William L. Luyben

Principles and Case Studies of Simultaneous Design (eBook, ePUB)

• Format: ePub

Produktbeschreibung

There are many comprehensive design books, but none of them provide a significant number of detailed economic design examples of typically complex industrial processes. Most of the current design books cover a wide variety of topics associated with process design. In addition to discussing flowsheet development and equipment design, these textbooks go into a lot of detail on engineering economics and other many peripheral subjects such as written and oral skills, ethics, "e;green"e; engineering and product design. This book presents general process design principles in a concise readable form that can be easily comprehended by students and engineers when developing effective flow sheet and control structures. Ten detailed case studies presented illustrate an in-depth and quantitative way the application of these general principles. Detailed economic steady-state designs are developed that satisfy economic criterion such as minimize total annual cost of both capital and energy or return on incremental capital investment. Complete detailed flow sheets and Aspen Plus files are provided. Then conventional PI control structures are be developed and tested for their ability to maintain product quality during disturbances. Complete Aspen Dynamics files are be provided of the dynamic simulations.

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Produktdetails

• Verlag: John Wiley & Sons
• Seitenzahl: 344
• Erscheinungstermin: 8. Februar 2012
• Englisch
• ISBN-13: 9781118001646
• Artikelnr.: 37357422

Autorenporträt

WILLIAM L. LUYBEN, PhD, is a professor at Lehigh University, and the author/co-author of thirteen textbooks. He has published over 250 technical papers in the area of process control and design and has supervised thirty-five PhD dissertations He has nine years of industrial experience with Exxon and DuPont.

Inhaltsangabe

PREFACE xv 1 INTRODUCTION 1 1.1 Overview
1 1.2 History
3 1.3 Books
4 1.4 Tools
4 Reference Textbooks
5 2 PRINCIPLES OF REACTOR DESIGN AND CONTROL 7 2.1 Background
7 2.2 Principles Derived from Chemistry
8 2.2.1 Heat of Reaction
8 2.2.2 Reversible and Irreversible Reactions
9 2.2.3 Multiple Reactions
10 2.3 Principles Derived from Phase of Reaction
11 2.4 Determining Kinetic Parameters
12 2.4.1 Thermodynamic Constraints
12 2.4.2 Kinetic Parameters from Plant Data
13 2.5 Principles of Reactor Heat Exchange
13 2.5.1 Continuous Stirred-Tank Reactors
13 2.5.2 Tubular Reactors
14 2.5.3 Feed-Effluent Heat Exchangers
16 2.6 Heuristic Design of Reactor
Separation Processes
17 2.6.1 Introduction
17 2.6.2 Process Studied
18 2.6.3 Economic Optimization
21 2.6.4 Other Cases
22 2.6.5 Real Example
27 2.7 Conclusion
28 References
29 3 PRINCIPLES OF DISTILLATION DESIGN AND CONTROL 31 3.1 Principles of Economic Distillation Design
32 3.1.1 Operating Pressure
32 3.1.2 Heuristic Optimization
33 3.1.3 Rigorous Optimization
33 3.1.4 Feed Preheating and Intermediate Reboilers and Condensers
34 3.1.5 Heat Integration
34 3.2 Principles of Distillation Control
35 3.2.1 Single-End Control
36 3.2.2 Dual-End Control
38 3.2.3 Alternative Control Structures
38 3.3 Conclusion
39 References
39 4 PRINCIPLES OF PLANTWIDE CONTROL 41 4.1 History
42 4.2 Effects of Recycle
42 4.2.1 Time Constants of Integrated Plant with Recycle
42 4.2.2 Recycle Snowball Effect
43 4.3 Management of Fresh Feed Streams
45 4.3.1 Fundamentals
45 4.3.2 Process with Two Recycles and Two Fresh Feeds
46 4.4 Conclusion
52 5 ECONOMIC BASIS 53 5.1 Level of Accuracy
53 5.2 Sizing Equipment
54 5.2.1 Vessels
54 5.2.2 Heat Exchangers
55 5.2.3 Compressors
56 5.2.4 Pumps, Valves, and Piping
56 5.3 Equipment Capital Cost
56 5.3.1 Vessels
56 5.3.2 Heat Exchangers
56 5.3.3 Compressors
57 5.4 Energy Costs
57 5.5 Chemical Costs
57 References
57 6 DESIGN AND CONTROL OF THE ACETONE PROCESS VIA DEHYDROGENATION OF ISOPROPANOL 59 6.1 Process Description
60 6.1.1 Reaction Kinetics
61 6.1.2 Phase Equilibrium
62 6.2 Turton Flowsheet
62 6.2.1 Vaporizer
63 6.2.2 Reactor
64 6.2.3 Heat Exchangers, Flash Tank, and Absorber
64 6.2.4 Acetone Column C1
66 6.2.5 Water Column C2
66 6.3 Revised Flowsheet
66 6.3.1 Effect of Absorber Pressure
66 6.3.2 Effect of Water Solvent and Absorber Stages
68 6.3.3 Effect of Reactor Size
68 6.3.4 Optimum Distillation Design
69 6.4 Economic Comparison
69 6.5 Plantwide Control
71 6.5.1 Control Structure
71 6.5.2 Column Control Structure Selection
75 6.5.3 Dynamic Performance Results
76 6.6 Conclusion
81 References
81 7 DESIGN AND CONTROL OF AN AUTO-REFRIGERATED ALKYLATION PROCESS 83 7.1 Introduction
84 7.2 Process Description
84 7.2.1 Reaction Kinetics
85 7.2.2 Phase Equilibrium
85 7.2.3 Flowsheet
86 7.2.4 Design Optimization Variables
88 7.3 Design of Distillation Columns
89 7.3.1 Depropanizer
89 7.3.2 Deisobutanizer
89 7.4 Economic Optimization of Entire Process
91 7.4.1 Flowsheet Convergence
91 7.4.2 Yield
91 7.4.3 Effect of Reactor Size
91 7.4.4 Optimum Economic Design
93 7.5 Alternative Flowsheet
94 7.6 Plantwide Control
96 7.6.1 Control Structure
96 7.6.2 Controller Tuning
100 7.6.3 Dynamic Performance
101 7.7 Conclusion
103 References
105 8 DESIGN AND CONTROL OF THE BUTYL ACETATE PROCESS 107 8.1 Introduction
108 8.2 Chemical Kinetics and Phase Equilibrium
108 8.2.1 Chemical Kinetics and Chemical Equilibrium
108 8.2.2 Vapor-Liquid Equilibrium
110 8.3 Process Flowsheet
112 8.3.1 Reactor
112 8.3.2 Column C1
113 8.3.3 Column C2
113 8.3.4 Column C3
113 8.3.5 Flowsheet Convergence
115 8.4 Economic Optimum Design
117 8.4.1 Reactor Size and Temperature
117 8.4.2 Butanol Recycle and Composition
118 8.4.3 Distillation Column Design
119 8.4.4 System Economics
120 8.5 Plantwide Control
121 8.5.1 Column C1
121 8.5.2 Column C2
122 8.5.3 Column C3
122 8.5.4 Plantwide Control Structure
123 8.5.5 Dynamic Performance
124 8.6 Conclusion
133 References
133 9 DESIGN AND CONTROL OF THE CUMENE PROCESS 135 9.1 Introduction
136 9.2 Process Studied
136 9.2.1 Reaction Kinetics
136 9.2.2 Phase Equilibrium
137 9.2.3 Flowsheet
137 9.3 Economic Optimization
140 9.3.1 Increasing Propylene Conversion
140 9.3.2 Effects of Design Optimization Variables
141 9.3.3 Economic Basis
142 9.3.4 Economic Optimization Results
143 9.4 Plantwide Control
147 9.5 Conclusion
158 References
158 10 DESIGN AND CONTROL OF THE ETHYL BENZENE PROCESS 159 10.1 Introduction
159 10.2 Process Studied
160 10.2.1 Reaction Kinetics
161 10.2.2 Phase Equilibrium
162 10.2.3 Flowsheet
163 10.3 Design of Distillation Columns
164 10.3.1 Column Pressure Selection
166 10.3.2 Number of Column Trays
169 10.4 Economic Optimization of Entire Process
169 10.5 Plantwide Control
172 10.5.1 Distillation Column Control Structure
172 10.5.2 Plantwide Control Structure
173 10.5.3 Controller Tuning
174 10.5.4 Dynamic Performance
174 10.5.5 Modified Control Structure
176 10.6 Conclusion
183 References
183 11 DESIGN AND CONTROL OF A METHANOL REACTOR
COLUMN PROCESS 185 11.1 Introduction
185 11.2 Process Studied
186 11.2.1 Compression and Reactor Preheating
186 11.2.2 Reactor
187 11.2.3 Separator, Recycle, and Vent
187 11.2.4 Flash and Distillation
188 11.3 Reaction Kinetics
188 11.4 Overall and Per-Pass Conversion
189 11.5 Phase Equilibrium
191 11.6 Effects of Design Optimization Variables
192 11.6.1 Economic Basis
192 11.6.2 Effect of Pressure
193 11.6.3 Effect of Reactor Size
195 11.6.4 Effect of Vent
Recycle Split
196 11.6.5 Effect of Flash-Tank Pressure
197 11.6.6 Optimum Distillation Column Design
198 11.7 Plantwide Control
201 11.7.1 Control Structure
201 11.7.2 Column Control Structure Selection
203 11.7.3 High-Pressure Override Controller
203 11.7.4 Dynamic Performance Results
204 11.8 Conclusion
209 References
210 12 DESIGN AND CONTROL OF THE METHOXY-METHYL-HEPTANE PROCESS 211 12.1 Introduction
211 12.2 Process Studied
212 12.2.1 Reactor
212 12.2.2 Column C1
213 12.2.3 Column C2
213 12.2.4 Column C3
213 12.3 Reaction Kinetics
213 12.4 Phase Equilibrium
215 12.5 Design Optimization
215 12.5.1 Economic Basis
216 12.5.2 Reactor Size versus Recycle Trade-Off
216 12.6 Optimum Distillation Column Design
220 12.6.1 Column Pressures
220 12.6.2 Number of Stages
220 12.6.3 Column Profiles
222 12.7 Plantwide Control
223 12.7.1 Control Structure
225 12.7.2 Dynamic Performance Results
227 12.8 Conclusion
230 References
231 13 DESIGN AND CONTROL OF A METHYL ACETATE PROCESS USING CARBONYLATION OF DIMETHYL ETHER 233 13.1 Introduction
233 13.2 Dehydration Section
234 13.2.1 Process Description of Dehydration Section
234 13.2.2 Dehydration Kinetics
235 13.2.3 Alternative Flowsheets
236 13.2.4 Optimization of Three Flowsheets
240 13.3 Carbonylation Section
245 13.3.1 Process Description
246 13.3.2 Carbonylation Kinetics
247 13.3.3 Effect of Parameters
248 13.3.4 Flowsheet Convergence
250 13.3.5 Optimization
251 13.4 Plantwide Control
255 13.4.1 Control Structure
255 13.4.2 Dynamic Performance
261 13.5 Conclusion
262 References
262 14 DESIGN AND CONTROL OF THE MONO-ISOPROPYL AMINE PROCESS 263 14.1 Introduction
263 14.2 Process Studied
264 14.2.1 Reaction Kinetics
264 14.2.2 Phase Equilibrium
265 14.2.3 Flowsheet
266 14.3 Economic Optimization
268 14.3.1 Design Optimization Variables
268 14.3.2 Optimization Results
269 14.4 Plantwide Control
270 14.4.1 Dynamic Model Sizing
271 14.4.2 Distillation Column Control Structures
272 14.4.3 Plantwide Control Structure
276 14.5 Conclusion
289 References
290 15 DESIGN AND CONTROL OF THE STYRENE PROCESS 291 15.1 Introduction
292 15.2 Kinetics and Phase Equilibrium
293 15.2.1 Reaction Kinetics
293 15.2.2 Phase Equilibrium
294 15.3 Vasudevan et al. Flowsheet
295 15.3.1 Reactors
295 15.3.2 Condenser and Decanter
295 15.3.3 Product Column C1
296 15.3.4 Recycle Column C2
298 15.4 Effects of Design Optimization Variables
298 15.4.1 Effect of Process Steam
298 15.4.2 Effect of Reactor Inlet Temperature
301 15.4.3 Effect of Reactor Size
302 15.4.4 Optimum Distillation Column Design
303 15.4.5 Number of Reactors
304 15.4.6 Reoptimization
304 15.4.7 Other Improvements
305 15.5 Proposed Design
305 15.6 Plantwide Control
306 15.6.1 Control Structure
306 15.6.2 Column Control Structure Selection
310 15.6.3 Dynamic Performance Results
312 15.7 Conclusion
317 References
317 NOMENCLATURE 319 INDEX 321