1
Q
the basic science for chemical industries
A
Chemistry
2
Q
Chemical Engineer’s function:
A
- To apply the chemistry of a particular process through the use of coordinated scientific and engineering principles
- Develop the research laboratory results of the chemist into an
economical chemical process
3
Q
Chemical Engineer’s goal:
A
To have the conversion equal the yield
4
Q
– fraction of raw material recovered as the main (desired) product
– the most important single factor in cost
A
Yield
5
Q
– fraction changed to something else, whether products or by-products
– indicates the amount changed by a single pass through an apparatus when multiple passes are used
A
Conversion
6
Q
Lower conversions =
A
larger plant size
7
Q
Higher operating pressure =
A
greater yields but higher equipment costs
8
Q
Faster reaction time =
A
closer approach to equilibrium, but requires larger, more expensive equipment
9
Q
Improved catalysts =
A
shorter reaction time, but equilibrium remains unaffected
10
Q
- is the study of reaction speeds
- It is essential in plant design, since reaction speed determines equipment size
A
Kinetics
11
Q
are materials that increase reaction speed
A
Catalysts
12
Q
- Invented by German chemists Fritz Haber & Carl Bosch in 1909-1910 & won the Nobel prize
- converts atmospheric nitrogen (N2) to ammonia (NH3) by combining it with hydrogen (H2)
A
The Haber-Bosch Process
13
Q
provide a perfectly porous and high surface area material for the reaction
A
Iron (Fe) catalyst
14
Q
Costs are most strongly affected by
A
material use and distribution
15
Q
- is an essential first step in any processing study
– shows the original and ultimate disposition of all materials used in a process
A
Material Balance
16
Q
is an energy-intensive industry
A
Chemical processing
17
Q
Goal of chemical processing
A
towards reducing energy use
18
Q
provide data on all phases of technical reactions
A
Thermodynamics
19
Q
performing of an industrial process on material in batches of a limited quantity or number
A
Batch process
20
Q
process where product comes out without interruption and not in groups
A
Continuous process
21
Q
is a graphical representation of a process, coordinating the sequence of unit operations and unit processes
A
Flowchart
22
Q
show material and energy flows and operating conditions
A
Simple blocks
23
Q
show everything in a process and become extremely complicated
A
More elaborate blocks
24
Q
show details, ex. fire lines, instruments & control systems, air lines, drains, etc.
A
Special blocks
25
Some factors that must be considered in planning a plant:
Pilot plants
Equipment
Corrosion, Materials of Construction
26
a specialist in current aspects of chemical process design
Process engineer
27
foresee and solve even the “less obvious” plant problems (maintenance, safety, conformation to standards)
Senior design engineer
28
advise, design, and/or erect chemical processing plants
Experienced consultants
29
small-scale units
Pilot plants
30
Pilot plants are designed to:
- allow experiments that obtain design data for larger plants
- (sometimes) produce significant quantities of a new product to permit user evaluation
31
Design engineers use ______ of procedures to determine data required for the design of a pilot plant
statistical analysis
32
“items necessary for a purpose”
Equipment
33
Chemical engineers must be familiar with industrial equipment
Pump
Filter press
Distillation tower
etc
34
the gradual destruction of materials (usually metals) by chemical and/or electrochemical reaction with their environment
Corrosion
35
Corrosion-resistant materials:
Rubber-covered steel
Resin-bonded carbon
Tantalum to resist HCl
Polymeric organic materials
36
Construction materials used by Chemical Engineers:
Brick
Cast iron
Steel
Wood
Cement
Platinum
Tantalum
Silver
37
Function of Instruments:
Not only to record process variables
To assure consistent quality, i.e. sensing, controlling, recording, maintaining desired operating conditions
38
Function of workers and supervisory chemical engineer:
To maintain the plant in proper running order
39
Reasons for instrumentation
Increase in continuous procedures
Increased cost of labor and supervision
Unreliability of human actions
Availability of instruments
40
Present current data, value or deviation from a norm
Indicating instruments
41
Permit study and analysis
Recording instruments
42
Permit study and analysis and present current data, value or deviation from a norm and control the operation
Indicating/Recording and Controlling instruments
43
Show results by mechanical movement of some type of device, which is proportional to the quantity being measured
Analog instruments
44
Utilize a transducer and electronic circuitry to convert signals to readable numerical figures (digits), which are displayed and/or recorded
Digital instruments
45
a device to convert the quantity being measured into some type of signal (electrical or pneumatic)
Transducer
46
conventional procedure used in factories for analysis of incoming raw material and outgoing product
Chemical analytical control
47
fast, reliable, sensitive, has become economically feasible
Automated control
48
Examples of systems that have been automated and used industrially
1. Chromatography
2. pH sensors and conductivity analysis
3. Mass spectroscopy
49
Engineers are distinguished from scientists by
their consciousness of costs and profits
50
Engineers’ primary objective:
To safely deliver the best product or most efficient services at the lowest cost to employer and consumers
51
is an outstanding characteristics of chemical procedures
Change
52
Functions of the Research and Development (R&D) Division
To be updated of progress
To make knowledge of improvements or fundamental changes, which leads to the creation of any of the products of interest of the organization
To know about the developments in other companies, and be able to advise the management of the relative competitive position of (actual or anticipated) processes or products
53
must be exerted in most of the important discussions of the chemical engineer
Judgment based on comparative facts
54
Yields and conversions of the chemical process form the basis for ____ which in turn are the foundation for cost determination.
material balances
55
Engineers are concerned with the direction and control of
Energy
56
Energy may be employed in the form of _______, or may be ________
heat of steam or electricity, given out in exothermic or absorbed in endothermic reactions.
57
contribute as much to a plant’s success as excellence in design.
Skilled operators
58
CPIs have moved rapidly into labor-saving techniques:
Rapid extension of continuous processing
Use of process controllers
Optimizing procedures
59
The single largest cost is
raw material
60
Most errors in cost estimation are due to
underestimation of overhead, sales, customer service, and capital required to finance daily operations of the business.
61
- is the eye, ears, and nose of a company
- brings information to aid in economic forecasting
Salesperson
62
Prudent and proper location of a chemical plant is determined
largely by the availability of
raw materials, energy, transportation, and markets.
63
Many other factors tor plant locations:
environmental constraints, water supply, availability of efficient labor, cost of land, waste disposal facilities
64
Three Types of OSHA Standards:
Initial standards
Emergency temporary standards
Permanent standards
65
a natural process that converts a refined metal into a more chemically-stable form such as oxide, hydroxide, or sulfide
Corrosion
66
are the real key to quality production.
Good operators and careful plant supervisors
67
has a great influence on marketability.
The physical condition of the products
68
substances that cause cancer
Carcinogens
69
Substances that cause malformation of fetus
Teratogens
70
The plant manager’s first responsibility is
to run a plant (trained personnel and efficient machines) so that they will safely turn out market-acceptable goods at a profit.
71
Results and Benefits of Research
1. New and improved processes
2. Lower costs and lower prices of products
3. Services and products never before known
4. Change of rarities to common commercial supplies of practical
usefulness
5. Adequate supply of materials previously obtained only as byproducts
6. Freedom from domination from foreign control
7. Stabilization of business and industrial employment
8. Products of improved quality
72
are limited monopolies extending over 17 years and are given in exchange for the detailed public disclosure of new products and methods.
Patents
73
are necessary in our competitive system of free enterprise so that research funds can be generously spent for improvements on old processes and for new and useful discoveries with a reasonable hope of at least return of the investment.
Patents
74
the act of finding something that is new.
Invention
75
– a grant of exclusive right to the inventor to his invention for a limited period of time.
Patent
76
serves to protect the inventor and those who develop, manufacture, and sell the product from uncontrolled competition of parties who have not shared the burden of invention and commercialization.
Patent
77
To produce a marketable product
- a new idea in the form of an invention must be developed and embodied in a form suitable for manufacture, and
- appropriate tools must be available so that the product can be manufactured at a cost acceptable to the public
78
Commercial chemical processing involves
chemical conversions and physical operations and presupposes factory scale equipment and Chemical Engineering experience.
CPI
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