05 Chapter 5 PPK

Chemical Plant Design 1210384 Chapter-5
V
BATCH PROCESS
Dr.Eng. Yulius Deddy Hermawan

Department of Chemical Engineering
UPN Veteran Yogyakarta
Outline
1. Introduction to Batch Processes
2. Batch Reactor
3. Batch Separation
4. Gantt Chart
5. Production Schedules for Single Products
6. Production Schedules for Multiple Products
7. Equipment Cleaning and Material Transfer
Dr. Eng. Y. D. Hermawan ChemEng - UPNVY
Department of Chemical Engineering - UPN Veteran Yogyakarta Page 1 of 21

V.1
INTRODUCTION TO
BATCH PROCESSES
Batch and Continuous Processes

(Smith, R, 2005)
However, not all processes operate continuously.

In a batch process, the main steps operate discontinuously.
In contrast with a continuous process, a batch process does
not deliver its product continuously but in discrete amounts.
This means that heat, mass, temperature, concentration and
other properties vary with time.
In practice, most batch processes are made up of a series of
batch and semicontinuous steps.
A semicontinuous step runs continuously with periodic start-
ups and shutdowns.

Various modes of operation for batch and semibatch reactors.

(Smith, R, 2005)
Batch Processes:
(R. Smith)
are economical for small volumes;
are exible in accommodating changes in product formulation;
are exible in changing production rate by changing the
number of batches made in any period of time;
allow the use of standardized multipurpose equipment for the
production of a variety of products from the same plant;
are best if equipment needs regular cleaning because of fouling
or needs regular sterilization;
are amenable to direct scale-up from the laboratory and
allow product identication.

Batch Processes:
(R. Smith)
One of the major problems with batch processing is batch to-
batch conformity.
Minor changes to the operation can mean slight changes
in the product from batch to batch.
Fine and specialty chemicals are usually manufactured in
batch processes. Yet, these products often have very tight
tolerances for impurities in the nal product and demand
batch-to-batch variation being minimized.
Batch Processes:
(James M. Dauglas)
Select batch, if:
1. Production rate
a. Sometimes batch if less than 10million lb/year
b. Usually batch if 1million lb/year
c. Multiproduct plant
2. Market forces:
a. Seasonal production
b. Short product lifetime
3. Scale up problems:
a. Very long reaction times
b. Handling slurries at low flowrates
c. Rapidly fouling materials

V.2.
BATCH REACTOR
Example of parallel reaction

Ratio:
Minimize Byproduct:
If a2 > a1 and b2 > b1: The concentration of both feeds should be minimized
and each added progressively as the reaction proceeds. Predilution of the feeds
might be considered.
If a2 > a1 and b2 < b1: The concentration of FEED1 should be minimized by
charging FEED2 at the beginning of the batch and adding FEED1 progressively
as the reaction proceeds. Predilution of FEED1 might be considered.
If a2 < a1 and b2 > b1: The concentration of FEED2 should be minimized by
charging FEED1 at the beginning of the batch and adding FEED2 progressively
as the reaction proceeds. Predilution of FEED2 might be considered.
If a2 < a1 and b2 < b1: The concentration of FEED1 and FEED2 should be
maximized by rapid addition and mixing.

A temporal superstructure for a well-mixed batch reactor.

(Smith, R., 2005)
The greater the number of the time intervals, the closer the
model approaches the batch reactor modeled.
A temporal superstructure for a multiphase well-mixed batch reactor

(Smith, R., 2005)

Some examples of mixing compartment networks to represent agitated

vessels.

V.3.
BATCH SEPARATION
Batch Distillation
Advantages Disadvantages
The same equipment can be used to process High purity products require the careful
many different feeds and produce different control of the column because of its dynamic
products state
There is exibility to meet different product The mixture is exposed to a high temperature
specications for extended periods
One distillation column can separate a Energy requirements are generally higher.
multicomponent mixture into relatively pure
products
Simple distillation from a batch pot
Find other examples of

batch separation!

V.4.
GANTT CHART
Gantt Chart for a simple batch process

Overlapping batches allows the batch cycle time to be

decreased
Example 5.4.1: determine reactor capacity

Filling time = 0.25 h
Reaction time = 2.5 h Cycle time = 3 h
Reactor emptying = 0.25 h
Production capacity = 3000 ton/year (active: 330 day/year)
30001000 kg
Production rate ton
378.8
kg
30024 h h
1 kg of FEED produces 0.8 of main product
378.8 kg
Reactor capacity 3 h 1420.5 kg
0.8 h

Single Step Single Reactor
time
STEP Hour
FILLING 0.25
REACTION 2.50
EMPTYING 0.25
total 3.00
Single Step 3 Parallel Reactors

1
time STEP Hour

FILLING 0.25
REACTION 2.50
1
EMPTYING 0.25
2 total 3.00
time
time

V.5.
PRODUCTION
SCHEDULE FOR
SINGLE PRODUCTS
Production schedules for a three-step process.

Subsequent batches are only started once the previous batch

has been completely nished. For this sequential production
schedule, the cycle time is 20 h. This clearly leads to very poor
utilization of equipment.
It has already been noted that overlapping batches can reduce the cycle time.
Subsequent batches are started as soon as the appropriate equipment becomes
available. Cycle time decreases to 10 h for overlapping batches (the length of the
longest step).
If a specied volume of production needs to be achieved over a given period of
time, then the equipment in the process that uses overlapping batches in Figure
(b) can in principle be half the size of the equipment for sequential production in
Figure (a).

There are two items of equipment operating Step A, but in parallel.

This allows both Step B and Step C to be carried out with complete utilization.
If the sizes of the equipment are compared to the sequential production schedule,
then each of the two Steps A1 and A2 in Figure (c) can in principle be one-quarter
the size of the equipment for Step A for sequential production in Figure (a).
The size of the equipment for Steps B and C in Figure (c) will also be one-quarter
the size of those in the sequential production schedule in Figure (a).
The nal option shown in Figure (d) is to use intermediate storage for the limiting
step.
Material from Step A is sent to storage, from which Step B draws its feed. Material
is still passed directly from Step B to Step C. Now all three steps are fully utilized.
For the same rate of production over a period of time, the size of Step A can in
principle be half that relative to the sequential production in Figure (a) and the
sizes of Steps B and C can in principle be one-quarter those for sequential
production. However, this is at the cost of introducing intermediate storage.

V.6.
PRODUCTION
SCHEDULE FOR
MULTIPLE PRODUCTS
Production schedule for two products with a

three-step process.

Figure (a) shows a production cycle involving a sequential

production schedule.
Production alternates between Product 1 and Product 2.
The cycle time to produce a batch each of Product 1 and 2 is
30 h.
The rst thing that can be considered in order to reduce the

cycle time and increase equipment utilization is to overlap the
batches as shown in Figure (b).
This reduces the cycle time to 18 h.

All of the schedules considered so far involved transferring material from one step
to another, from a step to storage or from storage to a step without any time
delay. This is known as zero-wait transfer.
An alternative is to exploit the equipment in which a production step has taken
place to provide hold-up.
In this situation, material is held in the equipment until it is required by the
production schedule. A schedule using equipment hold-up is shown in Figure (c).
This reduces the cycle time to 15 h.
Finally, Figure (d) shows the use of intermediate storage.

The use of storage is only necessary for Product 2.
Use of intermediate storage in this way reduces the cycle timeto14 h.

Single versus mixed-product campaigns for

three batches each of two products.
The production cycle for three batches each of Product 1 and Product 2.
The batches have been overlapped to increase equipment utilization.
In order to produce three products each of Product 1 and Product 2, the
schedule involves single-product campaigns.
Three batches of Product 1 and three batches of Product 2 follow directly
from each other.
The cycle time is 47 h.
The total time required to produce a given number of batches, in this case
three batches of each Product 1 and Product 2, is known as the
makespan, it is 53 h.

An alternative production schedule can be suggested by

following a mixed-product campaign.
Alternating between batches of Product 1 and Product 2 in
allows the cycle time to be reduced to 45 h and the makespan
to be reduced to 51 h.

V.7.
EQUPIMENT CLEANING
AND
MATERIAL TRANSFER
Cleaning between product changes extends the cycle times.
Once cleaning is introduced, the

mixed-product campaigns are
seen to be less efcient than
single-product campaigns

Transfer times extend the cycle times.
Compare to the the

schedule without
transfer time,
Cycle time increases
from 20 h to 24 h.
Compare to the the

schedule without
transfer time,
Cycle time increases
from 10 h to 12 h.
Good luck

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Chemical Plant Design 1210384 Chapter-5

Dr.Eng. Yulius Deddy Hermawan

Dr. Eng. Y. D. Hermawan ChemEng - UPNVY

Department of Chemical Engineering - UPN Veteran Yogyakarta Page 1 of 21

Dr. Eng. Y. D. Hermawan ChemEng - UPNVY

Batch and Continuous Processes

However, not all processes operate continuously.

Dr. Eng. Y. D. Hermawan ChemEng - UPNVY

Department of Chemical Engineering - UPN Veteran Yogyakarta Page 2 of 21

Various modes of operation for batch and semibatch reactors.

Dr. Eng. Y. D. Hermawan ChemEng - UPNVY

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Department of Chemical Engineering - UPN Veteran Yogyakarta Page 3 of 21

Dr. Eng. Y. D. Hermawan ChemEng - UPNVY

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Dr. Eng. Y. D. Hermawan ChemEng - UPNVY

Example of parallel reaction

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A temporal superstructure for a well-mixed batch reactor.

Dr. Eng. Y. D. Hermawan ChemEng - UPNVY

A temporal superstructure for a multiphase well-mixed batch reactor

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Some examples of mixing compartment networks to represent agitated

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Dr. Eng. Y. D. Hermawan ChemEng - UPNVY

Simple distillation from a batch pot

Find other examples of

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Gantt Chart for a simple batch process

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Overlapping batches allows the batch cycle time to be

Dr. Eng. Y. D. Hermawan ChemEng - UPNVY

Example 5.4.1: determine reactor capacity

Production capacity = 3000 ton/year (active: 330 day/year)

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Single Step Single Reactor

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Single Step 3 Parallel Reactors

time STEP Hour

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Production schedules for a three-step process.

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Subsequent batches are only started once the previous batch

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There are two items of equipment operating Step A, but in parallel.

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Production schedule for two products with a

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Figure (a) shows a production cycle involving a sequential