Ludwig's Applied Process Design for Chemical and Petrochemical Plants Incorporating Process Safety Incidents, Fifth Edition, Volume One is ever evolving and provides improved techniques and fundamental design methodologies to guide the practicing engineer in designing process equipment and applying chemical processes to properly detailed hardware. Like its predecessor, this new edition continues to present updated information for achieving optimum operational and process conditions and avoiding problems caused by inadequate sizing and lack of internally detailed hardware. The volume provides both fundamental theories, where applicable, and direct application of these theories to applied equations essential in the design effort. This approach in presenting design information is essential for troubleshooting process equipment and in executing system performance analysis. Volume 1 covers process planning, flow-sheeting, scheduling, cost estimation, economic factors, physical properties of liquids and gases, fluid flow, mixing of liquids, mechanical separations, process safety, pressure-relieving devices, metallurgy and corrosion, and process optimization. The book builds upon Ludwig's classic text to further enhance its use as a chemical engineering process design manual of methods and proven fundamentals. This new edition includes new content on three-phase separation, ejectors and mechanical vacuum systems, process safety management, HAZOP and hazard analyses, and optimization of chemical process/blending. ? Provides improved design manual for methods and proven fundamentals of process design with related data and charts? Covers a complete range of basic day-to-day petrochemical operation topics. Extensively revised with new materials on Non-Newtonian fluids, homogeneous and heterogeneous flow, and pressure drop, ejectors, phase separation, metallurgy and corrosion and optimization of chemical process/blending? Presents many examples using Honeywell UniSim Design software, developed and executable computer programs, and Excel spreadsheet programs? Includes case studies of process safety incidents, guidance for troubleshooting, and checklists? Includes Software of Conversion Table and 40+ process data sheets in excel format

Ludwig's Applied Process Design for Chemical and Petrochemical Plants Incorporating Process Safety Incidents is ever evolving starting with the first edition some 60 years ago. The volumes in this fifth edition provide improved techniques and fundamental design methodologies to guide the practicing engineer in designing process equipment and applying chemical processes to the properly detailed hardware. As indicative of the new title, process safety incidents are incorporated in many of the chapters, reviewing the root causes, and how these could be mitigated in future. Like its predecessor, this new edition continues to present updated information for achieving optimum operational and process conditions and to avoid problems caused by inadequate sizing and lack of internally detailed hardware. The volumes provide both fundamental theories where applicable and direct application of these theories to applied equations essential in the design effort. This approach in presenting design information is essential for troubleshooting process equipment and in executing system performance analysis. Volume 1B continues to cover mixing of liquids, process safety and pressure[1]relieving devices, metallurgy and corrosion, and process optimization. It builds upon Ernest E. Ludwig's classic text to further enhance its use as a chemical engineering process design manual of methods and proven fundamentals. This new edition includes new content on three-phase separation, mixing of liquids, ejectors, and mechanical vacuum systems, process safety and pressure-relieving devices, metallurgy and corrosion, and optimization of chemical process/blending. Some chapters review pressure-relieving devices and provide case studies for process safety incidents, which are well illustrated from US Chemical Safety Hazard Investigation Board (www.csb.gov). Finally, this book contains a glossary of Petroleum and Petrochemical Terminologies and Physical and Chemical Characteristics of Major Hydrocarbons.? Provides improved design manual for methods and proven fundamentals of process design with related data and charts? Covers complete range of basic day-to-day petrochemical operation topics? Extensively revised with new material added on three-phase separation, metallurgy, and corrosion? Process safety management/HAZOP and hazard analyses, and optimization of chemical process/blending? Presents many examples using Honeywell UniSim Design software, developed and executable computer programs, and Excel spreadsheet programs? Includes case studies of process safety incidents, guidance for troubleshooting, and checklists? Includes Software of Conversion Table and 30+ process data sheets in excel format

Chemical Engineering Design, Second Edition, deals with the application of chemical engineering principles to the design of chemical processes and equipment. Revised throughout, this edition has been specifically developed for the U.S. market. It provides the latest US codes and standards, including API, ASME and ISA design codes and ANSI standards. It contains new discussions of conceptual plant design, flowsheet development, and revamp design; extended coverage of capital cost estimation, process costing, and economics; and new chapters on equipment selection, reactor design, and solids handling processes. A rigorous pedagogy assists learning, with detailed worked examples, end of chapter exercises, plus supporting data, and Excel spreadsheet calculations, plus over 150 Patent References for downloading from the companion website. Extensive instructor resources, including 1170 lecture slides and a fully worked solutions manual are available to adopting instructors. This text is designed for chemical and biochemical engineering students (senior undergraduate year, plus appropriate for capstone design courses where taken, plus graduates) and lecturers/tutors, and professionals in industry (chemical process, biochemical, pharmaceutical, petrochemical sectors). New to this edition: - Revised organization into Part I: Process Design, and Part II: Plant Design. The broad themes of Part I are flowsheet development, economic analysis, safety and environmental impact and optimization. Part II contains chapters on equipment design and selection that can be used as supplements to a lecture course or as essential references for students or practicing engineers working on design projects. - New discussion of conceptual plant design, flowsheet development and revamp design - Significantly increased coverage of capital cost estimation, process costing and economics - New chapters on equipment selection, reactor design and solids handling processes - New sections on fermentation, adsorption, membrane separations, ion exchange and chromatography - Increased coverage of batch processing, food, pharmaceutical and biological processes - All equipment chapters in Part II revised and updated with current information - Updated throughout for latest US codes and standards, including API, ASME and ISA design codes and ANSI standards - Additional worked examples and homework problems - The most complete and up to date coverage of equipment selection - 108 realistic commercial design projects from diverse industries - A rigorous pedagogy assists learning, with detailed worked examples, end of chapter exercises, plus supporting data and Excel spreadsheet calculations plus over 150 Patent References, for downloading from the companion website - Extensive instructor resources: 1170 lecture slides plus fully worked solutions manual available to adopting instructors

This expanded edition introduces new design methods and is packed with examples, design charts, tables, and performance diagrams to add to the practical understanding of how selected equipment can be expected to perform in the process situation. A major addition is the comprehensive chapter on process safety design considerations, ranging from new devices and components to updated venting requirements for low-pressure storage tanks to the latest NFPA methods for sizing rupture disks and bursting panels, and more.*Completely revised and updated throughout*The definative guide for process engineers and designers*Covers a complete range of basic day-to-day operation topics

There is a renaissance that is occurring in chemical and process engineering, and it is crucial for today's scientists, engineers, technicians, and operators to stay current. With so many changes over the last few decades in equipment and processes, petroleum refining is almost a living document, constantly needing updating. With no new refineries being built, companies are spending their capital re-tooling and adding on to existing plants. Refineries are like small cities, today, as they grow bigger and bigger and more and more complex. A huge percentage of a refinery can be changed, literally, from year to year, to account for the type of crude being refined or to integrate new equipment or processes. This book is the most up-to-date and comprehensive coverage of the most significant and recent changes to petroleum refining, presenting the state-of-the-art to the engineer, scientist, or student. Useful as a textbook, this is also an excellent, handy go-to reference for the veteran engineer, a volume no chemical or process engineering library should be without. Written by one of the world's foremost authorities, this book sets the standard for the industry and is an integral part of the petroleum refining renaissance. It is truly a must-have for any practicing engineer or student in this area.

On August 28, 2008, at about 10:35 p.m., a runaway chemical reaction occurred inside a 4,500 gallon pressure vessel known as a residue treater, causing the vessel to explode violently in the methomyl unit at the Bayer CropScience facility in Institute, West Virginia. Highly flammable solvent sprayed from the vessel and immediately ignited, causing an intense fire that burned for more than 4 hours. The fire was contained inside the Methomyl-Larvin insecticide unit by the Bayer CropScience fire brigade with mutual aid assistance from local volunteer and municipal fire departments. The incident occurred during the restart of the methomyl unit after an extended outage to upgrade the control system and replace the original residue treater vessel. Two company employees who had been dispatched by the control room personnel to investigate why the residue treater pressure was increasing were near the residue treater when it ruptured. One died from blunt force trauma and burn injuries sustained at the scene; the second died 41 days later at the Western Pennsylvania Burn Center in Pittsburgh, Pennsylvania. Six volunteer firefighters who assisted in the unit fire suppression activities and two contractors working at the facility were treated for possible toxic chemical exposure. The Kanawha-Putnam County Emergency Management Director advised more than 40,000 residents, including the resident students at the West Virginia State University adjacent to the facility, to shelter-in-place for more than three hours as a precaution. The fire and drifting smoke forced the state police and local law enforcement authorities to close roads near the facility and the interstate highway, which disrupted traffic for hours. The Chemical Safety Board (CSB) investigation team determined that the runaway chemical reaction and loss of containment of the flammable and toxic chemicals resulted from deviation from the written start-up procedures, including bypassing critical safety devices intended to prevent such a condition. Other contributing factors included an inadequate pre-startup safety review; inadequate 1 operator training on the newly installed control system; unevaluated temporary changes, malfunctioning or missing equipment, misaligned valves, and bypassed critical safety devices; and insufficient technical expertise available in the control room during the restart. Poor communications during the emergency between the Bayer CropScience incident command and the local emergency response agency confused emergency response organizations and delayed public announcements on actions that should be taken to minimize exposure risk. Although Bayer CropScience reported that “no toxic chemicals were released because they were consumed in the intense fires,” the CSB later confirmed that the only air monitors suitably placed near the unit to detect toxic chemicals were, in fact, not operational at the time of the incident. No reliable data or analytical methods were available to determine what chemicals were released, or predict any exposure concentrations. The methomyl unit used the highly toxic chemical, methyl isocyanate (MIC), in a series of complex chemical reactions to produce methomyl, a dry chemical used to make the pesticide, Larvin. MIC is manufactured in a separate production unit at the facility and stored in large underground pressure vessels. Liquid MIC was pumped to a “day tank” pressure vessel near the Methomyl-Larvin unit, which provided the daily production quantity of MIC for the methomyl unit and the carbofuran unit, which is about 200 feet west of the methomyl unit. The MIC storage tank adjacent to the methomyl unit and the MIC transfer piping between the production unit and the manufacturing units were not damaged, nor did the MIC storage tank overheat or pressurize above the operating limits during the fire.