Process Synthesis and

Modeling
By:
Ahmed BHRAN, Ph.D. Chemical Engineering
Chapter 3 –
Batch
Processing
 Contents
• Design Calculations
• Gantt Charts and Scheduling
• NonOverlapping and Overlapping Operations
• Cycle Times
• Flowshop Plants
• Jobshop Plants
• Product and Intermediate Storage
• Parallel Process Units
• Equipment Design for Multiproduct Batch Processes
 Design Calculations
• Description of production steps (Recipe)
• Operations/processes are unsteady state
• Often existing equipment is used – not designed
specifically for recipe
• Transfer from equipment and cleaning are important
• Recycling and energy integration issues

4
Recipe (Production of Active Pharmaceutical Ingredient)

Step 1: 500 kg of reactant A (MW = 100 kg/kmol) is added to 5000 kg

of a mixture of organic solvent (MW = 200 kg/kmol) containing 60%
excess of a second reactant B (MW = 125 kg/kmol) in a jacketed
reaction vessel (R-301), the reactor is sealed, and the mixture is stirred
and heated (using steam in the jacket) until the temperature has risen to
95C. The density of the reacting mixture is 875 kg/m3 (time taken = 1.5
h).
Step 2: Once the reaction mixture has reached 95C, a solid catalyst is
added, and reaction takes place while the batch of reactants is stirred.
The required conversion is 94% (time taken = 2.0 h).
Step 3: Reaction mixture is drained (time taken =0.5 h)
Step 4 : Reaction mixture is distilled for separation (time taken =3.5 h)
Step 5 : Products is crystallized (time taken =2.0 h)
Step 6 : Products is filtered (time taken =4.0 h)
Step 7 : Products is packaged (time taken =1.0 h)
 Design Calculations
5500[kg]
V  6.286 m3
875[kg/m3 ]

5500[kg] 1 3
Vrequired  3
 10.48 m  2768 gal
875[kg/m ] 0.6
60% fill

 Because reactors of this sort come in standard sizes, a

3000-gallon (Vtank) reactor is selected.

6
 Design Calculations
Find the time to heat vessel contents from ambient to 95C

dT Ts  T final  UAt

VC p  UA Ts  T  ln 
dt Ts  To  VC p
where
 ρ is the liquid density,
 CP is the liquid heat capacity,
 Tfinal is the desired temperature (95 C),
 U is the overall heat transfer coefficient,
 A is the heat transfer area of the jacket
(cylinder surface),
 Ts is the temperature of the condensing
steam.
 To is the initial temperature.
7
 Design Calculations

• Transfer from equipment and cleaning important

Gravity drain or pump
Cleaning – GMP (general management program)/
documentation
• Recycling and energy integration issues
Recycling – often use dump tank and accumulate material
from several runs

8
Gantt Charts and Scheduling

9
NonOverlapping and Overlapping Operations
m
TNO  n  ti
i 1

10
NonOverlapping and Overlapping
Operations

11
NonOverlapping and Overlapping
Operations
m
TO  T  ( n  1) max (t i )   t i
i 1,..., m
i 1

12
 Cycle Times

tcycle = total time/number of batches

m

T
n  ti m
tcycle, NO  NO 
n
i 1
n
  ti
i 1
m
(n  1) max (t i )   t i
T i 1,..., m
i 1
t cycle,O  t cycle  
n n

13
 Cycle Times

From the overlapping scheme – when the number of batches (n)

to be produced is large,

tcycle  max {ti }

i 1,..,m

14
 Cycle Times
Example
A batch process involves 4 pieces of equipment with the following
process times
Heating and Mixing 2.5 h
Reaction 3.5 h
Filtration and Drying 1.5 h
Crystallization and packaging 2.0 h
Determine the cycle times for non-overlapping and overlapping
operation.

15
 Cycle Times
Example

TNO = 2.5+3.5+1.5+2.0 = 9.5 h

TO,5 = [(5-1)×3.5+9.5]/5 = (14+9.5)/5 = 4.7 h

TO,10 = [(10-1)×3.5+9.5]/5 = (31.5+9.5)/10 = 4.1 h

TO,∞ = 3.5 h

16
 Multiple Products

When we have multiple products that can be produced in the

same equipment, the scheduling of multiple batches requires
careful planning

The different products may require the same processing steps, or

more often will require only a subset of all possible steps.
Moreover, the order in which a batch process uses different
equipment might also differ from product to product

17
 Flowshop Plants

If all the products use the same equipment in the

same order or sequence, but not necessarily for the
same lengths of time then the plant is referred to as a
flowshop plant

18
 Flowshop Plants
Consider 3 products A, B, C each requiring to be run nA, nB, and
nC times in a given period.

When we want to produce multiple products using the same

equipment then we can either:

• run campaigns of the same product followed by campaigns of

the next product followed by……
i.e., run A - nA times followed by B - nB times followed by C -nC
times - AAAAAAAABBBBBBBBCCCCCCC

• Intermingle the products so that we run ABCABCABC… or

ACBACBACB…, or AABCAABCAABC
19
 Flowshop Plants

For multiple- (single) product campaigns the total

processing time, or production cycle time, is found by
adding the operation times for each product.

If the number of batches per campaign is large (for

example, >10), then the production cycle time can be
approximated by
C C
 
T   j 
n j tcycle  n j  max {ti }
i 1,..,m  j
j A j A

20
 Flowshop Plants
Example – production of three products A, B, and C

Use Single Product Campaigns

21
 Flowshop Plants

What if we want to run as ABCABCABC. What is the

cycle time and how many batches can we produce of
each product in 500h?

22
Flowshop Plants

23
 Flowshop Plants
3.5h not 2.5 h

Cycle times > 10.5h

24
 Jobshop Plants

When not all products use the same equipment or

the sequence of using the equipment is different
for different products, then the plant is referred to
as a jobshop plant.

25
 Jobshop Plants

26
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu
Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved.
 Jobshop Plants

For running sequential (multiple) single-product

campaigns, the cycle time and number of batches can
be determined by the same method used for the
flowshop plant.
For sequential operation of batches ABCABC.. or
ACBACB… we need to draw the Gantt chart.

27
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved.
 Jobshop Plants

For equal batches of A, B, and C how many batches can

be produced in 500 h?
28
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu
Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved.
 Jobshop Plants

29
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu
Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved.
 Jobshop Plants

30
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu
Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved.
 Jobshop Plants

31
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu
Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved.
 Jobshop Plants

32
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu
Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved.
 Outline

• Product and Intermediate Storage

• Parallel Process Units
• Equipment Design for Multiproduct Batch Processes

33
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu
Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved.
 Product Storage

Product Storage for Single-Product Campaigns

When using combinations of single-product campaigns in a multi-
product plant, it is necessary to store product during the
campaign.

The amount of storage is dependent on the rate of production and

rate of demand for each product and the cycle time.

34
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved.
 Product Storage

35
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu
Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved.
 Product Storage

Campaign time

Vs   rp  rd  tramp

Rate of production Rate of demand

36
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved.
 Product Storage

For products A, B, and C, determine the minimum storage capacities

for a single-product campaign strategy.

Assume that 1 month = 500 hours. Note that 43 batches of each

unit are required for each product per month.
37
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved.
 Product Storage

Product Vs   rp  rd  tramp
A (0.093 – 0.020)(43×2.5) = 7.85 m3
B (0.07752 – 0.06202)(43×4.5) = 9.20 m3
C (0.06202 – 0.024)(43×4.5) = 7.36 m3
38
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved.
 Intermediate Storage

For Multi-product Campaigns

So far, assumed no intermediate product storage
available. This type of process is a zero wait, or a
zw-process.
Flow to equipment directly from previous equipment in
recipe.
Delay in one step propagates through batch to all
steps.

39
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu
Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved.
 Intermediate Storage
It may be possible to store product in the equipment
that has just been used.
e.g. if two feed streams are mixed in a vessel, the
mixture could be stored until the next process unit in
the production sequence becomes available. This
holding-in-place method may not work for some unit
operations, e.g. in a reactor.

The upper limit of the intermediate storage concept

occurs when there is unlimited intermediate
storage (uis) available, and this is referred to as a
uis-process.
40
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu
Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved.
 Intermediate Storage

Limiting Case

41
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved.
 Intermediate Storage
A B C

42
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu
Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved.
 Outline

• Product and Intermediate Storage

• Parallel Process Units
• Equipment Design for Multiproduct Batch Processes

43
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved.
 Parallel Process Units

Reduce bottlenecks caused by a single piece of equipment

by duplicating the equipment.
Trade-off between added equipment (and maintenance)
cost vs. higher throughput.
Makes sense when one equipment dominates cycle time.

44
Parallel Process Units
A B C

45
 Outline

• Product and Intermediate Storage

• Parallel Process Units
• Equipment Design for Multiproduct Batch Processes

46
 Equipment Design for Multi-product
Batch Processes

The design of equipment sizes for multiproduct

batch processes depends on the
• Production cycle time
• Whether single- or multi-product campaigns are
used
• The sequence of products for multi-product
campaigns,
• Use of parallel equipment. 47
 Equipment Design for Multi-product
Batch Processes

Example

Clearly the reactor is the limiting piece of equipment

– determine the size of the reactor required.
48
 Equipment Design for Multi-product
Batch Processes
From the recipe for each batch, calculations for the specific
volume of each reactor can be made – see Chapter 3.

Equations required total time taken to produce A

Total time for batches tA + tB + tC = 500

Reactor volumes VA = VB = VC

49