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Objective of Lecture Session

Introduce the subject Introduce subjects key concepts Define chemical processing Elucidate elements of chemical processing

# Content of subject
PART I CHANGING LANDSCAPE 1 MODERN INORGANIC CHEMICAL PROCESSES IN THE FRAMEWORK OF GLOBALIZATION, SUSTAINABILITY AND TECHNICAL INNOVATION 2 MAJOR INORGANIC CHEMISTRY INDUSTRIES PART II LATEST DEVELOPMENTS IN INORGANIC CHEMICAL PROCESS 3 TRADITIONAL & NOVEL INORGANIC PROCESSES 4 NEW CHEMICAL SCIENCE & ENGINEERING TECHNOLOGY 5 SOPHISTICATED INFORMATION SYSTEMS IN PRODUCT AND PROCESS DESIGN AND DEVELOPMENT 6 MANUFACTURING AND OPERATIONS PART III FUTURE OF INORGANIC CHEMICAL PROCESS 7 R&D NEEDS FOR NEWPROCESS CHEMISTRY

TEXT
Austin, G. T., (1984), Shreves Chemical Process Industry,

(5th Edition), McGraw-Hill, Inc. McCabe, W.L., Smith, J.C. and Harriot, P., (2005), Unit Operations of Chemical Engineering, (7th Edition), McGraw-Hill, Inc. Allcock, H.R., (2008), Introduction to Materials Chemistry, John Wiley & Son, Inc, Hoboken, New Jersey.

ASSESSMENT
Item
Test Assignment and quiz Project Final Exam Total

Percentage (%) 30 15 15 40 100

CONTACT
PROFESSOR DR MOHD RIDZUAN NORDIN 09-5492406/012-6023798 mridzuan@ump.edu.my Faculty of Industrial Sciences and Technology (First Floor of A1)

Consultation time: 12noon -4 pm Tuesday & Wednesday

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INTRODUCTION
Process Chemical Industry Inorganic Chemistry Chemical Process

# Process
Raw Materials PROCESS Product A process transforms raw materials into product in a reaction vessel called the reactor. It involves 1. the raw materials, 2. the processing conditions and 3. the desired products. The desired products should have the required level of purity for its usage. The process used should transform the raw material into product in a cost effective manner and cause the least negative effect on the environment. The raw materials used should meet the process requirement and should be cost effective. In inorganic chemistry process, products are primarily inorganic in nature such as metal, metal oxides, inorganic compounds and composite materials. These products may be in the form of solid, liquid or gas. The raw materials also tend to be inorganic substance while the inorganic chemistry process may use organic substance such as hydrocarbon as fuels and solvents.
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# Process
This subject in essence is the study of how inorganic materials are produced. Since there are many different products, then representative inorganic products will be discussed and the processes leading to their production highlighted. The major emphasis of this subject is on the different chemical principles used in inorganic chemistry processes. This is reflected in the process condition such as processing temperature and pressure. Other process variables include pH of reaction solution, reduction potential, presence of catalyst, solvent and other co-reactants. The processes chosen to transform a raw material to a particular product are normally optimized. The widely adopted process are normally the one that is most cost effective and lead to minimum environmental concern or damage.

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# Chemical Industry
The chemicals industry is a global enterprise with revenues of nearly EUR 2.1 trillion in 2008 and is a keystone for the global economy, converting raw materials (oil, natural gas, air, water, metals, minerals) into more than 70,000 different products. A few goods are manufactured without some input from the chemicals industry. Major product groups which make use of chemical inputs include rubber and plastic products, textiles, apparel, petroleum refining, pulp and paper, and primary metals. Example
The largest corporate producers worldwide, with plants in numerous countries, are BASF, Dow, Eastman Chemical Company, Shell, Bayer, INEOS, ExxonMobil, DuPont, SABIC, Braskem and Mitsubishi, along with thousands of smaller firms.
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# Chemical Industry
Further Examples

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# Chemical Industry

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# Chemical Industry

As the global economy emerges from the recession of the late 2000s, the chemicals industry finds itself passing through a period of profound transformation. Profit margins have been shrinking; return on capital has been in a steady decline. The recent recession has worsened the problems. The commodity side of the business has been investing in large-scale advantaged capacity in developing markets and is now struggling with overcapacity. Among the fragmented specialty producers in developed markets, competition is growing tougher. Integrated players, wary of declining profits on the commodities side, are searching for ways to shift their portfolios to include more specialized products.
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Inorganic Chemicals

# Inorganic Chemistry
This sector covers the production of chlor-alkali, acids and some specialty chemicals, e.g. silicates, oxides, hydroxide, acids, electronic chemicals, catalysts and waste treatment chemicals. Other inorganic chemicals manufactured locally include zinc oxide, zinc dust, phospor, ferric chloride, calcium nitrate, activated colloidal calcium carbonate, potassium carbonate, etc.

Generally, Malaysia is self-sufficient for these chemicals and is also a net exporter

of hydrochloric acid, sodium silicate, phosphoric acid and titanium dioxide.

Imports of these chemicals are mainly of special grades, which are not produced locally.
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# Chemical Process

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# Chemical Process

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# Chemical Process

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# Chemical Process

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# Chemical Process

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# Chemical Process
Basic chemicals (including bulk petrochemicals1) are often referred to as low-value bulk or commodity chemicals as opposed to high-value non-basic chemicals (NCMS 2003). The typical values of petrochemicals are 1/5 (or less) of that of typical non-basic chemicals per ton (Heaton 1996). Basic chemicals are typically produced at above one million tons per year worldwide, but the number of these chemical substances only account for less than 2% of all chemicals produced in Europe and US (OECD 2001, EC-BREF 2002). There are in total approximately 70,000-100,000 different of chemical substances produced worldwide (OECD 2001). In terms of volume, basic chemicals account for 95% of the total production volume worldwide (OECD 2001).
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#1 Chemical Processing
Chemicals are processed into consumers goods and as

intermediate for further processing. More than 25% of chemical produced are used for manufacturing other chemicals. Unit operations are physical operation necessary to manufacture chemical such as heat transfer, fluid flow and others. In chemical process the unit process refer to generic reaction such as nitration, sulfonation, oxidation and others. The focus here is chemical conversion.

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#1 Chemical Processing
Principal Chemical Conversion Acylation Alcoholysis Alkylation Amination by reduction Ammonolysis Aromatization or cyclization Calcination Carboxylation Causticization Combustion (controlled) Condensation Dehydration Dehydrogenation Diazotization coupling Double decomposition Electrolysis Esterification Fermentation Fischer-Tropsch reaction Friedel-crafts reaction Halogenation Hydroformylation Hydrogenation, hydrogenolysis Hydrolysis and hydration (saponification, alkali fusion) Ion exchange Isomerization Neutralization Nitration Oxidation (controlled) Polymerization Pyrolysis or cracking Reduction Silicate formation Sulfonation and sulfation

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#1 Chemical Processing
CHARACTERISTIC OF CHEMICAL PROCESSING 1. Each chemical conversion is one of a family of numerous individual reactions with similar energy change, reaction pressure, reaction temperature, reaction time, equilibrium and raw materials. 2. Frequently there is factory segregation wherein a building or section is devoted to making many different products through a single chemical conversion. 3. Close relationship among the type of equipment used for making many different product through a single type of chemical conversion. 4. If volume is small, same equipment could be used for different product produced through the same chemical conversion. 5. The chemical conversion classification enable innovation in chemical process/product based on what is known. 6. The emphasis of chemical conversion is chemical reaction. 7. Design of equipment could benefit from the knowledge of the reaction of similar chemicals.
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#1 Chemical Processing
Chemical conversion are characterized as: % Conversion : % of raw material reacted % Selectivity : percentage of reacted raw materials ending as product % Yield: percentage of raw materials used ending as product % Yield = % Conversion x % Yield/100 The objective of chemical conversion is to have maximum yield.
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Chemical conversion is dependent on reaction kinetics and in the case of reversible reaction on reaction equilibrium. The two factors tend to have compensating effect on each other. Higher kinetics tend to jeopardize maximum conversion achieved (not arriving at equilibrium). Reaction having low yield because of low conversion would require the unreacted reactant to be recirculated. If the equilibrium is the stumbling block then the reaction condition favoring the formation of the product would have to be used.
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Elements of Chemical Processing

Material Balance: Facilitate the effort to maximize yield. Energy changes and Energy Balances: Required to facilitate better control of reaction condition and to ensure effective use of energy. Batch Process: Situation where reaction proceeds in close reactor and the product were obtained at the end of the reaction. Facilitate good control of reaction condition and suitable for low volume production. Continuous process: Reaction is conducted in a flowing process that facilitate higher volume production. Pose bigger challenge to the control of reaction condition.
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Chemical Process Selection, Design and Operation: The construction of industrial plant is preceded by the pilot plant and the lab scale chemical conversion. The material used must take into account of the reaction conditions (T,P) and the corrosiveness of the reaction. Chemical Process Control and Instrumentation: Process control are highly automated and in many cases plants are bought as a package. This include control on the quality of raw materials and products. Instrumentation made up to 25% of the cost of plant. The instruments are important component of plant that indicate and record process data and control process condition.

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Chemical process economics: Process condition will always be enhance to improve profitability. A more cost effective reaction pathway is obtained through continuous R&D activities. This could be achieved through higher yield and through better utilization of energy. Market evaluation: Purity on the basis of fit for purpose; The physical form of the product has great influence on their marketability. The packaging and transport are two expensive component in chemical processing. It should be done only on needs basis to reduce cost and maintain purity.

Plant location: availability of raw materials, energy, transportation and market strongly influenced the location of a plant.

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OSHA: Safety is a very important element of chemical processing. Strong measures are introduced to prevent chemical hazard real and imagined from harming employees, consumers and the public at large. Generally OSHA involves the implementation of three standards being: i. Initial standards ii. Emergency temporary standards and ii. Permanent standards

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#1 Chemical Processing
R&D: Adequate and skilled research with patent protection is necessary for future profit. The activities are meant for: a. New and improved processes b. Lower cost and lower prices for products c. Services and products never before known d. Change of rarities to common commercial supplies of practical usefulness e. Adequate supply of materials previously obtained only as by-product f. Freedom from domination by foreign control g. Stabilization of business and industrial control h. Product of improved quality
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