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Content
Preface to Second Edition
Acknowledgements
Introduction

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1

I How to Use This Book

(A) The Case Study Approach
(B) A "Road Map"
II Some Advice
(A) General Advice to the Student
(B) Advice from a Former Design Project Student
(C) To the Lecturer
(D) The Designer or Project Engineer
III Presentation of Design Projects
(A) Effective Communications
(B) General Comments on Preparation of Literature Surveys
IV Details of Particular Design Projects, and Information Sources
(A) IChemE Design Projects
Instructions for the IChemE Design Project, 1980
(B) Information Sources

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PART 1 TECHNICAL AND ECONOMIC FEASIBILITY STUDY

Chapter 1
1.1

The Design Problem

Initial Considerations and Specification

1.1.1 The Feasibility Study
1.1.2 Time Management
1.1.3 Stages in a Design Problem
1.1.4 The Search for Information
1.1.5 Scope of the Project
1.1.6 Evaluating the Alternatives - Making Decisions

Some Questions to Ask for the Chemical to be Produced

Further Reading

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Case Study: Production of Phthalic Anhydride

Overall Summary for the Technical and Economic Feasibility Study
1.2 Case Study - Defining the Problem and Background Information
Summary
1.2.1 Background and Objectives
1.2.2 Chemical Structure and Physical Properties
1.2.3 Applications and Uses
1.2.4 Basic Chemistry
1.2.5 Evaluation of Alternative Processing Schemes
1.2.6 Conclusions
1.2.7 Recommendations
Chapter 2 Feasibility Study and Market Survey
2.1
Initial Feasibility Study
2.2
Preliminary Market Survey/Economic Analysis
References
2. 3 Information Sources
2.4
Evaluation of Available Literature
2.5
Considerations for Literature Surveys
References
2.6
Case Study - Feasibility Study and Market Assessment
Summary
2.6.1 Market Assessment
2.6.1.1 Production: Worldwide
2.6.1.2 Production: Regional
2.6.1.3 Production: National
2.6.2 Current and Future Prices
2.6.3 Demand
2.6.4 Australian Imports and Exports
2.6.5 Plant Capacity
2.6.6 Product Value and Operating Costs
2.6.6.1 Capital Costs
2.6.6.2 Operating Costs
2.6.6.3 Approximate Selling Price
2.6.7 Conclusions
2.6.8 Recommendations

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Chapter 3 Process Selection, Process Description and Equipment List

3.1
Process Selection Considerations
3.1.1 Flow Diagrams - PFD and P&ID
3.1.2 The Reactor
3.1.3 Product Purity
3.1.4 Process Conditions

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3.1.5
3.1.6
3.1.7
3.1.8
3.1.9
3.1.10

Process Data
Energy Efficiency
Factors in Process Evaluation and Selection
Choices and Compromises
The Optimum Design
Process Control and Instrumentation
References
3.2
Process Description
3.3
Preparing the Equipment List
3.4
Rules of Thumb
3.5
Safety Considerations and Preliminary HAZOP Study
References
3.6
Case Study - Process Selection and Equipment List
Summary
3.6.1 Trends in Phthalic Anhydride Processing
3.6.2 Raw Material
3.6.3 Process Configurations
3.6.4 Detailed Process Description
3.6.5 Advantages of the LAR Process
3.6.6 Advantages of the LEVH Process
3.6.7 Process Selection
3.6.8 Initial Equipment Design
3.6.9 Equipment List
3.6.10 Conclusions
3.6.11 Recommendations
Appendix A: Preliminary Equipment Specifications
Chapter 4 Site Considerations: Site Selection and Plant Layout
4.1
Site Selection/ Location
4.1.1 Local Industrial Areas
4.1.2 Some Important Factors
4.1.3 Prioritizing the Factors
References
4.2
Plant Layout
4.2.1 Plant Layout Strategies
4.2.2 Factors Influencing Plant Layout
References
4.3
Case Study - Site Considerations: Site Selection and Plant Layout

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Summary
4.3.1 Background and Objectives
4.3.2 Potential Sites
4.3.2.1 Kemerton
4.3.2.2 Geraldton

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4.3.2.3 Karratha
4.3.2.4 Kwinana
4.3.3 Preferred Site and Layout
4.3.4 Conclusions
4.3.5 Recommendations
Chapter 5 Environmental Considerations
5.1
Environmental Impact Assessment
5.2
General Considerations
5.3
EIA Policy and Scope
5.4
EIA Reports
5.5
Australia
5.6
United Kingdom
5.7
United States
5.8
ISO-14000
5.9
Legislation
References
5.10 Case Study - Environmental Considerations
Summary
5.10.1 Purpose
5.10.2 Airborne Emissions
5.10.3 Waterborne Emissions
5.10.4 Solid Waste
5.10.5 Process Hazards
5.10.6 Accidental Spills and Tank Breaches
5.10.7 Personnel Safety Precautions and Procedures
5.10.8 Conclusions
5.10.9 Recommendations
Chapter 6 Economic Evaluation
6.1
Introductory Notes
6.2
Capital Cost Estimation
6.2.1 Cost of Equipment (Major Items)
(I) Cost Correlations
(II) Factored Estimate Method
6.2.2 Module Costs
6.2.3 Auxiliary Services
6.3
Operating Costs - Fixed and Variable
6.3.1 Depreciation
6.4
Profitability Analysis
6.4.1 The Payback Period
6.4.2 Return on Investment (ROI)
6.4.3 Evaluating Different Scenarios
6.4.4 Economic Evaluation and Analysis

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6.4.5 Evaluating Different Projects: Use of DCF and NPV

The Engineers' Approach to Economic Evaluation
The Final Word?
References

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6.5
Case Study - Economic Evaluation
Summary
6.5.1 Background and Objectives
6.5.2 Equipment Costs
6.5.3 Installed Plant Cost by Lang Factor
6.5.4 Installed Plant Cost from Recent Plant Construction Data
6.5.5 Production Costs
6.5.6 Profitability Analysis
6.5.7 Conclusions
6.5.8 Recommendations

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Chapter 7 Mass and Energy Balances

7.1
Preparation of Mass and Energy Balances
References
7.2
Preliminary Equipment Design
References
7.3
Computer-Aided Design
What design work is there left to do now that we have
simulation packages?
References
7.4
Case Study-Mass and Energy Balances, and Utilities
Summary
7.4.1 Scope and Objectives
7.4.2 Mass Balances
7.4.3 Energy Balances
7.4.4 Optimisation of Mass and Energy Balances
7.4.5 Utilities
7.4.6 Conclusions
7.4.7 Recommendations

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Chapter 8 Additional Design Considerations

8.1
Energy Integration and Conservation
8.2
Process Control, Instrumentation and Alarms
8.3
Safety, Health and the Environment
References
Energy Conservation

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Process Control
Safety, Health and the Environment
(including Loss Prevention and HAZOP)
8.4 Case Study Energy Integration, Piping Specifications
Process Control and the P&ID
Summary
8.4.1 Energy Management and Integration
8.4.2 Plant Piping Specifications
8.4.3 Control and Instrumentation
8.4.4 The Piping and Instrumentation Diagram (P&ID
8.4.5 Conclusions
8.4.6 Recommendations
References for Case Study Sections in Chapters 1 to 8
Comments
References
PART II DETAILED EQUIPMENT DESIGN
Chapter 9 The Detailed Design Stage
9.1
Detailed Equipment Design
9.1.1 Equipment Design - HELP!!!
How to Begin to Design an Item of Equipment
9.2
Standards and Codes
9.3
Additional Design Considerations
References
Some General Textbooks
Design Books
Chapter 10 Case Study -Phthalic Anhydride Reactor Design
Overall Summary
Updated Material and Energy Balance for the Phthalic
Anhydride Reactor (R101)
Engineering Specification Sheet for the Reactor (R101)
Schematic Drawing of the Reactor (R101)
Part I Chemical Engineering Design
10.1 Overall Design Strategy
10.2 Design Basis
10.3 Design Parameters
10.4 Design Criteria
10.5 Chemical Engineering Design Methods
10.5.1 Catalyst Properties
10.5.2 Kinetics

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10.5.3 Reactor Simulation

10.5.4 Heat Transfer
10.5.5 Pressure Drop
10.6 Detailed Design
10.6.1 Reactor Configuration
10.6.2 Coolant
10.6.3 Computer Model
10.6.4 Shell Configuration
10.6.5 Salt Cooler
10.6.6 Salt Circulation Pump
10.7 Chemical Engineering Design Specification
10.7.1 Reactor Specification
10.7.2 Salt Cooler Specification
10.7.3 Salt Circulation Pump Specification
Part II Mechanical Engineering Design
10.8 Mechanical Engineering Design Parameters
10.9 Mechanical Engineering Design Methods
10.9.1 Shell Design
10.9.2 Supports and Foundations
10.10 Materials of Construction
10.11 Pressure Vessel Design (AS1210)
10.12 Insulation
10.13 Supports and Foundations
10.14 Costing
10.15 Engineering Specification
Specification Sheets
Engineering Drawings
Part III Operational Considerations
10.16 HAZOP Analysis
10.17 Process Hazards
10.18 Safety
10.19 Operability
10.20 Environmental Considerations
10.21 Control and Instrumentation
10.22 Operating Considerations
10.22.1 Operation Under Normal Conditions
10.22.2 Commissioning
10.22.3 Shut-Down
10.22.4 Start-Up
10.22.5 Regular Maintenance
Part IV Conclusions, Recommendations and References
10.23 Conclusions
Chemical Engineering Design
Mechanical Engineering Design

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Operational Considerations
10.24 Recommendations
10.25 References
Appendix B. Calculations for Phthalic Anhydride Reactor Design
B.1 Reactions
B.2 Derivation of Simulation Model Equations
B.3 Tube-Side Heat Transfer Coefficient
B.4 Shell-Side Heat Transfer Coefficient
B.5 Overall Heat Transfer Coefficient (Clean)
B.6 Tube Count
B.7 Tube-Side Pressure Drop
B.8 Shell-Side Pressure Drop
B.9 Salt Cooler Design
B.10 Shell Design (AS1210)
B.11 Tube-Plate Design
B.12 Vessel Openings
B.13 Protective Devices (AS1210)
B.14 Insulation
B.15 Supports
B.16 Foundation
Appendix C. FORTRAN Program for Phthalic Anhydride Reactor Simulation
Appendix D. Hazard and Operability Studies for Phthalic Anhydride Reactor

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Chapter 11 Case Study -Phthalic Anhydride After-Cooler Design

Overall Summary
Updated Material and Energy Balance for the After-Cooler (E105)
Engineering Specification Sheet for the After-Cooler (E105)
Schematic Drawing of the After-Cooler
Part I Chemical Engineering Design
11.1 General Design Considerations
11.2 Design Strategy and Criteria
11.3 Preliminary Design Decisions
11.3.1 Condenser Type
11.3.2 Coolant
11.4 Chemical Engineering Design Methods
11.4.1 Heat Transfer Coefficient
11.4.2 After-Cooler Simulation
11.4.3 Pressure Drop
11.5 Detailed Design
11.5.1 General Considerations
11.5.2 Simulation Results
11.5.3 Vessel Configuration

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11.6 Chemical Engineering Design Specification

Part II Mechanical Engineering Design
11.7 Mechanical Engineering Design Requirements
11.8 Materials of Construction
11.9 Vessel Dimensions
11.10 Insulation
11.11 Supports and Foundation
11.12 Costing
11.13 Engineering Specification
Part III Operational Considerations
11.14 HAZOP Analysis
11.15 Process Hazards
11.16 Safety
11.17 Operability
11.18 Environmental Considerations
11.19 Control and Instrumentation
11.20 Operating Considerations
11.20.1 Operation Under Normal Conditions
11.20.2 Commissioning
11.20.3 Shut-Down and Start-Up
11.20.4 Regular Maintenance
Part IV Conclusions, Recommendations and References
11.21 Conclusions
Chemical Engineering Designc
Mechanical Engineering Design
Operational Considerations
11.22 Recommendations
11.23 References
Appendix E. Calculations for Phthalic Anhydride After-Cooler Design
E.1 Provisional After-Cooler Design
E.2 Shell-Side Cross-Flow Area
E.3 Pressure Drops
E.4 Mechanical Design
E.5 Supports
E.6 Foundation
Appendix F. FORTRAN Program for Phthalic Anhydride
After-Cooler Simulation
Appendix G. Hazard and Operability Study for Phthalic Anhydride
After-Cooler (Tables G.1 to G.5)
Final Comments
INDEX

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Preface to Second Edition

The main difference between this edition and the original (1989) is the inclusion of a new
case study - the production of phthalic anhydride. Although the design process is
essentially similar for most chemicals, no two designs are ever the same. A comparison
between the original case study and this new one should emphasise the need for
originality and flexibility in process design.
As with the earlier edition, the case study has been incorporated throughout the book so
that application of the principles and ideas which are discussed in the main text can be
illustrated sequentially. The case study should not be viewed merely as a design blue-print
but as an integral part of the book. Two items of equipment have been desinged in detail
in this new case study (Part 11) whereas only the first item was considered to that depth
in the first edition.
All sections of the text material have been revised and new material has been added, e.g.
loss prevention and safety, economic evaluation and environmental considerations. The
new material reflects important developments and shifting emphasis in chemical
engineering over the intervening years. However, the focus is again on the approach of
learning by doing. It is necessary to consider a broad range of topics in a design problem,
hence the retention of the Technical and Economic Feasibility Study.
The advice is intended to be practical and the reader is directed to an extensive list of
useful references - fully updated in this edition. This book is not intended to be a design
handbook, it should be considered as a 'road map' for performing a design project.