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Chapter 1-Fundamentals of Chemical Manufacturing

The document outlines the course 'Process Industries I' at Addis Ababa Science and Technology University, detailing its objectives, content, and key components of process industries. It covers various topics including chemical manufacturing fundamentals, nitrogen and sulfur industries, chlor-alkali industries, agro-chemical industries, and pulp and paper technology. The course aims to equip students with the knowledge to recognize industrial processes, raw materials, and develop new process technologies.

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Alazar Tafese
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23 views31 pages

Chapter 1-Fundamentals of Chemical Manufacturing

The document outlines the course 'Process Industries I' at Addis Ababa Science and Technology University, detailing its objectives, content, and key components of process industries. It covers various topics including chemical manufacturing fundamentals, nitrogen and sulfur industries, chlor-alkali industries, agro-chemical industries, and pulp and paper technology. The course aims to equip students with the knowledge to recognize industrial processes, raw materials, and develop new process technologies.

Uploaded by

Alazar Tafese
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Addis Ababa Science and Technology University

College of Biological and Chemical Engineering

Process Industries I
Course Outline
Name: Process Industries I (ChEg3141)
Course Objectives & Competences to be Acquired
Upon completion of the course:
• Recognize flow charts, raw materials, energy, fuels and industrial
gases
• Identify the process technologies for nitrogen, sulphuric acid, cement,
chloro-alkali, phosphorus and pulp and paper industries
• The student will be able to understand process technology and also
develop new and better process technology
Course Outline: Content
1. Fundamentals of chemical manufacture
 Batch versus Continuous Processing
Flowcharts of Raw materials for chemical Industries
Energy and fuels
Industrial Gases
Course Outline: Content
2. Nitrogen Industries
Ammonia synthesis, nitric acid, ammonium nitrate, ammonium sulphate,
ammonium phosphate, sodium nitrate, potassium nitrate, cyanide

3. Sulfur and Sulfuric acid


Mining and manufacture of sulfur
Sulfuric acid
Recovery of used sulfuric acid
Course Outline: Content
4. Chlor-alkali Industries
Manufacture of soda ash
Manufacture of sodium bicarbonate
Manufacture of Caustic soda
Bleaching Powder
5. The process technology of phosphoric acid industries
Course Outline: Content
6. Agro-chemical Industries
Nitrogen Fertilizers
Phosphate Fertilizers
Potash Fertilizers
Mixed Fertilizers
Pesticides
7. Pulp and paper Technology
8. Cement Processing
9. Industrial visit
Chapter one: Fundamentals of Process Industries
• Introduction to process development
• Batch vs Continuous processing
• Flowcharts
• Raw materials for chemical engineering
• Energy and Fuels
• Industrial gases
What is process industry and its main component?
• As the word indicates process industries comes from two words, process
and industries.

 Process:- sequence of unit operation in which (physical changes) +


chemical changes (reactor) is occurred.

• A series of actions or steps towards achieving a particular end and a natural


series of changes.

 Industries:- the processing of raw materials and manufacture of goods in


factories .
COMPONENTS OF PROCESS INDUSTRIES
1) Chemical industries

 Organic (oil, fats, soap, detergent, pulp and paper, pharmaceutical, flavor) industries

 Inorganic (phosphorus, potassium, sulfur and sulfuric acid, photographic, surface coating,
HCL, explosives and toxic) industries

 Petrochemical (nuclear, petroleum, fibers, cycle intermediates and dyes)industries

 Plastica (plastic, rubber and etc) industries

 Combustible and gases (coal, carbon, fuel, ceramic, glass, chloro-alkali) industries

2) Food industries

Sugar (beet, cane) industries

Food complex (biscuit, pasta, milk, fruit, cereal, beverage) industries


3) Other industries Nano industries and metal industries
Introduction to process development
• The preliminary feasibility survey
 Laboratory and pilot plant data is required
 Pilot scale and/or semi-work scale is considered for data accuracy

Valuable Information's:
• Material and energy balance
• Process conditions (temp, pressure, variations)
• Yield/ rates
• Grade of raw materials and product
• Batch vs continuous process operations
• Material of constructions
• Operation characteristics….etc
Batch Vs Continuous Processing

Loading Processing Output

Loading
Processing
Output
Batch Vs Continuous Processing
• A process is consider to be a batch process if the process consists of a sequence
of one or more steps that must be performed in a definite order.
• In a continuous process, as suggested by the name, the flow of material or
product is continuous
• Each machine operates in a single steady state and performs a specific processing
function
• Continuous transformation of mass, energy and momentum.
• The target is a product which is uniform in time.
• The process is stopped only for maintenance (scheduled or not), cleaning,
irregular working
Batch Vs Continuous Processing
In many cases continuous operation is advantageous over batch
Costs can be reduced by using continuous instead of batch
Why:-
 Less-labor is required
Reduce waste
 Easy of control of the equipment's
 Grade of the final product is simplified
Batch Vs Continuous Processing
• Batch processes are common in the early stages of chemical
industries
• Mostly used for small scale production
Note:- Most process have been switched completely or partially to
continuous operations
Example: Agitated batch crystallizations
Batch reactors
Batch Vs Continuous Processing
Examples of batch and Continuous unit processes

1. Mixing : - Batch Mixer (for batch process), and Pumps (for


continuous process)
2. Reactors:- Batch reactors , and continuous stirred tank /semi-batch
3. Distillation:- Batch distillation and Continuous distillation
4. Extraction processes:- Batch/continuous
5. Evaporators:- Batch, semi-batch or continuous process
6. Crystallization:- Batch/ semi-batch is preferable
Process flowcharts
• Also called process flow diagram
• Flowchart is a picture of the separate steps of a process in sequential
order.
What to include?
sequence of actions
material entering/leaving (simply, inputs/outputs)
decisions that must be made
Process conditions
Process flowcharts
When to use flowchart?

 To develop a process
To study for improvement
 For communication
To document a process
Process flowcharts
Commonly used symbols

Process step Direction of flow

Input/output Start/end

Delay/wait Decision
Process flowcharts
• For the case of butanol production from ethanol:
Flowcharts
• For the case of butanol production from ethanol:
Raw material for chemical industries
Definitions:

 Raw materials are defined to be the natural materials and semi-products used
in the manufacture of industrial products

 The raw materials are among the main elements determining to a considerable
extent the production technology, the quality and cost of the products.

 Both the raw materials and the products must meet definite requirements
corresponding to the relevant state standards.
Raw material classifications
• The material are classified according to a variety of features:
• Chemical composition (inorganic and organic)
• Origin (mineral, vegetative, and animal), and
• State (solid, liquid and gaseous)

Mineral raw materials are divided into


ore (metallic),
non-metallic and
combustible (organic)
Raw material classifications
1. Ore mineral raw materials
Ore mineral raw materials used for producing commercially pure
metals consist of natural minerals.
oOre minerals mainly contain metal oxides and sulfides (Cu2S,
CuS, Fe2O3, Fe3O4, ZnS, etc.).
o In ferrous metallurgy, they include SiO2, Al2O3, CaO and MgO.
oBut these oxides can be used as the ores of non-ferrous metals
(ex. Al2O3 was raw material in Al production).
Raw material classifications

2. Non-metallic mineral raw materials


Non-metallic mineral raw materials are diverse in their chemical
composition
 Used either in their natural state (sand, clay, asbestos, and mica) or
 Delivered for chemical processing (chloride, phosphates, sulphates,
carbonates, and aluminosilicates).
Raw material classifications
3. Combustible mineral raw materials
Combustible mineral raw materials such as
o lignite, peat, coal, shale, and also petroleum and natural gas
which are relate to organic compounds and are also used as
energy source.
o Vegetative and animal raw materials include wood, cotton, oils
and fats, milk, hides and wool.
o They are processed either in to food products (food raw
materials) or into products for domestic and industrial use. Such
available and cheap raw materials as water and air are also widely
used in the chemical industry.
Raw material for chemical industries
Note: The cost of the raw materials in the chemical industry about 60-70% of the
product cost.

To determine the main trends in solving the raw material problem :


1) the surveying and use of cheaper raw materials
2) the used of concentrated raw materials (Extraction/Importing)
3) the complete utilization of raw materials (waste minimization/Cleaner P.)
4) replacement of cheaper raw materials (considering quality standard)
Energy and Fuels
• Commonly considered as utilities
• Fuels such as, Benzene, diesel oil, Furnace oil, acetylene, (generally
derivatives of petroleum products and natural gas could be used as
direct heating
• Energy from fuels/electricity/ steam are common
• 3 to 30 bar steam are common in industrial processes
• Renewable energies (such as energy from biomass, from waste
materials, electricity from sun light and wind are considered due to
Environmental concern.
Energy and Fuels
Unit process that required excessive energies are,
• kilns
• Distillation columns,
• Heat exchangers,
• Evaporators,
• Pumps,
• Crystallizations,
• Endothermic reactors, …and so on
Industrial gases
• Industrial gases are a group of gases that are specifically manufactured
or use in a wide range of industries.
• The principal gases are:
o Acetylene : mainly used in oxy-acetylene flames for cutting mild
steel and for welding
o Hydrogen : As a fuel and as raw material (Hydrogenation)
o Carbon dioxide: For carbonation, as a raw material for production
of other chemicals .
o Nitrogen : cooling and as an inert atmosphere
o Argon: highly unreactive/ inert atmosphere
o Oxygen : oxidizing agent,
End

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