Chemical Engineering for Non-Chemical Engineers

JACK HIPPLE is a chemical engineering graduate of Carnegie Mellon University, a 30-year veteran of the chemical industry, and a fellow of the American Institute of Chemical Engineers (AIChE). His consulting company, TRIZ and Engineering Training Services, was formed in 2001 to provide basic chemical engineering training and innovation problem-solving training to Fortune 1000 companies as well as the AIChE and American Society of Mechanical Engineers (ASME). His industrial experience includes leading several of Dow Chemical's discovery research efforts and managing its corporate chemical engineering R&D. He has been the Chemical Engineering for Non-Chemical Engineers instructor for AIChE for 15 years and was elected to the National Board of Directors of AIChE in 2012, serving on its Center for Chemical Process Safety and Finance Committees. He has also chaired AIChE's Management Division.

• Preface xiiiAcknowledgments xvii1 What is Chemical Engineering? 1What Do Chemical Engineers Do? 4Topics to Be Covered 6Discussion Questions 13Review Questions (Answers in Appendix with Explanations) 13Additional Resources 142 Safety and Health: The Role and Responsibilities in Chemical Engineering Practice 15Basic Health and Safety Information: The Material Safety Data Sheet (MSDS) 15Procedures 19Fire and Flammability 20Chemical Reactivity 23Toxicology 23Emergency Response 24Transportation Emergencies 24HAZOP 25Layer of Protection Analysis (LOPA) 28Summary 29Discussion Questions 31Review Questions (Answers in Appendix with Explanations) 32Additional Resources 343 The Concept of Balances 35Mass Balance Concepts 35Energy Balances 40Momentum Balances 41Summary 42Discussion Questions 43Review Questions (Answers in Appendix with Explanations) 43Additional Resources 444 Stoichiometry, Thermodynamics, Kinetics, Equilibrium, and Reaction Engineering 45Stoichiometry and Thermodynamics 45Kinetics, Equilibrium, and Reaction Engineering 50Physical Properties Affecting Energy Aspects of a Reaction System 53Kinetics and Rates of Reaction 55Catalysts 59Summary 61Discussion Questions 63Review Questions (Answers in Appendix with Explanations) 65Additional Resources 675 Flow Sheets, Diagrams, and Materials of Construction 69Materials of Construction 73Summary 74Discussion Questions 75Review Questions (Answers in Appendix with Explanations) 76Additional Resources 776 Economics and Chemical Engineering 79Summary 85Discussion Questions 86Review Questions (Answers in Appendix with Explanations) 86Additional Resources 877 Fluid Flow, Pumps, and Liquid Handling and Gas Handling 89Fluid Properties 89Characterizing Fluid Flow 93Pump Types 96Net Positive Suction Head (NPSH) for Centrifugal Pumps 100Positive Displacement Pumps 101Variable Speed Drive Pumps 103Water “Hammer” 103Piping and Valves 103Flow Measurement 104Gas Laws 105Gas Flows 107Gas Compression 107Discussion Questions 109Review Questions (Answers in Appendix with Explanations) 110Additional Resources 1138 Heat Transfer and Heat Exchangers 115Types of Heat Exchangers 117Heat Transfer Coefficient 121Utility Fluids 123Air Coolers 124Scraped Wall Exchangers 124Plate and Frame Heat Exchangers 125Leaks 125Mechanical Design Concerns 125Cleaning Heat Exchangers 126Radiation Heat Transfer 127High Temperature Transfer Fluids 127Summary 129Discussion Questions 130Review Questions (Answers in Appendix with Explanations) 131Additional Resources 1339 Reactive Chemicals Concepts 135Summary 137Discussion Questions 138Review Questions (Answers in Appendix with Explanations) 139Additional Resources 14010 Distillation 141Raoult’s Law 146Batch Distillation 148Flash Distillation 148Continuous Multistage Distillation 149Reflux Ratio and Operating Line 150Pinch Point 154Feed Plate Location 154Column Internals and Efficiency 155Unique Forms of Distillation 156Multiple Desired Products 161Column Internals and Efficiencies 163Tray Contacting Systems 163Packed Towers in Distillation 165Summary 168Discussion Questions 168Review Questions (Answers in Appendix with Explanations) 169Additional Resources 17111 Other Separation Processes: Absorption, Stripping, Adsorption, Chromatography, Membranes 173Absorption 173Stripping/Desorption 178Adsorption 180Ion Exchange 185Reverse Osmosis 187Gas Separation Membranes 189Leaching 191Liquid–Liquid Extraction 192Summary 197Discussion Questions 197Review Questions (Answers in Appendix with Explanations) 198Additional Resources 20112 Evaporation and Crystallization 203Evaporation 203Operational Issues with Evaporators 205Vacuum and Multi‐effect Evaporators 207Crystallization 209Crystal Phase Diagrams 214Supersaturation 215Crystal Purity and Particle Size Control 216Summary 216Discussion Questions 217Review Questions (Answers in Appendix with Explanations) 217Additional Resources 21913 Liquid–Solids Separation 221Filtration and Filters 221Filtration Rates 222Filtration Equipment 223Centrifuges 227Particle Size and Particle Size Distribution 228Liquid Properties 228Summary 228Discussion Questions 231Review Questions (Answers in Appendix with Explanations) 231Additional Resources 23314 Drying 235Rotary Dryers 236Spray Dryers 237Fluid Bed Dryers 238Belt Dryer 239Freeze Dyers 240Summary 240Discussion Questions 242Review Questions (Answers in Appendix with Explanations) 242Additional Resources 24315 Solids Handling 245Safety and General Operational Concerns 245Solids Transport 248Pneumatic Conveyors 251Solids Size Reduction Equipment 256Cyclones 259Screening 260Hoppers and Bins 261Solids Mixing 263Discussion Questions 264Review Questions (Answers in Appendix with Explanations) 265Additional Resources 265Videos of Solids Handling Equipment 26616 Tanks, Vessels, and Special Reaction Systems 267Categories 267Corrosion 268Heating and Cooling 275Power Requirements 275Tanks and Vessels as Reactors 278Static Mixers 280Summary 280Discussion Questions 281Review Questions (Answers in Appendix with Explanations) 281Additional Resources 28217 Chemical Engineering in Polymer Manufacture and Processing 285What are Polymers? 285Polymer Types 287Polymer Properties and Characteristics 288Polymer Processes 290Polymer Additives 293End‐Use Polymer Processing 293Plastics Recycling 294Summary 295Discussion Questions 295Review Questions (Answers in Appendix with Explanations) 296Additional Resources 29718 Process Control 299Elements of a Process Control System 300Control Loops 302On–off Control 303Proportional Control 304Proportional–Integral Control 305Derivative Control 306Ratio Control 307Cascade Control 307Measurement Systems 308Control Valves 308Valve Capacity 312Utility Failure 312Process Control as a Buffer 313Instruments that “Lie” 314Summary 314Discussion Questions 316Review Questions (Answers in Appendix with Explanations) 316Additional Resources 31819 Beer Brewing Revisited 321Appendix I: Future Challenges for Chemical Engineers and Chemical Engineering 325Appendix II: Additional Downloadable Resources 331Appendix III: Answers to Chapter Review Questions 337Index 377