Chemical Process Engineering Volume 2: Design, Analysis, Simulation,

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A. Kayode Coker, PhD, is an engineering consultant for AKC Technology, an honorary research fellow at the University of Wolverhampton, UK, a former engineering coordinator at Saudi Aramco Shell Refinery Company, and chairman of the Department of Chemical Engineering Technology at Jubail Industrial College, Saudi Arabia. He has been a chartered chemical engineer for more than 30 years. He is a fellow of the Institution of Chemical Engineers, UK, and a senior member of the American Institute of Chemical Engineers. He holds a BSc honors degree in chemical engineering, a master of science degree in process analysis and development and PhD in chemical engineering, all from Aston University, Birmingham, UK, and a Teacher's Certificate in Education at the University of London, UK. He has directed and conducted short courses extensively throughout the world and has been a lecturer at the university level. His articles have been published in several international journals. He is an author of seven books in chemical engineering, a contributor to the Encyclopedia of Chemical Processing and Design, Vol 61 and a certified train-the-mentor trainer. He is also a technical report assessor and interviewer for chartered chemical engineers (IChemE) in the U.K. He is a member of the International Biographical Centre in Cambridge, UK, is in "Leading Engineers of the World for 2008." He is also a member of "International Who's Who of ProfessionalsTM" and "Madison Who's Who in the U.S." Rahmat Sotudeh-Gharebaagh, PhD, is a full professor of chemical engineering at the University of Tehran. He teaches process modeling and simulation, transport phenomena, plant design and economics and soft skills. His research interests include computer-aided process design and simulation, fluidization, and engineering education. He holds a BEng degree in chemical engineering from Iran's Sharif University of Technology, plus a MSc and a PhD in fluidization engineering from Canada's Polytechnique. He has been an invited Professor at Qatar University and Polytechnique de Montréal. Professor Sotudeh has more than 300 publications in major international journals and conferences, plus four books and four book chapters. He is the co-founder and editor-in-chief of the journal, Chemical Product and Process Modeling, a member of the Iranian Elite Foundation, and an official expert (OE) on the oil industry with the Iranian Official Expert Organization.

Preface xxi Acknowledgments xxiii About the Authors xxv 8 Heat Transfer 505 8.1 TYPES OF HEAT TRANSFER EQUIPMENT TERMINOLOGY 506 8.2 DETAILS OF EXCHANGE EQUIPMENT 507 8.3 FACTORS AFFECTION SHELL SELECTION 528 8.4 COMMON COMBINATIONS OF SHELL AND TUBE HEAT EXCHANGERS 528 8.5 THERMAL DESIGN 547 8.6 THE EFFECTIVENESS -- NTU METHOD 612 8.7 PRESSURE DROP, Delta-p 621 8.8 HEAT BALANCE 635 8.9 TRANSFER AREA 636 8.10 FOULING OF TUBE SURFACE 636 8.11 EXCHANGER DESIGN 643 8.12 APPROXIMATE VALUES FOR OVERALL HEAT TRANSFER COEFFICIENTS 647 8.13 DESIGN AND RATING OF HEAT EXCHANGERS 681 8.14 SHELL AND TUBE HEAT EXCHANGER DESIGN PROCEDURE (SI UNITS) 702 8.15 BELL-DELAWARE METHOD 734 8.16 RAPID DESIGN ALGORITHMS FOR SHELL AND TUBE AND COMPACT HEAT EXCHANGERS: POLLEY et al. 742 8.17 FLUIDS IN THE ANNULUS OF TUBE-IN-PIPE OR DOUBLE PIPE HEAT EXCHANGER, FORCED CONVECTION 744 8.18 PLATE AND FRAME HEAT EXCHANGERS 784 8.19 AIR-COOLED HEAT EXCHANGERS 788 8.20 SPIRAL HEAT EXCHANGERS 819 8.21 SPIRAL COILS IN VESSELS 821 8.22 HEAT-LOSS TRACING FOR PROCESS PIPING 821 8.23 BOILING AND VAPORIZATION 833 8.24 HEATING MEDIA 837 8.25 BATCH HEATING AND COOLING OF FLUIDS 840 9 Process Integration and Heat Exchanger Network 947 10 Process Safety and Pressure-Relieving Devices 1093 10.1 TYPES OF POSITIVE PRESSURE-RELIEVING DEVICES 1094 10.2 TYPES OF VALVES/RELIEF DEVICES 1096 10.3 RUPTURE DISK 1098 10.4 DESIGN PRESSURE OF A VESSEL 1107 10.5 MATERIALS OF CONSTRUCTION 1107 10.6 RUPTURE DISKS 1108 10.7 UNFIRED PRESSURE VESSELS ONLY, BUT NOT FIRED OR UNFIRED STEAM BOILERS 1110 10.8 RELIEVING CAPACITY OF COMBINATIONS OF SAFETY RELIEF VALVES AND RUPTURE DISKS OR NON-RECLOSURE DEVICES (REFERENCE ASME CODE, PAR. UG-127, U-132) 1113 10.9 ESTABLISHING RELIEVING OR SET PRESSURES 1120 10.10 SELECTION AND APPLICATION 1121 10.11 CAPACITY REQUIREMENTS EVALUATION FOR PROCESS OPERATION (NON-FIRE) 1121 10.12 SELECTION FEATURES: SAFETY, SAFETY RELIEF VALVES, AND RUPTURE DISKS 1134 10.13 CALCULATIONS OF RELIEVING AREAS: SAFETY AND RELIEF VALVES 1136 10.14 STANDARD PRESSURE RELIEF VALVES RELIEF AREA DISCHARGE OPENINGS 1136 10.15 SIZING SAFETY RELIEF TYPE DEVICES FOR REQUIRED FLOW AREA AT TIME OF RELIEF 1137 10.16 EFFECTS OF TWO-PHASE VAPOR-LIQUID MIXTURE ON RELIEF VALVE CAPACITY 1137 10.17 SIZING FOR GASES OR VAPORS OR LIQUIDS FOR CONVENTIONAL VALVES WITH CONSTANT BACKPRESSURE ONLY 1137 10.18 ORIFICE AREA CALCULATIONS 1144 10.19 SIZING VALVES FOR LIQUID RELIEF: PRESSURE RELIEF VALVES REQUIRING CAPACITY 10.20 SIZING VALVES FOR LIQUID RELIEF: PRESSURE RELIEF VALVES NOT REQUIRING CAPACITY CERTIFICATION [5d] 1149 10.21 REACTION FORCES 1152 10.22 CALCULATIONS OF ORIFICE FLOW AREA USING PRESSURE-RELIEVING BALANCED BELLOWS VALVES, WITH VARIABLE OR CONSTANT BACK PRESSURE 1158 10.23 SIZING VALVES FOR LIQUID EXPANSION (HYDRAULIC EXPANSION OF LIQUID-FILLED SYSTEMS/EQUIPMENT/PIPING) 1163 10.24 SIZING VALVES FOR SUBCRITICAL FLOW: GAS OR VAPOR BUT NOT STEAM [5D] 1168 10.25 EMERGENCY PRESSURE RELIEF: FIRES AND EXPLOSIONS RUPTURE DISKS 1171 10.26 EXTERNAL FIRES 1171 10.27 SET PRESSURES FOR EXTERNAL FIRES 1171 10.28 HEAT ABSORBED 1172 10.29 SURFACE AREA EXPOSED TO FIRE 1173 10.30 RELIEF CAPACITY FOR FIRE EXPOSURE 1175 10.31 CODE REQUIREMENTS FOR EXTERNAL FIRE CONDITIONS 1175 10.32 DESIGN PROCEDURE 1175 10.33 RUNAWAY REACTIONS: DIERS 1179 10.34 HAZARD EVALUATION IN THE CHEMICAL PROCESS INDUSTRIES 1180 10.35 HAZARD ASSESSMENT PROCEDURES 1181 10.36 EXOTHERMS 1182 10.37 ACCUMULATION 1182 10.38 THERMAL RUNAWAY CHEMICAL REACTION HAZARDS 1183 10.39 HEAT CONSUMED HEATING THE VESSEL. THE Phi-FACTOR 1183 10.40 ONSET TEMPERATURE 1185 10.41 TIME-TO-MAXIMUM RATE 1185 10.42 MAXIMUM REACTION TEMPERATURE 1185 10.43 VENT SIZING PACKAGE (VSP) 1186 10.44 VENT SIZING PACKAGE 2TM (VSP2TM) 1189 10.45 ADVANCED REACTIVE SYSTEM SCREENING TOOL (ARSST) 1191 10.46 TWO-PHASE FLOW RELIEF SIZING FOR RUNAWAY REACTION 1191 10.47 RUNAWAY REACTIONS 1192 10.48 VAPOR PRESSURE SYSTEMS 1192 10.49 GASSY SYSTEMS 1192 10.50 HYBRID SYSTEMS 1193 10.51 SIMPLIFIED NOMOGRAPH METHOD 1193 10.52 VENT SIZING METHODS 1199 10.53 VAPOR PRESSURE SYSTEMS 1199 10.54 FAUSKE'S METHOD 1201 10.55 GASSY SYSTEMS 1202 10.56 HOMOGENEOUS TWO-PHASE VENTING UNTIL DISENGAGEMENT 1203 10.57 TWO-PHASE FLOW THROUGH AN ORIFICE 1204 10.58 CONDITIONS OF USE 1205 10.59 DISCHARGE SYSTEM 1206 10.60 SAFE DISCHARGE 1206 10.61 DIRECT DISCHARGE TO THE ATMOSPHERE 1206 10.62 DIERS FINAL REPORTS 1215 10.63 SIZING FOR TWO-PHASE FLUIDS 1215 11 Chemical Kinetics and Reactor Design 1253 12 Engineering Economics 1335 13 Optimization in Chemical/Petroleum Engineering 1363 Epilogue 1405 Index 1415