Principles of Chemical Engineering

Introduction:
Role of chemical engineering in design and analysis of chemical processes.

The process design engineers sometimes find themselves in different situations, such as:
1. The Output is known and a desirable route to its production is to be designed, including selecting appropriate inputs.
2. The Inputs are known and a desirable output is required along with 1.
3. The desirable properties are known and a product along with its manufacturing process is to be designed.
4. The inputs, outputs and route are known, but an optimization of the route is to be performed. In either Product or
Process Engineering, the primary objective of the design engineer is usually to produce something at the lowest
possible cost, with the most commercially desirable attributes, and to do so in a way that meets all applicable laws and
standards and ensures safety and protection of society. In the realm of the process designer, the objectives can be open
ended, such as producing a more environmentally friendly or safer stream, or to meet a legislative requirement. But,
more commonly, the end product is known and the route to its production is being designed, which tends to make the
design problem less open ended. Another example of an open ended design problem would be when the objective of a
process is to make use of a waste stream in any manner possible, which may or may not, require changing it’s
molecular properties (i.e. convert it to a useful product, burn it to recover energy, or digest it using biological means).
A number of processes require a chemical reaction as part of the modification step(s). The choice of the reaction
pathway often significantly affects the overall commercial, safety, and environmental aspects of the process. Process
Synthesis Steps Synthesis Step Process Operations 1. Eliminate differences in molecular types Chemical Reactions 2.
Distribute the chemicals by matching sources and sinks Mixing 3. Eliminate differences in composition Separation 4.
Eliminate differences in temperature, pressure and phase Temperature, pressure, and phase change 5. Integrate tasks;
that is, combine operations into unit processes and decide between continuous and batch processing When multiple
solutions remain, or if one must be carried to financial analysis, the next step in the design is to produce a model of the
process. This model is documented in the format of a “process flow diagram” (PFD) along with accompanying heat
and material balances (for discussion purposes, further reference to the PFD will also include a heat and material
balance). The PFD provides the first glimpse at what equipment will have to be purchased, and what utilities or
additional chemicals will be required to make the process work. A variety of software tools are available for
accomplishing the task, such as Unisim, HYSYS, Aspen, and PRO II., but a common spreadsheet style computer
program are also necessary to do the required process modelling.
Process Synthesis Steps Synthesis Step Process Operations:
1. Eliminate differences in molecular types -Chemical Reactions
2. Distribute the chemicals by matching sources and sinks - Mixing
3. Eliminate differences in composition – Separation.
4. Eliminate differences in temperature, pressure and phase -Temperature, pressure, and phase change.
5. Integrate tasks; that is, combine operations into unit processes and decide between continuous and batch processing.
Historical and most recent developments in chemical engineering:
History of chemical Engineering:
Chemical engineering is a branch of engineering that deals with the processes (production, transformation,
transportation and usage) necessary to produce useful materials and energy. Chemical engineers apply knowledge
from the physical and biological sciences as well as mathematics and economics.
Chemical engineering is one of today’s broadest and most in-demand engineering disciplines. Chemical engineers
work in a variety of industries, including energy, mining, chemical production, food production, and water treatment.
Because of their diverse skillset and the industries in which they work, chemical engineers are highly sought-after.

There is no set definition of what chemical engineering is because of how broad chemical engineering is and the
diversity of industries in which chemical engineers work. A good definition might be “the union of chemistry, physics,
biology, mathematics, and economics to refine and add value to raw materials and to develop and optimise chemical
processes, often at an industrial level”. This definition captures the disciplines relied upon by chemical engineers and
the key functions of the discipline.      

The chemical engineering discipline is less than 150 years old, yet still has a fascinating history. From manufacturing
dyes and perfumes in small batches to the largest chemical plant in operation today, this discipline has evolved by
leaps and bounds in a relatively short time.

Recent developments in chemical engineering:

Chemical engineers are in an ideal position to develop solutions for some of today’s most important problems, such as
providing food, potable water, goods, and energy to a growing population . Satisfying these needs via conventional
methods would be impossible and potentially disastrous for the planet. Significant advances are needed to improve
productivity and yield of crops, reduce environmental contamination, improve energy and water stewardship, and
more.

Some specific examples of chemical engineering solutions that have great potential for wider application, and thus are
avenues for potential innovation, include:

 process intensification, i.e., any chemical engineering development that leads to a substantially smaller,

cleaner, and more energy-efficient technology (6)
 alternative/clean energy systems
 alternative production processes and chemical reactions that can reduce waste generation, consume less water,
require less dangerous materials, and result in greater energy efficiency or higher yields of the desired product
 automation systems that can optimize production and quality and reduce production costs
 nanotechnology and nanomaterials
 advanced pharmaceuticals
 more-sustainable building and construction materials
 drones and robots to minimize or avoid risks to people associated with handling hazardous chemicals and work
in confined spaces or elevated locations (e.g., for flare inspections).
Chemical engineers throughout the CPI can innovate in their day-to-day work — regardless of the type of role or job
they have, whether in R&D, manufacturing, engineering, supply chain, marketing, etc. (Figure 1).
 ▲Figure 1. Opportunities abound for innovation in the chemical process industries (CPI). In the innermost (purple)
circle are a variety of job functions a chemical engineer may fulfill at their company. The next (green) circle shows
innovation opportunities. The outermost circle (blue) gives more specific examples of how to go about innovating. 
Energy sector. We hear about new innovative solutions in the energy sector almost daily. Unfortunately, some of these
are just ideas and inventions, not innovations. They may have validity from the strictly scientific viewpoint, but do not
make much sense from a practical viewpoint. For example, the fact that methane and other chemicals and fuels can be
produced using CO2 as raw material does not mean that doing so in a lab or in a pilot plant will become the solution
for CO2 disposal or a great opportunity for the energy sector, as some of such ideas are advertised. For an invention to
become a valid solution, it needs to meet some stringent criteria regarding economics, practicality, thermodynamics,
etc. Likewise, many of these inventions do not make sense from an economic viewpoint because they require a
tremendous amount of resources for industrial-scale implementation.

Unfortunately, the general public often does not understand the science and engineering concepts behind energy
production. Chemical engineers have the opportunity to help educate the general public about what is practical and
feasible. They can also make contributions to the energy sector through their work in developing:

 alternative fuels
 batteries that are lighter, have more storage capacity, etc.
 solar panels that are less expensive, more efficient, more economical, easier to install, etc.
 lighting elements that are energy efficient and durable
 materials for transportation applications that are stronger and lighter
 insulation for housing and commercial buildings that is more efficient.
Food and agriculture. The chemical industry has played a major role in the food production and food conservation
sector for more than a century. For example, without the use of ammonia-based fertilizers, humankind would only be
able to provide food for a fraction of the world’s current population.

Opportunities in agricultural sciences go much further than fertilizers and pesticides. Innovation will be driven by the
increasing demand for food by a fast-growing population coupled with an increasing demand for beef and other animal
proteins in the developing world. Food shortages are a real and pressing problem in many parts of the globe. In fact,
according to the Food and Agricultural Organization (FAO), more than 840 million people go without enough to eat
every day.

Food waste is another pressing concern. Every year, the U.S. throws out $180 billion worth of food, which ends up in
landfills and creates the greenhouse gas methane, which can cause environmental harm (7).

Feeding a growing population that is expected to surpass 9 billion by 2050, while minimizing negative environmental
impacts, will require major innovations from chemical engineers. These goals will only be achieved via technologies
that significantly improve land productivity and minimize food waste.

Role of chemical engineering in biological processes:

For the chemical engineer, however, the major distinction is in terms of the scale of operation. The majority of
products of the new biotechnology are extremely high value, low volume biochemicals. Thus recovery (separation)
processes for such products may be relatively costly and energy intensive, because of the small quantities involved, but
at the same time must be highly efficient in order to minimize loss of valuable product. This contrasts with the more
traditional biotechnological processes of the food and beverage industries, antibiotic and medium value
pharmaceuticals production, and wastewater treatment. Here, the problems for the chemical engineer are more like
those in the chemical or process industries.

Just as the chemical industry for decades was dominated by the chemist, so the bioprocess industry is still dominated
by the industrial microbiologist. There are consequently many areas in which improvements can be made to
established industrial biological processes by the application of simple engineering concepts.

Unit operations and unit processes in chemical industry:

Chemical engineering is all about chemical reactions and elements, factors, and optimization of those to understand
the mechanics of chemical reactions and production products. The combination of both unit operation and the process
is called the manufacturing process or chemical process.

Unit Operation

Unit operation is a basic step in a process that involves physical change or chemical transformation during the
process like polymerization separation, evaporation crystallization, filtration, isomerization, and other reactions. 

Example of Unit operation

Example 1 – Distillation of Methylene Di Chloride with water

Explanation – In a process, the separation of Methylene Di Chloride with water using a liquid-liquid separation
technique can be called as a unit operation.|
Explanation – In the above process, only separation is taking place which will be done base on density difference. This
is a physical change and no chemical reaction taking place, hence this process is considered as unit operation.

Classification of Unit Operation

Now we had seen the definition of unit operation and hereby learned what is unit operation. There are 4 classifications
of unit operation, classification of unit operation are listed below.

1. Material handling, transportation / Fluid flow process

Pumping
Compression
fluidization
2. Mechanical unit operations
Size reduction
Size enlargement
Mixing, agitation, blending, etc
3. Mass transfer operations
Evaporation
Distillation
Absorption
Extraction
leaching.
4. Heat transfer operations
conduction
convection
radiation
Unit Process

The unit process is a process in which chemical changes take place to the material present in the reaction and result in
the chemical reaction is known as the Unit process. This basically consists of a reaction between two or more chemical
which results in another chemical and can also be defined as a unit process. Sulphonation, nitration, oxidation,
halogenation, and many more.

Example of Unit process

Example 1 – Electrolysis of sodium chloride solution

Explanation – Here, electrolysis of NaCl is being done and the concentration of sodium chloride is taken as 305
(around) GPL (gram per liter) concentration is feed to electrolysis cell in which electricity is passed and sodium
hydroxide is produced. In this reaction, a decomposition reaction takes place hence, this is a unit operation. If you are
interested, you can read Fundamentals of Electrolysis

Example 2 – Production of Hydrogen

 Hydrogen is produced using very popular method i.e. Steam-methane reforming reaction. In this method, methane
reacts with steam at a pressure under 3–25 bar pressure in the presence of a

Difference between unit operation and unit process

Unit Operation Unit Process

Process in which only physical changes and not chemical Process in which chemical changes takes place
changes takes place are known as a unit operation. are considered as unit process.

Mixing, blending, crushing distillation, etc are considered as Bromination, halogenation, sulphonation, etc
unit operations are called unit process

Units and conversion factors:

Base and Derived Units:

A measured or counted quantity has numerical value and a unit. It is essential and useful to write
both the value and the unit of each quantity appearing in an equation. A dimension is a property that can be
measured such as velocity: length/time, volume: lenth 3, density: Mass/length3. Measurable units are specific
values of dimensions that have been defined by convention, custom or law. Units can be treated like
algebraic variables when quantities are added, subtracted, multiplied or divided. The numerical values of
two quantities may be added or subtracted only if the units are the same.

A system of units has the following components:

1. Base Units for mass, length, time, temperature, electrical current and ligh intensity
2. Multiple units which are defined as multiples or fractions of base units.
3. Derived units are obtained by multiplying and deviding base or multiple units. They are also
obtained as defined equivalents of compound units.
SI Units: Systeme Interantionale d’Units were put into practice at the 10th General conference on weights
and measures in 1954 at paris. This consists of six base units.
 Two supplementary units namely radian and stearadian were defined to measure planer and solid angles.
Later concept of the to quanitify ‘amount of substance’ one more base unit called mole was introduced.

CGS System:This is almost similar to SI, the principle difference being that grams (g) and centimeters (cm) are used
instead of kilograms and meters as the base units of mass and length.

FPS system: The base units of american engineering system are foot (ft) for legth, the pound mass (lb m) for
mass and second for time. The two principle difficulties of this system are decimal system is not followed
here and there is not unit for force.

Conversion of Units:

A measured quantity can be expressed in terms of any units having the appropriate dimension. Velocity may
be expressed in ft/s, miles/h, cm/yr or any other ratio of a length unit to a time unit. The equivalence
between two expressions of the same quantity may be defined in terms of a ratio. To convert a quantity
expressed in terms of one unit to its equivalent in terms of another unit, multiply the given quantity by the
conversion factor (New unit/old Unit).
 1g 
Ex: Convert 36 mg to (36mg)x   0.036mg
grams: 1000mg
Important conversion Factors:

Length: 1 m = 1.093 Yard = 3.28 ft; 1 cm = 0.393 inch.

Volume: 1 m3 = 1000 Litres = 35.315 ft3 1 Litre = 0.0353 ft3 = 0.264 US gal.
Mass: 1 Kg = 1000 gr = 2.204 lb
Density: 1 g/cm3 = 62.427
lb/ft3 Specific Volume: 1 m3/Kg =
16.018 ft /lb Force: 1 N = 0.101972 Kgf
3

Pressure: 1 KPa = 0.01019 Kgf/cm2 = 0.145038 lbf/in2; 1 bar = 0.1 MPa = 14.695 lbf/in2 = 760 mmHg
1 torr = 1 mm Hg = 133.3234 Pa
Energy: 1 J = 0.238 Cal = 9.478 x 10-4 BTU
Power: 1 KW = 1.341 HP

Introduction to dimensional analysis (Pi-Theorem)

The principle of dimensional homogeneity with an example and also list the steps involved in the pi- theorem of
dimensional analysis.
The Basic principle is Dimensional Homogeneity, which means the dimensions of each terms in an equation on both
sides are equal.
So such an equation, in which dimensions of each term on both sides of equation are same, is known as
Dimensionally Homogeneous equation. Such equations are independent of system of units. For example;  Lets
consider the equation V=(2gH)1/2
Dimensions of LHS=V=L/T=LT-1
Dimensions of RHS=(2gH)1/2=(L/T2 xL)1/2=LT-1
Dimensions of LHS= Dimensions of RHS  So the equation V=(2gH)1/2 is dimensionally homogeneous equation. 
Buckingham’s π-Theorem: Since Rayleigh’s Method becomes laborious if variables are more than fundamental
dimensions (MLT), so the difficulty is overcome by Buckingham’s π-Theorem which states that  “If there are n
variables (Independent and Dependent) in a physical phenomenon and if these variables contain m fundamental
dimensions then the variables are arranged into (n-m) dimensionless terms which are called π-terms.”  Let X1, X2,
X3,…,X4, Xn are the variables involved in a physical problem. Let X1 be the dependent variable and X2, X3, X4,
…,Xn are the independent variables on which X1 depends. Mathematically it can be written as 
X1=f(X2 ,X3 ,X4 ,Xn) which can be rewritten as  f1(X1,X2 X3 X4 Xn)=0  Above equation is dimensionally
homogenous. It contain n variables and if there are m fundamental dimensions then it can be written in terms of
dimensions groups called π-terms which are equal to (n-m) 
Hence f1(π1 π2 π3,…πn-m)=0