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Chemical Engineering

Raw Materials Processes Products

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• 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."

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Job opportunities 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

Job opportunities and Industries

• Chemical engineers are, on

average, the highest paid among the "Big

Four".

• Electrical, Mechanical , Chemical and Civil Engineers.

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Future of Chemical Engineering

• Biotechnology emerging into a “real” commercial activity

• Nano technology……looking for applications

• Advanced materials including: bi functional materials, conducting polymers, bio materials (e.g., tissue engineering) continue development for specialized applications

Biotechnology

• Research at the interface between health, biotechnology and engineering

• Constructing a pilot-scale facility for the production of biomolecules

• Molecular design of bio-products, tissue engineering etc

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Nanotechnology

Creating products “bottom-up” using nano-assembly methods.

Synthesis of novel nanoporous carbon materials for membranes and catalysts.

Synthesis of nanostructured carbons for hydrogen storage.

Fluidisation and reaction kinetics in beds of nanoparticles.

Environment

• Increasing environmental awareness is creating new opportunities in the energy and sustainability industries.

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CH 211 ( Industrial Processes ): Fall 2013

Syllabus:

1. History and development of various chemical and process industries in Pakistan. 2. Gases: Production of hydrogen, oxygen, nitrogen and carbon dioxide. 3. Nitrogen industries: Production process of ammonia, urea and nitric acid. 4. Sulfur industries: Production process of sulfur dioxide, sulfur trioxide and sulfuric acid. 5. Phosphorous industries: Production process of phosphoric acid. 6. Chlor-alkali industries: Production process of chlorine, caustic soda and soda ash. 7. Glass industry: Production process of glass and special glasses. 8. Sodium compounds: Production process of sodium chloride and sodium sulfate. 9. Paper industry: Pulp production through soda, sulfite and kraft process, production of paper from pulp. 10. Production of hydrochloric acid, soap making, process description of sugar industry, cement industry

and paint industry.

Text & Reference Books:

1. George Austin, R. Shreve, Joseph Brink. Shreve’s Chemical Process Industries. 5th ed. McGraw-Hill. 2. Elvers, Barbara, and Giuseppe Bellussi. Ullmann’s Encyclopedia of Industrial Chemistry. 5th

ed. Weinheim: Wiley-VCH. 3. Kirk, Raymond E, and Donald F Othmer. Kirk-Othmer Encyclopedia of Chemical Technology. 5th ed. New

York; Chichester: Wiley.

Topic wise course contents Lectures

1. General Information, Grading policy, Syllabus, Learning outcomes 1,2

2. Gases: Production of hydrogen, oxygen, nitrogen, carbon dioxide 3,4,5,6

3. Nitrogen industries: Production process of ammonia, urea and nitric acid. 7,8,9

4. Sulfur industries: Production process of sulfur dioxide, sulfur trioxide and sulfuric acid.

10,11,12

5. Phosphorous industries: Production process of phosphoric acid. 13

6. Chlor-alkali industries: Production process of chlorine, caustic soda and soda ash.

14,15,16

7. Glass industry: Production process of glass and special glasses. 17

8. Sodium compounds: Production process of sodium chloride and sodium sulfate.

18,19,20

9. Paper industry: Pulp production through soda, sulfite and kraft process, production of paper from pulp.

21,22,23

10. Production of hydrochloric acid, soap making, process description of sugar industry, cement industry and paint industry.

24, 25, 26,27,28,29,30

Lectures on each Topic

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Dr. Imtiaz Ali / Office: FMSE-G06, Off.Ext: 2216, E-mail: imtiazali@giki.edu.pk Teaching Assistant: Mr. Jehanzaib Ahmad Ansari Office: Chemical Lab I

Office Hours: Anytime on working days from 8 am to 5 pm

Assignments (one) = 4% Quizzes ( four) = 24% Midterm Exam = 30% Final Exam = 42%

What about Attendance in the Class?

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Learning Outcomes of CH 211 course

• Explain the basic history, current issues, and trends in chemical process industries. • Understand basic roles, responsibilities and expectations for a career in chemical

process industry. • List some of the leading chemical process industry companies in Pakistan. • (range: manufacturers of inorganic- and organic-industrial chemicals,

petrochemicals, polymers and rubber, cement, water treatment and purification, detergents and surfactants, agrochemicals, glass, pulp and paper, gases, paints and coatings, explosives, food processing).

• Classify the chemical process industry into industrial categories of base (commodity products), intermediate (secondary products), end-products (consumer products) and specialty chemicals (fine chemicals) manufacturers.

• List the raw materials used in the manufacturing of chemicals and processed materials (range: coal, crude oil, natural gas, metal and mineral deposits, organic materials, air and water).

• Describe the sources and methods of recovering raw materials used in the production of chemicals and processed materials.

• Describe the manufacturing processes of different chemicals and processed materials.

Why – an expertise in Process?

– functional role and importance of various processes and operations in the process plan

– the selection of important parameters such as T, P and underlying physical principles of a process

– distinguish various process streams and their conditions of operation (T, P and phases)

– process troubleshooting and necessary safety precautions

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How - master fundamentals of process?

• Raw-Materials and reactions

• Conceptual process flow-sheet

• Process intensification

• Additional critical issues

• Alternate technologies

To what extent - memorize a process?

• Atleast remember process flow-sheets with logical sequence of unit processes/operations.

– A conceptual process flow diagram; an abstract representation of the actual process flow-sheet will enable quicker learning

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Advantages of learning approach

a) more analytical/concept-oriented with logical reasoning

b) Systematic approach enables the growth of students’ interest in the subject.

c) Additional concepts further reveal to the student how to gradually complicate process technologies for maximum efficiency.

d) Inculcate strong interest in the student towards technology research and innovation by enabling a learning environment that fundamentally targets the technological know-how.

Unit-operations /processes in chemical industry

Category Unit operations/processes Functional role

Fluid operations

a) Centrifugal, Reciprocating pumps, Compressor d) Expander

a) To pressurize liquids and gases. b) To depressurize gases

Solid operations

Crusher and Grinder To reduce the size of solids

Solid-fluid separators

Cyclone separator, Centrifuge, Electrostatic precipitator, Classifier & Thickener, Liquid-liquid separator

To separate solid particles from solid-liquid/gas mixtures

Heat exchangers

Shell & Tube heat exchangers, Fired heaters and furnaces, Coolers

a) To either remove or add heat to process streams so as to meet desired conditions in other units. b) Either utilities or other process streams are used to carry out heating/cooling requirements.

Mass transfer units

Phase separation, Distillation, Absorption, Stripping, Adsorption, Extraction, Leaching, Crystallization, Membrane

a) To separate a feed into products with different compositions. b) A third agent (heat or compound) is usually used to carry out separation.

Reactor units Completely stirred tank reactor (CSTR), Plug flow reactor (PFR), Packed bed reactors (PBR), Slurry & Trickle bed reactors

a) To carry out reactions in homogenous fluids (gases/liquids). b) To carry out catalytic and multi-phase reactions.

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Classification of industries

• Heavy chemical industries

• Fine chemical industries

Classifications

1. Based on quantities of produced and consumed

• Heavy chemicals – large quantity normally crude or less purified

chemicals e.g. mineral acid, NaOH, Na2CO3 etc

• Fine chemicals – purified substances and produced in limited quantity. e.g. speciality solvent, perfumes, medicines etc

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Classifications

2. Based on chemical composition • Organic compound

e.g. hydrocarbons, phenols, carboxylic acid etc.

• Inorganic compound

e.g. Na2CO3, K2Cr2O7, MgCl2

• Polymers – macromolecular mass compounds; covalent bonding of repeating

structured units which may be natural, synthetic or semi synthetic. e.g. polystyrene, polyvinylchloride etc.

Classification

3. Based on availability

• Natural compounds – Available in nature or produced or extracted from

plant and animals. Due to large utilization & limited production the natural source is depleting.

e.g. coal, petroleum etc.

• Synthetic products – Man made compounds. They may be synthesized

using natural product or synthetic materials.

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Description of Process

• Flow Diagrams / Flow Sheets

(3 Levels of Diagram)

– Block Flow Diagrams (BFD) or Block flow sheet

– Process Flow Diagrams (PFD) or Process flow sheet

– Process (Piping) and Instrument Diagrams (P&ID)

As chemical engineers, we are most familiar with BFD and PFD

The Block Flow Diagram

• BFD shows overall processing picture of a chemical complex

– Flow of raw materials and products may be included on a BFD

– BFD is a superficial view of facility –information is missing

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The Block Flow Diagram

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Comparison of PFD and P&ID

Process Flow Diagrams Process (Piping) and

Instrumentation Diagram General process flows between major

equipment clearly presented in a

simplified manner

General process flows present but

convoluted due to many sheets and

abundance of information

Omits valves, controls and minor

pipelines

Includes all valves, controls and minor

pipelines

Provides baseline for operating

conditions for flows, compositions, etc.

(min, nonnal, max)

Information on piping (material of

construction and schedule) and safety

features (i.e. pressure relief valves,

interlocks)

Stream labeled with infonnation

presented at the bottom of each sheet

Safe operating ranges of equipment

presented at bottom of each sheet

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