plant design and economics for chemical engineers

I And Petroleum Engineering enw’-u ?N McGraw-Hill Chemical Engineering Series Editorial Advisory Board James J. Carberry, Professor of Chemical Engineering, University of Notre Dame James R Fair, Professor of Chemical Engineering, University of Texas, Austin William P. Schowalter, Dean, School of Engineering, University of Illinois Matthew Tipell, Professor of Chemical Engineering, University of Minnesota James Wei, Professor of Chemical Engineering, Massachusetts Institute of Technology Max S. Peters, Emeritus, Professor of Chemical Engineering, University of Colorado Building the Literature of a Profession Fifteen prominent chemical engineers first met in New York more than 60 years ago to plan a continuing literature for their rapidly growing profession. From industry came such pioneer practitioners as Leo H. Baekeland, Arthur D. Little, Charles L. Reese, John V. N. Dorr, M. C. Whitaker, and R. S. McBride. From the universities came such eminent educators as William H. Walker, Alfred H. White, D. D. Jackson, J. H. James, Warren K. Lewis, and Harry A. Curtis. H. C. Parmelee, then editor of Chemical and Metallu~cal Engineering, served as chairman and was joined subsequently by S. D. Kirkpatrick as consulting editor. After several meetings, this committee submitted its report to the McGraw-Hill Book Company in September 1925. In the report were detailed specifications for a correlated series of more than a dozen texts and reference books which have since become the McGraw-Hill Series in Chemical Engineer- ing and which became the cornerstone of the chemical engineering curriculum. From this beginning there has evolved a series of texts surpassing by far the scope and longevity envisioned by the founding Editorial Board. The McGraw-Hill Series in Chemical Engineering stands as a unique historical record of the development of chemical engineering education and practice. In the series one finds the milestones of the subject’s evolution: industrial chem- istry, stoichiometry, unit operations and processes, thermodynamics, kinetics, and transfer operations. Chemical engineering is a dynamic profession, and its literature continues to evolve. McGraw-Hill, with its editor, B. J. Clark and consulting editors, remains committed to a publishing policy that will serve, and indeed lead, the needs of the chemical engineering profession during the years to come. The Series Bailey and Ollis: Biochemical Engineering Fundamentals Bennett and Myers: Momentum, Heat, and Mass Transfer Beveridge and Schechter: Optimization: Theory and Practice Brudkey and Hershey: Transport Phenomena: A Unified Approach Carberry: Chemical and Catalytic Reaction Engineering Constantinides: Applied Numerical Methodr with Personal Computers Coughanowr and Koppel: Process Systems Analysis and Control ’ . Douglas: Conceptual Design of Chemical Processes Edgar and Himmelblau: Optimization of Chemical Processes Gates, Katzer, and Schuit: Chemistry of Catalytic Processes Holland: Fundamentals of Multicomponent Distillation Holland and Liapis: Computer Methods for Solving Dynamic Separation Problems Katz and Lee: Natural Gas Engineering: Production and Storage King: Separation Processes Lee: Fundamentals of Microelectronics Processing * Luybeo: Process Modeling, Simulation, and Control for Chemical Engineers McCabe, Smith, J. C., and Harriott: Unit Operations of Chemical Engineering Mickley, Sherwood, and Reed: Applied Mathematics in Chemical Engineering Nelson: Petroleum Refinery Engineering Perry and Green (Editors): Chemical Engineers’ Handbook Peters: Elementary Chemical Engineering Peters and Timmerhaus: Plant Design and Economics for Chemical Engineers Reid, Prausoitz, and Rolling: The Properties of Gases and Liquids Sherwood, Pigford, and Wilke: Mass Transfer Smith, B. D.: Design of Efluilibrium Stage Processes Smith, J. M.: Chemical Engineering Kinetics Smith, J. M., and Van Ness: Introduction to Chemical Engineering Thermodynamics Treybal: Mass Transfer Operations Valle-Riestra: Project Evolution in the Chemical Process Industries ’ Wei, Russell, and Swartzlander: The Structure of the Chemical Processing Industries Weotz: Hazardous Waste Management S + CH,-CH, + Cl, CH2CICH,CI + S Ddhn Ethykne chlorioc Ethykne dichlorii DolLn (C. F. Bruun and Co.) ‘Ike complete plant-the complete economic process. Here is the design en@neer’s goal. PLANT DESIGN AND ECONOMICS FOR CHEMICAL ENGINEERS Fourth Edition Max S. Peters Klaus D. Timmerhaus Professors of Chemical Engineering University of Colorado I, :’ ’ : !‘. J. , $ McGraw-Hill, Inc. New York St. Louis San ijranciko Auckland Bogotfi Caracas ‘Hamburg Lisbon London Madrid Mexico Milan Montreal New Delhi Paris San Juan SHo Paula Singapore Sydney Tokyo Toronto PLANT DESIGN AND ECONOMICS FOR CHEMICAL ENGINEERS INTERNATIONAL EDITION 1991 Exclusive rights by McGraw-Hill Book Co. - Singapore for manufacture and export. This book cannot be reexported from the countty to which it is consigned by McGraw-Hill. 234567890CMOPMP95432 Copyright 0 1991, 1980, 1968, 1958 by McGraw-Hill, Inc. All rights reserved. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any means, or stored in a data base or retrieval system, without the prior written permission of the publisher. This book was set in Times Roman by Science Typographers. Inc. The editors were B.J. Clark and$hn M. Morriss; the production supervisor was Richard Ausburn. The cover was designed by Carla Bauer Project supervision was done by Science Typographers, Inc. Library of Congress Cataloging-in-Publication Data Peters, Max Stone, (date) Plantdesign and economics for chemical engineers/Max S. Peters. Klaus D. Timmerhaus.4th ed. P. cm (McGraw-Hill chemical engineering series) Includes bibliographical references. ISBN 0-07-0496137 1. Chemical plants Design and construction. I. Timmerhaus, Klaus D. II. Title. III. Series. TP155.5P4 1991 660’2Mc20 89-77497 When ordering this title me ISBN 0-97-100871-3 Printed in Singapore ABOUTTHEAUTHORS MAX S. PETERS is currently Professor Emeritus of Chemical Engineering and Dean Emeritus of Engineering’ at the University of Colorado at Boulder. He received his B.S. and M.S. degrees in chemical engineering from the Pennsylva- nia State University, worked for the Hercules Power Company and the Treyz Chemical Company, and returned to Penn State for his Ph.D. Subsequently, he joined the faculty of the University of Illinois, and later came to the University of Colorado as Dean of the College of Engineering and Applied Science and Professor of Chemical Engineering. He relinquished the position of Dean in 1978 and became Emeritus in 1987. Dr. Peters has served as President of the American Institute of Chemical Engineers, as a member of the Board of Directors for the Commission on Engineering Education, as Chairman of the President’s Committee on the National Medal of Science, and as Chairman of the Colorado Environmental Commission. A Fellow of the American Institute of Chemical Engineers. Dr. Peters is the recipient of the George Westinghouse Award of the American Society for Engineering Education, the Lamme Award of the ASEE, the Award of Merit of the American Association of Cost Engineers, the Founders Award of the American Institute of Chemical Engineers, and the W. K. Lewis Award of the AIChE. He is a member of the National Academy of Engineering. KLAUS D. TIMMERHAUS is currently Professor of .Chemical Engineering and Presidential Teaching Scholar at the University of Colorado at Boulder. He received his B.S., M.S., and Ph.D. degrees in Chemical Engineering from the University of Illinois. After serving as a process design engineer for the California Research Corporation, Dr. Timmerhaus joined the faculty of the University of Colorado, College of Engineering, Department of Chemical Engineering. He was subsequently appointed Associate Dean of the College of Engineering and Director of the Engineering Research Center. This was fol- lowed by a term as Chairman of the Chemical Engineering Department. The vii . . . VII1 ABOUT THE AUTHORS author’s extensive research publications have been primarily concerned with cryogenics, energy, and heat and mass transfer, and he has edited 25 volumes of Advances in Cryogenic Engineering and co-edited 24 volumes in the International Cqvogenics Monograph Series. He is past President of the American Institute of Chemical Engineers, past President of Sigma Xi, current President of the International Institute of Refrigeration, and has held offices in the Cryogenic Engineering Conference, the Society of Sigma Xi, the American Astronautical Society, the American Association for the Advancement of Science, the American Society for Engi- neering Education-Engineering Research Council, the Accreditation Board for Engineering and Technology, and the National Academy of Engineering. A Fellow of AIChE and AAAS Dr. Timmerhaus has received the ASEE George Westinghouse Award, the AIChE Alpha Chi Sigma Award, the AIChE W. K. Lewis Award, the AIChE Founders Award, the USNC/IIR W. T. Pentzer Award, the NSF Distinguished Service Award, the University of Colorado Stearns Award, and the Samuel C. Collins Award, and has been elected to the National Academy of Engineering and the Austrian Academy of Science. CONTENTS Preface Prologue-The International System of Units (SI) 1 Introduction 2 Process Design Development 3 General Design Considerations 4 Computer-Aided Design 5 Cost and Asset Accounting 6 Cost Estimation 7 Interest and Investment Costs 8 Taxes and Insurance 9 Depreciation 10 Profitability, Alternative Investments, and Replacements 11 Optimum Design and Design Strategy 12 Materials Selection and Equipment Fabrication Xi xv 1 13 47 110 137 150 216 253 267 295 341 421 ix X CONTENTS 13 14 15 16 17 A B C D The Design Report Materials Transfer, Handling, and Treatment Equipment-Design and Costs Heat-Transfer Equipment-Design and Costs Mass-Transfer and Reactor Equipment-Design and Costs Statistical Analysis in Design Appendixes The International System of Units 61) Auxiliary, Utility, and Chemical Cost Data Design Problems Tables of Physical Properties and Constants Indexes Name Index 893 Subject Index 897 452 478 579 649 740 778 800 817 869 [...]... pilot -plant data are necessary, and a program to obtain this information may be initiated Process development ,on,a pilot -plant or semiworks scale is usually desirable in order to -obtain accurate design data.- 16 PLANT DESIGN AND ECONOMICS FOR CHEMICAL ENGINEERS Valuable information on material and energy balances can be obtained, and process conditions can be examined to supply data on temperature and. .. necessary for a detailed-estimate design The following factors should be tSee Chap 13 for assistance in preparing more concise and clearer de&n rebrts 18 PLANT DESIGN AND ECONOMICS FOR CHEMICAL ENGINEERS established within narrow limits before a detailed-estimate design is developed: 1 Manufacturing process 2 Material and energy balances 3 Temperature and pressure ranges 4 Raw-material and product... problem A plant- design project moves to completion through a series of stages such as is shown in the following: 1 Inception 2 Preliminary evaluation of economics and market 3 Development of data necessary for final design 4 Final economic evaluation 5 Detailed engineering design 6 Procurement 7 Erection 8 Startup and trial runs 9 Production t ’ I 1 - 2 PLANT DESIGN AND ECONOMICS FOR CHEMICAL ENGINEERS. .. arrangements, and other information required for the actual construction of the plant The final stage * I _ 4 PLANT DESIGN AND ECONOMICS FOR CHEMICAL ENGINEERS consists of procurement of the equipment, construction of the plant, startup of the plant, overall improvements in the operation, and development of standard operating procedures to give the best possible results The development of a design project proceeds... process designs (or detailed designs) can be prepared for purchasing and construction from a detailed-estimate design Detailed drawings are made for the fabrication of special equipment, and specifications are prepared for purchasing standard types of equipment and materials A complete plant layout is prepared, and blueprints and instructions for construction are developed Piping diagrams and other... gives descriptive and background information for the SI units along with a detailed set of rules for SI usage and lists of conversion factors presented in various forms which should be of special value for chemical engineering usage Chemical engineers in design must be totally familiar with SI and its rules Reading of Appendix A is recommended for those readers who have not worked closely and extensively... Fundamentals, Industrial and Engineering Chemistry Process Design and Development, Journal of the American Chemical Society, Journal tAbstracts of general engineering articles are available in the En@etik Inks a 20 PLANT DESIGN AND ECONOMICS FOR CHEMICAL ENGINEERS of Physical Chemistv, Hydrocarbon Processing, Engineering News-Record, Oil and Gas Journal, and Canadian Journal of Chemical Engineering A... the design of individual pieces of equipment or to develop the strategy for a full plant design This application of computer usage in design is designated as computer-aided design and is the subject of Chap 4 Record keeping and accounting procedures are also important factors in general design considerations, and it is necessary that the design engineer be familiar with the general terminology and. .. engineer be led to believe that plants are designed around computers They are used to determine design data and are used as models for optimization once a design is established They are also used to maintain operating plants on the desired operating conditions The latter function is a part of design and supplements and follows process design The general approach in any plant design involves a carefully... process -design phase is ready to begin All the design details are worked out in this phase including controls, services; piping layouts, firm price quotations, specifications and designs for individual pieces of equipment, and all the other design information necessary for the construction of the final plant A complete construction design is then made with elevation drawings, plant- layout arrangements, and . Engineering Perry and Green (Editors): Chemical Engineers Handbook Peters: Elementary Chemical Engineering Peters and Timmerhaus: Plant Design and Economics for Chemical Engineers Reid, Prausoitz, and Rolling:. CONTENTS 13 14 15 16 17 A B C D The Design Report Materials Transfer, Handling, and Treatment Equipment -Design and Costs Heat-Transfer Equipment -Design and Costs Mass-Transfer and Reactor Equipment -Design and Costs Statistical. - I 1 2 PLANT DESIGN AND ECONOMICS FOR CHEMICAL ENGINEERS This brief outline suggests that the plant- design project involves a wide variety of skills. Among these are research, market analysis, design