PROCESS DESIGN

1. Basic chemical and physical operations

of a process
2. Choice of Process
a.The choice o f process can be made
at the library an or laboratory research
level.
b.Consultation among the designers,
the research an development staff and
the legal department
Continuous vs. Batch Processing
Selection based purely on economic reasons. By
operation on a continuous 24-hr/day basis,
smaller-size, less expensive processing
equipment is used. Process operation is steady
state and easier to control by automatic
instrumentation than is batch operation. Thus,
capital investment, fixed charges, and labor
requirements are minimized.
Batch operation is feasible in such cases as :
1. Small-volume output of relatively expensive
products when sales demand is not steady, or
when the same equipment can be used for
several processes of this mixture.


2. When batch equipment from an abandoned
process is available at a low transfer cost to the
current project.
3. When continuous process equipment has not
been satisfactorily developed and batch-process
equipment has been satisfactorily demonstrated.
4. When yields and quality of products cannot be
achieved bay continuous processing because of
such things as very low reaction rates and
correspondingly long residence times in the
processing equipment.

Continuous vs. Batch Processing
a. Around the clock operation : three shifts of
operation per day, seven days a week, using
four shifts of labor, with or without scheduled
maintenance shutdown.
b. Five-day operation : one, two, or three shifts of
operation and labor; stand-by conditions on
weekends and holidays; overtime if production
demands must the temporarily increased;
maintenance done during periods of non
operation.
c. Scheduled shutdown : periods up to 2 years or
annually for 2 weeks (inspection, repair and
replacement work on the plant).
Shifts and Operating Time Schedules.
Shifts and Operating Time Schedules.
d. Unscheduled shutdowns : lack of raw
materials, labor strikes, failure of utilities such,
as power and water, fire and explosions, and
extreme weather conditions, or most probably
equipment failure.
e.The names of shifts encountered in the
chemical industry are :
a. First or day shift (e.g. 7 A.M. to 3 P.M.)
b. Second, evening or swing shift (e.g. 3 P.M.
to 11 P.M.)
c. Third, midnight or graveyard (e.g. 11 P.M. to
7 A.M.)
a. Raw material specifications
b. Reaction conditions
c. Characteristics of product layer in reactor
d. Characteristics of aqueous or gas from
reactor
e. Treatment conditions after reactor
f. Solubility data
g. Distribution coefficient
h. Volatile relative or vapour pressure.

Process Design Project Required :
Process Design Project Required :
i. Specifications of product and by-product
j. Heat of reaction (heat of formation, heat of
combustion, heat of solubility, etc)
k. Average specific heat data
l. Vapor-pressure data
m.Temperature at critical points
n. Available stream-line temperature and
pressure