Process Engineering: Addressing the Gap between Study and Chemical Industry

by Michael Kleiber, Gökce Adali (Contribution by), Michael Benje (Contribution by), Verena Haas (Contribution by)

Overview

"Reading the book, you can feel the long practical experience of the author. The text is easy to read, even where concepts can be complex. The strong theoretical background of the author is well known from other publications. In this book, however, the topics are presented on a level that every engineer and scientist in the chemical industry and process industry should know and can understand... This book would have been very helpful at the beginning of my career to close the addressed gap. Therefore, I can strongly recommend it not only to all students close to their degree, but also to engineers and scientists just starting their industrial career in the related industrial sectors that are subsumed under the term process industry (chemical or petrochemical industry, pharmaceutical industry, food industry, biochemical industry, environmental technology, etc.). The book is like an investment. Doing a better job and getting a better job evaluation might pay for the book …" Prof. Dr.-Ing. Claus Fleischer, Frankfurt University of Applied Sciences

Process Engineering is based on almost 30 years of practical experience of the author in process simulation, design and development. The book is a missing link between students and practitioners. The author has coached many graduates in their first months and knows what the typical questions are.

Coming from the university, graduates often do not know which relevance their knowledge has and how to apply it in real life, whereas established practitioners often stick to the narrow way of their experience, forgetting that science continuously makes progress. There is a gap to be bridged.

From his own professional experience, the author covers many topics of the process engineering business, but three guest contributions are a valuable supplement to the content of the third edition. Already in the 2nd edition, Verena Haas from BASF SE wrote an excellent chapter on dynamic process simulation. For the new 3rd edition, Gökce Adali and Michael Benje added two chapters on digitalization and patents, respectively.

Preparing the reader for the everyday business!

Product Details

ISBN-13:	9783111028118
Publisher:	De Gruyter
Publication date:	11/20/2023
Series:	De Gruyter Textbook
Edition description:	3rd, Revised and Extended Edition
Pages:	574
Product dimensions:	6.69(w) x 9.45(h) x (d)
Age Range:	18 Years

About the Author

Michael Kleiber started his career as a scientific assistant at the TU Brunswick, where he completed his doctoral thesis in 1994. He has worked for the former Hoechst AG and its successors in the fields of process development, process simulation and engineering calculations, before moving to ThyssenKrupp Uhde as a Chief Development Engineer. Dr. Kleiber is a member of the German Board of Thermodynamics and contributor to several standard works on process engineering, such as the VDI Heat Atlas, Winnacker-Kuechler and Ullmann's Encyclopedia of Industrial Chemistry.

Table of Contents

Preface vii

Preface to the 2^nd edition ix

1 Engineering projects 1

1.1 Process engineering activities 1

1.2 Realization of a plant 8

1.3 Cost estimation 18

2 Thermodynamic models in process simulation 25

2.1 Phase equilibria 27

2.2 φ-φ-approach 32

2.3 γ-φ-approach 40

2.3.1 Activity coefficients 40

2.3.2 Vapor pressure and liquid density 49

2.3.3 Association 54

2.4 Electrolytes 56

2.5 Liquid-liquid equilibria 59

2.6 Solid-liquid equilibria 62

2.7 φ-φ-approach with g^E mixing rules 64

2.8 Enthalpy calculations 66

2.9 Model choice and data management 69

2.10 Binary parameter estimation 73

2.11 Model changes 75

2.12 Transport properties 76

3 Working on a process 81

3.1 Flowsheet setup 82

3.2 PID discussion 92

3.3 Heat integration options 97

3.4 Batch processes 105

3.5 Equipment design 109

3.6 Troubleshooting 110

3.7 Dynamic process simulation 113

3.7.1 Basic considerations for dynamic models 115

3.7.2 Basics of Process Control for Dynamic Simulations 118

4 Heat exchangers 127

4.1 Something general 127

4.2 Shell-and-tube heat exchangers 129

4.3 Heat exchangers without phase change 130

4.4 Condensers 141

4.5 Evaporators 143

4.6 Plate heat exchangers 152

4.7 Double pipes 154

4.8 Air coolers 154

4.9 Fouling 156

4.10 Vibrations 158

5 Distillation and absorption 163

5.1 Thermodynamics of distillation and absorption columns 166

5.2 Packed columns 168

5.3 Maldistribution in packed columns 179

5.4 Tray columns 181

5.5 Comparison between packed and tray columns 201

5.6 Distillation column control 203

5.7 Constructive issues in column design 208

5.8 Separation of azeotropic systems 211

5.9 Rate-based approach 214

5.10 Dividing wall columns 216

5.11 Batch distillation 219

5.12 Troubleshooting in distillation 221

6 Two liquid phases 225

6.1 Liquid-liquid separators 225

6.2 Extraction 228

6.2.1 Mixer-settler arrangement 231

6.2.2 Extraction columns 232

6.2.3 Centrifugal extractors 235

7 Alternative separation processes 237

7.1 Membrane separations 237

7.2 Adsorption 245

7.3 Crystallization 252

8 Fluid flow engines 257

8.1 Pumps 257

8.2 Compressors 265

8.3 Jet pumps 274

8.4 Vacuum generation 277

9 Vessels and separators 283

10 Chemical reactions 291

10.1 Reaction basics 291

10.2 Reactors 299

11 Mechanical strength and material choice 307

12 Piping and measurement 313

12.1 Pressure drop calculation 313

12.1.1 Single-phase flow-through pipes 313

12.1.2 Pressure drops in special piping elements 318

12.1.3 Pressure drop calculation for compressible fluids 318

12.1.4 Two-phase pressure drop 321

12.2 Pipe specification 327

12.3 Valves 329

12.3.1 Isolation valves 329

12.3.2 Control valves 332

12.4 Measurement devices 334

13 Utilities and waste streams 339

13.1 Steam and condensate 339

13.2 Heat transfer oil 346

13.3 Cooling media 346

13.4 Exhaust air treatment 348

13.4.1 Condensation 351

13.4.2 Combustion 354

13.4.3 Absorption 359

13.4.4 Biological exhaust air treatment 361

13.4.5 Exhaust air treatment with membranes 362

13.4.6 Adsorption processes 363

13.5 Waste water treatment 364

13.6 Biological waste water treatment 367

14 Process safety 371

14.1 HAZOP procedure 375

14.2 Pressure relief 380

14.2.1 Introduction 380

14.2.2 Mass flow to be discharged 384

14.2.3 Fire case 386

14.2.4 Actuation cases 392

14.2.5 Safety valve peculiarities 399

14.2.6 Maximum relief amount 402

14.2.7 Two-phase-flow safety valves 411

14.3 Explosions 414

Glossary 419

List of Symbols 427

Bibliography 431

A Some numbers to remember 443

B Pressure drop coefficients 447

Index 451

Editorial Reviews

From reviews of the previous editions:

1. "As a chemical engineer and process engineer, I transferred twice between the academic world and the industrial world. After 20 years of working experience in the chemical industry I am know back teaching various courses in chemical engineering: (e. g., separation processes, heat and mass transfer, process simulation, thermodynamics, etc.). While our academic education focuses mostly on the theoretical knowledge, junior engineers and scientists starting their first job in the industry are faced with many new practical terms and concepts. After crossing that gap between academia and industry twice, it was especially the subtitle of this book that caught my interest: "Addressing the gap between study and chemical (process) industry". Reading through the well written book was like a reminder of the practical learning curve I walked along as a junior engineer. All (yes all) the topics presented in the book played a role in my working career … Reading the book, you can feel the long practical experience of the author. The text is easy to read, even where concepts can be complex. The strong theoretical background of the author is well known from other publications. In this book, however, the topics are presented on a level that every engineer and scientist in the chemical industry and process industry should know and can understand... This book would have been very helpful at the beginning of my career to close the addressed gap. Therefore, I can strongly recommend it not only to all students close to their degree, but also to engineers and scientists just starting their industrial career in the related industrial sectors that are subsumed under the term process industry (chemical or petrochemical industry, pharmaceutical industry, food industry, biochemical industry, environmental technology, etc.). The book is like an investment. Doing a better job and getting a better job evaluation might pay for the book …" Prof. Dr.-Ing. Claus Fleischer, Frankfurt University of Applied Sciences

2. "Very readable and recommendable! The title of this book is really suitable. It fills the gap between studies and industrial practice with informations and knowledge from practical experience of the author in the process industry. None of the essential areas – from the cost estimation about the unit operations in chemical engineering to process safety – is omitted. So, students and young professionals get in-depth views on the themes and issues that expect them in practice. Very readable and recommendable!"

3 ."Chemical process engineering review Great book! Used the book to bridge the gap between theoretical knowledge and practical approaches in the industry."

From the Publisher