Synthesis and Analysis

of Batch Processes

Hierarchical Method of Douglas

How to create a flowsheet?
Input info

Batch or Continuous

0
1

Input/output structure for flows

Conversion section & recycle structure

Separation section: gases, liquids, & solids

Energy & utilities: heat exchange network

5
Design Hierarchy Revisited

Delft Conceptual Process Design

Matrix
Level

Basis of
Design

Assessment
of
Knowledge

Synthesis
(structure &
scale)

Analysis
(phys.
behavior)

Evaluation
(of perform.)

Report of
Design
(decisions)

Transfer to
next level

1. Plant type
2. Input/
Output
3. Functional
blocks
4. Unit
operations
5. Equipment
6. Process
integration
7. Control &
safety

Design Hierarchy Revisited

Batch Process Design

level 1 decision: batch or
continuous

Factors affecting BATCH operation:

1.

2.

3.

4.

Production rate
a. sometimes batch if < 500 ton/yr
b. usually batch if < 500 ton/yr
c. multi-product / multi-purpose plants
Product quality
a. narrow distributions (e.g., mol. weight)
b. issue: consistency between batches
Market forces
a. seasonal production (e.g., herbicides)
b. short product lifetime
Scale-up problems
a. very long reaction times
b. rapidly fouling materials
c. handling of slurries at low flow rates

Concepts in Batch Processing

Modes of Batch Operation

1.

2.

3.

4.

Purely batch
a. charging of all material at the start
b. varying temperature or pressure patterns in time
c. removal of all material at the end
Semi-batch (bio: fed-batch)
a. charging of some material at the start
b. varying feed rates and volume-time pattern
c. varying temperature- or pressure-time patterns
d. varying pattern of removal of material
e. automatic/manual control of patterns
Intermittent batch
a. special case of semi-batch
b. repetitive pattern of additions and removals
c. Automatic control of repetitive patterns
Repeated (fed) batch
a. special case of (fed) batch
b. some biomass is left at the end to start the next batch

Concepts in Batch Processing

Batch Process Design Recipe

Tasks

b.

State
Fill vessel V01 with 90 ton water of 15oC (1000 kg per min.)

Heat water in vessel V01 to 75oC (1o per min.)

c.

Add 1000 kg of solid crystals of A to V01 (1000 kg per min.)

d.

Stir V01 to dissolve crystals in water (100 kg per min.)

e.

Discharge solution in vessel V01 to storage V02 (1000 kg per min.)

f.

Rinse vessel V01 with water (> 5 min.)

g.

Vessel V01 sits idle (waiting time)

(till next cycle)
MAKE SPAN

Empty, clean
90 min.
Water full
60 min.
Water heated
10 min.
Solids added
100 min.
Solids dissolved
100 min.
Empty, used A
10 min.
Empty, clean
50 min.
Empty, clean
420 min.

Concepts in Batch Processing

Batch Process Design: Some concepts

in batch processing
Recipe:
Time ordered set of tasks
Some tasks may run parallel
Recurrent nature
Task:
Action changing the state of the
process
Action has a rate, hence a
duration
State:
Continuous intensive variables
(p,T,x)
Continuous extensive variables (V)
Discrete operational variables
(clean)

Stage:
Unit in which a task is done
Storage:
Holding of state between tasks
Event:
A change of tasks, as well as the
Instance of change
Event chart
Plot of tasks & events versus time
GANTT CHART

Concepts in Batch Processing

Batch Process Design: Timing Aspects

of batch processing
Processing time
- time (i) for task in stage i
Transfer time
- Time (i,j) needed to transfer
material from stage i to next stage
j
Z-W transfer
- No waiting time after a task is
completed in a stage

Cycle time
- Sum over all processing times of
tasks & transfer times in a recipe
(non overlapping tasks)
-

Maximum of the processing &

transfer times of the individual
tasks in a recipe (overlapping
tasks)
Make span
- Total processing time of a recipe

Concepts in Batch Processing

Synthesis of Batch Processes: Some additional

complexities
1.

Uncertainties in
a. feed composition
b. physical properties
c. reactivity

Impact on cycle time!!!!

2.

3.

Multiple products in plant

a. critical cycle time
b. flexibility
c. sequencing of production
d. storage demands
Semi-batch & continuous plant
a. critical cycle time
b. interfacing batch & continuous

Features of Batch Process Synthesis