Unit Processes and Unit Operation in Chemical Process Industries

Chemical process is combination of unit processes and Unit operation. Unit process
involves principle chemical conversions leading to synthesis of various useful
product and provide basic information regarding the reaction temperature and
pressure, extent of chemical conversions and yield of product of reaction nature of
reaction whether endothermic or exothermic, type of catalyst used. Unit operations
involve the physical separation of the products obtained during various unit
processes (NPTEL, 2014).

A structure of logic used for synthesizing and analyzing processing schemes in the
chemical and allied industries, in which the basic underlying concepts is that all can
becomposed from and decomposed into a series of individual, or unit, steps. If a step
involves a chemical change, it is called a unit process; if a physical change, a unit
operation. This unit operation cut across widely different application, including the
manufacture of chemicals, fuels, pharmaceuticals, pulp and paper, processed food,
and primary metals. Most operations are based mechanistically upon the
fundamental transport processes of mass transfers, heat transfer, and fluid flow or
momentum transfer (TheFreeDictionary's Encyclopedia, 2016).

Comparison of Unit Process and Unit Operation

In the chemical process industry, many processes are involved before getting the
desired product is made. Through the process, there is a function of chemical
changes and physical changes. There are two things that is happening in case of
any chemical plants, the chemical changes that is the product we produced by some
reactions through chemical reactions and physical changes that is how to separate
the product from unwanted co-products and how the raw materials goes like
transport process, distillation or evaporation without chemical changes. The chemical
change in the chemical process is called Unit process while physical change is
called unit operations.
Types of Unit Operations and Unit Processes involved in Chemical
Process Industries
Some types of Unit Processes and Unit Operation and Some of its Industries
Unit Process Industry or Product
1. Combustion Fuel and power
2. Oxidation Sulfuric acid, Phosphoric acid Paints and pigments,
3. Neutralization Water treatment, Sodium salts, soap from fatty acids
4. Silicate Formations Ceramics, Sand-lime bricks, cements, glass
5. Causticization Caustic soda
6. Electrolysis Industrial Gases, aluminum
7. Double decomposition Water softening, sodium salts
8. Calcination Lime, Soda ash
9. Nitration Explosives, perfumes
10. Esterification Ethyl and Vinyl acetate
11. Reduction Phosphorus, Sulfur from SO2
12. Amination by Ammonilysis Aniline from Chloro-benzene
13. Halogenation Insecticides, Chemical for warfare
14. Sulfonation Explosives, Sulfite paper
15. Hydration and hydrolysis Glycerine, soap, corn sugar
16. Hydrogenationand Hydrogenolysis Petroleum industry, Methanol from CO
17. Alkylation Photography,Styrene, Petroleum industry
18. Condensation Phenolphthalein, Resinification
19. Polymerization Rubber, Petroleum industry
20. Diazotization and coupling Dyes
21. Fermentation Alcohol, Wines, beers, Lactic acid, penicillin
22. Pyrolysis or cracking Distillation of coal Carbon black
23. Aromatization Petroleum industry
24. Isomerization Petroleum industry
25. Miscellaneous (ion exchange, allotropic change and Calcium carbide, graphite leather
etc.)

Unit operation Industry or product

1. Fluid flow or fluid dynamics Water and waste, Oils and fats
2. Heat transfer Fuel and power, Distillation of coal, Industrial gases
3. Evaporation Potassium salts, Caustic soda, sugar
4. Humidification Textile fibers
5. Gas absorption Distillation, bleach, Nitric acid
6. Solvent extraction Coal gases, insecticides. Perfumes, oils
7. Adsorption Water and waste water purification
8. Distillation and sublimation Distillation of coal, Perfumes, Alcohol
9. Drying Ceramics, Sodium salts, Soap
10. Mixing Fertilizers, Dynamite, paints

11. Classification or sedimentation Cement rock, Potassium Salts

12. Filtration Ceramics, Sugar, Rayon
13. Screening Cement, Soda ash, sugar
14. Crystallization Sodium Salts, Sugar
15. Centrifugation Ca and Mg salts, Potassium salts
16. Size Reduction Ceramics, Cements, Paints
17. Material Handling Fuels, Ceramics, Glass, Wood
References:

http://nptel.ac.in/courses/103107082/module1/lecture3/lecture3.pdf
retrieved on 18 June 2016.

http://nsdl.niscair.res.in/jspui/bitstream/123456789/596/1/revised%20Uni
t%20Process%20and%20unit%20operation.pdf retrieved on 18 June
2016.

Shreve, N.R.(1984). The Chemical Process Industries. McGraw-Hill

Book Press.
Unit Processes and Unit Operations in
Chemical Process Industries
(A Written Report)

Prepared by: Ganzon, Rowel B.