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    Martyn Ray Design Book

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    Steve Wright
    This document provides an overview and outline of a chemical engineering design project textbook. It introduces the case study approach and stages of a design problem. It then outlines several chapters that would be included in the textbook, providing summaries of the content and focus of each chapter. The chapters cover topics such as feasibility studies, process selection, site selection, environmental considerations, economic evaluation, mass and energy balances, additional design factors, and detailed equipment design. An example case study is also provided on the design of a phthalic anhydride production process.

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    Martyn Ray Design Book

    Uploaded by

    Steve Wright
    870 views345 pages
    This document provides an overview and outline of a chemical engineering design project textbook. It introduces the case study approach and stages of a design problem. It then outlines several chapters that would be included in the textbook, providing summaries of the content and focus of each chapter. The chapters cover topics such as feasibility studies, process selection, site selection, environmental considerations, economic evaluation, mass and energy balances, additional design factors, and detailed equipment design. An example case study is also provided on the design of a phthalic anhydride production process.

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    Engineering, Process Plant Design, Design Project

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    This document provides an overview and outline of a chemical engineering design project textbook. It introduces the case study approach and stages of a design problem. It then outlines several chapters that would be included in the textbook, providing summaries of the content and focus of each chapter. The chapters cover topics such as feasibility studies, process selection, site selection, environmental considerations, economic evaluation, mass and energy balances, additional design factors, and detailed equipment design. An example case study is also provided on the design of a phthalic anhydride production process.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    870 views345 pages

    Martyn Ray Design Book

    Uploaded by

    Steve Wright
    This document provides an overview and outline of a chemical engineering design project textbook. It introduces the case study approach and stages of a design problem. It then outlines several chapters that would be included in the textbook, providing summaries of the content and focus of each chapter. The chapters cover topics such as feasibility studies, process selection, site selection, environmental considerations, economic evaluation, mass and energy balances, additional design factors, and detailed equipment design. An example case study is also provided on the design of a phthalic anhydride production process.

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    © All Rights Reserved
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    Content
    Preface to Second Edition
    Acknowledgements
    Introduction

    xv
    xvii
    1

    I How to Use This Book


    (A) The Case Study Approach
    (B) A "Road Map"
    II Some Advice
    (A) General Advice to the Student
    (B) Advice from a Former Design Project Student
    (C) To the Lecturer
    (D) The Designer or Project Engineer
    III Presentation of Design Projects
    (A) Effective Communications
    (B) General Comments on Preparation of Literature Surveys
    IV Details of Particular Design Projects, and Information Sources
    (A) IChemE Design Projects
    Instructions for the IChemE Design Project, 1980
    (B) Information Sources

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    PART 1 TECHNICAL AND ECONOMIC FEASIBILITY STUDY


    Chapter 1
    1.1

    The Design Problem

    Initial Considerations and Specification


    1.1.1 The Feasibility Study
    1.1.2 Time Management
    1.1.3 Stages in a Design Problem
    1.1.4 The Search for Information
    1.1.5 Scope of the Project
    1.1.6 Evaluating the Alternatives - Making Decisions

    Some Questions to Ask for the Chemical to be Produced


    Further Reading

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    Case Study: Production of Phthalic Anhydride


    Overall Summary for the Technical and Economic Feasibility Study
    1.2 Case Study - Defining the Problem and Background Information
    Summary
    1.2.1 Background and Objectives
    1.2.2 Chemical Structure and Physical Properties
    1.2.3 Applications and Uses
    1.2.4 Basic Chemistry
    1.2.5 Evaluation of Alternative Processing Schemes
    1.2.6 Conclusions
    1.2.7 Recommendations
    Chapter 2 Feasibility Study and Market Survey
    2.1
    Initial Feasibility Study
    2.2
    Preliminary Market Survey/Economic Analysis
    References
    2. 3 Information Sources
    2.4
    Evaluation of Available Literature
    2.5
    Considerations for Literature Surveys
    References
    2.6
    Case Study - Feasibility Study and Market Assessment
    Summary
    2.6.1 Market Assessment
    2.6.1.1 Production: Worldwide
    2.6.1.2 Production: Regional
    2.6.1.3 Production: National
    2.6.2 Current and Future Prices
    2.6.3 Demand
    2.6.4 Australian Imports and Exports
    2.6.5 Plant Capacity
    2.6.6 Product Value and Operating Costs
    2.6.6.1 Capital Costs
    2.6.6.2 Operating Costs
    2.6.6.3 Approximate Selling Price
    2.6.7 Conclusions
    2.6.8 Recommendations

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    Chapter 3 Process Selection, Process Description and Equipment List


    3.1
    Process Selection Considerations
    3.1.1 Flow Diagrams - PFD and P&ID
    3.1.2 The Reactor
    3.1.3 Product Purity
    3.1.4 Process Conditions

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    3.1.5
    3.1.6
    3.1.7
    3.1.8
    3.1.9
    3.1.10

    Process Data
    Energy Efficiency
    Factors in Process Evaluation and Selection
    Choices and Compromises
    The Optimum Design
    Process Control and Instrumentation
    References
    3.2
    Process Description
    3.3
    Preparing the Equipment List
    3.4
    Rules of Thumb
    3.5
    Safety Considerations and Preliminary HAZOP Study
    References
    3.6
    Case Study - Process Selection and Equipment List
    Summary
    3.6.1 Trends in Phthalic Anhydride Processing
    3.6.2 Raw Material
    3.6.3 Process Configurations
    3.6.4 Detailed Process Description
    3.6.5 Advantages of the LAR Process
    3.6.6 Advantages of the LEVH Process
    3.6.7 Process Selection
    3.6.8 Initial Equipment Design
    3.6.9 Equipment List
    3.6.10 Conclusions
    3.6.11 Recommendations
    Appendix A: Preliminary Equipment Specifications
    Chapter 4 Site Considerations: Site Selection and Plant Layout
    4.1
    Site Selection/ Location
    4.1.1 Local Industrial Areas
    4.1.2 Some Important Factors
    4.1.3 Prioritizing the Factors
    References
    4.2
    Plant Layout
    4.2.1 Plant Layout Strategies
    4.2.2 Factors Influencing Plant Layout
    References
    4.3
    Case Study - Site Considerations: Site Selection and Plant Layout

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    Summary
    4.3.1 Background and Objectives
    4.3.2 Potential Sites
    4.3.2.1 Kemerton
    4.3.2.2 Geraldton

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    4.3.2.3 Karratha
    4.3.2.4 Kwinana
    4.3.3 Preferred Site and Layout
    4.3.4 Conclusions
    4.3.5 Recommendations
    Chapter 5 Environmental Considerations
    5.1
    Environmental Impact Assessment
    5.2
    General Considerations
    5.3
    EIA Policy and Scope
    5.4
    EIA Reports
    5.5
    Australia
    5.6
    United Kingdom
    5.7
    United States
    5.8
    ISO-14000
    5.9
    Legislation
    References
    5.10 Case Study - Environmental Considerations
    Summary
    5.10.1 Purpose
    5.10.2 Airborne Emissions
    5.10.3 Waterborne Emissions
    5.10.4 Solid Waste
    5.10.5 Process Hazards
    5.10.6 Accidental Spills and Tank Breaches
    5.10.7 Personnel Safety Precautions and Procedures
    5.10.8 Conclusions
    5.10.9 Recommendations
    Chapter 6 Economic Evaluation
    6.1
    Introductory Notes
    6.2
    Capital Cost Estimation
    6.2.1 Cost of Equipment (Major Items)
    (I) Cost Correlations
    (II) Factored Estimate Method
    6.2.2 Module Costs
    6.2.3 Auxiliary Services
    6.3
    Operating Costs - Fixed and Variable
    6.3.1 Depreciation
    6.4
    Profitability Analysis
    6.4.1 The Payback Period
    6.4.2 Return on Investment (ROI)
    6.4.3 Evaluating Different Scenarios
    6.4.4 Economic Evaluation and Analysis

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    6.4.5 Evaluating Different Projects: Use of DCF and NPV


    The Engineers' Approach to Economic Evaluation
    The Final Word?
    References

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    6.5
    Case Study - Economic Evaluation
    Summary
    6.5.1 Background and Objectives
    6.5.2 Equipment Costs
    6.5.3 Installed Plant Cost by Lang Factor
    6.5.4 Installed Plant Cost from Recent Plant Construction Data
    6.5.5 Production Costs
    6.5.6 Profitability Analysis
    6.5.7 Conclusions
    6.5.8 Recommendations

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    Chapter 7 Mass and Energy Balances


    7.1
    Preparation of Mass and Energy Balances
    References
    7.2
    Preliminary Equipment Design
    References
    7.3
    Computer-Aided Design
    What design work is there left to do now that we have
    simulation packages?
    References
    7.4
    Case Study-Mass and Energy Balances, and Utilities
    Summary
    7.4.1 Scope and Objectives
    7.4.2 Mass Balances
    7.4.3 Energy Balances
    7.4.4 Optimisation of Mass and Energy Balances
    7.4.5 Utilities
    7.4.6 Conclusions
    7.4.7 Recommendations

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    Chapter 8 Additional Design Considerations


    8.1
    Energy Integration and Conservation
    8.2
    Process Control, Instrumentation and Alarms
    8.3
    Safety, Health and the Environment
    References
    Energy Conservation

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    Process Control
    Safety, Health and the Environment
    (including Loss Prevention and HAZOP)
    8.4 Case Study Energy Integration, Piping Specifications
    Process Control and the P&ID
    Summary
    8.4.1 Energy Management and Integration
    8.4.2 Plant Piping Specifications
    8.4.3 Control and Instrumentation
    8.4.4 The Piping and Instrumentation Diagram (P&ID
    8.4.5 Conclusions
    8.4.6 Recommendations
    References for Case Study Sections in Chapters 1 to 8
    Comments
    References
    PART II DETAILED EQUIPMENT DESIGN
    Chapter 9 The Detailed Design Stage
    9.1
    Detailed Equipment Design
    9.1.1 Equipment Design - HELP!!!
    How to Begin to Design an Item of Equipment
    9.2
    Standards and Codes
    9.3
    Additional Design Considerations
    References
    Some General Textbooks
    Design Books
    Chapter 10 Case Study -Phthalic Anhydride Reactor Design
    Overall Summary
    Updated Material and Energy Balance for the Phthalic
    Anhydride Reactor (R101)
    Engineering Specification Sheet for the Reactor (R101)
    Schematic Drawing of the Reactor (R101)
    Part I Chemical Engineering Design
    10.1 Overall Design Strategy
    10.2 Design Basis
    10.3 Design Parameters
    10.4 Design Criteria
    10.5 Chemical Engineering Design Methods
    10.5.1 Catalyst Properties
    10.5.2 Kinetics

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    10.5.3 Reactor Simulation


    10.5.4 Heat Transfer
    10.5.5 Pressure Drop
    10.6 Detailed Design
    10.6.1 Reactor Configuration
    10.6.2 Coolant
    10.6.3 Computer Model
    10.6.4 Shell Configuration
    10.6.5 Salt Cooler
    10.6.6 Salt Circulation Pump
    10.7 Chemical Engineering Design Specification
    10.7.1 Reactor Specification
    10.7.2 Salt Cooler Specification
    10.7.3 Salt Circulation Pump Specification
    Part II Mechanical Engineering Design
    10.8 Mechanical Engineering Design Parameters
    10.9 Mechanical Engineering Design Methods
    10.9.1 Shell Design
    10.9.2 Supports and Foundations
    10.10 Materials of Construction
    10.11 Pressure Vessel Design (AS1210)
    10.12 Insulation
    10.13 Supports and Foundations
    10.14 Costing
    10.15 Engineering Specification
    Specification Sheets
    Engineering Drawings
    Part III Operational Considerations
    10.16 HAZOP Analysis
    10.17 Process Hazards
    10.18 Safety
    10.19 Operability
    10.20 Environmental Considerations
    10.21 Control and Instrumentation
    10.22 Operating Considerations
    10.22.1 Operation Under Normal Conditions
    10.22.2 Commissioning
    10.22.3 Shut-Down
    10.22.4 Start-Up
    10.22.5 Regular Maintenance
    Part IV Conclusions, Recommendations and References
    10.23 Conclusions
    Chemical Engineering Design
    Mechanical Engineering Design

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    Operational Considerations
    10.24 Recommendations
    10.25 References
    Appendix B. Calculations for Phthalic Anhydride Reactor Design
    B.1 Reactions
    B.2 Derivation of Simulation Model Equations
    B.3 Tube-Side Heat Transfer Coefficient
    B.4 Shell-Side Heat Transfer Coefficient
    B.5 Overall Heat Transfer Coefficient (Clean)
    B.6 Tube Count
    B.7 Tube-Side Pressure Drop
    B.8 Shell-Side Pressure Drop
    B.9 Salt Cooler Design
    B.10 Shell Design (AS1210)
    B.11 Tube-Plate Design
    B.12 Vessel Openings
    B.13 Protective Devices (AS1210)
    B.14 Insulation
    B.15 Supports
    B.16 Foundation
    Appendix C. FORTRAN Program for Phthalic Anhydride Reactor Simulation
    Appendix D. Hazard and Operability Studies for Phthalic Anhydride Reactor

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    Chapter 11 Case Study -Phthalic Anhydride After-Cooler Design


    Overall Summary
    Updated Material and Energy Balance for the After-Cooler (E105)
    Engineering Specification Sheet for the After-Cooler (E105)
    Schematic Drawing of the After-Cooler
    Part I Chemical Engineering Design
    11.1 General Design Considerations
    11.2 Design Strategy and Criteria
    11.3 Preliminary Design Decisions
    11.3.1 Condenser Type
    11.3.2 Coolant
    11.4 Chemical Engineering Design Methods
    11.4.1 Heat Transfer Coefficient
    11.4.2 After-Cooler Simulation
    11.4.3 Pressure Drop
    11.5 Detailed Design
    11.5.1 General Considerations
    11.5.2 Simulation Results
    11.5.3 Vessel Configuration

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    11.6 Chemical Engineering Design Specification


    Part II Mechanical Engineering Design
    11.7 Mechanical Engineering Design Requirements
    11.8 Materials of Construction
    11.9 Vessel Dimensions
    11.10 Insulation
    11.11 Supports and Foundation
    11.12 Costing
    11.13 Engineering Specification
    Part III Operational Considerations
    11.14 HAZOP Analysis
    11.15 Process Hazards
    11.16 Safety
    11.17 Operability
    11.18 Environmental Considerations
    11.19 Control and Instrumentation
    11.20 Operating Considerations
    11.20.1 Operation Under Normal Conditions
    11.20.2 Commissioning
    11.20.3 Shut-Down and Start-Up
    11.20.4 Regular Maintenance
    Part IV Conclusions, Recommendations and References
    11.21 Conclusions
    Chemical Engineering Designc
    Mechanical Engineering Design
    Operational Considerations
    11.22 Recommendations
    11.23 References
    Appendix E. Calculations for Phthalic Anhydride After-Cooler Design
    E.1 Provisional After-Cooler Design
    E.2 Shell-Side Cross-Flow Area
    E.3 Pressure Drops
    E.4 Mechanical Design
    E.5 Supports
    E.6 Foundation
    Appendix F. FORTRAN Program for Phthalic Anhydride
    After-Cooler Simulation
    Appendix G. Hazard and Operability Study for Phthalic Anhydride
    After-Cooler (Tables G.1 to G.5)
    Final Comments
    INDEX

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    Preface to Second Edition


    The main difference between this edition and the original (1989) is the inclusion of a new
    case study - the production of phthalic anhydride. Although the design process is
    essentially similar for most chemicals, no two designs are ever the same. A comparison
    between the original case study and this new one should emphasise the need for
    originality and flexibility in process design.
    As with the earlier edition, the case study has been incorporated throughout the book so
    that application of the principles and ideas which are discussed in the main text can be
    illustrated sequentially. The case study should not be viewed merely as a design blue-print
    but as an integral part of the book. Two items of equipment have been desinged in detail
    in this new case study (Part 11) whereas only the first item was considered to that depth
    in the first edition.
    All sections of the text material have been revised and new material has been added, e.g.
    loss prevention and safety, economic evaluation and environmental considerations. The
    new material reflects important developments and shifting emphasis in chemical
    engineering over the intervening years. However, the focus is again on the approach of
    learning by doing. It is necessary to consider a broad range of topics in a design problem,
    hence the retention of the Technical and Economic Feasibility Study.
    The advice is intended to be practical and the reader is directed to an extensive list of
    useful references - fully updated in this edition. This book is not intended to be a design
    handbook, it should be considered as a 'road map' for performing a design project.

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