Scope, chemical industries, raw materials, Chemical production, raw materials, Pollution control, Human resources, Safety measures, R & D, objectives, Trade mark, copyright act, Patent act, pollution control
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Basic approach to Chemical Industries.pdf
1. Basic Approach to
Chemical Industry
Dr. Thakur Vikas A.
Asstt. Professor & Ph.D. Research Guide,
Rayat Shikshan Sanstha’s
K.B.P.College Vashi(Autonomous)
2. Contents
➢Introduction
➢Basic requirements of chemical industries.
➢Chemical Production.
➢Raw materials.
➢Unit process and Unit operations.
➢Quality control and Quality assurance
➢Process control,
➢Research and development.
➢Pollution control
➢Human resource, Safety measures
4. Introduction
➢Indian Economy was previously based on an agricultures.
➢But now the industries are contributing 60% to Indian economy.
➢India is next to China in exporting of the chemicals.
➢India exports the basic chemicals, drug intermediates.
➢The wide and diverse spectrum of Chemical products can be broken
down into a number of categories.
➢Inorganic and Organic (Commodity) chemicals, drug and
pharmaceuticals, plastic and petrochemicals, dyes and pigments, fine
and speciality chemicals, pesticides and agrochemicals and fertilizers.
5. Basic requirements of chemical industries
➢Chemical industries are the place where the unit processes,unit operations are carried out
on large scale.
➢The term marketing is not involved with the production but it is very important term for
industry.
❖If any XYZ person wanted to establish industry, he should solve the following questions.
➢1. What chemicals I wanted to prepare?.
➢What are its uses.?
➢3.Who will be my customer?.
➢4.How much they need it?
➢5.What are other competitors available?
➢6. What raw material is required?
➢7. Where it will be available.
6. Basic requirements of chemical industries
➢8. Is their any alternative raw material, which is cheaper and abundantly
available.?
➢9.What is technical knowledge of the process? What will be the capital
investment and working capital required.
❖After getting satisfactory answer, he should select proper place, where skill
labours are available in minimum wages and
❖The required space with the facility of water and electricity.
❖The basic requirements to start the chemical industry are the satisfactory
answer of these questions
❖Out of these, the selection of products, raw material availability, skill labors
and process know are the prime important factors to start manufacturing
process.
7. Chemical Production
❖Chemical production means manufacture of desired products.
❖The required raw material passes through series of the physical and
chemical processes to obtain final product.
❖The chemical product involved several important factors as per the
following equation.
❖Chemical Production = Raw material + Unit Processes(Chemical
reactions) + Unit Operation(Physical
operation) + Quality Control + Process
Control + Pollution control.
8. Chemical Production
❖All the above processes are commercialized to get economic yield of the desired
product.
❖The choice of cheap, pure, abundant and readily nearby available raw material is one
of very important asset in the chemical production.
❖The purity of the raw material must be checked before processing it.
❖If it is not to the level of desired purity then its purification become necessary.
❖The quality and yield of the chemical product depends on the purity of raw material.
❖Cost of Chemical product = Cost of raw material + Process cost +
Pollution control
The process cost includes the labour, electricity water and other charges.
The pollution control involved treatment of the pollution and wastes which is essential
part of the industry and required higher expenses.
10. Raw materials.
❖It is prime essential to have good quality of raw materials because the cost and
quality of the product totally depend upon the raw material.
❖Many industries are locked due to either shortage of raw material.
❖Qualities of raw material.
➢1.It must be available in abundant.
➢2.It should be cheap.
➢3.If possible renewable raw material should be selected.
➢4.It should be available near factory so that the industry can save the
transportation charges.
➢5. It should be stable and safe to storage.
➢6. It must be in pure form. Otherwise the purification of raw materials is required
which will increase the cost of the product and also a lot of time is wasted.
11. Raw materials.
❖There are two types of raw materials.
❖1.Natural raw materials.
➢These are obtained from natural resources like coal, minerals, natural
gas, atmospheric gases like H2, N2, CO2, O2 etc., water, fossil fuel,
vegetable origin materials(renewable sources etc.)
❖2. Synthetic raw materials.
➢The product of one industry became the starting material for other
industries.
➢Exam. Basic chemicals, drug intermediates, various organic acids,
phenols, amines etc.
12. Unit Process and Unit Operations
➢The conversion of raw material into final product by carrying out
chemical reaction is called unit process.
➢The chemical reaction is commercialization by using physico
chemical parameters to save
➢The time required, energy inputs, labours, number of steps during the
reaction to make it economically favourale.
➢There are several ways for the above transformations.
➢But one has to chose most economically favoourable way to get the
higher yield of pure product in minimum cost
13. Types of Unit Processes of Chemical
reactions
Nitration All name reactions Substitution
Sulphonation Rearrrangement reactions Ellimination.Addition.
Halogenation Diazotisation
Friedel Craft’s reaction. Combustion
Oxidations Neutralization
Reductions Isomerization.
Ammonolysis Electrolysis.
Cracking/Pyrolysis Dehydration
Esterification, Hydrolysis,
Condensation
Polymerization
Cyclisation.FermentationS
14. Unit Operations
• Unit operations are the physical phenomenon,used for heatand mass
transfers.
• The unit operations are needed to do the unit process in economic way.
• For isolation and purification of product.
• The chemical engineer designed the necessary machinery to do unit
operation and to handle the material on large scale.
• The controlling of rate of reaction and unit operations are also used in
operating physico-chemical principles of yield of the product also
depends on unit operations.
15. Types of Unit Operations
Heat Transfer Adsorption
Fluid dynamics Absorption
Distillation Centrifugation
Solvent extractin Mixing
Crystallization Handling of various types of materials
Filltration Dissolution
Sedimentation Evaporation
Precipitation Reduction of particle size
Washing Increasing or decreasing pressure.
16. Quality Control, Quality Assurance
➢To sustain the product of industry in market, they have to compete with other manufacturers for
quality and cost of their products.
➢In this respect the quality control(QC) and Quality Assurance (QA) department is playing very
important role.
➢Industry has to supply the product of required specifications to user group.
➢If quality is not to the specific level, then industry will lose their market and will go in loss.
➢Each industry has separate Quality Control(QA) and Quality Assurance (QA) department.
➢Various analytical techniques are used for qualitative and quantitative analysis of the impurities in
raw materials and in final products.
➢The physical parameters such as M.P., B.P., density, viscosity measurements, refractive index,
dissolution etc. are determine with the starting material required to increase efficiency of the
process.
➢Now modern instrumental techniques such as IR, 1H and 13C NMR, Mass Spectrometry, GC-MS,
HPLC, HPTLC are used for identification of the new products and also for purity.
17. Quality Control, Quality Assurance
➢The QC/QA can reject the raw material or final product, if they find the
impurities above permissible limit.
➢The instrumental methods are more accurate and efficient than manual
methds.
➢Hence all industries are now using instrumental methods.
➢The industries have to send QC report of the final product in specific format
with the product.
➢If the raw material is impure, the wastage of reagent and solvents increases
and process gave impure product of underired color and odour.
➢The purification of such product became expensive.
18. Research and Development(R & D)
➢Similar to QC/QA department, it is very necessary to have Research and Development (R
& D) department in Chemical Industry.
❖The R & D Department has following functions.
➢1.To update the industry with the users’s needs.
➢2.Optimize the reaction condition to obtain higher product yield in low cost and low
reaction time.
➢3.Design the safe reaction vasal to handle huge quantity of raw material at one time.
➢4.Design and synthesize new products.
➢5. Search cheap and inexpensive raw materials.
➢6.Find new route for economic production of the products.
➢7. Increase the quality of the products to sustain in the market.
➢8. Use all by-products properly and make industry profitable.
19. Research and Development(R & D)
➢9. Minimize the wastage and decrease the cost of pollution control.
➢10.Patended the new products and processes.
➢11.Find know-how of the chemical reactions.
➢12.Develop new efficient inexpensive catalyst.
➢13.Avoid the accidents in the industry.
20. Pollution Control
❖Scenario of pollution due to chemical industries.
Industry Level of
Pollution
Causes/Pollutants
Petrochemical
Industries
0.2-0.3% Full utilization of by-product
and high technology.
Food /paper/leather
industries
8-12% Solid waste, water pollution.
Chhemical and pharma
industries
12-15% Solid waste, water and air
pollution
21. Pollution Control
➢From above table it is clear that, chemical industries are responsible for major pollution
on mother earth.
➢One can not stop the product of chemicals to save our environment.
➢Instead, we should have strict control of pollutions.
➢There is also a pollution control board to monitor the pollution level in industries.
➢The industries have to obtain certificate from this Government body to run the industry.
➢The pollutants like hydrocarbons in the form of solvents are recollected in the process and
reused.
➢The gaseous pollutants like CO2, Chlorides, SOX, NOX are scribbled in water or in
NaOH solutions.
➢Particulate pollutants are removed by gravity setting or electronic precipitator.
➢Solid by products are used to manufacture other allied products or sold as raw materials
for other industries.
22. Pollution Control
➢If they are of no usethen, disposed at proper places out of the public
domain.
❑Following are the major causes of pollution.
❖Excess use of organic solvents.
❖By products formation.
❖Requirements of more organic solvent for purification.
❖Use of hazardous reagents and chemicals.
❖Use of stoichiometric reagents.
23. Human Resources
❖Human resources are the major factor associated with all activities of the chemical or any
type of industries.
❖The progress of the industries depends on the availability of the skilled and cheap human
resources.
❖Each process of industry is dependent on the other process.
❖Hence expert and skilled labour are required.
❖The industries give proper training to these workers.
❖They are given incentives for their extra work.
❖The separate provision is made in budget for welfares of staff.
❖Canteen, transportation, insurance and medical facilities are provided to the staff to
maintain physical and mental efficiency and also make industries profitable.
❖In our huge country like India, there is shortage of skilled workers.
❖The labour wages in India is very cheap as compare to foreign countries.
24. Safety Measures
➢Human life is important than anything.
➢If developed processes are safe, the workers will happy to work.
❑The following are the safety precautions required to be taken by chemical industry.
❖1.Industry should design the plant in such a way that there will be no chance of accident.
Prevention is always better than cure/remedies.
❖2.The workers must train to hand hazardous chemicals.
❖3.The fuming hoods must use to carry the chemical reactions with hazardous chemicals.
❖4.The chemical store should be away from the working place.
❖5.Solvents must be stored separately from the other chemicals.
❖6.Regular stock checking should be done.
❖7.Chemicals should not be handled without hand gloves, safety spectacles.
25. Safety Measures
❖8.Fire extinguisher, first aid box should be kept in each department
near the working places.
❖9.Arrangements of water showers are necessary.
❖10.Training should be given to use the safety equipments at the time
of accidents.
❖11.The industry must appoint a physician.
❖12. Accident and Mediclaim policies of each person in the industry
should be made compulsory.
26. Classification of Chemical Reactions
❖Chemical reactions are classified into two main types.
❖I. Catalytic reactions.
➢1. Homogeneous catalytic reactions
➢2. Heterogenous catalytic reactions.
❖II. Non-catalytic Reactions.
➢1. Homogeneous reactions
➢2. Heterogenous reactions
28. Copyright Act and Patent Act
❖Copyright act is the set of exclusive rights granted to the author or
creator of an original work including the right of copy, distribute
and adapt the work.
❖Copyright can be licened, transferred and /or assigned.
❖Copyright lasts for a certain time period after which the work is said
to be enter the public domain.
❖Since 19th century copyright is described under the umbrella term
Intellectual property alongwith patents and trademarks.
❖Q.Define or explain the term copyright act .
29. Trade Mark
❖A trademark or Trade Mark is a distinctive sign or indicator used by an
individual, business organization or other legal entity to identify that the
products or services to consumers with which the trademark appears
originate from a unique source.
❖A trade marks is designated by the following symbols.
❖1. TM . For an unregistered trade mark. i.e. mark used to promote or brand
goods.
❖2.SM. For an unregistered service mark i.e. mark used to promote or brand
services.
❖@for a registered trade mark.
❖Q. Define or explain the term trade mak.
30. References
• Industrial Chemistry By Dr. Raghunath B. Toche, Dr. Satish B. Kale,
Eknath H. Gade. Vision Publications, Ist Edition(2010)
