ee to Saree at ered DIS Fed >) Ta att ae) 2. | ean | in ete * it y 4 BEE i. me = + | in (il oe eee = SBThakore BI BhattIN Yj NZ) Na] Tata McGraw-Hill Published by the Tata McGraw-Hill Publishing Company Limited, 7 West Patel Nagar, New Delhi 110 008. Copyright © 2007, by Tata McGraw-Hill Publishing Company Limited. No part of this publication may be reproduced or distributed in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise or stored in a database or retrieval system without the prior written permission of the publishers. The program listings (if any) may be entered, stored and executed in a computer system, but they may not be reproduced for publication. This edition can be exported from India only by the publishers, Tata McGraw-Hill Publishing Company Limited ISBN-13: 978-007063415-2 ISBN-10: 0-07-063415-7 Head—Higher Education & School: 5. 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If such services are required, the assistance of ‘an appropriate professional should be sought. Typeset at The Composers, 260, C.A. Apt., Paschim Vihar, New Delhi 110063 and printed at Rashtriya Printer, M-135, Panchsheel Garden, Naveen Shahdara, Delhi 110 032 Cover Design: Rashtriya Printer RZCLCRLYDZLXQ Me LA mer en ceForeword ix Preface xi 1.1_Intraduction _J 1.2 Fundamental Quantities or Dimensions __/ 3 Derived Units 2 1.4 Recommended Rules for Writing Unit Symbols 7 L.5__Conversion Factors 9 References 9 2.__Stoichiometry 10 21 Introduction 10 2.3 Energy Balances 19 2.4 Enthalpy Changes Accompanying Chemical Reactions 21 2.5 Heat Changes in Mixing Processes 27 Exercises 32 References 37 3._ Process Engineering 38 3.1__Introduction _38 3,.2__ Examples of Alternative Routes in Process Engineering 38 3.3__ Generalized Approach to the Chemical Plant Design 39 3.4 ition of Operating Instructions Manual _ 45 3.5 Conductance of Performance Test Runs 46 3.6_Troubleshooting 47 3.7__ Cost Cutting Measures 47 3.8 Green Engineering 48 3.9__ Process Intensification 50 3.10 Conclusion 52 re Exercises 52 EAZN-ZRF -3UGH4. Contents Importance of Process Diagrams in Process Engineering 54 41 Introduction 54 42 Need for PFD and P&ID 54 43 Block Diagrams 55 4A Development and Utility of Process Flow Diagrams 55 4.5 Development of Piping and Instrumentation Diagrams 60 Exercises 67 References 69 Process Design of Piping, Fluid Moving Devices and Flow Meters _70 5.1__Introduction 70 5.2 Process Design of Piping 70. 5.3 Process Design of Fluid Moving Devices 83 5.4 Evaluation of Centrifugal Pump Performance when Handling Viscous Liquids 07 5.5 Power Required in Fan. Blower and in 5.6 Flow Meters 110 5.7 Process Design of Orifice Meter 115 5.8 Process Design of Rotameter_//9 5.9 Two Phase Flow 127 5.10 Troubleshooting of Fluid Flow Systems 130 Rxerris 20 References 133 Process Design of Heat Exchangers 134 61 Shell and Tube Heat Exchanger /3-4 6.2 Design of Heat Exchangers 137 6.3 General Design Method for Shell and Tube Heat Exchanger 155 Vertical Condenser “182 Sica wi a ables 19: 6.6 Multicomponent Condensation 2 6.7 Process Design of Reboilers and Vaporizers 2/7 6.8 Tinker's Flow Model 247 69 Air Cooled Heat Exchangers and Air Heaters 249 610 Plate Heat Exchangers 270 6.11 Spiral Flow Heat Exchangers 28/ 6.12 _Brazed Aluminium Plate-fin Heat Exchanger 294 6.13 Heat Exchanger Networking for Energy Integration 295 6.14 Heat Transfer in Solids 377 Exercises 321 References 324 Design of Liquid—Liquid Extractor 325 7.1 Introduction 325 7.2 Important Industrial Applications of Liquid-Liquid Extraction 326Contents i_| 73 Phase Equilibrium 326 7.5 Design of Counter Current Multistage Extractor 329 7.6 Industrially Important Extractors 342 7.7 Supercritical Extraction (SCE) 364 Exercises 375 References 377 Process Design of Distillation Columns 378 &1 Introduction 378 8.2__Criteria of Selection _378 8.3 Selection of Equipment for Distillation 379 8.4 Distillation Column Design 380 8.5 Batch Distillation 475 8.6 Short Path Distillation 493 8.7_Reactive and Catalytic Distillation _50/ 8.8 _Azeotropes and Separation Thereof 5/2 8.9 Energy Conservation in Distillation 538 Exercises 556 References 565 10. Process Design of Absorbers 567 91 Introduction 567 9.2 Criteria of Selection 568 9.3 Design of Packed Tower Type Absorber 569 9.4 Process Design of Spray Chamber or Spray Tower Type Absorber 606 9.5 Venturi Scmbber 611 9.6 Process Design of Falling Film Absorber 615 Exercises 654 References 656 Process Design of Reactors 657 10.1 Introduction 657 10.2 Different Types of Reactors _657 10.4 Continuous Flow Reactors 671 10.5 Degree of Completion of Reaction 682 10.6 Mixing for the Different Type of Reaction Systems 684 10.7 Bubble Column Reactor 697 10.8 Design of Fixed Catalyst Bed Reactors for Gaseous Reactions 7/3 References 728 Appendix 1 Conversion Tables 730 Appendix 2 _Viscometer Conversion Chart 735 Index 736| | Foreword Dr. Jack Welch, CEO of General Electric, built its market cap by more than $450 billion and established himself as the most admired business leader in the world. He is Doctorate in Chemical Engineering and is proud to be a Chemical Engi- neer. In his business autobiography he wrote, “I have always felt that chemical engineering was one of the best backgrounds for a business career because both the class-work and required thesis teach you one very important lesson: There are no finite answers to many questions.” A chemical process engineer’s job is, therefore, tough. It is hard because he has to find not only a finite answer but to select the best answer for the situation from a variety of options. That is why process engineering is interesting and at the same time intriguing. A process engineer has to design a plant or a part of it. He may have to design a unit operation or a unit process or a system. The important aspect is that it must work and operate reliably and smoothly. The unit is to be designed for a commer- cial purpose and, hence, it has to be economical and cost effective. A good proc- ess engineer has to have plant experience and, in addition, a good understanding of process economics and knowledge of current costs and trends. Chemical process industry covers a very wide spectrum of industrial products. Apart from the chemicals they handle, the quantities and sizes also vary. This requires the process engineer to have flexibility of mind and vision to adopt itself to any scale. Selection and design of the equipment should therefore be capable to handle the capacities and instruments to measure the parameters for large chemi- cal plants to micro units to manufacture enzymes. Till 1973, fuel and energy costs were a small component of the manufacturing costs of a chemical product. Since then, the rising fuel prices have made it man- datory that the plant design and its operation be energy efficient. The approach to process design has undergone a paradigm change. Bhopal gas leakage disaster and Chernobyl catastrophe made another impact on the minds of process engineers and changed the practices followed till then. Greater responsibility now rests on the process engineers for safer designs of the plants. HAZAN (Hazard Analysis) and HAZOP (Hazard and Operatability) studies have become a part of process studies, attaching one more design aspect in thea Foreword minds of process engineers. Several lessons regarding storage and handling were learnt by the process engineer. He has to now respect environmental and ecologi- cal sustainability of the process and its design. Software for the design of equipment such as heat exchangers, distillation columns, etc. are available. It has simplified piping design. Drawing and drafting has become easier, error free and faster. But without understanding the design principles, explained in this book, one cannot use them efficiently. Yet, the process flow sheeting or the development of a process scheme still remains a brain teasing function. It can be explained and perhaps taught but can- not be standardized. Process engineer has to be innovative and creative. Prepara- tion of a Process Flow Diagram is still a prominent and challenging domain of a process engineer. It is more admirable that Mr. Bharat I. Bhatt and Prof. Shuchen B. Thakore decided to go deeper into some of these topics and write a book on Process Engi- neering and Design. They have done it with success. I had the opportunity of working with Mr. Bhatt. He is one of the best process engineers I have come across. The long industrial experience of Mr. Bhatt and extensive teaching expe- rience of Prof. Thakore have made them eminently suitable to offer their knowl- edge to student fraternity and practicing engineers. I have no doubt that the book will find its place with most academicians involved in teaching the subject. The book describes systematic methods for the process design with many il- lustrations, drawn from various sections of the industry. They have included sev- eral solved and unsolved problems with sufficient details. Authors’ approach is user friendly and result oriented. Indepth study of these examples will boost con- fidence of the students in solving real life design and operating problems. Large number of references, cited at the end of each chapter, indicates the extensive literature study made by the authors. Further, study of these references will provide more insight to process design aspects. An exclusive chapter is devoted on development of Process Flow Diagrams (PFD) and Piping and Instrumentation Diagrams (P&ID) which is justified by my earlier comments. Sufficient emphasis is placed on ‘green’ engineering. These aspects have made this book anique. Many recent topics like pinch technology, energy conservation in distillation, two-phase flow of fluids, design of loop reactors and many others are to be ap- preciated which arc hard to find in other books on process design. Thave no doubt that the book will make the library of a student and practicing engineer richer. Suhas M Mokashi Ex-Director of Technology & Marketing Kaevernar Powergas Pvt. Ltd.Philosophy and Goals Chemical industry in India is facing challenges from the international market due to globalization. Role of research and development cannot, therefore, be under- mined in the face of such stiff competition. At the same time, energy conserva- tion is gaining importance due to the spiraling prices of petroleum crude. Man- agement is, therefore, constrained to use the resources to the optimum. Industry is required to deliver cheaper and better quality products. Better not only means better product quality but it also means the process, adopted for the manufacture should be environmentally compatible. Also the supplier has to as- sure the quality on a regular basis. Above challenges call for changes in processes and technologies. These changes are necessitated not only due to research and innovations, but are also dictated by alternate raw materials and environmental factors. Since, every production proc- ess and technology has a life cycle, entrepreneurs must take advantage of techno- logical advancements. The task of a process engineer is to convert the research and development efforts into industrial reality. This amounts to taking into account the safety and ecological boundary conditions and economics as also using the latest technol- ogy available. The present book covers applications of the basic principles to design alter- nate systems, develop process diagrams and select the best alternative to be adopted. Chapter on Process Engineering emphasizes on evaluation of alternate processes and designs. Process design in its truest sense does lead to a unique solution. Although the type of design problems given in the text may not be the actual design in the strictest form, the authors believe that it is a first step in learning the design process. Eventually the student should be able to analyze and design the process system by himself. Inspiration Prof. Shuchen Thakore has been engaged in teaching the subject to the under- graduate and postgraduate students for more than a decade. Teaching experiencePreface has helped in deciding the appropriate coverage in the book for the course sylla- bus. Prior to his teaching experience, he worked as a process engineer in indus- tries for five years. Thereafter he worked as a consultant for process design of various chemical equipment. Few problems covered in the book are derived from his actual assignments. Bharat Bhatt spent more than 15 years in the Process Engineering Section of a large chemical plant. He also carried out the design of many chemical plant equipments, which were successfully commissioned. The present work reflects the experience gained by him during his tenure of service. Features e Only a limited number of unit operations are covered to highlight the proc- ess design aspects. In each of these operations, current developments are included which provide energy efficient, more reliable and safer designs. Networking of heat exchangers (pinch technology), two-phase fluid flow system, solids cooling, supercritical extraction, separation of azeotropic mixtures, energy conservation in distillation, design of jet reactors, han- dling of liquids saturated with gases and many other topics are covered in the book which would be of interest of the readers in process engineering and design. © Use of correct property values in process design plays an important role. Property data are extracted from various literature sources which should help readers think of the various sources that are available for the specific data. Syllabus of many universities were gathered and a sincere attempt is made to cover most (if not all) topics of these syllabii. © A number of ready to use software packages are available in the market. However, we believe that basic approach to process design should be clear to the chemical engineers. This knowledge should help the engineers to utilize the software in an efficient manner. Use of mathematical software (such as Mathcad®, Maple®, etc.) and spreadsheet software such as (Ex- cel®) is made in solving many problems. Preparation of process diagrams with Autocad® or Visio® is encouraged to enhance the skills and speedy execution of the project. © Every effort has been made to make the approach to the subject student friendly. Presentation is made in a lucid, logical and step-by-step manner. Writing style is kept relatively simple for easy understanding. Industrial examples are cited for each concept/principle so that the student can appre- ciate the concept. © A large number of solved problems are drawn from the industry to make the book practical, The worked examples are regarded as part of the text and are clearly explained without expecting the student to fill in missing steps. They will give students a good understanding of the design steps and the confidence to solve problems themselves in real life.Preface vai | e A large number of exercise problems are given at the end of each chapter. Design problems as well as problems with varying degree of difficulty are included. The approach adopted in the book will enable a student to progress from theory to practice smoothly. At the same time a practicing process design engineer may like to use the book as a ready reference. Who will Benefit from this Book? The text is an introduction to the vast subject of process design. It is intended to provide course material for a two-semester course in process design for under- graduate students of chemical engineering. It can be also used for the students pursuing higher studies for M. Tech. in Process Engineering and Design. It can serve as a reference text for other subjects like advanced separation techniques, advanced heat and mass transfer, etc. The main prerequisites for the course using the text are chemistry, stoichiom- etry and unit operations. Although familiarity with computer and various soft- ware packages will be helpful, the user friendly methodology adopted in the book does not make knowledge of these mandatory. Acknowledgements We are greatly honoured by the Foreword written by Mr. S. M. Mokashi who is a well known process design expert. His industrial and consulting experience spans over 40 years. He has handled many large industrial projects. We are extremely thankful for his encouragement in our scholastic work. We have been rendered help by many of our colleagues who were also a source of inspiration. We thank all of them for their indirect contributions. We are grate- ful to the Principal, Vishwakarma Government Engineering College, Gandhinagar, Gujarat for granting us the permission to publish this book. We are also thankful to the reviewers who read the original manuscript and offered valuable com- ments/suggestions. We would like to express our appreciation for loving support we had received from our wives; Dimple Thakore and Minaxi Bhatt. We want to thank many at Tata McGraw-Hill for their overwhelming support. In particular, we wish to place on record our thanks to Ms Vibha Mahajan, Ms Shukti Mukherjee, Ms Mini Narayanan and Ms Anjali Razdan for their support and encouragement. Suggestions and Comments Suggestions and comments of the readers are welcome to improve the utility of the book in future. We can be reached through the publisher or directly at sbthakore@ yahoo.co.in for Shuchen Thakore and b_bhatt26@hotmail.com for Bharat Bhatt. Saucnen B. THakore Buarar I. Buarr