have to be made to hold several days, or weeks, storage to smooth out fluctuations and interruptions in supply. Even when the materials come from an adjacent plant some provision is usually made to hold a few hours, or even days, supply to decouple the processes. The storage required will depend on the nature of the raw materials, the method of delivery, and what assurance can be placed on the continuity of supply. If materials are delivered by ship (tanker or bulk carrier) several weeks stocks may be necessary; whereas if they are received by road or rail, in smaller lots, less storage will be needed.
Stage 2. Feed preparation
Some purification, and preparation, of the raw materials will usually be necessary before they are sufficiently pure, or in the right form, to be fed to the reaction stage. For example, acetylene generated by the carbide process contains arsenical and sulphur compounds, and other impurities, which must be removed by scrubbing with concentrated sulphuric acid (or other processes) before it is sufficiently pure for reaction with hydrochloric acid to produce dichloroethane. Liquid feeds will need to be vaporised before being fed to gas- phase reactors, and solids may need crushing, grinding and screening.
Stage 3, Reactor The reaction stage is the heart of a chemical manufacturing process. In the reactor the raw materials are brought together under conditions that promote the production of the desired product; invariably, by-products and unwanted compounds (impurities) will also be formed.
Stage 4. Product separation
In this first stage after the reactor the products and by-products are separated from any unreacted material. If in sufficient quantity, the unreacted material will be recycled to the reactor. They may be returned directly to the reactor, or to the feed purification and preparation stage. The by-products may also be separated from the products at this stage.
Stage 5. Purification Before sale, the main product will usually need purification to meet the product specifi- cation. If produced in economic quantities, the by-products may also be purified for sale.
Stage 6. Product storage
Some inventory of finished product must be held to match production with sales. Provision for product packaging and transport will also be needed, depending on the nature of the product. Liquids will normally be dispatched in drams and in bulk tankers (road, rail and sea), solids in sacks, cartons or bales. The stock held will depend on the nature of the product and the market.
Ancillary processes In addition to the main process stages shown in Figure 1.3, provision will have to be made for the supply of the services (utilities) needed; such as, process water, cooling INTRODUCTION TO DESIGN 7
water, compressed air, steam. Facilities will also be needed for maintenance, firefighting, offices and other accommodation, and laboratories; see Chapter 14.
1.3.1. Continuous and batch processes
Continuous processes are designed to operate 24 hours a day, 7 days a week, throughout the year. Some down time will be allowed for maintenance and, for some processes, catalyst regeneration. The plant attainment; that is, the percentage of the available hours in a year that the plant operates, will usually be 90 to 95%. . . „ hours operated Attainment % = ~ x 100 8760 Batch processes are designed to operate intermittently. Some, or all, the process units being frequently shut down and started up. Continuous processes will usually be more economical for large scale production. Batch processes are used where some flexibility is wanted in production rate or product speci- fication.
Choice of continuous versus batch production
The choice between batch or continuous operation will not be clear cut, but the following rules can be used as a guide.
Continuous L Production rate greater than 5 x 106 kg/h 2. Single product 3. No severe fouling 4. Good catalyst life 5. Proven processes design 6. Established market
1. Production rate less than 5 x 106 kg/h
2. A range of products or product specifications 3. Severe fouling 4. Short catalyst life 5. New product 6. Uncertain design
1.4. THE ORGANISATION OF A CHEMICAL ENGINEERING
PROJECT The design work required in the engineering of a chemical manufacturing process can be divided into two broad phases. Phase 1. Process design, which covers the steps from the initial selection of the process to be used, through to the issuing of the process flow-sheets; and includes the selection,
Contribution To The Comparison of Conventional Concentric Magnetic Gear and Double Stage Concentric Magnetic Gear For High Power Offshore Wind Applications
