Chemical Process Industries: Introduction: Chemical Engineering Department Universitas Muhammadiyah Surakarta

CHEMICAL PROCESS
INDUSTRIES: INTRODUCTION
Chemical Engineering Department

Universitas Muhammadiyah Surakarta
COMPETENCE
 Students are expected to explain the process
flow diagram and process of organic and
inorganic chemicals
 Students can apply workflow application
examples of synthesis processes in plants (i.e.
Sodium compounds, Phosphate compounds,
Iron and Steel, Cement, Citric Acid)
Organic and inorganic chemical
industries
 Kinetic and thermodinamic views

 Ethanol
 Ammonia
 Urea
 Ammonium sulfate & ammonium nitrate
 Sulfuric acid
 Nitric acid
REFERENCES
 Coulson, JM., Richardson, JF., 1989, Chemical
Engineering Vol. 6 An Introduction to Chemical
Engineering Design, Oxford, New York
 Kirk Othmer, 2003, Concise Encyclopedia of Chemical
Technology Vol. 2, 4th. ed., Wiley-Interscience, New
York
 Ullmans Encyclopedia of Industrial Chemistry, 6th ed.,
Wiley-VCH
 Austin, GT., 1996, Shreve’s Chemical Process
Industries, MGH, New York
Basic terminologies (1)
 In science, a process is a sequence of
changes of a real object/body which is
observable using scientific method.
 A chemical process is a method or means
of somehow changing one or more
chemicals or chemical compounds. Such a
chemical process can occur by itself or be
caused by somebody. Such a chemical
process commonly involves a chemical
reaction of some sort.
 A chemical reaction is a process that
always results in the inter conversion of
chemical substances
 Chemical science is the scientific study of
interaction of chemical substances that are
constituted of atoms or the subatomic
particles: protons, electrons and neutrons
 Chemical engineering is the application of
science, in particular chemistry and
physics along with mathematics and
economics to the process of converting
raw materials or chemicals into more
useful or valuable forms. Its practitioners
are called chemical engineers.
 Process engineering is often a synonym for
chemical engineering and focuses on the
design, operation and maintenance of chemical
and material manufacturing processes. Process
engineering and process engineers are found in
a vast range of industries, such as the
petrochemical, mineral processing, material,
Information Technology, food and
pharmaceutical and biotechnological industries
 Chemical engineering unit operations and
chemical engineering unit processing form the
main principles of all kinds of chemical
industries and are the foundation of designs of
chemical plants, factories, and equipment used.
 Each genre of unit processing follows the same
chemical law.
 Each genre of unit operations follows the same
physical law
 The chemical process industry comprises the

companies that produce industrial chemicals
and other useful products with the help of
different unit operations and unit processes. It
is central to modern world economy, converting
raw materials (oil, natural gas, air, water,
metals, minerals) into more than 70,000
different products in the world.
 Block flow diagram is a diagram of a system, in

which the principal parts or functions are
represented by blocks connected by lines, that
show the relationships of the blocks. They are
heavily used in the engineering world in
hardware design, software design, and process
flow diagrams.
 A process flow diagram (PFD) is a diagram
commonly used in chemical and process
engineering to indicate the general flow of
plant processes and equipment. The PFD
displays the relationship between major
equipment of a plant facility and does not show
minor details such as piping details and
designations. Another commonly-used term for
a PFD is a flowsheet.
 A piping and instrumentation diagram is a
diagram which shows the interconnection of
process equipment and the instrumentation
used to control the process.
 In the process industry, a standard set of
symbols is used to prepare drawings of
processes. The instrument symbols used in
these drawings are generally based on
Instrumentation, Systems, and Automation
Society (ISA) Standard
Standard
symbols
CHEMICAL ENGINEERING
RAW MATERIALS PRODUCTS

PROCESS
- UNIT PROCESS (CHEMICAL)
- UNIT OPERATION (PHYSICS)

Aspects of Industrial Chemical
Processes (1)
 Products
 Types of process
 Flowsheets
 Mass balances
 Energy balances
 Heat transfer and heat exchangers
 Reactor design and operation
 Separation and purification processes
Aspects of Chemical Process
Industries (2)
 Process instrumentation and process
control
 Materials handling
 Process economics
 Safety and environmental issues
 Quality
etc
Classification of chemical products
 Bulk chemicals e.g. sulphuric acid

 Fine chemicals e.g. ‘ibuprofen’
 Speciality chemicals e.g. adhesives
 Inorganic/organic
Classification of chemical products
Bulk chemicals are characterised by a combination of two

parameters – large volume production, which is
supported by market demand, and lower unit costs,
where the principle of economy of scale is important.
Fine chemicals are produced on a relatively smaller scale
in more versatile (less dedicated generally) production
units using batch operations. Product specifications may
be more exacting and unit cost is relatively higher. Fine
chemicals may be used as ingredients in formulations or
as intermediates in the production of more complex
chemicals. For example bulk pharmaceuticals.
Characteristics of fine versus bulk
chemicals
Characteristic Fine chemical Bulk chemical

e.g. ibuprofen e.g sulphuric acid
Scale small large
Price 22 $/kg 0.08 $/kg
Process type batch continuous
Synthesis Multi-step Few steps

Characteristic Fine chemical Bulk chemical
e.g. ibuprofen e.g sulphuric acid
Raw material high low

consumption
(kg/kg)
Energy consumption high low
(kJ/kg)
Uses specific diverse
Value added high low
Molecular high low

complexity
Speciality chemicals
These are chemically formulated products

manufactured from basic chemicals which
are used by industry and domestic
consumers for specific purposes. For
example: coatings, adhesives,
pharmaceutical products, pesticides,
cosmetics, disinfectants etc
BATCH or CONTINUE?
BATCH CONTINUE
No input and Input and output at the
output at the same same time
time
Unsteady state Steady state
Small production Larger production
Function of time Not function of time
Variation in Products in unity
products
Easy to control More complex in control
THERMOCHEMISTRY
 CaO + H2O → Ca(OH)2 + Q
 A→B
 ∆H = HB - HA
 ∆H = Hproduct – Hreactant
EXOTHERMIC / ENDOTHERMIC
Enthalpy of Reaction
 ΔH of an equation in which the substances
contained in the equation is expressed in
units of moles and the coefficients of the
equation is simple.
 Example:
 2Al + 3H2SO4 → Al2(SO4)3 + 3H2
 ∆H = -1468 kJ
Enthalpy of Neutralisation
 ΔH (always exothermic) of the

neutralization of acid or alkaline reaction.
Example:
 NaOH(aq) + HCl(aq) → NaCl(aq) + H2O(l)
 ∆H = -890.4 kJ/mol
∆Hcombustion= ∆Hc
 ∆H of combustion of 1 mole of substances

using O2 from air measured at 298 K and
1 atm.
 Example:
 CH4(g) + 2O2(g) → CO2(g) + 2H2O(l)
 ∆Hc0 = -802 kJ
∆Hformation= ∆Hf
 ∆H to form 1 mol substances directly from

the their components measured at 298 K
and 1 atm.
 Example:
 H2(g) + 1/2 O2(g) → H20 (l)
 ∆Hf0 = -285.85 kJ
∆Hdecomposition= -∆Hf
 ∆H of the decomposition 1 mol substances

to their components (opposite of ∆H
formation).
 Example:
 H2O (l) → H2(g) + 1/2 O2(g)
 ∆H = +285.85 kJ
Lavoisier-Laplace Law
The amount of heat released in the formation of
one mole of a substance from elements =
amount of heat required to decompose the
substance into its constituent elements. So, if the
reaction is reversed the sign of the heat that is
formed is also reversed from positive to negative
or vice versa
Example:
N2(g) + 3H2(g) → 2NH3(g) ; ∆H = – 112 kJ
2NH3(g) → N2(g) + 3H2(g) ; ∆H = + 112 kJ

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CHEMICAL PROCESS

Chemical Engineering Department

 Kinetic and thermodinamic views

 The chemical process industry comprises the

 Block flow diagram is a diagram of a system, in

RAW MATERIALS PRODUCTS

- UNIT PROCESS (CHEMICAL)

- UNIT OPERATION (PHYSICS)

 Safety and environmental issues

 Bulk chemicals e.g. sulphuric acid

Bulk chemicals are characterised by a combination of two

Characteristic Fine chemical Bulk chemical

Price 22 $/kg 0.08 $/kg

Process type batch continuous

Synthesis Multi-step Few steps

Raw material high low

Uses specific diverse

Value added high low

Molecular high low

These are chemically formulated products

 CaO + H2O → Ca(OH)2 + Q

 ΔH (always exothermic) of the

 ∆H of combustion of 1 mole of substances

 ∆H to form 1 mol substances directly from

 ∆H of the decomposition 1 mol substances

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