SCI 202: Introduction to Unit Operations

Dr. Marina Leonidovna Mukabi

Department of Chemistry
Room B-2
mmukabi@uonbi.ac.ke
https://profiles.uonbi.ac.ke/mmukabi/

Course outline
Industrial chemistry and the chemical industry
The difference between Classical and Industrial chemistry
The general Industry
The Manufacturing Industry
The chemical industry
The Global Chemical Industry
Different types of chemicals produced
Characteristics of the chemical Industry
Raw materials for the Chemical Industry
Raw materials from Atmosphere
Raw materials from Hydrosphere
Raw materials from Lithosphere
Raw materials from Biosphere

Introduction to unit operations

Chemical Processes
Classification of processes
Anatomy of chemical manufacturing process
Units that make up a chemical process
Unit operations
Unit processes
Flow diagrams
Block diagrams
Pictorial representation
Process streams and equipment numbering and identification

Feasibility study for a chemical plant project

The scope of a chemical plant project
 Conceiving the idea
Prefeasibility/Idea study
Feasibility study
Feasibility study judgment criteria
Factors considered in a feasibility study
Plant location
Quotations
Price in relation to location of goods
Validity of quotations
Using contractors and consultants
Contractors
Consultants
Why projects fail

Characteristics of particulate solids

Characterization of a single particle
Particle shape
Particle size
Measuring techniques
Particle size distribution
Mean particle size
Particulate solids in bulk
General characteristics
Agglomeration
Resistance to shear and tensile forces
Angles of repose
Flow of solids in hoppers

Unit operations involving size reduction and enlargement

Size reduction
Mechanism of size reduction
Nature of the material to be crushed
Principles of size reduction
Energy and power requirements in size reduction
Characteristics of comminution products
Types of crushing equipment
The Jaw crusher
The Gyratory crusher
The Hammer mill
The single roll crusher
 Crushing rolls
Roller mill
The ball mill
Methods of operating crushers
Criteria for comminution
Size enlargement of particles
Purposes of size enlargement
Bonding mechanisms
Size enlargement processes
Laboratory strength tests carried out on agglomerates

Separations of solid-solid mixtures

Screening (Sieving)
Screening Effectiveness
Blinding
Screening equipment
Grizzly screen
The Trommel screen
Size separation by settling
The settling tank
The double-cone classifier
The hydraulic jig
The mechanical classifier
The riffled table
Flotation
Magnetic separators
Electrostatic separators

Separation of solids from liquids

Movement of a particle through a fluid
Sedimentation
Thickening and clarifying
Liquid cyclone
Filtration
A typical Filtration operation
Batch Cake filter
Filter Media
Filter aids
The Rotary Drum Vacuum Filter
Horizontal belt filter
Cenrifugal separations
Centrifugal fields
Centrifugal equipment
Classification of centrifuges
Simple bowl centrifuge
Pusher-type centrifuge

Evaporation
Heat transfer
Evaporation operation
Capacity and Economy
Boiling Point Elevation (BPE)
Heat transfer in evaporators
Single-effect evaporator
Multiple-effect evaporators
Classification based on the mode of feed supply
Evaporator selection
Natural circulation evaporators
Forced circulation evaporators
Film-type unit

Solid - gas separations

Separating methods
Gravity separators
Gas cyclones
Inertia or momentum separators
Fabric filters
Electrostatic precipitator
Liquid washing
Agglomeration and coalescence
Odour removal

Liquid liquid separation

Decanters
Continuous gravity decanter
Coalescers
Centrifugal separators

Mixing and blending

 Agitation equipment
Standard tank geometry
Impellers
Propellers
Paddles
Turbines
Flow patterns in agitated vessels
Prevention of swirling
Mixing
Blending of miscible liquids
Mixing of low viscosity fluids
o Static motionless mixer
o Inline mixer
Mixing of liquid solid suspensions
o The variables of mixing suspensions
Mixing of solids
Mixing and Segregation of free-flowing powders
Mechanisms of Mixing
Mixing equipment
Mixers for cohesive solids
Mixers for free-flowing solids

Materials of construction

Material properties
Mechanical properties
Effect of temperature on the mechanical properties
Corrosion resistance
Material costs
Contamination
Surface finish

Material handling
System Selection
Mechanical Conveyors
Belt Conveyors
Oscillating Conveyors
Screw Conveyors
Bucket Elevators
Apron Feeders
 Rotary Table Feeders
Pneumatic Conveying
Pneumatic Conveying Systems

Plant services
Electricity
Steam
Combined heat and power (co-generation)
Water
Cooling water
Water for general use
Demineralised water
Refrigeration
Compressed air
Inert gases
Effluent disposal

Industrial waste management and introduction to cleaner production

Causes of waste
Physical forms of waste
Gaseous wastes
Liquid wastes
Solid wastes
Aqueous wastes
Noise
Visual impact
Legislation
Environmental auditing
Cleaner production
Waste reduction and minimization
o Recycling
o Physical methods of waste treatment
o Chemical treatment
o Thermal treatment methods
o Hazardous-waste fuel
o Biodegradation of wastes
o Land Treatment
Industrial water treatment and purification
Introduction
Treatment of Water for Industrial Use
 Sources of water
Types of impurities present in water
Effects of impurities in natural waters
Methods of treatment of water for industrial purposes
Material and energy balances
Nomenclature and Units of Measurement
Precision of quantities
Mass balances
Process Analysis Procedure
o Mass Balance on a Continuous Distillation Process
o Mass Balance on a Process with Reaction
Energy balances
Energy Balance on a Distillation Column

Course objectives
Define a chemical industry and describe its raw materials
Draw simple flow diagram of a chemical process
Explain the purpose of a feasibility studies
Name the main characteristics of particulate solids
Determine the mean size of solids in bulk
Describe different size reduction equipment used in industry
State the purpose of size enlargement
Explain how separation of different mixtures is achieved in industry
Describe material handling techniques
Explain how mixing of different materials is done
Explain the importance of different plant services
Describe how the industrial waste can be managed
Describe different industrial water treatment techniques
Perform simple material and energy balance calculations
Course Evaluation
CAT (30 marks)
Final Exam (70 marks)

Recommended textbooks

1. McCabe W.L., Smith J.C., Harriott P., Unit Operations of Chemical Engineering, 5th ed.,
McGraw-Hil, Inc.
2. Coulson & Richardsons Chemical Engineering, vol. 6, 4th Ed. Chemical Engineering
Design, R. K. Sinnott, Amsterdam.

3. Peters M.S., Timmerhaus K.D, Plant Design and Economics for Chemical Engineers, 4th Ed.
McGraw-Hill Inc. 1991.

4. J. F. Richardson , J. H. Harker and J. R. Backhurst, Coulson and Richardsons Chemical

engineering Particle technology and Separation processes, vol 2, 5th edition.

5. Martin Rhodes, Introduction to ParticleTechnology, 2nd edition, Monash University,

Australia.