Contents

Foreword
Preface

ix
xi

1. Dimensions and Units

1.1 Introduction 1
1.2 Fundamental Quantities or Dimensions 1
1.3 Derived Units 2
1.4 Recommended Rules for Writing Unit Symbols
1.5 Conversion Factors 9
References 9

2. Stoichiometry
2.1 Introduction 10
2.2 Basic Chemical Calculations 10
2.3 Energy Balances 19
2.4 Enthalpy Changes Accompanying Chemical Reactions 21
2.5 Heat Changes in Mixing Processes 27
Exercises 32
References 37

10

3. Process Engineering
3.1 Introduction 38
3.2 Examples of Alternative Routes in Process Engineering 38
3.3 Generalized Approach to the Chemical Plant Design 39
3.4 Preparation of Operating Instructions Manual 45
3.5 Conductance of Performance Test Runs 46
3.6 Troubleshooting 47
3.7 Cost Cutting Measures 47
3.8 Green Engineering 48
3.9 Process Intensification 50
3.10 Conclusion 52
Exercises 52
References 53

38

vi

Contents

4. Importance of Process Diagrams in Process Engineering

4.1
Introduction 54
4.2
Need for PFD and P&ID 54
4.3
Block Diagrams 55
4.4
Development and Utility of Process Flow Diagrams 55
4.5
Development of Piping and Instrumentation Diagrams 60
4.6
Conclusion 67
Exercises 67
References 69

54

5. Process Design of Piping, Fluid Moving Devices and Flow Meters

5.1
Introduction 70
5.2
Process Design of Piping 70
5.3
Process Design of Fluid Moving Devices 83
5.4
Evaluation of Centrifugal Pump Performance
when Handling Viscous Liquids 101
5.5
Power Required in Fan, Blower and in
Adiabatic Compressor 105
5.6
Flow Meters 110
5.7
Process Design of Orifice Meter 115
5.8
Process Design of Rotameter 119
5.9
Two Phase Flow 127
5.10 Troubleshooting of Fluid Flow Systems 130
Exercises 130
References 133

70

6. Process Design of Heat Exchangers

6.1
Shell and Tube Heat Exchanger 134
6.2
Design of Heat Exchangers 137
6.3
General Design Method for Shell and Tube Heat Exchanger
6.4
Criteria of Selection between Horizontal Condenser and
Vertical Condenser 182
6.5
Condensation with Non-condensables 192
6.6
Multicomponent Condensation 200
6.7
Process Design of Reboilers and Vaporizers 217
6.8
Tinkers Flow Model 247
6.9
Air Cooled Heat Exchangers and Air Heaters 249
6.10 Plate Heat Exchangers 270
6.11 Spiral Flow Heat Exchangers 281
6.12 Brazed Aluminium Plate-fin Heat Exchanger 294
6.13 Heat Exchanger Networking for Energy Integration 295
6.14 Heat Transfer in Solids 311
Exercises 321
References 324
7. Design of LiquidLiquid Extractor
7.1
Introduction 325
7.2
Important Industrial Applications of LiquidLiquid
Extraction 326

134
155

325

Contents

7.3
7.4
7.5
7.6
7.7

vii

Phase Equilibrium 326

Desirable Solvent Properties or Choice of Solvent 327
Design of Counter Current Multistage Extractor 329
Industrially Important Extractors 342
Supercritical Extraction (SCE) 364
Exercises 375
References 377

8. Process Design of Distillation Columns

8.1 Introduction 378
8.2 Criteria of Selection 378
8.3 Selection of Equipment for Distillation 379
8.4 Distillation Column Design 380
8.5 Batch Distillation 475
8.6 Short Path Distillation 493
8.7 Reactive and Catalytic Distillation 501
8.8 Azeotropes and Separation Thereof 512
8.9 Energy Conservation in Distillation 538
Exercises 556
References 565

378

9. Process Design of Absorbers

9.1 Introduction 567
9.2 Criteria of Selection 568
9.3 Design of Packed Tower Type Absorber 569
9.4 Process Design of Spray Chamber or Spray Tower Type
Absorber 606
9.5 Venturi Scrubber 611
9.6 Process Design of Falling Film Absorber 615
Exercises 654
References 656

567

10. Process Design of Reactors

10.1 Introduction 657
10.2 Different Types of Reactors 657
10.3 Batch Reactor 658
10.4 Continuous Flow Reactors 671
10.5 Degree of Completion of Reaction 682
10.6 Mixing for the Different Type of Reaction Systems 684
10.7 Bubble Column Reactor 697
10.8 Design of Fixed Catalyst Bed Reactors for Gaseous Reactions
Exercises 725
References 728

657

713

Appendix 1

Conversion Tables

730

Appendix 2

Viscometer Conversion Chart

735

Index

736