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.

• PREFACE xv 1 INTRODUCTION 11.1 Overview / 11.2 History / 31.3 Books / 41.4 Tools / 4Reference Textbooks / 52 PRINCIPLES OF REACTOR DESIGN AND CONTROL 72.1 Background / 72.2 Principles Derived from Chemistry / 82.2.1 Heat of Reaction / 82.2.2 Reversible and Irreversible Reactions / 92.2.3 Multiple Reactions / 102.3 Principles Derived from Phase of Reaction / 112.4 Determining Kinetic Parameters / 122.4.1 Thermodynamic Constraints / 122.4.2 Kinetic Parameters from Plant Data / 132.5 Principles of Reactor Heat Exchange / 132.5.1 Continuous Stirred-Tank Reactors / 132.5.2 Tubular Reactors / 142.5.3 Feed-Effluent Heat Exchangers / 162.6 Heuristic Design of Reactor/Separation Processes / 172.6.1 Introduction / 172.6.2 Process Studied / 182.6.3 Economic Optimization / 212.6.4 Other Cases / 222.6.5 Real Example / 272.7 Conclusion / 28References / 293 PRINCIPLES OF DISTILLATION DESIGN AND CONTROL 313.1 Principles of Economic Distillation Design / 323.1.1 Operating Pressure / 323.1.2 Heuristic Optimization / 333.1.3 Rigorous Optimization / 333.1.4 Feed Preheating and Intermediate Reboilers and Condensers / 343.1.5 Heat Integration / 343.2 Principles of Distillation Control / 353.2.1 Single-End Control / 363.2.2 Dual-End Control / 383.2.3 Alternative Control Structures / 383.3 Conclusion / 39References / 394 PRINCIPLES OF PLANTWIDE CONTROL 414.1 History / 424.2 Effects of Recycle / 424.2.1 Time Constants of Integrated Plant with Recycle / 424.2.2 Recycle Snowball Effect / 434.3 Management of Fresh Feed Streams / 454.3.1 Fundamentals / 454.3.2 Process with Two Recycles and Two Fresh Feeds / 464.4 Conclusion / 525 ECONOMIC BASIS 535.1 Level of Accuracy / 535.2 Sizing Equipment / 545.2.1 Vessels / 545.2.2 Heat Exchangers / 555.2.3 Compressors / 565.2.4 Pumps, Valves, and Piping / 565.3 Equipment Capital Cost / 565.3.1 Vessels / 565.3.2 Heat Exchangers / 565.3.3 Compressors / 575.4 Energy Costs / 575.5 Chemical Costs / 57References / 576 DESIGN AND CONTROL OF THE ACETONE PROCESS VIA DEHYDROGENATION OF ISOPROPANOL 596.1 Process Description / 606.1.1 Reaction Kinetics / 616.1.2 Phase Equilibrium / 626.2 Turton Flowsheet / 626.2.1 Vaporizer / 636.2.2 Reactor / 646.2.3 Heat Exchangers, Flash Tank, and Absorber / 646.2.4 Acetone Column C1 / 666.2.5 Water Column C2 / 666.3 Revised Flowsheet / 666.3.1 Effect of Absorber Pressure / 666.3.2 Effect of Water Solvent and Absorber Stages / 686.3.3 Effect of Reactor Size / 686.3.4 Optimum Distillation Design / 696.4 Economic Comparison / 696.5 Plantwide Control / 716.5.1 Control Structure / 716.5.2 Column Control Structure Selection / 756.5.3 Dynamic Performance Results / 766.6 Conclusion / 81References / 817 DESIGN AND CONTROL OF AN AUTO-REFRIGERATED ALKYLATION PROCESS 837.1 Introduction / 847.2 Process Description / 847.2.1 Reaction Kinetics / 857.2.2 Phase Equilibrium / 857.2.3 Flowsheet / 867.2.4 Design Optimization Variables / 887.3 Design of Distillation Columns / 897.3.1 Depropanizer / 897.3.2 Deisobutanizer / 897.4 Economic Optimization of Entire Process / 917.4.1 Flowsheet Convergence / 917.4.2 Yield / 917.4.3 Effect of Reactor Size / 917.4.4 Optimum Economic Design / 937.5 Alternative Flowsheet / 947.6 Plantwide Control / 967.6.1 Control Structure / 967.6.2 Controller Tuning / 1007.6.3 Dynamic Performance / 1017.7 Conclusion / 103References / 1058 DESIGN AND CONTROL OF THE BUTYL ACETATE PROCESS 1078.1 Introduction / 1088.2 Chemical Kinetics and Phase Equilibrium / 1088.2.1 Chemical Kinetics andChemical Equilibrium / 1088.2.2 Vapor-Liquid Equilibrium / 1108.3 Process Flowsheet / 1128.3.1 Reactor / 1128.3.2 Column C1 / 1138.3.3 Column C2 / 1138.3.4 Column C3 / 1138.3.5 Flowsheet Convergence / 1158.4 Economic Optimum Design / 1178.4.1 Reactor Size and Temperature / 1178.4.2 Butanol Recycle and Composition / 1188.4.3 Distillation Column Design / 1198.4.4 System Economics / 1208.5 Plantwide Control / 1218.5.1 Column C1 / 1218.5.2 Column C2 / 1228.5.3 Column C3 / 1228.5.4 Plantwide Control Structure / 1238.5.5 Dynamic Performance / 1248.6 Conclusion / 133References / 1339 DESIGN AND CONTROL OF THE CUMENE PROCESS 1359.1 Introduction / 1369.2 Process Studied / 1369.2.1 Reaction Kinetics / 1369.2.2 Phase Equilibrium / 1379.2.3 Flowsheet / 1379.3 Economic Optimization / 1409.3.1 Increasing Propylene Conversion / 1409.3.2 Effects of Design Optimization Variables / 1419.3.3 Economic Basis / 1429.3.4 Economic Optimization Results / 1439.4 Plantwide Control / 1479.5 Conclusion / 158References / 15810 DESIGN AND CONTROL OF THE ETHYL BENZENE PROCESS 15910.1 Introduction / 15910.2 Process Studied / 16010.2.1 Reaction Kinetics / 16110.2.2 Phase Equilibrium / 16210.2.3 Flowsheet / 16310.3 Design of Distillation Columns / 16410.3.1 Column Pressure Selection / 16610.3.2 Number of Column Trays / 16910.4 Economic Optimization of Entire Process / 16910.5 Plantwide Control / 17210.5.1 Distillation Column Control Structure / 17210.5.2 Plantwide Control Structure / 17310.5.3 Controller Tuning / 17410.5.4 Dynamic Performance / 17410.5.5 Modified Control Structure / 17610.6 Conclusion / 183References / 18311 DESIGN AND CONTROL OF A METHANOL REACTOR/COLUMN PROCESS 18511.1 Introduction / 18511.2 Process Studied / 18611.2.1 Compression and Reactor Preheating / 18611.2.2 Reactor / 18711.2.3 Separator, Recycle, and Vent / 18711.2.4 Flash and Distillation / 18811.3 Reaction Kinetics / 18811.4 Overall and Per-Pass Conversion / 18911.5 Phase Equilibrium / 19111.6 Effects of Design Optimization Variables / 19211.6.1 Economic Basis / 19211.6.2 Effect of Pressure / 19311.6.3 Effect of Reactor Size / 19511.6.4 Effect of Vent/Recycle Split / 19611.6.5 Effect of Flash-Tank Pressure / 19711.6.6 Optimum Distillation Column Design / 19811.7 Plantwide Control / 20111.7.1 Control Structure / 20111.7.2 Column Control Structure Selection / 20311.7.3 High-Pressure Override Controller / 20311.7.4 Dynamic Performance Results / 20411.8 Conclusion / 209References / 21012 DESIGN AND CONTROL OF THE METHOXY-METHYL-HEPTANE PROCESS 21112.1 Introduction / 21112.2 Process Studied / 21212.2.1 Reactor / 21212.2.2 Column C1 / 21312.2.3 Column C2 / 21312.2.4 Column C3 / 21312.3 Reaction Kinetics / 21312.4 Phase Equilibrium / 21512.5 Design Optimization / 21512.5.1 Economic Basis / 21612.5.2 Reactor Size versus Recycle Trade-Off / 21612.6 Optimum Distillation Column Design / 22012.6.1 Column Pressures / 22012.6.2 Number of Stages / 22012.6.3 Column Profiles / 22212.7 Plantwide Control / 22312.7.1 Control Structure / 22512.7.2 Dynamic Performance Results / 22712.8 Conclusion / 230References / 23113 DESIGN AND CONTROL OF A METHYL ACETATE PROCESS USING CARBONYLATION OF DIMETHYL ETHER 23313.1 Introduction / 23313.2 Dehydration Section / 23413.2.1 Process Description of Dehydration Section / 23413.2.2 Dehydration Kinetics / 23513.2.3 Alternative Flowsheets / 23613.2.4 Optimization of Three Flowsheets / 24013.3 Carbonylation Section / 24513.3.1 Process Description / 24613.3.2 Carbonylation Kinetics / 24713.3.3 Effect of Parameters / 24813.3.4 Flowsheet Convergence / 25013.3.5 Optimization / 25113.4 Plantwide Control / 25513.4.1 Control Structure / 25513.4.2 Dynamic Performance / 26113.5 Conclusion / 262References / 26214 DESIGN AND CONTROL OF THE MONO-ISOPROPYL AMINE PROCESS 26314.1 Introduction / 26314.2 Process Studied / 26414.2.1 Reaction Kinetics / 26414.2.2 Phase Equilibrium / 26514.2.3 Flowsheet / 26614.3 Economic Optimization / 26814.3.1 Design Optimization Variables / 26814.3.2 Optimization Results / 26914.4 Plantwide Control / 27014.4.1 Dynamic Model Sizing / 27114.4.2 Distillation Column Control Structures / 27214.4.3 Plantwide Control Structure / 27614.5 Conclusion / 289References / 29015 DESIGN AND CONTROL OF THE STYRENE PROCESS 29115.1 Introduction / 29215.2 Kinetics and Phase Equilibrium / 29315.2.1 Reaction Kinetics / 29315.2.2 Phase Equilibrium / 29415.3 Vasudevan et al. Flowsheet / 29515.3.1 Reactors / 29515.3.2 Condenser and Decanter / 29515.3.3 Product Column C1 / 29615.3.4 Recycle Column C2 / 29815.4 Effects of Design Optimization Variables / 29815.4.1 Effect of Process Steam / 29815.4.2 Effect of Reactor Inlet Temperature / 30115.4.3 Effect of Reactor Size / 30215.4.4 Optimum Distillation Column Design / 30315.4.5 Number of Reactors / 30415.4.6 Reoptimization / 30415.4.7 Other Improvements / 30515.5 Proposed Design / 30515.6 Plantwide Control / 30615.6.1 Control Structure / 30615.6.2 Column Control Structure Selection / 31015.6.3 Dynamic Performance Results / 31215.7 Conclusion / 317References / 317NOMENCLATURE 319INDEX 321

"I highly recommend the important and all encompassing book Principles and Case Studies of Simultaneous Design by William L. Luyben, to any chemistry or engineering students, practicing chemical engineers, product designers in industry, and business leaders looking for a fresh approach to simultaneous design issues. This book will transform your company's industrial processes and product design into one of a leader in process design." (Blog Business World, 26 November 2011)

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.

• PREFACE xv 1 INTRODUCTION 11.1 Overview / 11.2 History / 31.3 Books / 41.4 Tools / 4Reference Textbooks / 52 PRINCIPLES OF REACTOR DESIGN AND CONTROL 72.1 Background / 72.2 Principles Derived from Chemistry / 82.2.1 Heat of Reaction / 82.2.2 Reversible and Irreversible Reactions / 92.2.3 Multiple Reactions / 102.3 Principles Derived from Phase of Reaction / 112.4 Determining Kinetic Parameters / 122.4.1 Thermodynamic Constraints / 122.4.2 Kinetic Parameters from Plant Data / 132.5 Principles of Reactor Heat Exchange / 132.5.1 Continuous Stirred-Tank Reactors / 132.5.2 Tubular Reactors / 142.5.3 Feed-Effluent Heat Exchangers / 162.6 Heuristic Design of Reactor/Separation Processes / 172.6.1 Introduction / 172.6.2 Process Studied / 182.6.3 Economic Optimization / 212.6.4 Other Cases / 222.6.5 Real Example / 272.7 Conclusion / 28References / 293 PRINCIPLES OF DISTILLATION DESIGN AND CONTROL 313.1 Principles of Economic Distillation Design / 323.1.1 Operating Pressure / 323.1.2 Heuristic Optimization / 333.1.3 Rigorous Optimization / 333.1.4 Feed Preheating and Intermediate Reboilers and Condensers / 343.1.5 Heat Integration / 343.2 Principles of Distillation Control / 353.2.1 Single-End Control / 363.2.2 Dual-End Control / 383.2.3 Alternative Control Structures / 383.3 Conclusion / 39References / 394 PRINCIPLES OF PLANTWIDE CONTROL 414.1 History / 424.2 Effects of Recycle / 424.2.1 Time Constants of Integrated Plant with Recycle / 424.2.2 Recycle Snowball Effect / 434.3 Management of Fresh Feed Streams / 454.3.1 Fundamentals / 454.3.2 Process with Two Recycles and Two Fresh Feeds / 464.4 Conclusion / 525 ECONOMIC BASIS 535.1 Level of Accuracy / 535.2 Sizing Equipment / 545.2.1 Vessels / 545.2.2 Heat Exchangers / 555.2.3 Compressors / 565.2.4 Pumps, Valves, and Piping / 565.3 Equipment Capital Cost / 565.3.1 Vessels / 565.3.2 Heat Exchangers / 565.3.3 Compressors / 575.4 Energy Costs / 575.5 Chemical Costs / 57References / 576 DESIGN AND CONTROL OF THE ACETONE PROCESS VIA DEHYDROGENATION OF ISOPROPANOL 596.1 Process Description / 606.1.1 Reaction Kinetics / 616.1.2 Phase Equilibrium / 626.2 Turton Flowsheet / 626.2.1 Vaporizer / 636.2.2 Reactor / 646.2.3 Heat Exchangers, Flash Tank, and Absorber / 646.2.4 Acetone Column C1 / 666.2.5 Water Column C2 / 666.3 Revised Flowsheet / 666.3.1 Effect of Absorber Pressure / 666.3.2 Effect of Water Solvent and Absorber Stages / 686.3.3 Effect of Reactor Size / 686.3.4 Optimum Distillation Design / 696.4 Economic Comparison / 696.5 Plantwide Control / 716.5.1 Control Structure / 716.5.2 Column Control Structure Selection / 756.5.3 Dynamic Performance Results / 766.6 Conclusion / 81References / 817 DESIGN AND CONTROL OF AN AUTO-REFRIGERATED ALKYLATION PROCESS 837.1 Introduction / 847.2 Process Description / 847.2.1 Reaction Kinetics / 857.2.2 Phase Equilibrium / 857.2.3 Flowsheet / 867.2.4 Design Optimization Variables / 887.3 Design of Distillation Columns / 897.3.1 Depropanizer / 897.3.2 Deisobutanizer / 897.4 Economic Optimization of Entire Process / 917.4.1 Flowsheet Convergence / 917.4.2 Yield / 917.4.3 Effect of Reactor Size / 917.4.4 Optimum Economic Design / 937.5 Alternative Flowsheet / 947.6 Plantwide Control / 967.6.1 Control Structure / 967.6.2 Controller Tuning / 1007.6.3 Dynamic Performance / 1017.7 Conclusion / 103References / 1058 DESIGN AND CONTROL OF THE BUTYL ACETATE PROCESS 1078.1 Introduction / 1088.2 Chemical Kinetics and Phase Equilibrium / 1088.2.1 Chemical Kinetics andChemical Equilibrium / 1088.2.2 Vapor-Liquid Equilibrium / 1108.3 Process Flowsheet / 1128.3.1 Reactor / 1128.3.2 Column C1 / 1138.3.3 Column C2 / 1138.3.4 Column C3 / 1138.3.5 Flowsheet Convergence / 1158.4 Economic Optimum Design / 1178.4.1 Reactor Size and Temperature / 1178.4.2 Butanol Recycle and Composition / 1188.4.3 Distillation Column Design / 1198.4.4 System Economics / 1208.5 Plantwide Control / 1218.5.1 Column C1 / 1218.5.2 Column C2 / 1228.5.3 Column C3 / 1228.5.4 Plantwide Control Structure / 1238.5.5 Dynamic Performance / 1248.6 Conclusion / 133References / 1339 DESIGN AND CONTROL OF THE CUMENE PROCESS 1359.1 Introduction / 1369.2 Process Studied / 1369.2.1 Reaction Kinetics / 1369.2.2 Phase Equilibrium / 1379.2.3 Flowsheet / 1379.3 Economic Optimization / 1409.3.1 Increasing Propylene Conversion / 1409.3.2 Effects of Design Optimization Variables / 1419.3.3 Economic Basis / 1429.3.4 Economic Optimization Results / 1439.4 Plantwide Control / 1479.5 Conclusion / 158References / 15810 DESIGN AND CONTROL OF THE ETHYL BENZENE PROCESS 15910.1 Introduction / 15910.2 Process Studied / 16010.2.1 Reaction Kinetics / 16110.2.2 Phase Equilibrium / 16210.2.3 Flowsheet / 16310.3 Design of Distillation Columns / 16410.3.1 Column Pressure Selection / 16610.3.2 Number of Column Trays / 16910.4 Economic Optimization of Entire Process / 16910.5 Plantwide Control / 17210.5.1 Distillation Column Control Structure / 17210.5.2 Plantwide Control Structure / 17310.5.3 Controller Tuning / 17410.5.4 Dynamic Performance / 17410.5.5 Modified Control Structure / 17610.6 Conclusion / 183References / 18311 DESIGN AND CONTROL OF A METHANOL REACTOR/COLUMN PROCESS 18511.1 Introduction / 18511.2 Process Studied / 18611.2.1 Compression and Reactor Preheating / 18611.2.2 Reactor / 18711.2.3 Separator, Recycle, and Vent / 18711.2.4 Flash and Distillation / 18811.3 Reaction Kinetics / 18811.4 Overall and Per-Pass Conversion / 18911.5 Phase Equilibrium / 19111.6 Effects of Design Optimization Variables / 19211.6.1 Economic Basis / 19211.6.2 Effect of Pressure / 19311.6.3 Effect of Reactor Size / 19511.6.4 Effect of Vent/Recycle Split / 19611.6.5 Effect of Flash-Tank Pressure / 19711.6.6 Optimum Distillation Column Design / 19811.7 Plantwide Control / 20111.7.1 Control Structure / 20111.7.2 Column Control Structure Selection / 20311.7.3 High-Pressure Override Controller / 20311.7.4 Dynamic Performance Results / 20411.8 Conclusion / 209References / 21012 DESIGN AND CONTROL OF THE METHOXY-METHYL-HEPTANE PROCESS 21112.1 Introduction / 21112.2 Process Studied / 21212.2.1 Reactor / 21212.2.2 Column C1 / 21312.2.3 Column C2 / 21312.2.4 Column C3 / 21312.3 Reaction Kinetics / 21312.4 Phase Equilibrium / 21512.5 Design Optimization / 21512.5.1 Economic Basis / 21612.5.2 Reactor Size versus Recycle Trade-Off / 21612.6 Optimum Distillation Column Design / 22012.6.1 Column Pressures / 22012.6.2 Number of Stages / 22012.6.3 Column Profiles / 22212.7 Plantwide Control / 22312.7.1 Control Structure / 22512.7.2 Dynamic Performance Results / 22712.8 Conclusion / 230References / 23113 DESIGN AND CONTROL OF A METHYL ACETATE PROCESS USING CARBONYLATION OF DIMETHYL ETHER 23313.1 Introduction / 23313.2 Dehydration Section / 23413.2.1 Process Description of Dehydration Section / 23413.2.2 Dehydration Kinetics / 23513.2.3 Alternative Flowsheets / 23613.2.4 Optimization of Three Flowsheets / 24013.3 Carbonylation Section / 24513.3.1 Process Description / 24613.3.2 Carbonylation Kinetics / 24713.3.3 Effect of Parameters / 24813.3.4 Flowsheet Convergence / 25013.3.5 Optimization / 25113.4 Plantwide Control / 25513.4.1 Control Structure / 25513.4.2 Dynamic Performance / 26113.5 Conclusion / 262References / 26214 DESIGN AND CONTROL OF THE MONO-ISOPROPYL AMINE PROCESS 26314.1 Introduction / 26314.2 Process Studied / 26414.2.1 Reaction Kinetics / 26414.2.2 Phase Equilibrium / 26514.2.3 Flowsheet / 26614.3 Economic Optimization / 26814.3.1 Design Optimization Variables / 26814.3.2 Optimization Results / 26914.4 Plantwide Control / 27014.4.1 Dynamic Model Sizing / 27114.4.2 Distillation Column Control Structures / 27214.4.3 Plantwide Control Structure / 27614.5 Conclusion / 289References / 29015 DESIGN AND CONTROL OF THE STYRENE PROCESS 29115.1 Introduction / 29215.2 Kinetics and Phase Equilibrium / 29315.2.1 Reaction Kinetics / 29315.2.2 Phase Equilibrium / 29415.3 Vasudevan et al. Flowsheet / 29515.3.1 Reactors / 29515.3.2 Condenser and Decanter / 29515.3.3 Product Column C1 / 29615.3.4 Recycle Column C2 / 29815.4 Effects of Design Optimization Variables / 29815.4.1 Effect of Process Steam / 29815.4.2 Effect of Reactor Inlet Temperature / 30115.4.3 Effect of Reactor Size / 30215.4.4 Optimum Distillation Column Design / 30315.4.5 Number of Reactors / 30415.4.6 Reoptimization / 30415.4.7 Other Improvements / 30515.5 Proposed Design / 30515.6 Plantwide Control / 30615.6.1 Control Structure / 30615.6.2 Column Control Structure Selection / 31015.6.3 Dynamic Performance Results / 31215.7 Conclusion / 317References / 317NOMENCLATURE 319INDEX 321

"I highly recommend the important and all encompassing book Principles and Case Studies of Simultaneous Design by William L. Luyben, to any chemistry or engineering students, practicing chemical engineers, product designers in industry, and business leaders looking for a fresh approach to simultaneous design issues. This book will transform your company's industrial processes and product design into one of a leader in process design." (Blog Business World, 26 November 2011)

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.

• PREFACE xv 1 INTRODUCTION 11.1 Overview / 11.2 History / 31.3 Books / 41.4 Tools / 4Reference Textbooks / 52 PRINCIPLES OF REACTOR DESIGN AND CONTROL 72.1 Background / 72.2 Principles Derived from Chemistry / 82.2.1 Heat of Reaction / 82.2.2 Reversible and Irreversible Reactions / 92.2.3 Multiple Reactions / 102.3 Principles Derived from Phase of Reaction / 112.4 Determining Kinetic Parameters / 122.4.1 Thermodynamic Constraints / 122.4.2 Kinetic Parameters from Plant Data / 132.5 Principles of Reactor Heat Exchange / 132.5.1 Continuous Stirred-Tank Reactors / 132.5.2 Tubular Reactors / 142.5.3 Feed-Effluent Heat Exchangers / 162.6 Heuristic Design of Reactor/Separation Processes / 172.6.1 Introduction / 172.6.2 Process Studied / 182.6.3 Economic Optimization / 212.6.4 Other Cases / 222.6.5 Real Example / 272.7 Conclusion / 28References / 293 PRINCIPLES OF DISTILLATION DESIGN AND CONTROL 313.1 Principles of Economic Distillation Design / 323.1.1 Operating Pressure / 323.1.2 Heuristic Optimization / 333.1.3 Rigorous Optimization / 333.1.4 Feed Preheating and Intermediate Reboilers and Condensers / 343.1.5 Heat Integration / 343.2 Principles of Distillation Control / 353.2.1 Single-End Control / 363.2.2 Dual-End Control / 383.2.3 Alternative Control Structures / 383.3 Conclusion / 39References / 394 PRINCIPLES OF PLANTWIDE CONTROL 414.1 History / 424.2 Effects of Recycle / 424.2.1 Time Constants of Integrated Plant with Recycle / 424.2.2 Recycle Snowball Effect / 434.3 Management of Fresh Feed Streams / 454.3.1 Fundamentals / 454.3.2 Process with Two Recycles and Two Fresh Feeds / 464.4 Conclusion / 525 ECONOMIC BASIS 535.1 Level of Accuracy / 535.2 Sizing Equipment / 545.2.1 Vessels / 545.2.2 Heat Exchangers / 555.2.3 Compressors / 565.2.4 Pumps, Valves, and Piping / 565.3 Equipment Capital Cost / 565.3.1 Vessels / 565.3.2 Heat Exchangers / 565.3.3 Compressors / 575.4 Energy Costs / 575.5 Chemical Costs / 57References / 576 DESIGN AND CONTROL OF THE ACETONE PROCESS VIA DEHYDROGENATION OF ISOPROPANOL 596.1 Process Description / 606.1.1 Reaction Kinetics / 616.1.2 Phase Equilibrium / 626.2 Turton Flowsheet / 626.2.1 Vaporizer / 636.2.2 Reactor / 646.2.3 Heat Exchangers, Flash Tank, and Absorber / 646.2.4 Acetone Column C1 / 666.2.5 Water Column C2 / 666.3 Revised Flowsheet / 666.3.1 Effect of Absorber Pressure / 666.3.2 Effect of Water Solvent and Absorber Stages / 686.3.3 Effect of Reactor Size / 686.3.4 Optimum Distillation Design / 696.4 Economic Comparison / 696.5 Plantwide Control / 716.5.1 Control Structure / 716.5.2 Column Control Structure Selection / 756.5.3 Dynamic Performance Results / 766.6 Conclusion / 81References / 817 DESIGN AND CONTROL OF AN AUTO-REFRIGERATED ALKYLATION PROCESS 837.1 Introduction / 847.2 Process Description / 847.2.1 Reaction Kinetics / 857.2.2 Phase Equilibrium / 857.2.3 Flowsheet / 867.2.4 Design Optimization Variables / 887.3 Design of Distillation Columns / 897.3.1 Depropanizer / 897.3.2 Deisobutanizer / 897.4 Economic Optimization of Entire Process / 917.4.1 Flowsheet Convergence / 917.4.2 Yield / 917.4.3 Effect of Reactor Size / 917.4.4 Optimum Economic Design / 937.5 Alternative Flowsheet / 947.6 Plantwide Control / 967.6.1 Control Structure / 967.6.2 Controller Tuning / 1007.6.3 Dynamic Performance / 1017.7 Conclusion / 103References / 1058 DESIGN AND CONTROL OF THE BUTYL ACETATE PROCESS 1078.1 Introduction / 1088.2 Chemical Kinetics and Phase Equilibrium / 1088.2.1 Chemical Kinetics andChemical Equilibrium / 1088.2.2 Vapor-Liquid Equilibrium / 1108.3 Process Flowsheet / 1128.3.1 Reactor / 1128.3.2 Column C1 / 1138.3.3 Column C2 / 1138.3.4 Column C3 / 1138.3.5 Flowsheet Convergence / 1158.4 Economic Optimum Design / 1178.4.1 Reactor Size and Temperature / 1178.4.2 Butanol Recycle and Composition / 1188.4.3 Distillation Column Design / 1198.4.4 System Economics / 1208.5 Plantwide Control / 1218.5.1 Column C1 / 1218.5.2 Column C2 / 1228.5.3 Column C3 / 1228.5.4 Plantwide Control Structure / 1238.5.5 Dynamic Performance / 1248.6 Conclusion / 133References / 1339 DESIGN AND CONTROL OF THE CUMENE PROCESS 1359.1 Introduction / 1369.2 Process Studied / 1369.2.1 Reaction Kinetics / 1369.2.2 Phase Equilibrium / 1379.2.3 Flowsheet / 1379.3 Economic Optimization / 1409.3.1 Increasing Propylene Conversion / 1409.3.2 Effects of Design Optimization Variables / 1419.3.3 Economic Basis / 1429.3.4 Economic Optimization Results / 1439.4 Plantwide Control / 1479.5 Conclusion / 158References / 15810 DESIGN AND CONTROL OF THE ETHYL BENZENE PROCESS 15910.1 Introduction / 15910.2 Process Studied / 16010.2.1 Reaction Kinetics / 16110.2.2 Phase Equilibrium / 16210.2.3 Flowsheet / 16310.3 Design of Distillation Columns / 16410.3.1 Column Pressure Selection / 16610.3.2 Number of Column Trays / 16910.4 Economic Optimization of Entire Process / 16910.5 Plantwide Control / 17210.5.1 Distillation Column Control Structure / 17210.5.2 Plantwide Control Structure / 17310.5.3 Controller Tuning / 17410.5.4 Dynamic Performance / 17410.5.5 Modified Control Structure / 17610.6 Conclusion / 183References / 18311 DESIGN AND CONTROL OF A METHANOL REACTOR/COLUMN PROCESS 18511.1 Introduction / 18511.2 Process Studied / 18611.2.1 Compression and Reactor Preheating / 18611.2.2 Reactor / 18711.2.3 Separator, Recycle, and Vent / 18711.2.4 Flash and Distillation / 18811.3 Reaction Kinetics / 18811.4 Overall and Per-Pass Conversion / 18911.5 Phase Equilibrium / 19111.6 Effects of Design Optimization Variables / 19211.6.1 Economic Basis / 19211.6.2 Effect of Pressure / 19311.6.3 Effect of Reactor Size / 19511.6.4 Effect of Vent/Recycle Split / 19611.6.5 Effect of Flash-Tank Pressure / 19711.6.6 Optimum Distillation Column Design / 19811.7 Plantwide Control / 20111.7.1 Control Structure / 20111.7.2 Column Control Structure Selection / 20311.7.3 High-Pressure Override Controller / 20311.7.4 Dynamic Performance Results / 20411.8 Conclusion / 209References / 21012 DESIGN AND CONTROL OF THE METHOXY-METHYL-HEPTANE PROCESS 21112.1 Introduction / 21112.2 Process Studied / 21212.2.1 Reactor / 21212.2.2 Column C1 / 21312.2.3 Column C2 / 21312.2.4 Column C3 / 21312.3 Reaction Kinetics / 21312.4 Phase Equilibrium / 21512.5 Design Optimization / 21512.5.1 Economic Basis / 21612.5.2 Reactor Size versus Recycle Trade-Off / 21612.6 Optimum Distillation Column Design / 22012.6.1 Column Pressures / 22012.6.2 Number of Stages / 22012.6.3 Column Profiles / 22212.7 Plantwide Control / 22312.7.1 Control Structure / 22512.7.2 Dynamic Performance Results / 22712.8 Conclusion / 230References / 23113 DESIGN AND CONTROL OF A METHYL ACETATE PROCESS USING CARBONYLATION OF DIMETHYL ETHER 23313.1 Introduction / 23313.2 Dehydration Section / 23413.2.1 Process Description of Dehydration Section / 23413.2.2 Dehydration Kinetics / 23513.2.3 Alternative Flowsheets / 23613.2.4 Optimization of Three Flowsheets / 24013.3 Carbonylation Section / 24513.3.1 Process Description / 24613.3.2 Carbonylation Kinetics / 24713.3.3 Effect of Parameters / 24813.3.4 Flowsheet Convergence / 25013.3.5 Optimization / 25113.4 Plantwide Control / 25513.4.1 Control Structure / 25513.4.2 Dynamic Performance / 26113.5 Conclusion / 262References / 26214 DESIGN AND CONTROL OF THE MONO-ISOPROPYL AMINE PROCESS 26314.1 Introduction / 26314.2 Process Studied / 26414.2.1 Reaction Kinetics / 26414.2.2 Phase Equilibrium / 26514.2.3 Flowsheet / 26614.3 Economic Optimization / 26814.3.1 Design Optimization Variables / 26814.3.2 Optimization Results / 26914.4 Plantwide Control / 27014.4.1 Dynamic Model Sizing / 27114.4.2 Distillation Column Control Structures / 27214.4.3 Plantwide Control Structure / 27614.5 Conclusion / 289References / 29015 DESIGN AND CONTROL OF THE STYRENE PROCESS 29115.1 Introduction / 29215.2 Kinetics and Phase Equilibrium / 29315.2.1 Reaction Kinetics / 29315.2.2 Phase Equilibrium / 29415.3 Vasudevan et al. Flowsheet / 29515.3.1 Reactors / 29515.3.2 Condenser and Decanter / 29515.3.3 Product Column C1 / 29615.3.4 Recycle Column C2 / 29815.4 Effects of Design Optimization Variables / 29815.4.1 Effect of Process Steam / 29815.4.2 Effect of Reactor Inlet Temperature / 30115.4.3 Effect of Reactor Size / 30215.4.4 Optimum Distillation Column Design / 30315.4.5 Number of Reactors / 30415.4.6 Reoptimization / 30415.4.7 Other Improvements / 30515.5 Proposed Design / 30515.6 Plantwide Control / 30615.6.1 Control Structure / 30615.6.2 Column Control Structure Selection / 31015.6.3 Dynamic Performance Results / 31215.7 Conclusion / 317References / 317NOMENCLATURE 319INDEX 321

"I highly recommend the important and all encompassing book Principles and Case Studies of Simultaneous Design by William L. Luyben, to any chemistry or engineering students, practicing chemical engineers, product designers in industry, and business leaders looking for a fresh approach to simultaneous design issues. This book will transform your company's industrial processes and product design into one of a leader in process design." (Blog Business World, 26 November 2011)