Page 8 - Design of Simple and Robust Process Plants

Contents IX
5 Process Simplification and Intensification Techniques 143
5.1 Introduction 143
5.2 Avoidance or Elimination of Process Functions 145
5.2.1 Tanks and Vessels 145
5.2.2 Transport of Fluids 146
5.2.3 Recovery Systems 146
5.3 Combination of Process Functions 147
5.3.1 Reaction 148
5.3.2 Distillation 152
5.3.3 Extraction, Evaporation, Extrusion 159
5.3.4 Furnaces 162
5.4 Integration of Process Equipment 164
5.5 Intensification of Process Functions 167
5.5.1 Building More Compact Units 168
5.5.2 Increased Heat, Mass and Impulse Transport 170
5.5.3 Benefits from Centrifugal Fields: ªHigeeº 174
5.6 Overall Process Simplification 176
5.6.1 Overall Process Design Improvements 177
5.6.2 Single Train Design 185
5.6.3 Strategy Around Supplies and Storage 186
5.6.4 Strategy Around Single Component Design 187
5.7 Simplification and Ranking per Unit Operation 189
5.7.1 Reactors 190
5.7.2 Distillation and Absorption 198
5.7.3 Liquid±Liquid Extraction 204
5.7.4 Adsorption/Chemisorption 205
5.7.5 Heat Exchange 206
5.7.6 Fluid Transport 207
5.7.7 Piping 207
5.7.8 Instruments 210
5.8 Contradiction between Simplification and Integrated Designs? 213

6 Process Design Based on Reliability 219
6.1 Introduction 219
6.1.1 Reliability Engineering is an Evolution to More Optimal Designs 220
6.2 Basic Theory of Reliability 222
6.2.1 Availability and Unavailability 226
6.2.2 Reliability Data and Distribution 228
6.2.3 Estimation of Failure Parameters 231
6.2.4 Reliability Modeling 232
6.3 Methodology of Reliability Engineering Techniques for
the Design of Process Plants 236
6.4 Application of Reliability Studies for a Process and Utility Plant 239
6.4.1 Application of a Reliability Study for a Continuous Process Plant 239
6.4.2 Application of a Reliability Study for a Utility Steam Plant 241