Seatwork for Reading Assignment

Directions:

• Bring out your small booklets.

• CHEATING in any form is not allowed.
• NO ERASURES OR ANY FORM OF ALTERATION are
allowed. Kindly think about your answer before writing
it. :D
• At the end of the today’s lesson, the answers will be
given. Check you own papers

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Reading Assignment:

Question 1: The two basic or primary “unit operations”

involved in the School of Chemical Engineering Practice
are:

A. Flow of Heat and Flow of Fluid

B. Flow of Heat and Flow of Mass
C. Flow of Mass and Flow of Fluid
D. Flow of Time and Flow of Mass

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Reading Assignment:

Question 2: As mentioned by Lewis and Haslam (1922),

flow of fluid and flow of heat affects the following factors
except for:

A. Generation of Valuable Products

B. Efficiency of Product Formation
C. Rate of Product Formation
D. None of these

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Reading Assignment:

Question 3: The “primary unit operations” mentioned by

Lewis and Haslam (1922) is known today as ______.

A. Unit Processes
B. Transport Phenomena
C. Chemical Process Fundamentals
D. Core Chemical Engineering

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Reading Assignment:

Question 4: Which of the following statements is true?

A. Not all unit operations requires the knowledge of both fluid flow
and heat flow
B. The student spends eight months in the School of Chemical
Engineering Practice after completing their four-year study in
the Institute
C. In classroom training, students are expected to find out the
necessary data for problem course.
D. None of these

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Reading Assignment:

Question 5: Which of the following statements about the

early process of air-drying is correct?

A. The knowledge in flow of heat is sufficient enough to design air-

drying operation
B. Air from the surrounding is directly pumped to the drying
material.
C. The design of air-drying operation is based on how increasing
the air velocity aids in the transfer of heat from the heater to air.
D. None of these

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Reading Assignment:

Question 6: Which of the following is true about plant

experimentation and chemical engineering laboratory?

A. Laboratory experimentation is sufficient enough for chemical

engineering practice
B. In plant experimentation, student develops technical judgment
and mental resourcefulness.
C. Laboratory experimentation has a higher level of difficulty as
plant experimentation.
D. None of these

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Reading Assignment:

Question 7: Which of the following processes is not

mentioned in the reading as illustration of experimental
methods and results ?

A. Drying
B. Distillation
C. Extraction
D. Combustion

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Chemical Process Industries

Part I
• History of Chemical Engineering
• Role of a Chemical Engineer
• Unit Operations
• Unit Processes
• Fundamentals of Chemical processing
• Process Flow Chart

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Unit Operations and Unit Processes

"Chemical engineering…is not a

composite of chemistry and mechanical
and civil engineering, but a science of
itself, the basis of which is those unit
operations which in their proper sequence
and coordination constitute a chemical
process as conducted on the industrial
scale.”
Arthur D. Little
http://ichemeblog.org/2015/05/18/t
Not only unit operations, en-chemical-engineers-that-shaped-
our-world-day-356/
but describing and designing each unit
using kinetics, thermodynamics,
and transport phenomena.
Chemical Process Industries (INPRCHE)
Term 2, AY 2017-2018
Definitions
from RA # 9297 (The Chemical Engineering Law)

Unit process shall mean the chemical change which is

involved in the manufacture of industrial or consumer
products or the treatment of industrial or chemical wastes.

Unit operation shall mean the physical operation by which a

desired step in an industrial process is conducted or
controlled. This includes, but is not limited to: storage of
gases, liquids, solids, heat transfer, evaporation; mass
transfer, i.e. distillation, absorption, adsorption, drying,
humidification, extraction, leaching, mixing and dispersion,
separation, i.e. filtration, screening, molecular sieving and
coalescing. 11
Chemical Process Industries (INPRCHE)
Term 2, AY 2017-2018
Definitions

unit operations [CHEM ENG] The basic operations of

chemical engineering in a chemical process plant, that
is, distillation, fluid transport, heat and mass transfer,
evaporation, extraction, drying, crystallization,
filtration, mixing, size separation, crushing and
grinding, and conveying.

unit process [CHEM ENG] In chemical manufacturing, a

process that involves chemical conversion.

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
 Material Balance in Unit Operations and Processes

For Steady-State Unit Processes, the material balance equation is

INPUT GENERATION OUTPUT CONSUMPTION

For Steady-State Unit Operations, the material balance equation is

INPUT OUTPUT

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Rationale for Learning Unit Operations and Processes

• Chemical Engineering Design requires the manipulation

of physical and chemical changes.
• The change in the property of the output stream should
also be considered.
Physical (Unit Operations) Chemical (Unit Processes)
Filtration Distillation Combustion
Evaporation Extraction Oxidation
Crystallization Leaching Halogenation
Size Reduction Gas Absorption Chemical Precipitation
Screening Drying Coagulation
Centrifugation Humidification
Distillation Adsorption

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Unit Operations
• Unit operations involve a physical change or chemical
transformation such as separation, crystallization,
evaporation, filtration, polymerization, isomerization,
and other reactions.
• A unit operation is a basic step in a process.
Unit Operations
Five Classes
1. Fluid flow: including fluids
transportation, filtration, and solids
fluidization.
2. Heat transfer: including evaporation and
heat exchange.
3. Mass transfer: including gas absorption,
distillation, extraction, adsorption, and
drying.
4. Thermodynamic: including gas
liquefaction, and refrigeration.
5. Mechanical: including solids
transportation, crushing and
pulverization, and screening and sieving.
Unit Operations
Fluid Flow Operations
1. Fluid transport: delivery of fluid from one point to another
using pumps, fans, blowers.

2. Filtration: the separation of solids from liquids when the

amount of solid is relatively small as compared to the liquid
phase.

3. Fluidization: a process similar to liquefaction whereby a

granular material is converted from a static solid-like state to a
dynamic fluid-like state
Unit Operations
Heat Transfer Operations
1. Evaporation: process by which a slurry is
concentrated by heat exchange with steam.

2. Heat Exchanger: change the temperature of a flowing

stream using another flowing stream.

3. Crystallization = the process whereby a solution is

supersaturated in order to produce crystals.
Unit Operations
Mass Transfer Operations
• Distillation: This is an operation whereby components of a liquid
mixture are separated by boiling because of their differences in vapor
pressure.
• Gas Absorption: this process involves the removal of a component
from a gas stream by treatment with liquid
• Drying: In this operation, volatile liquids, usually water, are removed
from solid material.
• Liquid-liquid Extraction: In this case a solute in a liquid solution is
removed by contacting with another liquid solvent which is relatively
immiscible with the solution.
• Leaching: This involves treating finely divided solid with a liquid that
dissolves out and removes a solute contained in the solid
• Adsorption: In this operation, a component of a gas or liquid stream is
removed by a solid adsorbent
Unit Operations
Thermodynamic Operations
1. Humidification: The process in which the moisture or
water vapor or humidity is added to the air without
changing its dry bulb

2. Dehumidification: removal of moisture from air, a

process with principle opposite that of humidification.

3. Refrigeration- a process of removing heat from a low-

temperature reservoir and transferring it to a high-
temperature reservoir through the application of
mechanical work.
Unit Operations
Mechanical Operations
1. Crushing/Size Reduction: reduction of
particle size through application of
mechanical force

2. Screening: separation of particles

depending on the screen size

3. Particle Transport: operations involving

transporting particle streams using
conveyors, etc.

4. Agglomeration: enlargement of particle

size through lumping
Transport Phenomena
• It concerns the exchange of mass, energy, and
momentum between observed and studied systems.

• The use of mathematics to

understand the behaviour of
many diverse chemical
engineering system (unit
operation & processes).
Transport Phenomena

• Momentum Transfer involves velocity gradient as

driving force.
𝑑𝑣
𝜏=𝜇∙
𝑑𝑡
• Heat Transfer involves temperature gradient as driving
force.
𝑑𝑇
𝑄 = 𝑘𝐴 ∙
𝑑𝑥
• Mass Transfer involves concentration gradient as
driving force.
𝑑𝐶𝐴
𝑁𝐴 = 𝐷𝐴𝐵
𝑑𝑥
Transport Phenomena

 World War II creation of new technologies by

scientists without engineering education: atomic
bomb, radar.
 Engineering students needed to master new
concepts and tools in chemistry and physics.
 Unit Operations no longer created streams of
exciting new research problems that were
challenging to professors and students, and useful
in industry.
Transport Phenomena

• First textbook “Transport Phenomena” by Bird-

Stewart-Lightfoot, 1960, based on kinetic theory
of gases
Mathematical Modelling

 Textbook by Amundson
“Mathematical Methods in
Chemical Engineering”,
(1966).
 A new burst of creative
research activities.
 American chemical industry
dominated world, DuPont
and Exxon content to recruit
academically educated
graduates, willing to teach
them technology.
Unit Process
Unit processing is the basic processing in chemical
engineering. Together with unit operations it forms the main
principle of the varied chemical industries. Each genre of unit
processing follows the same chemical law much as each
genre of unit operations follows the same physical law.

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Origins
• About 1930, P.H.
Groggins suggested a
somewhat similar approach
to classifying chemical
operations as “unit
processes”
• This concept has not proved
as useful as the unit
operations idea nor have its
concepts been reduced to
mathematical procedures Unit Processes In Organic
Synthesis Hardcover – 1938
by P H Groggins

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Example of Unit Process
Combustion = chemical reaction of oxygen with materials/compound
accompanied by the emission of light and raid generation of heat.

Oxidation = reaction of oxygen with materials without the emission of

light usually slower process with slow generation of heat.

Thermal Cracking = is usually carried out by pumping the gas oil through
a coil of tubes in a furnace.

Chemical Precipitation = involves the addition of chemicals to alter the

physical state of dissolved and suspended solids.

Coagulation = employed to separate suspended solids from water

through the destabilization of colloids by neutralizing the forces that keep
them apart.

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Named Processes
• Birkeland-Eyde Process - one of the competing industrial processes in
the beginning of nitrogen based fertilizer production. Nitrates are
produced from nitric acid.
• Haber-Bosch Process – catalyzed process in production ammonia
from air.
• Solvay Process – process the convert salt brine and limestone into
soda ash.
• Mond Process- process to extract nickel from nickel through the
reaction with syngas and carbon monoxide.
• Kraft Process- process to produce paper from wood or wood pulp
• Ostwald Process- chemical process for making nitric acid from
ammonia

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Chemical Processes
In an "engineering" sense, a chemical process is a method
intended to be used in manufacturing or on an industrial
scale to change the composition of chemical(s) or
material(s), usually using technology similar or related to
that used in chemical plants or the chemical industry.

“a series of unit operations used

to produce a material in large
quantities.”

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Chemical Processes
In the chemical industry, chemical engineers will use the
following to define or illustrate a process:
1. Process Flow Diagram (PFD)
2. Piping and instrumentation diagram (P&ID)
3. Simplified process description
4. Detailed process description
5. Project management
6. Process simulation

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Challenges in Chemical Processes
• Chemical Processes involves the use of available
technologies and resources in the environment.
• From a chemical engineer’s standpoint, the following
challenges are encountered in chemical processes
• The extraction of desired input material from natural
resources
• The control emissions and waste materials generated
by the process
• The product yield required and the quality of the
output stream.
• The energy requirement for each process.

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Typical Production Life Cycle
(Culaba and Purvis, 1999)

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Case Study: Aluminum Production
Bayer Process
• Conversion of Bauxite (aluminum ore) to aluminum oxide.

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Case Study: Aluminum Production
Hall-Heroult Process
• Conversion of Aluminum Oxide into Aluminum

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Video on Aluminum Production
https://www.youtube.com/watch?v=fa6KEwWY9HU
Impacts of Aluminum Production
• Based on Lupis and McMichael(1999), 1 ton of aluminum
products have the following environmental impacts:
Energy Conservation in Unit Operations
Energy Conservation in Unit Operations
Energy Conservation in Unit Operations
Objectives for Unit Operations and Processes
• To reduce environmental impacts by process
improvement and development of newer ways to
integrate different unit operations and processes.

• To reduce energy used for unit operations by integrating

heat exchanger networks

• To improve degrees of separation for unit operations.

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Answers

1) A
2) D
3) B
4) D
5) C
6) B
7) B

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Reading Assignment (for 1/23/2018)

Cresmaschi, S. (2015) A perspective on process synthesis:

Challenges and prospects. Computers and Chemical
Engineering 81, 130-137.

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018