Product and Process Design Principles

Warren D. Seider is Professor of Chemical Engineering at the University of Pennsylvania. He received a B.S. degree from the Polytechnic Institute of Brooklyn and M.S. and Ph.D. degrees from the University of Michigan. Seider has contributed to the fields of process analysis, simulation, design, and control. He has authored or coauthored over 110 journal articles and authored or edited seven books. He helped to organize the CACHE (Computer Aids for Chemical Engineering Education) Committee in 1969 and served as its chairman. Seider is a member of the Editorial Advisory Board of Computers and Chemical Engineering.Daniel R. Lewin is Professor of Chemical Engineering, the Churchill Family Chair, and the Director of the Process Systems Engineering (PSE) research group at the Technion, the Israel Institute of Technology. He received his B.Sc. from the University of Edinburgh and his D.Sc. from the Technion. He has authored or co-authored over 100 technical publications in the area of process systems engineering, as well as the first three editions of this textbook, and the multimedia CD that accompanies it.J. D. Seader is Professor Emeritus of Chemical Engineering at the University of Utah. He received B.S. and M.S. degrees from the University of California at Berkeley and a Ph.D. from the University of Wisconsin. In 2004, he received, with Professor Warren D. Seider, the Warren K. Lewis Award for Chemical Engineering Education from the AIChE. In 2008, his textbook, "Separation Process Principles" with co-author Ernest J. Henley, was cited as one of 30 ground-breaking books in the last 100 years of chemical engineering.Soemantri Widagdo is a retired R&D executive after a 15-year career at 3M. His last position was the R&D Head of 3M Southeast Asia. He received his B.S. degree in chemical engineering from Bandung Institute of Technology, Indonesia, and his M.Ch.E. and Ph.D. degrees from Stevens Institute of Technology. He has been involved in a variety of technology and product-development programs involving renewable energy, industrial and transportation applications, consumer office products, electrical and electronics applications, health care and dentistry, and display and graphics applications. He has authored and co-authored over 20 technical publications and two patents.Rafiqul Gani is Professor of System Design at the Department of Chemical & Biochemical Engineering, The Technical University of Denmark and the head and co-founder of the Computer Aided Product-Process Engineering Center (CAPEC). He received a B.S degree from the Bangladesh University of Engineering and Technology, and M.S., DIC and Ph.D. degrees from Imperial College, London. He has published more than 200 peer-reviewed journal articles and delivered over 300 lectures, seminars and plenary/keynote lectures at international conferences, institutions and companies all over the world. Professor Gani is currently (2014-2016) the president of the EFCE (European Federation of Chemical Engineering); a member of the Board of Trustees of the AIChE; a Fellow of the AIChE and also a Fellow of IChemE.Ka Ming Ng is Chair Professor of Chemical and Biomolecular Engineering at the Hong Kong University of Science and Technology. He obtained his B.S. degree from the University of Minnesota and his Ph.D. from the University of Houston. His research interests center on product conceptualization, process design and business development involving water, natural herbs, nanomaterials, and advanced materials. He is a fellow of the American Institute of Chemical Engineers where he received the Excellence in Process Development Research Award in 2002.

• PART ONE INTRODUCTION TO PRODUCT AND PROCESS DESIGN 1Chapter 1 Introduction to Chemical Product Design 31.0 Objectives 31.1 Introduction 31.2 The Diversity of Chemical Products 31.3 Product Design and Development 71.4 Summary 16References 17Exercises 17Chapter 2 Introduction to Process Design 192.0 Objectives 192.1 Introduction 192.2 Experiments 212.3 Preliminary Process Synthesis 212.4 Next Process Design Tasks 402.5 Preliminary Flowsheet Mass Balances 412.6 Summary 45References 45Exercises 45Chapter 3 Design Literature, Stimulating Innovation, Energy, Environment, Sustainability, Safety, Engineering Ethics 473.0 Objectives 473.1 Design Literature 473.2 Stimulating Invention and Innovation 503.3 Energy Sources 513.4 Environmental Protection 563.5 Sustainability 603.6 Safety Considerations 633.7 Engineering Ethics 703.8 Summary 73References 73Exercises 743S Supplement to Chapter 3—NSPE Code of Ethics (Online www.wiley.com/college/Seider)PART TWO DESIGN SYNTHESIS—PRODUCT AND PROCESSES 77Chapter 4 Molecular and Mixture Design 794.0 Objectives 794.1 Introduction 794.2 Framework for Computer-Aided Molecular-Mixture Design 814.3 Case Studies 984.4 Summary 107References 107Exercises 108Chapter 5 Design of Chemical Devices, Functional Products, and Formulated Products 1105.0 Objectives 1105.1 Introduction 1105.2 Design of Chemical Devices and Functional Products 1125.3 Design of Formulated Products 1175.4 Design of Processes for B2C Products 1235.5 Summary 126References 127Exercises 127Chapter 6 Heuristics for Process Synthesis 1326.0 Objectives 1326.1 Introduction 1336.2 Raw Materials and Chemical Reactions 1336.3 Distribution of Chemicals 1356.4 Separations 1416.5 Heat Removal From and Addition to Reactors 1456.6 Heat Exchangers and Furnaces 1486.7 Pumping, Compression, Pressure Reduction, Vacuum, and Conveying of Solids 1506.8 Changing the Particle Size of Solids and Size Separation of Particles 1536.9 Removal of Particles From Gases and Liquids 1546.10 Considerations that Apply to the Entire Flowsheet 1546.11 Summary 155References 159Exercises 160Chapter 7 Simulation to Assist in Process Creation 1627.0 Objectives 1627.1 Introduction 1627.2 Principles of Process Simulation 1637.3 Process Creation through Process Simulation 1767.4 Case Studies 1847.5 Principles of Batch Flowsheet Simulation 1947.6 Summary 201References 202Exercises 202Chapter 8 Synthesis of Networks Containing Reactors 2098.0 Objectives 2098.1 Introduction 2098.2 Reactor Models in the Process Simulators 2108.3 Reactor Network Design Using the Attainable Region 2158.4 Reactor Design for Complex Configurations 2208.5 Locating the Separation Section with Respect to the Reactor Section 2248.6 Trade-Offs in Processes Involving Recycle 2278.7 Optimal Reactor Conversion 2288.8 Recycle to Extinction 2298.9 Snowball Effects in the Control of Processes Involving Recycle 2318.10 Summary 231References 232Exercises 232Chapter 9 Synthesis of Separation Trains 2349.0 Objectives 2349.1 Introduction 2349.2 Criteria for Selection of Separation Methods 2419.3 Selection of Equipment 2449.4 Sequencing of Ordinary Distillation Columns for the Separation of Nearly Ideal Liquid Mixtures 2459.5 Sequencing of Operations for the Separation of Nonideal Liquid Mixtures 2579.6 Separation Systems for Gas Mixtures 2779.7 Separation Systems for Solid-Fluid Mixtures 2799.8 Summary 280References 280Exercises 282Chapter 10 Second-Law Analysis 28710.0 Objectives 28710.1 Introduction 28710.2 The System and the Surroundings 28910.3 Energy Transfer 28910.4 Thermodynamic Properties 29010.5 Equations for Second-Law Analysis 29510.6 Examples of Lost-Work Calculations 29710.7 Thermodynamic Efficiency 29910.8 Causes of Lost Work 30010.9 Three Examples of Second-Law Analysis 30010.10 Summary 310References 310Exercises 310Chapter 11 Heat and Power Integration 31611.0 Objectives 31611.1 Introduction 31611.2 Minimum Utility Targets 31911.3 Networks for Maximum Energy Recovery 32511.4 Minimum Number of Heat Exchangers 32911.5 Threshold Approach Temperature 33411.6 Optimum Approach Temperature 33611.7 Multiple Utilities 33711.8 Heat-Integrated Reactors and Distillation Trains 34211.9 Heat Engines and Heat Pumps 34811.10 Summary 351Heat Integration Software 351References 352Exercises 35211S-1 Supplements to Chapter 11—MILP and MINLP Applications in HEN Synthesis (Online www.wiley.com/college/Seider)11S-1.0 Objectives11S-1.1 MER Targeting Using Linear Programming (LP)11S-1.2 MER Design Using Mixed-Integer Linear Programming (MINLP)11S-1.3 Superstructures for Minimization of Annual Costs11S-1.4 Case StudiesCase Study 11S-1.1 Optimal Heat-Integration for the ABCDE ProcessCase Study 11S-1.2 Optimal Heat-Integration for an Ethylene Plant11S-1.5 Summary11S-1.6 References11S-2 Supplement to Chapter 11—Mass Integration (Online www.wiley.com/college/Seider)11S-2.0 Objectives11S-2.1 Introduction11S-2.2 Minimum Mass-Separating Agent11S-2.3 Mass Exchange Networks for Minimum External Area11S-2.4 Minimum Number of Mass Exchangers11S-2.5 Advanced Topics11S-2.6 Summary11S-2.7 ReferencesChapter 12 Heat Exchanger Design 35812.0 Objectives 35812.1 Introduction 35812.2 Equipment for Heat Exchange 36312.3 Heat-Transfer Coefficients and Pressure Drop 37512.4 Design of Shell-and-Tube Heat Exchangers 38012.5 Summary 384References 384Exercises 384Chapter 13 Separation Tower Design 38613.0 Objectives 38613.1 Operating Conditions 38613.2 Fenske-Underwood-Gilliland (FUG) Shortcut Method for Ordinary Distillation 38713.3 Kremser Shortcut Method for Absorption and Stripping 38813.4 Rigorous Multicomponent, Multiequilibrium-Stage Methods with a Simulator 38913.5 Plate Efficiency and HETP 39113.6 Tower Diameter 39213.7 Pressure Drop and Weeping 39313.8 Summary 395References 395Exercises 396Chapter 14 Pumps, Compressors, and Expanders 39714.0 Objectives 39714.1 Pumps 39714.2 Compressors and Expanders 40114.3 Summary 403References 404Exercises 404Chapter 15 Chemical Reactor Design 40515.0 Objectives 40515.1 Introduction 40515.2 Limiting Approximate Models for Tubular Reactors 40515.3 The COMSOL CFD Package 40715.4 CFD for Tubular Reactor Models 41015.5 Nonisothermal Tubular Reactor Models 41815.6 Mixing in Stirred-Tank Reactors 42315.7 Summary 424References 425Exercises 425Chapter 16 Cost Accounting and Capital Cost Estimation 42616.0 Objectives 42616.1 Accounting 42616.2 Cost Indexes and Capital Investment 43416.3 Capital Investment Costs 43816.4 Estimation of the Total Capital Investment 44416.5 Purchase Costs of the Most Widely Used Process Equipment 44916.6 Purchase Costs of Other Chemical Processing Equipment 47016.7 Equipment Costing Spreadsheet 48616.8 Equipment Sizing and Capital Cost Estimation Using Aspen Process Economic Analyzer (APEA) 48616.9 Summary 493References 493Exercises 494Chapter 17 Annual Costs, Earnings, and Profitability Analysis 49817.0 Objectives 49817.1 Introduction 49817.2 Annual Sales Revenues, Production Costs, and the Cost Sheet 49917.3 Working Capital and Total Capital Investment 50917.4 Approximate Profitability Measures 51017.5 Time Value of Money 51317.6 Cash Flow and Depreciation 52017.7 Rigorous Profitability Measures 52517.8 Profitability Analysis Spreadsheet 52917.9 Summary 545References 546Exercises 546PART THREE DESIGN ANALYSIS—PRODUCT AND PROCESS 551Chapter 18 Six-Sigma Design Strategies 55318.0 Objectives 55318.1 Introduction 55318.2 Six-Sigma Methodology in Product Design and Manufacturing 55318.3 Example Applications 55718.4 Summary 564References 564Exercises 56518S Supplement to Chapter 18 (Online www.wiley.com/college/Seider)18S.1 Penicillin Fermenter Model18S.2 Reactive Extraction and Re-extraction ModelReferencesChapter 19 Business Decision Making in Product Development 56619.0 Objectives 56619.1 Introduction 56619.2 Economic Analysis 56619.3 Make-or-Buy Decisions 57019.4 Microeconomics of Product Development 57219.5 Company and Societal Factors Affecting Product Development 57319.6 Summary 574References 575Exercises 575Chapter 20 Plantwide Controllability Assessment 57620.0 Objectives 57620.1 Introduction 57620.2 Control System Configuration 57920.3 Qualitative Plantwide Control System Synthesis 58420.4 Summary 590References 590Exercises 59120S Supplement to Chapter 20 (Online www.wiley.com/college/Seider)20S.0 Objectives20S.1 Generation of Linear Models in Standard Forms20S.2 Quantitative Measures for Controllability and Resiliency20S.3 Towards Automated Flowsheet C&R Diagnosis20S.4 Control Loop Definition and Tuning20S.5 Case StudiesCase Study 20S.1 Exothermic Reactor Design for the Production of Propylene GlycolCase Study 20S.2 Two Alternative Heat Exchanger NetworksCase Study 20S.3 Interaction of design and Control in the MCB Separation Process20S.6 MATLAB for C&R Analysis20S.7 SummaryReferencesExercisesChapter 21 Design Optimization 59721.0 Objectives 59721.1 Introduction 59721.2 General Formulation of the Optimization Problem 59821.3 Classification of Optimization Problems 59921.4 Linear Programming (LP) 60121.5 Nonlinear Programming (NLP) with a Single Variable 60321.6 Conditions for Nonlinear Programming (NLP) by Gradient Methods with Two or More Decision Variables 60521.7 Optimization Algorithm 60721.8 Flowsheet Optimizations—Case Studies 60921.9 Summary 611References 612Exercises 612Chapter 22 Optimal Design and Scheduling of Batch Processes 61622.0 Objectives 61622.1 Introduction 61622.2 Design of Batch Process Units 61722.3 Design of Reactor–Separator Processes 62022.4 Design of Single-product Processing Sequences 62222.5 Design on Multiproduct Processing Sequences 62522.6 Summary 626References 626Exercises 627PART FOUR DESIGN REPORTS—PRODUCT AND PROCESS 629Chapter 23 Written Reports and Oral Presentations 63123.0 Objectives 63123.1 Contents of the Written Report 63223.2 Preparation of the Written Report 63623.3 Oral Design Presentations 63823.4 Award Competition 64123.5 Summary 641References 641PART FIVE CASE STUDIES—PRODUCT AND PROCESS DESIGNS 643Chapter 24 Case Study 1—Home Hemodialysis Devices 64524.0 Objectives 64524.1 Hemodialysis Technology 64524.2 Design Specifications of Home Hemodialysis Device 65224.3 Summary 655References 655Bibliography Patents—Hemodialysis Devices—General 655Patents—Hemodialysis Devices—Hollow-Fiber Membranes 656Patents—Hemodialysis Devices—Dialysate Regeneration 656Patents—Hemodialysis Devices—Alarms/User Interface 656Exercises 656Chapter 25 Case Study 2—High Throughput Screening Devices for Kinase Inhibitors 65725.0 Objectives 65725.1 Background Technology For High Throughput Screening of Kinase Inhibitors 65725.2 Product Concept 66525.3 Prototyping 66925.4 Product Development 67225.5 Summary 672References 672Patents 673Exercises 673Chapter 26 Case Study 3—Die Attach Adhesive: A Case Study of Product Development 67426.0 Objectives 67426.1 Background of Technology 67426.2 Market Study 67426.3 Product Design 67726.4 Process Design 67826.5 Prototyping 67826.6 Estimation of Product Cost 67926.7 Summary 680References 680Exercises 681Chapter 27 Case Study 4—Ammonia Process 68327.0 Objectives 68327.1 Introduction 68327.2 Initial Base Case Design 68627.3 Design Refinement 692Postscript 699References 703Exercises 703APPENDICESI. Residue Curves for Heterogeneous Systems 704II. Design Problem Statements by Area 705III. Materials of Construction 709INDICESTable of Acronyms 711Author Index 719Subject Index 725