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Tutorials
Process Synthesis and Design
A Self-Instructional Problem Workbook
David Kauffman
Chemical and Nuclear Engineering Department
The University of New Mexico, Albuquerque NM
Published by ETS Professional Training
Institute
© 1992 Louis Theodore. 254 pages. ISBN 1-882767-08-X.
Table of Contents
Basic Operations
Process Synthesis
Known Processes · New Processes
Process Economics
Capital Costs · Operating Costs · Overall Economics
Flow Sheets
Block Diagrams · Process Flow Sheets · Piping and Instrumentation
Diagrams
Continuous and Batch Operations
Continuous Operations · Batch Operations
Material and Energy Balances
Once-through Systems · Recycle Systems
Short-cut Equipment Design Methods
Liquid Handling · Gas Handling · Solids Handling ·
Heating and Cooling · Chemical
Reactions · Separations
Materials of Construction
Strength of Materials · Corrosion · Comparative Costs
Utility Systems
Steam Systems · Cooling Water · Other Utilities
Shipping and Storage
Shipping Facilities · Tank Farms
Plant Layout
Process Flow Approach · Common Equipment Approach
Process Control and Instrumentation
Instrumentation and Measurement · Control Loops · Alarms
and Trips · Computer Control
Plant Reliability
Safety Factors in Design · Redundancy in Design
Plant Safety
Fire and Explosion Hazards · Toxic Materials Hazards · Plant
Safety Analyses · Operating Procedures
Worker Health and Safety
Protective Equipment · Training · Operating Procedures
Environmental Controls
Air Emissions · Toxic Air Emissions · Water Pollution Control
· Solid Waste · Hazardous Waste
Problems
Process Synthesis and Selection (PSS)
PSS 1: Scale-up of a
Lab Process: Sulfur Removal from Oil
PSS 2: Scale-up of an Existing Process: Ethanol Synthesis
PSS 3: Batch vs. Continuous Processing: Lube Oil Refining
PSS 4: Material Balance, Once Through: BTX Separations
PSS 5: Material Balance with Recycle: Toluene Disproportionation
PSS 6: Energy Balance: Manufacture of Ammonia
PSS 7: Material Balance: Accounting for By-Products
Process Economics (PE)
PE 1: Capital Cost Estimation: Heat Exchanger
PE 2: Operating Cost Estimation: Pump
PE 3: Simple Process Comparison: Ethylene Oxide Manufacture, Air vs. Oxygen
PE 4: Economic Equipment Selection: Pumps
PE 5: Economic Process Selection: Heat Exchange
Short-Cut Equipment Design Methods
(SCD)
SCD 1: Pump Specification
SCD 2: Compressor Specification
SCD 3: Heat Exchanger Sizing
SCD 4: Distillation Column Sizing
SCD 5: Liquid-Vapor Separator Design
SCD 6: Storage Tank Design
The Overall Process Plant (OPP)
OPP 1: Steam Distribution
OPP 2: Cooling Tower Operation
OPP 3: Maximum Flare System Capacity
OPP 4: Heat Exchanger Networks
OPP 5: Storage Requirements for a Chemical Plant
Process Control (PC)
PC 1: Instrument Accuracy and Precision: Flow Measurement
PC 2: Temperature Measurement: Use as Indirect Composition Measurement
PC 3: Trip and Alarm Logic
PC 4: Control Stability: Heat Exchanger
Process Hazards (PH)
PH 1: Estimating Air missions: Tank Filling
PH 2: Estimating Effect of Worst-Case Explosion
PH 3: Estimating Energy of an Explosion from Damage Assessment
PH 4: Fire Water Requirements to Cool a Tank
PH 5: Maintenance Problem: Purging a Vessel to Permit Entry
Process Reliability and Safety (PRS)
PRS 1: Fault Tree Analysis: Constructing a Fault Tree for Rupture of
a Reactor
PRS 2: Fault Tree Analysis: Calculating Overall Event Probability
PRS 3: HAZOP Applied to a Tank Car Loading Facility
Solutions to Problems
Appendix: SI Units and Conversion
Factors
References
Index
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