Chemical Technology

Subject Code: CH2001

Lecture 1

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 Course Outcomes
• Understand the objectives of chemical process engineer in chemical
industry.
• Able to identify the different unit operations and unit processes in a given
process flow diagram.
• Knowing the chronological developments in the chemical process industry in
global scenario.
• Acquire thorough knowledge about some important process industries
(chloro-alkali, fertilizers, soaps and detergents, sugar, petroleum, paper and
fermentation etc).
• Able to appreciate the importance of physical, chemical and physic-chemical
transformations of the material in process industries.
• Recognize the importance of process economics in the industry

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 Module 1 (9 hours)

• Chlor-alkali industries, manufacture of soda-ash, sodium bicarbonate,

chlorine and caustic soda.
• Mining and manufacture of sulfur and manufacture of sulphuric acid,
• Cement, Types and manufacture of Portland cement,
• Manufacture of paints and pigments.

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 Module 2 (9 hours)

• Nitrogen fertilizers, synthetic ammonia, nitric acid, urea, ammonium

chloride, ammonium sulphate,
• Phosphorous fertilizers, phosphate rock, phosphoric acid, super
phosphate and triple super phosphate, MAP, DAP,
• Potassium fertilizers, potassium chloride and potassium sulphate.

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 Module 3 (10 hours)

• Soaps and detergents, manufacturing of detergents,

biodegradability
• Purification of fatty acids, soap manufacture, glycerin manufacture,
oils and fats- expression, hydrogenation of oils,
• Manufacture of sugar, starch and starch derivatives
• Manufacture of pulp, paper and paperboards
• Fermentation industries, industrial alcohol, absolute alcohol, beers,
wines.

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 Module 4 (14 hours)
• Fuel and industrial gases, petroleum refining to produce naphtha, fuel
hydrocarbons and lubricants
• Processes for the production of petrochemical precursors, ethylene,
propylene, butadiene, acetylene, synthetic gas, benzene, toluene and
xylene.
• Cracking-Catalytic reforming and separation of products
• Polymers production (thermoplastic and thermosetting materials) such
as polyethylene, polypropylene, phenolic resins and epoxy resins,
natural and synthetic rubbers, rubber compounding.

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 References

1. George T Austin, Shreve’s Chemical Process Industries-

International Student Edition, 5thEdn.., McGraw Hill Inc., 1985.
2. Gopal Rao, R. and Sittig, M., Dryden's Outlines of Chemical
Technology, 3rdEdn, Affiliated East-West Publishers, 1997.
3. Shukla, S.D. and Pandey, G.N., Text book of Chemical
Technology, Vol. I, 1977.
4. Jacob A. Moulijn, Michiel Makkee and Annelies van Diepen ,
Chemical Process Technology, 1stEdn, 2001.

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 Chemists vs Chemical Engineers
Chemists
• Design reaction pathways to
produce a chemical from raw
materials
• Work in the laboratory setting to
produce material on the gram to
kilogram scale
Chemical Engineers
• Design a process to
scale the chemist’s
process to mass
produce the product
• Work in a chemical
plant to produce
material in the ton and
beyond range
 Introduction
• Important role in the social, cultural and
economic growth of a nation.
• Contributes about 3% in the GDP of the
country.
• Chemical industry produces more than
80,000 commercial products.
• Indian ranks 14th in export and 8th in
import of chemicals
• projected to reach $304 bn by 2025
• grow at approximately 9% p.a.
• employs more than 2 million people

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Why do we care about Chemical Engineering?

Chemicals Are All Around

Dyes
Toothpaste Hydrogen
Shampoo
Gasoline
Fertilizer Food
additives
Decaffeinated Coffee Soap
Cosmetics Polymers

Paint Sugar

Pharmaceuticals
 Segments of the Indian Chemical Industry
• Basic Chemicals ( 49.05%): Market value:32.78USD
• Specialty Chemicals (24.69%): Market value:16.50USD
• Knowledge Chemicals (26.6%): Market value:17.55USD

Characteristic of the Indian Chemical Industry

➢ High domestic demand potential as the Indian markets develops and per capita
consumption levels increases.
➢ High degree of fragmentation and small scale of operations
➢ Limited emphasis on exports due to domestic market focus
➢ Low cost Competitiveness as compared to other countries due to the high cost
of feed stocks and power
➢ Low focus on R & D despite initiatives to innovate processes to synthesis
products effectively

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 INDIAN CHEMICAL INDUSTRY WEAKNESSES:

• Sizes of older units well below global levels

• High cost structures
• Higher cost of raw materials
• Long gestation periods
• Integration and infrastructure inadequacies
• Process development, low R&D investments.
• Mindset

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TYPICAL ISSUES FOR CHEMICAL INDUSTRIES

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 A timeline of chemical manufacturing

• https://www.icis.com/explore/resources/news/2008/05/12/9
122818/a-timeline-of-chemical-manufacturing/
• https://www.acs.org/content/acs/en/education/whatischemis
try/landmarks/landmarks-timeline.html

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 How to Produce Chemicals

• Two methods to obtain a desired chemical

– Design a reactor to produce a chemical from raw materials

– To isolate the compound that exists in combination with other

substances through separation processes
 Chemical Reactions

Reactor
Products
Raw Raw
Materials Materials
Energy Byproducts
Catalysts Energy
Catalysts
Possible Problem with Exothermic Reactions

Reactor Energy Produced by reaction is

proportional to reactor volume
L3
Energy Removed is proportional
A+B->C to surface area L2

Possible Scale up Problem

Water Bath
 Separations
Exploits Differences of Material Properties

• Molecular Property • Separation Process

– Boiling Point – Distillation

– Freezing Point – Crystallization
– Particle size – Filtration
– Affinity to a – Chromatography
stationary phase
– Density – Centrifuge
– Selective affinity to – Adsorption
solid particles
 Separations: Unit Operations

Use separation processes to:

• Purify raw materials
• Purify products
• Purify and separate unreacted feed. • Absorption

• Stripping
Most common types:
• Distillation • Extraction
• Flash distillation
• Chromatography
• Batch distillation
• Column distillation
Mass and Energy Balances

Balance Equation
Input + generation – Output =
Accumulation

Control
Volume
 Mass and Energy Balances

• For non-reacting systems Generation = 0

• For systems operated at steady state Accumulation = 0

Mass and Energy Balances reduce to

Input = Output
 Separations Calculation

V moles
40% C2H5OH
100 moles
Magic
10% C2H5OH
Separating
90% H2O
Machine

80 moles
x % C2H5OH
1/1/2001
 Separation Calculation
V moles
40% C2H5OH

Magic
100 moles Separating
10% C2H5OH
Machine
90% H2O
80 moles
x % C2H5OH
Conservation of total Moles 100 – (V+80) = 0
V =20
Conservation of moles of C2H5OH 100*.1 – (.4*V+x*80) = 0
x = 2.5%
Separations: Distillation
(Distillation Column)

Magic
Separating
Machine

Equilibrium Stages
 Distillation
Separates liquids based on differences in volatility!
Consider a liquid mixture of A and B:

Boiling point of A: 70 C
Boiling point of B: 100 C

As mixture begins to boil, the vapor phase becomes richer in A

than the liquid phase!

Condense vapor phase to get a mixture with a higher concentration of A!

As temperature increases, the concentration of B in the vapor

phase increases.
What would be the composition of the vapor phase if the entire liquid mixture
vaporized?
Distillation
BASIC PRINCIPLES CHEMICAL PROCESSES, UNIT PROCESSES AND
UNIT OPERATIONS IN CHEMICAL INDUSTRIES
• Chemical process is combination of unit processes and Unit
operation.
• Unit process involves principle chemical conversions to synthesis of
various useful product.
✓ Reaction temperature and pressure
✓ Extent of chemical conversions
✓ Yield of product of reaction
✓ Nature of reaction (endothermic or exothermic)
✓ Type of catalyst used.
• Unit operations involve the physical separation of the products
obtained during various unit processes.

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UNIT PROCESSES IN CHEMICAL INDUSTRIES

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UNIT OPERATIONS IN CHEMICAL INDUSTRIES

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