Chapter 1

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 What is Process Engineering?
Process Engineering is the profession in which a
knowledge of mathematics, chemistry, physics, and
biology gained by study, experience, and practice is
applied with judgment to develop economic ways of
using materials and energy for the benefit of mankind.

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 Quick Quiz

Which four physical sciences are

used in process engineering?

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 What is a process process?
A chemical process is a combination of steps in which
starting materials are converted into desired products
using equipment and conditions that facilitate that
conversion.
For example:
A+BC

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Laboratory Scheme vs Industrial Process

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Laboratory Scheme vs Industrial Process

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 Quick Quiz
Reading question (pages 15-16)
Q.3 In our example of making chemical “C” from
“A” and “B” we formulated an industrial process to
replace a laboratory scheme. What equipment in
the industrial process replaced each of the following
laboratory equipment items?
• Test tubes
• Laboratory burner
• Reaction vessel
• Distillation apparatus

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 Process Classification

(a) Batch process (closed system)

(b) Continuous process (open system)
(c) Semi-batch process
(d) Steady-state
(e) Unsteady-state (transient)

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 Process Classification (cont.)
(a) Batch process – An allotment of starting material
is introduced into the process, and a sequence of
steps to treat that material is started and finished
within a certain period of time, often within the same
piece of equipment. The process is then interrupted,
the processed material is removed, another allotment
of the starting material is introduced, and the
sequence of steps is repeated.
Examples: fermentation, water heating, sterilisation,
manufacture of speciality chemicals, etc.
Industry uses for small scale manufacture of high-
value products.

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 Process Classification (cont.)
Batch process

http://www.cheng.cam.ac.uk/research/groups/polymer/OFM/images/
batch.jpg
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 Process Classification (cont.)
(b) Continuous process – operates without
interruptions in the flows and reactions of the process.
The starting material enters continuously, is usually
subjected to various steps by moving from one piece
of equipment to another, and exits the process
continuously.
Examples: oil refining, desalination, power generation,
air conditioning (refrigerative or evaporative),
wastewater treatment, etc.
In industry, continuous processes are normally utilised
for large scale manufacture of commodity products.

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 Process Classification (cont.)
Continuous process

http://www.rbfuels.com/images/PN3D2.gif

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 Process Classification (cont.)
Semi-Batch Processes
Very few true batch processes exist.
 Most are semi-batch processes.
For example,
Glucose and nutrients may be added during
the fermentation of microorganisms.
Allow the contents of a pressurized gas
container to escape to the atmosphere.

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 Process Classification (cont.)
Semi-Batch Processes

http://www.chem17.net/products/member/images/chem1728392.jpg

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 Process Classification (cont.)

(d) Steady-state – is one in which none of

the process characteristics
(temperatures, flow rates, volumes, etc.)
change with time.
(e) Unsteady-state – A process that is not
steady-state as defined above is termed
unsteady-state or transient.

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 Helpful Hint
• Batch process is clearly not a steady-state
process.
• A continuous process may or may not be a
steady state.
• Steady-state should not be confused with the
fact that the process variables may vary
between different locations in the process.
That is when a steady-state process is
observed at a certain point in time and then
observed again in a few minutes later, no
change is seen.
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 Example of Ideal Reactors
Uniformly
Feed mixed

Plug-flow reactor (PFR) Product

Mixed-flow reactor
(CSTR)

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 Example
A plant containing a reactor is being started up (being put
into operation). In the start-up phase, with fluid flowing in
all of the streams, the temperatures of the reactor and
some of the streams are seen to be changing with time as
they move toward the values at which they will eventually
be held. The chemical composition of the material coming
from the reactor is also changing with time in response to
the changing reactor conditions. The start-up phase is over
when the temperatures and compositions reach their
desired values and no longer change with time. Classify
the start-up phase and the period after the start-up phase
in terms of being batch or continuous and steady-state or
unsteady-state.
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