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Poly Eng PDF
Poly Eng PDF
PST 105
Basic Chemical Engineering and
Polymer Industry
Semester 2
Polymer
• In polymers repeating units are bonded by
covalent bonds
– Monomer
– Oligomer
• Dimer
• Trimer
• Tetramer
Classification of Polymers
• Basic classifications
– Natural /Synthetic
– Polymer structure
• Liner, branched cross linked, ladder Vs functionality
– Amorphous or crystalline
– Homopolymers and copolymers
– Polymerization mechanism
– Thermal behavior
Properties of Polymers
• Mechanical Properties
• Solution Properties
• Electrical and Electronic Properties
• Weatherability
• Magnetic Properties
• Optical Properties
• Thermal Properties
• Biocompatibility
• Chemical Properties
Types of Polymer Processing Industries
• Dry Rubber Manufacturing
• Liquid Rubber Manufacturing
• Plastic Manufacturing
Polymer Applications
Tyers
• Natural rubber (cis -1,4 polyisoprene)
• Styrene-butadiene co-polymer (SBR) is a synthetic rubber
which is often substituted in part for natural rubber
based on the comparative low materials cost
• Polybutadiene is used in combination with other rubbers
because of its low heat-buildup properties
• Polyisobutadiene (Low gas permeability) Use for tyer iner
tubes
• shock-absorbing polyurethane spokes
Clothing
• Nylons
• Polyester
• Cotton (cellulose)
• PET (Polyehyleneterepthalate)
Furniture
• Polypropylene
• Polypropylene copolymers
• Polyurethane
Dinner wear
Melamine formaldehyde
Shoes/toys/chewing gum
• Polyurethanes
• Natural Rubber
• Styrene butadiene co-polymers
Shampoos/Toothpaste
• Siloxane polymers
– Dimethicone, also known as polydimethylsiloxane
(PDMS), is a silicone oil
Non stick Kitchen wear
• Polytetrafloroethlene
Grocery bags
• Polyethylene
• Polypropylene
Disposable cups
• Polystyrene (Expanded)
Polycarbonate
• Polymethylmethacrylate (PMMA)
• Silicone and Acrylic -soft foldable inert
materials
• Collamer
Contact lenses
• Rigid -Polymethyl methacrylate (PMMA or
Perspex/Plexiglas)
• Soft- Silicon hydrogel (Polymethyle Siloxane)
• Hybrid- rigid center and a soft "skirt”
Polymeric Heart Valves
• Polymers have been widely studied as an
alternative the biological valves that might be
bio-compatible while still durable
• PU, PTFE, Silicon rubber, PE
Artificial Bones
• Natural bones (Biominaralisation): Collegen (A Protein)
+ Hydroxipeptite (Ceramic)
• Ultrahigh molecular weight polyethyene (UHMWPE) -
odorless, tasteless, and nontoxic
• UHMWPE 250,000 monomer units per molecule each
compared to HDPE's 700 to 1,800 monomers.
Polymeric Drugs
• Polymers have played an integral role in the advancement of drug
delivery technology by providing controlled release of therapeutic
agents in constant doses over long periods
• chitosan, gelatin, polycaprolactone and poly-alkyl-cyanoacrylates
Structural Applications
• Air planes, vehicles, ships, boats
• Fiberglass-Glass fiber reinforced unsaturated
polyester (polymer composite)
– Glass fiber reinforcing agent
– Composite: materials made from two or more constituent
materials with significantly different physical or chemical
properties, that when combined, produce a material with
characteristics different from the individual components.
– Polymer resins: Unsaturated polyesters, Epoxy resins, vinyl
esters
Electronic/Electrical Applications
• Most of the polymers are electrical insulators
• Some are semiconductors (LED)
• Molecular wire: electrical conducting
polymers – Polyaniline(PANI)
Optical Polymers – PMMA
and polyperfluorobutenylvinylether
Polymer Degradation
• Biodegradation
• Reaction with chlorine, ozone, oxygen in the
environment
• Heat
• UV radiation
Home work assignment
• Write 5 sentences on “Smart Polymers”.
03 credits
Hours per week: Lectures 02
Lab/Tutorials/Assignments 03
•Economic
•Efficient
PROCESS
•Controllable
(INDUSTRY) •Safe
•Flexible
•Environmental
issues
By-products Effluents
PRODUCTS
Some products whose manufacture
involves the application of Chemical
Engineering
Product grouping or Some of the more familiar
production process examples
Household products in daily use Soaps, detergents, polishes,
including direct consumer disinfectants, cosmetics
products
Healthcare products Pharmaceuticals, toiletries,
antiseptics, anaesthetics
Automotive fuels/Petroleum Gasoline, diesel, kerosene,
refining lubricants, aviation fuels
Other chemicals in daily use Paints and surface coatings,
adhesives, anti-freeze agents,
refrigerants, insulation materials
Horticulture products Fertilisers, fungicides, insecticides
Metals Steel, zinc
Cont.
Introduction
Process converts raw materials in to finished products. A
typical process is usually a group of small sub systems that
work together to produce the products that leave the main
process. A system is a collection of equipments that works
together to complete a process. The basic sub systems of a
typical process can be shown by blocks, which represent the
each stage of overall process.
By products
Recycle or Unreacted
material
wastes
wastes
Product
purification
1. Continuous reactor
2. Batch reactor
Product Separation
Following the completion of reaction, output stream consists of
products, byproducts and un-reacted materials. These are separated
in the separation system. Some of the un-reacted materials are
recycled back to the fed stream.
Drying : In this operation volatile liquids are removed from solid materials by
the application of heat
Leaching: This involves treating finely divided solid with a liquid that
dissolves out and removes a solute contained in solid
Crystallization: This is the removal of solute such as salt or sugar from
a concentrated solution by precipitating the solute from solution
Reactor Clarification
Filter Filtration
Evaporator Evaporation
Crystallizer Crystallization
Centrifuge Centrifugation
Sugar molasses
Raw sugar
Introduction to separation processes
In processes most of the materials and substances occur as mixtures of
various components in gas, liquid, or solid phase. Original mixture is
normally contacted with another phase to remove or separate
components.
Transfer of solute
material in molecular
Phase 2 manner from one phase
to another
Phase 1
When the two phases are brought into intimate contact with each other a
solute or solutes can diffuse from one phase into another. The two
phases may be Gas-Liquid, Liquid-Liquid, Gas-Solid, or Solid-Liquid.
By selecting appropriate operating conditions, one phase is enriched
while the other phase is depleted with required component.
Distillation
Liquid mixtures are separated in to their constituents by using boiling
point variations. When a liquid mixture containing two or more
components is heated to its boiling point, the composition of vapour is
different from that of the liquid. The vapour phase is rich in more volatile
components (i.e. Low boiling points) and less volatile components
concentrate in liquid phase. The vapour is separated out and
condensed. Distillation is an equilibrium stage operation.
Evaporation
In the evaporation solution is concentrated by vaporizing the volatile solvent
(usually water)
Steam
Feed
(Low Evaporator Thick
concentration) liquor
+Vapor
Condensate
Drying
Drying of solutes defines the removal of small amounts of water or other
liquid from the solid material to reduce the residual liquid in to acceptable
values.
E.g. Crystals, Flakes, Granules, Powders, Sheets etc.
Gas
Liquid
phase
solute phase
A solute rich gas enters at the bottom of the tower and flows upwards
through the packing materials. Packing provides the large interfacial area
for contact. The solute in the rich gas is absorbed by the liquid or solvent
sent at the top of the tower and dilutes gas leaves at the top. The liquid
enriched with solute leaves at the bottom of the tower.
For (NH3 + air): liquid solvent used at the top of the tower is water.
For (SO2+ Air): liquid solvent used at the top of the tower is alkaline
solution.
Liquid – Liquid extraction
When a solute or solutes are removed from one liquid phase into
another liquid phase, the process is called L-L extraction. The two
phases are chemically quite different. This leads to the separation of
the components according to the physical and chemical properties.
Extraction Tower
Leaching
Industrial Crystallizer
Membrane separation
Material balance
Energy balance
When the material being processed or in contact for any length of time
under specified conditions such as pressure, temperature, composition, they
tend to achieve equilibrium which is determined by specific conditions. This
is important in understanding those unit operations involving transferring of
material from one phase to another. E.g. Absorption, Distillation, Leaching,
Extraction etc.
Rate of an operation
Block Diagram
Material Flow Sheet
Energy Flow Sheet
Process Flow Diagram
Information Flow Diagram
Piping & Instrumentation Diagram
Block Diagram
Simplest form of presentation
Each Block can be represent
a single piece of equipment or
a complete stage in the process
For complex processes,
usage of block diagram is limited to showing the overall process
represent only the principle stages
Useful for representing a process in a simplified form in reports and text books,
but have only a limited use as engineering document
M-03 R-04
For recycling
Liquid
storage
LS- 02
Process Flow Diagram (PFD)
Heat exchange
Reactor Sealed tank
Fluid contacting
Tray column column
Fragment of PFD
Material Flow Sheet
• Is drawn with standard symbols and labeled and include all data obtained
C1
R2
Draw a block diagram for the above process and indicate all process streams
by arrows and label all streams and process units with pressure, temperature
and compositions as per the above process description
Material Balances
Material Balance
Boundary - The real or imaginary surface that separates the system from
its surroundings
There are two types of systems
1. Open system:
An open system is one in which material is transferred across
the system boundary, that is, enters the system, leaves the system, or
both.
mass transfer
Work transfer
system
System Heat transfer
boundary
2. Closed system ( Non flow system)
There is no transfer of mass across the boundary during the
time interval of interest. But work and heat transfer is possible.
Eg. Batch reactor, Drying, gas heated in cylinder.
No mass transfer
Work transfer
system
System Heat transfer
boundary
Input
flow Output
streams SYSTEM Flow
streams
Water: W . WW + G . WG = A . WA + F . W F
W x 1 + 1400 x 0.02 = 0.005A + 0.81F
W = (1336.7 x 0.005) + (221.05 x 0.81) – 28 = 157.7 kg
System 2 3
D (kg)
Condenser
Distillate
Ac 0.99
D
W 0.01
Distillation D
column Material Balance on the Units 2 & 3
F 221.05 kg B (kg)
2 Bottoms
Ac 0.19 Ac 0.04
F
W 0.81
F
B
W 0.96
B
Material in = Material out
Water: F . WF = D . WD + B . W B
0.81 F = 0.01 D + 0.96 B ……………(2)
By-pass
By-pass stream is one that skips one or more stages of the
process and goes directly to another downstream stage.
Processes with by-pass streams are similar to those involving
recycle, except that the stream is fed forward instead of
backward.
Purge
This is a stream use to remove an accumulation of inert or
unwanted material that might build up in the recycle stream
By-pass
Fresh
Feed Product
Process Process
Separator
Unit 1 Unit 2
Recycle Purge
In the feedstock preparation section of a plant manufacturing
natural gasoline, isopentane is removed from feed. The process
and components are shown in the figure. What fraction of the
butane free gasoline is passed through the isopentane tower? The
process is in the steady state and no reaction occurs.
S
i-C5H12 100%
Iso-
De- X
pentane n-C5H12
butanizer
tower 100%
Y To natural
F P gasoline plant
n-C5H12 80%
n-C5H12 90%
i-C5H12 20%
i-C5H12 10%
Basis 100 kg of F
S i-C5H12 100 %
Boundary line
for overall
balance
Iso-
De- X n-C5H12
pentane
butanizer 100%
tower
Y
To natural
P gasoline plant
n-C5H12 80 %
F n-C5H12 90 %
i-C5H12 20 %
100 kg i-C5H12 10 %
S i-C5H12100% Basis 100 kg of F
Boundary line
for overall
balance
Total Material Balance
Iso-
De- X propane
pentane n-C5H12100% Material in = Material out
butanizer
tower Y
F
To natural
P gasoline plant F = S + P …….. (1)
100 kg
n-C5H1280% n-C5H1290%
i-C5H12 20% i-C5H1210%
N-pentane
F . NF = S . NS + P .NP
100 x 0.8 = 0 + 0.9 P ……(2)
P = 88. 9 kg
n-C5H12 80 % Iso-
i-C5H12 20 % pentane
Tower
X (2) Y n-C5H12 100 %
P 88.9 kg To natural
gasoline plant
F 100 kg n-C5H12 90 %
n-C5H12 80 % i-C5H12 10 %
i-C5H12 20 %
METHOD 1 Isopentane balance on unit (2)
X . IX = S . IS + Y .IY
X x 0.2 = S x 1 + 0 ……(3)
S i -C H 100 %
11.1 kg 5 12 S = 0.2 X
X = 55.5 kg
n-C H 80 % Iso -
5 12
i -C H 20 % pentane
propane
5 12
Tower n-C H 100 %
X Y 5 12
(2)
P 88.9 kg To natural
gasoline plant
F 100 kg n-C H 90 %
5 12
n-C H 80 % i -C H 10 %
5 12 5 12
i -C H 20 %
5 12
S i-C5H12 100 %
11.1 kg METHOD 2
Material Balance on unit (2)
P 88.9 kg To natural
gasoline plant N-pentane balance on unit (2)
F 100 kg n-C5H12 90 %
n-C5H12 80 % i-C5H12 10 % X . NX = S . NS + Y .NY
i-C5H12 20 %
0.8 X = 0 + Y x 1
Y = 0.8 X ……(5)
Molecular weights
ZnS = 97.4, H2O = 18, SO2 = 64.1, S = 32.1, H2SO4 = 98.1
Basis 1 day
Waste gases
F
SO2 + Air
Water
W
Air C
B
Oxidizer
(2) SO2 + 1/2O2 = SO3
D
S balance on unit (2)
SO3 + Air
Moles of SC = Moles of SD
Moles of SD = 142.3 moles
Waste gases
E
S balance on unit (3)
Water
W Moles of SD = Moles of SP
Moles of SP = 142.3 moles
D 13,957 x 100
Product P 98 % H2SO4 produced =
SO3 + Air H2SO4 - 98 % 98
Water – 2% = 14,242 kg
D
Mass balance for Water
P
W x WW = P x PW + consumption
SO3 + Air Product W = 0.02 x 14242 + 2561
H2SO4 - 98%
Water – 2% = 2846 kg
NATURAL RESOURCES
• Plants growing on the geosphere already provide, and have the potential
to provide much more, biomass for use as renewable materials, such as
wood, fiber, raw materials, and fuel.
• Sources of fresh water are stored in lakes and rivers on the surface of the
geosphere, move by means of streams, rivers, and canals on the
geosphere, and occur in aquifers underground.
Continental crust –
is made up of SIAL, in
which Silicon
and Aluminum dominate
These elements form the building blocks of most of the inorganic materials.
eg. glass (SiO2), concrete (CaCO3) and iron (Fe).
Mostly silicon oxides or silicates, such as quartz, SiO2, and potassium feldspar, KAlSi3O8.
Materials from Geosphere
Minerals
Main uses:
Raw material
Ground water-
Water from wells springs, etc.
Contains dissolved solids, and saturated with various minerals and
salts
NaCl is a raw material for soda ash, sodium hydroxide and chlorine
manufacture
Sea water-
Contains NaCl (2.73%) and other salts (0.8%)
Chemicals that produced from sea water includes gypsum salt
(CaSO4.2H2O), Epsom salt (MgSO4.2H2O), Mg(OH) 2, NaOH,
bleaching powder, etc.
MATERIALS FROM ATMOSPHERE
Air 78% N2
21% O2
1% other gases
Uses of oxygen
Support combustion, oxidation, steel manufacture, welding,
to sustain animal life, explorer s of outer surface.
Uses of nitrogen
Manufacture of ammonia, nitric acid and nitrous acid
Materials from Biosphere
Wood
use in pulp and paper industry, manufacture of particle boards, fiberboards
use as a bio fuel
chemicals by steam distillation and solvent extraction
Animal and vegetable oil (occur in seeds, flesh from some fruits, stem,
branches, roots and leaves of plants)
coconut, olive, palm – food industry
corn – soap and detergent industry
soya bean, linseed - paint and varnishes industry
castor oil – paint industry
cotton seed – animal feed
Combustion of fuel
Gaseous fuels – natural gas, coal gas, liquefied petroleum gas,
liquefied refinery gas, water gas, town gas, etc.
Liquid fuels – gasoline, kerosine, diesel fuel, furnace gas oil,
aviation fuels
Solid fuels - Coal, peat, wood, wastes
Nuclear energy
Uranium and Plutonium
Is released by 03 exothermic processes called radioactive
decay, fission , fusion)
Nonrenewable
Energy obtained from static deposits of any source that remains bound
unless exploited by human interaction
Renewable
Coal
-Chemical industry
-Synthetic fiber manufacture
-Plastic industry
-Synthetic rubber industry
-Fertilizer manufacture
Petroleum Refining
Pillars of refining
Natural Gas
Process research
• Determines operating conditions for a commercially feasible
process
• Determines yield data for a preliminary economic evaluation
• Discover what variable (temperature, pressure, concentration etc)
must be carefully controlled and suitable operating conditions
(temperature, pressure, concentration etc.) in order to optimise
laboratory synthesis
• Provides information for further development of the process.
Scale-up problem
3. Pilot Plant
• a trial plant with much higher capacity - a few kg/hr or MT/yr
• should be designed as a scaled down version of the industrial
scale plant and not as a larger copy of the existing mini plant
• products are used in application tests or large scale
deliveries to be made to customers
• issues which have not been fully dealt with in the mini plant,
should be solved
• Process selection
Possible designs - within the external constraints
Plausible designs - within the internal constraints
Probable design - likely candidate
Best design - judge the best solution to the problem
Design Constraints
Plausible
designs
Possible designs
Steps involved in Process Design
1. Feasibility survey
• Examination of technical and economic factors of the
proposed process
• All data to be assembled, including information on possible
processes, equipment performance, and physical property
data, which are obtained from design manuals and
national standards
• Outcome
Plant capacity on the basis of the market research
The projected capital outlay
The projected production costs for the product
The payout time and profitability
The potential site for the plant
2. Development of flow sheets – both qualitative and quantitative
Block Diagram
Material Balance
Energy Balance
Engineering Flow Diagrams (Process flow sheets)
Piping and Instrumentation (P and I) Diagrams
4. Fabrication
5. Commissioning and operation
• Commissioning refers to preparing the plant for the production
process
• main objective is to eliminate any problems, which might arise
at later and more critical stages of the plant operation
• During commissioning the need for plant modifications will
arise.
Laboratory phase The cyclic pattern of
Process development
Draft a process plan
Development of the
Individual steps
Evaluate Abandon
development
Development of entire process
in mini plant and of individual
Steps in pilot plants
Abandon
Evaluate
development
Cost of
eliminating
mistakes
100
10
1
Investment cost
Utilities
Uses of steam
Heating
Engines
Turbines
Ejectors
Pumping
Cooking
Steam
Water tube boiler:
used for high pressure boilers
Steam is either saturated (wet or dry) or superheated (to 730 °F (388 °C)
or higher to ensure that there is no water entrained in the steam)
Formation of steam at constant pressure
Fire tube boiler:
Locomotive type boilers - to produce hot combustion gases
Steam Distribution
Steam Traps
Cooling water
• Natural and forced draft cooling towers are used
• Can be drawn from a convenient river or lake
• Sea water or brackish water can be taken for coastal sites
Compressed air
Centrifugal pumps
Reciprocating pumps
Piston Pumps
Plunger Pumps
Reciprocating pumps
Diaphragm Pumps
Rotary pumps
Lobe pumps
Vane pumps
Rotary pumps
Screw pumps
Rotary pumps
Peristaltic pumps
Gate Valves
Globe Valves
Diaphragm Valves
Plug Valves
Butterfly Valves
Ball Valves
Needle Valves
Control Valves
• De-mineralized water
• Inert-gas supplies
• Refrigeration
• Effluent disposal facilities