Open-Ended Problems

LOUIS THEODORE, EngScD, is a retired professor of chemical engineering (50 years). He is the author of several Wiley publications, including Fluid Flow for the Practicing Chemical Engineer, Thermodynamics for the Practicing Engineer, Mass Transfer Operations for the Practicing Engineer, and Air Pollution Control Equipment Calculations. Dr. Theodore is also a contributor to Perry's Chemical Engineer's Handbook.J. Patrick Abulencia is an Associate Professor in the Department of Chemical Engineering at Manhattan College. He received his B.S. degree in Chemical Engineering from Manhattan College, and his Ph.D. in Chemical and Biomolecular Engineering from Johns Hopkins University. Dr. Abulencia typically teaches material and energy balances, thermodynamics, fluid flow, and unit operations laboratory. His research interests include water filtration, life cycle assessment, and engineering education. He co-authored with Louis Theodore Fluid Flow for the Practicing Chemical Engineer.

• Preface  xixAcknowledgements xxi Part I: Introduction to the Open-Ended Problem Approach 1Part II: Chemical Engineering Topics 131 Materials Science and Engineering 151.1 Overview 151.2 Crystallography of Perfect Crystals (CPC) 171.3 Crystallography of Real Crystals (CRC) 251.4 Materials of Construction 271.5 Resistivity 281.6 Semiconductors 291.7 Illustrative Open-Ended Problems 301.8 Open-Ended Problems 34References 372 Applied Mathematics 392.1 Overview 392.2 Differentiation and Integration 412.3 Simultaneous Linear Algebraic Equations 422.4 Nonlinear Algebraic Equations 432.5 Ordinary and Partial Differential Equation 442.6 Optimization 452.7 Illustrative Open-Ended Problems 482.8 Open-Ended Problems 51References 563 Stoichiometry 593.1 Overview 593.2 The Conservation Law 603.3 Conservation of Mass, Energy, and Momentum 623.4 Stoichiometry 643.5 Illustrative Open-Ended Problems 673.6 Open-Ended Problems 72References 774 Thermodynamics 794.1 Overview 794.2 Enthalpy Effects 814.3 Second Law Calculations 844.4 Phase Equilibrium 864.5 Chemical Reaction Equilibrium 884.6 Illustrative Open-Ended Problems 904.7 Open-Ended Problems 94References 975 Fluid Flow 995.1 Overview 995.2 Basic Laws 1015.3 Key Fluid Flow Equations 1025.4 Fluid-Particle Applications 1085.5 Illustrative Open-Ended Problems 1105.6 Open-Ended Problems 114References 1186 Heat Transfer 1196.1 Overview 1196.2 Conduction 1216.3 Convection 1226.4 Radiation 1256.5 Condensation, Boiling, Refrigeration, and Cryogenics 1266.6 Heat Exchangers 1276.7 Illustrative Open-Ended Problems 1296.8 Open-Ended Problems 134References 1397 Mass Transfer Operations 1417.1 Overview 1417.2 Absorption 1437.3 Adsorption 1487.4 Distillation 1527.5 Other Mass Transfer Processes 1587.6 Illustrative Open-Ended Problems 1607.7 Open-Ended Problems 163References 1668 Chemical Reactors 1698.1 Overview 1698.2 Chemical Kinetics 1718.3 Batch Reactors 1748.4 Continuous Stirred Tank Reactors (CSTRs) 1768.5 Tubular Flow Reactors 1788.6 Catalytic Reactors 1818.7 Thermal Effects 1848.8 Illustrative Open-Ended Problems 1878.9 Open-Ended Problems 192References 1969 Process Control and Instrumentation 1979.1 Overview 1979.2 Process Control Fundamentals 1999.3 Feedback Control 2039.4 Feedforward Control 2049.5 Cascade Control 2059.6 Alarms and Trips 2069.7 Illustrative Open-Ended Problems 2079.8 Open-Ended Problems 209References 21210 Economics and Finance10.1 Overview 21310.2 Capital Costs 21610.3 Operating Costs 21710.4 Project Evaluation 21810.5 Perturbation Studies in Optimization 21910.6 Principles of Accounting 22010.7 Illustrative Open-Ended Problems 22110.8 Open-Ended Problems 225References 23011 Plant Design 23311.1 Overview 23311.2 Preliminary Studies 23511.3 Process Schematics 23611.4 Material and Energy Balances 23711.5 Equipment Design 23811.6 Instrumentation and Controls 24011.7 Design Approach 24011.8 The Design Report 24211.9 Illustrative Open-Ended Problems 24311.10 Open-Ended Problems 246References 25012 Transport Phenomena 25312.1 Overview 25312.2 Development of Equations 25512.3 The Transport Equations 25612.4 Boundary and Initial Conditions 25712.5 Solution of Equations 25812.6 Analogies 25812.7 Illustrative Open-Ended Problems 26212.8 Open-Ended Problems 264References 26713 Project Management 26913.1 Overview 26913.2 Managing Project Activities 27113.3 Initiating 27213.4 Planning/Scheduling 27313.5 Gantt Charts 27513.6 Executing/Implementing 27613.7 Monitoring/Controlling 27713.8 Completion/Closing 27813.9 Reports 27913.10 Illustrative Open-Ended Problems 28013.11 Open-Ended Problems 284References 29114 Environmental  Management 29314.1 Overview 29314.2 Environmental Regulations 29514.3 Classification, Sources, and Effects of Pollutants 29614.4 Multimedia Concerns 29714.5 ISO 14000 29814.6 The Pollution Prevention Concept 29914.7 Green Chemistry and Green Engineering 30014.8 Sustainability 30114.9 Illustrative Open-Ended Problems 30214.10 Open-Ended Problems 309References 31515 Environmental Health and Hazard Risk Assessment 31715.1 Overview 31715.2 Safety and Accidents 31915.3 Regulations 32015.4 Emergency Planning and Response 32115.5 Introduction to Environmental Risk Assessment 32215.6 Health Risk Assessment 32315.7 Hazard Risk Assessment 32615.8 Illustrative Open-Ended Problems 32915.9 Open-Ended Problems 333References 34116 Energy Management 34316.1 Overview 34316.2 Energy Resources 34516.3 Energy Quantity/Availability 34616.4 General Conservation Practices in Industry 34616.5 General Domestic Conservation Applications 34716.6 General Commercial Real Estate Conservation Applications 34816.7 Architecture and the Role of Urban Planning 34916.8 The U.S. Energy Policy/Independence 35016.9 Illustrative Open-Ended Problems 35216.10 Open-Ended Problems 355References 36117 Water Management 36317.1 Overview 36317.2 Water as a Commodity and as a Human Right 36517.3 The Hydrologic Cycle 36617.4 Water Usage 36717.5 Regulatory Status 36717.6 Acid Rain 37017.7 Treatment Processes 37117.8 Future Concerns 37217.9 Illustrative Open-Ended Problems 37317.10 Open-Ended Problems 376References 38118 Biochemical  Engineering 8318.1 Overview 38318.2 Enzyme and Microbial Kinetics 38518.3 Enzyme Reaction Mechanisms 38618.4 Effectiveness Factor 38918.5 Design Procedures 39118.6 Illustrative Open-Ended Problems 39418.7 Open-Ended Problems 399References 40319 Probability and Statistics 40519.1 Overview   40519.2 Probability Definitions and Interpretations 40719.3 Introduction to Probability Distributions 40819.4 Discrete and Continuous Probability Distributions 41019.5 Contemporary Statistics 41019.6 Regression Analysis (3) 41119.7 Analysis of Variance 41219.8 Illustrative Open-Ended Problems 41319.9 Open-Ended Problems 418References 42520 Nanotechnology 42720.1 Overview 42720.2 Early History 42920.3 Fundamentals and Basic Principles 42920.4 Nanomaterials 43020.5 Production Methods 43120.6 Current Applications 43220.7 Environmental Concerns 43320.8 Future Prospects 43420.9 Illustrative Open-Ended Problems 43620.10 Open-Ended Problems 440References 44321 Legal Considerations 44521.1 Overview 44521.2 Intellectual Property Law 44721.3 Contract Law 44821.4 Tort Law 44821.5 Patents 44921.6 Infringement and Interferences 45121.7 Copyrights 45221.8 Trademarks 45321.9 The Engineering Professional Licensing Process 45421.10 Illustrative Open-Ended Problems 45421.11 Open-Ended Problems 45722 Ethics 46322.1 Overview 46322.2 The Present State 46422.3 Moral Issues 46622.4 Engineering Ethics 46722.5 Environmental Justice 46822.6 Illustrative Open-Ended Problems 47022.7 Open-Ended Problems 473References 480Part III: Term Projects 48323 Term Projects (2): Applied Mathematics 48523.1 Term Project 23.1 48623.2 Term Project 23.2 487References 48824 Term Projects (2): Stoichiometry 48924.1 Term Project 24.1 49024.2 Chemical Plant Solid Waste 493Reference 49325 Term Projects (2): Thermodynamics 49525.1 Estimating Combustion Temperatures 49625.2 Generating Entropy Data 496References 49726 Term Projects (6): Fluid Flow 49926.1 Pressure Drop - Velocity - Mesh Size Correlation 50026.2 Fanning?s Friction Factor: Equation Form 50026.3 An Improved Pressure Drop and Flooding Correlation 50326.4 Ventilation Model I 50526.5 Ventilation Model II 50626.6 Two ? Phase Flow 50627 Term Projects (4): Heat Transfer 50927.1 Wilson?s Method 51027.2 Heat Exchanger Network I 51127.3 Heat Exchanger Network II 51327.4 Heat Exchanger Network III 514References 51528 Term Projects (5): Mass Transfer Operations 51728.1 An Improved Absorber Design Procedure 51828.2 An Improved Adsorber Design Procedure 51928.3 Multicomponent Distillation Calculations 52028.4 A New Liquid-Liquid Extraction Process 52328.5 Designing and Predicting the Performance of Cooling Towers 525References 52629 Term Projects (2): Chemical Reactors 52929.1 Minimizing Volume Requirements for CSTRs in Series I 53029.2 Minimizing Volume Requirements for CSTRs in Series II 531References 53130 Term Projects (4): Plant Design 53330.1 Chemical Plant Shipping Facilities 53430.2 Plant Tank Farms 53530.3 Chemical Plant Storage Requirements 53630.4 Inside Battery Limits (ISBL) and Process Flow Approach 538References 54131 Term Projects (4): Environmental Management 54331.1 Dissolve The USEPA 54431.2 Solving Your Town's Sludge Problem 54731.3 Benzene Underground Storage Tank Leak 54931.4 An Improved MSDS Sheet 55132 Term Projects (4): Health and Hazard Risk Assessment 55332.1 Nuclear Waste Management 55432.2 An Improved Risk Management Program 55532.3 Bridge Rail Accident: Fault and Event Tree Analysis 55732.4 HAZOP: Tank Car Loading Facility 558References 56033 Term Projects (3): Unit Operations Laboratory Design Projects 56133.1 Hand Pump 56233.2 Rooftop Garden Bed 56333.3 Hydration Station Counter 564Reference 56634 Term Projects (4): Miscellaneous Topics 56734.1 Standardizing Project Management 56834.2 Monte Carlo Simulation: Bus Section Failures in Electrostatic Precipitators 56934.3 Hurricane and Flooding Concerns 57034.4 Meteorites 571References 573Index 575