PRELIMINARY CHEMICAL ENGINEERING PLANT DESIGN

Preface x i
1 . INTRODUCTION TO PROCESS DESIGN 1
Research, 2.
Other Sources of Innovations, 3.
Process Engineering,4.
Professional Responsibilities, 7.
Competing Processes,8 .
Typical Problems a Process Engineer Tackles, 9.
Comparison with A l t e r n a t i v e s , 1 4 .
C o m p l e t i n g t h e Project, 16.
Units,17.
References, 18.
Bibliography, 18.

2 . SITE SELECTION
Major Site Location Factors, 25.
Other Site Location Factors, 34.
Case Study: Site Selection, 48.
References, 54.

3 . THE SCOPE 57
The Product, 60.
Capacity, 60.
Quality, 66. Raw Material Storage,67.
Product Storage, 68.
The Process, 69.
Waste Disposal,Utilities, Shipping and Laboratory Requirements, 70.
Plans for Future Expansion,70.
Hours of Operation, 71.
Completion Date, 71.
Safety, 71.
Case Study: Scope, 72.
Scope Summary,75.
References, 78.

4 . PROCESS DESIGN AND SAFETY
Chemistry, 79.
Separations, 80.
Unit Ratio Material Balance,8 4 .
Detailed Flow Sheet, 85.
Safety, 89.
Case Study: Process Design,97.
Change of Scope, 103.
References, 103.

5 . EQUIPMENT LIST
Sizing of Equipment, 106.
Planning for Future Expansion,111.
Materials of Construction, 113.
Temperature and Pressure,113.
Laboratory Equipment, 114.
Completion of Equipment List,114.
Rules of Thumb, 114.
Case Study: Major Equipment Required,117.
Change of Scope, 132.
References, 133.

6. LAYOUT 141
New Plant Layout, 141.
Expansion and Improvements of Existing Facilities, 152.
Case Study: Layout and Warehouse Requirements,153.
References, 158.
7 . PROCESS CONTROL AND INSTRUMENTATION
Product Quality 160.
Product Quantity, 160.
Plant Safety,161.
Manual or Automatic Control, 161.
Control System,162.
Variables to be Measured, 162.
Final Control Element,163.
Control and Instrumentation Symbols, 164.
Averaging versus Set Point Control, 166.
Material Balance Control, 167.
Tempered Heat Transfer, 168.
Cascade Control, 170.
Feedforward Control,171.
Blending, 172.
Digital Control, 172.
Pneumatic versus Electronic Equipment, 173.
Case Study: Instrumentation and Control,174.
References, 180.

8. ENERGY AND UTILITY BALANCES
AND MANPOWER NEEDS 181
Conservation of Energy, 182.
Energy Balances, 183.
Sizing Energy Equipment, 191.
Planning for Expansion, 204.
Lighting,205.
Ventilation, Space Heating and Cooling, and Personal Water Requirements,207.
Utility Requirements, 209.
Manpower Requirements,210.
Rules of Thumb, 2 11.
Case Study: Energy Balance and Utility Assessment, 213.
Change of Scope, 231.
References, 232.

9 . COST ESTIMATION 237
Cost Indexes, 237.
How Capacity Affects Costs, 239.
Factored Cost Estimate, 246.
Improvements on the Factored Estimate, 249.
Module Cost Estimation, 254.
Unit Operations Estimate, 258.
Detailed Cost Estimate, 263.
Accuracy of Estimates, 264.
Case Study: Capital Cost Estimation, 264.
References, 275.

1 0 . ECONOMICS
Cost of Producing a Chemical, 28 1.
Capital, 284.
Elementary Profitability Measures, 285.
Time Value of Money, 293. Compound Interest,295.
Net Present Value-A Good Profitability Measure, 307.
Rate of Return-Another Good Profitability Measure, 311.
Comparison of Net Present Value and Rate of Return Methods, 316.
Proper Interest Rates,317.
Expected Return on the Investment, 323.
Case Study: Economic Evaluation, 324.
Problems, 330.
References, 338.


1 1 . DEPRECIATION, AMORTIZATION, DEPLETION
AND INVESTMENT CREDIT
Depreciation, 339.
Amortization, 348.
Depletion Allowance,
348. Investment Credit, 349.
Special Tax Rules, 350.
Case Study:The Net Present Value and Rate of Return, 350.
Problems.351.
References, 352.

1 2 . DETAILED ENGINEERING,
CONSTRUCTION, AND STARTUP
Detailed Engineering, 353.
Construction 361.
Startup,363.
References. 367.

PLANNING TOOLS-CPM AND PERT CPM, 370.
Manpower and Equipment Leveling, 376.
Cost and Schedule Control, 380.
Time for Completing Activity, 380.
Computers, 381.
PERT, 382.
Problems, 386.
References, 390.

OPTIMIZATION TECHNIQUES
Starting Point, 392.
One-at-a-Time Procedure, 393.
Single Variable Gptimizations, 396.
Multivariable Optimizations, 396.
End Game,409.
Algebraic Objective Functions, 409.
Optimizing Optimizations ,409.
Optimization and Process Design, 410.
References, 412.

DIGITAL COMPUTERS AND PROCESS ENGINEERING
Computer Programs, 416.
Sensitivity, 420.
Program Sources,420.
Evaluation of Computer Programs, 421.
References, 422.

POLLUTION AND ITS ABATEMENT
What is Pollution?, 424.
Determining Pollution Standards,425.
Meeting Pollution Standards, 428.
Air Pollution Abatement Methods, 431.
Water Pollution Abatement Methods, 437.
BOD and COD, 447.
Concentrated Liquid and Solid Waste Treatment Procedures,452.
References, 454.
ix

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