Process Engineering: Addressing the Gap between Study and Chemical Industry

✍ Scribed by Kleiber M.

• Publisher: Walter de Gruyter
• Year: 2024
• Tongue: English
• Leaves: 572
• Series: De Gruyter Textbook
• Edition: 3
• Category: Library

✦ Synopsis

"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!
Connects the academic theory of Process Engineering with the industrial practice.
Essential reading for students considering a career in the chemical industry.
New in the 3nd Edition: digital twin, process flowcharts & devlopment, troubleshooting, CFD

✦ Table of Contents

Cover
Half Title
Also of Interest
Process Engineering: Addressing the Gap between Study and Chemical Industry
Copyright
Dedication
Preface
Preface to the 2nd edition
Preface to the 3rd edition
Contents
1. Engineering projects
1.1 Process engineering activities
1.2 Realization of a plant
1.3 Cost estimation
2. Thermodynamic models in process simulation
2.1 Phase equilibria
2.2 φ-φ-approach
2.3 γ-φ-approach
2.3.1 Activity coefficients
2.3.2 Vapor pressure and liquid density
2.3.3 Vapor phase association
2.4 Electrolytes
2.5 Liquid-liquid equilibria
2.6 Solid-liquid equilibria
2.7 φ-φ-approach with gE mixing rules
2.8 Enthalpy calculations
2.9 Model choice and data management
2.10 Binary parameter estimation
2.11 Model changes
2.12 Transport properties
3. Working on a process
3.1 Flowsheet setup
3.2 PID discussion
3.3 Heat integration options
3.4 Batch processes
3.5 Equipment design
3.6 Troubleshooting
3.7 Dynamic process simulation
3.7.1 Basic considerations for dynamic models
3.7.2 Basics of process control for dynamic simulations
3.8 Patents
3.8.1 Novelty
3.8.2 Inventiveness
3.8.3 Industrial applicability
3.8.4 Exceptions from patentability [334, 339]
3.8.5 Patent research and patent monitoring
3.8.6 Inventor’s bonus
4. Heat exchange
4.1 Thermal conduction
4.2 Convective heat transfer
4.3 Heat transition
4.4 Shell-and-tube heat exchangers
4.5 Heat exchangers without phase change
4.6 Condensers
4.7 Evaporators
4.8 Plate heat exchangers
4.9 Double pipes
4.10 Air coolers
4.11 Fouling
4.12 Vibrations
4.13 Heat transfer by radiation
5. Distillation and absorption
5.1 Thermodynamics of distillation and absorption columns
5.2 Packed columns
5.3 Maldistribution in packed columns
5.4 Tray columns
5.5 Comparison between packed and tray columns
5.6 Distillation column control
5.7 Constructive issues in column design
5.8 Separation of azeotropic systems
5.9 Rate-based approach
5.10 Dividing wall columns
5.11 Batch distillation
5.12 Troubleshooting in distillation
6. Two liquid phases
6.1 Liquid-liquid separators
6.2 Extraction
6.2.1 Mixer-settler arrangement
6.2.2 Extraction columns
6.2.3 Centrifugal extractors
7. Alternative separation processes
7.1 Membrane separations
7.2 Adsorption
7.3 Crystallization
8. Fluid flow engines
8.1 Pumps
8.2 Compressors
8.3 Jet pumps
8.4 Vacuum generation
9. Vessels and separators
9.1 Agitators
10. Chemical reactions
10.1 Reaction basics
10.2 Reactors
11. Mechanical strength and material choice
12. Piping and measurement
12.1 Pressure drop calculation
12.1.1 Single-phase flow-through pipes
12.1.2 Pressure drops in special piping elements
12.1.3 Pressure drop calculation for compressible fluids
12.1.4 Two-phase pressure drop
12.2 Pipe specification
12.3 Valves
12.3.1 Isolation valves
12.3.2 Control valves
12.4 Pressure surge
12.5 Measurement devices
13. Utilities and waste streams
13.1 Steam and condensate
13.2 Heat transfer oil
13.3 Cooling media
13.4 Exhaust air treatment
13.4.1 Condensation
13.4.2 Combustion
13.4.3 Absorption
13.4.4 Biological exhaust air treatment
13.4.5 Exhaust air treatment with membranes
13.4.6 Adsorption processes
13.5 Waste water treatment
13.6 Biological waste water treatment
14. Process safety
14.1 HAZOP procedure
14.2 Pressure relief
14.2.1 Introduction
14.2.2 Mass flow to be discharged
14.2.3 Fire case
14.2.4 Actuation cases
14.2.5 Safety valve peculiarities
14.2.6 Maximum relief amount
14.2.7 Two-phase-flow safety valves
14.3 Flame arresters
14.4 Explosions
15. Digitalization
15.1 Digital transformation
15.2 Digitalization and sustainability
15.3 Digitalization in process industry and green transformation
15.4 Key terms explained
Industry 4.0
(Industrial) internet of things ((I)IoT)
Big data
Smart data
Data mining
Cloud computing and storage
Artificial intelligence (AI)
Machine learning
How exactly does a machine learn?
Deep learning
15.5 Models for digitalization
Model types
Data-based model building
15.6 Data science vs. domain expertise
Role of domain experts
15.7 Digitalization trends in process industry Digital twins
Dynamic simulation
Operator training simulators (OTS)
Model accuracy in an OTS application
Advanced process control
Real-time optimization
Predictive maintenance
Computer vision
Virtual commissioning
Drone applications
15.8 Catching up with the times
Glossary
List of Symbols
Bibliography
A. Some numbers to remember
Molecular weights
Standard cubic meter
Some other useful physical property data
Critical temperatures
Normal boiling points
Rough values for the vapor pressure of water
Some values for heat transfer
B. Pressure drop coefficients
90° bend
Bend with arbitrary angles ϕ ≠ 90°
Elbow pipe with circular cross-flow area
Elbow pipe with rectangular cross-flow area
Corrugated expansion joint
U-bend
Sharp-edged tube entrance
Smooth tube entrance
Tube entrance with orifice
Discontinuous transition from A1 to A2 > A1
Continuous cross-flow area expansion (diffusor)
Discontinuous cross-flow area restriction from A1 to A2 < A1
Continuous cross-flow area restriction
Vessel outlet
Index