Unit Description and General Aims

The objective in presenting this unit is to impart to students the fundamental principles of chemical engineering – stoichiometry, process variables, material balance, single and multi-phase systems, and thermodynamics. The subject matter covered in this unit will also include: process equipment design and layout, accompanied by examples of common industrial processes such as distillation, evaporation, condensation, and piping and instrumentation, all based on standard industrial practices.

Learning Outcomes

On successful completion of this Unit, students are expected to be able to:

1. Comprehend and apply the fundamental principles of chemical engineering.
   Bloom's Level 3
2. Examine Stoichiometry fundamentals and solve equations in relation to basic chemical engineering principles.
   Bloom's Level 3
3. Underline the importance of sustainable and environmental considerations in chemical processes.
   Bloom's Level 2
4. Evaluate the basic requirements and principles of process plant layout and design.
   Bloom's Level 5
5. Interpret typical process plant layout documentation.
   Bloom's Level 4
6. Create plant piping documentation.
   Bloom's Level 3

Student assessment

Overall requirements: Students must achieve a result of 50% or above in the exam itself to pass the exam and must pass the exam to be able to pass the unit. An overall final unit score of 50% or above must be achieved to pass the unit once all assessment, including the exam, has been completed.

Prescribed and Recommended Readings

Suggested Textbook

• Ghasem, N, Henda, R 2014, Principles of Chemical Engineering Processes – Material and Energy Balances, 2nd edn, CRC Press, ISBN-13: 978-1482222289

Reference Materials

• Couper, JR, Penney, WR, Fair, JR & Walas, SM 2012, Chemical Process Equipment - Selection and Design, 3rd edn, Elsevier, ISBN 978-0-12-397236-1. Online version available at: http://app.knovel.com/hotlink/toc/id:kpCPESDE16/chemical-process-equipment/chemical-process-equipment
• Dimian, Alexandre C. Bildea, Costin Sorin Kiss, Anton A.. (2019). Applications in Design and Simulation of Sustainable Chemical Processes. Elsevier
• Kleiber, Michael. (2016). Process Engineering - Addressing the Gap between Studies and Chemical Industry. De Gruyter
• Iván Darío Gil Chaves et al. (2016) Process Analysis and Simulation in Chemical Engineering. Elsevier

Peer reviewed Journals

• Knovel library: http://app.knovel.com
• IDC Technologies publications

Other material and online collections as advised during the lectures

Unit Content

One topic is delivered per contact week, with the exception of part-time 24-week units, where one topic is delivered every two weeks.

Topic 1

Chemical reaction, equilibrium

1. Evidence for a chemical reaction
2. Chemical equations
3. Reactions in which a solid forms
4. Reactions in aqueous solutions
5. Reactions of metals with non-metals
6. Chemical equilibrium

Topic 2

Phase behaviour and equation of state

1. Single-Phase systems (solid and liquid densities, ideal gases, equations of state)
2. Water and its phase changes
3. Intermolecular forces, pressure
4. Evaporation
5. Vapour pressure
6. Gas laws
7. Principles of multiphase systems

Topic 3

Acids, bases, solutions

1. Acids and bases
2. The pH scale
3. Buffered solutions
4. Solubility, mass percent
5. Molarity
6. Dilution
7. Fundamentals of Stoichiometry

Topic 4

Thermodynamics

1. Thermodynamic states
2. Thermodynamic equilibrium
3. Laws of thermodynamics
4. Thermodynamic properties (entropy, enthalpy and chemical reactions)

Topic 5

Process engineering

1. Process engineering activities
2. Front End Loading
3. Realization of a plant
4. Batch and continuous processes
5. Equipment used in process engineering

Topic 6

Process documentation, diagrams, and safety

1. Process and instrumentation diagrams
2. Process plant layout
3. Documentation
4. Site location and equipment spacing
5. Process safety (HAZOP procedure and documentation)

Topic 7

Processes and operations

1. Process units: Divider, Mixer, Dryer, Filter, Distillation column, Evaporator, Dehumidication, Humidifier, Leaching and Extraction, Absorber, Condenser, Crystallizer, Reactors, Batch reactor, CSTR and fluidized bed reactor
2. Process Flow Diagram
3. Labelling a PFD

Topic 8

Material balances

1. Material balance fundamentals
2. Mass balance on steady-state processes
3. Material balance on reactive systems
   1. Stoichiometry equation , coefficients, ratio...
   2. Combustion reactions
4. Multiple-unit process flowcharts

Topic 9

Energy balances

1. Energy balance for closed and open systems
   1. Steam turbine
   2. Heaters and coolers
   3. Compressors
2. Energy balance with reaction
   1. Heat of reaction
   2. Heats of formation and heat of combustion
   3. Energy balance for reactive processes
   4. Simultaneous material and energy balances

Topic 10

Sustainable process technology

1. Sustainable development
2. Chemicals from biomass
3. Biofuels
4. Process design issues
5. Environmental and economic challenges

Topic 11

Process simulation in chemical engineering

1. Chemical process simulators (Aspen Plus, Simulink)
2. Computer-Aided Design
3. Process optimization
4. Examples of simulation models (chemical reaction, heat exchange, distillation, absorption...)

Topic 12

Unit Review

In the final week, students will have an opportunity to review the contents covered so far. Opportunity will be provided for a review of student work and to clarify any outstanding issues. Instructors/facilitators may choose to cover a specialized topic if applicable to that cohort.

Software/Hardware Used

Software

• Software: UniSim Design by Honeywell
• Version: R460.1 build 21106
• Instructions: Use remote Lab to access this software.
• Additional resources or files: N/A

Hardware

• Hardware: N/A

Unit Changes Based on Student Feedback