Table of Contents

1 Chemical engineering- an overview 1

1.1 Basics of chemical engineering 1
1.2 Unit operations 2
1.3 Thermodynamics 8
1.4 Chemical Kinetics 8
1.5 Chemical engineer – scope & responsibilities 9
1.6 “Ten greatest achievements” of chemical engineering 14
1.7 Chemical engineering “Today & Tomorrow” 16

2 Stoichiometry 17
2.1 Introduction 17
2.2 Balancing chemical equations 17
2.3 Chemical periodicity 20
2.4 Fundamental constants 20

3 Classification of process diagrams/data sheets & their

application 21
3.1 Introduction 21
3.2 Types of process drawings 21
3.3 Block Flow Diagram (BFD) 21
3.4 Process Flow Diagram (PFD) 22
3.5 Piping and Instrument Diagram (P&ID) 23
3.6 Utility Flow Diagram (UFD) 24
3.7 Data sheets 24

4 Fluid mechanics 26
4.1 Introduction 26
4.2 Liquid - column manometers 26
4.3 Mechanical pressure gauges 29
4.4 Measurement of fluid flow 32
4.5 Valves 50
4.6 Fluid moving machinery 58
4.7 Centrifugal pumps 59
4.8 Positive-displacement pumps 60
4.9 Agitation equipments 64

5 Heat transfer & its applications 69

5.1 Heat transfer mechanism 69
5.2 Heat exchangers 69
5.3 Boilers 78
5.4 Evaporators 82

6 Mass transfer and its applications 93

6.1 Mass transfer phenomena 93
6.2 Distillation 93
6.3 Types of distillation columns 95
6.4 Column internals 96
6.5 The Types of distillation 111
6.6 Sublimation 111
6.7 Leaching 111
6.8 Centrifugal extractors 117
6.9 Gas absorption 117
6.10 Cooling towers 120
6.11 Desiccant dehumidifiers 125
6.11 Adsorptions systems 127
6.13 Drying 130
6.14 Drying equipment 132

7 Thermodynamics 150
7.1 Applications of thermodynamics principles 150
7.2 Compressor 154
7.3 Ejector-system 160
7.4 Heat conversion & power cycles 161
7.5 Refrigeration & liquefaction 177

8 Process design 182

8.1 Introduction 182
8.2 Process design considerations 183
8.3 Equipment design factors 183
8.4 A look at common industrial chemicals 184
8.5 Materials of construction 186
8.6 Types of corrosion 187
8.7 Linings for chemical plants and equipment 188
8.8 Rules of thumb 189

9 Process control 195

9.1 Overview 195
9.2 Control system 195
9.3 Practical control examples 198
9.4 Control actions 204
9.5 Examples of control 205
9.6 Control loop diagrams 212
9.7 Modes of automatic control 213

10 Chemical process safety 223

10.1 Safety responsibilities 223
10.2 Standard safety rules and regulations 224
10.3 Chemical hazards and chemical safety data sheets 225
10.4 General safety practices 229
10.5 Good housekeeping plan 238
10.3 Personal protective equipments 239

11 Chemical kinetics 240

11.1 Chemical reactions – Basic concepts 241
11.2 Classification of chemical reactions 224
11.3 Chemical reaction profile 242
11.4 Classification of reactors 243
11.5 Catalysts 248
11.3 Promoters 251

12 Unit operations of particulate solids 253

12.1 Storage of solids 253
12.2 Feeders 256
12.3 Crushers and mills 258
12.4 Cutting machines 266
12.5 Crystallization 267
12.6 Mixers 269
12.7 Mechanical separation 272
12.8 Powder compacting equipments 277
12.9 Filtration 281
12.10 Cryogenic grinding 285
12.11 Blending 286

13 Process economics 288

13.1 Capital investment 288
13.2 Total product costs 290
13.3 Economic analysis 291
13.4 Life cycle analysis 292
13.5 Real-Time Optimization (RTO) of chemical processes 294

Appendix A: Periodic Table of Elements

Appendix B: Fundamental Physical Constants

Appendix C: Equipments Symbols

Appendix D: Typical Instrumentation Symbols

Appendix E: Typical P&ID

Appendix F: Typical Process Data Sheet