ETS/Theodore 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

Copyright 1999, ETS Incorporated



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