DESIGN OF BATCH
PROCESSES
Siti Nurkhamidah
Annas Wiguno
WHAT IS BATCH PROCESS
• In a batch process, the main steps of process
operate discontinuously.
• In contrast with a continuous process, a batch
process does not deliver its product continuously
but in discrete amounts.
• This means that temperature, concentration, and
other properties vary with time.
• In practice, most batch processes are made up of
a series of batch and semicontinuous steps.
• A semicontinuous step runs continuously with
periodic start-ups and shutdowns
ADVANTAGES OF BATCH
PROCESS
• Are economical for small volume
• Are flexible in accommodating changes in
product formulation.
• Are flexible in changing production rate
• Allow the use of standardized multipurpose
equipment for the production of a variety of
products from the same plant
ADVANTAGES OF BATCH
PROCESS
• Are best if equipment needs regular cleaning
because of fouling or needs regular sterilization.
• Are amenable to direct scale-up from the
laboratory.
• Allow product integrity. Each batch of product
can be clearly identified in terms of the feeds
involved and conditions of processing. This is
particularly important in industries such as
pharmaceuticals and foodstuffs.
EXAMPLE OF BATCH PROCESS
Reactor
Steam Product
Storage
Feed Storage
C.W.
C.W.
Steam
Process Steps
• Feed material is withdrawn from storage using a pump
• The feed material is preheated in a heat exchanger
before being fed to the reactor
• After the reactor is full, further heating takes place inside
the reactor using steam in the reactor jacket.
• During the later stages of the reaction, cooling water is
applied to the reactor jacket.
• The reactor product is withdrawn using a pump.
• The reactor product is cooled in a heat exchanger before
going to storage.
GANTT CHARTS
Process
Step Tahapan proses untuk 1X produksi
Reactor filling & Feed Preheat
Reactor filling & Feed Preheat
Reaction
Reaction
Reactor Emptying & Product Cooling
Batch Distillation
Batch Cycle Time Time
SEQUENCIAL BATCHES àharus nunggu 1 rangkaian lengkap utk 1 proses
produksi selesai baru mulai dari awal lagi
GANTT CHARTS
Proses produksi yg kedua tdk perlu
Process Steps menunggu 1 tahapan lengkap selesai
asalkan alatnya sdh bisa dipakai
RFFP
REACTION
REPC
BATCH DISTILLATION
BATCH CYCLE TIME Time
OVERLAPPING BATCHES
PRODUCTION SCHEDULES FOR SINGLE
PRODUCT
SEQUENTIAL PRODUCTION SCHEDULE
Step 10 hr 10 hr 10 hr
A
5 hr 5 hr
B
5 hr 5 hr
C
Cycle Time
20 hr
The batch cycle time is the time interval between successive batches of product
being produced à waktu yg diperlukan untuk 1x produksi
PRODUCTION SCHEDULES FOR SINGLE
PRODUCT
EVERLAPPING BATCHES
Step 10 hr 10 hr 10 hr
A
5 hr 5 hr
B
5 hr 5 hr
C
Cycle Time= 10 hr
Time
PRODUCTION SCHEDULES FOR SINGLE
PRODUCT
PARALLEL UNITS FOR THE LIMITING STEP
Cycle Time=10 hr
Step 10 hr 10 hr 10 hr
A
10 hr 10 hr
A
5 hr 5 hr
B Paralel yg kedua
tidak bisa mulai
dg waktu yang 5 hr 5 hr
sama karena utk
C proses yang
kedua, alatnya
harus gantian,
hanya 1
Time
THE LIMITING STEP à proses yg waktunya paling lama
PRODUCTION SCHEDULES FOR SINGLE
PRODUCT
INTERMEDIATE STORAGE FOR THE LIMITING STEP
Cycle Time=10 hr
Step 10 hr 10 hr 10 hr
Cycle 3
Cycle 1 Cycle 2
A
Intermediate storage
5 hr 5 hr
B
Proses kedua dari cycle 2
5 hr 5 hr tidak harus menunggu
C proses 1 selesai, karena
ada storage. Tetapi proses
ketiga harus menunggu
proses 2 selesai
Time
PRODUCTION SCHEDULES FOR
MULTIPLE PRODUCTS
Produksi 2 produk dengan 3 tahapan proses
Start cycle 1 – produk A Start cycle 2 – produk A
Produksi A Karena sequensial maka:
1. produksi produk B harus nunggu A selesai dulu
Produksi B semua tahapan proses
2. produk A dan B harus selesai semua (1 proses),
baru mulai ke proses ke 2 (cycle ke 2)
PRODUCTION SCHEDULES FOR
MULTIPLE PRODUCTS
Start cycle 1 – Produksi 2 produk dengan 3 tahapan proses
produk A Start cycle 2 Kemudian, maju kedepan
– produk A utk step kedua dari
produk B, harus
nyambung dg step
terakhir dr produk B
10 hr
(2)
5 hr 2 hr
5 hr 2 hr
Letakkan dulu step
terakhir dr produk B (1)
setelah step terakhir
produk A selesai
Karena Overlapping maka:
Produksi A 1. produksi produk B TIDAK harus nunggu tahapan produksi A
selesai semua. Mulai step 1 dr produk B dari mana? Mulai dari
Produksi B step terakhir dr produk B, tunggu step terakhir dr produk A
selesai. Lalu, step 2 dan 1 dr produk B mengikuti
2. Untuk mulai cycle kedua, tidak harus nunggu produksi produk
B selesai semua.
PRODUCTION SCHEDULES FOR
MULTIPLE PRODUCTS
Produksi 2 produk dengan 3 tahapan proses
Start cycle 1 – produk A Start cycle 2 – produk A
Hold up
• Karena ada equipment hold up, maka utk step 1 produk B bisa
langsung dilakukan
• Demikian juga dengan step kedua utk produk B
Bandingkan dengan OVERLAPPING BATCH pada slide sebelumnya
PRODUCTION SCHEDULES FOR
MULTIPLE PRODUCTS
Start cycle 1 – Produksi 2 produk dengan 3 tahapan proses
produk A
Start cycle 2 – produk A
1. Step 1 dan 2 dr
produk B pd
cycle 1 bisa lgsg
dilakukan jika
step 1 dan 2
produk A selesai
2. Step 1 cycle 2 dr
produk A bisa
lgsg dilakukan
tanpa harus
menunggu step 2
dr produk A cycle
1 selesai.
• Karena ada Intermediate storage utk step 1 dan 2, maka utk step 1
produk A cycle ke2 bisa langsung dilakukan
Bandingkan dengan EQUIPMENT HOLP UP pada slide sebelumnya
PRODUCTION SCHEDULES FOR
MULTIPLE PRODUCTS
Produksi 2 produk dengan 3 tahapan proses dan
masing-masing produk ada 3 batch
harus nunggu 3 batch
produk A selesai semua baru
produksi produk B
AAABBB
Produk A dan B diproduksi
secara bergantian
ABABAB
Makespan: waktu yg diperlukan utk
produksi suatu produk sesuai
dengan jumlah batch produksinya
PRODUCTION SCHEDULES FOR
MULTIPLE PRODUCTS
Ketika alat akan
digunakan utk produksi B
setelah digunakan utk
produksi A, maka alat
harus di bersihkan, misal
perlu waktu 2 jam.
Maka proses cleaning ini
akan memperpanjang
cycle time dan makespan
PRODUCTION SCHEDULES FOR
MULTIPLE PRODUCTS
Perpindahan produk dr
step 1 ke step 2
memerlukan waktu
transfer, akan
memperbesar cycle time
dan makespan
