CH19401 - CHEMICAL

PROCESS
INDUSTRIES
Ms.N. KALAIARASI
Assistant Professor
Department of Chemical Engineering
Rajalakshmi Engineering College
UNIT 1 INTRODUCTION AND
CHLORO- ALKALI INDUSTRIES
• The role of chemical engineers in process industries,
• Introduction to common devices used in manufacturing processes, INTRODUCTION
• Block diagrams, flowcharts and standard symbols used for devices,
• Industrial safety and pollution,
• Outline of plant and equipment design.

• Manufacture of Soda ash and sodium bicarbonate,

• Chlorine and caustic soda;
• Bleaching powder and related bleaching agents,
• Sodium chloride, By-products of common salt industry.
ROLE OF CHEMICAL ENGINEERS IN
PROCESS INDUSTRIES
• Who is a CHEMICAL ENGINEER :
• A Chemical engineer converts cheaper raw materials into finished
products through the processes usually involving physical and chemical
changes.
• A.I.Ch.E defines Chemical Engineering as
• The branch of engineering which deals with the application of the
principles of physical science, together with the principles of economics
and human relations, to fields that pertain directly to processes and
process equipments in which matter is treated to effect a change in state,
energy content and composition.
ROLE OF CHEMICAL ENGINEERS IN
PROCESS INDUSTRIES
• Chemical engineering has to do with industrial processes in which raw
materials are converted or separated into useful products.
• The chemical engineer must develop, design, and engineer both the
complete process and the equipment used;
• Choose the proper raw materials;
• Operate the plants efficiently, safely, and economically;
• and see it to that products meet the requirements set by the customers.
• Thus, Role of a CHEMICAL ENGINEER is to design & develop a optimised
process in the process industries also taking consideration of Process
Safety, Quality, Quantity, Economy, etc.
ROLE OF CHEMICAL ENGINEERS
IN PROCESS INDUSTRIES
• The areas of most concern to chemical engineers were
• ore beneficiation,
• petroleum refining,
• genetically modified biochemical agents in areas of food
processing and biotechnology,
• drug manufacture and drug delivery in pharmaceuticals,
• and the manufacture of heavy chemicals and organics.
ROLE OF CHEMICAL
ENGINEERS IN PROCESS INDUSTRIE
S
• In simple terms, Task of chemical engineer in process industries
includes:
• Ensuring compliance with health, safety and environmental regualations
• Conducting research into improved manufacturing processes
• Designing and planning equipment layout
• Incorporating safety procedures
• Monitoring and optimizing the performance.
INTRODUCTION TO COMMON
DEVICES USED IN MANUFACTURING
PROCESSES
• List of the machinery and equipment that manufacturing companies
most often use in their unit operations.
• Tanks – Many manufacturers find themselves needing to store bulk quantities of
product. from alloy, aluminum, and carbon steel to cryogenic, gas, glass-lined, plastic,
fiberglass, rubber, and stainless steel—the tank options are diverse and many.
• Mixers – Manufacturing operations often depend on mixing materials properly. Ribbon
mixers, batch compounders, continuous mixers, homogenizer mixers, paddle mixers, are
just some of the options to choose from.
• Centrifuges – When it comes to separating liquids from other liquids or from solids, a
centrifuge is a vital piece of manufacturing support equipment. Basket bottom dump
centrifuges, disc automatic centrifuges, and disc batch centrifuges are just a few of the
varieties available.
INTRODUCTION TO COMMON
DEVICES USED IN MANUFACTURING
PROCESSES
• Generators
• Compressors / Pumps
• Chillers / Refrigeration Equipment
• Shredders – Industrial shredders help break down large materials into more
manageable sizes. They are indispensable pieces of equipment in every
manufacturing facility, but particularly in the plastics, rubber and computer industries.
• Distillation column
• Agitated vessel
• Driers
• Extractors
• Filters
• conveyers
INTRODUCTION TO COMMON DEVICES USED IN
MANUFACTURING PROCESSES
• All these equipment's in process industries includes reactions of the
raw material and unit operation processes which are required for
separation techniques
• Some of the common unit operations involved are:
• Screening – sorting the different size particles – required cutoff dia
• Crushing / grinding – size reduction techniques – gives output in required size
• Evaporation – to remove the excess water/liquid from the solution mixture
• Crystallization – formation of crystal of solids or the ptd required
• Transport – transport of solids done by conveyers –pneumatic and belt
conveyer
Block diagrams, flowcharts and standard
symbols used for devices
BLOCK DIAGRAM AND FLOW CHART
• Block diagram is a diagram of a system in which the principal parts or functions
are represented by blocks connected by lines that show the relationships of the
blocks.
• They are heavily used in the engineering world in hardware design, electronic
design, software design, and process flow diagrams.
• In process industries, Block diagram are simplified diagram with limited
information on the process.
BLOCK DIAGRAM AND FLOW CHART
• A flowchart is a type of diagram that represents a workflow or
process.
• A flowchart is simply a graphical representation of steps
• A flowchart can also be defined as a diagrammatic representation of
an algorithm, a step-by-step approach to solving a task.
• The flowchart shows the steps as boxes of various kinds, and their
order by connecting the boxes with arrows.
• It shows steps in sequential order and is widely used in presenting
the flow of algorithms, workflow or processes.
BLOCK DIAGRAM AND
FLOWCHARTS
STANDARD SYMBOLS USED FOR DEVICES
STANDARD SYMBOLS USED FOR
DEVICES
STANDARD SYMBOLS USED FOR
DEVICES
STANDARD SYMBOLS USED FOR
DEVICES
STANDARD SYMBOLS USED FOR
DEVICES
OUTLINE OF PLANT AND EQUIPMENT
DESIGN
• The design of chemical plants is categorized into 2 parts:
• Process design
• Mechanical Design
• Process design is concerned with unit operation and processes
• Mechanical design deals with construction details of equipment,
process auxiliaries, installation, operations and maintenance details.
OUTLINE OF PLANT AND EQUIPMENT
DESIGN
• Design Steps:
• Collect all laboratory and process development information
• Prepare flowsheets
• Choose conventional design procedures for equipment designated on flow
sheets as unit operation oriented
• Design the reactors
• Select the control instrumentation for process monitoring and analysis
• Select and size materials handling equipment's, pumps piping and conveyors.
• Design all process auxiliaries
• Make plant layouts
• Itemize all design for cost estimation
OUTLINE OF PLANT AND EQUIPMENT
DESIGN
• Indicate the point of entrance of raw materials
• Necessary energy change
• Removal of by product
• Flowcharts help to visualize series of rational steps for a process.
INDUSTRIAL SAFETY AND
POLLUTION
• Industrial safety is primarily a management activity which is
concerned with
• Reducing
• Controlling
• Eliminating hazards from the industries or industrial units.
• Significance of Industrial Safety
Significance of Industrial Safety
• Industrial causes a great loss to both the Employer & Employee, that’s
it is having importance
Cost of compensation
Cost of medical-aid
Cost of the lost time
Cost of investigation
Cost of supervision & inspections
Cost to the Govt. in terms of factory inspectors, & public health services
Cost of spoilage of materials
Cost of the damage of machinery
Cost of cost of wages payble during injury
Cost of loss to the worker and his family
INDUSTRIAL SAFETY AND
POLLUTION
• Fire & explosion hazards
• Causes
• Smoking in the factory
• Defective heating equipment, electrical equipment & wiring.
• Explosive gas leakage.
• Inadequate protection of electric motors
• Sparking of electric wires & equipment
INDUSTRIAL SAFETY AND
POLLUTION
• Preventive measures
• Prohibition of smoking in manufacturing areas.
• Oxygen present in the inflammable atmosphere may be ↓by dilution with
gases such as nitrogen, co 2 ,steam or combination of these.
• Hazardous operation should be isolated
• Eliminating the ignition sources
• Using fire resistant material in construction
• Suitable emergency exits and Adequate venting
INDUSTRIAL SAFETY AND POLLUTION
OSHAS – Occupational Health and Safety rules are to be implented in
industries
Regulations are required to be followed as per norms of the
acts enacted by the Indian government.
It provides dynamic mechanism for development for effective health
and safety management systems.
Effective sewage disposal system to be followed and maintained.
The sewage or effluent from industry needs to be regulated or
monitored for its quality levels before letting into the drainage system.
The air emission standards are to be followed the control equipments
like bag filters, cyclone separator, electrostatic precipitators, are
employed to maintain air quantity.
UNIT 1 -
CHLORO- ALKALI INDUSTRIES
• Manufacture of Soda ash and sodium bicarbonate,
• Chlorine and caustic soda;
• Bleaching powder and related bleaching agents,
• Sodium chloride, By-products of common salt industry.