Example sheet: Scheduling of batch processes

1. Consider the following multiproduct batch plant described in table 1:

Table 1: Equipment processing times (in hours) for processes A,B,C

Process Mixer Reactor Separator
A 2 5 4
B 3 4 3.5
C 1 3 4.5

a. It is required to produce the same number of batches of each product.

Determine the number of batches that can be produced in a 500 h operating
period using the following strategies:

i. Single-product campaigns for each product

ii. A multicomponent campaign using the sequence ABCABCABC
iii. A multicomponent campaign using the sequence CBACBACBA

b. Determine the number of batches that can be produced in 500 h using a series
of single-product campaigns when the required number of batches for product
A is twice that of either product B or product C.

c. If unlimited storage space is available, how can the cycle time be improved in
this process for the campaign ABCABCABC?

d. If a new reactor is purchased to be used as a parallel unit, determine the

system bottleneck by following the zero wait policy.

e. Assume that a single-product campaign strategy is used over a 500 h operating

period. The production rates (for a year =6000 h) for products A,B, C are 18000
kg/y, 24000 kg/y and 30000 kg/y, respectively. Determine the minimum
volume of product storage required. The densities of A,B and C are 1100, 1200
and 1000 kg/m3 respectively.

2. Consider the processes given in Example 4 of lecture slides:

a. Determine the number of batches that can be produced in a month (500 h)

using a series of single-product campaigns when the required number of
batches for product A is twice that of either product B or product C.

b. Determine the number of batches that can be produced in a month (500 h)

using a multiproduct campaign strategy with the sequence ACBACBACB. Are
there any other sequences for this problem other than the one used in Example
4 and the one used here?
3. The products A, B and C are produced in lab scale by the following procedure.

A: 10 kg of liquid x with density 950kg/m3 is reacted with 50 kg of liquid y with

density 1050 kg/m3 in a jacketed reactor. 10.6 kg of A is produced and the time
taken is 6 hours.

B: 25 kg of liquid x is heated with a catalyst in a jacketed reactor. 3.7 kg of B

is produced and the time taken is 9.5 hours.

C: 30 kg of liquid y is heated in the presence of a catalyst in a jacketed reactor.

8.1 kg of C is produced and the time taken is 18.5 hours.

In all these processes, reactor is filled to 75% f maximum capacity. It can be

assumed that the reaction is the longest step in the entire process to produce
these products.

If the required yearly production rates of A,B and C are 150, 210 and 360 ton
respectively, determine the number of batches and limiting reactor size for each
product. Assume 6000 h operation of plant in one year.