Changes in the 2^nd Edition

Based on feedback from colleagues and students, we have revised the latest edition of our textbook Analysis, Synthesis, and Design of Chemical Processes (http://vig.prenhall.com/catalog/academic/product/1,4096,0130647926,00.html) to incorporate the following:

• Chapter 0 on Outcomes assessment addresses the subject from both student and faculty perspectives, including the relationship issues relating to the ABET EC- 2000 criteria for accreditation of engineering programs in the US.

• The material in Chapter 1 on process diagrams has been expanded to include some preliminary plant layout information. The topology of the chemical plant is introduced with the help of 3 -dimensional graphics tools. A digital "movie" is included in on the CD accompanying the book that gives a "virtual plant tour" of a simple chemical process.

  View a Section of the Virtual Plant Tour
  

• Material on the structure, synthesis, and conceptual design of chemical processes is added in the new Chapter 2. The hierarchical approach to conceptual design is presented with several examples.

• The chapter on capital cost estimation (new Chapter 5) has been revised and new capital cost estimates for process equipment are presented (in Appendix A) that are based on an extensive survey of equipment manufacturers carried out during 2001.

• The CAPCOST program for estimating the fixed capital cost of building a new chemical plant has been revised extensively. The program is now written in the form of a Microsoft^© Excel^TM template. The new capital costs from Chapter 5 and Appendix A are included. In addition, a full financial analysis including operating costs, raw material costs, cash flow diagrams, and a Monte Carlo simulation feature are included.

  Preview Capcost Help Movies

• Detailed calculations on how to estimate utility costs are included in the new Chapter 6 (old Chapter 3). Raw material costs and fuel costs have also been updated.

• The latest tax code information and details of the Modified Accelerated Cost Recovery System (MACRS) method of depreciation are included in Chapter 7 (old Chapter 4).

• A new section has been added to Chapter 8 (old Chapter 5) on how to quantity risk and the application of probabilistic (Monte Carlo) techniques to the evaluation of project profitability.

  Preview Monte Carlo Option in Capcost

• The chapter detailing the synthesis of a process, Chapter 10 (old Chapter 17), has been expanded. Specifically, the section on separation sequencing has been greatly enhanced. Examples of alternative distillation sequences for both non-azeotropic systems and azeotropic systems are discussed. A qualitative description of the use of residual curve analysis and its application to azeotropic systems has been included.

• The section detailing the choice of which thermodynamic package to use in a simulation has been expanded and several examples of how and when to use different thermodynamic options is are covered in Chapter 11 (old Chapter 18).

• The old Chapter 18 on optimization has been split into two Chapters (12 and 13).

• Chapter 12 covers the overall process optimization.

• Chapter 13 covers the area of Pinch Technology. The heat exchanger networks (HENs) section has been expanded to cover issues relating to the estimation of heat exchanger surface area for the network and the effect of materials of construction on the cost of the network. The design of Mass Exchanger Networks that parallels the design of HENs and has been added to this chapter.

• New software HENSAD (Heat Exchanger NetworkSynthesisAnalysis and Design) is provided on the CD accompanying the textbook. This software allows the user to construct temperature interval, cascade, temperature-enthalpy diagrams, estimate the optimal approach temperature, and design HENs.

  View a Preview of the HENSAD Program

• The Chapters of on Ethics (21) and Safety (22) have been updated to include current web sites and additional examples have been added.

• The new Chapter 23 gives a brief introduction to green engineering design methods. The pollution prevention hierarchy is introduced. Green chemistry principles are presented, and flowsheet analysis for pollution prevention is discussed. Examples of the economics of pollution prevention activities and the life cycle analysis module, previously in old Chapter 21 (new Chapter 22) are presented.

• Chapter 24 introduces the topic of chemical product design. This subject is defined to include application of chemical engineering principles to the development of new devices, development of new chemicals, development of new processes to produce these new chemicals, and development of marketable technology. Examples from our experience with class assignments involving chemical product design are included.

• Chapter 25 covers the essential elements of team building and teamwork. The reader is guided though the essential stages of team work in the context of a design assignment. Choice of group members, initial organization determination, roles within and outside the group, group management, team building, team member roles and responsibilities, and team self-evaluation are described. References to the most accessible team-building literature are given. Examples of problems typically encountered by poorly functioning teams are included.

  As a result of our integrated approach to design, and in response to feedback on the first edition, we have rearranged and modularized this book into six sections. These sections are

  Section 1 - Conceptualization and Analysis of Chemical Processeses

  Section 2 - Engineering Economic Analysis of Chemical Processeses

  Section 3 - Synthesis and Optimization of a Chemical Processeses

  Section 4 - Analysis of System Process Performance

  Section 5 - The Impact of Chemical Engineering Design on Society

  Section 6 - Interpersonal and Communication Skills

  This reorganization of material gives provides a more logical ordering of topics. In Section 1, the student is introduced first to the principal diagrams that are used to describe a chemical process. Next, the evolution and generation of different process configurations is are covered. and Ffinally, the analysis of existing processes is covered. In Section 2, the information needed to assess the economic feasibility of a process is covered. This includes the estimation of fixed capital investment and manufacturing costs, the concepts of the time value of money and financial calculations, and finally the combination of these costs into profitability measures for the process. Section 3 covers the synthesis of a chemical process. The minimum information required to simulate a process is given, as are the basics of using a process simulator. The choice of the appropriate thermodynamic model to use in a simulation is covered and the choice of separation operations is covered. In addition, process optimization and heat integration techniques are covered in this section. In Section 4, the analysis of the performance of existing processes and equipment is covered. The material in Section 4 is substantially different from that found in most textbooks. We consider equipment that is already built and operating and analyze how the operation can be changed, how an operating problem may be solved, and how to analyze what has occurred in the process to cause an observed change. In Section 5, the impact of chemical engineering design on society is covered. The role of the professional engineer in society is addressed. Separate chapters addressing ethics and professionalism, health, safety, and the environment, green engineering, and chemical product design are givenincluded. Finally, in Section 6, the interpersonal skills required by the engineer to function as part of a team and to communicate both orally and written are covered. An entire chapter is devoted to addressing some of the common mistakes that students make in written reports.

  Finally, two appendices are included. Appendix A gives a series of cost charts for equipment. This information is embedded in the CAPCOST^© program for evaluating fixed capital investments and process economics. Appendix B gives the preliminary design information for four chemical processes: dimethyl ether, acrylic acid, acetone, and heptenes production. This information is used in many of the end-of-chapter problems in the book. These processes can also be used as the starting point for more detailed analyses, for example, optimization studies. Other projects are included on the CD accompanying this book. The reader (faculty and students) is also referred to our web site at http://www.che.cemr.wvu.edu/publications/projects/index.php, where a variety of design projects for sophomore- through senior-level chemical engineering courses are provided. There is also a link to another web site that contains environmentally related design projects.

  Corrections to the 2^nd Edition

  For a list of Corrections to the 2^nd Edition, Click here

  For educational resources (Powerpoint Presentations on Book Material), Click here

  Other Design Projects

  For a variety of design projects suitable for sophomore, junior, and senior courses click here:

  For a list of environmentally related design projects click here: