Chemical Process Industries Chemical Engineering Department

CHPE 306 Chemical Process Industries 2016 Sunday, Tuesday, Thursday 8:00 – 8:50 PM Instructor : Dr. Qazi Nasir Room 2A-2

Chemical Process Industries ASSESSMENTS Course Works Assignments (2) 10% Quizzes (2 ) 10% Project and /or Site visit Reports (2) 10% Two In-term exams (2) 30% Final Examination 40% REFERENCES Austin, G.T., "Shreve's Chemical Process Industries", 5thed McGraw- Hill: New York, 1984. 3

Introduction Dr Salam Al-Dawery

Summary of the Course Provide introduction of definition and working principles of equipment for unit operations coupled with flowsheeting of process design such as PFD and P&ID. Illustration of the chemical process of various industries such as in refinery, petrochemicals, sulfuric acid, chlor-alkali industry, cement, glass, fertilizer, dairy, sugar, water, soap, etc, with particular emphasis on sultanate applications. Dr Salam Al-Dawery Dr Salam Al-Dawery

Objective of the Course Identify the relationship between industrial chemistry and chemical engineering. Explain the basic operation of the chemical industry. Define a process flow diagram (PFD) and a process and instrumentation diagram (P&ID). Create a PFD from a written description of a process. Evaluate feeds and products from written descriptions of chemical processes. Conduct actual survey of the process operation by visiting the plants. Practice research a topic independently or as a team member, prepare a written and report, and make an oral presentation Dr Salam Al-Dawery Dr Salam Al-Dawery

Definition of Chemical Engineering & Unit Operations Chapter One Definition of Chemical Engineering & Unit Operations Dr Salam Al-Dawery

What is Chemical Engineering Definition found in a standard dictionary: “A branch of engineering which involves the design and operation of large scale chemical plants, petrochemical, refineries, and the like.” Another definition : “Concerned with processes that cause substances to undergo required changes in their chemical or physical composition, structure, energy content or physical state.” Dr Salam Al-Dawery

Chemical Engineer Tasks Chemical Engineers convert scientific discoveries into marketable products. They are involved in many aspects of chemical production, research, and design, as well as in the construction and operation of industrial plants. They design equipment for safe storage and transportation of chemical solids, liquids, and gases, Design control systems for chemical plants based upon data from lab experiments and pilot plant operations. Chemical Engineers also perform tests and take measurements in order to determine the most efficient production methods Dr Salam Al-Dawery

General Steps of Chemical Process SEPARATION PROCESS REACTION PROCESS RAW MATERIALS INTERMEDIATE PRODUCT FINAL PRODUCT Dr Salam Al-Dawery

Chemical Process Design There is no standard steps There is no single correct solution There is always a need to find a better solution from several alternatives Dr Salam Al-Dawery

Given Information for a Process Design Products needed and production rate Purity of the desired product Raw material to be used Utility available The process route Expected market Site selection Dr Salam Al-Dawery

Results of Process Design Project Process flowsheet description Mass and energy balances results Equipment sizing and specification Economic feasibility analysis Environmental requirements The final report Dr Salam Al-Dawery

Plant Operation In the design of an industrial plant, the methods which will be used for plant operation and control help to determine many of the design variables. For example, the extent of instrumentation can be a factor in choosing the type of process and setting the labor requirements. It should be remembered that maintenance work will be necessary to keep the installed equipment and facilities in good operating condition. Dr Salam Al-Dawery

Lets look at the overall process flow of a modern oil refinery: Dr Salam Al-Dawery

The overall process is broken down into individual subsets: Physical Chemical Thermal Catalytic Distillation Solvent extraction Propane deasphalting Solvent dewaxing Blending Visbreaking Delayed coking Flexicoking Hydrotreating Catalytic reforming Catalytic cracking Hydrocracking Catalytic dewaxing Alkylation Dr Salam Al-Dawery

With Their Own Flow Arrangement: Distillation Dr Salam Al-Dawery

Fluid Catalytic Cracking Dr Salam Al-Dawery

We notice….. Fluid Dynamics Heat Transfer Evaporation Humidification The number of individual processes is large, each one can be broken down into a series of steps that appear in process after process The individual “steps” have common techniques and are based upon the same scientific principles Fluid Dynamics Heat Transfer Evaporation Humidification Gas absorption Solvent Extraction Adsorption Distillation Drying Mixing Classification Fluidization Filtration Screening Crystallization Centrifugation Materials handling Dr Salam Al-Dawery

Fluid Dynamics A study of the behaviour of fluids In Chemical processes fluid streams flow from one process to another through pipes and ducts. Process fluids are moved by pumps and compressors Fluid flowrates must be monitored by meters and are controlled by valves. Dr Salam Al-Dawery

Heat Transfer: Process fluids may need to be heated up to a certain temperature Heat from a process stream may be recovered This can be done by contacting two streams in a heat exchanger. Dr Salam Al-Dawery

Evaporation: A special case of heat transfer, where a phase change takes place. Concentrate a solution consisting of a volatile solute and a nonvolatile solvent The volatile solute evaporates leaving a more concentrated solution. Dr Salam Al-Dawery

Humidification: Transfer of material between a pure liquid phase and a fixed gas phase that is nearly insoluble in the liquid Example: Water vapor is added to a air, and thus, cooling tower is used to decrease water temperature Dr Salam Al-Dawery

Gas Absorption Also known as stripping process It is mass transfer operation A soluble vapor is absorbed from its mixture with an inert gas by means of a liquid in which the solute gas is more soluble. Example: the removal of CO2 and H2S from natural gas or syngas by absorption into amines or alkaline salts Dr Salam Al-Dawery