Preface xiii

Acknowledgements xv

Nomenclature xvii

1 The Nature of Chemical Process Design and Integration 1

2 Process Economics 19

3 Optimization 37

4 Chemical Reactors I – Reactor Performance 59

5 Chemical Reactors II – Reactor Conditions 81

6 Chemical Reactors III – Reactor Configuration 107

7 Separation of Heterogeneous Mixtures 125

8 Separation of Homogeneous Fluid Mixtures I – Distillation 139

9 Separation of Homogeneous Fluid Mixtures II – Other Methods 185

10 Distillation Sequencing 221

11 Distillation Sequencing for Azeotropic Distillation 247

12 Heat Exchange 275

13 Pumping and Compression 349

14 Continuous Process Recycle Structure 377

15 Continuous Process Simulation and Optimization 393

16 Batch Processes 417

17 Heat Exchanger Networks I – Network Targets 457

18 Heat Exchanger Networks II – Network Design 501

19 Heat Exchanger Networks III – Stream Data 543

20 Heat Integration of Reactors 555

21 Heat Integration of Distillation 563

22 Heat Integration of Evaporators and Dryers 577

23 Steam Systems and Cogeneration 583

24 Cooling and Refrigeration Systems 647

25 Environmental Design for Atmospheric Emissions 687

26 Water System Design 721

27 Environmental Sustainability in Chemical Production 781

28 Process Safety 811

Appendix A Physical Properties in Process Design 827

Appendix B Materials of Construction 853

Appendix C Annualization of Capital Cost 861

Appendix D The Maximum Thermal Effectiveness for 1–2 Shell-and-Tube Heat Exchangers 863

Appendix E Expression for the Minimum Number of 1–2 Shell-and-Tube Heat Exchangers for a Given
Unit 865

Appendix F Heat Transfer Coefficient and Pressure Drop in Shell-and-Tube Heat Exchangers 867

Appendix G Gas Compression Theory 875

Appendix H Algorithm for the Heat Exchanger Network Area Target 881

Index 883

The Concept Chemical processing should form part of a sustainable industrial activity. For chemical processing, this means that processes should use raw materials as efficiently as is economic and practicable, both to prevent the production of waste that can be environmentally harmful and to preserve the reserves of raw materials as much as possible. Processes should use as little energy as economic and practicable, both to prevent the build-up of carbon dioxide in the atmosphere from burning fossil fuels and to preserve reserves of fossil fuels. Water must also be consumed in sustainable quantities. Aqueous and atmospheric emissions must not be environmentally harmful, and solid waste to landfill must be avoided. Finally, all aspects of chemical processing must feature good health and safety practice.

The Book is intended to be a textbook for undergraduate and postgraduate students of chemical engineering, and to be a practical guide for practicing process designers and chemical engineers and applied chemists working in process development.

Chemical Process Design and Integration deals in detail with the design and integration of chemical processes, emphasizing the conceptual issues. Chemical process design requires the selection of a series of processing steps and their integration to form a complete manufacturing system. The text emphasizes both the design and selection of the steps as individual operations and their integration. The design of utility systems has been dealt with in the text so that the interactions between processes and the utility system and interactions between different processes through the utility system can be exploited to maximize the performance of the site as a whole. Chemical Process Design and Integration offers:

• A combination of comprehensive textbook and practical guide
• A wide range of process technologies
• Details of the latest process integration design methods
• Emphasizes sustainable process development
• A practical guide to clean process technology
• Comprehensive coverage of the design of energy and water systems Large number of worked examples and class exercises