Principles of Chemical Engineering Practice

Enables chemical engineering students to bridge theory and practice Integrating scientific principles with practical engineering experience, this text enables readers to master the fundamentals of chemical processing and apply their knowledge of such topics as material and energy balances, transport phenomena, reactor design, and separations across a broad range of chemical industries. The author skillfully guides readers step by step through the execution of both chemical process analysis and equipment design. Principles of Chemical Engineering Practice is divided into two sections: the Macroscopic View and the Microscopic View. The Macroscopic View examines equipment design and behavior from the vantage point of inlet and outlet conditions. The Microscopic View is focused on the equipment interior resulting from conditions prevailing at the equipment boundaries. As readers progress through the text, they'll learn to master such chemical engineering operations and equipment as: Separators to divide a mixture into parts with desirable concentrations Reactors to produce chemicals with needed properties Pressure changers to create favorable equilibrium and rate conditions Temperature changers and heat exchangers to regulate and change the temperature of process streams Throughout the book, the author sets forth examples that refer to a detailed simulation of a process for the manufacture of acrylic acid that provides a unifying thread for equipment sizing in context. The manufacture of hexyl glucoside provides a thread for process design and synthesis. Presenting basic thermodynamics, Principles of Chemical Engineering Practice enables students in chemical engineering and related disciplines to master and apply the fundamentals and to proceed to more advanced studies in chemical engineering.

Preface P–1 Part I. Macroscopic View 1–1 1. Chemical Process Perspective 1–1 1.1. Some basic concepts in chemical processing 1–2 1.2. Acrylic acid production 1–6 1.3. Biocatalytic Processes – Enzymatic systems 1–38 1.4 Basic database 1–44 Problems 1–47 2. Macroscopic Mass Balances 2–1 2.1 Chemical Processing Systems 2–2 2.2 Steady state mass balances without chemical reactions 2–29 2.2.1 Degrees of freedom 2–30 2.3.1 Degrees of freedom: reaction rate and key component 2–42 2.4 Steady state mass balances with multiple chemical reactions 2–53 Problems 2–68 3. Macroscopic Energy and Entropy Balances 3–1 3.1 Basic thermodynamic functions 3–2 3.2 Evaluation of H and S for pure materials 3–9 3.3 Evaluation of H and S Functions for Mixtures 3–22 3.4 Energy flows and the First Law 3–32 3.5 Energy Balances without Reaction 3–37 3.6 Energy Balances with reaction– ideal solution 3–54 3.7 Entropy balances 3–78 3.7.4.2 Distillation 3–92 Problems 3–97 4. Macroscopic Momentum and Mechanical Energy Balances 4–1 4.1 Momentum balance 4–1 4.2 Mechanical energy balance 4–7 4.3 Applications to incompressible flow systems 4–9 Problems 4–28 5. Completely Mixed Systems Equipment Considerations 5–1 5.1 Mixing and residence time distributions–definitions 5–2 5.2 Measurement and interpretation of residence time distributions 5–6 5.3 Basic aspects of stirred tank design 5–13 Problems 5–31 6. Separation and reaction processes in completely mixed systems 6–1 6.1 Phase equilibrium: single stage separation operations 6–1 6.2 Gas liquid operations 6–7 6.3 Flash vaporization 6–67 6.4 Liquid–liquid extraction 6–99 6.5 Adsorption 6–121 6.6. Single phase stirred tank reactors 6–141 6.7 Chemical reaction equilibrium 6–184 Problems 6–199 Part II. Microscopic View 7–1 7. Multistage Separation and Reactor Operations 7–1 7.1 Absorption and stripping 7–3 7.2 Distillation 7–28 7.3 Liquid Liquid Extraction 7–81 7.4 Multiple reactor stages 7–104 7.5 Staged fixed bed converters for exothermic gas phase reaction 7–115 Problems 7–121 8. Microscopic Equations of Change 8–1 8.1 Mass Flux: Average velocities and diffusion 8–3 8.2 Momentum flux: Stress tensor 8–18 8.3 Energy flux: Conduction 8–23 8.4 Balance equations 8–26 8.5 Entropy Balance and Flux Expressions 8–37 8.6 Turbulence 8–83 8.7 Application of Balance Equations 8–92 Problems 8–115 9. Nonturbulent Isothermal Momentum Transfer 9–1 9.1 Rectangular models 9–4 9.2 Cylindrical systems 9–10 9.4 Spherical systems 9–33 9.5 Microfluidics – gas phase systems 9–42 Problems 9–56 10. Nonturbulent Isothermal Mass Transfer 10–1 10.1 Membranes 10–3 10.2 Diffusion models for porous solids 10–31 10.3 Heterogeneous catalysis 10–42 10.4 Transient adsorption by porous solid 10–55 10.5 Diffusion with Laminar flow 10–63 Problems 10–76 11. Energy Transfer under Non–turbulent Conditions 11–1 11.1 Conduction in solids – composite walls 11–3 11.2 Thermal effects in porous catalysts 11–10 11.3 Heat transfer to falling film–short contact times 11–19 11.4 Moving boundary problem 11–24 Problems 11–30 12. Isothermal Mass Transfer under Turbulent Conditions 12–1 12.1 Intraphase mass transfer coefficients 12–1 12.2 Interphase mass transfer coefficients– Controlling resistances 12–10 12.3 Measurement and correlation of mass transfer coefficients 12–13 12.4 Fixed bed 12–21 12.5 Pipes 12–28 12.6 Particles, drops, and bubbles in agitated systems 12–33 12.7 Packed towers– gas absorption 12–40 12.8 Applification of experimental mass transfer coefficients 12–66 Proble m s 12–92 13. Interphase Momentum Transfer under Turbulent Conditions 13–1 13.1 Pressure drop in conduits and fixed beds 13–3 13.2 Flow over submerged spheres 13–30 Problems 13–46 14. Interphase Energy Transfer under Turbulent Conditions 14–1 14.1 Heat transfer coefficients analogy with mass transfer 14–1 14.2 Heat exchangers 14–4 14.3 Multi–tubular catalytic reactors 14–33 Problems 14–44 15. Microscopic to Macroscopic 15–1 15.1 Macroscopic mass balance 15–3 15.2 Macroscopic energy balance 15–6 15.3 Macroscopic mechanical energy balance 15–10 Problems 15–16 Appendix A: Periodic table A–1 Appendix B: Conversion factors B–1 Appendix C: Partial database for acrylic acid process C–1 Appendix D: Some mathematical results D–1 Appendix E: Mass balance in cylindrical coordinates and laminar flow in z direction E–1 Nomenclature N–1 Thermodynamic T–1 References R–1 Index I–1

GEORGE DeLANCEY, PhD, is Professor Emeritus in the Department of Chemical Engineering and Materials Science at Stevens Institute of Technology. He has more than forty years experience in chemical engineering education, having taught process analysis and process control in the undergraduate school. He has twice been the recipient of the Outstanding Teacher Award at Stevens. He has served as Senior Academic Advisor to the International Programs Office at Stevens with curriculum development responsibilities in gas and plastics engineering and technology programs at the Algerian Petroleum Institute. Dr. DeLancey has more than thirty publications in the areas of multicomponent mass and energy transfer with chemical reaction, interfacial mass and energy transfer in gas–liquid systems, and chemical engineering education and assessment.