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Rules of Thumb for Chemical Engineers
- 5th Edition - June 18, 2012
- Author: Stephen M Hall
- Language: English
- Paperback ISBN:9 7 8 - 0 - 1 2 - 3 8 7 7 8 5 - 7
- eBook ISBN:9 7 8 - 0 - 1 2 - 3 8 7 7 8 9 - 5
Rules of Thumb for Chemical Engineers, Fifth Edition, provides solutions, common sense techniques, shortcuts, and calculations to help chemical and process engineers deal with prac… Read more
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Request a sales quoteRules of Thumb for Chemical Engineers, Fifth Edition, provides solutions, common sense techniques, shortcuts, and calculations to help chemical and process engineers deal with practical on-the-job problems. It discusses physical properties for proprietary materials, pharmaceutical and biopharmaceutical sector heuristics, and process design, along with closed-loop heat transfer systems, heat exchangers, packed columns, and structured packings.
Organized into 27 chapters, the book begins with an overview of formulae and data for sizing piping systems for incompressible and compressible flow. It then moves to a discussion of design recommendations for heat exchangers, practical equations for solving fractionation problems, along with design of reactive absorption processes. It also considers different types of pumps and presents narrative as well as tabular comparisons and application notes for various types of fans, blowers, and compressors. The book also walks the reader through the general rules of thumb for vessels, how cooling towers are sized based on parameters such as return temperature and supply temperature, and specifications of refrigeration systems. Other chapters focus on pneumatic conveying, blending and agitation, energy conservation, and process modeling. Online calculation tools, Excel workbooks, guidelines for hazardous materials and processes, and a searchable Rules of Thumb library are included.
Chemical engineers faced with fluid flow problems will find this book extremely useful.
- Rules of Thumb for Chemical Engineers brings together solutions, information and work-arounds that engineers in the process industry need to get their job done.
- New material in the Fifth Edition includes physical properties for proprietary materials, six new chapters, including pharmaceutical, biopharmaceutical sector heuristics, process design with simulation software, and guidelines for hazardous materials and processes
- Now includes SI units throughout alongside imperial, and now accompanied by online calculation tools and a searchable Rules of Thumb library
Chemical Engineers
Dedication
Publisher’s Note
1. Fluid Flow
Introduction
Data Required
General Procedure
Recommended Velocity
Equivalent Length
Shortcut Equation for Pressure Drop Due to Friction
Reynolds Number
Friction Factor
Incompressible Flow
Compressible Flow – Isothermal
Compressible Flow – Transmission Equations
Compressible Flow – Adiabatic
Visual Basic Subroutines for Pressure Drop Due to Friction
Orifices
Control Valves
Partially Full Horizontal Pipes
Two-Phase Flow
References
2. Heat Exchangers
Introduction
TEMA
Selection Guides
Design Recommendations
Process Data
Heat Exchanger Configuration and Area
Determining the LMTD Configuration Correction Factor
Tubeside Pressure Drop
Tube Side Film Coefficient
Shell Diameter
Ideal Shell Side Film Coefficient
Shell Side Film Coefficient Correction Factors
Overall Heat Transfer Coefficient
Shell Side Pressure Drop
Heat Transfer Coefficients
Fouling Resistances
Installation Recommendations
Thermal Conductivity of Metals
Vacuum Condensers
Air-cooled Heat Exchangers: Forced vs. Induced Draft
Air-cooled Heat Exchangers: Air Data
Air-cooled Heat Exchangers: Thermal Design
Air-cooled Heat Exchangers: Pressure Drop, Air Side
Air-cooled Heat Exchangers: Temperature Control
References
3. Fractionators
Introduction
Separation Factor
Relative Volatility
Vapor-Liquid Equilibrium
Activity Coefficients
Establishing the Column Pressure
Minimum Reflux – Binary
Minimum Reflux−Multicomponent
Minimum Stages
Relationship of Theoretical Stages to Reflux Ratio
Feed Location
Reflux-to-Feed Ratio
Actual Trays
Graphical Methods – The McCabe-Thiele Diagram
Plotting With Murphree Tray Efficiency
Tray Efficiency Rules of Thumb
Using the McCabe-Thiele Plot
Column Internals – Trays and Packing
Column Tray Spacing
Tower Diameter – Souders-Brown Correlation
Pressure Drop – Trays
Control Schemes
Reboilers
Packed Columns
References
4. Absorbers
Introduction
Hydrocarbon Absorber Design
Inorganic Absorbers
Packing Height for Mass Transfer in Packed Columns
Overall Mass Transfer Coefficient
References
5. Pumps
Introduction
Pump Types and Selection
Pump Testing
System Curves
Operating Point and Pump Selection
Flow Control with Throttling Valve
Charting Control Characteristics
Flow Control by Changing the Pump Speed
Affinity Laws
Power
Minimum Flow
Temperature Rise
Suction System NPSH Available
Suction System NPSH for Studies
Multiple Centrifugal Pumps in Parallel or in Series
References
6. Fans, Blowers, and Compressors
Introduction
Rules of Thumb
Fans
Fan Noise
Blower Types
Compressor Types
Surge Control
Performance Calculations
Affinity Laws
Power – Fan
Power – Reciprocating Compressor
Power – Centrifugal Compressor
Comparison with Manufacturer’s Data
Power with P-E Diagram
Cost of Compressed Air
Receiver Volume
Time to Pump System to Pressure
References
7. Drivers
Introduction
Electric Motors
Motor Voltages
Motors: Efficiency
Motors: Starter Sizes
Motors: Useful Equations
Motors: Overloading
Air-Driven Motors
Hydraulic Motors
Steam Turbines: Steam Rate
Steam Turbines: Efficiency
Gas Turbines: Performance
Internal Combustion Engines: Fuel Rates
Gas Expanders: Available Energy
References
8. Vessels
Introduction
General Rules of Thumb for Vessels
Tank Dimensions
Liquid Volume at Any Fill Height
Time to Drain a Tank
Emissions from Storage Tanks
Load Cells
Liquid-Liquid Separators
Vapor-Liquid Separators
Liquid Surge Volume
Vapor Velocity in the Disengagement Section
Vapor-Liquid Separator Size
Vessel Specifications
Good Engineering Practices for Storage Tank and Vent Relief Design
References
9. Boilers
Introduction
Boiler Horsepower
Types of Packaged Boilers
Power Plants
Controls
Thermal Efficiency
Stack Gas Enthalpy
Steam Drum Stability
Deaerator Venting
Water Alkalinity
Source Water Impurities
Conductivity versus Dissolved Solids
Silica in Steam
Caustic Embrittlement
Waste Heat
Boiler Feedwater
Blowdown Control
Best Practices – Burner System Piping
References
10. Cooling Towers
Introduction
Mechanical Draft Cooling Towers
Material and Energy Balance Calculations
Rating Nomenclature
Performance Calculations
Operations and Accessories
Water Quality Guidelines
Scale Prevention
References
11. Refrigeration
Introduction
Specifications
Indirect and Direct System Design
Horsepower per Ton
Refrigerants
Refrigerant Containment
Steam Jet Ejectors
Ammonia Absorption Utilities Requirements
References
12. Closed Loop Heat Transfer Systems
Introduction
Selecting the Heat Transfer Fluid
Types of Heat Transfer Fluids
Heat Transfer Coefficient
System Design
Temperature Control
Physical Properties of Commercial Heat Transfer Fluids
References
13. Biopharmaceutical Systems
Introduction
Contamination Root Causes
Contamination Investigation and Recovery
Microbiology Investigation
Risk Assessment
Validation
References
14. Vacuum Systems
Introduction
Vacuum Units
Conversion between Mass Flow, Actual Volume Flow, and Standard Volume Flow
Comparison of Vacuum Equipment
Vacuum Jets
Liquid Ring Vacuum Pumps
Dry Vacuum Pumps
Typical Jet Systems
Steam Supply
Measuring Air Leakage
Time to Evacuate
Instrumentation and Controls
References
15. Pneumatic Conveying
Introduction
Flow Regimes
Types of Systems
System Design Procedure
Saltation Velocity
Pressure Drop
Prime Movers
Feed Systems
Conveyor Piping
Disengagement
References
16. Blending and Agitation
Introduction
Basics
Impeller Types
Dimensional Analysis
Blending
Solids Suspension
Gas Dispersion
In-Line Mixers
High Shear Mixers
Mixing Solids
Mechanical Design
Impeller Weight
References
17. Process Evaluation
Introduction
Accuracy of Cost Estimates
User Requirements
Block Diagrams
Process Flow Diagrams (PFDs)
Basis of Design
Block-Sequential Diagrams
Piping & Instrumentation Diagrams (P&IDs)
Data Sheets and Specifications
Capital Cost Estimates
Organization of a Cost Estimate
Engineering
References
18. Reliability
Introduction
Initial Design
Risk Analysis
Sustainable Practices
References
19. Metallurgy
Introduction
Cost Comparison
Embodied Energy
Embrittlement
Stress-Corrosion Cracking
Hydrogen Attack
Pitting Corrosion
Creep and Creep-Rupture Life
Naphthenic Acid Corrosion
Thermal Fatigue
Abrasive Wear
Pipeline Toughness
Common Corrosion Mistakes
References
20. Safety
Introduction
Process Safety Management (PSM)
Process Hazard Analysis (PHA)
Safe Design Practices
Emergency Vent Systems
Flash Point of Binary Mixtures
Deflagration Prevention or Control
Prevent Backflow
Equipment Purging
Electrical Area Classification
Causes for Loss of Containment
Dust Explosion Hazards
References
21. Controls
Introduction
Basic Nomenclature
Definitions of Control Modes
Cascade Control
Specifying Instruments to Measure Values
Control Ranges
Drawing Conventions
Artistic Expression
Safety Instrumented Systems
Enclosures: NEMA and IP
References
22. Troubleshooting
Introduction
General Troubleshooting Approach
Diagnostic Tools
Instruments
Control Valves (Process Control)
Shell-and-Tube Heat Exchangers
Plate-and-Frame Heat Exchangers
Fractionation Towers
Fractionation Case Histories
Centrifugal Pumps
Compressors
Steam Jet Vacuum Systems
Refrigeration
References
23. Startup
Introduction
Startup Management
Change Control During Startup
Startup Cost
Systems Approach
Construction Quality
Startup Checklists
Operating Modes
References
24. Energy Conservation
Introduction
Calculating Steam Cost
Steam System Rules of Thumb
Equivalent Cost of Fuels
Steam Traps
Energy Efficient Design for Fractionators
Pinch Analysis
Insulation
References
25. Process Modeling
Introduction
Concepts and Terminology
Equipment Design
Mass and Energy Transfer
Flowsheet Simulation – Continuous Process
Flowsheet Simulation – Dynamic Process
Discrete Process Simulation
General Purpose Simulation Environments
References
26. Conversion Factors and Constants
Significant Figures and Rounding
Gas Constant
Standard Gas Volume
Atmospheric Pressure
Irrigation Conversion
References
27. Properties
Introduction
Approximate Physical Properties
Vapor Pressure Equation
Liquid Viscosity
Relative Humidity
Surface Tension
Thermodynamic Properties of Water and Steam
Gas Diffusion Coefficients
Bulk Modulus
Water and Hydrocarbons
Compressibility Factor
Inorganic Gases in Petroleum
Foam Density
Equivalent Diameter
Properties Data Sheet
References
APPENDIX A. Resources
APPENDIX B. Tank Cleaning
Index
- No. of pages: 456
- Language: English
- Edition: 5
- Published: June 18, 2012
- Imprint: Butterworth-Heinemann
- Paperback ISBN: 9780123877857
- eBook ISBN: 9780123877895
SH
Stephen M Hall
P.E. is consultant to chemical and pharmaceutical manufacturers. His career in the chemical process industries has spanned plant design and construction, operations, and engineering contracting. He has been project designer on more than 100 projects in sectors including food, pharmaceutical, specialty chemical, heavy chemical and petrochemical installations. He has published several articles on chemical engineering topics, and is an experienced process modeling software developer.
Affiliations and expertise
P.E. is consultant to chemical and pharmaceutical manufacturers.Read Rules of Thumb for Chemical Engineers on ScienceDirect