Martyn Ray Design Book

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Content Preface to Second Edition Acknowledgements Introduction

xv xvii 1

I How to Use This Book (A) The Case Study Approach (B) A "Road Map" II Some Advice (A) General Advice to the Student (B) Advice from a Former Design Project Student (C) To the Lecturer (D) The Designer or Project Engineer III Presentation of Design Projects (A) Effective Communications (B) General Comments on Preparation of Literature Surveys IV Details of Particular Design Projects, and Information Sources (A) IChemE Design Projects Instructions for the IChemE Design Project, 1980 (B) Information Sources

1 1 2 3 3 4 5 7 7 7 9 14 14 16 20

PART 1 TECHNICAL AND ECONOMIC FEASIBILITY STUDY Chapter 1 1.1

The Design Problem

Initial Considerations and Specification 1.1.1 The Feasibility Study 1.1.2 Time Management 1.1.3 Stages in a Design Problem 1.1.4 The Search for Information 1.1.5 Scope of the Project 1.1.6 Evaluating the Alternatives - Making Decisions

Some Questions to Ask for the Chemical to be Produced Further Reading

27 27 27 28 28 28 29 29 30 30

Case Study: Production of Phthalic Anhydride Overall Summary for the Technical and Economic Feasibility Study 1.2 Case Study - Defining the Problem and Background Information Summary 1.2.1 Background and Objectives 1.2.2 Chemical Structure and Physical Properties 1.2.3 Applications and Uses 1.2.4 Basic Chemistry 1.2.5 Evaluation of Alternative Processing Schemes 1.2.6 Conclusions 1.2.7 Recommendations Chapter 2 Feasibility Study and Market Survey 2.1 Initial Feasibility Study 2.2 Preliminary Market Survey/Economic Analysis References 2. 3 Information Sources 2.4 Evaluation of Available Literature 2.5 Considerations for Literature Surveys References 2.6 Case Study - Feasibility Study and Market Assessment Summary 2.6.1 Market Assessment 2.6.1.1 Production: Worldwide 2.6.1.2 Production: Regional 2.6.1.3 Production: National 2.6.2 Current and Future Prices 2.6.3 Demand 2.6.4 Australian Imports and Exports 2.6.5 Plant Capacity 2.6.6 Product Value and Operating Costs 2.6.6.1 Capital Costs 2.6.6.2 Operating Costs 2.6.6.3 Approximate Selling Price 2.6.7 Conclusions 2.6.8 Recommendations

31 31 32 32 32 32 33 33 34 35 35 37 37 37 40 40 41 42 42 43 43 43 43 44 44 45 45 46 46 47 47 47 47 48 49

Chapter 3 Process Selection, Process Description and Equipment List 3.1 Process Selection Considerations 3.1.1 Flow Diagrams - PFD and P&ID 3.1.2 The Reactor 3.1.3 Product Purity 3.1.4 Process Conditions

51 51 51 51 52 52

3.1.5 3.1.6 3.1.7 3.1.8 3.1.9 3.1.10

Process Data Energy Efficiency Factors in Process Evaluation and Selection Choices and Compromises The Optimum Design Process Control and Instrumentation References 3.2 Process Description 3.3 Preparing the Equipment List 3.4 Rules of Thumb 3.5 Safety Considerations and Preliminary HAZOP Study References 3.6 Case Study - Process Selection and Equipment List Summary 3.6.1 Trends in Phthalic Anhydride Processing 3.6.2 Raw Material 3.6.3 Process Configurations 3.6.4 Detailed Process Description 3.6.5 Advantages of the LAR Process 3.6.6 Advantages of the LEVH Process 3.6.7 Process Selection 3.6.8 Initial Equipment Design 3.6.9 Equipment List 3.6.10 Conclusions 3.6.11 Recommendations Appendix A: Preliminary Equipment Specifications Chapter 4 Site Considerations: Site Selection and Plant Layout 4.1 Site Selection/ Location 4.1.1 Local Industrial Areas 4.1.2 Some Important Factors 4.1.3 Prioritizing the Factors References 4.2 Plant Layout 4.2.1 Plant Layout Strategies 4.2.2 Factors Influencing Plant Layout References 4.3 Case Study - Site Considerations: Site Selection and Plant Layout

52 52 53 53 54 54 54 55 55 56 57 57 58 58 58 58 59 61 62 62 62 63 63 64 64 65 69 69 69 70 70 71 71 72 72 73 74

Summary 4.3.1 Background and Objectives 4.3.2 Potential Sites 4.3.2.1 Kemerton 4.3.2.2 Geraldton

74 74 75 76 76

4.3.2.3 Karratha 4.3.2.4 Kwinana 4.3.3 Preferred Site and Layout 4.3.4 Conclusions 4.3.5 Recommendations Chapter 5 Environmental Considerations 5.1 Environmental Impact Assessment 5.2 General Considerations 5.3 EIA Policy and Scope 5.4 EIA Reports 5.5 Australia 5.6 United Kingdom 5.7 United States 5.8 ISO-14000 5.9 Legislation References 5.10 Case Study - Environmental Considerations Summary 5.10.1 Purpose 5.10.2 Airborne Emissions 5.10.3 Waterborne Emissions 5.10.4 Solid Waste 5.10.5 Process Hazards 5.10.6 Accidental Spills and Tank Breaches 5.10.7 Personnel Safety Precautions and Procedures 5.10.8 Conclusions 5.10.9 Recommendations Chapter 6 Economic Evaluation 6.1 Introductory Notes 6.2 Capital Cost Estimation 6.2.1 Cost of Equipment (Major Items) (I) Cost Correlations (II) Factored Estimate Method 6.2.2 Module Costs 6.2.3 Auxiliary Services 6.3 Operating Costs - Fixed and Variable 6.3.1 Depreciation 6.4 Profitability Analysis 6.4.1 The Payback Period 6.4.2 Return on Investment (ROI) 6.4.3 Evaluating Different Scenarios 6.4.4 Economic Evaluation and Analysis

76 76 76 80 81 83 83 83 85 86 88 88 89 90 90 91 92 92 93 93 95 95 96 96 98 98 99 101 101 102 103 103 104 105 105 106 108 109 110 110 110 111

6.4.5 Evaluating Different Projects: Use of DCF and NPV The Engineers' Approach to Economic Evaluation The Final Word? References

112 112 112 113

6.5 Case Study - Economic Evaluation Summary 6.5.1 Background and Objectives 6.5.2 Equipment Costs 6.5.3 Installed Plant Cost by Lang Factor 6.5.4 Installed Plant Cost from Recent Plant Construction Data 6.5.5 Production Costs 6.5.6 Profitability Analysis 6.5.7 Conclusions 6.5.8 Recommendations

114 114 115 115 116 117 118 118 121 121

Chapter 7 Mass and Energy Balances 7.1 Preparation of Mass and Energy Balances References 7.2 Preliminary Equipment Design References 7.3 Computer-Aided Design What design work is there left to do now that we have simulation packages? References 7.4 Case Study-Mass and Energy Balances, and Utilities Summary 7.4.1 Scope and Objectives 7.4.2 Mass Balances 7.4.3 Energy Balances 7.4.4 Optimisation of Mass and Energy Balances 7.4.5 Utilities 7.4.6 Conclusions 7.4.7 Recommendations

123 123 125 125 126 126

Chapter 8 Additional Design Considerations 8.1 Energy Integration and Conservation 8.2 Process Control, Instrumentation and Alarms 8.3 Safety, Health and the Environment References Energy Conservation

149 149 153 155 159 159

130 130 131 131 131 134 135 139 146 147 147

Process Control Safety, Health and the Environment (including Loss Prevention and HAZOP) 8.4 Case Study – Energy Integration, Piping Specifications Process Control and the P&ID Summary 8.4.1 Energy Management and Integration 8.4.2 Plant Piping Specifications 8.4.3 Control and Instrumentation 8.4.4 The Piping and Instrumentation Diagram (P&ID 8.4.5 Conclusions 8.4.6 Recommendations References for Case Study Sections in Chapters 1 to 8 Comments References PART II DETAILED EQUIPMENT DESIGN Chapter 9 The Detailed Design Stage 9.1 Detailed Equipment Design 9.1.1 Equipment Design - HELP!!! How to Begin to Design an Item of Equipment 9.2 Standards and Codes 9.3 Additional Design Considerations References Some General Textbooks Design Books Chapter 10 Case Study -Phthalic Anhydride Reactor Design Overall Summary Updated Material and Energy Balance for the Phthalic Anhydride Reactor (R101) Engineering Specification Sheet for the Reactor (R101) Schematic Drawing of the Reactor (R101) Part I Chemical Engineering Design 10.1 Overall Design Strategy 10.2 Design Basis 10.3 Design Parameters 10.4 Design Criteria 10.5 Chemical Engineering Design Methods 10.5.1 Catalyst Properties 10.5.2 Kinetics

160 161

162 162 163 164 164 166 167 167 171 174 174 177 177 178 179 181 181 181 181 182 185 185

185 185 189 189 190 191 191 192

10.5.3 Reactor Simulation 10.5.4 Heat Transfer 10.5.5 Pressure Drop 10.6 Detailed Design 10.6.1 Reactor Configuration 10.6.2 Coolant 10.6.3 Computer Model 10.6.4 Shell Configuration 10.6.5 Salt Cooler 10.6.6 Salt Circulation Pump 10.7 Chemical Engineering Design Specification 10.7.1 Reactor Specification 10.7.2 Salt Cooler Specification 10.7.3 Salt Circulation Pump Specification Part II Mechanical Engineering Design 10.8 Mechanical Engineering Design Parameters 10.9 Mechanical Engineering Design Methods 10.9.1 Shell Design 10.9.2 Supports and Foundations 10.10 Materials of Construction 10.11 Pressure Vessel Design (AS1210) 10.12 Insulation 10.13 Supports and Foundations 10.14 Costing 10.15 Engineering Specification Specification Sheets Engineering Drawings Part III Operational Considerations 10.16 HAZOP Analysis 10.17 Process Hazards 10.18 Safety 10.19 Operability 10.20 Environmental Considerations 10.21 Control and Instrumentation 10.22 Operating Considerations 10.22.1 Operation Under Normal Conditions 10.22.2 Commissioning 10.22.3 Shut-Down 10.22.4 Start-Up 10.22.5 Regular Maintenance Part IV Conclusions, Recommendations and References 10.23 Conclusions Chemical Engineering Design Mechanical Engineering Design

193 194 194 195 195 195 196 200 202 203 207 207 209 209 210 210 210 210 211 212 213 215 216 218 220 224 224 224 225 226 226 227 229 229 230 232 232 233 235 235 235 236

Operational Considerations 10.24 Recommendations 10.25 References Appendix B. Calculations for Phthalic Anhydride Reactor Design B.1 Reactions B.2 Derivation of Simulation Model Equations B.3 Tube-Side Heat Transfer Coefficient B.4 Shell-Side Heat Transfer Coefficient B.5 Overall Heat Transfer Coefficient (Clean) B.6 Tube Count B.7 Tube-Side Pressure Drop B.8 Shell-Side Pressure Drop B.9 Salt Cooler Design B.10 Shell Design (AS1210) B.11 Tube-Plate Design B.12 Vessel Openings B.13 Protective Devices (AS1210) B.14 Insulation B.15 Supports B.16 Foundation Appendix C. FORTRAN Program for Phthalic Anhydride Reactor Simulation Appendix D. Hazard and Operability Studies for Phthalic Anhydride Reactor

237 239 239 241 241 241 243 243 244 245 245 246 247 248 250 251 252 253 254 257 259 263

Chapter 11 Case Study -Phthalic Anhydride After-Cooler Design Overall Summary Updated Material and Energy Balance for the After-Cooler (E105) Engineering Specification Sheet for the After-Cooler (E105) Schematic Drawing of the After-Cooler Part I Chemical Engineering Design 11.1 General Design Considerations 11.2 Design Strategy and Criteria 11.3 Preliminary Design Decisions 11.3.1 Condenser Type 11.3.2 Coolant 11.4 Chemical Engineering Design Methods 11.4.1 Heat Transfer Coefficient 11.4.2 After-Cooler Simulation 11.4.3 Pressure Drop 11.5 Detailed Design 11.5.1 General Considerations 11.5.2 Simulation Results 11.5.3 Vessel Configuration

269 269

269 269 274 275 275 276 277 277 280 281 282 282 282 287

11.6 Chemical Engineering Design Specification Part II Mechanical Engineering Design 11.7 Mechanical Engineering Design Requirements 11.8 Materials of Construction 11.9 Vessel Dimensions 11.10 Insulation 11.11 Supports and Foundation 11.12 Costing 11.13 Engineering Specification Part III Operational Considerations 11.14 HAZOP Analysis 11.15 Process Hazards 11.16 Safety 11.17 Operability 11.18 Environmental Considerations 11.19 Control and Instrumentation 11.20 Operating Considerations 11.20.1 Operation Under Normal Conditions 11.20.2 Commissioning 11.20.3 Shut-Down and Start-Up 11.20.4 Regular Maintenance Part IV Conclusions, Recommendations and References 11.21 Conclusions Chemical Engineering Designc Mechanical Engineering Design Operational Considerations 11.22 Recommendations 11.23 References Appendix E. Calculations for Phthalic Anhydride After-Cooler Design E.1 Provisional After-Cooler Design E.2 Shell-Side Cross-Flow Area E.3 Pressure Drops E.4 Mechanical Design E.5 Supports E.6 Foundation Appendix F. FORTRAN Program for Phthalic Anhydride After-Cooler Simulation Appendix G. Hazard and Operability Study for Phthalic Anhydride After-Cooler (Tables G.1 to G.5) Final Comments INDEX

289 290 290 291 292 294 295 297 299 302 302 302 303 304 305 306 308 308 310 311 313 314 314 314 315 316 318 318 319 319 321 321 322 324 325 326 333 338 339

Preface to Second Edition The main difference between this edition and the original (1989) is the inclusion of a new case study - the production of phthalic anhydride. Although the design process is essentially similar for most chemicals, no two designs are ever the same. A comparison between the original case study and this new one should emphasise the need for originality and flexibility in process design. As with the earlier edition, the case study has been incorporated throughout the book so that application of the principles and ideas which are discussed in the main text can be illustrated sequentially. The case study should not be viewed merely as a design blue-print but as an integral part of the book. Two items of equipment have been desinged in detail in this new case study (Part 11) whereas only the first item was considered to that depth in the first edition. All sections of the text material have been revised and new material has been added, e.g. loss prevention and safety, economic evaluation and environmental considerations. The new material reflects important developments and shifting emphasis in chemical engineering over the intervening years. However, the focus is again on the approach of learning by doing. It is necessary to consider a broad range of topics in a design problem, hence the retention of the Technical and Economic Feasibility Study. The advice is intended to be practical and the reader is directed to an extensive list of useful references - fully updated in this edition. This book is not intended to be a design handbook, it should be considered as a 'road map' for performing a design project.