Lecture-1 (2018)

Rabia Sabir
Lecture -1
Course Code: Ch. E-201
Course Title: Chemical Process Industry
Credit Hours: 2-1-3
Course Designation: Core
No of Sessions per week: 1 (Total 16 sessions)
Session Duration: 120 min
Knowledge profile: WK-6
 Chemical Processing and the work of the Chemical Engineer.
 Water Treatment Industry, Water Conditioning, Environmental Protection, Energy, Fuels, Air
Conditioning and Refrigeration,
 Chlor-Alkali Industries,
 Explosives, propellants and Toxic Chemical Agents
 Sulfur and Sulfuric Acid,
 Nitrogen Industries,
 Production of Benzene,
 Pulp and Paper Industries,
 Sugar and Starch Industries,
 Glass Industries,
 Phosphorous Industries,
 Portland Cements,
 Calcium and Magnesium Compounds,
 Agrichemical Industries
 Text book :
 Austin George T. “Shreve’s Chemical Processes Industries” 6th Ed. 1997, McGraw-Hill
International Edition.
 Reference books:
1. Haidari Iqbal “Chemical Industry in Pakistan”.1992. Industrial Research Service Karachi, Pakistan.
2. Pandey G.N. “A Textbook of Chemical Technology” 2ndEd.Vol-I & II. 2000.Vikas Publishing House (Pvt)
Limited
3. Riegels Handbook of Industrial Chemistry, James A. Kent 2000, Springer/ Van Norstrand/Rein Hold.
4. Kirk Othmer “Encyclopedia of Chemical Technology” 1999, Inter Science Publishers.
 This course is designed in conjunction with the following PLOs.
 PLO-5: Modern Tool Usage: An ability to create, select and apply appropriate
techniques, resources, and modern engineering and IT tools, including prediction
and modeling, to complex engineering activities, with an understanding of the
limitations.

 PLO-10: Communication: An ability to communicate effectively, orally as well as
in writing, on complex engineering activities with the engineering community and
with society at large, such as being able to comprehend and write effective reports
and design documentation, make effective presentations, and give and receive
clear instructions.

 CLO-1: Demonstrate and Sketch process flow diagram of production processes
through modern tools.
 CLO-2: Develop strong written and oral communication skills in order to present
and defend technical information related to chemical process industries.

Course Learning Program Learning Learning Domain
Outcome Outcome
CLO-1 PLO-5 Cognitive 3
CLO-2 PLO-10 Cognitive 2, Affective 2,4

Chemical Process Industry
Building up Confidence
Chemical
S S+L
S+L+G
L
S+G L+G
G
Examples ?
Chemical Sulfur
Coal
Water
Oil
S L
Slurry
Wet Solid
S+L
S+L+G
Foam Moist Air
Dust Strom Aerated Water
S+G L+G
G
Air
Hydrogen
S+L+G: Oil Hydrogenation
Chemical
Hygienic Fluids
Chemical
Flammable
Chemical
Hazardous
Chemical
Corrosive
Chemical
Slurry
Chemical
Viscous Liquids
Chemical
Explosive
Chemical
Steam
Chemical
Freezing Liquids
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Chemical
Fine Solids
Chemical
Crystalline Solids
Chemical
?
Process
Utility
Raw Material Process Product
Waste
Process Fuel, Water, Electricity
Utility
Raw Product
Preprocessing Conversion Separation Finishing
Material
Waste Treatment
Solid,Liquid,Gas Wastes
Koncept Learning Center klcenter@gmail.com

Process
 Chemical Transportation
 Chemical Conversion
 Chemical Separation

Process
 Chemical Transportation
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Process
 Physical
 Thermal
 Molecular

Process
 Physical
oSize
oPhase

Process
 Physical
oSize

Process
 Physical
oPhase

Process
 Thermal

Process
 Molecular
klcenter@gmail.com
Process
 Molecular
oMixing
oReaction

Process
 Chemical Separation
oSolid – Solid
oLiquid – Solid
oGas – Solid

Industry
oEquipment
oPiping
oInstrument
oElectrical
oStructure
oCivil

Industry
oEquipment
Storage
Transportation
Processing
Separation

Industry
oEquipment
Storage

Industry
oEquipment
Transportation

Industry
oEquipment
Processing

Industry
oEquipment
Separation

Industry
oPiping

Industry
oPiping

Industry
oInstrument

Industry
oInstrument

Industry
oInstrument

Industry
oElectrical

Industry
oElectrical

Industry
oElectrical

Industry
oStructure

Industry
oStructure

Industry
oCivil

Industry
oCivil

Industry
oCivil

• More typically, chemical engineers concern themselves with
the chemical processes that turn raw materials into valuable
products.
• The necessary skills encompass all aspects of design, testing,
scale-up, operation, control, and optimization, and require a
detailed understanding of the various "unit operations", such as
distillation, mixing, and biological processes, which make these
conversions possible.
• Chemical engineering science utilizes mass, momentum, and
energy transfer along with thermodynamics and chemical
kinetics to analyze and improve on these "unit operations."
huge variety of sector :
• Chemical and allied products
• Plastics and polymers
• Fertilizers
• Cement
• Pulp and paper
• Paints
• Energy
• Water
• Food & drink
• Petrochemicals, petroleum and natural gas processing
• Biotechnology
• Pharmaceuticals
• Environmental control
• Business and management
• Consultancy
 Chemical engineering emerged as a separate discipline in 1910 by the professors at
Massacusetts Institute of Technology. They characterized the “physical operations”
necessary for manufacturing chemicals as “Unit Operations”
 Heat Transfer
 Fluid Flow
 Distillation
 Filtration, etc
 In 1930, P.H. Groggins suggested a somewhat similar approach to classifying

“chemical operations” as “Unit Processes”
 Nitration
 Sulfonation
 Oxidation
 Chlorination, etc.
• Chemistry (Basic Science)
The engineer must develop the research laboratory results of the chemist into an
economical chemical process.
 Yield:
The fraction of raw material recovered as the main (or desired) product.
 Conversion:
The fraction changed to something else---by-product as well as products.
The goal of Chemical Engineer, always concerned with cost, is to have the conversion equal the
yield.
 The study of reactions speed
 The effects of process conditions on these rates
 Temperature
 Pressure
 Reactant concentration
 Cost is strongly affected by material use and distribution.
 Material Balance:
A study showing the origin and ultimate disposition of all materials used
 Energy Balance:
Concerned with energy changes and energy flow in a chemical process
Batch Process Continuous Processing
 Can be measured most concisely  Require far smaller, less expensive
equipment, have much less material
 Temperature control can be trouble
in process
some
 Hence have less chance to ruin large
 Production of Small quantities of
quantities
chemical
 Have more uniform operating
conditions and products
 Require more concise control of flows
and conditions
 Flow Diagrams
 Block Flow Diagrams (BFD)
 Process Flow Diagrams (PFD)
 Piping and Instrument Diagrams (P&ID)
 Adequate and flexible initial design is essential
 Process engineer is a specialist in current aspects of chemical process design
 Senior design engineer is able to foresee and solve plant problems of less obvious
nature, such as
 Maintenance
 Safety
 Conformation to government environmental controls, etc.
 Experienced consultants, either individuals or professional consulting firms, are

available to advise, design, or erect chemical process plants
 Pilot plants are small- scale units designed to allow experiments that obtain design
data for larger plants and sometimes to produce significant quantities of a new product
to permit user evaluation of it.
 Expensive but essential
 It is cheaper to correct errors in judgment by experimentation in the pilot plant
 The pilot plant should be constructed with equipment identical in material with that to
be used by commercial plant in order to ascertain the effects of corrosion and
“to commit blunders on a small scale and make profits on a large scale”
 Equipment is emphasized in conjunction with descriptions of various processes
and with flowcharts representing these processes
Examples
 Pumps
 Filter presses
 Distillation towers
 Nitrators, etc.
 Successful operation of chemical plants depends not only on the original strength
of the materials of construction but also upon proper selection to resist corrosion
 Corrosion cannot be prevented; it can be minimized
 Advances in material science have provided many corrosion resistant materials:
 Rubber-covered steel
 Resin-bonded carbon
 Tantalum to resist hydrochloric acid
 Stainless steel to resist the action of aqueous nitric acid and organic acids even
under pressure
 Nickel or nickel-clad steel to resist caustic solutions, hot or cold
 Automatic and instrument-controlled chemical processes are common and essential
 Some instruments can even optimize plant conditions to meet changing feed
conditions
 Instruments should not be chosen simply to record process variables; their function is
to assure consistent quality, usually by sensing, controlling, recording and maintaining
desired operating conditions
 Types
 Indicating instruments—presenting current data, value, or deviation from a norm
 Recording instruments– permit study and analysis
 Indicating/recording and controlling instruments– permit all the above and using a variety of
kinds of responses to deviations from the chosen set point, control the operation.
 Analog instruments:
Such as pressure spring thermometers and Bourdon pressure gauges, show results by
mechanical movement of some type of device which is proportional to the quantity
being measured
 Digital instruments:
Transducers-a device to convert the quantity being measured into some type of signal
(usually electrical or pneumatic)– and electronic circuitry to convert this signal to
readable numerical figures (digits)which are displayed and or recorded
 Engineers are distinguished from scientists by their consciousness of costs and profits
 Every engineering decision involves cost considerations
 Engineers must continue to keep abreast of economic changes that may effect their
products
The primary objective of the engineer’s endeavors should be to deliver safely the best
product or the most efficient services at the lowest cost to the employer and the
consuming public
 Change is an outstanding characteristic of chemical procedures
 One of the functions of research and development (R&D) division is to keep abreast of
progress and to make available knowledge of improvements or even fundamental
changes leading to the making of any given product in which the organization is
interested
 For instance, there are many technical processes for making phenol, ethanol, and
acetic acid. Choosing the one from among many that is best for a particular location or
time is an economic decision.
Yields and conversions of the chemical process from the basis for the material
balances, which in turn are the foundation for the cost determination. When
obtainable, materials and quantities from standard practice are tabulated under the
flowcharts
 Engineers are concerned with the direction and control of energy
 Expended in moving of raw materials by ships, trucks, or pipeline
 It may be employed in the form of heat of steam or electricity
 Or it may be the energy given out in exothermic reactions
 Or that which is absorbed in endothermic chemical reactions
 Energy costs from oil, gas coal, solar, nuclear or electrical energy from air or water
are all constantly changing , so it is extremely difficult to make long-range plans
 It is possible to reduce energy use by altering processing procedures, particularly
by using new separations technologies
 Skilled operators contribute as much to a plant’s success as excellence in design
 The chemical process industries have moved rapidly into labor-saving techniques:
particularly, rapid extension of continuous processing, the use of process
controllers, and optimizing procedures.
 Labor requirements in the chemical industry are comparatively small, but many
jobs require above average skills and pay above average wages
 Raw material
 Energy
 Labor
 Depreciation
 Sales
 Customer service
 Time delays
 Purity and Uniformity of product
 Required purity effects the cost
 Physical condition of the products has a great influence on marketability
 Packaging
 Packaging and storing are expensive and should be avoided
 Refillable bulk ones such as tanks, tank ships, pipelines, tank cars etc are
economical containers
 Ways to reduce transportation cost, iterruptions in supply can be expensive
 The sales person is the eyes, ears and nose of a company, bringing information to
aid in economic forecasting
 Sales and customer service form the major contact between buyer and seller
 Availability of raw materials
 Transportation
 Markets
 Environmental constraints
 Water supply
 Availability of efficient labor
 Cost of land
 Waste disposal facilities
 Fire
 Toxic materials
 Safety devices and fire protection measures
 Acts and laws
 Construction engineering organizations to build a plant and also to participate in
its design
 Large companies have their own construction departments
 Top engineers must be registered or licensed
 Plants superintendents and plant managers
 The combination of a B.S. in chemical engineering followed by an M.B.A in
business has been very popular as a springboard to middle management.
 Pilot plants
 Electronic simulators
 With the simulators, emergency procedures under hazardous conditions can be
worked out without danger
 New and improved processes
 Lower costs and lower process of products
 Services and products never before known
 Change of rarities to common commercial supplies of practical usefulness
 Adequate supply of material previously obtained only as by-product.
 Products of improved quality

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Rabia Sabir

CLO-1 PLO-5 Cognitive 3

CLO-2 PLO-10 Cognitive 2, Affective 2,4

Raw Material Process Product

Process Fuel, Water, Electricity

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

Koncept Learning Center klcenter@gmail.com

 In 1930, P.H. Groggins suggested a somewhat similar approach to classifying

 Experienced consultants, either individuals or professional consulting firms, are

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