There are many comprehensive design books, but none of them provide a significant number of detailed economic design examples of typically complex industrial processes. Most of the current design books cover a wide variety of topics associated with process design. In addition to discussing flowsheet development and equipment design, these textbooks go into a lot of detail on engineering economics and other many peripheral subjects such as written and oral skills, ethics, "green" engineering and product design. This book presents general process design principles in a concise readable form that can be easily comprehended by students and engineers when developing effective flow sheet and control structures. Ten detailed case studies presented illustrate an in-depth and quantitative way the application of these general principles. Detailed economic steady-state designs are developed that satisfy economic criterion such as minimize total annual cost of both capital and energy or return on incremental capital investment. Complete detailed flow sheets and Aspen Plus files are provided. Then conventional PI control structures are be developed and tested for their ability to maintain product quality during disturbances. Complete Aspen Dynamics files are be provided of the dynamic simulations.

WILLIAM L. LUYBEN, PhD, is a professor at Lehigh University, and the author/co-author of thirteen textbooks. He has published over 250 technical papers in the area of process control and design and has supervised thirty-five PhD dissertations He has nine years of industrial experience with Exxon and DuPont.

Presenting general design principles in a concise format, Principles and Case Studies of Simultaneous Design guides readers in building an effective flowsheet and control structure when developing a chemical process. Aided by detailed economic design examples of typically complex industrial processes, this book encompasses all the methods and techniques essential to chemical process design in the creation of new facilities or the modifications of existing ones. In addition, it shows ways in which these methods can be applied to reactive distillation, reactor design, plant design, and various other chemical engineering processes. Principles and Case Studies of Simultaneous Design:

• Is presented in a well-illustrated, large-size format with detailed schematics
• Discusses conventional proportionalintegralderivative (PID) control structures to emphasize importance of maintaining product quality during disturbances
• Includes ten detailed case studies that illustrate the principles of process design
• Supplies case studies that contain rigorous steady-state economic evaluations and dynamic plant-wide control studies
• Provides completed detailed flowsheets with Aspen Plus files included, along with examples of dynamic simulations using Aspen Dynamics

Principles and Case Studies of Simultaneous Design offers students and engineers in the chemical, petroleum, and biochemical industries the essential principles of design and control in a manner that cuts directly to the core of the most important technical information. Written in style that is approachable and easy to comprehend, this invaluable reference is sure to become a treasured reference for any seasoned or aspiring engineer.

1 INTRODUCTION 1

1.1 Overview / 1

1.2 History / 3

1.3 Books / 4

1.4 Tools / 4

Reference Textbooks / 5

2 PRINCIPLES OF REACTOR DESIGN AND CONTROL 7

2.1 Background / 7

2.2 Principles Derived from Chemistry / 8

2.2.1 Heat of Reaction / 8

2.2.2 Reversible and Irreversible Reactions / 9

2.2.3 Multiple Reactions / 10

2.3 Principles Derived from Phase of Reaction / 11

2.4 Determining Kinetic Parameters / 12

2.4.1 Thermodynamic Constraints / 12

2.4.2 Kinetic Parameters from Plant Data / 13

2.5 Principles of Reactor Heat Exchange / 13

2.5.1 Continuous Stirred-Tank Reactors / 13

2.5.2 Tubular Reactors / 14

2.5.3 Feed-Effluent Heat Exchangers / 16

2.6 Heuristic Design of Reactor/Separation Processes / 17

2.6.1 Introduction / 17

2.6.2 Process Studied / 18

2.6.3 Economic Optimization / 21

2.6.4 Other Cases / 22

2.6.5 Real Example / 27

2.7 Conclusion / 28

References / 29

3 PRINCIPLES OF DISTILLATION DESIGN AND CONTROL 31

3.1 Principles of Economic Distillation Design / 32

3.1.1 Operating Pressure / 32

3.1.2 Heuristic Optimization / 33

3.1.3 Rigorous Optimization / 33

3.1.4 Feed Preheating and Intermediate Reboilers and Condensers / 34

3.1.5 Heat Integration / 34

3.2 Principles of Distillation Control / 35

3.2.1 Single-End Control / 36

3.2.2 Dual-End Control / 38

3.2.3 Alternative Control Structures / 38

3.3 Conclusion / 39

References / 39

4 PRINCIPLES OF PLANTWIDE CONTROL 41

4.1 History / 42

4.2 Effects of Recycle / 42

4.2.1 Time Constants of Integrated Plant with Recycle / 42

4.2.2 Recycle Snowball Effect / 43

4.3 Management of Fresh Feed Streams / 45

4.3.1 Fundamentals / 45

4.3.2 Process with Two Recycles and Two Fresh Feeds / 46

4.4 Conclusion / 52

5 ECONOMIC BASIS 53

5.1 Level of Accuracy / 53

5.2 Sizing Equipment / 54

5.2.1 Vessels / 54

5.2.2 Heat Exchangers / 55

5.2.3 Compressors / 56

5.2.4 Pumps, Valves, and Piping / 56

5.3 Equipment Capital Cost / 56

5.3.1 Vessels / 56

5.3.2 Heat Exchangers / 56

5.3.3 Compressors / 57

5.4 Energy Costs / 57

5.5 Chemical Costs / 57

References / 57

6 DESIGN AND CONTROL OF THE ACETONE PROCESS VIA DEHYDROGENATION OF ISOPROPANOL 59

6.1 Process Description / 60

6.1.1 Reaction Kinetics / 61

6.1.2 Phase Equilibrium / 62

6.2 Turton Flowsheet / 62

6.2.1 Vaporizer / 63

6.2.2 Reactor / 64

6.2.3 Heat Exchangers, Flash Tank, and Absorber / 64

6.2.4 Acetone Column C1 / 66

6.2.5 Water Column C2 / 66

6.3 Revised Flowsheet / 66

6.3.1 Effect of Absorber Pressure / 66

6.3.2 Effect of Water Solvent and Absorber Stages / 68

6.3.3 Effect of Reactor Size / 68

6.3.4 Optimum Distillation Design / 69

6.4 Economic Comparison / 69

6.5 Plantwide Control / 71

6.5.1 Control Structure / 71

6.5.2 Column Control Structure Selection / 75

6.5.3 Dynamic Performance Results / 76

6.6 Conclusion / 81

References / 81

7 DESIGN AND CONTROL OF AN AUTO-REFRIGERATED ALKYLATION PROCESS 83

7.1 Introduction / 84

7.2 Process Description / 84

7.2.1 Reaction Kinetics / 85

7.2.2 Phase Equilibrium / 85

7.2.3 Flowsheet / 86

7.2.4 Design Optimization Variables / 88

7.3 Design of Distillation Columns / 89

7.3.1 Depropanizer / 89<...