Week #2a

SECTION-I
FUNDAMENTALS OF CHEMICAL
PROCESSING
Dr. M. A. Shehzad
aamirshehzad@uet.edu.pk

10/7/2020 9:55:39 AM Department of Polymer & Process Engineering, U.E.T. Lahore 1

 SECTION-I
Fundamentals of Chemical
Processing
1. Batch versus continuous processing
2. Chemical process control and
instrumentation
3. Process flow sheeting
4. Chemical process economics

10/7/2020 9:55:47 AM Department of Polymer & Process Engineering, U.E.T. Lahore 2

 Chemical Processing
Raw materials Products
(Intermediates)

Final product
 Basic Chemical Data
❖ Conversion: Fraction of raw material
converted into desired as well as undesired
product.
(It gives just the change in a single pass)

❖ Yield: Fraction of raw material converted

into desired product e.g. titration containing
salts as desired product.
 Goal of an Engineer
➢ Conversion = Yield (to minimize cost)

➢ Kinetics
Study of Reactions Speed
➢ Important in plant design, since reaction
speed determines equipment sizes.
➢ Catalysts ….Change reaction speed
 Material Balance, Energy Changes,
Energy Balances
❖ 1ststep in any processing study. (Basis:%
age yield)
❖ Energy use and distribution.
❖ Chemical Processing is an Energy Intensive
Industry.
❖ Thermodynamics is widely used
❖ Heat of reaction (∆H) (-ve when heat
evolved)
 Types of Processing
1) Batch Processing
2) Continuous Processing
3) Semi continuous processing.
 Batch vs. Continuous Processing
Batch Process Continuous Process

Batch process refers to a process Continuous process refers to the

that involves a sequence of steps flow of a single unit of product
Definition followed in a specific order.
Scheduling is done to maintain
Coordination the timing between move to
earth.
Quantities A whole unit of products are
produced produced.
Batch process is involved if the
Fouling
fouling expectations are high
between every step of the process
without any break in time,
substance or extend.
Each machine performs a certain
processing function and they
operates in a steady state.
Large quantities of products are
obtained.
Continuous process is involved if
fouling is not considered
 Batch Process Continuous Process

Product life Short, 1-2 years Longer than batch process

span
Cost of Low cost equipment High cost equipment
factory
equipment
Batch process can be Control batch process requires
Controlling
controlled very easily sophisticated control systems
Shut Down Often Rare
times
Small workforce is Continuous process is generally
Workforce needed available in fully automated plants. If
not, large workforce will be necessary.
 Chemical Process Selection
❖ Adequate & Flexible initial design is
essential.
❖ Pilot Plants: Small scale units designed to
allow experiments that obtain design data
for larger plants
❖ Statistical Analyses
❖ To commit blunders on a small scale and
make profits on a large scale.
 Corrosion, Materials of Construction
Successful operation of a chemical plant
depends on

❖ Original strength of material of construction

❖ Proper selection of material to resist
corrosion.
❖ Mechanical Failures
❖ Erosion
Corrosion, Materials of Construction

➢ Corrosion cannot be prevented ,it can only

be minimized.

➢ Corrosion resistant materials (Polymeric

Organic Materials)
 References
1) Fundamentals of chemical processing Shreve’s
chemical process industries by George T. Austin.

10/7/2020 9:55:48 AM Department of Polymer & Process Engineering, U.E.T. Lahore 13