All about Chemical Plant Operations in brief.

1. Chemical Plant Operations
Prepared by: Makineedi Venkat
Roll No:16BE01043
CHEMICAL ENGINEERING

2. CONTENTS
• Introduction
• Boilers,Pumps,Heat exchangers,Valves,Pipes,Storage tanks,
Reactors
• Unit operations
• Filteration
• Sedimentation
• Crystallization
• Drying
• Extraction
• Distillation
• Screening
• Mixing

3. INTRODUCTION
What is a chemical
1. It is any organic or inorganic materials which are forms by
chemical reactions.
2. Unit process involves Principle chemical conversions leading t
o synthesis of various useful product and provide basic inform
ation regarding the reaction temperature and pressure.
3. Unit operations involve the physical separation of the products
obtained during various unit processes.
Chemical Process
Unit process Unit operation

4. • Types of chemical industry
1. Basic-35%
2. Bio product-30%
3. Specialty product-5%
4. Soaps ,detergents,cosmatics-10%
• Equipments used in chemical plants
i. Boilers
Boiler is a closed vessel which uses any fuel and convert raw water into hot w
ater or steam.
Types of boilers
a) Fire tube boiler
① Hot air is passes into pipes
② Steam capacity is less
③ Low pressure boiler
④ Chances of accidents are high

5.  High pressure boiler
 Chances of accidents are low
2. Pumps
Pumps are used to transport fluid from one place to anther place.
Types of pumps
A. Centrifuge pump
I. Open impeller pump
II. Closed impeller pump
III. Semi open impeller pump
B. Positive displacement pump
a) Rotary pump
I. Rotary lobe pump
II. Rotary van pump
b) Reciprocal pumps
I. Piston pump
II. Diaphragm pump
III. Screw pump
IV. Gear pump

6. 3.Heat Exchangers
 They are used to transport heat from one fluid to other fluid.
 Types of heat exchangers
1. Shell and tube type heat exchanger
2. Plate type heat exchanger
4. Valves
Valves are used to control the flow of fluid
 Types of valve
I. Gate valve
II. Globe valve
III. Butterfly valve
IV. Control valve
V. Pressure release valve
VI. Needle valve
VII. Plug valve
VIII. Plunger valve
IX. Diaphragm valve
X. Ball valve

7. Pipes
6.Storage tanks
7.Reactors
 Reactors are vessels in which chemical reaction is carried out
 Types of reactors
I. Agitated reactors
II. Batch reactors
III. Continuous reactors
IV. Jacketed reactors
V. catalytic reactors
•

8. Unit operations
1. Filtration
To remove solid and liquid from reaction mixture
 Factors that affects the filtration
I. Filter equipment
II. Filter media
III. Filtrate
IV. cake
1. Methods of Filtration
I. Sand Filtration
II. Filter press
1. Centrifuge Filtration
I. Vacuum Filtration
2. Sedimentation
Is a process of separating heavier , suspended matters , from solutions.
 Mainly use in food and waste water treatment industry

9. Crystallization
 It is a separation process in which liquid is phase is converted into crystal phase .
 Equipments used for crystallization
Agitated reactor
I. Crystallization tank
II. Walker crystallizer
III. Vacuum crystallizer
IV. Oslo crystallizer
V. Evaporation crystallizer
 Methods of crystallization
I. Walker crystallization
II. Vacuum crystallization
III. Oslo crystallization
IV. Evaporation crystallization
 Crystal shape
 Square
 Needle
 Round
 Triangle

10. Drying
 Purpose of drying
1. To reduce cost of transportation
2. To handle materials
3. To store the materials easily
4. Avoid corrosion
 Factors affecting the drying rate
1. Temp
2. Humidity of atmosphere
3. Velocity of wind
4. Falling rate of materials
5. Effect of shrinking
 Methods of drying
 Direct drying
 Indirect drying
 Continuous drying
 Batch drying

11. Classification of drying equipments
1. Tray dryer
a) vacuum
b) normal
2. FBD (fluid bed dryer)
3. Rotary dryer
4. Mechanical agitated
5. Drum
a) Normal
b) vacuum
6. Spray

12. Extraction
 It is separation process
 Types of extraction process
I. Liquid-liquid extraction
II. solid extraction
 Equipment used for extraction
I. Agitated vessel
II. Pack column
III. Plate column
IV. Rotated disk

13. Distillation
 Distillation is a process of separating the components or substances
from liquid mixture by evaporation and condensation.
 Equipments used for Distillation
I. Distillation pot
II. Condenser
III. Receiver
IV. Steam
size reduction
 Purpose of size reduction
I. Increase the area of materials
II. For batter mixing
III. For faster the reaction

14. Method of size reductions
I. Compression
II. Impact
III. Attrition
IV. rubbing
V. Crushing
 Equipments
1. Crushing
a). Jo crusher
b). Roll mill
2. Grinding
a). Hammer mill
b). Rolling mill
c). Ball mill
3. ultra fine
a). Ball mill
4. Cutting kife

15. Screening
 It is defined as separation of fine size particles
 It is used to get uniform particles of products and to remove over
size particles.
 Over size particles are known as tails
 under size particles are known as fine
 Method of screening
I. Magnetic
II. Electrostatic
III. Fluid motion
 Equipments used for screening
I. Grizzled screen
II. Vibrator screen
III. Oscillation screen
IV. Trammel screen
V. Cyclone separator

16. Mixing
 Types of mixing
A. Liquid-liquid
B. Solid-liquid
C. Solid-solid
D. Liquid-gas
 Importants of the mixing
 To get uniform physical properties of solid particles
 To form miscible liquid
 Equipments used for mixing
I. Agitated reactors
II. Propellers
III. Turbine
IV. paddles