Process Plant Design

ISBN : 9781119689911

Author : Robin Smith

Publisher : Wiley

Year : 2023

Language : English

Type : Book

Description : Table of Contents Preface xi Acknowledgments xiii Nomenclature xv About the Companion Website xix 1 Chemical Process Projects 1 1.1 The Process Plant Design Problem 1 1.2 Continuous and Batch Processes 2 1.3 New Design and Retrofit 3 1.4 Hazard Management in Process Plant Design 4 1.5 Project Phases 4 1.6 Chemical Process Projects – Summary 5 References 6 2 Process Economics 7 2.1 Capital Cost Estimates 7 2.2 Class 5 Capital Cost Estimates 8 2.3 Class 4 Capital Cost Estimates 9 2.4 Class 3 to Class 1 Capital Cost Estimates 15 2.5 Capital Cost of Retrofit 15 2.6 Annualized Capital Cost 16 2.7 Operating Cost 17 2.8 Economic Evaluation 20 2.9 Investment Criteria 23 2.10 Process Economics − Summary 23 Exercises 24 References 25 3 Development of Process Design Concepts 27 3.1 Formulation of Design Problems 27 3.2 Evaluation of Performance 27 3.3 Optimization of Performance 28 3.4 Approaches to the Development of Design Concepts 29 3.5 Screening Design Options 32 3.6 Influencing the Design as the Project Progresses 33 3.7 Development of Process Design Concepts – Summary 34 References 35 4 Heating Utilities 37 4.1 Process Heating and Cooling 38 4.2 Steam Heating 39 4.3 Water Treatment for Steam Generation 44 4.4 Steam Generation from the Combustion of Fuels 45 4.5 Steam Generation from Electrical Energy 48 4.6 Gas Turbines 50 4.7 Steam Turbines 51 4.8 Steam Distribution 55 4.9 Steam Heating Limits 64 4.10 Fired Heaters 64 4.11 Other Heat Carriers 68 4.12 Heating Utilities – Summary 74 Exercises 74 References 76 5 Cooling Utilities 77 5.1 Waste Heat Steam Generation 77 5.2 Once-Through Cooling Water Systems 77 5.3 Recirculating Cooling Water Systems 78 5.4 Air Coolers 80 5.5 Refrigeration 82 5.6 Choice of a Single Component Refrigerant for Compression Refrigeration 88 5.7 Mixed Refrigerants for Compression Refrigeration 89 5.8 Absorption Refrigeration 93 5.9 Indirect Refrigeration 93 5.10 Cooling Utilities − Summary 94 Exercises 95 References 96 6 Waste Treatment 97 6.1 Aqueous Emissions 97 6.2 Primary Wastewater Treatment Processes 101 6.3 Biological Wastewater Treatment Processes 104 6.4 Tertiary Wastewater Treatment Processes 109 6.5 Atmospheric Emissions 109 6.6 Treatment of Solid Particulate Emissions to Atmosphere 111 6.7 Treatment of VOC Emissions to Atmosphere 114 6.8 Treatment of Sulfur Emissions to Atmosphere 120 6.9 Treatment of Oxides of Nitrogen Emissions to Atmosphere 123 6.10 Treatment of Combustion Emissions to Atmosphere 124 6.11 Atmospheric Dispersion 127 6.12 Waste Treatment − Summary 128 Exercises 128 References 129 7 Reliability, Maintainability, and Availability Concepts 131 7.1 Reliability, Maintainability, and Availability 131 7.2 Reliability 133 7.3 Repairable and Non-repairable Systems 136 7.4 Reliability Data 139 7.5 Maintainability 141 7.6 Availability 143 7.7 Process Shut-down for Maintenance 144 7.8 Reliability, Maintainability, and Availability Concepts − Summary 145 Exercises 145 References 146 8 Reliability, Maintainability, and Availability of Systems 147 8.1 System Representation 147 8.2 Reliability of Series Systems 147 8.3 Reliability of Parallel Systems 149 8.4 Availability of Parallel Systems 153 8.5 Availability of Series Systems 153 8.6 Redundancy 156 8.7 k-out-of-n Systems 159 8.8 Common Mode Failure 161 8.9 Capacity 166 8.10 Reliability, Availability, and Capacity 169 8.11 Monte Carlo Simulation 169 8.12 Reliability, Maintainability, and Availability of Systems − Summary 172 Exercises 172 References 174 9 Storage Tanks 175 9.1 Feed, Product, and Intermediate Storage 175 9.2 Intermediate (Buffer) Storage and Process Availability 177 9.3 Optimization of Intermediate Storage 181 9.4 Storage Tanks − Summary 182 Exercise 182 References 183 10 Process Control Concepts 185 10.1 Control Objectives 185 10.2 The Control Loop 185 10.3 Measurement 186 10.4 Control Signals 187 10.5 The Controller 187 10.6 Final Control Element 191 10.7 Feedback Control 195 10.8 Cascade Control 197 10.9 Split Range Control 198 10.10 Limit and Selector Control 200 10.11 Feedforward Control 201 10.12 Ratio Control 204 10.13 Computer Control Systems 205 10.14 Digital Control 207 10.15 Safety Instrumented Systems 210 10.16 Alarms and Trips 211 10.17 Representation of Control Systems 211 10.18 Process Control Concepts – Summary 215 Exercise 215 References 216 11 Process Control – Flowrate and Inventory Control 217 11.1 Flowrate Control 217 11.2 Inventory Control of Individual Operations 217 11.3 Inventory Control of Series Systems 223 11.4 Inventory Control of Recycle Systems 226 11.5 Flowrate and Inventory Control – Summary 227 References 228 12 Process Control – Degrees of Freedom 229 12.1 Degrees of Freedom and Process Control 229 12.2 Degrees of Freedom for Process Streams 231 12.3 Individual Single-Phase Operations 233 12.4 Heat Transfer Operations with No Phase Change 237 12.5 Pumps and Compressors 241 12.6 Equilibrated Multiphase Operations 243 12.7 Control Degrees of Freedom for Overall Processes 246 12.8 Degrees of Freedom – Summary 256 Exercises 256 References 257 13 Process Control – Control of Process Operations 259 13.1 Pump Control 259 13.2 Compressor Control 262 13.3 Heat Exchange Control 267 13.4 Furnace Control 271 13.5 Flash Drum Control 274 13.6 Absorber and Stripper Control 274 13.7 Distillation Control 278 13.8 Reactor Control 291 13.9 Control of Process Operations – Summary 301 Exercises 301 References 302 14 Process Control – Overall Process Control 303 14.1 Illustrative Example of Overall Process Control Systems 303 14.2 Synthesis of Overall Process Control Schemes 310 14.3 Procedure for the Synthesis of Overall Process Control Schemes 311 14.4 Evolution of the Control Design 323 14.5 Process Dynamics 324 14.6 Overall Process Control – Summary 325 Exercises 325 References 328 15 Piping and Instrumentation Diagrams – Piping and Pressure Relief 329 15.1 Piping and Instrumentation Diagrams 329 15.2 Piping Systems 330 15.3 Pressure Relief 335 15.4 Relief Device Arrangements 338 15.5 Reliability of Pressure Relief Devices 341 15.6 Location of Relief Devices 345 15.7 P&ID Piping and Pressure Relief – Summary 346 Exercises 346 References 348 16 Piping and Instrumentation Diagrams – Process Operations 349 16.1 Pumps 349 16.2 Compressors 355 16.3 Heat Exchangers 359 16.4 Distillation 361 16.5 Liquid Storage 366 16.6 P&ID Process Operations – Summary 373 Exercises 373 References 374 17 Piping and Instrumentation Diagrams – Construction 375 17.1 Development of Piping and Instrumentation Diagrams 375 17.2 A Case Study 376 17.3 P&ID Construction – Summary 387 References 387 18 Materials of Construction 389 18.1 Mechanical Properties 389 18.2 Corrosion 392 18.3 Corrosion Allowance 393 18.4 Commonly Used Materials of Construction 393 18.5 Criteria for Selection of Materials of Construction 397 18.6 Materials of Construction – Summary 398 References 398 19 Mechanical Design 399 19.1 Stress, Strain, and Deformation 399 19.2 Combined Stresses 423 19.3 Spherical Vessels Under Internal Pressure 426 19.4 Cylindrical Vessels Under Internal Pressure 428 19.5 Design of Heads for Cylindrical Vessels Under Internal Pressure 431 19.6 Design of Vertical Cylindrical Pressure Vessels Under Internal Pressure 434 19.7 Design of Horizontal Cylindrical Pressure Vessels Under Internal Pressure 439 19.8 Buckling of Cylindrical Vessels Due to External Pressure and Axial Compression 445 19.9 Welded and Bolted Joints 448 19.10 Opening Reinforcements 451 19.11 Vessel Supports 453 19.12 Design of Flat-bottomed Cylindrical Vessels 462 19.13 Shell-and-Tube Heat Exchangers 463 19.14 Mechanical Design – Summary 464 Exercises 465 References 467 20 Process Plant Layout − Site Layout 469 20.1 Site, Process, and Equipment Layout 469 20.2 Separation Distances 470 20.3 Separation for Vapor Cloud Explosions 472 20.4 Separation for Toxic Emissions 477 20.5 Site Access 477 20.6 Site Topology, Groundwater, and Drainage 479 20.7 Geotechnical Engineering 481 20.8 Atmospheric Discharges 481 20.9 Wind Direction 482 20.10 Utilities 483 20.11 Process Units 483 20.12 Control Room 483 20.13 Ancillary Buildings 485 20.14 Pipe Racks 485 20.15 Constraints on Site Layout 487 20.16 The Final Site Layout 487 20.17 Site Layout − Summary 487 References 487 21 Process Plant Layout − Process Layout 489 21.1 Process Access 489 21.2 Process Structures 489 21.3 Hazards 492 21.4 Preliminary Process Layout 492 21.5 Example – Preliminary Process Layout 493 21.6 Process Layout – Summary 498 References 498 Appendix A Weibull Reliability Function 499 Appendix B MTTF for the Weibull Distribution 501 Appendix C Reliability of Cold Standby Systems 503 Reference 504 Appendix D Corrosion Resistance Table 505 Appendix E Moment of Inertia and Bending Stress for Common Beam Cross-Sections 509 E.1 Solid Rectangular Cross-Section 509 E.2 Hollow Rectangular Cross-Section 509 E.3 Solid Circular Cylinder 510 E.4 Hollow Circular Cross-Section 511 E.5 Approximate Expressions for Thin-Walled Cylinders 511 Appendix F First Moment of Area and Shear Stress for Common Beam Cross-Sections 513 F.1 Solid Rectangular Cross-Section 513 F.2 Hollow Rectangular Cross-Section 513 F.3 Solid Circular Cross-Section 514 F.4 Hollow Circular Cross-Sections 515 Reference 515 Appendix G Principal Stresses 517 Appendix H Dimensions and Weights of Carbon Steel Pipes 521 Appendix I Bending Moment on Horizontal Cylindrical Vessels Resulting from a Liquid Hydraulic Head 525 References 526 Appendix J Equivalent Cylinder Approximation 527 Index 529

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