Process Design & Development

Understand Pilot-Plant Design Specifications

May
2016
Plant Design
Adam Whalley, P.Eng.,
Although pilot- and commercial-scale plants may appear similar, they must be designed with different objectives in mind. Find out how the design criteria for pilot and commercial plants differ, and why commercial specifications should not be applied to pilot plants.

Engineering Global Biological Solutions

Conference Presentation
AIChE Annual Meeting
November 17, 2014
The past decades have seen biopharmaceuticals begin to dominate the drug development pathway and already we can see potent biologics bringing...

The Design and Revamp of Cooling Water Networks

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
April 30, 2013
Cooling Water Networks G.T.Polley , M.Picon Nunez & E.Tamakloe Dept. of Chemical Engineering, University of Guanajuato, Mexico In Reality:...

Optimal Design of Transient Microreactor Experiments

Conference Presentation
AIChE Annual Meeting
October 30, 2012
Development of synthetic routes for active pharmaceutical ingredient (API) synthesis is increasingly performed using microreactors, because their use...

A Novel QbD Tool for Statistical Data Analysis

Conference Presentation
AIChE Annual Meeting
October 30, 2012
One of cornerstones of Quality by Design (QbD) is Design of Experiments (DoE). However, in addition to DoE, ICH Q8 (R2) recommends an enhanced...

Biofuels Process Development

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
April 28, 2009
Biofuels process development is exploding due to high crude oil prices, desire for energy independence, and government subsidy. Many challenges exist...

Integrate Process Simulation and Process Synthesis

October
2005
Computational Methods
Dominic Chwan Yee Foo, Zainuddin Abdul Manan, Michael Lynn McGuire, Murugan Selvan
The design of a new process using computer simulations to analyze a process flowsheet based on the onion model can save time, effort and, ultimately, money.

Designing Dust Collectors

September
2011
Fluids and Solids Handling
Greg Mehos, P.E.
To assure reliable and safe operation of a dust collector, apply the basic principles of chute and hopper design — which are based on the dust's fundamental flow properties.

Bioreactor Design for Chemical Engineers

August
2011
Back To Basics
Gregory T. Benz
Fermentation processes are based on chemical engineering principles. Understand these concepts to achieve optimal bioreactor design.

Optimal Automated Process Fault Analysis

January, 2013
With this book as their guide, readers have a powerful new tool for ensuring the safety and reliability of any chemical processing system. It details a tested and proven strategy to develop optimal automated process fault analyzers.

Easy Ways to Improve Energy Efficiency

December
2012
Alan P. Rossiter, Veerasamy Venkatesan
Managing the energy consumption of a process does not need to be complicated. This article presents some examples of less-complicated strategies.

Follow this Process Development Path

December
2013
Reactions and Separations
Paul Szabo
Bench-scale engineering (BSE) and the interdisciplinary no-transfer team (INTT) are valuable complements to the scale-down-before-scale-up method of process development.

Designing Pneumatic Conveying Systems

May
2006
Fluids and Solids Handling
Eric Maynard
Use this 9-step methodology to design and operate a reliable and cost-effective system to efficiently transport materials.

Succeed at Process Integration

January
2004
Career Catalyst
Alan P. Rossiter
In the application of pinch analysis for energy efficiency improvement and process optimization, technical excellence is necessary and human interactions are important for project success.

Improve Energy Efficiency via Heat Integration

December
2010
Heat Transfer
Alan P. Rossiter
Process heat integration using pinch analysis is a respected tool for achieving energy efficiency. This article explains what pinch analysis is and how to use it in process design and operation to attain real-world energy efficiency gains.

Rapid Process Design

September
2006
Reactions and Separations
Professor Michael F. Doherty, Sagar B. Gadewar
Use this structured approach, which combines preliminary experimental data with predictive methods and heuristics, to quickly generate and screen process alternatives at the early stages of a new venture.

Handle Bulk Solids Safely and Effectively

September
2009
Fluids and Solids Handling
Eric Maynard, Greg Mehos and Eric Maynard
Follow these guidelines for proper design of bins, hoppers, and feeders to avoid operational and safety problems.

Making EHS an Integral Part of Process Design

June, 2001
This book presents an approach—termed MERITT (Maximizing EHS Returns by Integrating Tools and Talents)—for enhancing process development through better integration of environmental, health, and safety evaluations. It draws upon critical components of inherent safety, pollution prevention, green...

Guidelines for Process Safety in Batch Reaction Systems

September, 1999
Batch reaction systems pose unique challenges to process safety managers because they do not operate in a steady state. The sequence of processing steps, and frequent start-ups and shutdowns, increase the possibility of human errors and equipment failures. And, since batch plants are often designed...

Guidelines for Design Solutions for Process Equipment Failures

August, 1998
While there is no "perfect" solution or absolute zero risk, engineering design can significantly reduce risk potential in the CPI. In Guidelines for Design Solutions to Process Equipment Failures, industry experts offer their broad experience in identifying numerous solutions to the more common...

Applying the Paradigm Case Method for Flowmeter Selection

September
2006
Fluids and Solids Handling
Jesse Yoder
This effective approach to flowmeter selection involves a step-by-step method that begins by matching the application with the flowmeter(s). Then, a series of criteria are applied to narrow the selection.

Cost Management in Heat-Transfer-Fluid Systems

July
2006
Heat Transfer
Conrad E. Gamble, P.E.
By taking ownership of fluid-related decisions for the entire life of the project, from design through dismantling, users can secure the best and lowest-cost approach in process heating and cooling.

Designing Suspension-Mixing Systems

January
2006
Fluids and Solids Handling
Pavel Ditl, Frantisek Rieger
Impeller and vessel geometries are key factors in selecting mixing equipment to efficiently suspend particulate solids in slurries

Apply an Integrated Approach to Catalytic Process Design

February
2007
Reactions and Separations
Mitrajit Mukherjee, James Nehlsen, Richard V. Porcelli
To ensure a practical, efficient and economically viable process, first consider how a successful catalytic reaction system would work, then focus on making a catalyst with the desired characteristics.

Successfully Scale Up Solids Handling

April
2008
Fluids and Solids Handling
K. Eric Bengtson, John W. Carson, Thomas G. Troxel
A sound theoretical model of the process to be scaled is the best approach; if one is not available, bench-scale testing, physical scale modeling or full-scale modeling is required. Here are guidelines as to which method is appropriate for various...

Selecting Elbows for Pneumatic Conveying Systems

September
2007
Fluids and Solids Handling
Paul Wagner
The right elbow can keep your system operating at peak performance, reduce maintenance costs, and minimize material attrition and elbow wear. This article describes common elbows and outlines factors to consider when selecting one.

Harnessing the Power of Virtual Reality

July
2012
On The Horizon
Li Guo, Zhouzhou Li, Jinghai Li, Xinhua Liu, Bona Lu, Fanxiao Meng, Zhaojie Xia, Mingkun Zhao
Advances in physical modeling and computational science will revolutionize the way engineers develop and design new technologies and processes.

Design and Control of Distillation Systems for Separating Azeotropes

March, 2010
Hands-on guidance for the design, control, and operation of azeotropic distillation systems Following this book's step-by-step guidance, readers learn to master tested and proven methods to overcome a major problem in chemical processing: the distillation and separation of azeotropes. Practical in...

Process Synthesis: Poised for a Wider Role

April
2001
On The Horizon
W. R. Johns
Software for generating process designs has made relatively limited inroads so far. But, it now is set to follow simulation and become a tool routinely used by chemical engineers.

Create Business Value Through Process Modeling

September
2007
Management
Bernard McGarvey
As businesses strive to improve productivity, process modeling can be a powerful tool. This article explores the role of modeling in enhancing the effectiveness and efficiency of process development and manufacturing.

Determine the Optimum Number of Process Trains

January
2010
Back To Basics
Gregory T. Benz
This article demonstrates that the repair and expense costs of process trains are not proportional to their capital costs and that, in most cases, building one plant with a single process train is the most economically efficient choice. <br>...

Understanding Electromagnetic Flowmeters

May
2010
Instrumentation
Ronald W. DiGiacomo
Consisting of a flow tube, field-generating coils, electrodes, and a transmitter, a magmeter accurately measures the flowrate of conductive fluids over a wide range of conditions.

Selecting In-Process Particle-Size Analyzers

August
2003
Fluids and Solids Handling
Paul Barrett
To select the proper instrument for process monitoring, one must determine what attribute of the particle system impacts the process or product parameter of concern. Once the size region is identified, it can be tracked in-process, opening up the...

Designing a Process Flowsheet

May
2009
Back To Basics
Vornel Walker
Piping and instrumentation diagrams belong to a family of flowsheets that includes block flow diagrams and process flow diagrams. Technology advances have transformed these resources into intelligent documents, capable of storing layers of digital...

Basic Process Measurements

June, 2009
A unique resource for process measurement Basic Process Measurements provides a unique resource explaining the industrial measuring devices that gauge such key variables as temperature, pressure, density, level, and flow. With an emphasis on the most commonly installed technologies, this guide...

The G-Value for Agitator Design: Time to Retire It?

March
2007
Fluids and Solids Handling
Gregory T. Benz
This commonly used number does not correctly address the influence of viscosity, and has no relationship to performance parameters such as fluid velocity and blend time. This article recommends actual measures of agitator performance that should be...

Understanding Steam Traps

February
2011
Back To Basics
James R. Risko
Steam trap failure can affect process operations and reduce profits. Choosing the right steam traps can improve reliability and reduce cost.

Improving the Reliability of Mechanical Seals

November
2005
Michael Huebner
With a better understanding of seals, their selection, material considerations, and operation requirements, users can greatly improve equipment reliability and reduce operating costs.

Choose the Right Elastomer

June
2008
Materials
William M. Stahl
Match a material's performance to process conditions to reduce leaks, improve safety and extend the mean time between failures (MTBF).

Understand the Fundamentals of Centrifugal Pumps

October
2010
Back To Basics
J. Howard Kelly, P.E.
Efficient and reliable pumps can significantly improve a plant’s bottom line. This article reviews important concepts that a chemical engineer must understand and the factors that need to be considered when selecting radial-flow centrifugal pumps.

Shortcut Distillation Calculations via Spreadsheets

December
2002
Reactions and Separations
Jake Jevric, Muhammad E. Fayed
This method uses a numerical solution to the McCabe-Thiele diagram to find the theoretical number of stages for binary and pseudo-binary systems,then calculates the actual number of stages, reflux ratio and column dimensions.

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