ADIGRAT UNIVERSITY

COLLEAGE OF ENGINEERING & TECHNOLOGY

CHEMICAL ENGINEERING DEPARTMENT

PROCESS INDUSTRIES –I

Course code ChEg 3141

Lecture-1
 1. Fundamentals of Chemical Manufacture

1.1 Batch versus Continuous Processing:

I) What is processing?
It is a serious of operations/processes connecting together
to produce a certain usable chemical products.
II) Type of processing:
1. Batch processing
2. Continuous processing
3. Semi –batch processing
4. Semi- continuous processing
 1. Batch Processing
• The feed is charged into a vessel at the beginning of the process
and the vessel content are removed sometimes letter.
• No mass crosses the system boundary between the time the feed is
charged and the time of the product discharged.
• OR,
 The reactants are added at the beginning of the process
 Reaction proceeds
 Composition changes with time
 Reaction is stopped after the desired conversion is reached
 Product(s) is(are) withdrawn
 2.Continous Processing
• It can be defined as: the input and output parts are flow
continuously through the duration of the process.
• OR
Reactants feed continuously and products withdrawn
continuously
 Almost always operates under steady state
 Usually lower production costs than batch processing
 Lacks flexibility of operations ( for only one operation)
 Usually suitable for large scale production
 Semi- batch & Continuous processing
• Semi-batch processing: some of the reactants may be added to
the batch as the reaction proceeds and some of the products may
be withdrawn from the batch as the reaction proceeds.

• Semi – continuous processing: Basically a continuous process

that is interrupted periodically.

Feed/input

System
product/output
 1.2 Flowchart
• It is a type of diagram that represents as process or an
algorithm, showing the steps as boxes or various kinds,
and their order by connecting them with arrows.

• This diagrammatic representation illustrates a solution

to a given problem.

• Used in analyzing, designing, documenting or managing

a process.
 1.3 Raw Materials for Chemical industries
• What does raw materials means?

• It is defined to be the natural materials and semi-products

used in the manufacture of industrial products.

• Raw materials are among the main elements determining to

a considerable extents the production technology, the
quality and cost of different products.

 Natural Raw Materials: Obtained by nature

 Semi- products: the residue/by products of other industries

 Classification of Raw Materials
• Classified according to a variety of features:
√ Based on their chemical composition ( like Organic
and Inorganic).
√ Based on their Original (Like mineral, vegetative,
animal).
√ Based on their state of aggregation( like Solid, liquid
and gaseous).

 Mineral raw materials: ● Ore ( metallic)

● Non-metallic

● Combustible ( organic)
 Cont.
• Ore mineral raw materials: Are used for producing

commercially pure metals like: Cu2S, ZnS and Fe3O4.

• Non-metallic mineral raw materials: are diverse in their

chemical combustion and are used either in their natural state (

sand, clay, etc.)

• Combustible mineral raw materials: They are related to organic

compounds and also used as energy source. (Such as Lignite,

coal and natural gas)

 Vegetative and Animal raw materials
• Including: √ wood
√ cotton
√ Oil and fats
√ Milk
√ Hides and wools
 1.4 Energy and Fuels
• Since the chemical process industries consume more than one –third

of the energy used by all manufacturing industries,

• Chemical engineers should be familiar with the broad technical aspects

of energy production and use.

• Space heating, Transportation and industry are the major use of

energy.

• In chemical industries, high energy consumers steam for Evaporation,

Heating , drying, air conditioning, electric use for external use,

 1.4 Energy and Fuels
• Energy is defined as the ability to produce or do work
and that work can be divided into several main tasks and
easily recognize:

√Energy produce Light

√ Energy produce heat

√ Energy produce motion

√Energy produce sound

√ Energy produce growth

 Form of Energy
• There are many form of energy, but they all fail
into two categories:
1. Potential Energy
2. Kinetic Energy
 Energy and Its Various Forms:

→ Chemical Energy: is the energy which helps to "glue" atoms together in those

clusters called molecules, or chemical compounds. (Fuel grade ethanol C2H5OH)

CH3-CH2-OH ------ H-C-C-OH

Like: Natural gas, or propane, or oil --When we burn these fuels-- Release or Lost

→ Heat Energy --- Separate some of the atoms from each other and liberating the

chemically-bound energy that held them together. And this Chemical energy is

changed in form to high temperature heat energy.

 Energy and Its Various Forms:

→ Thermal Energy: Involves the microscopic movement of atoms and molecules in

everything around us. Often commonly referred to as heat or caused by Hot and warm.

Two types of thermal energy

√ "Sensible" Energy or sensible heat, is energy that “knock” molecules and atoms

in substances such as water. The more movement, the hotter the substance

becomes. Sensible energy gets its name from the fact that we can sense it, by touching
the substance directly or indirectly with a thermometer of some type.

√ "Latent" Energy or latent heat, is the energy that is needed to make a substance

such as water (a liquid) change to a different form (or phase) of the same

substance such as water vapor (a gas).

● Heat will always naturally flow from a higher temperature to a lower temperature.

● Managing every form of energy, its movement and transformations.

• Phase Change For Water
 INTRODUCTION

• Useful Thermal Energy

thermal energy is useful if it can do some thermal work for us

Some simple forms of useful thermal work might be:

 Heating a tank of cold liquid with an electric heater

 Heating a container of chemicals with steam to sustain a chemical reaction

 Heating a building in winter with a hot radiator

 Evaporating water from milk with a steam coil

 INTRODUCTION

Mechanical Energy

 Mechanical energy is the energy of physical movement. Many engineering systems

are designed to transport a fluid from one location to another at a specified flow rate,

velocity, and elevation difference, and the system may generate mechanical work in

a turbine or it may consume mechanical work in a pump or fan during this process

Electrical Energy

 Electrical energy involves the movement of electric current through wires.

 Electrical energy is a very useful form of energy because it can perform many

functions. Ultimately, most electrical energy or electricity also ends up as thermal

energy in the form of sensible heat .

 Energy Utilization in process industries
• Energy Utilization
Energy source can be electricity
or Liquid petroleum gas (LPG),
Heavy Fuel oil, Natural gas…
NONRENEWABLE
AND
RENEWABLE
RESOURCES
NONRENEWABLE RESOURCES

A nonrenewable resource is a natural

resource that cannot be re-made or
re-grown at a scale comparable to its
consumption.
NUCLEAR ENERGY
Nuclear fission uses
uranium to create
energy.
Nuclear energy is a
nonrenewable
resource because once
the uranium is used, it
is gone!
 COAL, PETROLEUM, AND GAS
Coal, petroleum, and
natural gas are
considered
nonrenewable because
they can not be
replaced in a short
period of time. These
are called fossil fuels.
 RENEWABLE RESOURCES
Renewable resources are
natural resources that can be
replenished in a short period
of time.

● Solar ● Geothermal
● Wind ● Biomass
● Water
SOLAR

Energy from the

sun.
Why is energy
from the sun
renewable?
 GEOTHERMAL

Energy from
Earth’s heat.

Why is energy
from the heat of
the Earth
renewable?
 Energy from
WIND
the wind.

Why is energy
from the wind
renewable?
 BIOMASS
Energy from
burning organic
or living matter.
Why is energy
from biomass
renewable?
WATER or HYDROELECTRIC
Energy from the
flow of water.
Why is energy of
flowing water
renewable?
 SUMMARY

What are the

differences
between
nonrenewable and
renewable
resources?
Energy Sources
 Fossil Fuels
Coal, Oil and Gas are
called "fossil fuels"
because they have been
formed from the fossilized remains of
prehistoric plants and animals.
They provide around 66% of the world's
electrical power, and 95% of the world's total
energy demands
 How Fossil Fuels
Work
• Coal is crushed to a fine
dust and burnt. Oil and
gas can be burnt directly.

Burn fuel> heat water to make steam>

steam turns turbine>turbine turns
generator>electrical power
sent around the country
• Coal provides around
28% of our energy, and
oil provides 40%.

• Crude oil (called "petroleum")

is easier to get out of the ground
than coal, as it can flow
along pipes. This also
makes it cheaper
to transport.
• Natural gas
provides around
20% of the world's
consumption of
energy
Advantages to Using Fossil Fuels
• Very large amounts of electricity can be
generated in one place using coal, fairly
cheaply.
• Transporting oil and gas to the power stations
is easy.
• Gas-fired power stations are very efficient.

• A fossil-fuelled power
• station can be built
• almost anywhere
 Disadvantages of Using Fossil Fuels
• Basically, the main drawback of fossil fuels is
pollution.

• Burning any fossil fuel produces carbon dioxide, which

contributes to the "greenhouse effect", warming the
Earth.

• Burning coal produces sulphur dioxide, a gas that

contributes to acid rain.

• With the United States importing 55% of its oil, oil

spills are a serious problem