CHEMICAL ENGINEERING DESIGN PROJECT

Contents
Introduction to the Series
Acknowledgements
I About this Book - The Case Study Approach
I I Advice to the Student
III To the Lecturer
I V The Scope of Design Projects
V Effective Communications
VI Comments on the Case Study Approach
The Case Study - Summary for the Completed Project
PART I PRELIMINARY DESIGN - TECHNICAL AND
ECONOMIC FEASIBILITY

CHAPTER 1 THE DESIGN PROBLEM
1.1 Initial Considerations and Specification
The Case Study - Summary for Part I
Feasibility Study and Initial Design Considerations
1.2 Case Study- Defining the Problem and Background
Information
Summary
1.2.1 Introduction
1.2.2 Properties and Uses
1.2.3 The Evolution of Nitric Acid Production
Processes
1.2.4 Ammonia Oxidation Chemistry

CHAPTER 2 FEASIBILITY STUDY AND LITERATURE
SURVEY
Initial Feasibility Study
Presentation of Literature Surveys for Projects
Case Study- Feasibility Study (Market Assessment)
Summary
2.3.1 Introduction
2.3.2 The Domestic Scene
2.3.3 The Global Market
2.3.4 Market Analysis Discussion
2.3.5 Market Assessment Conclusions
Case Study - Literature Survey
Summary
2.4.1 Introduction
2.4.2 General Information
2.4.3 Process Technology
2.4.4 Cost Estimation
2.4.5 Market Data
2.4.6 Thermodynamic Data
Case Study - Bibliography

CHAPTER 3 PROCESS SELECTION
3.1 Process Selection - Considerations
3.2 Case Study - Process Selection
Summary
3.2.1 Introduction
3.2.2 Process Comparison
Factors Favouring the Dual-Pressure Process
Factors Favouring the Single-Pressure Process
Other Considerations
3.2.3 Process Selection Conclusions

CHAPTER 4 PROCESS DESCRIPTION AND EQUIPMENT
LIST
4.1 Introductory Notes
4.2 Case Study - Process Description
4.2.1 Introduction
4.2.2 The Process
4.2.3 Requirements of Major Process Units
4.2.4 Mechanical Design Features of Major Units
4.2.5 Process Flow Diagram
4.2.6 Process Performance Assessment

CHAPTER 5 SITE CONSIDERATIONS
5.1 Site Selection
5.2 Plant Layout
5.3 Environmental Impact Analysis
5.3.1 General Considerations
5.3.2 EIA Policy and Scope
5.3.3 EIA Reports
5.3.4 Australia
5.3.5 United Kingdom
5.3.6 United States
5.4 Case Study - Site Considerations
5.4.1 Site Considerations - Introduction
5.4.2 Site Selection
5.4.3 Perth Metropolitan Region
5.4.4 Country Districts
5.4.5 Site Location Conclusions
5.4.6 Plant Layout
5.4.7 Environmental Impact Analysis

CHAPTER 6 ECONOMIC EVALUATION
6.1 Introductory Notes
6.2 Capital Cost Estimation
6.2.1 Cost of Equipment (Major Items)
6.2.2 Module Costs
6.2.3 Auxiliary Services
6.3 Operating Costs
6.4 Profitability Analysis
6.5 Case Study - Economic Evaluation
6.5.1 Introduction
CONTENTS
65.2 Capital Cost Estimation
(a) The Ratio Method
(b) The Factorial Method
(c) Capital Cost Conclusions
6.53 Investment Return

CHAPTER 7 MASS AND ENERGY BALANCES
7.1 Preparation of Mass and Energy Balances
7.2 Preliminary Equipment Design
7.3 Computer-Aided Design
7.4 Case Study - Mass and Energy Balances
7.4.1 Overall Process Mass Balance
7.4.2 Unit Mass and Energy Balances
7.4.2.1 Ammonia Vaporizer
7.4.2.2 Ammonia Superheater
7.4.2.3 Two-stage Air Compressor
7.4.2.4 Reactor Feed Mixer
7.4.2.5 Reactor
7.4.2.6 Steam Superheater
7.4.2.7 Waste-Heat Boiler
7.4.2.8 Platinum Filter
7.4.2.9 Tail-Gas Preheater
7.4.2.10 Oxidation Unit
7.4.2.11 Cooler/Condenser
7.4.2.12 Secondary Cooler
7.4.2.13 Absorber
7.4.2.14 Bleaching Column
7.4.2.15 Vapor/Liquid Separator
7.4.2.16 Tail-Gas Warmer
7.4.2.17 Refrigeration Unit


PART II DETAILED EQUIPMENT DESIGN
CHAPTER 8 THE DETAILED DESIGN STAGE
8.1 Detailed Equipment Design
8.1.1 Equipment Design - HELP!
8.2
CONTENTS
Additional Design Considerations
8.2.1 Energy Conservation
8.2.2 Process Control and Instrumentation
8.2.3 Safety, Loss Prevention and HAZOP
References
Case Study - Summary for Part II: Detailed Equipment
Design
Case Study-Amendments to Part I

CHAPTER 9 CASE STUDY - ABSORPTION COLUMN
DESIGN
9.1 introduction
9.2 The Design Method
9.2.1 The Mathematical Model
9.2.2 Sieve-Plate Hydraulic Design
9.2.3 Mechanical Design of Column
9.2.4 Process Control Scheme
Important Operating Considerations
Design Constraints
Absorption Column Specification
Sieve Tray Specifications
Process Control Scheme
Hazard and Operability Study
Discussion of Results
Assessment of the Design Method
Revised Absorption Column Costing
Conclusions
References


CHAPTER 10 CASE STUDY - STEAM SUPERHEATER
DESIGN
Summary
10.1 Introduction
10.2 Summary of Design Method
10.2.1 The Kern Method
10.2.2 The Bell Method
10.2.3 Mechanical Sizing 196
10.3 Design Selection Factors
10.3.1 Exchanger Type
10.3.2 Choice of Flow Mode
10.3.3 Materials Selection
10.3.4 Shell and Tube Sizing
10.4 Design Specification
10.5 Process Control
10.6 Design Method Evaluation
10.7 Revised Cost Estimation
10.8 Conclusions
References

CHAPTER 11 CASE STUDY - BLEACHING-COLUMN
FEED PUMP SPECIFICATION
Summary
11.1 Introduction
11.2 Design Method
11.3 Pump Specification
11.4 Discussion
11.5 Conclusions
References

CHAPTER 12 CASE STUDY - NITRIC ACID STORAGETANK
DESIGN
Summary
12.1 Introduction
12.2 Design Method
12.3 Tank Specification
12.4 Conclusions
References

Final Comments 220
APPENDICES
Appendix A Data for Section 1.2
Appendix B Data for Section 2.3
Appendix C Data for Section 3.2
Appendix D Data for Section 4.2
Appendix E Data for Section 6.5

Appendix F Calculations for Section 7.4 255
CONTENTS xi
Appendix G Absorption Column Calculations (Chapter 9) 281
Appendix H Steam Superheater Calculations (Chapter 10) 307
Appendix I Pump Calculations (Chapter 11) 325
Appendix J Tank Calculations (Chapter 12) 338
Appendix K Design Projects Information 343
Appendix L Information Sources 351
INDEX 355



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