Chemical Processing

(BTCMTOEC402)
(3 – 0 – 0)
Prof Projjal Basu
Department of Metallurgical Engineering

Dr Projjal Basu
Course Objectives
• To discuss the subject and various chemical processing
methods to make the students familiar with the various
processes

Course Outcomes
• At the end of the course, the students are expected to
understand the subject and practice in the regular mineral
processing industries without the aid of chemical
engineers

Dr Projjal Basu
Curriculum
• Module 1 : Unit Processes
• Unit processes of chemical processing

• Module 2 : Leaching Practices

• Leaching with various solvents for solid-liquid interaction with reference
to U, Al, Th, Zr, etc

• Module 3 : Leaching Parameters

• Effect of various parameters on rate of leaching

• Module 4 : Rate Controlling Steps

• Determination of rate controlling step in process design
Dr Projjal Basu
Curriculum
• Module 5 : Separation Practices
• Solid-Liquid separation practices

• Module 6 : Recovery Practices

• Recovery of valuable fraction for solution

• Module 7 : Enrichment Treatment and Metal Recovery

• Enrichment treatment of solvent like – solvent extraction, ion exchange,
precipitation technique, metal recovery from solvent and solid fraction

Dr Projjal Basu
 Module 1 : Unit Processes
ØUnit processes of chemical processing

Dr Projjal Basu
Unit Process / Unit Operation
Variety of chemical processes in various industries can
be sub-divided in to basic unit operations that follow
the same physical laws

Dr Projjal Basu
 Unit processes / operations
Making of salt from sea water

Goa
Sea Evaporation Evaporation
Water Tank 1 Tank 2

(Sand, clay, less solubles (Calcium Sulfate

settle at bottom) settles at bottom)

(Final Evaporation)
Italy
Evaporation Evaporation
Tank 3 (Crystallizer)
Tank 4

(MgCl, KCl, MgBr, etc. (Salt settles at

setle at bottom) bottom)

(Washing with saturated Fluid transportation, Evaporation, Heat transfer,

salt solution (brine) Drying, Crystallization, Solid transportation, Sieving
Drying
Salt ready Pure salt (wet)
for use
Dr Projjal Basu
 Unit processes / operations
Production of milk powder

Fluid transportation, evaporation, heat

transfer, drying, solid-gas separation,
condensation, solid transportation, sieving

Dr Projjal Basu
 Unit processes / operations Iron ore mining in
an Australian mine
for blast furnace

Iron ore mining in a

South African mine
Iron ore lumps for blast furnace

Iron ore fines for pellet plant

Dr Projjal Basu
Unit processes / operations
Classification 1 (involving process criteria)
Ø Fluid flow processes (fluids transportation, filtration, solid fluidization)
Ø Heat transfer processes (evaporation, heat exchange)
Ø Mass transfer processes (gas absorption, distillation, extraction, adsorption, drying)
Ø Thermodynamic processes (gas liquefaction, refrigeration)
Ø Mechanical processes (solid transportation, crushing & pulverization, screening &
sieving)

Classification 2 (involving elements from more than one class)

Ø Combination (mixing)
Ø Separation (distillation, crystallization)
Ø Reaction (chemical reaction)
Dr Projjal Basu
Unit processes / operations
Major operations in an integrated steel plant

Dr Projjal Basu
Unit processes / operations
Process flow diagram of an integrated steel plant

Dr Projjal Basu
Unit processes / operations

Flowsheet of processing
of steelmaking slag

Dr Projjal Basu
Unit processes / operations
The operation which involves physical changes
• distillation, fluid transportation, heat and mass transfer, evaporation, extraction,
drying, crystallization, filtration, mixing, size separation, crushing and grinding,
conveying
• Distillation (to purify or separate alcohol in the brewery industry)
• Distillation (to separate hydrocarbons in petroleum industry)
• Drying (dry fruits industry)
• Absorption (O2 in a fermentation process, H2 for liquid hydrogenation of oil
• Evaporation (production of salt)
• Settling and sedimentation of suspend solids (sewage treatment plant)
• Flow of liquid (petroleum refinery, dairy plant)
Dr Projjal Basu
Unit processes / operations
Mining industry
• Crushing
• Grinding
• Slurry transportation
• Solid-liquid separation
• Settling and sedimentation
• Surface adsorption
• Gaseous flow
• Solid transportation
• Filtration
Metallurgical industry
Unit operations (Physical operations)
• Crushing, Grinding, Sizing, Mixing
through agitation, Filtration,
Distillation, Comminution (size
reduction
Unit processes (Chemical processes)
• Leaching, Smelting, Roasting,
Electrolysis, Decarburization,
Dephosphorization, Degassing,
Deoxidation
Dr Projjal Basu
Reactor A counter-current reactor

• The heart of many metallurgical processes

• One / more unit operation / process can take place
in a single reactor
• Blast Furnace
Solid / Liquid
• Electric Arc Furnace move down
• Heat treatment furnace
• Autoclave (high temperature – high pressure reactor)
• The design of an industrial reactor must satisfy the
requirements for
• Chemical Factors Gas moves up
• Mass Transfer Factors
• Heat Transfer Factors
• Safety Factors
Dr Projjal Basu
Reactor Control factors for design, productivity,
product quality, energy efficiency,
(1) Chemical Factors safety, cost, environment issues, etc.
Ø Kinetics of the reaction(s)
Ø Must provide sufficient residence time to get required degree of reaction and
conversion to product
(2) Mass Transfer Factors
Ø Usually controlled by the rate of diffusion of reactants rather than the reaction rate
Ø Often agitation helps
(3) Heat Transfer Factors
Ø Reaction – exothermic or endothermic?
Ø The value of heat of reaction is necessary to operate the reactor
(4) Safety Factors
Ø Confinement of any hazardous reactant and products
Ø Control of reaction and process conditions
Dr Projjal Basu
Reactor
Reactor Types based on
I. Mode of Operation - Batch or Continuous
II. Phases Types - Homogeneous or Heterogeneous
III. Reactor Geometry - Flow Pattern & Process of contacting the phases

Major classes of Reactor

Industrial processes
A. Batch
Classified depending on the process output :
B. Stirred Ø Continuous processes
C. Tubular Ø Discrete processes
D. Packed Bed (Fixed) Ø Batch processes
E. Fludized Bed
Dr Projjal Basu
Reactor
CONTINUOUS PROCESSES
• Continuous flow of material / product
• Continuous transformation of mass / energy / momentum
• Processing materials in different equipment producing products
• Each machine operates in a single steady state and performs a specific
processing function
• Target is a product which is uniform in time
• Process is stopped only for maintenance / cleaning / irregular working
• Production of a narrow specification product (high and consistent
product quality)
• Reduced manufacturing cost
• Improved asset utilization
• Reduced waste Dr Projjal Basu
Reactor
DISCRETE PROCESSES
• The output of the process appears
one-by-one or in discrete quantities
• The products are produced in lots
based on common raw materials
and production history
• A specified quantity of products
moves as a unit or group of parts
between workstations
• Example : car assembly line

Dr Projjal Basu
Reactor
Single-path Batch / Multi-path Batch / Network Batch
BATCH PROCESS
Economic and technical factors could suggest that batch processes
are often more favorable than continuous processes
• Simple processing units like mixers and stirrers versus complex
production systems
• Multipurpose units which may be used for several processing
phases of the batch and could support multiproduct
manufacturing within the facility
• Batch manufacturing plants are comparatively more robust than a
continuous plant
• Batch process manufacturing facility is easier to scale up
depending on market demand and requirements LD converter
• Better control of process of a confined step
Dr Projjal Basu
Reactor
BATCH PROCESS
• Material is produced by a single execution of a batch process
• Production of a single material at any point of time in the process
• “Batch” = both the material produced by and during the process
• “Batch” = an entity that represents the production of that material
• Consists of a sequence of one or more steps that must be performed in a defined order
• At the end of the sequence of steps, a finite quantity of the finished product is produced
(the sequence is repeated to produce another batch of the product)
• It is a process that leads to the production of finite quantities of material by subjecting
finite quantities of input raw materials to an ordered set of processing activities over a
finite period of time using one or more pieces of equipment

Dr Projjal Basu
Reactor
BATCH PROCESS
• Easier tracking of inputs or products is possible and allowed
• More than one type of product can be processed simultaneously
• Movement of different products from different processing areas allowed
• Output of the process appears in quantities of materials or lots
• Neither continuous nor discrete, but have the characteristics of both
• Usually performed in a sequential way
• Generate a product but the sequential processes individually need not necessarily
generate a product
• Examples of batch processes : heat treatment, electric arc furnace melting of steel,
dairy processing, food processing, pharmaceutical formulations

Dr Projjal Basu
Reactor
BATCH PROCESS
• Nature of each step can be simple or complex, consisting of one or more unit
operations, and generally a step starts when the previous one is complete
• There is frequent provision to take “non-normal exits” because of operator
intervention, equipment failure, detection of hazardous conditions, etc
• Depending on the recipe for the product being processed, a step may be bypassed
for some products
• Quality control is sometimes required (automatic / manual) before leaving one step
and starting the next
• Processing operations for each step are generally under recipe control, but may be
modified by the operator

Dr Projjal Basu
Reactor

a) Fixed bed reactor b) Shaft furnace c) Fluidized bed d) Retort e) Rotary kiln f)
Reverberatory furnace g) Electric arc furnace h) Pneumatic/top blown converter

Dr Projjal Basu
 Batch Process vs Continuous Process
Factor Batch Process Continuous Process
Definition • A sequence of one or more steps that • A process involving moving a single work
should be performed in a defined order unit at a time between every step of the
• Finite quantity of product is produced at process without any breaks in time,
the end of sequence (which is repeated to substance, or sequence
produce another product batch) • Flow of material or product is continuous
Coordination • Equipments may/may not be coordinated • Every machine operates in a steady state
between • Time between units is maintained by and performs a certain processing function
equipments scheduling
Quantities produced Small quantities of products Large quantities of products
Product life span Short Long
Equipment cost Low High
Control Easy to control and maintain Needs sophisticated set up to control
Shutdown Often Rare
Workforce Small Large (if not fully automated)
Dr Projjal Basu
 Batch Process vs Continuous Process
Factor Batch Process
Size • Smaller throughput favorable
• As throughput increases, size of the
process equipment increases, product
handling more difficult
Batch • If product quality of each batch of
accountability/ material must be verified, batch
Product Quality operations are preferred (e.g. food
products)
• If reprocessing / waste recovery of off-
specification product is usually not
permitted, small batches are favored
Safety • Generally, worker exposure to chemicals • Safety is better maintained
and operator error are high
Continuous Process
• Economies of scale favors continuous
processes for large throughput
• Continuous or periodic testing of product
quality is carried out
• But some potentially large quantities of
off-specification product can be produced
• If off-specification material may be
blended or stored and reworked through
the process later, continuous processes are
favored
Dr Projjal Basu
 Batch Process vs Continuous Process
Factor Batch Process
Controllability • Difficult to control if the same equipment is
used for different unit operations and to
produce different products
• Efficient scheduling of equipment is very
important (scheduling control is complicated)
Operational • Often same equipment can be used for
flexibility multiple operations
Product demand • Seasonal demand for products (fertilizers,
gas-line antifreeze, food processing, etc) can
be easily accommodated
• Other products can be made during the off-
season
Continuous Process
• Generally, easier to control
• Better automation
• For complicated and highly integrated
plants, the control becomes complex and a
part of operational facility
• Operational flexibility can be built in to
the process but involves “idle” capital
• Equipment not required for one process
but needed for another will sit idle
• Difficult to make products other than
specified
• However, similar but different products
can be produced using the same processes
through a series of campaigns at different
times (lasting days/weeks/months)
Dr Projjal Basu
Unit Process/Operation based on Criteria
According to phases involved
• Gas-Solid : Roasting, Gas reduction
• Gas-liquid : Steelmaking blowing/refining, Distillation
• Liquid-Liquid : Slag-metal reactions
• Solid-solid : Phase transformation
According to equipments involved
• Fixed bed : Sintering, Percolation Leaching
• Fluidized bed : Fluidized roasting and reduction
• Shaft furnace : Iron blast furnace, lime calcination kiln
• Rotary kiln : Drying and calcination, Direct reduction
• Retort : Coke oven, Carbothermic zinc production, Mg production (Pidgeon process)
• Reverberatory furnace : Matte smelting (Cu etc.), Open hearth steelmaking
• Electric arc furnace : Steelmaking, Ferro-alloy production
• Cell for fused salt electrolysis : Production and refining of aluminium
• Cell for aqueous electrolysis : Electrolytic reduction and refining
Dr Projjal Basu
Unit Process/Operation
Classification based on Chemical Reaction
• Oxidation : roasting, sintering, LD steelmaking
• Reduction : blast furnace iron making
• Slag-metal reactions : steelmaking, matte smelting
• Chlorination : titanium (converting to tetrachloride)
• Electrolytic reduction: Zn and Al production
• Electrolytic refining : refining of Cu, Ni
Classification based on Methods of Metals Extraction
• Physical separation / Mineral processing
Ø Metallic content in ore is concentrated, crushing & grinding, screening & separation
• Pyrometallurgy
Ø Smelting, converting and refining of metal concentrate
• Hydrometallurgy
Ø Upgradation / extraction of metal in an aqueous solution at low temperature
• Electrometallurgy
Ø Electrolysis, Electrowinning, Electrorefining Dr Projjal Basu
Unit Process/Operation
Mass Balance
INPUT - OUTPUT = ACCUMULATION (I - O = A)
At steady-state, there is no accumulation of mass within the process. Then,
INPUT = OUTPUT (A = O)

∑ (Masses entering via feed streams) = ∑ (Masses exiting via product streams)

This equation can be applied to batch and continuous processes as

Batch Process : ∑(Mass in) = ∑(Mass out + Mass remaining in the reactor)
Continuous Process : ∑(Mass in by flow) = ∑(Mass out by flow)
If the process involves chemical reaction(s), we must account for the formation of product
and the consumption of feed :
∑(Mass in + Mass formed by reaction) = ∑(Mass out + Mass used by reaction)
(Mass in + Mass formed = Mass out + Mass consumed)
Dr Projjal Basu