Rules of Thumb for Chemical Engineers

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Author(s): Stephen M Hall
Edition: 6
Publisher: Elsevier
Year: 2018

Language: English
Pages: 517
City: Amsterdam

Title Page......Page 3
Copyright......Page 4
Contents......Page 6
Preface......Page 14
Process Safety Management (PSM)......Page 15
Safe Design Practices......Page 17
Fire Outside the Vessel......Page 19
Blocked-In Line......Page 21
Prevent Backflow......Page 22
Dilution Purging......Page 24
Evacuation-Replacement Purging......Page 25
Causes for Loss of Containment......Page 26
Dust Explosion Hazards......Page 27
References......Page 29
Further Reading......Page 30
Definition of Scope......Page 31
Treatment of Uncertainty and Contingency......Page 32
User Requirements......Page 34
Block Diagrams......Page 35
Basis of Design (BOD)......Page 37
Piping (P&IDs)......Page 39
Factory Assembled Skids and Modules......Page 42
Data Sheets and Specifications......Page 43
Example of a Screening Estimate for a Refinery (From [1], With Permission)......Page 45
Engineering......Page 48
Reference......Page 49
Concepts and Terminology......Page 51
Equipment Design......Page 52
Flow Sheet Simulation-Continuous Process......Page 53
Flow Sheet Simulation-Dynamic Process......Page 55
Discrete Process Simulation......Page 56
Software List......Page 57
References......Page 59
Introduction......Page 61
General Procedure......Page 62
Recommended Velocity......Page 63
Check Valves......Page 66
Equivalent Length......Page 67
Friction Factor......Page 69
Compressible Flow-Isothermal......Page 71
Compressible Flow-Transmission Equations......Page 72
Compressible Flow-Adiabatic......Page 73
Reynolds Number......Page 74
Darcy Friction Factor......Page 75
Pressure Drop Due to Friction......Page 76
Listing......Page 77
Incompressible Flow (Liquids)......Page 85
Control Valves......Page 86
Partially Full Horizontal Pipes......Page 87
Two-Phase Flow......Page 88
Homogeneous Model......Page 89
Comparison of the Two-Phase Models......Page 90
Further Reading......Page 92
Introduction......Page 93
Pressure Vessels and Reactors......Page 94
Time to Drain a Tank......Page 95
Emissions From Storage Tanks......Page 100
Load Cells......Page 101
Vapor-Liquid Separators......Page 102
Liquid Surge Volume......Page 103
Vapor Velocity in the Disengagement Section......Page 104
Horizontal Separator......Page 105
Horizontal Drum With Water Separation......Page 106
Vessel Specifications......Page 107
Storage tank vents......Page 110
Further Reading......Page 111
Blending and Agitation......Page 113
Basics......Page 114
Impeller Types......Page 116
Pumping Number......Page 117
Power and Power Number......Page 118
Blending......Page 119
Newtonian Fluids in Turbulent or Transitional Flow......Page 120
Shear-Thinning Fluids......Page 121
Solids Suspension......Page 122
Terminal Settling Velocity......Page 123
Impeller Speed and Agitator Power......Page 124
Gas Dispersion......Page 128
In-Line Mixers......Page 129
Mixing Solids......Page 130
Torque......Page 131
Shaft Diameter......Page 133
Impeller Weight......Page 134
Critical Speed......Page 135
References......Page 137
Further Reading......Page 138
Centrifugal Pumps......Page 139
Positive Displacement Pumps......Page 140
Good Design Practice......Page 142
Pump Testing......Page 143
System Curves......Page 144
Sensitivity......Page 145
Operating Point-and-Pump Selection......Page 146
Control Valve......Page 148
Charting Control Characteristics......Page 149
Flow Control by Changing the Pump Speed......Page 150
Affinity Laws......Page 152
Temperature Rise......Page 153
Suction System NPSH Available......Page 154
Multiple Centrifugal Pumps in Parallel or Series......Page 155
Further Reading......Page 156
Safety Considerations......Page 157
Compressed Air Systems......Page 158
Compressor Types......Page 159
Surge Control......Page 161
Performance Calculations......Page 163
Affinity Laws......Page 166
Power-Reciprocating Compressor......Page 167
Power-Centrifugal Compressor......Page 168
Power With P-E Diagram......Page 170
References......Page 172
Further Reading......Page 173
Vacuum Units......Page 175
Conversion Between Mass Flow, Actual Volume Flow, and Standard Volume Flow......Page 176
Comparison of Vacuum Equipment......Page 177
Vacuum Jets......Page 178
Dry Vacuum Pumps......Page 180
Steam Supply......Page 181
Measuring Air Leakage......Page 182
Instrumentation and Controls......Page 184
Further Reading......Page 185
Introduction......Page 187
Flow Regimes......Page 188
System Design Procedure......Page 189
Saltation Velocity......Page 191
Pressure Drop......Page 192
Pressure Drop of Carrier Gas......Page 193
Friction of Solids in Elbows......Page 194
Feed Systems......Page 195
Conveyor Piping......Page 197
Disengagement......Page 198
References......Page 199
Cartridge Filters......Page 201
Vacuum Drum Filters......Page 203
Filter Presses......Page 205
Membrane Filters......Page 207
References......Page 209
Heat Exchangers......Page 211
TEMA......Page 212
Selection Guides......Page 213
Shell-and-Tube Heat Exchangers......Page 214
Helical Coil Heat Exchangers......Page 217
Design Recommendations......Page 220
Process Data......Page 223
Heat Exchanger Configuration and Area......Page 224
Determining the LMTD Configuration Correction Factor......Page 225
Tube Side Film Coefficient......Page 226
Shell Diameter......Page 227
Ideal Shell Side Film Coefficient......Page 228
Shell Side Film Coefficient Correction Factors......Page 229
Baffle Leakage Effects, Jl......Page 230
Bundle and Partition Bypass Effects, Jb......Page 231
Overall Heat Transfer Coefficient......Page 232
Shell Side Pressure Drop......Page 233
Fouling Resistances......Page 234
Thermal Conductivity of Metals......Page 236
Vacuum Condensers......Page 237
Air-Cooled Heat Exchangers: Air Data......Page 238
Air-Cooled Heat Exchangers: Thermal Design......Page 239
Air-Side Heat Transfer Coefficient......Page 241
References......Page 243
Further Reading......Page 244
Introduction......Page 245
Selecting the Heat Transfer Fluid......Page 246
Types of Heat Transfer Fluids......Page 247
Heat Transfer Coefficient......Page 248
System Design......Page 249
Temperature Control......Page 253
Case1: Single-Temperature Central System......Page 254
Case3: Three-Temperature Central System......Page 255
Physical Properties of Commercial Heat Transfer Fluids......Page 256
References......Page 265
Introduction......Page 267
Safety Considerations......Page 268
Vapor-Liquid Equilibrium (VLE)......Page 269
Activity Coefficients......Page 272
Establishing the Column Pressure......Page 274
Dew Point Vapor Feed......Page 275
Minimum Reflux-Multicomponent......Page 276
Minimum Stages......Page 278
Feed Location......Page 279
Graphical Methods-The McCabe-Thiele Diagram......Page 280
Tray Efficiency Rules of Thumb......Page 284
Column Internals-Trays and Packing......Page 285
Tower Diameter-Souders-Brown Correlation......Page 287
Control Schemes......Page 289
Level in the Overhead Receiver......Page 290
Composition Control......Page 291
Reboilers......Page 292
Packed Columns......Page 298
References......Page 305
Further Reading......Page 306
Introduction......Page 307
Safety Considerations......Page 308
Hydrocarbon Absorber Design......Page 309
Inorganic Absorbers......Page 310
Packing Height for Mass Transfer in Packed Columns......Page 312
Overall Mass Transfer Coefficient......Page 314
Further Reading......Page 317
Basic Nomenclature......Page 319
Cascade Control......Page 320
Specifying Instruments to Measure Values......Page 321
Control Ranges......Page 322
Drawing Conventions......Page 323
Artistic Expression......Page 324
Safety Instrumented Systems......Page 325
Enclosures: NEMA and IP......Page 326
Further Reading......Page 329
General Design Considerations......Page 331
System Design Considerations......Page 332
CIP System Design Considerations......Page 333
Disposable System Economic Evaluation......Page 335
Disposable System Environmental Life Cycle Assessment......Page 336
Open or Closed?......Page 337
Human Error (Procedures, Execution)......Page 338
Go for Data......Page 339
Widen the Search......Page 340
Risk Assessment......Page 341
Validation......Page 342
Further Reading......Page 343
Bioreactor Systems......Page 345
Clean Gas Supply to Bioreactors......Page 347
Oxygen Transfer......Page 348
pH Control......Page 350
Downstream Processes......Page 351
Buffer Prep......Page 352
Liquid Waste Inactivation......Page 355
References......Page 358
Introduction......Page 359
Calculating Steam Cost......Page 360
Equivalent Cost of Fuels......Page 361
Steam Traps......Page 362
Energy Efficient Design for Fractionators......Page 363
Pinch Analysis......Page 364
Insulation......Page 366
References......Page 368
Electric Motors......Page 369
Motor Voltages......Page 370
Motors: Efficiency......Page 372
Motors: Useful Equations......Page 376
Hydraulic Motors......Page 378
Gas Turbines: Performance......Page 379
Gas Expanders: Available Energy......Page 380
References......Page 382
Power Plants......Page 385
Controls......Page 386
Thermal Efficiency......Page 387
Steam Drum Stability......Page 388
Water Alkalinity......Page 390
Conductivity Versus Dissolved Solids......Page 391
Waste Heat......Page 394
Boiler Feedwater......Page 397
Blowdown Control......Page 398
References......Page 399
Further Reading......Page 400
Introduction......Page 401
Safety Considerations......Page 402
Material and Energy Balance Calculations......Page 403
Operations and Accessories......Page 405
Scale Prevention......Page 407
References......Page 409
Specifications......Page 411
Horsepower Per Ton......Page 414
Refrigerants......Page 415
Refrigerant Containment......Page 420
Steam Jet Ejectors......Page 421
Ammonia Heat Transfer Coefficient......Page 422
References......Page 425
Introduction......Page 427
Risk Analysis......Page 428
Sustainable Practices......Page 429
Further Reading......Page 430
Embodied Energy......Page 431
Embrittlement......Page 432
Stress-Corrosion Cracking......Page 434
Hydrogen Attack......Page 435
Pitting Corrosion......Page 436
Creep and Creep-Rupture Life......Page 437
Naphthenic Acid Corrosion......Page 439
Thermal Fatigue......Page 440
Abrasive Wear......Page 442
Pipeline Toughness......Page 443
Further Reading......Page 444
General Troubleshooting Approach......Page 445
Diagnostic Tools......Page 447
Plate-and-Frame Heat Exchangers (PHEs)......Page 448
Pinch......Page 450
Cutting Corners......Page 452
Boilup Control......Page 453
Tilted Distributor......Page 454
Hot-Vapor Rules Bypassed......Page 455
Steam Jet Vacuum Systems......Page 456
Refrigeration......Page 460
Further Reading......Page 461
Startup Management......Page 463
Startup Cost......Page 464
Systems Approach......Page 465
Startup Checklists......Page 467
Normal Operation......Page 469
References......Page 472
Atmospheric Pressure......Page 473
References......Page 475
Introduction......Page 477
Approximate Physical Properties......Page 478
Vapor-Pressure Equation......Page 480
Emulsions......Page 482
Relative Humidity......Page 483
Gas Diffusion Coefficients......Page 484
Hydrocarbons in Water......Page 486
Methanol Injection......Page 489
Compressibility Factor......Page 492
Inorganic Gases in Petroleum......Page 493
Foam Density......Page 494
Estimating Equivalent Diameter of Solids......Page 495
Further Reading......Page 498
Appendix A......Page 499
Tank Cleaning......Page 507
C......Page 511
F......Page 512
I......Page 513
P......Page 514
T......Page 515
W......Page 516