTER 18 Specification and

18.1

Design

Solids-Handling Equipment

of

Introduction

937
937

18.2

Properties of Granular Materials

Storage and Transport of Solids
18.4 Separation and Mixing of Solids

938

18.3

952

18.5 Gas-Solids Separations (Gas Cleaning)

975

18.6
18.7

Separation
Separation

of Solids from
of

Liquids

18.8 Solids Formation,

18.10 Heat Transfer

to

987

Liquids

from Solids

Shaping,

18.9 Particle Size Reduction

966

1008

(Drying)

and Size

Enlargement

Processes

1026

(Comminution)

Flowing Solid

1021

Particles

1034
1035

18.11 Hazards of Solids Processing

References

1037

Nomenclature

1042

Problems

1045

CHAPTER 19 Heat-Transfer Equipment

1047

19.1

1047

Introduction

19.2 Basic

Design

Procedure and

1048

Theory

19.3 Overall Heat-Transfer Coefficient

1050

19.4 Fouling Factors (Dirt Factors)

1053

19.5 Shell and Tube Exchangers: Construction Details

1054

19.6 Mean Temperature Difference (Temperature Driving Force)

1069

19.7 Shell and Tube Exchangers: General Design Considerations

1074

19.8 Tube-Side Heat-Transfer Coefficient and Pressure

1077

19.9 Shell-Side Heat Transfer and Pressure

1083

Drop (Single Phase)

Drop (Single Phase)

19.10 Condensers

1107

19.11 Reboilers and Vaporizers

1130

19.12 Plate Heat

1156

Exchangers

19.13 Direct-Contact Heat

Exchangers

1165

Contents

19.14 Finned Tubes

1167

19.15 Double-Pipe Heat Exchangers

1168

19.16 Air-Cooled Exchangers

1169

19.17 Fired Heaters (Furnaces and Boilers)

1178

19.18 Heat Transfer

to Vessels

1184

19.19 Capital Cost of Heat Transfer

Equipment

References

1191

Nomenclature

1196

Problems

1201

CHAPTER 20 Transport and Storage

of Fluids

1207

20.1 Introduction

1207

20.2 Storage of Fluids

1207

20.3 Transport of Gases and

1209

20.4 Pressure Drop in

1213

Liquids
Pipelines

20.5 Valves

1219

20.6 Compression and

20.7 Pumping of

Expansion
Liquids

of Gases

20.8 Selection of Drivers for Rotating

1221

1230

Equipment

20.9 Mechanical Design of Piping Systems

1244
1245

20.10 Pipe Size Selection

1248

20.11 Sizing of Control Valves

1256

References

1259

Nomenclature

1261

Problems

1263

Appendices

1267

(visit booksite.elsevier.com/Towler
A

to download the

Graphical Symbols

for

following appendices)

Piping Systems

and Plant

B Corrosion Charts
C

Physical Property

C-l
1267

Design Projects (Shorter

Design Projects (Longer Problem Statements)

Equipment Specification (Data) Sheets
Typical Shell and Tube Heat Exchanger Tube-Sheet Layouts
Material Safety Data Sheet

G
H
I

A-l
B-l

Data Bank

D Conversion Factors

Index

1191

Problem

Statements)

E-l
F-l
G-l
H-l
1-1

1271