CHAPTER 5

DESIGN OF BATCH
PROCESSES
ALI ALTWAY
 WHAT IS BATCH PROCESS
• In a batch process, the main steps of process
operate discontinuously.
• In contrast with a continuous process, a batch
process does not deliver its product continuously
but in discrete amounts.
• This means that temperature, concentration, and
other properties vary with time.
• In practice, most batch processes are made up of
a series of batch and semicontinuous steps.
• A semicontinuous step runs continuously with
periodic start-ups and shutdowns
 ADVANTAGES OF BATCH
PROCESS
• Are economical for small volume
• Are flexible in accommodating changes in
product formulation.
• Are flexible in changing production rate
• Allow the use of standardized multipurpose
equipment for the production of a variety of
products from the same plant
 ADVANTAGES OF BATCH
PROCESS
• Are best if equipment needs regular cleaning
because of fouling or needs regular sterilization.
• Are amenable to direct scale-up from the
laboratory.
• Allow product integrity. Each batch of product
can be clearly identified in terms of the feeds
involved and conditions of processing. This is
particularly important in industries such as
pharmaceuticals and foodstuffs.
 EXAMPLE OF BATCH PROCESS

Reactor

Steam Product
Storage
Feed Storage

C.W.

C.W.

Steam
 Process Steps
• Feed material is withdrawn from storage using a pump
• The feed material is preheated in a heat exchanger
before being fed to the reactor
• After the reactor is full, further heating takes place inside
the reactor using steam in the reactor jacket.
• During the later stages of the reaction, cooling water is
applied to the reactor jacket.
• The reactor product is withdrawn using a pump.
• The reactor product is cooled in a heat exchanger before
going to storage.
 GANTT CHARTS
Process
Step

Reactor filling & Feed Preheat

Reaction

Reactor Emptying & Product Cooling

Batch Distillation

Batch Cycle Time Time

SEQUENCIAL BATCHES
 GANTT CHARTS
Process Steps

RFFP

REACTION

REPC

BATCH DISTILLATION

BATCH CYCLE TIME Time

OVERLAPPING BATCHES
 PRODUCTION SCHEDULES FOR SINGLE
PRODUCT
SEQUENTIAL PRODUCTION SCHEDULE

Step 10 hr 10 hr 10 hr
A
5 hr 5 hr
B
5 hr 5 hr
C

Cycle Time
20 hr
PRODUCTION SCHEDULES FOR SINGLE
PRODUCT
EVERLAPPING BATCHES

Step 10 hr 10 hr 10 hr
A
5 hr 5 hr
B
5 hr 5 hr
C

Cycle Time= 10 hr

Time
 PRODUCTION SCHEDULES FOR SINGLE
PRODUCT
PARALLEL UNITS FOR THE LIMITING STEP

Cycle Time=10 hr

Step 10 hr 10 hr 10 hr
A
10 hr 10 hr
A
5 hr 5 hr
B
5 hr 5 hr
C

Time
 PRODUCTION SCHEDULES FOR SINGLE
PRODUCT
INTERMEDIATE STORAGE FOR THE LIMITING STEP

Cycle Time=10 hr

Step 10 hr 10 hr 10 hr
A

5 hr 5 hr
B
5 hr 5 hr
C

Time
PRODUCTION SCHEDULES FOR
MULTIPLE PRODUCTS
PRODUCTION SCHEDULES FOR
MULTIPLE PRODUCTS
PRODUCTION SCHEDULES FOR
MULTIPLE PRODUCTS

SINGLE
AND MIXED
PRODUCT
CAMPAIGN
PRODUCTION SCHEDULES FOR
MULTIPLE PRODUCTS

THE EFFECT OF
MATERIAL
CLEANING ON
CYCLE TIME
PRODUCTION SCHEDULES FOR
MULTIPLE PRODUCTS

THE EFFECT OF
MATERIAL
TRANSFER ON
CYCLE TIME
 SYNTESIS OF REACTION AND SEPARATION
SYSTEMS FOR BATCH PROCESS

Design a continuous process for production of

Butadiene sulfone from butadiene and sulfur
dioxide (exothermic reversible reaction).The
butadiene feed contains 0.5% n-butane. Nbp of
Sulfur dioxide, Butadiene, n-Butane and Butadiene
sulfone are -10, -4, -1 and 151 C.
 SYNTESIS OF REACTION AND SEPARATION
SYSTEMS FOR BATCH PROCESS

Solution:
No recycle
 SYNTESIS OF REACTION AND SEPARATION
SYSTEMS FOR BATCH PROCESS

Solution:
with recycle
 SYNTESIS OF REACTION AND SEPARATION
SYSTEMS FOR BATCH PROCESS

Duration of
processing
steps:
Reaction 2.1 h
Evap 0.45
Stripping 0.65
Filling 0.25
Emptying 0.25
SYNTESIS OF REACTION AND SEPARATION
SYSTEMS FOR BATCH PROCESS

Sequensial batch
SYNTESIS OF REACTION AND SEPARATION
SYSTEMS FOR BATCH PROCESS

Overlapping batch
SYNTESIS OF REACTION AND SEPARATION
SYSTEMS FOR BATCH PROCESS
PARALEL UNIT FOR LIMITING STEP
SYNTESIS OF REACTION AND SEPARATION
SYSTEMS FOR BATCH PROCESS
INTERMEDIATE STORAGE
 EXCERSIZE
14.2 Ethyl acetate is to be manufactured in a batch reactor
from the reaction between ethanol and acetic acid in the liquid
phase according to the reaction: A + B = C + D A= acetic
acid, B = ethanol, C = ethyl acetate, D = water. The reaction
rate expression is -Ra = ka CA2 – ka’ CC where ka = 0.002688
m3.kmol-1.min-1 ka’=0.00464 min -1. Molar mass for the
components are 60.05, 46.07 , 88.11 and 18.02 for acetic
acid, ethanol, ethyl acetate and water respectively. The
densities for the components are 1018, 754, 847 and 980
kg/m3. The reactant are equimolar with product concentrations
of initially zero. (a) Calculatr the residence time required for a
conversion of 50%. (b0 The operating schedule for the reactor
requires it to be shut down between batch reactions for 1 h.
Calculate the volume of the reactor required to produce 10
t/day based on a conversion of 50% and operation of 24 h per
day
 EXCERSIZES

14.4 A batch processes consists of the four steps: Step A,

B, C, and D with duration 0.75, 3, 0.75, and 6 h
respectively. For repeated batch cycles of the same
process, calculate the cycle time for: a) a sequential
production schedule (b) overlapping batches

14.5 A batch process consists of three steps A,B, and C

with duration 12, 5, and 5 h respectively. For repeated
cycles of the same process, calculate the cycle time for: a)
a sequential production schedule (b) overlapping batches
(c) two parallel units for the limiting step (d) intermediate
storage for the limiting step