About The Subject

Process calculations in chemical engineering are essential for optimizing the design and operation of chemical processes. These calculations involve the application of fundamental principles such as mass and energy balances, thermodynamics, and reaction kinetics to ensure efficiency and safety in production. By systematically analyzing the inputs, outputs, and transformations within a system, engineers can predict performance, minimize waste, and enhance product yield. Whether designing reactors, distillation columns, or heat exchangers, accurate process calculations enable engineers to make informed decisions, improve process sustainability, and drive innovation in the chemical industry.

Course Objectives

• To understand material balance over a unit operation without chemical reaction.
• To understand material balance over a unit operation with chemical reaction.
• To understand energy balance over a unit operation without chemical reaction.
• To understand energy balance over a unit operation with chemical reaction..
• To understand steady state, recycle, by-pass, purge streams and material and energy balance for them

Course Syllabus

• Chemical calculations including mole, equivalent weight, solids, liquids, solutions and their properties of gases.
• Non ideal calculations for gas and liquid mixtures
• Process flow sheet concept
• Material balance calculations, material balance of unit operations such as distillation, crystallization, recycling, bypass and purge operations.
• Mass balance with chemical reactions
• Single and multiple reactions, excess and limiting reactants, conversion, yield and selectivity
• Material balance with recycle, bypass and purge operations.
• Sensible heat changes in gases, liquids and solids
• Latent heat of phase change
• Enthalpy changes in pure substances and their mixtures
• Heat of solutions, energy balance of unit operations
• Standard heat of formation and combustion
• Effect of heat of formation and heat of reaction
• Energy balance of unit processes
• Simultaneous material and energy balances, psychometric calculations

Real-life applications

• Chemical Engineering: Designing and optimizing chemical reactors, distillation columns, and separation processes. Engineers use process calculations to determine reaction rates, yield, and energy balances.
• Pharmaceuticals: In drug formulation and manufacturing, process calculations help ensure the correct dosages and concentrations of active ingredients, as well as compliance with safety regulations.
• Food Processing: Calculations are essential for scaling recipes, optimizing cooking times and temperatures, and ensuring food safety through proper sterilization processes.
• Energy Production: In power plants, process calculations help determine fuel efficiency, emissions, and energy conversion rates. This includes calculations for renewable energy systems like solar panels and wind turbines.
• Environmental Engineering: Designing systems for waste treatment and pollution control involves process calculations to assess the effectiveness of various treatments and the impact on the environment.
• Manufacturing: In industries like automotive or electronics, process calculations are used for material flow, production scheduling, and quality control to enhance efficiency and reduce costs.
• Water Treatment: Engineers calculate chemical dosages for water purification, determine flow rates, and design treatment plants to ensure safe drinking water.
• HVAC Systems: Process calculations in heating, ventilation, and air conditioning systems help determine load requirements, energy efficiency, and optimal system performance.
• Petroleum Industry: In refining processes, calculations are essential for optimizing distillation, extraction, and conversion processes to maximize yield and minimize costs.
• Construction: Structural engineers use process calculations to analyze load distribution, material strength, and environmental impacts when designing buildings and infrastructure.
• Biotechnology: In bioprocessing, calculations are used to optimize fermentation processes, enzyme reactions, and the production of biological products, such as vaccines and biofuels.
• Textile Industry: Process calculations help in dyeing, finishing, and textile manufacturing, ensuring the right chemical concentrations and process conditions for quality output.
• Mining and Metallurgy: In mineral processing, calculations determine the optimal extraction methods, material flow rates, and recovery efficiencies of valuable minerals.
• Transportation and Logistics: Process calculations are essential for route optimization, load planning, and fuel consumption analysis in shipping and freight operations.
• Construction Materials: Calculations are crucial for mix designs in concrete and asphalt production, ensuring the right proportions of materials for strength and durability.
• Pharmaceutical Development: In clinical trials, process calculations help analyze dosage regimens, pharmacokinetics, and the statistical modeling of trial results.
• Telecommunications: In network design and optimization, calculations determine bandwidth requirements, data flow, and resource allocation for efficient communication systems.
• Agricultural Engineering: Process calculations are used to optimize irrigation systems, fertilizer application, and crop yield predictions based on environmental conditions.
• Waste Management: Engineers apply calculations to assess landfill design, recycling processes, and waste-to-energy conversion efficiencies.
• Aerospace Engineering: In aircraft design, process calculations help analyze aerodynamic performance, fuel efficiency, and structural integrity under various flight conditions.
• Robotics and Automation: Calculations are vital for optimizing robotic motion, ensuring precise movements, and improving efficiency in manufacturing processes.
• Cement Production: In the production of cement, calculations determine the optimal raw material mix, kiln temperatures, and energy consumption.

Recommended books for process calculations

Here are some books that you may refer for this subject, they are easy to understand, based on concepts. Get the book PDF on one click, for FREE!

• Basic Principles and Calculations in Chemical Engieering - David M Himmelblau and James B Riggs
• Chemical Engineering Design (RC Volume 6) - Coulson and Richardson - Refer chapters 2 and 3 for process calculations