Introduction to

Chemical Batch Processing

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Outline
Characteristics of Chemical Batch Processes
Analysis and Optimization of Chemical Batch Processes
Examples and Software (Aspen Batch PlusTM)
Case Study (Anti-oxidant production)
Report and Presentation
Introduction to Chemical Batch Processing

ICB / ETH Zurich

Characteristics of Chemical Batch Processes

Chemical Batch Processes: Definition of Terms
Batch vs Continuous

Introduction to Chemical Batch Processing

ICB / ETH Zurich

What does Batch mean?

1. the quantity baked at one time
2. a: the quantity of material prepared or required for one operation
b: the quantity produced at one operation
c: a group of jobs (as programs) that are submitted for processing
(e.g. on a computer) and whose results are obtained at a later time
3. a quantity (as of persons or things) considered as a group
4.

Introduction to Chemical Batch Processing

ICB / ETH Zurich

What is chemical batch processing?

The discontinuous, charge wise production of chemicals
Several units are designed to be started and stopped frequently
(i.e. in a cycle-mode) for:

Charging (fill with material)

Task performing for a specified period of time

Shutting down and draining (discharging)

Cleaning
Combinations of batch and continuous mode (using holding
tanks as an interface) are possible.

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Connecting Continuous and Batch Processes: Holding Tanks

Feed holding tank
Continuous
stream for
batch charge
Batch
Charge
transferred
once each
cycle
Optional
stream for
continuous
feed

Reactor
Product holding tank
Reactor
product
transferred
once each
cycle

Introduction to Chemical Batch Processing

Continuous
stream for
reactor
product

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Semi-Batch
There are two classes of semi-batch processes:
Fed-batch processes with some or all chemicals being fed
continuously during the processing (or some time of the
processing). When the processing is finished the products are
removed batchwise.
In batch-product removal the chemicals are fed to the process
before processing begins, and then the product (or some of the
products) is removed continuously as the processing occurs.

Introduction to Chemical Batch Processing

ICB / ETH Zurich

(Some) History of Chemical Batch Processing

In the early days of chemical reaction engineering (1950s)

students might well have gained the impression that the ultimate
mission of the chemical engineer was to transform old-fashioned
batch processes into modern continuous ones

D.W.T. Rippin, 1983. Computers & Chemical Engineering 7: 137-156

Introduction to Chemical Batch Processing

ICB / ETH Zurich

(Some) History of Chemical Batch Processing

With such a perspective it would be surprising to find that,
today, thirty years later, a significant proportion of the worlds
chemical production by volume and a much larger proportion by
values is still made in batch plants and it does not seem likely
that this proportion will decline.
D.W.T. Rippin, 1983. Computers & Chemical Engineering 7: 137-156

With the recent trend of building small flexible plants that

are close to the markets of consumption, there has been
renewed interest in batch processes.
L.T. Biegler, I.E. Grossmann, A.W. Westerberg 1997. Systematic methods of
chemical process design. Prentice Hall, Upper Saddle River.
Introduction to Chemical Batch Processing

ICB / ETH Zurich

(Some) History of Chemical Batch Processing

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Hierarchy of Decisions in Chemical Process Design

1.
2.
3.
4.

Batch versus continuous

Input-output structure of the flowsheet
Recycle structure of the flowsheet
General structure of the separation system
a) Vapor recovery system
b) Liquid recovery system
5. Heat-exchanger network
J.M. Douglas, 1988. Conceptual Design of Chemical Processes. McGrawHill, New York.

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Batch vs Continuous (Capacity aspects)

1. Production rate
a. Sometimes batch if less than 10 * 106 lb/yr
b. Usually batch if less than 1 * 106 lb/yr
2. Market forces
a. Seasonal production or uncertain demand pattern
b. Short product lifetime
c. The process setup/design has to be fast (market
competition)

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Batch vs Continuous (Technical Aspects)

3. Scale-up problems
a. Very long reaction times
b. Handling slurries at low flow rates
c. Rapidly fouling materials
4. Flexibility
a. Operational problems
b. Feedstock variations
J.M. Douglas, 1988. Conceptual Design of Chemical Processes.
McGraw Hill, New York
Introduction to Chemical Batch Processing

ICB / ETH Zurich

Batch vs Continuous (Conclusively)

Because of their greater flexibility, batch plants are most

common, when a large number of products can/should be
produced in essentially the same processing equipment.

For seasonal products high storage cost arise when they are
produced over the complete year.

Batch production is typically used for high-value added

chemicals, e.g. pharmaceuticals, fine chemicals, pesticides,
bio-products, foods, polymers etc.
Introduction to Chemical Batch Processing

ICB / ETH Zurich

Batch vs Continuous (Conclusively)

There are indeed some products, for which it is not possible or
at least would be unreasonably demanding in time and
resources, to develop reliable continuous processes. However,
many more products which could be manufactured
continuously are in fact made in batch plants on economic
grounds.

D.W.T. Rippin, 1983. Computers & Chemical Engineering 7: 137-156

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Outline
Characteristics of Chemical Batch Processes
Analysis and Optimization of Chemical Batch Processes
Examples and Software (Aspen Batch PlusTM)
Case Study (Anti-oxidant production)
Report and Presentation
Introduction to Chemical Batch Processing

ICB / ETH Zurich

Analysis and Optimization of Chemical Batch

Processes
Design and Operation of Batch Process Units
Design of Reactor-Separator Processes
Dedicated, Multiproduct, Multipurpose Batch Plants

Introduction to Chemical Batch Processing

ICB / ETH Zurich

The batch reactor

exoth.

n2 B
Reaction: n1 A

0
A

0
B

r=

C , (C )
[mol / l ]
Batch
Charge
transferred
once each
cycle

V [l ]

= k1o e

dC A
= k1C An1 k2CBn2
dt

E1
RT

C An1 k2o e

E2
RT

CBn2

Reactor

(A formulation of) Optimal Control Problem:

Reactor
product
transferred
once each
cycle

Determine the profile of operating temperature T(t)

that reaches a certain conversion (or yield) in the
minimum batch time (min).
n0A nA (t ) C A0 C A (t )
XA =
=
n0A
C A0
(density = const.)

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Optimal Control Problem

(A general formulation of the) Optimal Control Problem:
Determine the profile of (all or some) operating parameters
(e.g. temperature, feed rate, removal rate, reflux ratio,) to
achieve a certain performance (e.g. minimum batch time for a
given conversion, minimum batch size etc.)

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Coding in Matlab

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Results for the Isothermal case

450 K

CA(t)

470 K

530 K
510 K
490 K

t
Introduction to Chemical Batch Processing

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Deriving the Optimum Profile

The minimum batch time is achieved by applying a
temperature profile that maximizes the reaction rate at each
point in time:
r = k1o e

E1
RT

C An1 k2o e

dr
= 0 Topt =
dT

E2
RT

CBn2

E2 E1
CBn2 k2o E2
R ln n1 o
C A k1 E1

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Deriving the Optimum Profile

900

850

0.9

800

0.8
750
Temperature [K]

solution Ca

0.7

0.6

700

650

0.5
600

0.4

550

0.3

0.2

500

450

500

1000

1500

2000

2500
time t

3000

3500

4000

4500

5000

Introduction to Chemical Batch Processing

500

1000

1500

2000

2500
time

3000

3500

4000

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4500

5000

Batch Distillation

A mixture of methanol, water and

propylene glycol has to be separated
using a batch distillation operation at
normal pressure.

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Batch Distillation
Operation:
Methanol Recovery:
1) Bring the column to total reflux operation, with the
distillate valve closed.
2) Using a constant reflux ratio distill with a constant
rate to the methanol receiver. Continue until the
mole fraction of water exceeds a specification.
3) Bring the column to total reflux.
4) Using a higher constant reflux ratio distill with a
lower rate to the methanol receiver. Continue until
the same water specification is reached.
Introduction to Chemical Batch Processing

ICB / ETH Zurich

Batch Distillation
Operation:
Propylene Glycol Recovery:
1) Bring the column to total reflux operation, with the
distillate valve closed.
2) Using a constant reflux ratio distill with a constant
rate to the water receiver. Continue until the mole
fraction of propylene glycol exceeds the given
specification.
3) Pump the contents of the still pot into the
propylene glycol receiver.

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Optimizing a Reactor-Separator Process1 in Batch Mode

The process consists of two units (with given capacities Vr, Vc)
with unlimited intermediate storage between them:

1Barrera

et al., 1989. Chem. Eng. Comm., 82, 45-66.

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Optimizing a Reactor-Separator Process in Batch Mode

Reactions are first order irreversible
reactions following the kinetics:

The molar density C (mol/L) in the

reactor is assumed to be constant.

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Optimizing a Reactor-Separator Process in Batch Mode

The column is assumed to
operate in a way that it produces
perfect splits (A, then B, then C).
The operation time to recover
product B is simply given by:

where Fd (mol/hr) is the constant

distillate rate.

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Optimizing a Reactor-Separator Process in Batch Mode

The objective is to minimize the total cost of the campaign to
produce a required amount of product Btot (mol) in a given
horizon time Thor (hr).
The following operational and cost factors are given:
tci: cleaning time between batches for i-equipment (i=r, c) (hr)
Pj: cost (or credit) of j-material (j=A, rA, C) ($/mol)
rk: equipment rental rates (k=r, s, c) ($/hr)
Ccli: equipment cleaning cost ($/batch)
Pu: distillation utility cost ($/mol)
Introduction to Chemical Batch Processing

ICB / ETH Zurich

Optimizing a Reactor-Separator Process in Batch Mode

Objective function

Introduction to Chemical Batch Processing

Equality and inequality constraints

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Optimizing a Reactor-Separator Process in Batch Mode

Feasible region

Introduction to Chemical Batch Processing

Unfeasible region

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Optimizing a Reactor-Separator Process in Batch Mode

Introduction to Chemical Batch Processing

ICB / ETH Zurich

What is needed to create a batch process ?

A market, a demand pattern, and product requirements

A recipe (or: process step procedure), i.e. a list of physicochemical operations (tasks) and their duration

Available equipment units

Introduction to Chemical Batch Processing

ICB / ETH Zurich

The Batch Process Recipe an Example

List of tasks to be completed:

Mix raw materials A and B. Heat to 80 oC and react during

2 hours to form product C
Add raw material D and react during 1 hour at 80 oC to
obtain product E
Mix with solvent F for 1.5 hours at ambient conditions; cool
and age for 3.5 hours; E will crystallize
Centrifuge for 2 hours to separate solid product E
Dry in a tray for 1 hour at 60 oC.

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Available Equipment Units an Example

3 reactors, 1 centrifuge, 1 dryer

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Challenges of Chemical Batch Processing

The general flexibility of batch processes offers a wide range of
possibilities. To take full advantage of this flexibility advanced
planning and modeling tools are required for:

Dynamic nature of operations/processes

Dynamic nature of plant operation (demand patterns, new
products, scheduling changes)
Good manufacturing practice (GMP rules)

Not taking full advantage might have severe economic

implications !
Introduction to Chemical Batch Processing

ICB / ETH Zurich

Design Tasks for Batch Processes

Which units in the flowsheet should be batch and which

continuous?

Which processing steps should be carried out in which

equipment with or without other steps?

When is it advantageous to use parallel batch units to speed

up production?

How much intermediate storage is required, and where

should it be located?
Introduction to Chemical Batch Processing

ICB / ETH Zurich

The Batch Process Layout one Example

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Types of Chemical Batch Plants

Single-product / dedicated plants: only one product

Multiproduct / flowshop plants: every product follows

(approximately) the same sequence through all the process
steps

Multipurpose / jobshop plants: each product follows its own

distinct processing sequence by using the available equipment
in a product specific layout; either only one production runs
in the plant at a given time or many run concurrently

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Single Product / Dedicated Batch Plant

Similarities with continuous processes:

Only one product is produced
Highly automated
Several continuous operations
Introduction to Chemical Batch Processing

ICB / ETH Zurich

Multiproduct / Flowshop Batch Plant

In this type of plant every product follows the same sequence of

operations and uses the same equipment units for (almost) all the
process steps.
Introduction to Chemical Batch Processing

ICB / ETH Zurich

Multipurpose / Jobshop Batch Plant

Here each product follows its own distinct processing sequence

by using the available equipment in a product-specific layout.
Introduction to Chemical Batch Processing

ICB / ETH Zurich

Design Levels for Multipurpose Batch Plant

Plant design

choice of equipment types, volumes and specifications

choice of transfer and intermediate storage policy

Process Design

selection of available equipment units

allocation of operations to equipment units

Plant Operation

campaign type and duration

sequencing of products and scheduling
Introduction to Chemical Batch Processing

ICB / ETH Zurich

Modes of Processing Subsequent Batches

Non-overlapping mode
A subsequent batch is only started when the previous one is
completed.

Overlapping mode
Several batches are processed simultaneously; this reduces
the idle (or dead) time of an equipment significantly.

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Modes of Processing Subsequent Batches

Gantt chart representation of example process layout

Introduction to Chemical Batch Processing

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Definition of Times
Occupancy time (OTj) of an equipment is the time that a stage taking
place in this equipment needs to be completed (ti). If more than one
stages take place in an equipment then OTj= ti.
Cycle time, CT= tf - ts

final time initial time of a cycle

Batch time, BT

the time required to produce 1 batch

Makespan, MT
(or Campaign time)

the time required to produce N batches

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Modes of Processing Subsequent Batches

Gannt chart representation of example process layout
CT=11 h
BT=11 h

CT=5 h
BT=11 h

Introduction to Chemical Batch Processing

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Occupancy times one Example

OT1=2 h

OT2=1 h

OT3=5 h

Introduction to Chemical Batch Processing

OT4=2 h

OT5=1 h

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Campaign Types in Flowshop / Jobshop batch plants

Single Product Campaign (SPC)

All batches of one product are manufactured before switching
to another product (A......AABB.........B).

Mixed Product Campaign (MPC)

The various batches are produced according to some selected
sequence (......AABAABAAB.........).

Introduction to Chemical Batch Processing

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Campaign Types in Flowshop / Jobshop Batch Plants

CT=? h
BT=? h
MT=? h
CT=? h
BT=? h
MT=? h

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Transfer and Storage Policies for Batch Plants

Zero-wait (ZW)
At any stage the material is transferred immediately to the
next stage.
No Intermediate Storage (NIS)
It is possible to hold the material inside the production vessel.
Unlimited Intermediate Storage (UIS)
The batch can be stored without any capacity limit in vessels.

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Transfer and Storage Policies for Batch Plants

Introduction to Chemical Batch Processing

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Bottlenecks in Batch Processes

Introduction to Chemical Batch Processing

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Special Characteristics of Batch Processes

Introduction to Chemical Batch Processing

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Special Characteristics of Batch Processes

Introduction to Chemical Batch Processing

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Storage / Inventory

Storage capacities have to be planned and managed well.

Cost factor.

Planning required, i.e. matching raw material availability and

customer requests.

Supply chain management is important.

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Structure of a Multipurpose Batch Plant

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Structure of a Multipurpose Batch Plant

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Typical Equipment Units in Batch Plants

Introduction to Chemical Batch Processing

ICB / ETH Zurich

Literature

Introduction to Chemical Batch Processing

ICB / ETH Zurich