CHE227: PRODUCT DESIGN & DEVELOPMENT

CHAPTER 4: SPECIALTY CHEMICAL MANUFACTURE

MEOR MUHAMMAD HAFIZ SHAH BUDDIN
meorhafiz7767@johor.uitm.edu.my

Ext:8523
1

LECTURE OUTLINE
First Step Towards Production
Separation

Specialty Scale Up

LEARNING OUTCOME
STUDENTS SHOULD BE ABLE
To determine optimum parameter involves in
the product design.

WHAT ARE WE GOING TO LEARN TODAY

Chap 1

Needs

Chap 2

Ideas

Chap 3

Selection
Specialty
Chemical
Manufacture

1st Step Toward Production

Extending Laboratory Result

Reaction Eng.

Separation

Heuristics For Separation

The Most Useful Separation

Specialty Scale Up

Reactor Scale Up
Separation Scale Up

REACTION ENGINEERING
BOTH

Ethylene oxide

Ethylene Glycol

Reactive Intermediate
6

Hydrolyzed to form EG
Ethylene Carbonate
7

HEURISTICS FOR SEPARATION

BASIC CONFIGURATION OF CHEMICAL PROCESS

HEURISTICS FOR SEPARATION

10

HEURISTICS FOR SEPARATION

11

HEURISTICS FOR SEPARATION

12

HEURISTICS FOR SEPARATION

13

14

HEURISTIC RULES FOR DISTILLATION SEQUENCE

1. Remove unstable, corrosive or chemically reactive components early
in the sequence
2. Remove final products one by one as overhead distillates
3. Remove, early in the sequence, those components of greatest molar
percentage in the feed
4. Make the most difficult separations in the absence of other
components
5. Leave for later in the sequence those separations that produce final
products of the highest purities
6. Select the sequence that favors near-equimolar amounts of overhead
and bottom in each column

16

17

SCALE UP
PROCESS DEVELOPMENT
CONTINUOUS INTERACTION BETWEEN EXPERIMENTATION AND ECONOMICS.

INPUT
OUTCOME

: CHEMICAL REACTION IN THE LAB

: PRODUCTION PLANT

DEVELOPMENT OF A PROCESS TO TAKE THE CHEMICAL REACTION IN THE LAB UP TO A LARGE

PLANT SCALE IN AN ECONOMIC WAY.

REACTOR SCALE UP

Time scale shown is very long

(8 years... due to time
associated with:
1. design
2. construction
3. operation of small
steps.

19

REACTOR SCALE UP
1) Lab Scale
Predictive models: Process steps
described in a Mathematical model
with predictive value
Predictive models are used to scale
up equipment and processes from
laboratory data or pilot plant to
eliminate steps and save time.

20

REACTOR SCALE UP
2) Mini Plant:
The reaction provides satisfactory yields.
Based on lab data and literature data, the
process concept is put together.
Individual steps are developed and tested on
a lab scale
A process flow sheet is drawn.
A small scale plant is designed (mini-plant) to
evaluate performance of the entire process.
21

REACTOR SCALE UP
3) Pilot Plant
A pilot plant may be designed
and built for further testing.
At each stage, evaluation
occurs. Continue, stop, or go
back to an earlier stage?
Decisions are based on
technical, cost and market
considerations.
22

REACTOR SCALE UP
1.
2.
3.
4.
5.
6.

Stoichiometry of reactions taking place

Range of T and P for the reactions
Phases of the reactions
Product distribution vs. conversion
Conversion vs. residence time
Information on the catalyst

Often available from the literature

Identify any side reactions that may take place
23

QUIZ: BATCH VS. CONTINUOUS?

1) PRODUCTION RATES
A) CAPACITY 10X106 LB/YEAR

> usually continuous

> usually batch

B) CAPACITY 1 X 106 LB/YEAR

2) MARKET FORCES
A) SEASONAL PRODUCTS (FERTILIZER)
B) PRODUCTS WITH A SHORT LIFETIME
C) PHARMACEUTICAL PRODUCTS

> usually batch

> usually batch/continous
> usually batch

3) OPERATIONAL
A) REACTION IS VERY FAST
B) RAPIDLY FOULING MATERIALS

> usually continous

> usually batch

SEPARATION SCALE UP
REACTION PRODUCT CONTAINS MULTIPLE
COMPONENTS, YOU MUST DECIDE HOW THEY WILL BE
SEPARATED AND AT WHAT CONDITIONS.

How ?

Look at the components and how they

differ (ie boiling point, solubility)
Identify possible unit operations (ie.
Distillation, absorption, adsorption,
solvent extraction, etc.)
25

SEPARATION SCALE UP
Decision : inputs and outputs
SHOULD YOU PURIFY THE FEED STREAMS BEFORE THEY ENTER THE PROCESS?
SHOULD YOU REMOVE OR RECYCLE A BY PRODUCT?
SHOULD YOU USE A GAS RECYCLE OR PURGE STREAM?
SHOULD YOU RECYCLE UNREACTED REACTANTS?

HOW MANY PRODUCT STREAMS WILL THERE BE?

26

SEPARATION SCALE UP
PROCESS EVALUATION

Technically

Economically
27

SEPARATION SCALE UP
RISK ASSESSMENT

Identify risks

Estimate risks
with proper
tools

Cost/time
Risks should be
well managed

How ?
28

THANK YOU

29