Seatwork for Reading Assignment

Directions:

• Bring out your small booklets.

• CHEATING in any form is not allowed.
• NO ERASURES OR ANY FORM OF ALTERATION are
allowed. Kindly think about your answer before writing
it. :D
• Use CAPITAL LETTERS
• At the end of the today’s lesson, the answers will be
given. Check you own papers
Reading Assignment:

Question 1: Which of the following statements is true?

A. Scopus search on articles about process synthesis gave over

3000 articles from 1972 to 2013
B. Process synthesis is where one invents the structure and
operating levels for a new chemical manufacturing process
C. Literature on process synthesis has an exponential increase over
the decade
D. Process synthesis will not be able to contribute to the solution of
some of the “Grand Challenges for Engineers” due to its complex
nature.
Reading Assignment:

Question 2: The major principle in process synthesis is …

A. Developing new processes by adding new technologies to

existing ones.
B. Developing new processes by replacing old technologies with
existing ones.
C. Developing new processes by selecting the best material
pathways
D. Developing new processes by manipulating molecular designs.
Reading Assignment:

Question 3: In process synthesis, methodologies can be

classified into:

A. Heuristic-based approach and surrogate modelling

B. Surrogate modelling and Stochastic programming.
C. Hierarchical decomposition and Heuristic Approaches
D. Hierarchical decomposition and mathematical programming
Reading Assignment:

Question 4: Which of the following statements is NOT true

about mathematical programming approaches?

A. Unlike in operations research, mathematical programming in

chemical engineering is based on superstructure modelling.
B. Mathematical programming approach aims to generate an
optimal process design by optimizing a desired performance
metric
C. Mathematical programming models are based on appropriate
representation
D. Mathematical programming models guarantees to generate an
optimal solution to the given problem.
Reading Assignment:

Question 5: Which of the following statements is true?

A. Top chemical companies are shifting their focus from bulk

chemicals to specialty products
B. The world population is expected to grow by 9 million in 2040
C. Trends suggest that the raw material and product portfolios of
CPI may grow steadily but will have the same direction as of
today’s.
D. None of these.
Reading Assignment:

Question 6: It is defined as “any chemical engineering

development that leads to a substantially smaller, cleaner,
safer and more energy efficient technology”.

A. Process Design
B. Process Intensification
C. Process Synthesis
D. Process Integration
Reading Assignment:

Question 7: Which operation is responsible for most

separations in chemical processes?

A. Extraction
B. Membrane Separation
C. Adsorption
D. Distillation
Reading Assignment:

Question 8: In Nfor et al.(2013) proposed hierarchical decomposition

approach to combine experimental studies and mathematical
programming approach, which of the following is NOT a major step
in the method?

A. Purification Task Definition

B. Model Parameter Determination
C. Generation of Alternatives
D. Model Validation
Reading Assignment:

Question 9: These models represent functional relationship between

input and output variables based from statistical combination of
input and the corresponding output values

A. Process Superstructure
B. Technical Coefficient Matrix
C. Surrogate Model
D. Computer-Aided Molecular Design
Reading Assignment:

Question 10: Which of the following is not a conventional distillation

set-up for tri-component systems?

A. B. C. D.
Chemical Process Industries

Part I
• History of Chemical Engineering
• Role of a Chemical Engineer
• Unit Operations
• Unit Processes
• Fundamentals of Chemical Processing
• Process Flow Charts
Chemical Process Industries
•The chemical process industry (CPI) is involved in the production of a
wide variety of products that improve the quality of our lives and generate
income for companies and their stockholders.
http://www.techchemical.com/5-future-pollution-ending-technologies/

http://www.lehigh.edu/~inchain/recentResearchProjects.html

http://www.worldbridge.com/Fine_Chemical_Engineering_Process_Industry.html

http://www.aiche.org/ccps/resources/education
Chemical Process Industries
• The raw materials undergo chemical conversion during their
processing into finished products, as well as (or instead of)
the physical conversions common to industry in general.
• The products differ chemically from the raw materials as a
result of undergoing one or more chemical reactions during
the manufacturing process.

http://krohne.com/en/industries/chemical-petrochemical-industry/

http://www.quatic.com/products.aspx
Chemical Process Industries
• It include the traditional chemical industries, both organic
and inorganic; the petroleum industry; the petrochemical
industry, which produces the majority of plastics, synthetic
fibers, and synthetic rubber from petroleum and natural-
gas raw materials; and a series of allied industries in which
chemical processing plays a substantial part.

http://www.veoliawatertechnologies.co.uk/processwat
er/markets/Industrial_Solutions/chemical_processing/

https://www.google.com.ph/search?q=Chemical+Process+Industry&espv=
2&biw=1266&bih=863&source=lnms&tbm=isch&sa=X&ved=0ahUKEwja2I
nEuavKAhXKl5QKHZbXBF8Q_AUIBigB#imgrc=mLVcH28vvxsVnM%3A
Objective of CPI
• To develop processes that
• Convert raw materials into valuable products
• Treat waste materials before disposal
• Are more efficient that existing processes
• Integrate existing processes that produces output of
the same industry.
• Reduces economic burden

• To develop ways of manufacturing products through

chemical process principles.
Process Integration vs Process
Intensification
• Process Integration: the unity of the process and considers the interactions
between different unit operations from the outset, rather than optimizing
them separately.
• Process integration includes tools such as mathematical programming,
pinch analysis, and other numerical and heuristic approaches.

• Process Intensification: Any chemical engineering development that leads to

a substantially smaller, cleaner safer and more energy efficient technology.

• Process design: a method to create ways of manufacturing new or existing

products through chemical engineering principles.
Product vs Process Engineering
Process engineering is the practice Product engineering is the design
of designing and troubleshooting and manufacturing of (chemically
processes for materials that are related) products that satisfy specific
well-defined from the standpoint of customer goals, starting from material
both purity and chemical screening through manufacture.
composition
• The scope of product engineering is
• The scope of process engineering the improvement of the product
is the improvement of the output.
process. • Thus, the focus is more on the
• Thus, the focus is more on product quality, and revenue
reducing heat and electricity generation.
requirements, equipment costs
and process configuration.

http://pillars.che.pitt.edu/student/slide.cgi?course_id=12&slide_id=5.0
Conceptual Design of Chemical Processes

• J. M. Douglas’ Conceptual Design of

Chemical Processes* contains
methodologies for process design of
chemical process systems

• A simplified approach is presented here.

Details can be found on this books

Douglas, J. M. (1988). Conceptual Design of Chemical

Processes. Singapore: McGraw-Hill.
Considerations for Process Design
• According to Douglas (1988), the following hierarchical structure can be
followed for process design:
• Level 1: Batch vs Continuous
• Level 2: Input-Output Structure of the Flow Sheet
• Level 3: Recycle Structure of the Flow Sheet and Reactor Consideration
• Level 4: Separation System Specification
• Level 5: Heat Exchanger Network

• For simplicity, the following assumptions are identified by Douglas (1988) to

obtain a well-posed problem:
• Assumptions that fix part of the flow sheet
• Assumptions that fix some of the design variables
• Assumptions that fix the connections to the environment
Batch vs Continuous
Batch design focuses on processing Continuous design focuses on
a certain amount material in bulk processing materials at a fixed,
quantities at a time. continuous rate.

• Advantage on batch design is its • Advantage on continuous design is

ease of monitoring for defective its ease of control on the process.
or low quality products
• Disadvantage is on the cost of
• Disadvantage is its often equipment
shutdown times and workforce
requirement

http://www.bbc.co.uk/schools/gcsebitesize/science/add_ocr_gateway/chemical_economics/batchcontinuo
usrev1.shtml
Input-Output Structure
• Some of the decision questions are the following:
• Should we purify the raw material stream before processing or process
the feed impurities?
• How many product streams will there be?
• Do we need a gas recycle and a purge stream? What are the costs
associated with a purge
• Should reversible byproducts be recovered or recycled to extinction?
• What are the costs associated with selectivity losses?

• Some heuristics:
• If impurities react, remove it
• If impurities are inert but present in large quantities and separable,
remove it
Recycle Structure

Heuristics for Recycle Structure

• Reactant: recycle
• Intermediate: recycle
• Reversible byproduct: recycle or
exit
• Azeotrope byproduct: recycle or
separate by breaking azeotrope.
• Primary Product: exit
• Valuable Byproduct: exit
• Fuel Byproduct: exit
• Waste Byproduct: exit
 Economic Considerations

• The Economic Potential of the Process can be illustrated by the following

equation:

• Other Process Considerations include Equipment Costs which can be illustrated

as:

𝟎.𝟔
𝑺𝒊𝒛𝒆 𝒐𝒇 𝑵𝒆𝒘 𝑬𝒒𝒖𝒊𝒑𝒎𝒆𝒏𝒕
𝑬𝒒𝒖𝒊𝒑𝒎𝒆𝒏𝒕 𝑪𝒐𝒔𝒕 = 𝑲𝒏𝒐𝒘𝒏 𝑪𝒐𝒔𝒕
𝑺𝒊𝒛𝒆 𝒐𝒇 𝑬𝒙𝒊𝒔𝒕𝒊𝒏𝒈 𝑬𝒒𝒖𝒊𝒑𝒎𝒆𝒏𝒕
Tools for Process Integration
• Some of the tools that are present in literature are
• (1) Mathematical Programming,
• (2) Pinch Analysis tools
• (3) Hierarchical and Heuristic-based tools.

• For this presentation, the scope will be on

mathematical programming and pinch-based
approaches
Mathematical Programming
Linear Sets of With Nonlinear
Equations and Equation and or
Inequalities Inequalities
Continuous Linear Program Nonlinear
Variables (LP) Program(NLP)
Integer Integer Linear Integer Nonlinear
2
Variables Program (ILP) Program (INLP)
Continuous Mixed Integer Mixed Integer
and Integer Linear Program Nonlinear Program
Variables (MILP) (MINLP

• Transportation • Fuzzy optimization

• Resource Allocation • Robust programming
• Scheduling • Stochastic programming
• Multi-objective optimization
Pinch Analysis-Based Tools

• Pinch Analysis-based tools are graphical-based tools used for heat and mass
integration.
• Early applications of pinch analysis focuses in heat and mass integration
Case Study: Palm Biorefinery
Case Study: Palm Biorefinery
Case Study: Palm Biorefinery
Case Study: Palm Biorefinery
• Palm Oil-Based and Palm Oil Mill Biorefinery systems iaer a multi-functional
system that converts Palm Trees into several products:
• Briquettes or Pellets from Empty Fruit Bunches (EFB)
• Steam, Electricity and Heat from Palm Mesocarp Fiber (PMF) and Palm
Kernel Shells (PKS)

• Some of the challenges in POM and POB are

• Allocation of raw materials to generate an optimal mix of products
• The conflict between:
• Strengthen dependencies to increase yield and reduce cost
• Weaken dependencies to lower risks of interconnection failure
Answers

1) B
2) C
3) D
4) D
5) A
6) B
7) D
8) D
9) C
10) D

Chemical Process Industries (INPRCHE)

Term 2, AY 2017-2018
Chemical Process Industries

Part I
• History of Chemical Engineering
• Role of a Chemical Engineer
• Unit Operations
• Unit Processes
• Fundamentals of Chemical Processing
• Process Flow Charts
Process Diagrams
• In general, chemical processes are complex, and chemical engineers in
industry encounter a variety of chemical process flow diagrams.
• Visual information is the clearest way to present material and is least
likely to be misinterpreted. For these reasons, it is essential that chemical
engineers be able to formulate appropriate process diagrams and be skilled in
analyzing and interpreting diagrams prepared by others.

Simple
representation
http://clui.org/ludb/site/texas-petrochemicals-houston
Block Flow Diagrams
Block Flow Process Diagram for the
Production of Benzene
This diagram consisted of a
series of blocks representing
different equipment or
unit operations that were
connected by input and output
streams.

Important information such as operating temperatures, pressures, conversions,

and yield was included on the diagram along with flowrates and some chemical
composition
Block Flow Diagrams

Block Flow Plant Diagram of a Coal to Higher Alcohol Fuels Process

Process Flow Diagrams

Process flow diagram (PFD) or Process Flowsheet shows the steps involved in the
manufacture of a certain product and contains:
•the major pieces of equipment in the process with a unique equipment number
and a descriptive name.
•All process flow streams will be shown and identified by a number. A
description of the process conditions and chemical composition of each stream
will be included. These data will be either displayed directly on the PFD or
included in an accompanying flow summary table.
•All utility streams supplied to major equipment
•Basic control loops, illustrating the control strategy used to operate the process
during normal operations
Process Flow Diagrams
Skeleton Process Flow Diagram (PFD) for the Production of Benzene via the
Hydrodealkylation of Toluene
Process Flow Diagrams

Typical content of a process flow diagram

 Process piping
 Major equipment items
 Control valves and other major valves
 Connections with other systems
 Major bypass and recirculation streams
 Operational data (temperature, pressure, mass flow
rate, density, etc.), often by stream references to a
mass balance
 Process stream names
Process Flow Diagrams
It does not contain the following:
 Pipe classes or piping line numbers
 Process control instrumentation (sensors and final
elements)
 Minor bypass lines
 Isolation and shutoff valves
 Maintenance vents and drains
 Relief and safety valves
 Flanges
 Piping and instrumentation
diagram
The piping and instrumentation diagram (P&ID), also known as mechanical
flow diagram (MFD), provides information needed by engineers to begin
planning for the construction of the plant.
The P&ID includes every mechanical aspect of the plant except the
information given below:

1. Operating Conditions T, P
2. Stream Flows
3. Equipment Locations
4. Pipe Routing
a.Pipe Lengths
b.Pipe Fittings
5. Supports, Structures, and
Foundations

http://www.informit.com/articles/article.aspx?p=1915161&seqNum=3 42
Piping and Instrumentation Diagram
The general conventions used in drawing P&IDs are given below:

For Equipment—Show Every Piece Including

Spare Units
Parallel Units
Summary Details of Each Unit
For Piping—Include All Lines Including Drains and Sample Connections, and Specify

Size (Use Standard Sizes)

Schedule (Thickness)
Materials of Construction
Insulation (Thickness and Type)
For Instruments—Identify
Indicators Recorders Controllers Show Instrument Lines
For Utilities—Identify
Entrance Utilities Exit Utilities Exit to Waste Treatment Facilities

http://www.informit.com/articles/article.aspx?p=1915161&seqNum=3 43
Piping and Instrumentation Diagram

Piping and Instrumentation Diagram for Benzene Distillation (adapted from Kauffman,
D., Flow Sheets and Diagrams, AIChE Modular Instruction, Series G: Design of
Equipment, series editor J. Beckman, AIChE, New York, 1986, vol. 1, Chapter G.1.5,
AIChE copyright © 1986 AIChE, all rights reserved)
44
http://ptgmedia.pearsoncmg.com/images/chap1_9780132618120/elementLinks/01fig07_alt.jpg
Symbol of Unit Operations

45
From Coco software
Symbol of Unit Operations

Austin, D. G., Chemical Engineering Drawing

46
Symbols (London: George Godwin, 1979).
Standards
 ISO 10628: Flow Diagrams For Process
Plants - General Rules
 ANSI Y32.11: Graphical Symbols For
Process Flow Diagrams (withdrawn
2003)
 SAA AS 1109: Graphical Symbols For
Process Flow Diagrams For The Food
Industry
 American Society of Mechanical
Engineers (ASME)
 In-house symbols

47
Software for Process Design
• Aspen HYSYS
• This is a chemical process simulator used to
mathematically model chemical processes,
from unit operations to full chemical plants and
refineries. HYSYS is able to perform many of the
core calculations of chemical engineering,
including those concerned with mass balance,
energy balance, vapor-liquid equilibrium, heat
transfer, mass transfer, chemical kinetics,
fractionation, and pressure drop.
• Honeywell UNISIM
• This s an intuitive process modeling software
that helps engineers create steady-state and
dynamic models for plant design, performance
monitoring, troubleshooting, business planning,
and asset management.

48
Software for Process Design
• ChemCAD
• Chemstations’ intuitive suite of chemical process
simulation software that broadens an engineer’s
capabilities and increases productivity.
• SuperPro
• Facilitates modeling, evaluation and optimization
of integrated processes in a wide range of
industries (Pharmaceutical, Biotech, Specialty
Chemical, Food, Consumer Goods, Mineral
Processing, Microelectronics, Water Purification,
Wastewater Treatment, Air Pollution Control,
etc.).

49
Scale-Up of Process based on Process Matrix

𝑨𝒙 = 𝒚
Where:
𝑨 is the process matrix
𝒙 is the equipment size or process sizing
𝒚 is the output matrix

50
 Case Study: Polygeneration System

Austin, D. G., Chemical Engineering Drawing

51
Symbols (London: George Godwin, 1979).
Austin, D. G., Chemical Engineering Drawing
52
Symbols (London: George Godwin, 1979).
53
Reading Assignment (for 1/30/2018)

Lutze, P., Gani, R., Woodley, J. M. (2010) Process

intensification: A perspective on process synthesis.
Chemical Engineering and Processing: Process
Intensification 49: 547-558.