Perry

Preliminary Chemical Engineering Plant Design
William D.Baasel
Professor of Chemical Engineering Ohio University

ELSEVIER
New York/Oxford/Amsterdam

Contents
Preface 1. INTRODUCTION TO PROCESS DESIGN Other Sources of Innovations, 3. Research, 2. Process Engineering, 4. Professional Responsibilities, 7. Competing Processes, 8. Typical Problems a Process Engineer Tackles, 9. Comparisonwith Alternatives, 14. Completing the Project, 16. Units, 17. References, 18. Bibliography, 18. 2. SITE SELECTION Other Site Location Factors, 34. Major Site Location Factors, 25. Study: Site Selection, 48. References, 54. 3. THE SCOPE The Product, 60. Capacity, 60. Quality, 66. Raw Material Storage, 67. Product Storage, 68. The Process, 69. Waste Disposal, Utilities, Shipping and LaboratoryRequirements, 70. Plans for Future Expansion, 70. Hours of Operation, 71. Completion Date, 71. Safety, 71. Case Study: Scope, 72. Scope Summary, 75. References, 78. 4. PROCESS DESIGN AND SAFETY Chemistry, 79. Separations, 80. Unit Ratio Material Balance, 84. Detailed Flow Sheet, 85. Safety, 89. Case Study: Process Design, 97. Change of Scope, 103. References, 103. 5. EQUIPMENT LIST Sizing 111. 113. 114.117. Planning for Future Expansion, of Equipment, 106. Materials of Construction, 113. Temperature and Pressure, Laboratory Equipment, 114. Completion of Equipment List, Rules of Thumb, 114. Case Study: Major Equipment Required, References, 133. Change of Scope, 132. 141 105 79 Case 23 xi 1

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6. LAYOUT New Plant Layout, 141. Expansion and Improvements of Existing Facilities, 152. CaseStudy: Layout and Warehouse Requirements, 153. References, 158. vii

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Contents PROCESS CONTROL AND INSTRUMENTATION Plant Safety, Product Quality 160. Product Quantity, 160. Control System, 161. Manual or Automatic Control, 161. Final Control Element, 162. Variables to be Measured, 162. Averaging versus Set 163. Control and Instrumentation Symbols, 164. Tempered Heat Point Control, 166.Material Balance Control, 167. Cascade Control, 170. Feedforward Control, Transfer, 168. Pneumatic versus Elec171. Blending, 172. Digital Control, 172. Case Study: Instrumentation and Control, tronic Equipment, 173. 174. References, 180. 159

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ENERGY AND UTILITY BALANCES AND MANPOWER NEEDS Energy Balances, 183. Sizing Energy Conservation of Energy, 182. Equipment, 191. Planning forExpansion, 204. Lighting, 205. Ventilation, Space Heating and Cooling, and Personal Water Requirements, 207. Utility Requirements, 209. Manpower RequireCase Study: Energy Balance and ments, 210. Rules of Thumb, 2 11. References, 232. Utility Assessment, 213. Change of Scope, 231.

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9.

COST

ESTIMATION

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Cost Indexes, 237. How Capacity Affects Costs, 239. Factored Cost Estimate, 246.Improvements on the Factored Estimate, 249. Module Cost Estimation, 254. Unit Operations Estimate, 258. Detailed Cost Estimate, 263. Accuracy of Estimates, 264. Case Study: Capital Cost Estimation, 264. References, 2 7 5 . 10. ECONOMICS Capital, 284. Elementary ProfitaCost of Producing a Chemical, 28 1. Compound Interest, bility Measures, 285. Time Value of Money, 293. Rate of 295. Net PresentValue-A Good Profitability Measure, 307. Comparison of Net Return-Another Good Profitability Measure, 311. Present Value and Rate of Return Methods, 316. Proper Interest Rates, Case Study: Economic 317. Expected Return on the Investment, 323. Evaluation, 324. Problems, 330. References, 338. 11. DEPRECIATION, AMORTIZATION, DEPLETION AND INVESTMENT CREDIT Depreciation, 339. Amortization, 348. Depletion348. Special Tax Rules, 350. Investment Credit, 349. The Net Present Value and Rate of Return, 350. 351. References, 352. 12. DETAILED ENGINEERING, CONSTRUCTION, AND STARTUP Detailed Engineering, 363. References. 367. 353. Construction 361. Startup, Allowance, Case Study: Problems. 279

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Contents 13. PLANNING TOOLS-CPM AND PERT CPM, 370. Manpower and Equipment Leveling, 376. Cost...