CHME 332 Resource Engineering-I

Lecture 1: Chemical Industries, its structure, raw material, energy

Dr. Dhawal Shah

Semester 2: 2011/12

Introduction
Dr. Dhawal Shah
Instructor with Ph.D. @ METU NCC

Ph.D. from Singapore-MIT Alliance at National University of Singapore July 2011. Contact hours: drop an email to meet me anytimeanyplace. dhawal@metu.edu.tr Phone: 2992 (O); 0533 835 4412 (H)

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Introduction
The course is jointly taught by
Dr. Dhawal Shah (Course coordinator; 7 lectures) Dr. Timur Dogu (3 lectures; tdogu@metu.edu.tr) Dr. Ufuk Bolukbasi (4 lectures; ufukb@metu.edu.tr)

Assistant : Mr Saltuk (saltuk@metu.edu.tr) Midterm: 13 April Tutorial: 20%; Midterm: 20%; Term-paper: 20%; final exam: 40% Course schedule is posted on METU ONLINE

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Classroom policy
You are free to move out of the class, if you feel so. But you should not disturb others. Its going to be very difficult to earn two grades in my course: AA and FFyou will have to work hard to earn them. Languagedialectwordsif not clear, you can stop me any time. If you fail to submit the term paper on time or any of the assignments on time: you are bound to fail. No question is smallif you do not understand something..trust me..at least half of the class does not.
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Course Objectives
Demonstrate the significance of natural resources (coal, oil, natural gas, biomass, water, air etc.) used in chemical process industries; Discuss the effective use of natural resources and their sustainable conversion to useful products through chemical, biological and physical processes; Apply the general principles of equilibrium and rate concepts to chemical and bio-processes; Analyze waste minimization, environmental concerns and process efficiency in selected case studies; Realize the importance of green process engineering, environmentally clean processes and products;
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Chemical Engineering
Chemical engineering: A branch of engineering which involves the design & operation of large-scale chemical plants, petroleum refineries, and the like (Life sciences/pharma/micro-electronics). Key: Process and (complex) system In such industries, chemical engineers work in production, research, design, process and product development, marketing, data processing, sales and throughout top management.

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Chemical Industries
Convert raw materials to useful products and improve the human environment

Multi Objective Multi Functional Multi Scale Engineering Branch

Multi objective industriesexamples

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Top chemical industries

COMPANY, HEADQUARTERS BASF SE, Ludwigshafen, Germany Dow Chemical, Midland, Michigan, United States INEOS, Lyndhurst, UK LyondellBasell, Houston, Texas, United States Formosa Plastics, Taiwan DuPont, Wilmington, Delaware, United States Saudi Basic Industries Corporation, Riyadh, Saudi Arabia Bayer, AG, Leverkusen, Germany Mitsubishi Chemical, Tokyo, Japan
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2007 Chemical Sales, billions $65.3 $53.5 $43.6 $42.8 $31.9 $28.5 $26.4 $24.2 $22.2
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Commonly used raw materials

water, air, salt, limestone, sulphur, coke and rock phosphate (abundantly available) To produce primary or heavy chemicals such as mineral acids and alkalis which in turn is used To produce secondary or intermediate chemicals like aniline, phenol To produce more complex chemicals like drugs, dyes, explosives.

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What do chemical engineers do: Multi functional

Design, development and operation of process plants Research and development of novel products and processes Management of technical operations and sales

In all these functions SUSTAINABILITY is important.

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Worldwide average profiles on sales

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Fine chemicals

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Multi-scale operations

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Atom-molecule state
Rate of reactions Mechanisms of reaction Equilibrium of a reaction Catalysis functioning Photolithography (silicon industries)

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Transport-in-bulk scale
Gas Liquid (Mass Transfer) Diffusion within the liquid Liquid Solid (Mass Transfer) Mixing in the reactor (unit) (Hydrodynamics) Heat transfer (Temperature distribution)

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Plant scale

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Typical chemical process structure

Physical Rate and Equilibrium Processes: Momentum, Heat, Mass Transfer (Heat treatment, combustion, separation processes, fluid flow, mixing etc.) Chemical Rate and Equilibrium Processes: Reaction Kinetics and Thermodynamics

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Factors that should be considered

Which reactions are involved? Thermodynamics of reactions, Kinetics (rates) of reactions, use of catalysts. Operating parameter selection; T, P etc. Mass transfer, heat transfer limitations. Feed purification, separation processes. Product stream purification. Economics of the process. Process safety issues. Environmental issues. Process sustainability.
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Birth of chemical engineering: Soap

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Soap making: Soda requirement

1700s the demand for soap increased requiring Na2CO3. The alkali compounds, soda ash(Na2CO3) and potash(K2CO3), were used in making glass, soap, and textile sand were therefore in great demand. Alkali in the form of wood ashes (potash)and in the form of barilla (a plant containing 25% alkali), or from soda mined in Egypt, were all very expensive. Large natural soda reserves (trona) (Na2CO3-NaHCO3-2H2O) are also available in Turkey (Beypazar)
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Birth of chemical industry

Na2CO3 (Sodium carbonate) Other uses: Glass, water softner, production of dynamite Problem: Natural resource French Academy of Sciences (1783): Make Na2CO3 from NaCl Leblanc process (1791) 2 NaCl + H2SO4 -> Na2SO4 + 2HCl (g) 800C Na2SO4 + CaCO3 + 2 C -> Na2CO3 + 2CO2 + CaS Problem: Pollution: HCl, CaS

British Alkali Act (1863): remove 95% of the HCl

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Solvay Process
Solvay process (1860) process view NaCl + CO2 + NH3 + H2O -> NaHCO3 + NH4Cl 2 NaHCO3 -> Na2CO3 + H2O + CO2 heat >70 C (CaCO3 -> CO2 + CaO) 2 NH4Cl + CaO -> 2 NH3 + CaCl2 + H2O ------------------------------------------------------------------------------2 NaCl + CaCO3 -> Na2CO3 + CaCl2 (overall reaction) Think about process/system Recycle everything: No more S, HCl
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Birth of chemical industry

Shifting of trends from chemistry-oriented to process-oriented. Understanding and design of different unit operations like reactors, mixers, filteration, sedimentation, etc.: 20th century

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Birth of chemical engineering ing

Lewis Norton
first course: Course X Applied Chemistry First program at MIT 1888. Chemical Engineering Program General training in mechanical engineering and application of chemistry for the manufacture of chemical products
In 1891, the Department of Chemistry granted seven Bachelor's degrees for Chemical Engineering, the first of their kind to be bestowed anywhere. After Norton's death in 1893 at the age of 39, Professor Frank H. Thorpe led Course X through a continued rise in popularity. Thorpe's Outlines of Industrial Chemistry, which was published in 1898, is considered one of the first textbooks in chemical engineering. Lewis Norton
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Ammonia synthesis
Ammonia is one of the base chemicals used in the production of synthetic fertilizers etc. About 175 000 000 tons of ammonia is produced per year, mostly for the production of fertilizers which are needed for the production of crops About 1-2% of world energy consumption is due to ammonia synthesis.

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Ammonia production process

N2 (g) + 3 H2 (g) 2 NH3 (g) (H = 92.22 kJmol1) By far the major source of the hydrogen required for the HaberBosch process is methane from natural gas, obtained through a heterogeneous catalytic process CH4 + H2O CO + 3 H2

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Novel Catalysts May Save Considerable Energy

Conventional Haber-Bosch process uses iron-oxide/alumina modified by potassium.This catalyst shows activity at T = 400 500 oC At this temperature p 100 atm is required due to chemical equilibrium limitations. As T increases equilibrium conversion decreases (H<0; exothermic). Operation at lower pressures (i.e., atmospheric pressure) requires development of novel catalysts which will be active at much lower temperatures .This will save significant energy.

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First paradigm of chemical engineering

First text book of chemical engineering

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Second major introduction to ChemE

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Recent frontiers in chemical engineering

Biotechnology, biomedical Electronic materials Advanced materials, polymers, composites Energy, alternative fuels Nanotechnology, nano-materials Environmentally clean processes and products; safe processes, waste management.

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Major responsibilities of chemical engineers in this age Development of new processes which are safe and sustainable Design and production of environmentally benign and safe products.

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Example of a benign process

Refrigerators and air conditioners are extensively used today all over the world. Can we do it with out them?

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Refrigerant
Before 1929, the common refrigerant were ammonia and methyl chloride, which are highly toxic gas. Until 1990 freons (CFC) were also very commonly used, which contributes to ozone depletion. They were phased out by Montreal Protocol.

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Ozone (O3) layer in the stratosphere absorbs some of the UV light coming from sun. Freons destroy O3

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New refrigerants are being designed

Example: R134: 1,1,1,2-Tetrafluoroethane CF3CH2F Performance in the refrigerators is as good as conventional freons. However, its ozone depletion capacity is zero. It is less stable than conventional freons, so that it is decomposed before reaching stratosphere For the car air conditioner, we are still using CFC-12 and HFC-134a, which are both potent green house gas and ozone depleting substance. On Mar 2, 2011, EPA has approved a new refrigerant HFO-1234yf, which will be used in car produced in 2013 (Announced by General Motors).
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Green processes
Fast depletion of natural resources and the resulting environmental problems opened a new and very important responsibility to chemical engineers to develop new environmentally clean and more efficient processes and environmentally benign products. Looking forward towards minimization of pollution.

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