Chemical Engineering Essentials, Volume 1
Description
In an era of rapid innovation and with a focus on sustainability, Chemical Engineering Essentials provides a definitive guide to mastering the discipline. Divided into two volumes, this series offers a seamless blend of foundational knowledge and advanced applications to address the evolving needs of academia and industry.
This volume lays a strong foundation with topics such as material and energy balances, thermodynamics, phase equilibrium, fluid mechanics, transport phenomena, and essential separation processes such as distillation and membrane technologies.
Volume 2 builds on these principles, delving into reaction engineering, reactor modeling with MATLAB and ASPEN PLUS, material properties, process intensification and nanotechnology. It also addresses critical global challenges, emphasizing green chemistry, waste minimization, resource recovery, and workplace safety.
Together, these volumes provide a holistic understanding of chemical engineering, equipping readers with the tools to innovate and lead in a dynamic and sustainable future.
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Persons
Raj Kumar Arya works at the Dr. B. R. Ambedkar National Institute of Technology in Jalandhar, India.
George D. Verros works in the Public Sector in Thessaloniki, Greece.
J. Paulo Davim works at the University of Aveiro in Aveiro, Portugal.
Content
Preface xv
Raj Kumar ARYA, George D. VERROS and J. Paulo DAVIM
Part 1. Fundamental Principles 1
Chapter 1. Overview of Chemical Engineering 3
Devyani THAPLIYAL, Kshitij TEWARI, Chitresh Kumar BHARGAVA, Avinash CHANDRA, Pramita SEN, Rahul KUMAR, Amit K. THAKUR, George D. VERROS and Raj Kumar ARYA
1.1. Introduction 3
1.2. History of chemical engineering 4
1.3. Chemical engineering profession 5
1.4. Features and challenges in chemical engineering 6
1.5. Conclusions 14
1.6. References 15
Chapter 2. Fundamentals of Material and Energy Balances 17
Kshitij TEWARI, Devyani THAPLIYAL, Chitresh Kumar BHARGAVA, Avinash CHANDRA, Pramita SEN, Rahul KUMAR, Amit K. THAKUR, George D. VERROS and Raj Kumar ARYA
2.1. Introduction 17
2.2. Process term definitions 18
2.3. Engineering calculations - introduction 21
2.4. International system of units (SI) 22
2.5. Analysis of processes and variables affecting density 25
2.6. Classification of material balances in process fundamentals 29
2.7. General balance equation 30
2.8. Flow charts and process balancing 33
2.9. Degree-of-freedom analysis. 33
2.10. Procedure for calculating material balances in single unit processes 35
2.11. Recycling and bypassing 35
2.12. Limiting reactant 36
2.13. Product separation and recycling 37
2.14. Combustion 37
2.15. Single-phase systems 38
2.16. Clausius-Clapeyron equation 39
2.17. Mass balance problem 42
2.18. Energy and the concept of energy balance 46
2.18.1. Energy balances for closed systems 46
2.19. Energy balances on open systems in the steady state 47
2.19.1. Steady-state energy balance of the open system 48
2.20. Estimation of heat capacity 51
2.21. Estimation and correlation of latent heat 52
2.22. Heats of solution and mixing 53
2.23. Heat of reaction measurement 55
2.24. Energy balance problem 60
2.25. References 63
Chapter 3. Laws of Thermodynamics 65
Girish GUPTA and Neha DHIMAN
3.1. Introduction 65
3.2. Thermodynamical systems 66
3.3. Types of system 68
3.4. Macroscopic system and properties 69
3.5. State of system and state variables 70
3.6. Zeroth law of thermodynamics 71
3.7. Heat 72
3.8. Work 73
3.9. State functions and path functions 73
3.10. First law of thermodynamics 74
3.11. Internal energy is a state function 74
3.12. Work and heat are path functions 75
3.13. Second law of thermodynamics 76
3.14. Thermal energy reservoir 76
3.15. Heat engines 77
3.16. The second law: Kelvin-Plank statement 77
3.17. The second law: Clausius' statement 78
3.18. Refrigerator and heat pumps 78
3.19. References 78
Chapter 4. Thermodynamic Properties and Equations of States 79
Dipaloy DATTA
4.1. Thermodynamic property relations of pure substances 80
4.2. Equations of states 99
4.3. References 102
Chapter 5. Thermodynamics and Phase Equilibrium 103
Vyomesh M. PARSANA, Abhishek GUPTA, Dharmesh SUR and Kedar JOSHI
5.1. Introduction 103
5.2. Fundamentals of thermodynamics 104
5.3. Vapor-liquid equilibrium 111
5.4. Solid-liquid equilibrium 128
5.5. Liquid-liquid equilibrium 130
5.6. References 132
5.7. Further reading 133
Part 2. Fluid Mechanics and Transport Phenomena 135
Chapter 6. Basics of Flow Through Equipment 137
Devyani THAPLIYAL, Kshitij TEWARI, Chitresh Kumar BHARGAVA, Avinash CHANDRA, Pramita SEN, Rahul KUMAR, Amit K. THAKUR, George D. VERROS and Raj Kumar ARYA
6.1. Fundamental laws of fluid mechanics 137
6.2. Pumps, compressors and flowmeters 153
6.3. Pressure drop in designing equipment 164
6.4. Computational fluid dynamics 175
6.5. Conclusions 183
6.6. References 183
Chapter 7. Conduction, Convection and Radiation 189
Thangallapalli SRINIVAS, G. SRINIVAS, B.K. PUROHIT and A.V. RAGHAVENDRA RAO
7.1. Fundamentals of heat transfer mechanisms 189
7.2. Conduction 193
7.3. Convection heat transfer 207
7.4. Radiation heat transfer 220
7.5. References 226
Chapter 8. Diffusion and Mass Transfer Coefficients 229
A.V. RAGHAVENDRA RAO, Rompicherla SRIVIDYA, V. Sravani SAMEERA, K.S.N.V. PRASAD and Thangallapalli SRINIVAS
8.1. Introduction 229
8.2. Diffusion mass transfer 231
8.3. Mass transfer coefficients 244
8.4. Nomenclature 252
8.5. References 253
Part 3. Separation Processes 263
Chapter 9. Extraction 265
Juli DAS, Diptanu DE, Aanchal MITTAL, G.C. JEEVITHA and Sangeeta GARG
9.1. Introduction 265
9.2. Conventional extraction methods 266
9.3. Modern extraction methods 286
9.4. Conclusion 294
9.5. References 295
Chapter 10. Distillation 303
Neha DHIMAN and Girish GUPTA
10.1. Introduction 303
10.2. Applications of distillation process 304
10.3. Relative volatility 305
10.4. Classification of distillation 307
10.5. References 330
Chapter 11. Mathematical Modeling of Binary and Multicomponent Distillation 331
Ananya MUNNANGI, MUTHAMIZHI K., KARTHIKEYAN C., K. TAMILSELVI and A.B. MOHAMMED BASITH
11.1. Introduction 331
11.2. Ideal simple distillation 332
11.3. Nonideal multicomponent distillation 337
11.4. Batch distillation 340
11.5. Applications and advancements 342
11.6. Conclusion 343
11.7. References 343
Chapter 12. Filtration and Membrane Processes 345
Esmaeil ALLAHKARAMI and Ebrahim ALLAHKARAMI
12.1. Introduction 346
12.2. Types of membranes 349
12.3. Membrane fabrication techniques 363
12.4. Application of membrane processes 367
12.5. Membrane fouling 374
12.6. Conclusion 380
12.7. References 381
Chapter 13. Pervaporation 393
Tapas PALAI, Abhishek KUMAR and Leela Manohar AESHALA
13.1. Introduction 393
13.2. Basics of membrane separation processes 394
13.3. Pervaporation 401
13.4. Selection of membrane 413
13.5. Recent developments 418
13.6. Future scope and emerging trends 420
13.7. References 421
List of Authors 427
Index 431
Summary of Volume 2 435
1
Overview of Chemical Engineering
1.1. Introduction
Chemical engineers have been enhancing our overall welfare for over a century. Chemical engineers have contributed to several advancements that impact our daily lives, ranging from the creation of more efficient computer chips to improvements in recycling, illness treatment, water purification and energy generation.
Chemical engineering (CE), also referred to as process engineering, is a branch of engineering that uses mathematics, economics, physical sciences and biological sciences to create and modify chemicals, energy and materials. Chemical Engineering was originally developed as a combination of mechanical engineering and applied chemistry, with a specific focus on its application in the petrochemical and heavy chemical industries.
Chemical engineers convert laboratory-developed procedures into practical applications for the commercial manufacturing of products, and then strive to uphold and enhance such processes. They depend on the fundamental principles of engineering, namely mathematics, physics and chemistry. Biology is assuming a progressively significant role.
Chemical engineers primarily conceptualize and develop procedures related to chemical production on a large scale. Chemical engineers primarily focus on designing and resolving issues related to the manufacturing of various substances such as chemicals, fuels, foods, pharmaceuticals and biologicals. They are primarily hired by industrial facilities of significant size to optimize efficiency and enhance the quality of products, while minimizing expenses.
Chemical engineering encompasses the synthesis and fabrication of goods using chemical reactions and procedures. This includes the creation of machinery, systems and procedures for the purification of basic substances and the blending, combining and treatment of chemical compounds.
Chemical engineers enhance food processing processes and develop more efficient methods for fertilizer production, with the aim of augmenting both the amount and quality of food resources. In addition, they fabricate artificial fibers that enhance the comfort and water resistance of our garments; they devise techniques for the large-scale production of pharmaceuticals, thereby reducing their cost; and they invent safer and more efficient processes for refining petroleum products, thereby increasing the productivity and cost-effectiveness of energy and chemical resources.
Additionally, chemical engineers devise strategies to address environmental issues, such as pollution control and remediation. Indeed, they engage in the manipulation of chemicals, which are employed in the production or enhancement of virtually all the objects within your surroundings.
1.2. History of chemical engineering
Chemical engineering is a field that emerged from the practice of "industrial chemistry" in the late 19th century, as stated by Wikipedia (2024a, 2024b). Prior to the Industrial Revolution in the 18th century, the production of industrial chemicals and consumer items such as soap primarily relied on batch processing methods. Batch processing involves manual labor, when workers combine predetermined quantities of materials in a container and then subject the mixture to heating, cooling or pressurization for a specific duration. Subsequently, the product can be separated, refined and examined in order to obtain a marketable product.
Currently, batch processes are still used for more valuable products, such as pharmaceutical intermediates, specialty and formulated products such as perfumes and paints, or in food production such as pure maple syrups. Despite being slower and less efficient in terms of labor and equipment usage, batch methods are still profitable in these cases.
Chemical engineering approaches have enabled the production of higher volumes of chemicals through continuous "assembly line" chemical processes in industrial process development. The Industrial Revolution marked the transition from batch processing to a more continuous processing approach. The Industrial Revolution resulted in an unparalleled increase in demand, in terms of both quantity and quality, for large quantities of chemicals such as soda ash. This entailed two objectives: firstly, expanding the scale of the activity and enhancing operational efficiency, and secondly, exploring viable alternatives to batch processing, such as continuous operation. The practice of industrial chemistry dates back to the 1800s, and its academic study in British universities commenced with the publishing of the influential book "Chemical Technology" in 1848 by Friedrich Ludwig Knapp, Edmund Ronalds and Thomas Richardson.
According to Wikipedia (2024a, 2024b), James F. Donnelly is credited with referencing an 1839 mention of chemical engineering in the context of sulfuric acid manufacturing. However, it was noted in the same piece that George E. Davis, an English consultant, was attributed with originating the word. In addition, Davis made an attempt to establish a Society of Chemical Engineering. However, it ended up being called the Society of Chemical Industry in 1881, with Davis serving as its inaugural secretary.
The term "chemical engineering", which refers to the application of mechanical equipment in the chemical industry, gained widespread usage in England after 1850. The inaugural effort to establish a Society of Chemical Engineers in London took place in 1880. Consequently, the Society of Chemical Industry was established in 1881. The American Institute of Chemical Engineers (AIChE) was established in 1908, while the U.K. Institution of Chemical Engineers (IChemE) was established in 1922. The term "chemical engineer" was widely used in Great Britain and the United States by 1910.
1.3. Chemical engineering profession
Commonly known as process engineering, chemical engineering is a discipline of engineering that uses physical and biological sciences, mathematics and economics to produce and modify chemicals, energy and materials, as stated by AIChE (2024).
Traditionally, it encompasses the fields of heat transfer, mass transfer, momentum transfer, kinetics and reaction engineering, chemical thermodynamics, control systems and dynamic simulation, separation processes and unit operations.
Chemical engineering, traditionally used in the petrochemical and heavy chemical sectors, has experienced significant advancements and expanded its applications to many domains such as climate change, environmental systems, biomedical science, novel materials and complex systems. Chemical engineers have a significant impact on the manufacturing of nearly every item produced on a large scale in industry.
Common tasks include:
- ensuring adherence to health, safety and environmental regulations;
- engaging in research to enhance manufacturing processes;
- creating and strategizing the arrangement of equipment implementing safety protocols for handling hazardous compounds;
- supervising and enhancing the efficiency of manufacturing procedures. Calculating the expenses associated with production.
Chemical engineers employed in corporate and managerial settings frequently make visits to research and production sites. Engaging with individuals and fostering teamwork are essential for the achievement of chemical engineering projects.
Chemical engineers commonly operate in manufacturing plants, research laboratories or pilot plant facilities. They operate in the vicinity of expansive manufacturing machinery that is located both indoors and outdoors. Hence, it is frequently necessary for them to don personal protective gear such as hard hats, goggles and steel-toe shoes. Chemical engineering is used in several industries and sectors, and is primarily employed in industrial facilities that focus on large-scale production, aiming to optimize efficiency and the excellence of the final product, while minimizing expenses. Chemical engineering is used by several industries including aerospace, automotive, biomedical, electronic, environmental, medical and military sectors to enhance and advance their technical goods. These products encompass a wide range of applications.
Advanced materials have exceptional strength, durability and bonding properties for use in automobiles. Materials that are compatible with living organisms can be used for implants and prosthesis. Optoelectronic devices are designed to use light for various purposes. One important aspect of these devices is the use of films, which play a crucial role in their functionality. These films are specifically engineered to enhance the performance and efficiency of optoelectronic devices.
1.4. Features and challenges in chemical engineering
According to Garnier (2014) and Hipple (2017), numerous captivating and productive difficulties in the field of chemical engineering arise from the amalgamation of chemical engineering with chemistry, physics and biology, which necessitates a redefining of the control volume. This list does not encompass all of the forthcoming difficulties in the field of chemical engineering and the areas where chemical engineering abilities will be applicable:
- Energy resources and use: in this context, it is necessary to disregard any "agendas" that may be primarily driven by political constituents, such as corn-based ethanol. Energy is necessary for the provision of food, shelter and transportation. In order to accommodate the...
