Chemical Industries

Course Description (reading only )

• chemical industry is an important branch of chemistry and its

structures usually centers on petroleum and hydrocarbon
derived chemicals. This course will generally cover very
important
Non-petroleum-based organic and inorganic industries such as
sulfuric acid ,cement , class , pulp and paper , soaps and
detergents, sugars, fermentation, chemical explosives, and
agrochemical industries.
Petroleum fuel and energy ,fuel gases ,natural gas , water gas , LPG
Water industries , sewage waste water treatment ,water
conditioning ,demineralization ,precipitation processes
• This course focuses primarily on the chemical processing of raw
materials. These materials are usually converted into useful and
profitable products that are, in general, used as consumer
goods.
 in d u strial
ch em istry H 2SO 4

Cover
n on p etroleu m -b ased organ ic cem en t
class
soap an d d etergen t
Focuses

p etroleu m fu el an d en ergy
fu el gas
n atu ral gas
w ater gas
LPG

p rim arily on th e ch em ical p rocess of raw m aterial

u sefu l an d p rofitab le p rod u cts

con vert
in to
Basic Terminologies

• Process
• Chemical process
• Chemical reaction
• Chemical science
• Chemical engineering
• Chemical Process Industries
 Basic terminologies

proccess sequence of changes a real object body

one or more changing

chemical process useful products
chemical compound

conversion of chemical substances

chemical reaction
atoms
interation
scientific study chemical substance
chemical science
sub atomis
P + , e_ , n 0
chemical engineering
application science chem istry
p h y si mathematic
cs
economic
chemical process industries c on
raw ver
ti n g
material to

valuable
unit operation industrial forms
unit processes produce
products
oil gas oil
natural gas kerosen
air gasoilne
water jet fuel
metals DW
mineral metals sheet
glass
cement
• process
Is a sequence of changes of a real object/body which is observable using scientific
method.

• Chemical Process
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.
• Chemical Reaction
A chemical reactions a process that always results in the inter conversion of chemical
substances

• Chemical Science
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.

The chemical process industry

comprises 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.
• BATCH processing
It is industrial unit produce acceptable amounts of product materials which is ready for
use
In batch ,mix of raw materials in known amounts and purities which are required in
industrial process ,sequence of reactions are taken place in limited period enough
for reaction to finished and produced desired products then stopping the reactors
and exhaust the products , secondary products and non reacted raw materials
and them separated from each another
Purification of products and re-used of raw materials is required
Cleaning ,repair ,restored is required in order to repeat same operation mentioned
above
The disadvantages of BATCH are :
1] required more laborers
2] high consumption of energy in spit of using the heat exchangers
3] hardly controlling the final products , lack on production accuracy, laborers
experiences
4] hardly mechanically control often non exist
5] little of total production capacity
6] taking long time due to storing ,cleaning, repairing
 B a t c h p r o c e s s in g
The requires

r a w m a te r ia l a c c e p ta b le
m
ix
i fi ed
d
b y 1 tim e
p rod uct + by
p rod uct sep a ra ted
ur ite n t

no long sequence reacti

p fr o m
lim o u
am n o n r e a c te d a n o th e r

stopping
r a w m a te r ia ls

th e r e q u ir e d
a fte r p r o d u c t fin is h e d
on

r e-u sed
th e d is a d v a n ta g e

lo o k to th e slid e
 continuous processing

can't be stopped

raw
m aterial long sequence reaction finished
product

m ore uniform operating over Batch

large quantities processing
less equipm ent
Continuous processing vs. Batch processing
• Continuous process which process can’t be stopped between in , once raw
materials is entered then getting processed until finished and product will come
out , which differ of Batch process

• in continuous process ,the equipments have much less in process hence have less
chance physically destruction ,large quantities and have more uniform operating
conditions and products than {batch process }

• Small quantities of chemical are usually made by Batch process operation , but
when markets enlarge may be made to continuous processing

• In Batch process as the volume of production increase ,the chemical engineer

calculates that point where the expense of labor research ,instrumentation but
continuous equipment justifies continuous process with it’s lower unit investment
,operating coast ,more uniform quality
ECONOMIC SITUATION AND CHEMICAL PROCESS
Economic influence the industrial either chemical industries or non chemical
industries specially of privet industries which desirous to have high products
quality in low price

THE FACTORS AFFECTING ON CAPITAL COST IN CHEMICAL INDUSTERIES

1] number of reaction steps :
Most material products and its chemical industries system based on the chemical
reaction ,this chemical reaction could be one step or several sequence chemical
reaction or non sequence chemical reaction , if the utilized chemical reaction for
one products type is done by one step chemical reaction so its needed a little extra
coast for separation and purification processes ,but if the reaction needs to be
done by several steps reaction for yielding the final products ,so the multistep
reaction is required reactor for each step and special extra coast too
However the number of chemical reaction proportionally direct with capital coast .
e.g Chloronaization of methane to tetrachloromethyle is done by single step of
chemical reaction
CH4 + 4 CL2 CCL4 +4HCl
h.v
 Economic situation and chemical process
chemical high products quality
ecnomic influence the desire
industry of
low price
non- chemical for

The factors affecting on capital cost in chemical industeries

1 step advantage little extra coast

(1) no of reaction steps for separation and purification

several steps
req o n
uir
ed ca sti
i
reactor for urif
p
each step

i on
a rat
CH4 + 4 CL2 sep
CCL4 +4HCl (1 step)
h.v
the reaction of polyester by condensation of benzoic acid with methyl glycol using
benzene as initial compound as following :
CH3

+ 2CH3CL + 2HCL

COONa
CH3

+
MnO2 + 2H2O
+ KMnO4

COONa

COONa COOH

+ HCl + 2HCl

cooNa COOH

COOH COOCH3

+ 2CH3OH + 2H2O

COOH COOCH3
2} separation and purification methods
Most chemical reaction produce undesirable substances as secondary products , e.g
toluene and methyl chloride reaction by catalyst to produced the pra xylene which
is considered to be primary important in chemical industries field by through this
reaction the ortho xylene is formed which undesirable in oxidation reaction of
phthalic acid ,so the separation of para xylene is considered so this method
increase the capital coast
3}Temperature and pressure
Chemical industries preferred using normal pressure and temperature for adequate
reaction
chemical Production which preferred high temperature and pressure reaction which
attends to high coast design engineering exploration
4} corrosive materials
The main problems of chemical industries are dealing with substances caused
corrosion
In different reaction .e.g. acids, based and acids oxide which are necessary for
chemical reaction
The using of Metals ,alloys are withstand the corrosion is mostly considered or
coating operation to prevent the chemical equipments so more expenses of
capital coast in chemical industries
5} Physical state of reactants
the chemical industries always preferred liquids , gases reactants which are ease to
deal with in chemical process than solid state reactants
As reactors qualities and manner of reactants addition ,technical method of secondary
products treatment so these technical added capital cost of chemicals reactions .\\

6} Raw materials, sources and its cost

Sources of raw material, its coast, and its position important as coast of final products
also important as products price determination , the correct chosen of raw material
as purification and its activity required to converting to final products without
costly modifications e.g. the phenol preparation from chlorobenzen by strong base
as following :
Cl

NaoH 360 HCi

O-Na OH + NaCl
4500 Ib\in

chlorobenzene sodium phenoxide Phenol

• This reaction is high productivity , but NaCl is secondary products considered as
low commercial benefit as well as the high coat of chlorobenzene compared with
phenol in the market so this reaction not commercially suitable so chosen of cheap
raw material is considered
• CUMENE is low coast raw material than CHLOROBENZENE and give Acetone as
secondary products has higher commercial benefit than sodium chloride[salt table]
• This reaction is done by oxidation o cumene in simple way and low coast as
following :

H2O H+
O2 CH3-C=O

CH3
H3C C H H3C C OOH OH

CH3 CH3
cumene Cumene hydroperoxide phenol Acetone
SAFETY IN THE CHEMICAL INDUSTIRY
• The significance of Safety & Health in chemical industries has been a vital issue in
achieving productivity
• This slide is an effort to present the various factors governing the safety and Health

FACETS OF SAFETY & HEALTH IN A CHEMICAL INDUSTRY

i) Dangerous Materials
ii) Hazards of Pressure Vessels
iii) Hazardous Chemical Reactions
iv) Hazardous of Unit Operations
v) Flammable Gases , Vapours and Dust Hazards
vi) Health Hazards
vii) Hazards due to corrosion
viii) Entry in To Confined Spaces
ix) Working with Pipelines
x) Plant Alteration and modification
xi) Sampling and Gauging
xii) Hazards due to Instrument Failures.
• Unit processes
It’s industries process which change the chemical formula of reactants e.g of the unit
processes are oxidation ,nitrification and chlorination as following :
CH3 COONa COOH

CH3Cl
KMnO4 HCl
AlCl3 NaOH NaCl

benzene tolluene benzoic acid

sodium bezoyate

the chemical formula changing in this reaction is done by converting benzene to

toluene by alkalinity then toluene converted to benzoic acid by substitution
oxidation
The Alkalinity , Substitution oxidation are called unit processes

• Unit operation
It’s industrial process which taken place on reactants and products for industrial
purposes as purification , impurities removing , secondary products separation but
chemical composition converted is not acceptable ,before unit operation taken
place ,e.g recrystallization distillation ,extraction by solvents and other operation
as following :
 CH3 CH3
CH3
CH3
fractional KMnO4
CH3Cl
+ Distillation
AlCl3 NaOH

o-xylene CH3 CH3

COOH COOH
COONa

Recrystallization

COOH COOH
COONa
benzoic acid
sodium salt of benzoic acid