Lecture Slides by Prof. Imitaz Ali at Ghulam Ishaq Khan Institute for Engineering Sciences and Technology (GIKI).

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Chemical Engineering
Raw Materials Processes Products

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• More typically, chemical engineers concern
themselves with the chemical processes that turn
raw materials into valuable products.
• The necessary skills encompass all aspects of design,
testing, scale-up, operation, control, and
optimization, and require a detailed understanding
of the various "unit operations", such as
distillation, mixing, and biological processes, which
make these conversions possible.
• Chemical engineering science utilizes mass,
momentum, and energy transfer along
with thermodynamics and chemical
kinetics to analyze and improve on these
"unit operations."

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Job opportunities
huge variety of sector :
• Chemical and allied products
• Plastics and polymers
• Fertilizers
• Cement
• Pulp and paper
• Paints
• Energy
• Water
• Food & drink
• Petrochemicals, petroleum and natural gas processing
• Biotechnology
• Pharmaceuticals
• Environmental control
• Business and management
• Consultancy
Job opportunities and Industries
• Chemical engineers are, on
average, the highest
paid among the "Big
Four".
• Electrical, Mechanical ,
Chemical and Civil
Engineers.

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Future of Chemical Engineering
• Biotechnology emerging into a “real”
commercial activity
• Nano technology……looking for
applications
• Advanced materials including: bi
functional materials, conducting polymers,
bio materials (e.g., tissue engineering)
continue development for specialized
applications
Biotechnology
• Research at the interface between
health, biotechnology and
engineering
• Constructing a pilot-scale facility
for the production of biomolecules
• Molecular design of bio-products,
tissue engineering etc

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Nanotechnology
Creating products “bottom-up” using
nano-assembly methods.
Synthesis of novel nanoporous carbon
materials for membranes and catalysts.
 Synthesis of nanostructured carbons for
hydrogen storage.
Fluidisation and reaction kinetics in beds
of nanoparticles.
Environment
• Increasing environmental awareness is
creating new opportunities in the
energy and sustainability industries.

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CH 211 ( Industrial Processes ): Fall 2013
Syllabus:
1. History and development of various chemical and process industries in Pakistan.
2. Gases: Production of hydrogen, oxygen, nitrogen and carbon dioxide.
3. Nitrogen industries: Production process of ammonia, urea and nitric acid.
4. Sulfur industries: Production process of sulfur dioxide, sulfur trioxide and sulfuric acid.
5. Phosphorous industries: Production process of phosphoric acid.
6. Chlor-alkali industries: Production process of chlorine, caustic soda and soda ash.
7. Glass industry: Production process of glass and special glasses.
8. Sodium compounds: Production process of sodium chloride and sodium sulfate.
9. Paper industry: Pulp production through soda, sulfite and kraft process, production of paper from pulp.
10. Production of hydrochloric acid, soap making, process description of sugar industry, cement industry
and paint industry.
Text & Reference Books:
1. George Austin, R. Shreve, Joseph Brink. Shreve’s Chemical Process Industries. 5th ed. McGraw-Hill.
2. Elvers, Barbara, and Giuseppe Bellussi. Ullmann’s Encyclopedia of Industrial Chemistry. 5th
ed. Weinheim: Wiley-VCH.
3. Kirk, Raymond E, and Donald F Othmer. Kirk-Othmer Encyclopedia of Chemical Technology. 5th ed. New
York; Chichester: Wiley.
Topic wise course contents Lectures
1. General Information, Grading policy, Syllabus, Learning outcomes 1,2
2. Gases: Production of hydrogen, oxygen, nitrogen, carbon dioxide 3,4,5,6
3. Nitrogen industries: Production process of ammonia, urea and nitric acid. 7,8,9
4. Sulfur industries: Production process of sulfur dioxide, sulfur trioxide and
sulfuric acid.
10,11,12
5. Phosphorous industries: Production process of phosphoric acid. 13
6. Chlor-alkali industries: Production process of chlorine, caustic soda and
soda ash.
14,15,16
7. Glass industry: Production process of glass and special glasses. 17
8. Sodium compounds: Production process of sodium chloride and sodium
sulfate.
18,19,20
9. Paper industry: Pulp production through soda, sulfite and kraft process,
production of paper from pulp.
21,22,23
10. Production of hydrochloric acid, soap making, process description of
sugar industry, cement industry and paint industry.
24, 25, 26,27,28,29,30
Lectures on each Topic

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Dr. Imtiaz Ali / Office: FMSE-G06, Off.Ext: 2216,
E-mail: imtiazali@giki.edu.pk
Teaching Assistant: Mr. Jehanzaib Ahmad Ansari
Office: Chemical Lab I
Office Hours: Anytime on working days from 8 am to 5 pm
Assignments (one) = 4% Quizzes ( four) = 24%
Midterm Exam = 30% Final Exam = 42%
What about Attendance in the Class?

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Learning Outcomes of CH 211 course
• Explain the basic history, current issues, and trends in chemical process industries.
• Understand basic roles, responsibilities and expectations for a career in chemical
process industry.
• List some of the leading chemical process industry companies in Pakistan.
• (range: manufacturers of inorganic- and organic-industrial chemicals,
petrochemicals, polymers and rubber, cement, water treatment and purification,
detergents and surfactants, agrochemicals, glass, pulp and paper, gases, paints and
coatings, explosives, food processing).
• Classify the chemical process industry into industrial categories of base
(commodity products), intermediate (secondary products), end-products
(consumer products) and specialty chemicals (fine chemicals) manufacturers.
• List the raw materials used in the manufacturing of chemicals and processed
materials (range: coal, crude oil, natural gas, metal and mineral deposits, organic
materials, air and water).
• Describe the sources and methods of recovering raw materials used in the
production of chemicals and processed materials.
• Describe the manufacturing processes of different chemicals and processed
materials.
Why – an expertise in Process?
– functional role and importance of various
processes and operations in the process plan
– the selection of important parameters such as T,
P and underlying physical principles of a process
– distinguish various process streams and their
conditions of operation (T, P and phases)
– process troubleshooting and necessary safety
precautions

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How - master fundamentals of
process?
• Raw-Materials and reactions
• Conceptual process flow-sheet
• Process intensification
• Additional critical issues
• Alternate technologies
To what extent - memorize a process?
• Atleast remember process flow-sheets with
logical sequence of unit
processes/operations.
– A conceptual process flow diagram; an abstract
representation of the actual process flow-sheet
will enable quicker learning

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Advantages of learning approach
a) more analytical/concept-oriented with logical
reasoning
b) Systematic approach enables the growth of
students’ interest in the subject.
c) Additional concepts further reveal to the
student how to gradually complicate process
technologies for maximum efficiency.
d) Inculcate strong interest in the student towards
technology research and innovation by enabling
a learning environment that fundamentally
targets the technological know-how.
Unit-operations /processes in
chemical industry
Category Unit operations/processes Functional role
Fluid
operations
a) Centrifugal, Reciprocating pumps,
Compressor
d) Expander
a) To pressurize liquids and gases.
b) To depressurize gases
Solid
operations
Crusher and Grinder To reduce the size of solids
Solid-fluid
separators
Cyclone separator, Centrifuge,
Electrostatic precipitator, Classifier &
Thickener, Liquid-liquid separator
To separate solid particles from solid-liquid/gas mixtures
Heat
exchangers
Shell & Tube heat exchangers, Fired
heaters and furnaces, Coolers
a) To either remove or add heat to process streams so as
to meet desired conditions in other units.
b) Either utilities or other process streams are used to carry
out heating/cooling requirements.
Mass transfer
units
Phase separation, Distillation,
Absorption, Stripping, Adsorption,
Extraction, Leaching, Crystallization,
Membrane
a) To separate a feed into products with different
compositions.
b) A third agent (heat or compound) is usually used to
carry out separation.
Reactor units Completely stirred tank reactor
(CSTR), Plug flow reactor (PFR),
Packed bed reactors (PBR), Slurry &
Trickle bed reactors
a) To carry out reactions in homogenous fluids
(gases/liquids).
b) To carry out catalytic and multi-phase reactions.

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Classification of industries
• Heavy chemical industries
• Fine chemical industries
Classifications
1. Based on quantities of produced and consumed
• Heavy chemicals
– large quantity normally crude or less purified
chemicals
e.g. mineral acid, NaOH, Na2CO3 etc
• Fine chemicals
– purified substances and produced in limited quantity.
e.g. speciality solvent, perfumes, medicines etc

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Classifications
2. Based on chemical composition
• Organic compound
e.g. hydrocarbons, phenols, carboxylic acid etc.
• Inorganic compound
e.g. Na2CO3, K2Cr2O7, MgCl2
• Polymers
– macromolecular mass compounds; covalent bonding of repeating
structured units which may be natural, synthetic or semi synthetic.
e.g. polystyrene, polyvinylchloride etc.
Classification
3. Based on availability
• Natural compounds
– Available in nature or produced or extracted from
plant and animals. Due to large utilization & limited
production the natural source is depleting.
e.g. coal, petroleum etc.
• Synthetic products
– Man made compounds. They may be synthesized
using natural product or synthetic materials.

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Description of Process
• Flow Diagrams / Flow Sheets
(3 Levels of Diagram)
– Block Flow Diagrams (BFD) or Block flow sheet
– Process Flow Diagrams (PFD) or Process flow sheet
– Process (Piping) and Instrument Diagrams (P&ID)
As chemical engineers, we are most familiar with BFD
and PFD
The Block Flow Diagram
• BFD shows overall processing picture of a
chemical complex
– Flow of raw materials and products may be
included on a BFD
– BFD is a superficial view of facility –information is
missing

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The Block Flow Diagram

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Comparison of PFD and P&ID
Process Flow Diagrams
Process (Piping) and
Instrumentation Diagram
General process flows between major
equipment clearly presented in a
simplified manner
General process flows present but
convoluted due to many sheets and
abundance of information
Omits valves, controls and minor
pipelines
Includes all valves, controls and minor
pipelines
Provides baseline for operating
conditions for flows, compositions, etc.
(min, nonnal, max)
Information on piping (material of
construction and schedule) and safety
features (i.e. pressure relief valves,
interlocks)
Stream labeled with infonnation
presented at the bottom of each sheet
Safe operating ranges of equipment
presented at bottom of each sheet

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