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Unit Operation and Unit Process

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Unit Operation and Unit Process

Uploaded by

Muhammad Ramzan
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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1 NUCLEAR CHEMISTRY

Sadia Bashir Industrial Chemistry


Basic principles and parameters for industrial plant unit
Assistant Professor
operations and unit process
Department of Chemistry
Industrial Chemistry
Industrial chemistry is the manufacturing art concerned with the
transformation of matter into useful materials in useful amounts.

This process uses chemical and physical processes to transform raw


materials into products that are beneficial to mankind
Industrial Chemistry
Usually this transformation of available materials into more desirable ones
involves some kind of process following a recipe.

In turn the process may involve


 grinding, mixing together various ingredients
 dissolving, heating, allowing ingredients to interact (chemically or
biochemically react forming new compositions of matter)
 cooling, evaporating or distilling, growing crystals, filtering
 and other physical-chemical-biological operations.
Chemical Processes
Chemical processes usually have three interrelated elementary processes

i. Transfer of reactants to the reaction zone


ii. Chemical reactions involving various unit processes
iii. Separation of the products from the reaction zone using various unit
operations
Chemical Processes

 Processes may involve homogeneous system or heterogeneous systems.


 Various type reactions involve maybe reversible or irreversible, endothermic
or exothermic, catalytic or non-catalytic.
 Various variables affecting chemical reactions are temperature pressure,
composition, catalyst activity, catalyst selectivity, catalyst stability, catalyst
life, the rate of heat and mass transfer.
 The reaction may be carried out in batch, semi batch or continuous.
 Reactors may be batch, plug flow, CSTR. It may be isothermal or adiabatic.
Catalytic reactors may be packed bed, moving bed or fluidised bed
Chemical Processes
Along with knowledge of various unit processes and unit operation following information
are very important for the development of a process and its commercialization.
Basic Chemical data:
 Yield conversion, kinetics
 Material and energy balance, raw material and energy consumption per tone of
product,
 Batch vs Continuous, process flow diagram
 Chemical process selection: design and operation, pilot plant data, Equipment
required, material of construction
 Chemical Process Control and Instrumentation
 Chemical Process Economics: Competing processes, Material and, Energy cost,
Labour,
Overall Cost of production
 Market evaluation: Purity of product and uniformity of product for further processing
 Plant Location
 Environment, Health, Safety and Hazard
 Management for Productivity and creativity: Training of plant personals and
motivation at all levels
Basic Steps in an Industrial Process
 All industrial processes are based on two steps which leads to produce a
desired product from raw materials

 Unit Operation:
The process that involves physical changes
 Unit Process:
The process that involves Chemical changes

Together with unit operations (physical conversions), unit processes (chemical


conversions) form the basic building blocks of a chemical manufacturing
process.

The raw materials undergo the unit operations to make it suitable for the
unit process
Unit Operation
The process which involves physical
conversions/changes or chemical
transformations in a chemical
process is known as Unit Operation.
Unit operation are physical treatments steps in a process which are required to
put raw materials in a form in which they can be reacted chemically and to put
the product in a form which is suitable for market.
Unit Operation
 The unit operations are primarily used to conduct the physical steps of
preparing the reactants, separating and purifying the products, recycling the
unconverted reactants and controlling the energy transfer into or out of
system.

 Unit operation is just primary activity in a chemical process

 Unit operations are reversible

 Unit operation does not involve any chemical reaction

 Unit operations also involve the physical separation of the products


obtained during various unit processes
Unit Operation
 Generally unit operations steps are carried out before subjecting the materials
to chemical reactions so that chemical reactions happen smoothly.

 There are equipment's which cause the materials to undergo physical


changes.

 The physical changes are carried out for variety of purposes. The physical
changes can imply phase changes such as; evaporation, condensation,
crystallization etc.

 Thus Distillation is a unit operation step because condensation and


evaporation happens inside the column. Evaporators, and crystallizers are
also unit operations equipment.

 Unit operation equipment's are also responsible for mechanical operations


which involves size reduction, physical separations, mixing, and grinding. The
mass transfer, heat transfer process all may happen together. Chemical
reaction doesn’t happen.
Classification of Unit Operations
 Material handling, transportation / Fluid flow process
Pumping
Compression
fluidization
 Mechanical unit operations
Size reduction
Size enlargement
Mixing, agitation, blending, etc
 Mass transfer operations
Evaporation
Distillation
Absorption
Extraction
leaching.
 Heat transfer operations
conduction
convection
radiation
Unit Operations in industry
 Screening
 Distillation
 Evaporation
 Decantation
 Centrifuging
 Mixing
 Pumping
 Grinding
 Separation
 Crystallization
 Polymerization
 Isomerization
 Desulfurization
 Distillation
Equipments in Unit Operation

Size reduction:
 Jaw crusher, ball mill,

Size enlargement:
 Pellet mills, agglomerators

 Evaporators

 Crystallizers
Unit Process
A ''unit process'' is one or more
grouped operations in a
manufacturing system that can be
defined and separated from others.
Unit process involves principle chemical conversions leading to synthesis of
various useful product
Unit Process provides basic information regarding the reaction temperature
and pressure, extent of chemical conversions and yield of product of reaction
nature of reaction whether endothermic or exothermic, type of catalyst used.
Unit Process
 Unit processes involve chemical changes/ conversions/ reactions.

 Unit processes are irreversible.

 Unit process is a secondary activity in a process

Unit process is based on the knowledge of following


 parameters for the chemical conversions:
 Stoichiometry
 Reaction kinetics
 Thermodynamics
 Chemical equilibrium
 Energy balance
 Mass balance
Unit Processes in Chemical Industry
 Combustion  Hydrolysis and Hydration
 Oxidation  Hydrogenation
 Neutralization  Hydrogenolysis
 Silicate Formation  Alkylation
 Electrodialysis  Condensation
 Double Decomposition  Causticization
 Calcination and Dehydration  Polymerization
 Nitration  Diazotization and Coupling
 Esterification  Fermentation
 Ammonolysis  Pyrolysis and Cracking
 Reduction  Aromatization
 Halogenation  Isomerization
 Sulfonation  Hydroformylation
 Ion Exchange
Equipment in unit process
There are two classes of equipment in unit process industries as follows:
Proprietary equipment:
 Pumps, compressors, filters, centrifuges, dryers
Non-proprietary equipment:
 Include special items as reactors, distillation columns & heat exchangers
Unit Operation vs Unit Process

Unit Operation Unit Process

Unit operations are reversible Unit process are irreversible

Unit operation involves physical Unit process involves chemical


changes changes

Unit operation is just a primary Unit process is just secondary


activity activity

Unit operation involves physical


Unit process involves chemicals
changes or chemical
reactions such as hydrogenation,
transformation such as
oxidation, nitration etc.
separation, crystallization etc.

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