Industrial Engineering

Prepared by:
Reina Joy Eborda
Matteo C. Gadon
Jeric E. Macaraig
Melba F. Mapa
Ronalyn C. Mayo
Jake Patrick C. Roxas
Bernadin C. Sarahan Jr.
History

Industrial Revolution

One of the first chemicals to be produced in large amounts through industrial

processes was sulfuric acid. In 1736, the pharmacist Joshua Ward developed a
process for its production that involved heating saltpeter, allowing the sulfur to
oxidize and combine with water. It was the first practical production of sulphuric
acid on a large scale. John Roebuck and Samuel Garbett were the first to
establish a large-scale factory in Prestonpans, Scotland, in 1749, which used
leaden condensing chambers for the manufacture of sulfuric acid
Joshua Ward (1685–1761)

 was an English doctor, most remembered

for the invention of Friar's Balsam

 He invented a medicine called "Joshua

Ward's drop", also known as the "Pill and
Drop“

 In 1736, Ward set up the Great Vitriol Works

in Twickenham for producing sulphuric acid
Chemical Process
In a scientific sense, a chemical process is a method or means of somehow changing one or
more chemicals or chemical compounds.

Chemical Changes Physical Changes

Endothermic VS Exothermic Reactions
Chemical Process Industry

An industry in which the raw materials

undergo chemical conversion during their
processing into finished products, as well as the
physical conversions common to industry in
general, includes the traditional chemical,
petroleum, and petrochemical industries.
 Chemist VS Chemical Engineers

Chemist Chemical Engineers

 Design reaction pathways to  Design a process to scale the

produce a chemical from raw
materials
 Work in the laboratory setting
to produce material on the
gram to kilogram scale
chemist’s process to mass
produce the product
 Work in a chemical plant to
produce material in the ton and
beyond range
Chemical Processes / Operations
1. Separation
2. Filtration
3. Distillation
4. Extraction
5. Crystallization
6. Evaporation, Condensation
7. Polymerization
8. Adsorption, Absorption
9. Dyeing
10. Refrigeration
11. Screening, Crushing, Pulverization
12. Mixing
13. Chemical Reactions
Separation Process
 A separation process is a method that converts a mixture or solution of
chemical substances into two or more distinct product mixtures. At least one
of results of the separation is enriched in one or more of the source mixture's
constituents.
 The individual substances in a mixture can be separated using different
methods, depending on the type of mixture. These methods include
filtration, evaporation, distillation and chromatography.
Separation Process
 Chromatography separates dissolved
substances by different interaction with
a material
 A laboratory technique for the
separation of a mixture. The mixture is
dissolved in a fluid called the mobile
phase, which carries it through a
structure holding another material
called the stationary phase. The various
constituents of the mixture travel at
different speeds, causing them to
separate.
Filtration Process
 a physical, biological or chemical operation that separates solid matter and
fluid from a mixture with a filter medium that has a complex structure
through which only the fluid can pass. Solid particles that cannot pass through
the filter medium are described as oversize and the fluid that passes through
is called the filtrate.

Diagram of simple filtration: oversize particles in the feed cannot pass through the

lattice structure of the filter, while fluid and small particles pass through,
becoming filtrate
Filtration Process
Methods

 Hot filtration method is mainly used to separate solids from a hot solution. This is done in
order to prevent crystal formation in the filter funnel and other apparatuses that comes in
contact with the solution.
 One of the most important measures to prevent the formation of crystals in the funnel and to
undergo effective hot filtration is the use stem less filter funnel.

Hot Filtration,
solution contained in
the Erlenmeyer flask
is heated on a hot
plate in order to
prevent re-
crystallization of
solids in the flask
itself

Hot Filtration for the separation of solids from a hot solution

Filtration Process
Methods
 Cold Filtration method is the use of ice bath in order to rapidly cool down the
solution to be crystallized rather than leaving it out to cool it down slowly in
the room temperature. This technique results to the formation of very small
crystals as opposed to getting large crystals by cooling the solution down at
room temperature.

Cold Filtration, the ice bath is used to cool down the temperature of the solution
before undergoing the filtration process
 Filtration Process
Methods
 Vacuum Filtration technique is most preferred for small batch of solution in
order to quickly dry out small crystals. This method requires a Buchner
funnel, filter paper of smaller diameter than the funnel, Buchner flask, and
rubber tubing to connect to vacuum source

A Büchner flask, also known

as a vacuum flask, filter
flask, suction flask, side-arm
flask, Kitasato
flask or Bunsen flask, is a
thick-walled Erlenmeyer flask
 with a short glass tube and 
hose barb protruding about
an inch from its neck. 

A Büchner funnel connected to a side-arm flask by means of a

neoprene adapter, with a tube leading to a vacuum pump
Distillation Process
 The process of separating the components or substances from a
liquid mixture by using selective boiling and condensation.
 Distillation may result in essentially complete separation or it may be a
partial separation that increases the concentration of selected components in
the mixture. In either case, the process exploits differences in the relative
volatility of the mixture's components.
 In industrial chemistry, distillation is a unit operation of practically universal
importance, but it is a physical separation process, not a chemical reaction
Distillation Process
 Boiling is the rapid vaporization of a liquid, which occurs when a
liquid is heated to its boiling point, the temperature at which
the vapor pressure of the liquid is equal to the pressure exerted on
the liquid by the surrounding atmosphere.

There are two main types of boiling:

1. Nucleate boiling where small bubbles of vapor form at discrete points,
and critical heat flux boiling where the boiling surface is heated above
a certain critical temperature and a film of vapor forms on the surface.
2. Transition boiling is an intermediate, unstable form of boiling with
elements of both types. The boiling point of water is 100 °C or 212 °F A cooking pot with
but is lower with the decreased atmospheric pressure found at higher asparagus in boiling
altitudes. water
Distillation Process
 Condensation is the change of the physical state of
matter from the gas phase into the liquid phase, and is the
reverse of vaporization.
 The word most often refers to the water cycle. It can also be
defined as the change in the state of water vapor to liquid
water when in contact with a liquid or solid surface or cloud
condensation nuclei within the atmosphere . When the
transition happens from the gaseous phase into the solid
phase directly, the change is called deposition.

Condensation forming in the low pressure

zone above the wing of an aircraft due
to adiabatic expansion
Distillation Process
Laboratory display of distillation

1. A source of heat  9. Vacuum/gas inlet 

2. Round bottomed flask  10. Still receiver 
3. Still head  11. Heat control 
4. Thermometer/Boiling point 12. Stirrer speed control
temperature 
13. Stirrer/heat plate 
5. Condenser
14. Heating (Oil/sand) bath 
6. Cooling water in 
15. Stirring
boiling chips or
7. Cooling water out 
mechanical stirrer 
8. Distillate/receiving flask 
16. Cooling bath
Extraction Process
 Extraction in chemistry is a separation
process consisting in the separation of a substance
from a matrix.
 Common examples include liquid to liquid Organic solvent 
extraction, and solid phase extraction. The
distribution of a solute between two phases is an
equilibrium condition described by partition
theory.
 The term washing may also be used to refer to an Aqueous phase
extraction in which impurities are extracted from
the solvent containing the desired compound.

Schematic of a separatory funnel showing two immiscible

liquids, where 1 is any phase less dense than 2.
Extraction Process
Methods
 Liquid–liquid extraction (LLE), also known as solvent
extraction and partitioning, is a method to separate compounds or metal
complexes, based on their relative solubilities in two different immiscible
liquids, usually water (polar) and an organic solvent (non-polar)

Laboratory-scale liquid-liquid
extraction. Photograph of
a separatory funnel in a
laboratory scale extraction of 2
immiscible liquids: liquids are a
diethyl ether upper phase, and
a lower aqueous phase
Extraction Process
Methods
 Solid-phase extraction (SPE) is a sample preparation process by which compounds that
are dissolved or suspended in a liquid mixture are separated from other compounds in
the mixture according to their physical and chemical properties. Analytical laboratories
use solid phase extraction to concentrate and purify samples for analysis. Solid phase
extraction can be used to isolate analytes of interest from a wide variety of matrices,
including urine, blood, water, beverages, soil, and animal tissue

A typical solid phase extraction

manifold. The cartridges drip
into the chamber below, where
tubes collect the effluent. A
vacuum port with gauge is used
to control the vacuum applied
to the chamber
Crystallization

 Crystallization or crystallisation is the (natural or artificial) process by which

a solid forms, where the atoms or molecules are highly organized into a
structure known as a crystal. Some of the ways by which crystals form
are precipitating from a solution, freezing, or more rarely deposition directly
from a gas. Attributes of the resulting crystal depend largely on factors such
as temperature, air pressure, and in the case of liquid crystals, time of fluid
evaporation.
Crystallization Process
Methods

 Crystal formation can be divided into two types, where the first type of
crystals are composed of a cation and anion, also known as a salt, such
as sodium acetate.
 Sodium acetate, CH3COONa, also abbreviated NaOAc, is the sodium
salt of acetic acid. This colorless deliquescent salt has a wide range of uses.

A crystal of sodium acetate trihydrate

(length 1.7 centimeters)
Crystallization Process
Methods

 The second type of crystals are

composed of uncharged species, for
example menthol
 Menthol is an organic compound made
synthetically or obtained from the oils
of corn mint, peppermint, or
other mints. It is a
waxy, crystalline substance, clear or
white in color, which is solid at room
temperature and melts slightly above.
Evaporation Process

 Evaporation is a type of vaporization that occurs on the surface of a liquid as

it changes into the gas phase.
  The surrounding gas must not be saturated with the evaporating substance.
When the molecules of the liquid collide, they transfer energy to each other
based on how they collide with each other.
 When a molecule near the surface absorbs enough energy to overcome
the vapor pressure, it will escape and enter the surrounding air as a gas.
 When evaporation occurs, the energy removed from the vaporized liquid will
reduce the temperature of the liquid, resulting in evaporative cooling
Evaporation

Aerosol of microscopic water droplets suspended in the air

above a hot cup of tea after that water vapor has
sufficiently cooled and condensed. 
Water Vapor is an invisible gas, but the clouds of condensed
water droplets refract and disperse the sun light and so are
visible

Vapor pressure of water vs.

temperature. 760 Torr =
1 atm
Condensation Process
 Condensation is a crucial component of distillation, an
important laboratory and industrial chemistry
application
 Condensation commonly occurs when a vapor is cooled
and/or compressed to its saturation limit when the
molecular density in the gas phase reaches its maximal
threshold. Vapor cooling and compressing equipment
that collects condensed liquids is called a ”condenser”
 A naturally occurring phenomenon, it can often be In cloud chambers a liquid condenses upon
used to generate water in large quantities for human contact with a particle of radiation thus
producing an effect similar to contrails
use. Many structures are made solely for the purpose of
collecting water from condensation, such as air
wells and fog fences.
Polymerization Process
 A process of reacting monomer molecules together in a chemical reaction to
form polymer chains or three-dimensional networks. There are many forms of
polymerization and different systems exist to categorize them.
 The process of converting a monomer or a mixture of monomers into
a polymer.

An example of alkene polymerization, in which each styrene monomer's double

bond reforms as a single bond plus a bond to another styrene monomer. The
product is polystyrene.
Adsorption Process
 Is the adhesion of atoms, ions or molecules from a gas, liquid or dissolved
solid to a surface. This process creates a film of the adsorbate on the surface
of the adsorbent.
 Increase in the concentration of a substance at the interface of a condensed
and a liquid or gaseous layer owing to the operation of surface forces.

Brunauer, Emmett and Teller's model of multilayer adsorption is a

random distribution of molecules on the material surface.
Absorption Process
 is a physical or
chemical phenomenon or a process in
which atoms, molecules or ions enter
some bulk phase
– liquid or solid material. This is a
different process from adsorption,
since molecules undergoing absorption
Laboratory absorber. 
are taken up by the volume, not by the
1. CO2 inlet
surface (as in the case for adsorption).
H2O inlet
A more general term is sorption, which
2. Outlet
covers absorption, adsorption, and ion
3. Absorption column
exchange. Absorption is a condition in
4. Packing
which something takes in another
substance.
Dyeing Process

 Dyeing is the application of dyes or pigments on textile materials such as fibers, yarns,

and fabrics with the goal of achieving color with desired color fastness.
 Dyeing is normally done in a special solution containing dyes and particular chemical
material. Dye molecules are fixed to the fibre by absorption, diffusion, or bonding with
temperature and time being key controlling factors.
Dyeing Process
Methods
 The bond between dye molecule and
fibre may be strong or weak, depending
on the dye used. Dyeing and printing
are different applications; in printing
color is applied to a localized area with
desired patterns and in dyeing it is
applied to the entire textile.
Dyeing in Fes, Morocco.
 Dyes are applied to textile goods by
dyeing from dye solutions and by Pigments for sale at a
printing from dye pastes and the market in Goa, India.
Methods that are included are direct
application and yarn dyeing.

Dyed wool reels

Refrigeration Process
 Refrigeration is the process of cooling a space, substance, or system to lower
and/or maintain its temperature below the ambient one (while the removed
heat is rejected at a higher temperature).
 In other words, refrigeration means artificial (human-made) cooling.
 Heat is removed from a low-temperature reservoir and transferred to a high-
temperature reservoir.

 Application
1. Household refrigerators
2. Industrial freezers
3. Cryogenics
4. Air conditioning
Screening Process
 Mechanical screening, often just called screening, is the
practice of taking granulated ore material and separating it
into multiple grades by particle size.
 This practice occurs in a variety of industries such as mining
and mineral processing, agriculture, pharmaceutical, food,
plastics, and recycling.
 A method of separating solid particles according to size alone is
called screening.
 As with any industrial process there is a group of terms that
identify and define what screening is. Terms like blinding,
contamination, frequency, amplitude, and others describe the Model of Screening Process
basic characteristics of screening, and those characteristics in
turn shape the overall method of dry or wet screening.
Crushing Process
 Crushing is the process of reducing the size of
materials so that they can be further processed. In
addition to being used in the chemical industry,
industrial crushing equipment can be very useful in a
variety of businesses. These include, but are not
limited to, waste and recycling, mining, food
processing, construction, and coal.
 Industrial crushers are primarily used to take very
large pieces of material and make them smaller.
Having smaller pieces of the material allows for
easier transportation, further processing, and/or
better ability to differentiate the different
compositions of the material.
Pulverization Process

  A solid substance in the form of tiny loose particles; a solid that has been
pulverized. Powder, pulverization. Solid - matter that is solid at room
temperature and pressure.
 The act of grinding to a powder or dust

Size reduction equipment

Particle Size Mesh to Micron Conversion
Mixing Process

 is a unit operation that involves

manipulation of a heterogeneous physical
system with the intent to make it
more homogeneous. Familiar examples
include pumping of the water in a swimming
pool to homogenize the water temperature,
and the stirring of pancake batter to
eliminate lumps.
 Mixing is performed to allow heat and/or
mass transfer to occur between one or more
streams, components or phases. 
 Homogeneous reactions are chemical reactions in which the reactants and
products are in the same phase
 Heterogeneous reactions have reactants in two or more phases.

 Reactions that take place on the surface of a catalyst of a different phase are
also heterogeneous.
 A reaction between two gases or two miscible liquids is homogeneous. A
reaction between a gas and a liquid, a gas and a solid or a liquid and a solid is
heterogeneous.
Thank You
For Your Attention