, Advanced Manufacturing
Operations Technologies
This book discusses and chronicles various types of manufacturing processes,
including casting and molding, machining, joining, shearing, and forming. It refers
to repetitive, discrete job shop process manufacturing (continuous) and process
manufacturing (batch). It also offers detailed examples from the nuclear, electronic,
plastics, adhesives, inks, packaging, chemical, and pharmaceutical industries.
Advanced Manufacturing Operations Technologies: Principles, Applications,
and Design Correlations in Chemical Engineering Fields of Practice fills the gap in
the connection between production and regulated applications in several industries.
It highlights established concepts and provides a new, fresh outlook by concentrating
on and creating linkages in the implementation of practices in manufacturing and
safe, clean energy systems. Case studies for the overall design, installations, and
construction of manufacturing operations in various industries as well as the standard
operating procedures are offered. The book also discusses the correlation between
design strategies including step-by-step processes to ensure the reliability, safety, and
efficacy of products. The fundamentals of controlled techniques, quality by design,
risk assessment, and management are covered in support of operations applications
and continuous improvement.
This comprehensive book is helpful to all professionals, students, and academicians
in many scientific disciplines that utilize fundamental principles of chemical
engineering. It is engineering-driven and will be of use to those in industrial and
manufacturing, chemical, biochemical, mechanical engineering, and automated
control systems fields.
,Advanced Manufacturing
Operations Technologies
Principles, Applications, and Design
Correlations in Chemical Engineering
Fields of Practice
Sam A. Hout
,Designed cover image: Shutterstock
First edition published 2024
by CRC Press
6000 Broken Sound Parkway NW, Suite 300, Boca Raton, FL 33487–2742
and by CRC Press
4 Park Square, Milton Park, Abingdon, Oxon, OX14 4RN
CRC Press is an imprint of Taylor & Francis Group, LLC
© 2024 Sam A. Hout
Reasonable efforts have been made to publish reliable data and information, but the
author and publisher cannot assume responsibility for the validity of all materials or
the consequences of their use. The authors and publishers have attempted to trace
the copyright holders of all material reproduced in this publication and apologize to
copyright holders if permission to publish in this form has not been obtained. If any
copyright material has not been acknowledged please write and let us know so we
may rectify in any future reprint.
Except as permitted under U.S. Copyright Law, no part of this book may be reprinted,
reproduced, transmitted, or utilized in any form by any electronic, mechanical, or
other means, now known or hereafter invented, including photocopying, microfilming,
and recording, or in any information storage or retrieval system, without written
permission from the publishers.
For permission to photocopy or use material electronically from this work, access
www.copyright.com or contact the Copyright Clearance Center, Inc. (CCC), 222
Rosewood Drive, Danvers, MA 01923, 978-750-8400. For works that are not
available on CCC please contact
Trademark notice: Product or corporate names may be trademarks or registered
trademarks and are used only for identification and explanation without intent to
infringe.
Library of Congress Cataloging-in-Publication Data
Names: Hout, Sam A., 1951– author.
Title: Advanced manufacturing operations technologies : principles, applications, and
design correlations in chemical engineering fields of practice / Sam A. Hout.
Description: First edition. | Boca Raton : CRC Press, [2023] | Includes bibliographical
references and index.
Identifiers: LCCN 2022061386 (print) | LCCN 2022061387 (ebook) |
ISBN 9781032469126 (hbk) | ISBN 9781032470115 (pbk) |
ISBN 9781003384199 (ebk)
Subjects: LCSH: Chemical plants. | Chemical processes. | Operations research.
Classification: LCC TP155.5 .H68 2023 (print) | LCC TP155.5 (ebook) |
DDC 660—dc23/eng/20230130
LC record available at https://lccn.loc.gov/2022061386
LC ebook record available at https://lccn.loc.gov/2022061387
ISBN: 978-1-032-46912-6 (hbk)
ISBN: 978-1-032-47011-5 (pbk)
ISBN: 978-1-003-38419-9 (ebk)
DOI: 10.1201/9781003384199
Typeset in Times
by Apex CoVantage, LLC
,Contents
Preface....................................................................................................................... xi
Acknowledgments................................................................................................... xiii
Author ...................................................................................................................... xv
Introduction: Heat, Mass, and Momentum Transfer ............................ 1
Chapter 1 Instrumentation..................................................................................... 3
Connection of Pressure Gauges in Chemical Plants ............................ 3
Instrumentation and Control of Distillation Columns .......................... 8
Instrumentation of Heat Exchangers .................................................. 10
Chapter 2 Chemical Plant—Engineering Materials ............................................ 13
Rheological Behavior ......................................................................... 18
Chapter 3 Pressure Vessels .................................................................................. 21
Stress = Force/Area Over Which It Acts ............................................ 21
Chapter 4 Thermodynamics—Mass, Enthalpy, Entropy, Free Energy,
and Internal Energy in Closed and Open Systems ............................. 25
Thermodynamic Properties of Fluids ................................................. 26
The Ideal Gas Model Assumes ........................................................... 27
Prediction of Vapor–Liquid Equilibria of Mixtures at Higher
Pressure .......................................................................................... 28
Chapter 5 Fluid Dynamics—Crystallization, Sedimentation, and Particle
Dynamics ............................................................................................ 31
Chapter 6 Fluid Mechanics ................................................................................. 33
Fluid Flow .......................................................................................... 33
Physical Properties of Fluids .............................................................. 33
Compressible Fluid Flow in Pipe ....................................................... 34
Steam .................................................................................................. 35
v
,vi Contents
Chapter 7 Heat Transmission—Natural Convection, Forced Convection,
and Single- and Two-Phase (Boiling) Flow Systems ......................... 37
Extend to Horizontal Surface ............................................................. 43
Chapter 8 Transport Phenomena ......................................................................... 47
Mass Balance (Steady State) .............................................................. 47
Τ Operates on a Vector to Give a Derivative ...................................... 49
Chapter 9 Chemical Reaction Engineering ......................................................... 51
Purge ................................................................................................... 51
Reactors .............................................................................................. 52
Batch Reactor ..................................................................................... 52
Catalytic Processes ............................................................................. 54
Reactor Types Are Based on Two Models .......................................... 55
Chapter 10 Fuel and Power ................................................................................... 57
Nuclear Power Production—Fission and Nuclear Reactor ................ 58
Carbon-Based Fuels ........................................................................... 61
Bond Breaking Is a Major Reaction in Cracking ............................... 61
Distillation Operations................................................................... 62
Reforming ...................................................................................... 64
Chapter 11 Electrochemistry/Corrosion................................................................ 67
Corrosion Testing ............................................................................... 71
Chapter 12 Unit Operations .................................................................................. 75
Solvent Extraction .............................................................................. 75
Fluidization......................................................................................... 77
Sedimentation ..................................................................................... 77
Crystallization .................................................................................... 77
Leaching ............................................................................................. 78
Distillation .......................................................................................... 78
Chapter 13 Process Dynamics............................................................................... 89
Quantifying Flow Sheets .................................................................... 89
System Stability Determination ......................................................... 92
Chapter 14 Mathematics ....................................................................................... 95
,Contents vii
Chapter 15 Numerical Methods—Computation ................................................... 97
DO-Loop ............................................................................................ 97
Least Square Regression .................................................................... 99
Numerical Integration....................................................................... 100
Chapter 16 Chemical Plant Design ..................................................................... 107
Chapter 17 Experimentation ............................................................................... 109
Batch Distillation at Constant Reflux Ratio in Packed Column ....... 111
Chapter 18 Multi-Phase Flow ............................................................................. 113
Chapter 19 Bio-Chemical Engineering ............................................................... 115
Catalytic Enzymes ............................................................................ 115
Fermentation..................................................................................... 115
Chapter 20 Industrial Inks, Dyes, and Pigments ................................................. 117
Composition of Printing Inks ........................................................... 117
Preparation of the Specimens ........................................................... 119
Dissolution ................................................................................... 119
Water Extraction for the Barium Determination .............................. 119
Fluorescent Pigments ....................................................................... 122
Application Areas ............................................................................. 124
Dispersion......................................................................................... 125
Heat Stability .................................................................................... 125
Additives........................................................................................... 125
Lightfastness..................................................................................... 125
Plate-Out........................................................................................... 126
Toxicity ............................................................................................. 126
UV Curing Offset Inks ..................................................................... 126
Ink Manufacturing ............................................................................ 128
Chapter 21 Industrial Plastics ............................................................................. 129
Plastic Materials ............................................................................... 129
Chapter 22 Coating ............................................................................................. 131
Cylinder and Roller Setting .............................................................. 131
,viii Contents
Chapter 23 Industrial Adhesives ......................................................................... 133
Packaging Systems ........................................................................... 133
Base Cup Adhesives ......................................................................... 133
Cigarette Adhesives .......................................................................... 136
Foamed Hot Melt.............................................................................. 136
Wood Adhesives ............................................................................... 137
Bag Adhesives ............................................................................. 137
Disposable Products ......................................................................... 138
Pressure-Sensitive Adhesives ........................................................... 138
Laminating Adhesives ...................................................................... 139
Cohesive Coating Welds ................................................................... 139
Labeling Adhesives .......................................................................... 139
Chapter 24 Electronic Materials Processing ....................................................... 141
Thick Film Systems .......................................................................... 141
Thin Film Systems ........................................................................... 142
Photo Resolution of Metal Lines on Insulating Materials ........... 142
Conductive Polymers........................................................................ 143
Thick Film—Case Study .................................................................. 144
Effect of Positive Material, Kiln Firing Temperature, and Drying
on TR and TCR ............................................................................ 144
Effect of Clearance and Squeegee Drive Pressure ........................... 144
Effect of Emulsion Thickness .......................................................... 144
Conclusions ...................................................................................... 145
Chapter 25 Nuclear Power Plant—Reactor Heat Removal................................. 153
Design Criteria ................................................................................. 154
Assumptions ..................................................................................... 156
System Description .......................................................................... 157
System Design .................................................................................. 157
Sample Calculation for Determination of RHR
HX Effectiveness ......................................................................... 162
Estimated RCS Thermal Capacity .................................................... 163
Chapter 26 Pharmaceutical Manufacturing......................................................... 169
Microbiological Limits ..................................................................... 175
Appendix I: Process Flow Diagram—Component Preparation,
Compounding, Fill/Finish, and Packaging of Liquid Aseptic Operation ....... 179
Appendix II: Master Validation Plan ................................................................. 181
,Contents ix
Appendix III: Hand Calculations—System Architecture
and Computations for Nuclear Reactor Heat Removal Systems
Computer Program .............................................................................................. 211
Appendix IV: Chemical Reaction Fouling ......................................................... 237
Appendix V: Proposal for New Plant Construction .......................................... 249
Appendix VI: The Accident at Three Mile Island ............................................. 265
Appendix VII: Water Hammer in Nuclear Power Plants ................................. 269
Appendix VIII: Selection and Design of Industrial Furnace Heaters ............. 271
Appendix IX: Chemical Reaction Fouling in Unit Operations ........................ 273
Appendix X: Analysis of Single-Phase Flow in Power Plant Drain Systems ..... 289
Appendix XI: Case Studies.................................................................................. 293
Appendix XII: Heavy Metals Testing ................................................................. 297
Bibliography ......................................................................................................... 305
Glossary of Terms ................................................................................................ 307
Index ...................................................................................................................... 319
, Preface
Chemical engineering is a highly mathematical discipline. It is my intent for this
book to minimize the detailed mathematical calculus, dimensionless numbers, math-
ematical modeling, differential equations, and several other mathematical analytical
and numerical methods and focus on fundamentals. Professional chemical engineers
and other professionals who want to understand the natural sciences behind chemical
engineering principles and practice for applied implementations can benefit from this
book’s comprehensive coverage that includes case studies for overall design, instal-
lations, and construction of manufacturing operations in various industries including
standard operation procedures.
The more complex the chemical and biochemical industry becomes, the more
vital the role of a comprehensive understanding of fluid flow and processing is. The
transport of fluids in nuclear reactors, petroleum refineries, pharmaceutical aseptic
processing, and food processing are all complex fluid transports in pipes and vessels
that require modeling for design conditions and conversion utilizing temperatures,
pressures, and fluid flow rate calculations. Extensive mathematical calculations and
equations based on theory and empirical knowledge allow us to build and construct
unit operations for processing, separation, and purification of various compounds
and products. This is extended from fuel and power, alternative energy, electronic
components and systems manufacturing, and other production systems of chemical
and biological conversion processes. The developments include powder systems, inks
and dyes, and paints that cover a spectrum of different materials that extend from
pure simple solutions to complex emulsions. Cleaning sanitizing agents and ster-
ilants, as well as synthetic detergents all played a major role in the development of
chemical engineering.
I conceptualized writing this book on manufacturing design and operation appli-
cations after spending over 30 years in drug manufacturing engineering including
aseptic liquid and lyophilized parenteral drug vial fill/finish, cartridge filling for
injector applications, sterile prefilled syringes, and ophthalmic bottle filling and
capping. Quality by design dictates process preparations and compounding of drug
formulations are key steps in transferring bulk product batches from beginning to
end. These processes all require diligent care and technical know-how in transferring
across process steps while maintaining clean and safe operations. Personnel flow and
materials flow separations and consideration for movement have rigorous require-
ments to ensure against cross-contamination and making a safe product. During my
career, I also worked on projects and consulted in other chemical engineering-
affiliated industries. I wanted to put it all together in one accessible simplified
experience-based reference to reinforce knowledge of design, processes, and com-
pliance regulations and provide an easy guide to follow. This book is important in
providing a step-by-step understanding of what is required to engineer and manufac-
ture products.
Process flow, product risk-based quality approach, and the significance of pro-
cess validation are emphasized. Critical step-by-step technologies and systems are
xi
Operations Technologies
This book discusses and chronicles various types of manufacturing processes,
including casting and molding, machining, joining, shearing, and forming. It refers
to repetitive, discrete job shop process manufacturing (continuous) and process
manufacturing (batch). It also offers detailed examples from the nuclear, electronic,
plastics, adhesives, inks, packaging, chemical, and pharmaceutical industries.
Advanced Manufacturing Operations Technologies: Principles, Applications,
and Design Correlations in Chemical Engineering Fields of Practice fills the gap in
the connection between production and regulated applications in several industries.
It highlights established concepts and provides a new, fresh outlook by concentrating
on and creating linkages in the implementation of practices in manufacturing and
safe, clean energy systems. Case studies for the overall design, installations, and
construction of manufacturing operations in various industries as well as the standard
operating procedures are offered. The book also discusses the correlation between
design strategies including step-by-step processes to ensure the reliability, safety, and
efficacy of products. The fundamentals of controlled techniques, quality by design,
risk assessment, and management are covered in support of operations applications
and continuous improvement.
This comprehensive book is helpful to all professionals, students, and academicians
in many scientific disciplines that utilize fundamental principles of chemical
engineering. It is engineering-driven and will be of use to those in industrial and
manufacturing, chemical, biochemical, mechanical engineering, and automated
control systems fields.
,Advanced Manufacturing
Operations Technologies
Principles, Applications, and Design
Correlations in Chemical Engineering
Fields of Practice
Sam A. Hout
,Designed cover image: Shutterstock
First edition published 2024
by CRC Press
6000 Broken Sound Parkway NW, Suite 300, Boca Raton, FL 33487–2742
and by CRC Press
4 Park Square, Milton Park, Abingdon, Oxon, OX14 4RN
CRC Press is an imprint of Taylor & Francis Group, LLC
© 2024 Sam A. Hout
Reasonable efforts have been made to publish reliable data and information, but the
author and publisher cannot assume responsibility for the validity of all materials or
the consequences of their use. The authors and publishers have attempted to trace
the copyright holders of all material reproduced in this publication and apologize to
copyright holders if permission to publish in this form has not been obtained. If any
copyright material has not been acknowledged please write and let us know so we
may rectify in any future reprint.
Except as permitted under U.S. Copyright Law, no part of this book may be reprinted,
reproduced, transmitted, or utilized in any form by any electronic, mechanical, or
other means, now known or hereafter invented, including photocopying, microfilming,
and recording, or in any information storage or retrieval system, without written
permission from the publishers.
For permission to photocopy or use material electronically from this work, access
www.copyright.com or contact the Copyright Clearance Center, Inc. (CCC), 222
Rosewood Drive, Danvers, MA 01923, 978-750-8400. For works that are not
available on CCC please contact
Trademark notice: Product or corporate names may be trademarks or registered
trademarks and are used only for identification and explanation without intent to
infringe.
Library of Congress Cataloging-in-Publication Data
Names: Hout, Sam A., 1951– author.
Title: Advanced manufacturing operations technologies : principles, applications, and
design correlations in chemical engineering fields of practice / Sam A. Hout.
Description: First edition. | Boca Raton : CRC Press, [2023] | Includes bibliographical
references and index.
Identifiers: LCCN 2022061386 (print) | LCCN 2022061387 (ebook) |
ISBN 9781032469126 (hbk) | ISBN 9781032470115 (pbk) |
ISBN 9781003384199 (ebk)
Subjects: LCSH: Chemical plants. | Chemical processes. | Operations research.
Classification: LCC TP155.5 .H68 2023 (print) | LCC TP155.5 (ebook) |
DDC 660—dc23/eng/20230130
LC record available at https://lccn.loc.gov/2022061386
LC ebook record available at https://lccn.loc.gov/2022061387
ISBN: 978-1-032-46912-6 (hbk)
ISBN: 978-1-032-47011-5 (pbk)
ISBN: 978-1-003-38419-9 (ebk)
DOI: 10.1201/9781003384199
Typeset in Times
by Apex CoVantage, LLC
,Contents
Preface....................................................................................................................... xi
Acknowledgments................................................................................................... xiii
Author ...................................................................................................................... xv
Introduction: Heat, Mass, and Momentum Transfer ............................ 1
Chapter 1 Instrumentation..................................................................................... 3
Connection of Pressure Gauges in Chemical Plants ............................ 3
Instrumentation and Control of Distillation Columns .......................... 8
Instrumentation of Heat Exchangers .................................................. 10
Chapter 2 Chemical Plant—Engineering Materials ............................................ 13
Rheological Behavior ......................................................................... 18
Chapter 3 Pressure Vessels .................................................................................. 21
Stress = Force/Area Over Which It Acts ............................................ 21
Chapter 4 Thermodynamics—Mass, Enthalpy, Entropy, Free Energy,
and Internal Energy in Closed and Open Systems ............................. 25
Thermodynamic Properties of Fluids ................................................. 26
The Ideal Gas Model Assumes ........................................................... 27
Prediction of Vapor–Liquid Equilibria of Mixtures at Higher
Pressure .......................................................................................... 28
Chapter 5 Fluid Dynamics—Crystallization, Sedimentation, and Particle
Dynamics ............................................................................................ 31
Chapter 6 Fluid Mechanics ................................................................................. 33
Fluid Flow .......................................................................................... 33
Physical Properties of Fluids .............................................................. 33
Compressible Fluid Flow in Pipe ....................................................... 34
Steam .................................................................................................. 35
v
,vi Contents
Chapter 7 Heat Transmission—Natural Convection, Forced Convection,
and Single- and Two-Phase (Boiling) Flow Systems ......................... 37
Extend to Horizontal Surface ............................................................. 43
Chapter 8 Transport Phenomena ......................................................................... 47
Mass Balance (Steady State) .............................................................. 47
Τ Operates on a Vector to Give a Derivative ...................................... 49
Chapter 9 Chemical Reaction Engineering ......................................................... 51
Purge ................................................................................................... 51
Reactors .............................................................................................. 52
Batch Reactor ..................................................................................... 52
Catalytic Processes ............................................................................. 54
Reactor Types Are Based on Two Models .......................................... 55
Chapter 10 Fuel and Power ................................................................................... 57
Nuclear Power Production—Fission and Nuclear Reactor ................ 58
Carbon-Based Fuels ........................................................................... 61
Bond Breaking Is a Major Reaction in Cracking ............................... 61
Distillation Operations................................................................... 62
Reforming ...................................................................................... 64
Chapter 11 Electrochemistry/Corrosion................................................................ 67
Corrosion Testing ............................................................................... 71
Chapter 12 Unit Operations .................................................................................. 75
Solvent Extraction .............................................................................. 75
Fluidization......................................................................................... 77
Sedimentation ..................................................................................... 77
Crystallization .................................................................................... 77
Leaching ............................................................................................. 78
Distillation .......................................................................................... 78
Chapter 13 Process Dynamics............................................................................... 89
Quantifying Flow Sheets .................................................................... 89
System Stability Determination ......................................................... 92
Chapter 14 Mathematics ....................................................................................... 95
,Contents vii
Chapter 15 Numerical Methods—Computation ................................................... 97
DO-Loop ............................................................................................ 97
Least Square Regression .................................................................... 99
Numerical Integration....................................................................... 100
Chapter 16 Chemical Plant Design ..................................................................... 107
Chapter 17 Experimentation ............................................................................... 109
Batch Distillation at Constant Reflux Ratio in Packed Column ....... 111
Chapter 18 Multi-Phase Flow ............................................................................. 113
Chapter 19 Bio-Chemical Engineering ............................................................... 115
Catalytic Enzymes ............................................................................ 115
Fermentation..................................................................................... 115
Chapter 20 Industrial Inks, Dyes, and Pigments ................................................. 117
Composition of Printing Inks ........................................................... 117
Preparation of the Specimens ........................................................... 119
Dissolution ................................................................................... 119
Water Extraction for the Barium Determination .............................. 119
Fluorescent Pigments ....................................................................... 122
Application Areas ............................................................................. 124
Dispersion......................................................................................... 125
Heat Stability .................................................................................... 125
Additives........................................................................................... 125
Lightfastness..................................................................................... 125
Plate-Out........................................................................................... 126
Toxicity ............................................................................................. 126
UV Curing Offset Inks ..................................................................... 126
Ink Manufacturing ............................................................................ 128
Chapter 21 Industrial Plastics ............................................................................. 129
Plastic Materials ............................................................................... 129
Chapter 22 Coating ............................................................................................. 131
Cylinder and Roller Setting .............................................................. 131
,viii Contents
Chapter 23 Industrial Adhesives ......................................................................... 133
Packaging Systems ........................................................................... 133
Base Cup Adhesives ......................................................................... 133
Cigarette Adhesives .......................................................................... 136
Foamed Hot Melt.............................................................................. 136
Wood Adhesives ............................................................................... 137
Bag Adhesives ............................................................................. 137
Disposable Products ......................................................................... 138
Pressure-Sensitive Adhesives ........................................................... 138
Laminating Adhesives ...................................................................... 139
Cohesive Coating Welds ................................................................... 139
Labeling Adhesives .......................................................................... 139
Chapter 24 Electronic Materials Processing ....................................................... 141
Thick Film Systems .......................................................................... 141
Thin Film Systems ........................................................................... 142
Photo Resolution of Metal Lines on Insulating Materials ........... 142
Conductive Polymers........................................................................ 143
Thick Film—Case Study .................................................................. 144
Effect of Positive Material, Kiln Firing Temperature, and Drying
on TR and TCR ............................................................................ 144
Effect of Clearance and Squeegee Drive Pressure ........................... 144
Effect of Emulsion Thickness .......................................................... 144
Conclusions ...................................................................................... 145
Chapter 25 Nuclear Power Plant—Reactor Heat Removal................................. 153
Design Criteria ................................................................................. 154
Assumptions ..................................................................................... 156
System Description .......................................................................... 157
System Design .................................................................................. 157
Sample Calculation for Determination of RHR
HX Effectiveness ......................................................................... 162
Estimated RCS Thermal Capacity .................................................... 163
Chapter 26 Pharmaceutical Manufacturing......................................................... 169
Microbiological Limits ..................................................................... 175
Appendix I: Process Flow Diagram—Component Preparation,
Compounding, Fill/Finish, and Packaging of Liquid Aseptic Operation ....... 179
Appendix II: Master Validation Plan ................................................................. 181
,Contents ix
Appendix III: Hand Calculations—System Architecture
and Computations for Nuclear Reactor Heat Removal Systems
Computer Program .............................................................................................. 211
Appendix IV: Chemical Reaction Fouling ......................................................... 237
Appendix V: Proposal for New Plant Construction .......................................... 249
Appendix VI: The Accident at Three Mile Island ............................................. 265
Appendix VII: Water Hammer in Nuclear Power Plants ................................. 269
Appendix VIII: Selection and Design of Industrial Furnace Heaters ............. 271
Appendix IX: Chemical Reaction Fouling in Unit Operations ........................ 273
Appendix X: Analysis of Single-Phase Flow in Power Plant Drain Systems ..... 289
Appendix XI: Case Studies.................................................................................. 293
Appendix XII: Heavy Metals Testing ................................................................. 297
Bibliography ......................................................................................................... 305
Glossary of Terms ................................................................................................ 307
Index ...................................................................................................................... 319
, Preface
Chemical engineering is a highly mathematical discipline. It is my intent for this
book to minimize the detailed mathematical calculus, dimensionless numbers, math-
ematical modeling, differential equations, and several other mathematical analytical
and numerical methods and focus on fundamentals. Professional chemical engineers
and other professionals who want to understand the natural sciences behind chemical
engineering principles and practice for applied implementations can benefit from this
book’s comprehensive coverage that includes case studies for overall design, instal-
lations, and construction of manufacturing operations in various industries including
standard operation procedures.
The more complex the chemical and biochemical industry becomes, the more
vital the role of a comprehensive understanding of fluid flow and processing is. The
transport of fluids in nuclear reactors, petroleum refineries, pharmaceutical aseptic
processing, and food processing are all complex fluid transports in pipes and vessels
that require modeling for design conditions and conversion utilizing temperatures,
pressures, and fluid flow rate calculations. Extensive mathematical calculations and
equations based on theory and empirical knowledge allow us to build and construct
unit operations for processing, separation, and purification of various compounds
and products. This is extended from fuel and power, alternative energy, electronic
components and systems manufacturing, and other production systems of chemical
and biological conversion processes. The developments include powder systems, inks
and dyes, and paints that cover a spectrum of different materials that extend from
pure simple solutions to complex emulsions. Cleaning sanitizing agents and ster-
ilants, as well as synthetic detergents all played a major role in the development of
chemical engineering.
I conceptualized writing this book on manufacturing design and operation appli-
cations after spending over 30 years in drug manufacturing engineering including
aseptic liquid and lyophilized parenteral drug vial fill/finish, cartridge filling for
injector applications, sterile prefilled syringes, and ophthalmic bottle filling and
capping. Quality by design dictates process preparations and compounding of drug
formulations are key steps in transferring bulk product batches from beginning to
end. These processes all require diligent care and technical know-how in transferring
across process steps while maintaining clean and safe operations. Personnel flow and
materials flow separations and consideration for movement have rigorous require-
ments to ensure against cross-contamination and making a safe product. During my
career, I also worked on projects and consulted in other chemical engineering-
affiliated industries. I wanted to put it all together in one accessible simplified
experience-based reference to reinforce knowledge of design, processes, and com-
pliance regulations and provide an easy guide to follow. This book is important in
providing a step-by-step understanding of what is required to engineer and manufac-
ture products.
Process flow, product risk-based quality approach, and the significance of pro-
cess validation are emphasized. Critical step-by-step technologies and systems are
xi
