Introduction to Chemical Engineering

Unit-1
Chemical Engineering in everyday life
Chemical engineering impacts many aspects of everyday life, including the production of
food, clothing, and energy:

 Food
Chemical engineers improve food processing techniques and fertilizer production to
increase the quantity and quality of food.

 Clothing
Chemical engineers create synthetic fibers that make clothes more comfortable and water
resistant.

 Energy
Chemical engineers refine petroleum products to make energy sources more productive and
cost effective. They also work on developing renewable energy sources like solar and
hydroelectric.

 Toilet paper
Chemical engineering processes are involved in the production of toilet paper, which can be
made from recycled or new paper.

 Environmental issues
Chemical engineers develop solutions to environmental problems like pollution control and
remediation.

 Pharmaceuticals
Chemical engineers develop methods to mass-produce drugs to make them more affordable.

 Medical devices
Chemical engineers create biocompatible materials for implants and prosthetics.

 Packaging
Chemical engineers create packaging materials.

 Electronics
Chemical engineers create films for optoelectronic devices.

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 Introduction to Chemical Engineering
Chemical engineers are responsible for designing production processes while also managing
resources, ensuring health and safety standards, and protecting the environment.

Lab scale to plant scale

Scaling up from a laboratory to a plant scale is a process that involves gradually increasing the
scale of chemical reactions. This process is also known as pilot plant scale-up, and it's a
critical step in developing a reliable manufacturing technique for a commercial product.

Here are some things to consider when scaling up from a lab to a plant:
 Planning
Thorough planning is essential, including identifying goals, setting success criteria, and
considering financial and resource aspects.

 Testing
Closely monitor reactions and make adjustments to ensure the scale-up meets expectations
for yield, purity, and performance.

 Identifying challenges
This phase is critical for identifying issues that could impact the process, such as heat
transfer issues or mixing inefficiencies.

 Optimizing parameters

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 Introduction to Chemical Engineering
Optimize operational parameters to ensure the process is robust and reliable.
 Adapting equipment
Adapt the manufacturing facility, equipment, and quality control measures to accommodate
the larger-scale production.
 Lab Scale and Commercial Scale The demand for a product can be a few hundred tons
per year. Under these circumstances, this large volume can be produced by carrying out
the reaction in tens of thousands of the small reactors in the Laboratory.
 This would mean that the production is carried out in parallel. This would be a very
inefficient way of doing things as it would require a large equipment inventory, it would
be highly labor intensive, etc.
 It is for this reason that most plants that we see in the industry are large in size. Here the
plant operation becomes economical when it has a large capacity.
 This is the so-called economies of scale where the utilization of energy, raw materials,
etc. on a per unit product formed basis is very efficient There are several challenges
(mixing, rate of heat generation, and heat loss) when the size of units is increased.
 New physical phenomena arise when the scale is increased and these have to be
accounted for. Hence increasing the size is usually not done in one step.
 The scale of the plant operation or the size of the plant is not increased by three orders of
magnitude, for instance. The system behavior in an intermediate scale called the pilot
plant is first analyzed.
 This has a production capacity which is in between the lab scale and the commercial
scale. For instance, it could be a plant with a capacity of tens of tons.
 The process is first extended from the lab scale to the pilot-plant scale. There is a
significant amount of learning or knowledge which is gained at this stage.
 This is achieved at a moderate cost, since the costs for building the pilot plant and
running it are much lower than that of building and running a commercial plant.
 This knowledge is then used to scale up further to the commercial scale. Sometimes pilot-
plant level tests maybe done at two intermediate scales before going for commercial
production
Challenges involved in the scaling-up

 The operating conditions (initial concentrations of the reactants, initial temperature,

etc.) which were safe for the pilot plant may be unsafe for the commercial scale reactor.

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 Introduction to Chemical Engineering
 These challenges make it important for us to obtain a good understanding of all the
processes (reaction, mixing, and heat transfer, etc.) which are taking place in the system
so that the scale-up can be done in a reliable way with minimum scope for any error.

Versatility of a Chemical/Petrochemical Engineer

Chemical and petrochemical engineers are versatile because they have a strong foundation in
engineering and can apply their skills in many industries:

 Industries
Chemical engineers can work in many industries, including energy, pharmaceuticals,
environmental protection, and materials science.

 Specialization
Chemical engineers can specialize in other fields, such as environmental engineering,
agricultural engineering, production engineering, nuclear engineering, and petrochemical
engineering.

 Problem solving
Chemical engineers are educated in chemical and physical fundamentals, economics,
mathematics, and systems analysis, which helps them solve problems that affect civilization.

 Collaboration
Chemical engineers can collaborate across different engineering fields to bring efficient
processes to reality.

 Lifelong learning
Chemical engineers should continue to learn throughout their careers and have a solid
foundation of process fundamentals.

Petrochemicals are chemical products obtained from petroleum by refining. They are the
building blocks for many materials, such as solvents, detergents, adhesives, plastics, resins,
fibers, elastomers, lubricants, and gels.

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 Introduction to Chemical Engineering
Role of Chemical Engineers in Petroleum refinery
Chemical engineers play a key role in the chemical processing side of a petroleum refinery,
where they design, develop, and operate equipment and processes. Their responsibilities
include:

 Research: Developing new and improved manufacturing processes

 Design: Planning the layout of equipment and establishing safety procedures

 Testing: Conducting tests and monitoring production processes

 Troubleshooting: Identifying and fixing problems in manufacturing processes

 Product quality: Ensuring product quality

Chemical engineers use principles from chemistry, biology, physics, and mathematics to solve
problems. They are often employed by large-scale manufacturing plants to maximize
productivity and product quality while minimizing costs.

Role of Chemical Engineers in Chemical Industry

Chemical engineers are responsible for designing, developing, and optimizing the processes
used in chemical manufacturing. They play a key role in the production of many industrial
products, including chemicals, fuels, food, pharmaceuticals, and biologicals.

Here are some of the responsibilities of chemical engineers:

 Process design
Chemical engineers use their knowledge of chemistry, physics, and engineering to design
and develop processes for manufacturing products.
 Equipment design
Chemical engineers use computer-aided design (CAD) software to design and plan the
layout of equipment.
 Safety
Chemical engineers establish safety procedures for working with dangerous chemicals and
ensure that work environments are safe for consumers.
 Production monitoring
Chemical engineers conduct tests, monitor production processes, and troubleshoot problems.

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 Introduction to Chemical Engineering
 Environmental compliance
Chemical engineers ensure that processes comply with environmental regulations.
 Cost estimation
Chemical engineers estimate production costs for management.

Chemical engineers work in many industries, including chemical, energy, oil, biotechnology,
pharmaceuticals, electronic device fabrication, and environmental engineering. Their skills are
transferable across industries, and many chemical engineers move into more senior
management roles or other areas of business.

Role of Chemical Engineers in petrochemical Industry

Chemical engineers are in high demand in the petrochemical industry and play a vital role in
the design and development of products and processes:

 Process design
Chemical engineers design and develop processes and equipment for manufacturing
petrochemicals.

 Research
Chemical engineers research ways to improve existing processes and develop new ones.

 Safety
Chemical engineers ensure that processes are safe and environmentally responsible. They
design safety guidelines for professionals working with chemicals.

 Quality control
Chemical engineers perform quality checks on current processes to ensure they remain up to
standards.

 Production monitoring
Chemical engineers monitor the performance and efficiency of production processes.

 Equipment maintenance
Chemical engineers maintain equipment and systems to ensure safe and efficient operation.

Chemical engineers use the principles of chemistry, physics, and engineering to design
processes and equipment. Their job descriptions can vary depending on their specialization.

Dr Bandi Chandra Sekhar

 Introduction to Chemical Engineering
Role of Chemical Engineers in petrochemical Industry
Chemical engineers are in high demand in the petrochemical industry and play a vital role in
the design and development of products and processes:

 Process design
Chemical engineers design and develop processes and equipment for manufacturing
petrochemicals.

 Research
Chemical engineers research ways to improve existing processes and develop new ones.

 Safety
Chemical engineers ensure that processes are safe and environmentally responsible. They
design safety guidelines for professionals working with chemicals.

 Quality control
Chemical engineers perform quality checks on current processes to ensure they remain up to
standards.

 Production monitoring
Chemical engineers monitor the performance and efficiency of production processes.

 Equipment maintenance
Chemical engineers maintain equipment and systems to ensure safe and efficient operation.

Chemical engineers use the principles of chemistry, physics, and engineering to design
processes and equipment. Their job descriptions can vary depending on their specialization.

Role of Chemical Engineers in Energy Industry

Chemical engineers play a vital role in the energy industry by developing and optimizing
processes to generate energy, reduce emissions, and improve efficiency:

 Renewable energy: Chemical engineers develop sustainable materials and technologies to

harness energy from renewable sources, such as solar power and fuel cells.

 Nonrenewable energy: Chemical engineers develop methods for using nonrenewable

feedstocks, and optimize conventional fuels.

 Efficiency: Chemical engineers improve energy efficiency and reduce operating costs.

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 Introduction to Chemical Engineering
 Emissions: Chemical engineers reduce refinery emissions and capture emissions.

 Sustainability: Chemical engineers drive clean energy innovations and address environmental
challenges.

 Project management: Chemical engineers often take on project management responsibilities,

including planning, execution, and completion of projects.

Role of Chemical Engineers in environment

Chemical engineers play a vital role in protecting the environment by developing solutions to
reduce emissions, minimize waste, and ensure compliance with environmental
regulations. Their work helps address global environmental challenges and promote
sustainable practices across industries.

Here are some ways chemical engineers help the environment:

 Pollution control
Chemical engineers develop technologies to control and remediate pollution. For example,
they invented catalytic converters, which destroy pollutants in engine exhaust.

 Carbon capture
Chemical engineers design and manufacture materials to capture carbon dioxide.

 Water treatment
Chemical engineers improve the efficiency of water filtration and treatment methods. They
also treat wastewater to ensure clean water for consumption and industrial use.

 Renewable energy
Chemical engineers develop processes to harness renewable sources of energy, such as solar
power.

 Clean energy storage

Chemical engineers develop advanced batteries, hydrogen fuel cells, and compressed air
energy storage.

Chemical engineers use their knowledge of physics, math, chemistry, and other subjects to
produce resources sustainably without damaging the environment.

Dr Bandi Chandra Sekhar

 Introduction to Chemical Engineering

Batch Processing
In chemical engineering, a batch process is a series of steps that are performed in a specific order
to produce a finite amount of a product:
Steps: A batch process involves a sequence of steps that are performed in a specific order.

 Quantity: The process produces a finite amount of the product.

 Repeat: The sequence of steps is repeated to produce another batch of the product.

 Product: The product is delivered in discrete amounts, rather than continuously.

Batch processes differ from continuous processes, where all operations occur simultaneously and
the material being processed is not divided into identifiable portions.

Here are some characteristics of batch processes:

 Raw materials
Batch processes deal with discrete quantities of raw materials.

 Products
Batch processes can process more than one type of product simultaneously, as long as the
products are separated by the equipment layout.

 Recipes
Each load of raw material has a recipe, or processing instructions, associated with it.
Control
Control and optimization objectives can be defined for a given batch or over several batches.
Advanced control
Advanced control techniques can be used to optimize the performance and efficiency of the
batch process.

Examples of batch processes include beer production and alcohol fermentation.

Batch processes generate a product but the sequential processes need not necessarily generate a
product. Some examples of batch processes are beverage processing, biotech products
manufacturing, dairy processing, food processing, pharmaceutical formulations and soap
manufacturing.

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 Introduction to Chemical Engineering
Transition from batch to continuous processing
 The transition from batch to continuous processing can improve efficiency, productivity, and
product quality. Continuous processes involve a constant flow of materials or products, which
can reduce the need to stop and start for each batch.
 Transition from batch to continuous production of dispersants is demonstrated. Batch process
is mass transport-limited by slow water evaporation. Continuous process is equilibrium-
limited due to lack of water removal.
The transition from batch to continuous processing in chemical engineering can lead to many
benefits, including:
 Improved product quality: Continuous manufacturing can lead to superior product quality.

 Enhanced efficiency: Continuous manufacturing can lead to enhanced efficiency.

 Reduced environmental impact: Continuous manufacturing can lead to reduced

environmental impact.

 Improved automation: Continuous manufacturing can lead to improved automation.

 Simpler scale-up: Continuous manufacturing can lead to simpler scale-up.

 Higher throughput: Continuous manufacturing can lead to higher throughput.

Some challenges to the transition include:

 Operational differences
Operational differences between batch and continuous reactors can change the effective
reaction kinetics.

 Switch from batch reactor vessels to continuous flow reactors (CFRs)

Switching from batch reactor vessels to continuous flow reactors is one of the most
challenging problems to solve.

Some things to consider when transitioning from batch to continuous processing include:
 Optimized equipment: Using optimized equipment can lead to significant process
improvements.
 Process analytics: Process analytics can help achieve continuous and stable startup and
steady operation.

 Residence time/mixing/pressure drop calculations: These calculations can help achieve

consistent yield and purity at scale

 Batch processing typically has higher unit costs compared to continuous processing. This is
due to lower production rates, smaller equipment, and more frequent equipment cleaning and
maintenance. Batch processes are often used for smaller productions or niche markets where
the cost of production is less critical.

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 Introduction to Chemical Engineering
Case study: Any chemical industry
Here are some case studies about the chemical industry:
 Advanced planning and scheduling
Nova Chemicals used PlanetTogether to streamline production workflows, optimize
resource allocation, and improve operational agility.

 Chemical handling
A contractor's employee died from asphyxia after being exposed to hydrogen sulfide gas
that was trapped in furnace waste residues.

 Chemical processing
Chemical companies have a variety of needs, including fire protection, and their processes
depend on the interaction and pumpability of externally stored components.

 Chemical alternatives assessment

KayDisplay, a fictitious small U.S. manufacturer, conducted a chemical alternatives
assessment to determine if they could sell their products in the European Union (EU).

 Tank and silo installations

Tank and silo installations can be hazardous, especially in places prone to earthquakes or
wind. METTLER TOLEDO's PinMount weigh modules with SafeLock features helped a
Chinese company install load cells quickly and safely.

A case study is a detailed examination of a particular case in a real-world context. Case

studies can be used to highlight individuals, groups, organizations, events, belief systems, or
actions.

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 Introduction to Chemical Engineering
Role of basic sciences in Chemical Engineering

Basic sciences like chemistry, physics, and mathematics are fundamental to chemical
engineering because they provide the foundation for solving complex problems:

 Design
Chemical engineers use basic sciences to design chemical reactions and processes that
convert raw materials into valuable products.

 Optimization
Chemical engineers use mathematics to optimize processes by arranging materials,
facilities, and energy to be productive and economical.

 Modeling
Chemical engineers use mathematics to create theoretical mathematical prototypes of
complex process systems.

 Safety
Chemical engineers use basic sciences to ensure safety and minimize environmental
impact.

 Efficiency
Chemical engineers use basic sciences to improve manufacturing techniques and ensure
efficiency and effectiveness in their projects.

Chemical engineers apply these principles to solve problems involving the production of
chemicals, fuel, drugs, food, and energy solutions.

Examples of the interaction between these disciplines will be discussed as they arise in
different applications.
o A common misconception which prevails is that chemical engineering is based
primarily on chemistry. It is not true. In fact, chemical engineering involves a
combination of principles of mathematics, physics, chemistry, biology, and
even economics.
o Biology comes in since some processes such as fermentation involve
microorganisms and are biochemical in nature.
o Economics is necessary so that the cost of production can be addressed. This
ensures that a technological concept is also economically viable.
o All systems must satisfy the principles of conservation of mass, momentum,
and energy.
o These principles are used to solve problems concerning the design of
equipment (such as a reactor or a distillation column) for a desired
performance level or predicting performance for a specific design.
o First, we will see different examples wherein we use physics and mathematics
to analyze a situation.

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 Introduction to Chemical Engineering
o Physics is used to formulate equations and mathematics is used to solve
equations. Equations arise from the applications of the fundamental laws which
any system must conform to.
o The three fundamental laws all systems must obey are the laws of conservation
of mass, momentum, and energy.
o One of the main responsibilities of the chemical engineer is to understand how
to apply these laws to specific systems and problems and obtain useful
information from them.
o This equation will arise in different forms in different situations or
applications. It is used to analyse the behaviour of different systems in various
contexts.
o Applications of this equation in different situations give rise to different kinds
of mathematical equations: algebraic equations, ordinary differential equations,
and partial differential equations.

Introduction to Natural Resources

Natural resources are resources that are found in nature and are used by humans. They are
products of biological, ecological, or geological processes. Some examples of natural resources
include: water, coal, wood, iron, game species, soils, mineral ores, and timber.

Natural resources can be classified as biotic or abiotic:

 Biotic resources
These are life forms that are found in nature, such as humans, animals, and plants. They are
usually renewable if used sustainably. Examples include forest products, animals for meat,
leather, and dairy products, and crops.
 Abiotic resources
These are resources that are found in nature but do not have life, such as metals, rocks, and
stones. Both biotic and abiotic resources can be renewable or non-renewable.

Natural resources are important to sustain life, but they are not unlimited. The demand for natural
resources is increasing due to the growing human population. There is a need to protect,
conserve, and augment natural resources.

Based on the availability are two types of natural resources:

1. Renewable: resources that are available in infinite quantity and can be used repeatedly are
called renewable resources. Example: Forest, wind, water, etc.
2. Non-Renewable: resources that are limited in abundance due to their non-renewable nature
and whose availability may run out in the future are called non-renewable resources.
Examples include fossil fuels, minerals, etc.

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 Introduction to Chemical Engineering
Difference between Renewable and Non-Renewable Resources

Renewable resource Non-renewable resource

It can be renewed as it is available in Once completely consumed, it cannot be renewed

infinite quantity due to limited stock

Sustainable in nature Exhaustible in nature

Low cost and environment-friendly High cost and less environment-friendly

Replenish quickly Replenish slowly or do not replenish naturally at all

The 5 Most Important Natural Resources are:

1. Air: Clean air is important for all the plants, animals and humans to survive on this planet. So,
it is necessary to take measures to reduce air pollution.
2. Water: 70% of the Earth is covered in water and only 2 % of that is freshwater. Initiative to
educate and regulate the use of water should be taken.
3. Soil: Soil is composed of various particles and nutrients. It helps plants grow.
4. Iron: It is found as mineral silica and is used to build strong weapons, transportation and
buildings
5. Forests: Forests provide clean air and preserve the ecology of the world. Trees are being cut
for housing and construction projects

Natural resources are used for many purposes, including:

 Food: Plants and animals are the source of food.
 Fuel: Natural resources like coal, natural gas, and oil provide heat, light, and power.
 Raw materials: Natural resources are used to produce goods.
 Fabrics: Biotic resources like cotton, leather, and hemp are used to make fabrics.
 Drinking water: Water is used for drinking, washing, bathing, cleaning, cooking, and
irrigation.

Some examples of natural resources include:


Oil Formed from decayed plants and animals over millions of years, oil is extracted from
the earth by drilling

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 Introduction to Chemical Engineering

. Coal: A nonrenewable fossil fuel that is burned to generate electricity.

Water An essential resource for life on earth, water is used for many
purposes.

Renewable energy
Comes from naturally replenished resources like the sun, tides, and wind.
Natural resource management includes land use planning, water management, biodiversity
conservation, and the sustainability of industries like agriculture, mining, tourism, fisheries,
and forestry.

Renewable and Non – Renewable Raw materials

Renewable resources are replenishable, while non-renewable resources can only be used
once:
 Renewable resources

These resources can be replenished if their environments remain intact. Examples of

renewable resources include:
 Sunlight: A renewable and sustainable energy source
 Wind: A renewable and sustainable resource that will never run out
 Water: A renewable resource
 Geothermal sources: These include hot springs and fumaroles. Geothermal energy
is considered renewable because the Earth's core is almost unlimited when compared
to human timescales.
 Bioenergy: A renewable source of energy that is produced from plants and animals
 Non-renewable resources
These resources can be extracted and used only once. Examples of non-renewable resources
include:

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 Introduction to Chemical Engineering
 Fossil fuels: These include coal, oil, and natural gas. Fossil fuels are non-renewable because
they take millions of years to form and are limited.
 The following are the major differences between renewable and non-renewable resources.

Renewable Resources Non-renewable Resources

Depletion

Non-renewable resources deplete over

Renewable resources cannot be depleted over time.
time.

Sources

Renewable resources include sunlight, water, wind and also Non-renewable resources includes fossil
geothermal sources such as hot springs and fumaroles. fuels such as coal and petroleum.

Environmental Impact

Non-renewable energy has a

Most renewable resources have low carbon emissions and
comparatively higher carbon footprint
low carbon footprint.
and carbon emissions.

Cost

The upfront cost of renewable energy is high. For instance,

generating electricity using technologies running on Non-renewable energy has a
renewable energy is costlier than generating it with fossil comparatively lower upfront cost.
fuels.

Infrastructure Requirements

Infrastructure for harvesting renewable energy is Cost-effective and accessible

prohibitively expensive and not easily accessible in most infrastructure is available for non-
countries. renewable energy across most countries.

Area Requirements

Requires a large land/ offshore area, especially for wind

Comparatively lower area requirements.
farms and solar farms.

 Interestingly, some resources, such as uranium, are touted as a renewable resource. However, it
is still a subject of debate as uranium is not exactly a renewable resource, according to many
statutory definitions.

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