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Analysis, Synthesis and Design of Chemical Processes with 3.5 Disk
Author: Turton, Richard / Bailie, Richard C.
Cover: Hard cover
List Price: $129.25
Published by Prentice Hall
Date Published: 11/1997
This book represents the culmination of many years of teaching experience in the
design program at West Virginia University. Although this program has evolved over
more than thirty years and is still evolving, it is fair to say that the current program
has gelled over the last ten years through the concerted effort of the authors to
integrate design throughout the undergraduate curriculum in chemical engineering.
We view design as the focal point of chemical engineering practice. Far more than
the development of a set of specifications for a new chemical plant, design is that
creative activity through which engineers continuously improve the operation of
facilities to create products that enhance the quality of life. Whether developing the
grass roots plant, proposing and guiding process modifications, or troubleshooting and
implementing operational strategies for existing equipment, engineering design
requires a broad spectrum of knowledge and intellectual skills to be able to analyze
the big picture and the minute details and, most importantly, to know when to
concentrate on each.
Our vehicle for helping students develop and hone their design skills is process
design rather than plant design, covering synthesis of the entire chemical process
through topics relating to the preliminary sizing of equipment, flowsheet
optimization, economic evaluation of projects, and the operation of chemical
processes. The purpose of this text is to assist chemical engineering students in
making the transition from solving well-posed problems in a specific subject to
integrating all the knowledge that they have gained in their undergraduate education
and applying it to solving open-ended process problems. Many of the "nuts and bolts"
issues regarding plant design (for example, what schedule pipe to use for a given
stream or what corrosion allowance to use for a vessel in a certain service) are not
covered. Although such issues are clearly important to the practicing engineer,
several excellent handbooks and textbooks are available to address such problems,
and these are cited in the text where they apply.
As a result of our integrated approach to design, we have divided this book into six
sections. Section 0, the first chapter in the book, covers the principal diagrams used
by chemical engineers. In particular, details of the most important diagram for the
analysis of chemical processes are given, namely the Process Flow Diagram (PFD).
Section 1 covers the engineering economic aspects of a process, including the
material needed for the Fundamentals of Engineering (FE or EIT) exam required as
the first step toward professional registration.
Section 2 looks at the common features of all processes and explains how and why
we choose the operating conditions in a process. This section also includes some
guidelines for preliminary process design.
Section 3 focuses on the performance of existing processes and equipment. This
material is substantially different from that found in most textbooks. We consider
equipment that is already built and operating and show how to analyze, evaluate,
and modify the performance of the system, including process troubleshooting to
determine the cause of a process upset.
Section 4 looks at the synthesis of a chemical process. The minimum information
required to simulate a process is covered as are the basics of using a process
simulator. This section also covers process optimization and heat integration
Section 5 addresses the role of the professional engineer in society. Separate
chapters on ethics and professionalism; health, safety, and the environment;
and oral and written communication cover topics crucial to an engineer's success but
sometimes overlooked in design courses. An entire chapter is devoted to addressing
some of the common mistakes that students make in written
Finally, three appendices are included. Appendix A gives a series of cost charts for
equipment. This cost information is also included in the CAPCOSTę program for
evaluating fixed capital investment introduced in Chapter 2. Appendix B gives the
preliminary design information for four chemical processes: dimethyl ether, acrylic
acid, acetone, and heptenes production. This information is used in many of the end-
of-chapter problems in the book. These processes can also be used as the starting
point for more detailed analyses, for example, optimization studies. Appendix C
gives six case study problems suitable for individual or group design projects.
For a one-term design course, we recommend including the following core:
- Chapter 1
- Section 2 (Chapters 6-9)
- Chapter 17
- Chapter 18
- Section 5 (Chapters 20-23)
For programs in which engineering economics is not a prerequisite to the design
course, Chapters 2 through 5 should also be included. If students have previously
covered engineering economics, Chapter 19 (Optimization) could be substituted.
For the second term of a two-term sequence, we recommend Chapters 10 through 14
(and Chapter 19 if not included in the first design course) plus design projects. If
time permits, we strongly recommend Chapter 15 (Regulating Process Conditions)
and Chapter 16 (Process Troubleshooting), as these tend to solidify as well as to
extend the concepts of Chapters 10 through 14. Section 3 (Chapters 10-16) addresses
the analysis of existing processes and mirrors the type of work that an entry-level
process engineer will encounter in the first few years of employment at a chemical
The chapters, however, can be covered in many different sequences, depending on
the background of the students entering the design course. At West Virginia
University, for example, we cover Chapters 1, 10-16, 2-5, 19, 21, and 20 (in that
order) because the students have covered the material of Chapters 6-9, 17, 18, much
of 19, 22, and 23 in prerequisite courses. The second semester is devoted almost
entirely to a large-group design project. In addition, during the two-semester
sequence, we give our students a sequence of individual design projects. Some
examples of these projects are given in Appendix C. Additional projects are
available from the authors. Projects C.1, C.3, and C.5 cover the analysis of existing
processes and should not be assigned without some coverage of Section 3. The other
projects (C.2, C.4, and C.6) are open-ended design projects for new processes. These
can be given as individual or small-group projects
We have found that the most effective way both to enhance and to examine student
progress is through oral presentations in addition to the submission of written reports.
During these oral presentations, individual students or a student group defend their
results to a faculty panel.
As design is at its essence a creative, dynamic, challenging, and iterative activity,
we welcome feedback on and encourage experimentation with this design textbook.
We hope that students and faculty will find the excitement in teaching and learning
engineering design that has sustained us over the years.
Finally, we would like to thank those people who have been instrumental to the
successful completion of this book. First, thanks are given to all the undergraduate
chemical engineering students at West Virginia University over the years,
particularly during the period 1987-1997. Their feedback and criticism have been a
constant source of ideas and stimulation. Second, we would like to thank those
people who have read, criticized, and used parts of this text in the course of its
preparation. In particular, we would like to recognize Dr. Mark Stadtherr of the
University of Notre Dame and Dr. Susan Montgomery of the University of Michigan
for their helpful criticism and support. Finally, on a personal note we (RT, RCB, and
WBW) would like to thank our long suffering wives (Becky, Judy, and Patricia) for
their continued support, love, and patience throughout this prolonged endeavor.