Orientation

1.1 Why a chemical engineer needs expertise in process technology ? A process engineer at operation in chemical plant shall have a deeper understanding of the technology on which the process plant is built to produce the profit making chemicals. A chemical engineer with sound knowledge in process technology has the following distinct advantages: a) Ability to clearly distinguish the functional role and importance of various processes and operations in the process plan

b) Technical knowledge with respect to the selection of important parameters such as Temperature, Pressure and underlying physical principles of a process.

c) Ability to distinguish various process streams and their conditions of operation Temperature, pressure and phases)

d) !asic knowledge for process troubleshooting and necessary safety precautions associated to a process"operation. 1.2 How to master fundamentals of process To master chemical process technology five crucial steps are involved namely: a) #aw$%aterials and reactions: A chosen process route to manufacture desired chemicals with appropriate purities will eventually lead to preparing a list of raw$materials and utilities. Thereby, prominent reactions can be also known. b) &onceptual process flow$sheet: A conceptual process flow$sheet where a chemical engineer has an abstract representation of the actual process flow$sheet will enable 'uicker learning. A conceptual process flow$sheet typically constitute the following attributes: technology?

#aw$material purification separators,...bag filters etc.) #aw$material processing furnace...heating, cooling etc.)

(olid$fluid operations such as cyclone

)eat

e*change

operations

such

as

#aw$material to product transformation #eaction operations using

&(T#,...P+#, P!# and !atch reactors)

Product purification ,n separation distillation,...absorption and e*traction)

processes

such

as

flash,

Product processing heat e*changers, phase change units)

#ecycle of un$reacted raw$materials as recycle streams to the reaction...operations. c) Technological know$how of each unit operation"process to eventually identify its functional role in the process flow$sheet

Temperature, pressure and composition of streams entering the

unit...process"operation

Temperature, pressure and composition of streams leaving the unit...process"operation Phases of various process"operation streams entering and leaving the unit

Associated waste and environmental ha-ardous products generation

d) Process intensification in the form of heat$integration, stream utili-ation and waste reduction and multiple recycle streams: These options are in fact optional and they enrich the energy enhancement and waste reduction efficiency of a process plant. .riginally, chemical plants developed without such process intensification policies have been sub/ected to rigorous research and case study investigations to identify opportunities for cost reduction and better energy"waste management. e) Additional critical issues related to various unit operations"processes &ost reduction approaches"process economics: )ow the operating variables such as temperature, pressure, flow$rates, reflu* rates, heating rate etc.) affect the cost of the unit operation"process

(afety issues: 0hat safety issues are most relevant and need
fre'uent...monitoring f) Alternate technologies: +or a desired function of a process unit, can thereby alternate technologies that could reduce the cost and even then provide the same functional role and desired flow rates and compositions of the emanating streams

1.3

How

much

to

memorize

for

chosen

technology

To a large extent, University education expects a chemical engineering undergraduate student to remember and draw at least a conceptual flow-sheet. However, when a systematic approach is not adopted in the learning process, it is rather difficult to remember all flow-sheets and relate to the logic behind their role in the process topology. Therefore, a well-trained student in process technology remembers process flow-sheets with logical sequence of unit processes/operations and not by strict memory.

1.4 Advantages of suggested learning approach for mastering process technology a Trains student to be more analytical/concept-oriented rather than with memori!ed "nowledge that is bereft of logical reasoning b #ystematic approach enables the growth of students$ interest in the sub%ect.

c &dditional concepts further reveal to the student how to gradually complicate process technologies for maximum efficiency. d 'nculcate strong interest in the student towards technology research and innovation by enabling a learning environment that fundamentally targets the technological "now-how. 1.5 Prominent unit operations and unit processes in chemical industry

& detailed summary of various prominent unit operations/processes and their functional role in the chemical plant are summari!ed in Table (.) along with suitable figures. !ategory "nit operations#processes $unctional role

*luid +ynamics

a ,entrifugal pump a To pressuri!e b -eciprocating pump b To depressuri!e gases c ,ompressor d .xpander a b /rinder

liquids

and

gases.

#olid-fluid units

,rusher a To reduce the si!e of solids

#olid-fluid separators

a ,yclone separator a To separate solid particles from solid-liquid/gas b ,entrifuge mixtures c .lectrostatic precipitator d ,lassifier 0 Thic"ener e 1iquid-liquid separator a #hell 0 Tube heat a To either remove or add heat to process streams exchangers so as to meet desired conditions in other units. b *ired heaters and b .ither utilities or other process streams are used furnaces to carry out heating/cooling requirements. c ,oolers 3hase separation +istillation &bsorption #tripping &dsorption .xtraction 1eaching ,rystalli!ation a To separate a feed into products with different compositions. b & third agent 4heat or compound is usually used to carry out separation.

Heat exchangers

2ass units

transfer a b c d e f g h

i 2embrane a ,ompletely stirred a To carry out reactions in homogenous fluids tan" reactor 4,#T- 4gases/liquids . b 3lug flow reactor 43*- b To carry out catalytic and multi-phase reactions. c 3ac"ed bed reactors 435d #lurry 0 Tric"le bed reactors

-eactor units

Table 0.1 ,mportant unit operations"unit processes and their functional role in chemical process technology.