过程设计原理：合成、分析和评估

Part one Process invention-heuristics and analysis
1.TheDesignProcess3
1.0Objectives3
1.1PrimitiveDesignProblems3
TypicalPrimitiveDesignProblem5
ProcessDesignTeam5
IndustrialConsultants5
1.2StepsinDesigningandRetrofittingChemical
Processes6
AssessPrimitiveProblem6
SurveyLiterature8
ProcessCreation10
DevelopmentofBaseCase10
DetailedProcessSynthesisUsingAlgorithmic
Methods11
PlantwideControllabilityAssessment11
DetailedDesign，EquipmentSizingandCost
Estimation，ProfitabilityAnalysis，and
Optimization12
WrittenProcessDesignReportandOral
Presentation12
FinalDesign，Construction，Start-up，and
Operation12
Summary13
1.3EnvironmentalProtection13
EnvironmentalIssues13
EnvironmentalFactorsinProcessDesign15
EnvironmentalDesignProblems18
1.4SafetyConsiderations19
SafetyIssues19
DesignApproachesTowardSafeChemical
Plants22
1.5EngineeringEthics23
1.6RoleofComputers27
Spreadsheets28
MathematicalPackages28
ProcessSimulators28
ComputationalGuidelines30
1.7Summary30
References31
2.ProcessCreation32
2.0Objectives32
2.1Introduction32
2.2PreliminaryDatabaseCreation32
ThermophysicalPropertyData33
EnvironmentalandSafetyData37
ChemicalPrices37
Summary38
2.3Experiments38
2.4PreliminaryProcessSynthesis38
ContinuousorBatchProcessing39
ChemicalState41
ProcessOperations42
SynthesisSteps44
ExampleofProcessSynthesis：Manufactureof
VinylChloride45
SynthesisTree56
Heuristics56
AlgorithmicMethods57
2.5DevelopmentoftheBase-CaseDesign57
DetailedProcessFlowsheet57
ProcessIntegration60
DetailedDatabase60
Pilot-PlantTesting61
ProcessSimulation62
2.6Summary62
References62
Exercises63
3.SimulationtoAssistinProcess
Creation64
3.0Objectives64
3.1Introduction65
3.2PrinciplesofFlowsheetSimulation66
ProcessandSimulationFlowsheets66
UnitSubroutines77
CalculationOrder79
Recycle79
RecycleConvergenceMethods87
FlashwithRecycleProblem89
DegreesofFreedom90
ControlBlocksTDesignSpecifications91
FlashVesselControl94
BidirectionalInformationFlow（HYSYS）94
3.3SynthesisoftheTolueneHydrodealkylation
Process98
ProcessSimulation101
3.4SimulationoftheMonochlorobenzene
SeparationProcess104
UseofProcessSimulators105
3.5Summary106
References107
Exercises107
4.HeuristicsforProcessSynthesis112
4.0Objectives112
4.1Introduction113
4.2RawMaterialsandChemicalReactions114
4.3DistributionofChemicals116
InertSpecies117
PurgeStreams119
RecycletoExtinction122
Selectivity123
ReactiveSeparations125
4.4Separations126
4.5HeatRemovalfromandAdditionto
Reactors128
HeatRemovalfromExothermic
Reactors128
HeatAdditiontoEndothermicReactors131
4.6PumpingandCompression132
4.7Summary134
References134
Exercises135
PartTwoDETAILEDPROCESSSYNTHESIS-ALGORITHMICMETHODS
5.SynthesisofSeparationTrains141
5.0Objectives141
5.1Introduction141
5.2CriteriaforSelectionofSeparation
Methods145
5.3SelectionofEquipment148
5.4SequencingofOrdinaryDistillation
Columns150
5.5SequencingofGeneralVapor-Liquid
SeparationProcesses156
5.6SequencingofAzeotropicDistillation
Columns170
AzeotropyandPolyazeotropy170
ResidueCurves175
DistillationTowers178
SeparationTrainSynthesis188
5.7SeparationSystemsforGasMixtures194
MembraneSeparationbyGas
Permeation197
Adsorption197
Absorption198
PartialCondensationandCryogenic
Distillation199
5.8SeparationSequencingforSolid-Fluid
Systems199
5.9Summary201
References201
Exercises202
6.SecondLawAnalysis207
6.0Objectives207
6.1Introduction207
6.2TheSystemandtheSurroundings210
6.3EnergyTransfer212
6.4ThermodynamicProperties213
6.5EquationsforSecondLawAnalysis215
6.6ExamplesofLost-WorkCalculations219
6.7ThermodynamicEfficiency222
6.8CausesofLostWork223
6.9ThreeExamplesofSecondLaw
Analysis224
6.10Summary237
References237
Exercises238
7.HeatandPowerIntegration243
7.0Objectives243
7.1Introduction244
HeatIntegrationSoftware247
7.2MinimizingUtilitiesinHeatIntegration247
Temperature-IntervalMethod248
UsingGraphicalDisplays251
LinearProgrammingMethod254
7.3StreamMatchingatMinimumUtilities256
StreamMatchingatthePinch256
StreamMatchingUsingaMixed-Integer
LinearProgram263
7.4MinimumNumberofHeat
Exchangers--BreakingHeatLoops267
7.5OptimumApproachTemperature271
7.6SuperstructuresforMinimizationof
AnnualizedCost274
7.7Heat-IntegratedDistillationTrains279
EffectofPressureonHeatIntegration279
Multiple-EffectDistillation281
HeatPumping，VaporReeompression，and
ReboilerFlashing284
SuperstructuresforMinimizationof
AnnualizedCost284
7.8HeatEnginesandHeatPumps286
PositioningHeatEnginesandHeat
Pumps289
OptimalDesign292
7.9Summary295
References295
Exercises296
Partthree detailed design，equipment sizing，economics ，and optimization
8.HeatExchangerDesign303
8.0Objectives303
8.1Introduction303
HeatDuty303
HeatTransferMedia305
Temperature-DrivingForceforHeat
Transfer308
PressureDrop312
8.2EquipmentforHeatExchange312
Double-PipeHeatExchangers312
Shell-and-TubeHeatExchangers314
Air-CooledHeatExchangers319
CompactHeatExchangers320
Temperature-DrivingForcesinShell-and-
TubeHeatExchangers321
8.3HeatTransferCoefficientsandPressure
Drop326
EstimationofOverallHeatTransfer
Coefficients327
EstimationofIndividualHeatTransfer
CoefficientsandFrictionalPressure
Drop327
TurbulentFlowinStraight，SmoothDucts，
Pipes，andTubesofCircularCross
Section329
TurbulentFlowintheAnnularRegion
BetweenStraight，Smooth，ConcentricPipes
ofCircularCrossSection331
TurbulentFlowontheShellSideofShell-and-
TubeHeatExchangers331
HeatTransferCoefficientsforLaminar-Flow，
Condensation，Boiling，andCompactHeat
Exchangers332
8.4DesignofShell-and-TubeHeat
Exchangers333
8.5Summary335
References335
Exercises336
9.CapitalCostEstimation338
9.0Objectives338
9.1Introduction338
9.2CostCharts339
CostIndices342
InstallationCosts342
MaterialsandPressureConsiderations344
EquipmentSizes344
OtherInvestmentCosts345
LangFactorMethod348
9.3Equations348
HeatExchangers348
CylindricalProcessVessels349
Trays349
BlowersandCompressors349
9.4ASPENPLUS351
ProjectDates353
EquipmentLists353
EquipmentSizeandCostSpecifications356
RemainingInvestmentCosts361
CostIndices363
Results364
9.5DetailedCostEstimation368
9.6Summary369
References369
Exercises370
10.ProfitabilityAnalysis374
10.0Objectives374
10.1Introduction374
10.2CostSheet375
10.3TotalCapitalInvestmentandApproximate
ProfitabilityMeasures378
WorkingCapital378
ApproximateProfitabilityMeasures378
10.4TimeValueofMoney384
CompoundInterest384
Annuities386
ComparisonofEquipmentPurchases388
10.5CashFlow391
Depreciation392
ProfitabilityMeasures393
NetPresentValue393
InvestorsRateofReturn394
10.6ASPENPLUS396
CostSheet396
WorkingCapital401
ProfitabilityMeasures401
Results404
10.7DetailedCostEstimation408
10.8Summary408
References409
Exercises409
11.OptimizationofProcessFlowsheets416
11.0Objectives416
11.1Introduction416
11.2NonlinearProgram417
ObjectiveFunction417
EqualityConstraints418
InequalityConstraints418
GeneralFormulation419
11.3OptimizationAlgorithm419
RepeatedSimulation421
InfeasiblePathApproach421
CompromiseApproach422
PracticalAspectsofFlowsheet
Optimization422
11.4FlowsheetOptimizations--Case
Studies423
11.5ASPENPLUS425
EnteringtheNLP425
AdjustingtheSimulationFlowsheet426
11.6Summary433
References433
Exercises433
PartFourPLANTWIDECONTROLLABILITYASSESSMENT
12.InteractionofProcessDesignandProcess
Control439
12.0Objectives439
12.1Introduction439
12.2ControlSystemConfiguration444
ClassificationofProcessVariables444
Degrees-of-FreedomAnalysis446
12.3QualitativePlantwideControlSystem
Synthesis449
12.4Summary454
References456
Exercises456
13.FlowsheetControllabilityAnalysis457
13.0Objectives457
13.1QuantitativeMeasuresforControllability
andResiliency458
Relative-GainArray（RGA）459
DisturbanceCostandDisturbanceCondition
Number467
13.2TowardAutomatedFlowsheetC&R
Diagnosis471
Short-CutC&RDiagnosis471
GeneratingLow-OrderDynamic
Models472
Tutorial：C&RAnalysisforHeat-Integrated
DistillationColumns474
13.3CaseStudies480
13.4MATLABforC&RAnalysis493
13.5Summary496
References496
Exercises497
14.DynamicSimulationofProcess
Flowsheets500
14.0Objectives500
14.1FundamentalConceptsinDynamic
Simulation500
14.2DynamicSimulationUsingHYSYS501
14.3Control-LoopDefinition502
14.4ControllerTuningMethods504
On-LinePIControllerTuning504
Model-BasedPIControllerTuning505
14.5TutorialExercise：ControlofaBinary
DistillationColumn509
14.6CaseStudies522
14.7Summary532
References532
Exercises532
PartFiveDESIGNREPORT15.WrittenProcessDesignReportandOral
Presentation-537
15.0Objectives537
15.1WrittenReport538
SectionsoftheReport538
PreparationoftheWrittenReport543
PageFormat544
SampleDesignReports545
15.2OralDesignPresentation546
TypicalPresentation546
MediaforthePresentation546
RehearsingthePresentation547
WrittenHandout547
EvaluationoftheOralPresentation547
Videotapes549
15.3AwardCompetition549
15.4Summary549
References549
APPENDIXES
I.ASPENPLUSinProcessDesign551
A-I.1ASPENPLUSInputForms551
A-I.2DrawinganASPENPLUSFlowsheet553
A-I.3ASPENPLUSParagraphs553
A-I.4NestedRecycleLoops554
A-I.5DesignSpecifications557
A-I.6InlineFORTRAN559
A-I.7CaseStudy：Monochlorobenzene
SeparationProcess565
ASPENPLUSSimulationFlowsheetand
Input565
InterpretationofProgramOutput565
II.HYSYSinProcessDesign581
A-II.1TheHYSYSModelingEnvironment581
A-II.2Steady-StateSimulation584
AcyclicProcesses584
ProcessesInvolvingRecycle605
Subflowsheets609
MultistageSeparationUsingtheColumn
Subflowsheet609
Optimization618
A-II.3CaseStudy627
References629
I.PhaseEquilibriaandProcessUnit
Models630
A-III.1PhaseEquilibria630
A-III.2FlashVessels630
A-III.3Pumps642
A-III.4CompressorsandExpanders644
A-III.5HeatExchangers646
HeatRequirementModels647
Shell-and-TubeHeatExchangers647
A-III.6ChemicalReactors651
StoichiometricReactorModels652
EquilibriumReactorModels654
KineticReactorModels655
A-III.7Separators666
Split-Fraction（BlackBox）Models667
Distillation：Fenske
（Winn）-Underwood-GillilandShortcut
Design667
Distillation：EdmisterApproximate
GroupMethod672
Distillation：RigorousSimulationUsing
theUnabridgedMESHEquations673
References679
IV.PhysicalPropertyEstimation，Solids
Handling，andElectrolytes680
A-IV.1PhysicalPropertyEstimation680
DataBanks680
PropertyEstimation681
ASPENPLUS686
EstimatingParametersforPure
Species690
SelectionofPropertyEstimationMethods
andPropertyDataRegression692
A-IV.2NonconventionalComponentsand
Substreams698
Substreams700
StreamClasses702
A-IV.3SolidsHandling703
A-IV.4Electrolytes709
ChemicalandPhaseEquilibrium709
ElectrolytesinProcessSimulators716
References720
V.ResidueCurvesforHeterogeneous
Systems722
VI.SuccessiveQuadraticProgramming723
A-VI.1NLPandStationarityConditions723
A-VI.2SolutionoftheStationarity
Equations724
References725
VII.GeneralAlgebraicModelingSystems
（GAMS）726
A-VII.1InputFile727
Statements728
A-VII.2ExpandedFeatures：Documentation，
VariableRedeclaration，and
Display730
A-VII.3ExpandedFeatures：Sets，Tables，
ParametersandScalars，andEquation
Grouping734
A-VII.4Debugging737
References739
VIII.DesignProblemStatements740
A-VIII.0ContentsandIntroduction740
A-VIII.1Petrochemicals742
A-VIII.2PetroleumProducts748
A-VIII.3GasManufacture749
A-VIII.4Foods752
A-VIII.5Pharmaceuticals754
A-VIII.6Polymers755
A-VIII.7Environmental--AirQuality758
A-VIII.8Environmental--Water
Treatment767
A-VIII.9Environmental--SoilTreatment771
A-VIII.10Environmental--Miscellaneous774
IX.DynamicSimulationUsing
DYNAPLUS778
A-IX.1Introduction778
A-IX.2ProcedureforDynamicSimulation779
A-IX.3Control-LoopDefinitionin
DYNAPLUS779
A-IX.4TutorialExercise：ControlofaBinary
DistillationColumn780A-IX.5DynamicSimulationoftheMCB
SeparationProcess791
X.HeuristicsforProcess，Equipment
Design795
CompressorsandVacuumPumps795
ConveyorsforParticulateSolids796
CoolingTowers796
CrystallizationfromSolution797
Disintegration797
DistillationandGasAbsorption798
DriversandPowerRecoveryEquipment799
DryingofSolids799
Evaporators800
Extraction，Liquid-Liquid800
Filtration801
FluidizationofParticleswithGases801
HeatExchangers802
Insulation802
MixingandAgitation803
ParticleSizeEnlargement803
Piping804
Pumps804
Reactors804
Refrigeration805
SizeSeparationofParticles805
Utilities：CommonSpecifications806
Vessels（Drums）806
Vessels（Pressure）806
Vessels（StorageTanks）807
Xl.MaterialsofConstruction808
XILGenerationofLinearModelsin
StandardForms810
AuthorIndex815
SubjectIndex817