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ProcessCalculations
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Lecture-01 Content Page
01 2-4
02 5-7
03 8 -15
04 16 – 24
05 25 – 33
06 34 - 42
07 43 - 50
08 51 – 56
09 57 – 64
10 65 – 76
11 77 – 83
12 84 – 89
13 90 – 94
14 95 - 100
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Lecture-01
Introduction of Chemical Engineering or Process engineering
Chemical Engineering is all about converting raw material to finished product at very
large scale or industrial scale. Chemical engineer is one who applies and uses principles of
chemical engineering in any of its various practical applications
Design, manufacture, and operation of plants and machinery in industrial chemical and
related processes
Development of new or adapted substances for products ranging from foods and
beverages to cosmetics to cleaners to pharmaceutical ingredients, petrochemical ,oil
refining are among many other products
Development of new technologies to make plants cost effective and eco friendly.
Chemical engineering- plants ccale or industrial scale with focus on large scale production.
Chemistry- Lab scale for small scale with focus on research and development.
Let's take some examples of some typical chemical plants to understand overview of
chemical engg.
1) Sugar industry
In sugar industries solid sugar in granular form is produced from sugarcane. Schematic line
diagram is given in figure [Link] will be first crushed and compressed into the
Crusher to extract sugarcane juice. This juice is sent to the evaporator for concentrating it by
[Link] liquor is sent to the crystallizer where sugar crystals will be formed. The
liquid and sugar crystal will be separated by using a centrifuge, remaining liquid is known as
molasses and it can be used as raw material for production of ethyl alcohol. For this
purpose molasses will be send to a fermentor in which biochemical reaction will happen and
ethyl alcohol will be form and finally ethyl alcohol is separated in a distillation column so we
are getting ethyl alcohol and solid sugar crystals as finished products from sugarcane.
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All the units of sugar industry can be divided into divided into two parts
1. Unit operation- Only Physical changes. No chemical Reaction
2. Unit processes- Chemical changes or Chemical reaction
Unit operation
Crusher
Evaporator
Crystalizer
Distillation
Unit Process
Fermenter
2) Crude Oil Refinery
In oil refineries numeros product's like LPG, gasoline, Petrol, diesel and aviation fuel are
produced by the processing of crude oil. Firstly crude-oil will be treated into a distillation
column where different components of crude oil will be separated on the basis of their boiling
points. further these products will be treated as in various units for converting it into a
finished product..
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Chemical Plant
1. raw material first will be treated through various unit operations so that it can be
conditioned or can be made ready for chemical conversion (Chemical Reaction).
2. Next step is the unit process, in this step a chemical reaction will happen in to a reactor.
Output of unit process will contain reactants, desired products and byproducts also.
3. finally unreacted and by products will be separated from desired products using various
unit operations.
Process calculation
process calculation uses the principle of material and energy balance to find raw material
requirement and energy requirement for given plant production capacity.
GATE syllabus process calculation
mass and energy balance
Tie Component
Recycle
bypass
Purge
Syllabus will be covered in following parts
Basic concept
mass and energy balance for unit operation
mass and energy balance for unit process
Combustion
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Lecture-02
Ideal gas
The molecules in a gas can be considered small hard spares.
all collisions between gas molecules are elastic and all motions is frictionless.
distance between molecules on an average is much larger than the size of
the molecules.
the gas molecules are constantly moving in random direction with a distribution of
speed.
there is no attraction or repulsive forces between molecules as well as the
surrounding
Boyle's law
P ∝ (1/V) : T is constant ⇒ V ∝ (1/P) :T is constant
Charles law
V ∝T : P is constant
Avogadro's law
the number of molecules per unit volume is same for all gases to a fixed temperature and
pressure
The number of molecules in 22.4 litres of any gas is 6.022 x 1023 . This number is
called Avogadro number
22.4 litre is volume of one mole gas at STP (273 K and 1 atm pressure)
V ∝ n ( number of moles of gases) at constant T & P.
Ideal gas law
V ∝ (1/P) Boyle's law
V ∝T Charles law
V∝n Avogadro's law
Hence,
V∝ ⇒ PV ∝ nT
⇒ PV= nRT
R= universal gas constant
Dalton's law
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Total pressure of a mixture of ideal gases is the sum of the partial pressures of individual
gases.
suppose a mixture of gases contains n n ,n ,........ moles of different gases 1 2 3
using ideal gas law
PV= ( n +n +n +.......) RT
1 2 3
PV= n RT+n RT+n RT+.......
1 2 3
P= (n RT/V)+(n RT/V)+(n RT/V)+..........
1 2 3
P=P +P +P +........
1 2 3
STP :(standard temperature and pressure)= 0 ℃and 1 atm
NTP:(Normal temperature and pressure)= 20 ℃ and 1 atm
R= 8.314 if all units are in IS units
Density of Ideal Gas
PV= nRT
PV= wRT/M (w= weight in grams, M= molecular weight)
ρ=w/V=PM/RT
Units of pressure
One atmospheric pressure or 1 atm
= 101.32x10 N/m or Pascal 5 2
=10.33 meter of water column
=76 cm of Hg column
=1.013 bar
=760 torr
Example-01
An O cylinder volume 30 litre has initial pressure 15 ATM and at 27 degree centigrade. after
2
some O is withdrawn from the cylinder the gauge Pressure drops to 11 atm temperature 17
2
degree centigrade. Estimate the oxygen taken out of the cylinder ?
Solution
Using ideal gas law
PV= nRT
for initial condition P V = P V 1 1 2 2
(15 x1.013x 10 ) x (30 x 10 )= n x 8.314 x 300
5 -3
1
initial number of moles of oxygen n =18.28 1
After removing some oxygen from cylinder n moles of oxygen remains 2
Applying ideal gas law PV= nRT
(11 x1.013x 10 ) x (30 x 10 )= n x 8.314 x 290
5 -3
2
Final number of moles of oxygen n = 13.867 2
Number of moles of oxygen removed = n -n = 4.41 1 2
Weight of oxygen removed= 32 x 4.41 = 141.19 gm
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Example-02
an air bubble of volume 1 cm cube risen from bottom of a lake 40 metre deep at temperature
of 12 degree centigrade to what volume does it grow when it reaches the surface which is at
temperature of 35 degree centigrade
Solution
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Lecture-11/Unit Process/ Purge
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