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Section 1. Conceptualization and Analysis of Chemical Processes

Section 1. Conceptualization and Analysis of Chemical Processes

The purpose of this section of the book is to introduce the tools necessary to understand, interpret, synthesize, and create chemical processes. The basis of interpreting chemical processes lies with understanding the principal diagrams that are routinely used to describe chemical processes, most important of which is the process flow diagram (PFD). Although PFDs are unique for each chemical product, they possess many of the same characteristics and attributes. Moreover, the conditions (pressure, temperature, and concentration) at which different equipment operate are unique to the chemical product and processing route chosen. In order for process engineers to understand a given process or to be able to synthesize and optimize a new process, they must be able to apply the principles outlined in this section.

Chapter 1: Diagrams for Understanding Chemical Processes

The technical diagrams commonly used by chemical engineers are presented. These diagrams include the block flow diagram (BFD), the process flow diagram (PFD), and the piping and instrumentation diagram (P&ID). A standard method for presenting a PFD is given and illustrated using a process to produce benzene via the catalytic hydrodealkylation of toluene. The 3-D topology of chemical processes is introduced, and some basic information on the spacing and elevation of equipment is presented. These concepts are further illustrated in the Virtual Plant Tour AVI file on the CD accompanying the textbook.

Chapter 2: The Structure and Synthesis of Process Flow Diagrams

The evolutionary process of design is investigated. This evolution begins with the process concept diagram that shows the input/output structure of all processes. From this simple starting point, the engineer can estimate the gross profit margins of competing processes and of processes that use different chemical synthesis routes to produce the same product. In this chapter, it is shown that all processes have a similar input/output structure whereby raw materials enter a process and are reacted to form products and by-products. These products are separated from unreacted feed, which is usually recycled. The product streams are then purified to yield products that are acceptable to the market place. All equipment in a process can be categorized into one of the six elements of the generic block flow process diagram. The process of process design continues by building preliminary flowsheets from these basic functional elements that are common to all processes.

Chapter 3: Batch Processing

In this chapter, key issues relating to the production of chemical products using batch processes are explored. The major difference between continuous and batch processes is that unsteady state operations are normal to batch plants whereas steady state is the norm for continuous processes. The chapter starts with an example illustrating typical calculations required to design a sequence of batch operations to produce a given product. The remainder of the chapter is devoted to how best to sequence the different operations required to produce multiple chemical products using a fixed amount of equipment. The concepts of Gantt charts, cycle times, batch campaigning, intermediate and final product storage, and parallel operations are covered.

Chapter 4: Chemical Product Design

Chemical product design is defined to include application of chemical engineering principles to the development of new devices, development of new chemicals, development of new processes to produce these new chemicals, and development of marketable technology. The design hierarchy for chemical product design is presented. The necessity of considering customer needs in chemical product design and the need to develop interdisciplinary teams are discussed.

Chapter 5: Tracing Chemicals through the Process Flow Diagram

In order to gain a better understanding of a PFD, it is often necessary to follow the flow of key chemical components through the diagram. This chapter presents two different methods to accomplish this. The tracing of chemicals through the process reinforces our understanding of the role that each piece of equipment plays. In most cases, the major chemical species can be followed throughout the flow diagram using simple logic without referring to the flow summary table.

Chapter 6: Understanding Process Conditions

Once the connectivity or topology of the PFD has been understood, it is necessary to understand why a piece of equipment is operated at a given pressure and temperature. The idea of conditions of special concern is introduced. These conditions are either expensive to implement (due to special materials of construction and/or the use of thick-walled vessels) or use expensive utilities. The reasons for using these conditions are introduced and explained.


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