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05 Chapter 5 PPK PDF
05 Chapter 5 PPK PDF
V
BATCH PROCESS
Outline
1. Introduction to Batch Processes
2. Batch Reactor
3. Batch Separation
4. Gantt Chart
5. Production Schedules for Single Products
6. Production Schedules for Multiple Products
7. Equipment Cleaning and Material Transfer
V.1
INTRODUCTION TO
BATCH PROCESSES
Batch Processes:
(R. Smith)
• are economical for small volumes;
• are flexible in accommodating changes in product formulation;
• are flexible in changing production rate by changing the
number of batches made in any period of time;
• allow the use of standardized multipurpose equipment for the
production of a variety of products from the same plant;
• are best if equipment needs regular cleaning because of fouling
or needs regular sterilization;
• are amenable to direct scale-up from the laboratory and
• allow product identification.
Batch Processes:
(R. Smith)
One of the major problems with batch processing is batch to-
batch conformity.
• Minor changes to the operation can mean slight changes
in the product from batch to batch.
• Fine and specialty chemicals are usually manufactured in
batch processes. Yet, these products often have very tight
tolerances for impurities in the final product and demand
batch-to-batch variation being minimized.
Batch Processes:
(James M. Dauglas)
Select batch, if:
1. Production rate
a. Sometimes batch if less than 10million lb/year
b. Usually batch if 1million lb/year
c. Multiproduct plant
2. Market forces:
a. Seasonal production
b. Short product lifetime
3. Scale up problems:
a. Very long reaction times
b. Handling slurries at low flowrates
c. Rapidly fouling materials
V.2.
BATCH REACTOR
Minimize Byproduct:
If a2 > a1 and b2 > b1: The concentration of both feeds should be minimized
and each added progressively as the reaction proceeds. Predilution of the feeds
might be considered.
If a2 > a1 and b2 < b1: The concentration of FEED1 should be minimized by
charging FEED2 at the beginning of the batch and adding FEED1 progressively
as the reaction proceeds. Predilution of FEED1 might be considered.
If a2 < a1 and b2 > b1: The concentration of FEED2 should be minimized by
charging FEED1 at the beginning of the batch and adding FEED2 progressively
as the reaction proceeds. Predilution of FEED2 might be considered.
If a2 < a1 and b2 < b1: The concentration of FEED1 and FEED2 should be
maximized by rapid addition and mixing.
The greater the number of the time intervals, the closer the
model approaches the batch reactor modeled.
V.3.
BATCH SEPARATION
Batch Distillation
Advantages Disadvantages
The same equipment can be used to process High purity products require the careful
many different feeds and produce different control of the column because of its dynamic
products state
There is flexibility to meet different product The mixture is exposed to a high temperature
specifications for extended periods
One distillation column can separate a Energy requirements are generally higher.
multicomponent mixture into relatively pure
products
V.4.
GANTT CHART
30001000 kg
Production rate ton
378.8
kg
30024 h h
1 kg of FEED produces 0.8 of main product
378.8 kg
Reactor capacity 3 h 1420.5 kg
0.8 h
Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY
time
STEP Hour
FILLING 0.25
REACTION 2.50
EMPTYING 0.25
total 3.00
time
time
Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY
V.5.
PRODUCTION
SCHEDULE FOR
SINGLE PRODUCTS
It has already been noted that overlapping batches can reduce the cycle time.
Subsequent batches are started as soon as the appropriate equipment becomes
available. Cycle time decreases to 10 h for overlapping batches (the length of the
longest step).
If a specified volume of production needs to be achieved over a given period of
time, then the equipment in the process that uses overlapping batches in Figure
(b) can in principle be half the size of the equipment for sequential production in
Figure (a).
Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY
The final option shown in Figure (d) is to use intermediate storage for the limiting
step.
Material from Step A is sent to storage, from which Step B draws its feed. Material
is still passed directly from Step B to Step C. Now all three steps are fully utilized.
For the same rate of production over a period of time, the size of Step A can in
principle be half that relative to the sequential production in Figure (a) and the
sizes of Steps B and C can in principle be one-quarter those for sequential
production. However, this is at the cost of introducing intermediate storage.
V.6.
PRODUCTION
SCHEDULE FOR
MULTIPLE PRODUCTS
All of the schedules considered so far involved transferring material from one step
to another, from a step to storage or from storage to a step without any time
delay. This is known as zero-wait transfer.
An alternative is to exploit the equipment in which a production step has taken
place to provide hold-up.
In this situation, material is held in the equipment until it is required by the
production schedule. A schedule using equipment hold-up is shown in Figure (c).
This reduces the cycle time to 15 h.
The production cycle for three batches each of Product 1 and Product 2.
The batches have been overlapped to increase equipment utilization.
In order to produce three products each of Product 1 and Product 2, the
schedule involves single-product campaigns.
Three batches of Product 1 and three batches of Product 2 follow directly
from each other.
The cycle time is 47 h.
The total time required to produce a given number of batches, in this case
three batches of each Product 1 and Product 2, is known as the
makespan, it is 53 h.
Dr. Eng. Y. D. Hermawan – ChemEng - UPNVY
V.7.
EQUPIMENT CLEANING
AND
MATERIAL TRANSFER
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