Integrated Design and Simulation of Chemical Processes

2nd Edition, Volume 13 - September 18, 2014
Authors: Alexandre C. Dimian, Costin Sorin Bildea, Anton A. Kiss
Language: English
Hardback ISBN:
9 7 8 - 0 - 4 4 4 - 6 2 7 0 0 - 1
eBook ISBN:
9 7 8 - 0 - 4 4 4 - 6 2 7 0 8 - 7

This comprehensive work shows how to design and develop innovative, optimal and sustainable chemical processes by applying the principles of process systems engineering, leading to… Read more

Integrated Design and Simulation of Chemical Processes

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This comprehensive work shows how to design and develop innovative, optimal and sustainable chemical processes by applying the principles of process systems engineering, leading to integrated sustainable processes with 'green' attributes. Generic systematic methods are employed, supported by intensive use of computer simulation as a powerful tool for mastering the complexity of physical models.

New to the second edition are chapters on product design and batch processes with applications in specialty chemicals, process intensification methods for designing compact equipment with high energetic efficiency, plantwide control for managing the key factors affecting the plant dynamics and operation, health, safety and environment issues, as well as sustainability analysis for achieving high environmental performance. All chapters are completely rewritten or have been revised.

This new edition is suitable as teaching material for Chemical Process and Product Design courses for graduate MSc students, being compatible with academic requirements world-wide. The inclusion of the newest design methods will be of great value to professional chemical engineers.

Preface
Acknowledgements
Chapter 1: Integrated Process and Product Design
- Abstract
- 1.1 Introduction
- 1.2 Integrated process and product design
- 1.3 Chemical product design
- 1.4 Systems engineering
- 1.5 Sustainable product and process design
- 1.6 Summary
Chapter 2: Introduction in Process Simulation
- Abstract
- 2.1 Computer simulation in process engineering
- 2.2 Steps in a simulation approach
- 2.3 Architecture of flowsheeting software
- 2.4 Integration of simulation tools
- 2.5 Summary and concluding remarks
Chapter 3: Steady-State Flowsheeting
- Abstract
- 3.1 Fundamentals of steady-state flowsheeting
- 3.2 Degrees of freedom analysis
- 3.3 Methodology in sequential-modular flowsheeting
- 3.4 Results
- 3.5 Analysis tools
- 3.6 Summary
Chapter 4: Dynamic Simulation
- Abstract
- 4.1 Introduction
- 4.2 Dynamic models
- 4.3 Introduction to dynamic modelling and dynamic simulation
- 4.4 CSTR with vapour–liquid equilibrium
- 4.5 Dynamic distillation column
- 4.6 Process control tools
- 4.7 Dynamic flowsheeting
- 4.8 Further reading
Chapter 5: Generalised Computational Methods in Thermodynamics
- Abstract
- 5.1 Introduction
- 5.2 PVT behaviour of fluids
- 5.3 Fundamentals of thermodynamics
- 5.4 Fugacity
- 5.5 Equations of state
- 5.6 Generalised computational methods using PVT relationship
- 5.7 Summary
Chapter 6: Phase Equilibria
- Abstract
- 6.1 Introduction
- 6.2 Computation of vapour–liquid equilibrium
- 6.3 Models for LACT
- 6.4 Combined EoS and excess Gibbs energy model
- 6.5 The regression of parameters in thermodynamic models
- 6.6 Special topics in phase equilibrium
- 6.7 Selection of a thermodynamic model
- 6.8 Further reading
Chapter 7: Process Synthesis by the Hierarchical Approach
- Abstract
- 7.1 Introduction
- 7.2 Outline of the Hierarchical Approach
- 7.3 Input data and requirements
- 7.4 Chemistry and thermodynamics
- 7.5 Input/Output analysis
- 7.6 Reactor/Separation/Recycle
- 7.7 General structure of the separation system
- 7.8 Optimisation of the material balance
- 7.9 Process Integration
- 7.10 Integration of design and control
- 7.11 Summary
Chapter 8: Synthesis of Reaction Systems
- Abstract
- 8.1 Chemical reaction network
- 8.2 Chemical equilibrium
- 8.3 Reaction rate
- 8.4 Reactors for homogeneous systems
- 8.5 Reactors for heterogeneous systems
- 8.6 Reactors for biochemical processes
- 8.7 Thermal design issues
- 8.8 Selection of chemical reactors
- 8.9 Synthesis of chemical reactor networks
- 8.10 Further reading
Chapter 9: Synthesis of Separation Systems
- Abstract
- 9.1 Methodology
- 9.2 Vapour recovery and gas separation system
- 9.3 Liquid separation system
- 9.4 Separation of zeotropic mixtures by distillation
- 9.5 Enhanced distillation
- 9.6 Hybrid separations
- 9.7 Azeotropic distillation
- 9.8 Summary
Chapter 10: Process Intensification
- Abstract
- 10.1 Introduction
- 10.2 Process intensification equipment
- 10.3 Dividing-wall column
- 10.4 Reactive distillation
- 10.5 Examples
- 10.6 Summary
Chapter 11: Batch Processes
- Abstract
- 11.1 Introduction
- 11.2 Batch distillation
- 11.3 Batch reactors
- 11.4 Integration of design and control of batch reactors
- 11.5 Other batch processes
- 11.6 Summary and further reading
Chapter 12: Chemical Product Design
- Abstract
- 12.1 Introduction
- 12.2 Classification of chemical products
- 12.3 Methodology for product and process design
- 12.4 Physical properties issues in product design
- 12.5 Application examples
- 12.6 Concluding remarks
Chapter 13: Pinch Point Analysis
- Abstract
- 13.1 Introduction
- 13.2 Targets for energy recovery
- 13.3 Placement of utilities
- 13.4 Design of the HEN
- 13.5 Mathematical Programming
- 13.6 Design evolution
- 13.7 Extensions of the Pinch principle
- 13.8 Software tools
- 13.9 Summary of PPA
Chapter 14: Applied Energy Integration
- Abstract
- Introduction
- 14.1 Heat and power integration
- 14.2 Energy saving in distillation
- 14.3 Integration of chemical reactors
- 14.4 Total site integration
- 14.5 Summary
Chapter 15: Plantwide Control
- Abstract
- 15.1 Introduction
- 15.2 Introduction to process control
- 15.3 Plantwide control
- 15.4 Summary of plantwide control methodology
- 15.5 Concluding remarks
- 15.6 Appendix
Chapter 16: Health, Safety and Environment
- Abstract
- 16.1 Introduction
- 16.2 Norms and regulations for HSE
- 16.3 Hazards description in HSE
- 16.4 Material safety data sheet
- 16.5 Inherently safer design
- 16.6 Pressure relief systems
- 16.7 Protection against fire and explosion risks
- 16.8 Hazard analysis and operability studies
- 16.9 Concluding remarks
Chapter 17: Sustainability Analysis
- Abstract
- 17.1 Introduction
- 17.2 Life cycle assessment
- 17.3 Eco-cost value ratio
- 17.4 Eco-efficiency analysis
- 17.5 Socio-eco-efficiency analysis
- 17.6 AIChE sustainability index
- 17.7 Sustainability metrics for design projects
- 17.8 Concluding remarks
Chapter 18: Process Design Project
- Abstract
- 18.1 Introduction
- 18.2 Organisation
- 18.3 Process design courses
- 18.4 Integrated design project
- 18.5 Plant design project
- 18.6 Subjects
- 18.7 Concluding remarks
Chapter 19: Economic Evaluation of Projects
- Abstract
- 19.1 Introduction
- 19.2 Basic concepts
- 19.3 Time value of money
- 19.4 Capital costs
- 19.5 Operating costs
- 19.6 Profitability analysis
- 19.7 Conclusions
Chapter 20: Equipment Selection and Design
- Abstract
- 20.1 Introduction
- 20.2 Reactors
- 20.3 Separators
- 20.4 Heat exchangers design
- 20.5 Transport of fluids
Chapter 21: Case Studies
- Abstract
- 21.1 Introduction
- 21.2 Design and simulation of a HDA plant
- 21.3 Design and robust optimisation of a process for GTBE manufacturing
- 21.4 Design and simulation of a reactive DWC for biodiesel production
Appendices
- Abstract
- 1 Appendix A – Estimation of basic equipment cost
- 2 Appendix B – Cost of utilities
- 3 Appendix C – Materials of construction
- 4 Appendix D – Saturated steam properties
- 5 Appendix E – Vapour pressure of some hydrocarbons
- 6 Appendix F – Vapour pressure of some organic components
- 7 Appendix G – Conversion factors to SI units
Index

Alexandre C. Dimian

Alexandre Dimian, PhD, is one of the pioneers in Europe in using computer-aided process engineering (CAPE) in industry and for teaching. He received his PhD in Chemical Engineering from the University “Politehnica” of Bucharest, and TU Hanover, and MSc in Computer Science from Ecole Centrale Paris. As professor in the Netherlands, he taught various process design and integration courses at graduate and postgraduate level from 1993 to 2011, at the University of Amsterdam and TU Eindhoven. He has a solid industrial experience working many years as consultant in CAPE applications with major companies in France and the Netherlands, namely in using computer simulation for design and operation of complex industrial processes. Professor Dimian is member of the Romanian Technical Academy and was awarded a Dr.H.C. title by the University “Politehnica” of Bucharest, where he is continuing the scientific activity.

Affiliations and expertise

University "Politehnica" of Bucharest, Romania

Costin Sorin Bildea

Costin S. Bildea, PhD, is professor at University “Politehnica” of Bucharest and invited professor at Delft University of Technology, teaching various courses in the field of Chemical Engineering. He holds MSc degrees in Chemical Engineering and Industrial Process Control, as well as a PhD title from University of Amsterdam. Professor Bildea is carrying on research activities in the field of integration between process design and process control, publishing more than 120 scientific papers and 2 books. In 2009, he received the prestigious "Nicolae Teclu" prize of Romanian Academy for his work in the field of design, control, and automation in industrial process engineering.

Affiliations and expertise

University "Politehnica" of Bucharest, Bucharest, Romania

Anton A. Kiss

Tony Kiss is a professor and chair in chemical engineering at The University of Manchester, and a Royal Society Wolfson Research Merit Award holder. He has over a decade of industrial experience, working as Senior Project Manager and RD&I Specialist in Separation Technology at AkzoNobel – Research, Development & Innovation. Besides his industrial role, he has been appointed as part-time professor of Separation Technology at University of Twente (Sustainable Process Technology group). He holds a PhD title from University of Amsterdam, and he was also Post Doctoral research fellow at TU Delft and University of Amsterdam. During the past decade, he carried out many research & industrial projects, supervised graduation projects, published several textbooks, book chapters, and over 100 scientific articles. For the pioneering research work, he received in 2013 the Hoogewerff Jongerenprijs – a very prestigious award recognizing the most promising young scientist in The Netherlands. He also led his research team to receive in 2013 the AkzoNobel Innovation Excellence Award for the most successful industrial innovation. More information is available at: www.tonykiss.com

Affiliations and expertise

University of Manchester

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Integrated Design and Simulation of Chemical Processes

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Alexandre C. Dimian

Costin Sorin Bildea

Anton A. Kiss