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While emphasizing conservation and sustainable strategies, this book provides steps to improve the manufacturing technologies used in creating products. By simplifying the chemistry, process development, manufacturing practices and processes, the book provides a structured approach to producing quality products with little waste, making the process not only efficient but environmentally friendly. Illustrated with case studies, this is an essential resource for chemical engineers, chemists, plant engineers, and operating personnel in any chemical related businesses.
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Chemical Process Simplification Chemical Process Simplification Improving Productivity and Sustainability Girish Malhotra, PE A JOHN WILEY & SONS, INC., PUBLICATION Copyright © 2011 by John Wiley & Sons, Inc. All rights reserved. Published by John Wiley & Sons, Inc., Hoboken, New Jersey. Published simultaneously in Canada. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, scanning, or otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without either the prior written permission of the Publisher, or authorization through payment of the appropriate per-copy fee to the Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923, (978) 750-8400, fax (978) 750-4470, or on the web at www.copyright.com. Requests to the Publisher for permission should be addressed to the Permissions Department, John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, (201) 748-6011, fax (201) 748-6008, or online at http://www.wiley.com/go/permission. Limit of Liability/Disclaimer of Warranty: While the publisher and author have used their best efforts in preparing this book, they make no representations or warranties with respect to the accuracy or completeness of the contents of this book and specifically disclaim any implied warranties of merchantability or fitness for a particular purpose. No warranty may be created or extended by sales representatives or written sales materials. The advice and strategies contained herein may not be suitable for your situation. You should consult with a professional where appropriate. Neither the publisher nor author shall be liable for any loss of profit or any other commercial damages, including but not limited to special, incidental, consequential, or other damages. For general information on our other products and services or for technical support, please contact our Customer Care Department within the United States at (800) 762-2974, outside the United States at (317) 572-3993 or fax (317) 572-4002. Wiley also publishes its books in a variety of electronic formats. Some content that appears in print may not be available in electronic formats. For more information about Wiley products, visit our web site at www.wiley.com. Library of Congress Cataloging-in-Publication Data: Malhotra, Girish, PE Chemical process simplification : improving productivity and sustainability / Girish Malhotra. p. cm. Includes bibliographical references and index. ISBN 978-0-470-48754-9 (cloth) 1. Chemical processes. I. Title. TP155.7.M355 2011 660'.28—dc22 2010031080 Printed in Singapore. 10 9 8 7 6 5 4 3 2 1 To Indu my known and unknown friend Contents Preface Process S i m p l i f i c a t i o n : Basic G u i d e l i n e s Application Areas References Process S o l u t i o n s Examples of Problem Solving Mass Balance Monitoring Plant Operations Filter Feed Pump Ester Manufacturing Process Simplification of a Product Solution Process Process "On Stream Time" Inventory Management and Process Repeatability Sampling and Size Antioxidant Production Novolac Resin Alkyd Resins Paint Making Continuous-Process Latex Polymer Wast