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Lecture Wise Topics1 11

This document contains summaries of lectures on chemical process industries from a course at IIT Kanpur. The lectures cover the history of the chemical industry, process development, types of reactors and unit operations, raw materials and fuels, petroleum refining processes like desalting, atmospheric distillation, and thermodynamics of distillation. The lectures also discuss process drawings, economics feasibility, utilities like power generation, and structure of the chemical industry.

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32 views

Lecture Wise Topics1 11

This document contains summaries of lectures on chemical process industries from a course at IIT Kanpur. The lectures cover the history of the chemical industry, process development, types of reactors and unit operations, raw materials and fuels, petroleum refining processes like desalting, atmospheric distillation, and thermodynamics of distillation. The lectures also discuss process drawings, economics feasibility, utilities like power generation, and structure of the chemical industry.

Uploaded by

pm020202pm
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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CHE261: Chemical Process Industries

Raghavendra Ragipani

Dept. of Chemical Engineering


Indian Institute of Technology Kanpur

January 31, 2024


Lecture-1: Chemical industry - past, present, and future

Chemical Industry
Process and Process development
Early chemical industry (sulfuric acid and sodium carbonate)
Thermodynamics, systematic development of catalysts -
sulfuric acid, ammonia production
Coal and Petroleum - How distillation led to clean burning
fuels?
Environmental pollution & shift towards cleaner processes -
sodium carbonate, HFCs etc.

Raghavendra Ragipani Dept. of Chemical EngineeringIndian Institute of Technology Kanpur


CHE261: Chemical Process Industries
Lecture-1: Chemical industry - past, present, and future

Chemical Industry
Strategic interests - ammonia for explosives during WWI,
catalytic cracking of petroleum for high-test aviation fuel
during WWII, Coal to liquid fuels via gasification and
Fischer-Tropsch process.
Polymers - natural, semi-synthetic, and synthetic
New opportunities for chemical engineers - climate change,
sustainability, AI/ML etc.

Raghavendra Ragipani Dept. of Chemical EngineeringIndian Institute of Technology Kanpur


CHE261: Chemical Process Industries
Lecture-2: Process development

Knowledge gap between laboratory studies and commercial


production
Scale up ratio, production capacity
Chemical reactor
Scale up problems - why scale up by geometric similarity may
fail for an exothermic batch reactor?
Block diagram, process flow diagram, material and energy
balance
Process development - example of domestic water purification

Raghavendra Ragipani Dept. of Chemical EngineeringIndian Institute of Technology Kanpur


CHE261: Chemical Process Industries
Lecture 3: Reactors

Reactors and its selection


What is a chemical reactor? Recap of H2SO4 production
Conversion, selectivity (multiple definitions) and yield
Product quality - purity, physical properties, particle size
distribution etc.
waste quality - environmental concerns, zero-discharge
Mode of operation - batch, semi-batch, and continuous
Ideal reactors - plug flow reactor (PFR) and continuously
stirred tank reactor (CSTR)

Raghavendra Ragipani Dept. of Chemical EngineeringIndian Institute of Technology Kanpur


CHE261: Chemical Process Industries
Lecture 4: Reactors

Reactors as a multi-functional devices


Reactors as a contacting apparatus
Homogeneous reactors - reaction and mixing timescales
Heterogeneous reactors - packed bed, fluidised bed, slurry
reactors, bubble column reactor etc.
Reactors as a heat exchanges - example of exothermic,
reversible reactions
Reactors as a separators - example of membrane reactors,
reactions with phase change etc.

Raghavendra Ragipani Dept. of Chemical EngineeringIndian Institute of Technology Kanpur


CHE261: Chemical Process Industries
Lecture 4 & 5: Unit operations

Unit operations as a toolbox


Reactors
heat exchangers, furnaces
Absorber, stripper, adsorber, ion-exchange, leaching,
extraction
Distillation, crystallizes, evaporators
Flow manipulators - pumps, compressors, valves
phase separators and mechanical equipment

Raghavendra Ragipani Dept. of Chemical EngineeringIndian Institute of Technology Kanpur


CHE261: Chemical Process Industries
Lecture 5 & 6: Structure of a chemical industry

Chemical tree
Raw materials, fuels, base chemicals, intermediates, final
products
Commodities and specialty chemicals - Volume vs Value
Survey of petrochemical industry

Raw materials and fuels


Natural gas, Crude oil, Coal, and biomass
C/H ratio, Oxygen content
NG - sour vs sweet, and dry vs wet

Raghavendra Ragipani Dept. of Chemical EngineeringIndian Institute of Technology Kanpur


CHE261: Chemical Process Industries
Lecture 6 & 7: Electricity generation and utilities,
drawings, economic feasibility
Utilities
Power generation through steam turbine and gas turbine -
Rankine and Brayton thermodynamic cycles
Co-generation - power and steam (HP, MP and LP steam)
Combined cycle - example of Gas turbine + Heat recovery
steam generator - higher efficiency

Engineering Drawings & process economics


Process flow diagram, Piping & Instrumentation diagram,
Isometrics, and Equipment drawings. ISBL vs OSBL.
CAPEX, OPEX, and economic feasibility of a process
Raghavendra Ragipani Dept. of Chemical EngineeringIndian Institute of Technology Kanpur
CHE261: Chemical Process Industries
Lecture 8: Petroleum Refining

Overview
Crude and refinery products (commodities and specialties)
Refining capacity and margin - an optimisation problem
(procurement, blending)
Bottom of the barrel & refinery complexity

Crude Assay
Sour vs Sweet
Lighter crude vs Heavier crude - API gravity

Raghavendra Ragipani Dept. of Chemical EngineeringIndian Institute of Technology Kanpur


CHE261: Chemical Process Industries
Lecture 9: Petroleum Refining
Crude Assay
Distillates from crude oil
Carbon number, boiling points
True boiling point curve (TBP) - dependence on API gravity
TBP for Heavier distillates & atmospheric equivalent
temperature

Fuel properties
Autoignition temperature, Flammability limits, Flash point
Octane number, Cetane number
Petrol vs Diesel engine - thermodynamic cycles, knocking
Reid Vapor pressure
Raghavendra Ragipani Dept. of Chemical EngineeringIndian Institute of Technology Kanpur
CHE261: Chemical Process Industries
Lecture 10: Petroleum Refining

Desalting of crude
Fouling and corrosion
oil-water separation by gravity and electric field
terminal velocity - role of crude density, and viscosity
Why perform desalting at high temperature and pressure?
Why addition of fresh water? Use of a static mixer.
Emulsifying naphthenic crude - de-emulsification

Raghavendra Ragipani Dept. of Chemical EngineeringIndian Institute of Technology Kanpur


CHE261: Chemical Process Industries
Lecture 11:Petroleum Refining

Crude (atm) furnace

Radiation and convection zone


Why we discharge combustion exhaust at about 130 C? -
condensation of acid gases (dew point) and corrosion of
convection heat exchanger tubes.
Start-of-run and end-of-run
Coking inside tubes, tube metal temperature and failure
Vaporisation of crude - over-flash

Raghavendra Ragipani Dept. of Chemical EngineeringIndian Institute of Technology Kanpur


CHE261: Chemical Process Industries
Lecture 11:Petroleum Refining

Crude Distillation Unit - atmospheric column


Binary distillation vs crude distillation (fractionation)
No reboiler. Use of crude furnace.
Overhead condenser, side-draw liquid flows, use of
pump-around for heat removal
Steam injection at the bottom to lower partial pressure
Imperfect cut points, steam stripping of side-draws - control
of fuel properties
Straight-run vs blended streams

Raghavendra Ragipani Dept. of Chemical EngineeringIndian Institute of Technology Kanpur


CHE261: Chemical Process Industries

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