Principles of Industrial Chemistry

Principles of
Industrial Chemistry
2nd stage (2020-2021)
Chemistry Department
Karim Ali Younis
19/10/2020 1
Industrial Chemistry
• Industrial chemistry is the branch of chemistry,
which applies physical and chemical procedures
towards the transformation of natural raw
materials and their derivatives to products that
are of benefit to humanity.
• The chemical processing industry is essential to
the modern global economy and plays a vital
role in almost every other industry in existence.
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Classification of
Industrial
Chemistry
Industrial
General Industrial Industrial Organic
Inorganic
Chemistry Chemistry
Chemistry
Chlor- Fermentati
Introduction alkali, Petroleum,
Unit Extracti on,
to ammonia, Petrochem
operatio ve ethanol,
industrial sulphuric i-cals
ns metallur Pharmace
chemistry acid, and
and unit gy uti-cals,
and fertilizer, polymers
processe soaps and
chemical cement
s detergents
industry
19/10/2020 3
Major Products of Chemical Industries and their Area of Application
Group of Product Areas
Plastics and Agricultural water management, packaging, automobiles,

Polymers telecommunications, health and hygiene, education
Synthetic rubber Transportation Industry, Textile, Industrial equipment lining
Synthetic fiber Non-woven and woven fibre in automobile , hosiery, textile

Soap and
Synthetic Health and hygiene domestic as well as industrial
detergents
Industrial Drugs & pharmaceuticals, pesticides, explosives, dyes, lube additives,
chemicals adhesive oil field, antioxidants, chemicals, printing ink, paints
Sugar & Alcohol Food, alcoholic beverage, Chemical Feed Stock, Ethoxylate, biofuel
Writing & Printing Paper, Culture Paper, News Printing Paper,

Pulp & Paper
Tissue Paper, Packaging Paper
Fertiliser Agriculture, Chemical industry ( ammonia and urea)
Agrochemicals Pesticides
Mineral acids Chemical industry- organic and inorganic 4

Industrial Chemistry Processes
Unreacted
feedstock
Reaction
Feedstock Mixer
Vessel
Separator
By-product Product
19/10/2020 5
The Structures of a Project:
Process
Process Process
Developm
Research Design
ent
Process Bench-
evaluati scale Evaluatio
on studies Marketin n of
g Design
Productio
Plant Constructi Plant
n
Technical on Design
Supervisi
Services
on
19/10/2020 6
The Structures of a Project
• Process Research
1. Process evaluation (Construct a preliminary technical, economic, and
financial feasibility of a process)
I. Construct a preliminary process flow diagram
II. Approximate equipment sizing.
III. Economic evaluation
IV. Locate areas requiring research.
2. Bench-scale studies (The objective is to obtain additional design data
for process evaluation)
I. Plan experiments
II. Design experimental setup
III. Correlate data
IV. Revise flow diagram
V. Revise economic evaluation
VI. Locate area requiring development
19/10/2020 7
• Process Development (The objective is to obtain more design

data and possibility product for market research).
a. Plan development program
b. Design pilot plant
c. Supervise pilot plant constrictions
d. Supervise pilot-plant operations
e. Correlate data
f. Revise flow diagram
g. Revise economic evaluation
19/10/2020 8
• Process Design (To establish process and equipment
specifications).
Process design is the design of processes for desired physical
and/or chemical transformation of materials.
A. Construct flow diagram
B. Perform mass and energy balances
C. Consider alternative process designs
D. Size equipment
E. Design control systems
F. Conduct economic studies
G. Conduct optimization studies
H. Evaluate safety and health
I. Conduct environmental impact studies
J. Design control systems
19/10/2020 9
• Plant Design and Construction (To implement the process
design).
A) Specific equipment
B) Design vessels (mechanical design of reactors, separators tanks)
C) Consider alternative design
D) Design process piping system
E) Design data acquisition and control system
F) Design electric-power distribution system
G) Design steam-distribution system
H) Design cooling-water distribution system
I) Purchase equipment
J) Coordinate and schedule project
K) Monitor progress
19/10/2020 10
• Plant Operations (To produce the products)
a) Plant start up
b) Troubleshooting
c) Process improvement
d) Production
e) Plant engineering
• Marketing (To sell the product)

A. Market research
B. Product sales
C. Technical customer service
D. Product development
19/10/2020 11
Factors Affecting the Manufacturing Costs
Production Costs
Variable costs Fixed costs

Capital costs
(Direct costs) (Indirect costs)
The one-off cost of The cost that The annual cost of

constructing the changes throughout the staff, local rates,
plant and all the the year and is advertising and
dependant on how
associated costs utility bills.
much product is
of all buildings.
19/10/2020 sold. 12
1. Direct Costs
• Raw Materials
• Catalysts
• Solvents
• Utilities (includes steam, electricity, fuel, cooling
water, process water, compressed air, refrigeration,
and waste treatment)
• Fuel costs
• Labor
• Operating Supplies
• Quality Control
19/10/2020 13
2. Indirect Costs
• Depreciation
• Local Taxes and Insurance
• Plant Overhead Costs
3. General Costs
• Administration Costs
• Distribution and Selling Costs
• Research and Development
19/10/2020 14

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Principles of

Karim Ali Younis

Plastics and Agricultural water management, packaging, automobiles,

Synthetic rubber Transportation Industry, Textile, Industrial equipment lining

Synthetic fiber Non-woven and woven fibre in automobile , hosiery, textile

Writing & Printing Paper, Culture Paper, News Printing Paper,

Fertiliser Agriculture, Chemical industry ( ammonia and urea)

Mineral acids Chemical industry- organic and inorganic 4

• Process Development (The objective is to obtain more design

• Marketing (To sell the product)

Variable costs Fixed costs

The one-off cost of The cost that The annual cost of

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