kmu 392-2017-week 1 - yunus.hacettepe.edu.tryunus.hacettepe.edu.tr/~gdilli/kmu392/kmu 392-2018-week...

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COURSEOUTLINE•  INSTRUCTOR:Asst.Prof.Dr.IşılGERÇEKBEŞKARDEŞ(KMÜ392-21/22)[email protected]•  TEACHINGASSISTANT:Res.Asst.GökçeALP(KMÜ392-21/22)[email protected]

COURSETEXTBOOK

Austin, G. T., Shreve's Chemical Process Industries, 5th Edition, McGraw-Hill, Singapore, 1984.

OBJECTIVES

•  To familiarize students with selected inorganic and organic chemical technologies in chemical engineering.

•  To train students to search on the Internet and in the library.

•  To train students to prepare written reports and give oral presentations.

•  To help students to develop conscience on engineering ethics.

LEARNINGOUTCOMES

•  To be able to understand the causes of the main problems such as air and water pollution that interests Turkey and the whole world and to discuss the necessary precautions.

•  To be able to understand how some industrial processes are employed in Turkey and in the world.

•  To be able to explain the changes from the raw materials to products in some chemical processes applied in the industry by basic flowcharts.

•  To be able to describe the physical and chemical changes in the flowcharts.

LEARNINGOUTCOMES(cont)

•  To be able to discuss the methods of utilizing the side products formed in the production processes and determine their possible effects on the human health as well as their disposal methods.

•  To be able to describe the quality of water along with the species leading to hardness of water and to be able to explain the methods applied to make the water appropriate for its usage.

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GRADING

2016-2017 SPRING SEMESTER 7. To be able to classify the wastewaters and explain the methods used for their

treatment. 8. To learn the classical and alternative energy sources and to understand the

importance of the energy saving. COURSE REQUIREMENTS: None DATE OF MIDTERM: March 30, 2017 GRADING: Activities Number Contribution (%)

Homeworks 1 5

Presentation 1 10

Projects (Report) 1 10+5

Midterms 1 25

Final Exam 1 45 TOPICS COVERED: Three 50-minute lectures are presented each week.

Week Date Topic

Week 1 February 16th, 2017 Introduction

Week 2 February 23th, 2017 Water conditioning

Week 3 March 2nd, 2017 Wastewater

Week 4 March 9th, 2017 Energy

Week 5 March 16th, 2017 Energy

Week 6 March 23rd, 2017 Energy

Week 7 March 30th, 2017 Midterm

Week 8 April 6th, 2017 Presentations


Week 10 April 20st, 2017 Presentations


Week 12 May 4th, 2017 Presentations



BONUS POINTS: •  Attendance to Thursday Seminars (5 points) •  Technical field trip (5 points)

TOPICS

Attendance is required at all Thursday seminars!! Full attendance to seminars will give you a bonus of 5 points. In the case of only one absence, students will gain only 4 points. Students with excessive absences will not gain any bonus points.

PRESENTATION/PROJECTGROUPS

•  Theremustbe6studentsinallgroups.

•  Allgroupsmuste-mailthenamesandstudentIDsofallgroupmemberstokmu3922016@gmail.combyFebruary22nd,2018.

CHEMICAL PROCESSING

•  Thechemicalindustryexiststoincreasewealth,ortoaddvaluebytakingrawmaterialssuchassalt,limestoneandoil,andturningthemintoawholerangeofchemicalswhicharetheneitherdirectly,orindirectly,convertedintoconsumerproducts.

•  Theseproductsimproveourlivesandlifestyles,andwecouldnotlivethewaywedowithoutthem.

RAWMATERIALSChemical

ProcessingPRODUCT

•  Usable•  Profitable

ChemicalProcesses:TheyareindustrialprocessestoconvertthechemicalRAWMATERIALStotheINDUSTRIALVALUABLEPRODUCTS.

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1)  EndProducts(ConsumerItems)Paints;soapanddetergents;oils;fats

2) Intermediates

H2SO4;sodaash;NaOH(sudkosic)

•  1/4thofthechemicaloutputisusedforthemanufactureofotherchemicals

•  Chemicalindustryèthebestconsumerforitsownproducts

ANTIBIOTICSETHANOLCITRICACID

MOLASSES Wasteproductofthesugarindustries

•  Chemicalmanufacture–  Chemicalengineers–  Chemists–  Entrepreneurs– Managers–  Businesspeople

•  ChemicalengineeringinindustrialchemistryisalwaysconcernedwithPROFIT!Becausewithoutprofitabusinesscannotoperate!

•  Upill1910,thechemicalindustryhadtorelymainlyonmechanicalengineersandchemists.

•  Chemical engineering emerged as a separatediscipl ine in 1910 when professors fromMassachuseOsInsituteofTechnology(MIT)realizedthat neither mechanical engineering nor chemistryoffered sound approaches to a chemical plant’sdesign.

•  So a new branch of engineering was started toprepare engineers specializing in the design,operaion, and construcion of chemical processingplants.

Processing and manufacturing of chemicals inindustriesisbasedonmanyoperaionssuchas

•  drying•  leaching•  mixing•  crystallizaion•  adsorpion•  humidificaion

•  heattransfer•  masstransfer•  fluidflow•  disillaion•  evaporaion•  absorpion

•  TheideaoftreaingtheseprocessesofthechemicalindustryasunitoperaionswasalsoputforwardbytheprofessorsoftheMIT.

•  Theycharacterizedthephysicaloperaionsnecessaryformanufacturingchemicalsasunitoperaions.

•  Bysystemaicallystudyingtheoperaionsinvolvedinthechemicalindustry,thetreatmentofallprocessesisunifiedandsimplified.

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BasicPhysicalChanges UNITOPERATIONS

Thephysicaloperaionsnecessaryformanufacturingchemicalsare

calledunitoperaJons

Theunitoperaionsarelargelyusedto•  conducttheprimaryphysicalstepsofpreparingthereactants,•  separaingandpurifyingtheproducts,•  recyclingunconvertedreactants,and•  controllingtheenergytransferintooroutofthechemicalreactors.

UnitOPERATIONS•  FluidMechanics•  HeatTransfer•  MassTransfer

– Disillaion– Absorpion– Adsorpion– Extracion– Someotherseparaionmethods– Transportandstorageoffluids– Handlingofbulkandpackagedsolids

xyx

dvdy

τ µ= −

xq dTkA dx= −

Ax AB

dCJ Ddx

= −

Newton’s Law

Fourier’s Law

Fick’s Law

These unit operations have been the object of vigorous study and now can be used with sound mathematical procedures for plant design predictions.

BasicChemicalChanges UNITPROCESSES

During1930,P.H.Grogginsproposedasimilarapproachtoclassifyingchemicaloperaionsasunitprocesses.SuchprocessesincludenitraJon,oxidaJon,hydrogenaJon,sulphonaJon,chlorinaJon,andesterificaJon.

UnitPROCESSES

•  Fermentaion•  Combusion•  Neutralizaion•  Polymerizaion•  Pyrolysis•  Oxidaion•  Electrolysis•  Esterificaion,etc.

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Electrolysis

CHEMICALPROCESSINGANDTHEWORKOFTHECHEMICALENGINEER

Ø Chemical engineers are employed in industryunderdifferentemployementareas:

• Process• Research&Development• Administraion• Design• Projectmanagement• Educaion

• Producion• Consuling• Markeingandbusiness• Maintenance• Purchasing• Qualitycontrol• Other

Chemicalengineer–scope&responsibiliJes•  “BIG FOUR” Engineering Fields

– Electrical engineering – Mechanical engineering – Civil engineering – Chemical engineering

Ofthese,chemicalengineersarenumericallythesmallestgroup.However,thisrelaivelysmallgroupholdsaveryprominentposiioninmanyindustries,andchemicalengineersare,onaverage,thehighestpaidofthe"BigFour".

•  Allengineersemploymathemaics,physics,andtheengineeringarttoovercometechnicalproblemsinasafeandeconomicalfashion.

•  Yet,itisthechemicalengineeralonethatdrawsuponthevastandpowerfulscienceofchemistrytosolveawiderangeofproblems.

•  “chemicalengineer”è"universalengineer”

•  Thechemicalengineers– develop,design,andengineerbothcompleteprocessesandtheequipmentused

– choosetheproperrawmaterials

– operatetheplantsefficiently,safely,andeconomically

tomakeproductsthatmeettherequirementssetbythecustomers.

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•  Chemistryisthebasicscienceuponwhichthechemicalprocessindustriesrest.

Researchlaboratoryresultsofthechemists

EconomicalchemicalprocessesThe Engineer

•  Chemicalengineeringisthatbranchofengineeringconcernedwiththedevelopmentandapplicaionofmanufacturingprocessesinwhichchemicalorcertainphysicalchangesofmaterialsareinvolved.

CommercialChemicalProcessingChemicalconversions+Physicaloperaions

Otherneeds:•  Factoryscaleequipment•  Chemicalengineeringexperience•  Corrosionresistantconstrucionmaterials•  Instrumentforrecording/controllingprocessvariables

•  Controlof–  (i)harmfulimpuriiesfromrawmaterialsand–  (ii)productimpuriies

•  Itisprimarilyconcernedwith–  theapplicaionofchemicalreacionsonacommercialscale

–  thestudyofreacionspeeds•  Itsgoalisthesuccessfuldesignandoperaionofchemicalreactors.

•  Thechemicaltreatmentstagesaretheheartofaprocessandthecorefactorthatmakesorbreakstheprocesseconomically.

Chemical Kinetics

•  Thermodynamics:– Thetransformaionofheatenergyintosomeotherformofenergyor

–  thetransformaionofsomeotherformofenergyintoheatenergy

•  Thermodynamicsenablesachemicalengineerto– determinetheheatandworkrequirementsformanyphysicalandchemicalprocesses,and

–  thedeterminaionofequilibriumcondiionsforchemicalreacionsandforthetransferofchemicalspeciesbetweenphases.

Thermodynamics Flowcharts

•  They show the coordinated sequenceofunit chemical conversions and unitoperaionsinproducion.

•  Iniially, they are very simple BLOCKDIAGRAMS. Then, gradually expanding,theybecomedetailedform.

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CRUDEOIL

ASimpleFlowchart

Water Salt

UpstreamProcesses

GAS,LPGLiquifiedPetroleumGases(metane,etane,propane,butane)

NAPHTHA ReformingGASOLINE

KEROSINE Jetfuel

MOTORGASOLINE Dieselfuel

HEAVYDISTILLATES(ASPHALT)

DownstreamProcesses

DISTILLA

TIONCOLU

MN

ADetailedFlowchart

•  Theselecionofaprocessisoneofthemostimportantandime-consumingaciviiesundertakenbyachemicalengineer.

•  Oneprocessmaybeenergyefficientthantheotherbuttheothermaybelesspolluingormayhaveitsrawmaterialsreadilyavailable.

Process selection

•  Selecingaprocesstobeinbatchesortobeconinuousisanothercriicaltask.

•  Batchprocesses:– Earlychemicalprocessing– Correctmeasurements– Suitableforsmall-scaleproducion– Temperatureandpressurecontrolcanbetroublesome.

Process selection: batch or continuous?

Process selection: batch or continuous?

•  Coninuousprocesses– Smallerandlessexpensiveequipment–  Lessmaterialinprocess(lesschancetoruinlargequaniies)

– Uniformoperaingcondiionsandmoreuniformproducts

– Suitableforlarge-scaleproducions– Concisecontrolofflow-ratesandcondiions(needforhighqualityinstrumentaion)

Objecive:H2producion

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Zn+2HClZnCl2+H2


Zn+2HClZnCl2+H2

Znpowder+H2O

slurry

HCl H2

BatchProcess:

ConinuousProcess:

Znpowder water

HClH2

Coldwater Coldwater

Coolingjacket

Processesconsistoftwosteps

1)  REACTION2)  SEPARATION

v  UpstreamProcesses(fortheseparaionofRAWMaterials)

v  DownstreamProcesses (fortheseparaionofPRODUCTS)

Process selection: separation

SeparaJonProcess•  Basedonphysicaland/orchemicalproperies

– Melingpoint– Boilingpoint– Density– Solubility– Moleculesize– Magneicproperies,etc.

•  Operaionofaprocessplantisanotherimportantacivitycarriedoutbyachemicalengineer.

•  Thequalityandquanityoftheproductisdirectlydependentontheefficientoperaionofaplant.

•  Manyproblemsliketemperatureandpressurecontrol,maintenance,andsafetyconinuetoariseduringtheplantoperaion.

Operation

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•  Troubleshooingisthecoreofplantoperaion.•  Almosteveryindustrywantsitsengineerstobeinimatelyfamiliarwitheverypipe&gaugeofthatindustry.

•  Wheneverthereisanyfaultinanyseciontheengineershouldbeabletoidenifythelocaionandproposeasoluionimmediately.

•  Constantcheck-upsandinspecionmustbemaintainedtoavoidcorrosion.

•  Successfuloperaion:– Originalstrengthofthematerials– Corrosionresistance

•  Mechanicalfailures:– Corrosion– WeakeningbychemicalaOacks

•  Corrosioncannotbepreventedbutminimized!

•  Corrosionresistantmaterials– Rubbercoveredsteel– Resinbondedcarbon– Tantalum– Stainlesssteel– Nickel/nickel-cladsteel– Polymericmaterials

•  Corrosiontesingmustbedonewithcommercialchemicalsratherthanpurelaboratorychemicals

(asmallamountofcontaminantsaffectcorrosion)

•  Economicsisavitalpartofanengineerswork.•  Engineersaredisinguishedfromscienistsbytheirconsciousnessofcostsandprofits.

•  Everyengineeringdecisioninvolvescostconsideraions.

•  Theprimaryobjeciveofanengineer'seffortsmustbeto– deliversafelythebestproductor–  themostefficientservicesATTHELOWESTCOSTtotheemployerandtheconsumer.

Chemical Process Economics

•  Themostimportantsinglefactorincostisusuallythe“YIELD”

Yield≠Conversion

•  Yield:thefracionofrawmaterialrecoveredasthemainproduct(muliplepasses)

•  Conversion:thefracionofrawmaterialconvertedtoproductsandbyproducts(singlepass)

CHEMICALPLANT

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CHEMICALPLANT

RAWMaterial

CAPITAL

ENERGY

TECHNOLOGY

LABOR

CHEMICALPLANT

RAWMaterial

CAPITAL

ENERGY

TECHNOLOGY

LABOR

PRODUCT

BY-PRODUCTS

EnvironmentalProblems• Health• Social

Researchanddevelopment

• WhyisRESEARCHdone?

– Newandimprovedprocesses– Lowercostsandlowerpricesofproducts– Productsofgreaterpurity– Productsofsuperiorservice

• Withoutforward-lookinginvesigaionorresearchacompanywouldlagbehindinthecompeiiveprogressofitsindustry.

•  Rapidlychangingprocedures,newprocesses,newrawmaterialsandnewmarketsè patentprotecionisrequiredforfutureprofits!

•  INVENTIONistheactoffindingsomethingthatisnew.

•  APATENT is aGRANTof exclusive right to theinventortohisinvenionforalimitedperiodofime.

INVENTIONMARKETABLEPRODUCT

PATENT

ü Heavychemicals

ü Finechemicals

MajorSectorsofChemicalIndustry

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MajorSectorsofChemicalIndustry

§  Petrochemicals§  Polymers§  Dyestuffs§  Pharmaceuicals§  Chlor-alkaliproducts§  Sulphuricacid§  Ammoniaandferilizers§  Soapanddetergents§  Phosphoricacidandphosphates§  Pulpandpaper

InTurkey;

6000companies

95large-scale

208medium-scale

Restaresmallscales

160companies-foreigninvestment

Chemicalengineersscaleup/downprocesses

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EnvironmentalIssuesandSafety

•  Theroleofachemicalengineerincontrollingpolluionandwastegeneraionisveryimportant.

•  Chemicalengineersdevelopnewmethodsandtechniquesto–  treatwastesgeneratedbytheprocessindustries,– minimizewastegeneraionand– developrenewablesourcesofmaterialandenergy.

•  Chemicalengineersdevelopeconomicalsoluionstocleanupyesterday'swasteandpreventtomorrow'spolluion.

•  Catalyicconverters,reformulatedgasolineandsmokestackscrubbersallhelpkeeptheworldclean.

•  Chemicalengineeralsohasroletoperforminplantsafety.

•  Nothingismoredangeroustoaplantthanfire.•  Employeesmustbeprotectedagainsttoxicchemicals.

•  Safetymeasuresnotonlykeeptheemployeesoutofdangerbutalsosavemoneyandimebyreducingaccidents

MajorEnvironmentalProblems/DisastersWhichAreAssociated

WithTheChemicalIndustry

Bhopal(India):AtoxicreleaseinthenightofDecember3,1984ataUnionCarbidepesicidefactoryinBhopal,Indiasentacloudofmethylisocyanateintotheairoverthecity.Anesimated6,000peoplediedintheimmediatea~ermath,mostsuffocaingfromthecloud’stoxicchemicals.Since1984,over20000peoplehavediedasaresultofthedisaster,accordingtosurvivorgroupsinBhopal.

Flixborough(UnitedKingdom):Thismajordisasteroccuredin1974attheFlixboroughworksofNypro(U.K.)Ltd.TheplantinvolvedwaspartoftheprocessforproducingNylon6,andwasusedforthestageinwhichcyclohexanewasoxidizedtocyclohexanolpluscyclohexanone.

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Oneofthereactorshadbeenremovedforrepairandtemporarilyreplacedbyalargediameterpipewhichwasinadequatelysupported.Cyclohexanebegantoleakandaverylargecloudofiteventuallyignited,causingamassiveexplosion.Thisresultedin28dead,almost100injuredanddamagetonearly2000factories,housesandshopsintheneighbourhood.

MinamataBay(Japan):Thisincident,in1965,ledtoalmost50deathsandto100seriouslyillpeople.Theydisplayedsymptomstomercurypoisoningandtheproblemwastracedtomercurywhichhadbeendischargedintothebaybyachemicalcompany.Thereitwasconvertedintoaverytoxicsubstance;dimethylmercurybymicroorganismsattheboOomofthesea.Thissubstanceconcentratedinfishwhichweresubsequentlyeatenbythevicims.

Thalidomideanddrugs:ThethalidomideTragedyin1961,inwhichsomepregnantwomenwhowereprescribedthedruggavebirthtogrosslymalformedbabies,isoneinwhichthecompaniesinvolvedwerecriicizedfornotdetecingthisproblemduringtesingofthedrugbeforeitwasmarketed.

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