PRELIMINARY CHEMICAL ENGINEERING PLANT DESIGN
CONTENTS PART I INTRODUCTION TO DESIGN AND SIMULATION 1 1 INTRODUCTION TO COMPUTER AIDED PROCESS DESIGN AND SIMULATION 3 1 1 PROCESS DESIGN 3 1 2 PROCESS CHEMISTRY CONCEPT 4 1 3 TECHNOLOGY CONCEPT 5 1 4 DATA COLLECTION 6 1 4 1 MATERIAL PROPERTIES DATA 6 1 4 2 PHASE EQUILIBRIUM DATA 6 1 4 3 REACTION EQUILIBRIUM AND REACTION KINETIC DATA 6 1 5 SIMULATION OF AN EXISTING PROCESS 6 1 6 DEVELOPMENT OF PROCESS FLOW DIAGRAMS 7 1 7 PROCESS SIMULATION PROGRAMS 7 1 7 1 SEQUENTIAL MODULAR VERSUS EQUATION ORIENTED APPROACH 9 1 7 2 STARTING A SIMULATION WITH ASPEN PLUS 10 1 7 3 STARTING A SIMULATION WITH ASPEN HYSYS 11 1 8 CONVENTIONAL VERSUS NONCONVENTIONAL COMPONENTS 11 1 9 PROCESS INTEGRATION AND ENERGY ANALYSIS 14 1 10 PROCESS ECONOMIC EVALUATION 14 REFERENCES 14 2 GENERAL PROCEDURE FOR PROCESS SIMULATION 15 2 1 COMPONENT SELECTION 15 2 2 PROPERTY METHODS AND PHASE EQUILIBRIUM 25 2 2 1 PHYSICAL PROPERTY DATA SOURCES 25 2 2 2 PHASE EQUILIBRIUM MODELS 27 2 2 3 SELECTION OF A PROPERTY METHOD IN ASPEN PLUS 31 2 2 4 SELECTION OF A PROPERTY PACKAGE IN ASPEN HYSYS 35 2 2 5 PURE COMPONENT PROPERTY ANALYSIS 36 2 2 6 BINARY ANALYSIS 38 2 2 7 AZEOTROPE SEARCH AND ANALYSIS OF TERNARY SYSTEMS 44 2 2 8 PT ENVELOPE ANALYSIS 47 2 3 CHEMISTRY AND REACTIONS 48 2 4 PROCESS FLOW DIAGRAMS 53 REFERENCES 58 PARTII DESIGN AND SIMULATION OF SINGLE UNIT OPERATIONS 61 3 HEAT EXCHANGERS 63 3 1 HEATER AND COOLER MODELS 63 3 2 SIMPLE HEAT EXCHANGER MODELS 66 3 3 SIMPLE DESIGN AND RATING OF HEAT EXCHANGERS 69 3 4 DETAILED DESIGN AND SIMULATION OF HEAT EXCHANGERS 72 3 4 1 HYSYS DYNAMIC RATING 74 3 4 2 RIGOROUS SHELL AND TUBE HEAT EXCHANGER DESIGN USING EDR 76 3 5 SELECTION AND COSTING OF HEAT EXCHANGERS 77 REFERENCES 82 4 PRESSURE CHANGING EQUIPMENT 85 4 1 PUMPS HYDRAULIC TURBINES AND VALVES 85 4 2 COMPRESSORS AND GAS TURBINES 88 4 3 PRESSURE DROP CALCULATIONS IN PIPES 92 4 4 SELECTION AND COSTING OF PRESSURE CHANGING EQUIPMENT 97 REFERENCES 99 5 REACTORS 101 5 1 MATERIAL AND ENTHALPY BALANCE OF A CHEMICAL REACTOR 101 5 2 STOICHIOMETRY AND YIELD REACTOR MODELS 101 5 3 CHEMICAL EQUILIBRIUM REACTOR MODELS 106 5 3 1 REQUIL MODEL OF ASPEN PLUS 108 5 3 2 EQUILIBRIUM REACTOR MODEL OF ASPEN HYSYS 108 5 3 3 RGIBBS MODEL OF ASPEN PLUS AND GIBBS REACTOR MODEL OF ASPEN HYSYS 109 5 4 KINETIC REACTOR MODELS 110 5 5 SELECTION AND COSTING OF CHEMICAL REACTORS 122 REFERENCES 124 6 SEPARATION EQUIPMENT 125 6 1 SINGLE CONTACT PHASE SEPARATION 125 6 2 DISTILLATION COLUMN 127 6 2 1 SHORTCUT DISTILLATION METHOD 128 6 2 2 RIGOROUS METHODS 131 6 3 AZEOTROPIC AND EXTRACTIVE DISTILLATION 136 6 4 REACTIVE DISTILLATION 141 6 5 ABSORPTION AND DESORPTION 145 6 6 EXTRACTION 148 6 7 SELECTION AND COSTING OF SEPARATION EQUIPMENT 150 6 7 1 DISTILLATION EQUIPMENT 150 6 7 2 ABSORPTION EQUIPMENT 151 6 7 3 EXTRACTION EQUIPMENT 152 REFERENCES 153 7 SOLID HANDLING 155 7 1 DRYER 155 7 2 CRYSTALLIZER 160 7 3 FILTER 162 7 4 CYCLONE 163 7 5 SELECTION AND COSTING OF SOLID HANDLING EQUIPMENT 166 REFERENCES 167 EXERCISES PART II 168 PARTIII PLANT DESIGN AND SIMULATION CONVENTIONAL COMPONENTS 173 8 SIMPLE CONCEPT DESIGN OF A NEW PROCESS 175 8 1 ANALYSIS OF MATERIALS AND CHEMICAL REACTIONS 175 8 1 1 ETHYL ACETATE PROCESS 175 8 1 2 STYRENE PROCESS 176 8 2 SELECTION OF TECHNOLOGY 176 8 2 1 ETHYL ACETATE PROCESS 176 8 2 2 STYRENE PROCESS 177 8 3 DATA ANALYSIS 180 8 3 1 PURE COMPONENT PROPERTY ANALYSIS 180 8 3 2 REACTION KINETIC AND EQUILIBRIUM DATA 181 8 3 3 PHASE EQUILIBRIUM DATA 185 8 4 STARTING ASPEN SIMULATION 188 8 4 1 ETHYL ACETATE PROCESS 188 8 4 2 STYRENE PROCESS 188 8 5 PROCESS FLOW DIAGRAM AND PRELIMINARY SIMULATION 188 8 5 1 ETHYL ACETATE PROCESS 188 8 5 2 STYRENE PROCESS 193 REFERENCES 200 9 PROCESS SIMULATION IN AN EXISTING PLANT 203 9 1 ANALYSIS OF PROCESS SCHEME AND SYNTHESES OF A SIMULATION SCHEME 203 9 2 OBTAINING INPUT DATA FROM THE RECORDS OF PROCESS OPERATION AND TECHNOLOGICAL DOCUMENTATION 205 9 3 PROPERTY METHOD SELECTION 206 9 4 SIMULATOR FLOW DIAGRAM 207 9 5 SIMULATION RESULTS 208 9 6 RESULTS EVALUATION AND COMPARISON WITH REAL DATA RECORDED 208 9 7 SCENARIOS FOR SUGGESTED CHANGES AND THEIR SIMULATION 211 REFERENCES 214 10 MATERIAL INTEGRATION 215 10 1 MATERIAL RECYCLING STRATEGY 215 10 2 MATERIAL RECYCLING IN ASPEN PLUS 216 10 3 MATERIAL RECYCLING IN ASPEN HYSYS 219 10 4 RECYCLING RATIO OPTIMIZATION 223 10 5 STEAM REQUIREMENT SIMULATION 230 10 6 COOLING WATER AND OTHER COOLANTS REQUIREMENT SIMULATION 232 10 7 GAS FUEL REQUIREMENT SIMULATION 233 REFERENCES 237 11 ENERGY INTEGRATION 239 11 1 ENERGY RECOVERY SIMULATION BY ASPEN PLUS 239 11 2 ENERGY RECOVERY SIMULATION IN ASPEN HYSYS 242 11 3 WASTE STREAM COMBUSTION SIMULATION 244 11 4 HEAT PUMP SIMULATION 250 11 5 HEAT EXCHANGER NETWORKS AND ENERGY ANALYSIS TOOLS IN ASPEN SOFTWARE 253 REFERENCES 261 12 ECONOMIC EVALUATION 263 12 1 ESTIMATION OF CAPITAL COSTS 263 12 2 ESTIMATION OF OPERATING COSTS 266 12 2 1 RAW MATERIALS 267 12 2 2 UTILITIES 268 12 2 3 OPERATING LABOR 269 12 2 4 OTHER MANUFACTURING COSTS 270 12 2 5 GENERAL EXPENSES 270 12 3 ANALYSIS OF PROFITABILITY 270 12 4 ECONOMIC EVALUATION TOOLS OF ASPEN SOFTWARE 274 12 4 1 ECONOMIC EVALUATION BUTTON 274 12 4 2 ECONOMICS ACTIVE 275 12 4 3 DETAILED ECONOMIC EVALUATION BY APEA 275 REFERENCES 278 EXERCISES PART III 279 PARTIV PLANT DESIGN AND SIMULATION NONCONVENTIONAL COMPONENTS 283 13 DESIGN AND SIMULATION USING PSEUDOCOMPONENTS 285 13 1 PETROLEUM ASSAYS AND BLENDS 285 13 1 1 PETROLEUM ASSAY CHARACTERIZATION IN ASPEN HYSYS 286 13 1 2 PETROLEUM ASSAY CHARACTERIZATION IN ASPEN PLUS 289 13 2 PRIMARY DISTILLATION OF CRUDE OIL 294 13 3 CRACKING AND HYDROCRACKING PROCESSES 307 13 3 1 HYDROCRACKING OF VACUUM RESIDUE 309 13 3 2 MODELING OF AN FCC UNIT IN ASPEN HYSYS 315 REFERENCES 319 14 PROCESSES WITH NONCONVENTIONAL SOLIDS 321 14 1 DRYING OF NONCONVENTIONAL SOLIDS 321 14 2 COMBUSTION OF SOLID FUELS 326 14 3 COAL BIOMASS AND SOLID WASTE GASIFICATION 329 14 3 1 CHEMISTRY 329 14 3 2 TECHNOLOGY 332 14 3 3 DATA 334 14 3 4 SIMULATION 334 14 4 PYROLYSIS OF ORGANIC SOLIDS AND BIO OIL UPGRADING 341 14 4 1 COMPONENT LIST 341 14 4 2 PROPERTY MODELS 342 14 4 3 PROCESS FLOW DIAGRAM 342 14 4 4 FEED STREAM 344 14 4 5 PYROLYSIS YIELDS 344 14 4 6 DISTILLATION COLUMN 344 14 4 7 RESULTS 344 REFERENCES 346 15 PROCESSES WITH ELECTROLYTES 347 15 1 ACID GAS REMOVAL BY AN ALKALI AQUEOUS SOLUTION 347 15 1 1 CHEMISTRY 347 15 1 2 PROPERTY METHODS 350 15 1 3 PROCESS FLOW DIAGRAM 351 15 1 4 SIMULATION RESULTS 353 15 2 SIMULATION OF SOUR GAS REMOVAL BY AQUEOUS SOLUTION OF AMINES 355 15 3 RATE BASED MODELING OF ABSORBERS WITH ELECTROLYTES 361 REFERENCES 365 16 SIMULATION OF POLYMER PRODUCTION PROCESSES 367 16 1 OVERVIEW OF MODELING POLYMERIZATION PROCESS IN ASPEN PLUS 367 16 2 COMPONENT CHARACTERIZATION 368 16 3 PROPERTY METHOD 369 16 4 REACTION KINETICS 370 16 5 PROCESS FLOW DIAGRAM 375 16 6 RESULTS 379 REFERENCES 383 EXERCISES PART IV 384