PLANT DESIGN AND ECONOMICS FOR CHEMICAL ENGINEERS PDF

Preview

Summary

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 Matt...

Description

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 Engineering 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 chemistry, 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, Ddhn Ethykne

+ Cl, -. CH2CICH,CI chlorioc

Ethykne

dichlorii

+ S DolLn

‘Ike complete plant-the complete economic process. Here is the design en@neer’s goal. (C. F. Bruun and Co.)

PLANT DESIGN AND ECONOMICS FOR CHEMICAL ENGINEERS Fourth Edition

Max S. Peters Klaus D. Timmerhaus Professors

:I, !‘. :’J. , $’

of Chemical Engineering University of Colorado

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 S i n g a p o r e S y d n e y T o k y o T o r o n t o

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. cm.-(McGraw-Hill chemical engineering series) P. 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 Pennsylvania 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 followed 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 Engineering 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

Xi xv 1

2 Process Design Development

13

3 General Design Considerations

47

Computer-Aided Design

110

5 Cost and Asset Accounting

137

6

150

4

Cost Estimation

7 Interest and Investment Costs

216

8 Taxes and Insurance

253

9 Depreciation

267

10 Profitability, Alternative Investments, and Replacements

295

11

Optimum Design and Design Strategy

341

12

Materials Selection and Equipment Fabrication

421

ix

X

CONTENTS

13

The Design Report

452

14

Materials Transfer, Handling, and Treatment Equipment-Design and Costs

478

15

Heat-Transfer Equipment-Design and Costs

579

16

Mass-Transfer and Reactor Equipment-Design and Costs

649

17

Statistical Analysis in Design

740

Appendixes A B C D

The International System of Units 61) Auxiliary, Utility, and Chemical Cost Data Design Problems Tables of Physical Properties and Constants

778 800 817 869

Indexes Name Index Subject Index

893 897

PREFACE

,

Advances in the level of understanding of chemical engineering principles, combined with the availability of new tools and new techniques, have led to an increased degree of sophistication which can now be applied to the design of industrial chemical operations. This fourth edition takes advantage of the widened spectrum of chemical engineering knowledge by the inclusion of considerable material on profitabilty evaluation, optimum design methods, continuous interest compounding, statistical analyses, cost estimation, and methods , for problem solution including use of computers. Special emphasis is placed on the economic and engineering principles involved in the design of chemical plants and equipment. An understanding of these principles is a prerequisite for any successful chemical engineer, no matter whether the final position is in direct design work or in production, administration, sales, research, development, or any other related field. The expression plant design immediately connotes industrial applications; consequently, the dollar sign must always be kept in mind when carrying out the design of a plant. The theoretical and practical aspects are important, of course; but, in the final analysis, the answer to the question “Will we realize a profit from this venture?” almost always determines the true value of-the design. The chemical engineer, therefore, should consider plant design and applied economics as one combined subject. The purpose of this book is to present economic and design principles as applied in chemical engineering processes and operations. No attempt is made to train the reader as a skilled economist, and, obviously, it would be impossible to present all the possible ramifications involved in the multitude of different plant designs. Instead, the goal has been to give a clear concept of the important principles and general methods. The subject matter and manner of presentation are such that the book should be of value to advanced chemical engineering undergraduates, graduate students, and practicing engineers. The xi

xii

PREFACE

information should also be of interest to administrators, operation supervisors, and research or development workers in the process industries. The first part of the text presents an overall analysis of the major factors involved in process .design, with particular emphasis on economics in the process industries and in design work. Computer-aided design is discussed early in the book as a separate chapter to introduce the reader to this important topic with the understanding that this tool will be useful throughout the text. The various costs involved in industrial processes, capital investments and investment returns, cost estimation, cost accounting, optimum economic design methods, and other subjects dealing with economics are covered both qualitatively and quantitatively. The remainder of the text deals with methods and important factors in the design of plants and equipment. Generalized subjects, such as waste disposal, structural design, and equipment fabrication, are included along with design methods for different types of process equipment. Basic cost data and cost correlations are also presented for use in making cost estimates. Illustrative examples and sample problems are used extensively in the text to illustrate the applications of the principles to practical situations. Problems are included at the ends of most of the chapters to give the reader a chance to test the understanding of the material. Practice-session problems, as well as longer design problems of varying degrees of complexity, are included in Appendix C. Suggested recent references are presented as footnotes to show the reader where additional information can be obtained. Earlier references are listed in the first, second, and third editions of this book. A large amount of cost data is presented in tabular and graphical form. The table of contents for the book lists chapters where equipment cost data are presented, and additional cost information on specific items of equipment or operating factors can be located by reference to the subject index. To simplify use of the extensive cost data given in this book, all cost figures are referenced to the all-industry Marshall and Swift cost index of 904 applicable for January 1, 1990. Because exact prices can be obtained only by direct quotations from manufacturers, caution should be exercised in the use of the data for other than approximate cost-estimation purposes. The book would be suitable for use in a one- or two-semester course for advanced undergraduate or graduate chemical engineers. It is assumed that the reader has a background in stoichiometry, thermodynamics, and chemical engineering principles as taught in normal first-degree programs in chemical engineering. Detailed explanations of the development of various design equations and methods are presented. The book provides a background of design and economic information with a large amount of quantitative interpretation so that it can serve as a basis for further study to develop complete understanding of the general strategy of process engineering design. Although nomographs, simplified equations, and shortcut methods are included, every effort has been made to indicate the theoretical background and assumptions for these relationships. The true value of plarj dwign and eco- . z nomics for the chemical engineer is not found merely in the ability to put

P R E F A C EXIII‘-’

numbers ‘in an equation and solve for a final answer. The true value is found in obtaining an understanding of the reasons why a given calculation method gives a satisfactory result. This understanding gives the engineer the confidence and ability necessary to proceed when new problems are encountered for which there are no predetermined methods of solution. Thus, throughout the study of plant design and economics, the engineer should always attempt to understand the assumptions and theoretical factors involved in the various calculation procedures and never fall into the habit of robot-like number plugging. Because applied economics and plant design deal with practical applications of chemical engineering principles, a study of these subjects offers an ideal way for tying together the entire field of chemical engineering. The final result of a plant design may be expressed in dollars and cents, but this result can only be achieved through the application of various theoretical principles combined with industrial and practical knowledge. Both theory and practice are emphasized in this book, and aspects of all phases of chemical engineering are included. The authors are indebted to the many industrial firms and individuals who have supplied information and comments on the material presented in this edition. The authors also express their appreciation to the following reviewers who have supplied constructive criticism and helpful suggestions on the presentation for this edition: David C. Drown, University of Idaho; Leo J. Hirth, Auburn University; Robert L. Kabel, Permsylvania State University; J. D. Seader, University of Utah; and Arthur W. Westerberg, Carnegie Mellon University. Acknowledgement is made of the contribution by Ronald E. West, Professor of Chemical Engineering at the University of Colorado, for the new Chapter 4 in this edition covering computer-aided design. Max S. Peters Klaus D. Timmerhaus

-

PROLOGUE

THE INTERNATIONAL SYSTEM OF UNITS 61) As the United States moves toward acceptance of the International System of Units, or the so-called SI units, it is particularly important for the design engineer to be able to think in both the SI units and the U.S. customary units. From an international viewpoint, the United States is the last major country to accept SI, but it will be many years before the U.S. conversion will be sufficiently complete for the design engineer, who must deal with the general public, to think and write solely in SI units. For this reason, a mixture of SI and U.S. customary units will be found in this text. For those readers who are not familiar with all the rules and conversions for SI units, Appendix A of this text presents the necessary information. This appendix 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 with SI.

CHAPTER

INTRODUCTION

In this modern age of industrial competition, a successful chemical engineer needs more than a knowledge and understanding of the fundamental sciences and the related engineering subjects such as thermodynamics, reaction kinetics, and computer technology. The eng...